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CHAPTER 5
PRODUCTION TECHNOLOGY
5.1 INTRODUCTION
Six (06) drainage points have been identified to achieve a plateau production rate
of 5000 bbl/day based on the results of reservoir simulation model. One (01)
Vertical, Three (03) Deviated and Two (02) horizontal production wells will be
drilled together with 2 water injectors with the highest recovery factor of 14.3 %,
obtained from reservoir simulation.
The MDT survey of the Gelama Merah shows that all sand units are in the same
pressure system. The producers and injectors will be completed as single string
and unit-9.0, 9.1 & 9.2 will be produced commingled. Different sand exclusion
techniques are considered and is modeled but will not be installed initially due to
high pressure drop however, if required, Wire Wrapped Screen will be used. It has
been identified that there will be no immediate need of artificial lift from the
initial production at the field but the wells ceases to flow at early water cut
therefore, considerations for future artificial lifting will be included to facilitate
future need when reservoir pressure has declined with increasing water cut.
The well deliverability analyses were carried out on the basis of performance
during Drill Stem Testing (DST) of the exploration well Gelama Merah-1, with
the help of EPS Wellflo software. One DST was carried out on Unit-8.0 using 3
½” string. Well model is based on the results from DST and PVT fluid samples
collected during the test as shown in Table 5.1, 5.2 and 5.3.
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Skin -2.1
Kh, md-ft 4130
Effective Permeability, md 140
Effective Thickness, ft 29.5
Initial Reservoir Pressure, psi 2151
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The completion string for Gelama Merah development wells will be designed on
the basis of MDT data, as shown in Table 5.4, which indicates that all the
hydrocarbon bearing zones in GM structure are from one pressure system.
Pressure Pressure
ZONE MD (m) TVD (m) (Psia) (Psia)
From To From To Top Bottom
1332 1587 1332 1587 2092.6 2238.7
The production strategy will be to produce the oil commingle from different sand
units with hydraulic retrievable packer for zonal isolations. Production from all
the units will be through perforations. Provision of gas lift mandrels will also be
provided in the vertical section of the wells for the future need of gas lifting.
Well
Well Type Perforated Sand Description Remarks
Name
Commingled flow from different
Unit-9.0, 9.1 and Single Oil
GLA Vertical units casedhole
9.2 Producer
Unit-9.0, 9.1 and Commingled flow from different Single Oil
GLB Deviated
9.2 units casedhole Producer
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For the designed casing configuration i.e 26” conductor casing, 13 3/8”
surface casing and 9 5/8” production casing a conventional spooled wellhead
is proposed where head housing is either screwed or welded to the top joint of
the casing. Each housing will have an internal profile to accommodate casing
hanger to hang the casing.
The basic criteria for wellhead and Christmas tree equipments are:
All wells are proposed to use the standard cross piece X-Mas Tree where a
series of valves which control physical or hydraulic access into the tubing
and/or annulus. The access capabilities are normally required for:
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ii. String will consist of 2 7/8” OD completion. Optimum tubing size selected
after running sensitivities for different tubing sizes in the generated wellflo
model as this will give us the desired rate.
iii. Downhole pressure gauges (PDG) will be installed in both producers and
injectors that will transmit real time pressure data for better reservoir
management. An important justification for PDGs is close reservoir
monitoring, production optimization and reduce intervention cost.
iv. A hydraulic retrievable packer and tailpipe is included in the design to:
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vi. Gas lift mandrels with dummy valves will be installed in the completion
string to enable future installation of gas lift valves.
viii. Selective landing nipples will be installed to provide receptacle for wireline
tool and equipment to perform well servicing or pressure testing jobs.
ix. No-go nipple with smaller ID compared to others will be installed at the
bottom of the string to avoid any wireline tool from dropping off the string.
Based on the PVT report, the CO2 content is 0.94 - 2.85 mole %. No H2S
found in the reservoir. Table 5.6, tabulated related parameters evaluated to
determine the material selection for the tubing and completion accessories.
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The CO2 partial pressure of the sands fall in the wet CO 2 domain, which
disqualifies the use of carbon steel and necessitates the use of CRA material.
Use of L-80 Carbon steel with Super 13Cr for tubing will be considered.
Please refer to Appendix 5-2, used for material selection, published chart by
Kawasaki and Sumitomo.
For the completion accessories, all equipment will be of the same material as
of production tubing to avoid galvanic corrosion due to dissimilar metals. For
the particular internal parts that require high strength, such as SCSSSV,
consideration for using higher-grade material will be made. The elastomer will
be selected to withstand anticipated problems related to exposure to high
temperature and amine-based fluids.
The gun used in Gelama Merah-1 i.e Tubing Conveyed Perforation (TCP) gun
4 5/8”, 12 Shot Per Foot (SPF) with 23 gm RDX explosive has been proven to
be effective with a negative skin of -2.1, as evidenced from DST results.
Therefore, the same is suggested for all the development wells.
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Based on the interpretation of Gelama Merah exploration well DST results, actual
PI of Unit-8.0 sand is 3.4819 bpd/psi. Low skin value of -2.1 was calculated from
the test that could have been caused by better underbalance achieved during
perforation. A model in Wellflo was generated utilizing the DST data. The
anticipated Productivity Index (PI) from the Wellflo model for unit-8.0 is 3.64
bpd/psi as shown in Figure 5.1 using skin value of S= -2.1 and effective
permeability value of 140 mD from well test analysis. Estimation PI was
calculated using Vogel correlation. However, we know that the wellflo model
created using DST results of exploration well can not be used to represent the
actual development wells, planned for GM field, since the exploration well was a
conventional vertical well whereas planned development wells include vertical,
deviated and horizontal wells. Therefore, well model is modified for further
studies/sensitivities.
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The first step carried out was to identify the correct flow correlation that match
and represent the actual well behavior as observed in DST as shown in Table 5.1
and 5.2. A “Hagedorn and Brown (mod)” correlation was found to best match the
DST data. However, model did not match 100 % with the DST data and an error
of 0.7 & 5 % in pressure and rate was observed respectively. Results for the
matching of the DST data and selecting appropriate inflow and outflow
correlations are attached as Appendix 5-3.
The sensitivity outflow prediction plots on tubing sizes of 2 3/8’’, 2 7/8’’ and 3
1/2’’ for base case and various reservoir parameters scenarios are plotted as in
Appendix 5-4 and the results are summarized in Table 5.7 to Table 5.9.
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A 2 7/8’’ tubing size is proposed for the optimum vertical flow as the size is more
than enough to produce the desired rate. With this tubing size well can produce
naturally upto 45% Water cut without any artificial lift assistance and field
maximum possible GOR of 1500 scf/stb. As shown in Table 5.8 and 5.9.
It has been observed from sensitivities run in wellflo that field development wells
will cease to flow at 46 % water cut and it is predicted that artificial lift will be
required at an early stage of field life. Therefore, consideration for future artificial
lift will be included to facilitate future selection. Selection of the artificial lift
method shall take following in to account:
Keeping above points in mind gas lift is the preferred choice for Gelama Merah
development wells. Other artificial lifting method i.e. Electric Submersible Pump
(ESP) is not favorable option due to unavailability of power at offshore and due to
high GOR exceeding 500 scf/stb later in field life.
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Wellflo modeling was also carried out to simulate vertical lift performance on
tubing sizes of 2 3/8’’, 2 7/8’’ and 3 1/2’’ and the results are summarized in Table
5.10 to 5.11.
A continuous gas lifting mode however, might not be required initially, unless
early water breakthrough occurs (more than 45% water cut) or reservoir pressure
depletes to less than 1,500 psi. The attempt to model the production rate by
introducing lift gas to boost-up production during the initial stage has resulted in
an adequate improvement on oil production rate. Sensitivities were run for
different parameters such as declining wellhead pressure, increasing water cut,
increasing GOR and declining layer pressure shown in Appendix 5-6.
The lifting gas for development wells will be obtained from the associated gas
produced from the field. If the produced gas from development wells is not
sufficient for gas lifting arrangement can be made from near by field or from gas
bearing sands of the developing field in future. Provision for future gas-driven
gaslift compressor should be made either on the drilling platform.
Table 5.10: Summary: Production Profile Natural Flow Vs. Gas Lift
Injection (Water Cut)
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Table 5.11: Production Profile Natural Flow Vs. Gas Lift Injection (Reservoir
Pressure Depletion)
Figure 5.2: Injection gas volume against produced oil flow rate
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Based upon Wellflo simulation, the Side Pocket Mandrels (SPM) shall be
placed between 3000 and 3900 ft TVD in the tubing for future installation of
gas lift valves. As shown in Appendix 5-5. At initial production condition,
one gaslift valve placed in each string should be able to improve the oil
production. To ensure optimized setting depth of the valves, further study
should be conducted prior to final design and selection of gas lift system.
Drill Stem Testing (DST) carried out on Gelama Merah-1 did not show any
indication of sand production problem. Since core analysis from the same well
is not available while completing this Field Development Plan (FDP)
therefore, the sand failure prediction model in GM field is based upon the
Sonic Transit Time and offset wells record.
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Keeping in view unconsolidated sands, based on the sonic log reading and off-
set wells data, some form of sand control measure is required for Gelama
Merah development wells. There are essentially two types of sand exclusions.
Tables 5.12 to 5.13 shows comparison of different options available for sand
exclusion.
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Wellbore
reinforcement, sand Formation sand exclusion or Gravel provide sand
Concept
bridges around gravel retention exclusion
slots
Stainless steel on mild steel Stainless steel on mild
Material Mild steel
base pipe steel base pipe
Sand Poor: 0.012” slot Better than slotted liner since Excellent: as with gravel
Exclusion width minimum slot width 0.006” – 0.040” pack
Works with Yes, but should not be
Yes Yes
gravel pack necessary
Flow Low, = 10 times flow area of High, as for wire
High
restriction slotted liner wrapped screen
Poor to collapse/tension if base
Mechanical Fair: base pipe reinforces
Good pipe omitted. Also susceptible
resistance structure
to erosion
Low (Too wide to High: Fine + mud cake.
Plugging
retain to formation Moderate Also impairment while
tendency
sand) RIH
2 – 3 x wire wrapped
Cost Cheapest 2 -3 x slotted liner screen, but often less
than gravel pack
Borehole High productivity wells
Retains sand grains of all
reinforcement medium grained
Application sizes
coarse grained formation.
formation Allows fines production
Advantages Comments
Effective overlong intervals > 100 m operationally possible
Clay / sand particles can pass through if large
Copes with varying rock properties
enough
Employs simple, non-toxic material Gravel placed with water based fluids
Disadvantages
Mechanical restriction in wellbore e.g. Production logging not possible
Requires removal (Fishing of packers/
Workover difficult
screens etc.)
Expensive for multiple intervals Consider commingled production
Difficult to identify source as well as shutoff
Diminished workover options
indescribable water and gas
Many points where permeability damage can
Sensitive to poor completion practices
be created
Based on the above mentioned merits and demerits of different sand exclusion
methods, stand alone screens the best option to be installed. The installation of
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The stand alone screen proposed is basically Wire Wrapped Screen (WWS),
which is surface filter screen. But in this case, the type of WWS being chosen
is the one which is robust (rotatable and high tensile-compressive strength),
having high accuracy of slot opening and proven track record.
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Median
Range Typical
US Gravel
Gravel Size Permeability Remarks
Mesh Diameter
(μm) (D)
(μm)
40/60 425 – 250 340 55 -
Since “528” exist between
“850-425” therefore,
20/40 850 – 425 640 170
permeability selected as
170 D.
12/20 700 – 850 1275 600
After selection of gravel size wellflo model was generated for gravel pack. Table
5.15 shows a comparison between with and without gravel pack with (50 – 60)%
loss in production as shown in Appendix 5-8, and wells ceases to flow at an early
water cut.
Keeping higher loss in production in mind and since no sand production has been
observed from the well testing it is proposed to live with sand or not to install
sand exclusion. However a strategy will be developed for the wells prone to sand
production such as to:
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Table 5.15: Summary: Production Profile Natural Flow Vs. Gas Lift
Injection (Water Cut)
Many crude oils will form a solid precipitate when they are cooled. This solid
is known as WAX. Wax varies in the form of soft to a brittle solid. The solid
wax is dissolved in the crude oil at reservoir temperature and forms a
crystalline precipitate when the temperature reduces below the cloud point
(The temperature at which the first seed crystal appear). Since pour point data
is not available for Gelama Merah field it is therefore suggested that analysis
of the fluid sample be carried out to observe the tendency for wax deposition.
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However, Provision of injection points for pour point depressant (PPD) and
wax dispersant shall be provided at the production header and at the pipeline
launcher to allow contingency action in case wax deposition is observed to
have occurred.
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