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SPE 16932
This paper was prepared for presentation at the 62nd Annual Technical Conference and Exhibition of the Society of Petroleum Engineers held in
Dallas, TX September 27-30, 1987.
This paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the
author(s). Contents of the paper, as presented, have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the
author(s). The material, as presented, does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or members. Papers
presented at SPE meetings are subject to publication review by Editorial Committees of the Society of Petroleum Engineers. Permission to copy is
restricted to an abstract of not more than 300 words. Illustrations may not be copied. The abstract should contain conspicuous acknowledgment of
II
where and by whom the paper is presented. Write Publications Manager, SPE, P.O. Box 833836, Richardson, TX 75083-3836. Telex, 730989 SPEDAL.
529
2 RECOMPLETION WORKOVER PROGRAM AT THE KUPARUK RIVER FIELD SPE 16932
The 11 A11 Sand is fine to very-fine grained, well (240 kg/m 3 ~ increasing to a final stage of 10 lbm/~al
sorted, interbedded with sha 1es, and cemented by (1200 kg/m ) in increments of 1 lbm/gal (120 kg/m ).
quartz and varying amounts of ankerite 5 . Hydraulic Intermediate strength proppants are also used more
fracture treatment is used to correct damage incurred frequently due to the need for maximum fracture
during drilling and completion operations. conductivity.
The middle zone ( 11 811 Sand) is typically non-productive GAS INJECTION MANAGEMENT
and made up of sands, siltstones, and shales rangigg
in gross thickness from 10 to 150 ft (3 to 46 m) • Approximately 250 million scf/D (7.1 X 10 6 std m3/d}
This zone isolates the more productive 11 A11 and 11 C11 of produced gas is reinjected into the oil rim on the
Sands allowing separate zone management to maximize eastern and western edges of the field. The 11 C11 Sand
recovery. The 11 811 Sand also provides a vertical is used for this purpose because of its higher
barrier to 11 A11 Sand hydraulic fractures preventing injectivity thereby 1 imiting the number of injection
undesirable communication between the 11 A11 and 11 C11 wells required. The selective single allows gas
Sands. injection to be restricted to the "C" Sand while pre-
serving low gas/oil ratios (GOR) in the 11 A11 Sand.
The formation parting pressure of the 11 C11 Sand is
typically less than the 11 A11 Sand. In addition, the Field oil rate is currently limited by the gas
highly-permeable 11 C11 Sand acts as a thief zone during handling capacity of the surface facilities. High-GOR
stimulation. This prevents successful 11 A11 Sand C Sands near the inj~ction areas must be shut-in to
11 11
fracture treatment in a single completion using a meet facility gas limits. The selective single allows
common wellbore. Completions progressed to the low GOR 11 A11 Sand production to continue after shut-
current selective single designs using either gas lift ting-in the "C 11 Sand. The gas affected "C" Sand areas
mandrels or a ported flow nipple (Figure 2) across the will be produced at a future date to meet field fuel
C Sand. These systems allow 11 A11 Sand fracture
11 11
needs and lift gas demands.
treatment to correct damage incurred during drilling
and completion. Gas injection in the "A" Sand was recently implemented
as part of an immiscible water-alternating-gas (WAG)
Production and spinner logs indicated inadequate 11 A11 injection process to improve waterfl ood sweep effi-
Sand depletion and water injection in the unfractured ciency. The "A" Sand permeability is lower and more
single completions. This was alarming since the 11 A11 uniformly distributed which will delay gas break-
Sand contained the majority of reserves. A recom- through compared to the "C 11 Sand. Gas production at
pletion workover program was initiated in 1984 to offset wells will be deferred until a later time when
improve 11 A11 Sand rates. The primary objective of higher GOR production can be handled. Gas break-
recompletion was to isolate the 11 A11 Sand for fracture through from WAG can actually improve tubing hydrau-
treatment. Resulting secondary benefits include·d 1 ics by providing in-situ gas to help 1 ift higher
enhanced reservoir management. To date, 86 recom- water/oil ratios (WOR).
pletions have been performed (Figure 3}. The single
completion ·is still used where the 11 C11 Sand is The selective single allows current WAG injection to
non-existent or of marginal thickness as in the be limited to the "A" Sand while continuing "C 11 Sand
peripheral areas of the field. waterflood on the same drill sites by shutting-in the
"C" Sand during the gas injection cycle. Future "C"
STIMULATION RESULTS Sand WAG injection can be implemented when desired.
The primary objective for recompletion to a selective Enhanced oil recovery projects under consideration
single was the ability to hydraulically fracture the include the injection of miscible gas through a WAG
A Sand and improve production or injection rate.
11 11
injection process. Recompletion workovers were
Historical pre and post-fracture 11 A11 Sand rates for 69 performed on some injectors to provide 11 A11 Sand
recompleted wells are shown in Figure 4. Average repressuri zati on needed to achi eve the required
post-fract~re A Sand rate for producers was 355
11 11
miscibility pressure at project start-up in 1988.
BOPD (56 m /d oil) which is a 370% in3rease above the Wellhead equipment rated for 3000 psi (21 MPa) was
pre-fracture rate of 95 BOPD (15 m /d oil). This also upgraded for 5000 psi (34 MPa) service. Conven-
agreed with th5 369% increase observed field wide in tional 8-round tubing couplings were replaced with
264 treatments • 11 A11 Sand water injection increased AS-modified to minimize potential leakage under
2~0% from an average pre-fract~re rate of 309 BWPD (49 high-pressure gas injection.
m /d water) to 906 BWPD (144 m /d water).
WATERFLOOD MANAGEMENT
Th~ treatments are currently designed to provide
highly conductive fractures with half lengths of 80 ft The higher permeability of the "C 11 Sand will acceler-
(24 m). Job size is limited to contain 11 A11 Sand ate uneconomic water production requiring high;.WOR "C"
fracture growth within the 11 811 Sand • Larger jobs Sand zones to be shut-in earlier than the "A" Sand.
might provide undesirable communication between the The selective single can be used to restrict "C" Sand
A and 11 C11 Sands.
11 11
. injection or production using ported orifices without
detriment to "A" Sand rates. Lost 11 C11 Sand production
A Sand fracture treatme11ts have progressed to the
11 11
must be offset by reduced operating costs and the
current pump schedule shown in Table 1 u5ing 20/40 incremental "A" Sand oil rate gained. Mechanical and
mesh proppant and a gelled diesel carrier . Gelled reservoir problems assoc~ated with water production
water presented an operational risk due to freezing. can include the following :
Recent jobs have eliminated the 100 mesh as a fluid
loss additive in order to maximize fracture * Reduced "A" Sand oi 1 rate due to increased
conductivity. Proppant stages now start at 2 lbm/gal bottomhole flowing pressures from unfavorable
530
SPE 16932 G. S. WOODLING 3
tubing hydraulics (high liquid rates and water * Ported flow nipple - 85 wells
cut.)
*Sliding sleeve - 2 wells
* Shortened life of surface and sub-surface equipment
due to scale and corrosion. * Waterflood mandrels - 1 well
* Increased costs for produced water processing and Gas lift mandrels with circulating valves account for
reinjection. the majority of selective single designs. Early wells
used 1 in. ( 2. 5 em) va 1ves camp a red to the current
* Increased gas-lift requirements and costs. 1-1/2 in. valve (3.8 em). The larger circulating
valve provides more cross-sectional flow area to
* Potential formation sand production. minimize valve erosion. Typical tubing size is 3-1/2
in. (8.9 em). However, a limited number of wells have
Ported orifices across the 11 C11 Sand can also be used 2-7/8 in. (7.3 em) tubing to accommodate reduced
to increase the bottomhole injection pressure for the production rates.
11
A11 Sand which has a higher formation parting pres-
sure. Current completions use a ported flow nipple across
the 11 C11 Sand which can be opened or closed by running
COMPLETION TRADEOFFS a commingling or blanking sleeve. This design re-
quires a 2-7/8 in. (7.3 em) tubing tail with landing
The flexibility provided by the selective single nipple for blanking off the 11 A11 Sand. A smaller
requires additional investment and operating expenses. landing nipple is used to receive a blanking plug run
Incremental cost for a selective single is approxi- through the restricted diameter of the 11 C11 Sand sleeve
mately $150,000 above a single completion in a newly as shown in Figure 2. A 1 in. (2.5 em) gas lift
drilled well. This increase includes additional rig mandrel is also used above the blast rings to equalize
time to run the more-complex hardware. Incremental pressures before opening the 11 C11 Sand with a
annual operating expense is $10,000 to $15,000 greater commingling sleeve.
·than a single completion based on the following:
Other completion systems under evaluation include
* Additional wireline activity to open or close sliding sleeves and waterflood mandrels. Both designs
sands. maintain a full 3-1/2 in. (8.9 em) tubing diameter
which simplifies wireline operations. The sliding
* Routine wireline inspection or replacement of 11 C11 sleeve may be more susceptible to mechanical failure
Sand completion equipment (circulating valves, from scale and corrosion due to the inability to
orifices, commingling sleeve, etc.) damaged by scale replace critical moving parts. Waterflood mandrels in
or eros ion. injection wells reduce casing erosion due to the
vertical discharge of injection parallel to the
* Increased fishing likelihood due to additional casing.
wireline activity and completion complexity.
Carbide blast rings are typically installed on the
Negative operational aspects of the selective single tubing across the 11 C11 Sand with a 5 ft ( 1. 5 m) overlap
also include the following: for tubing protection. High-GOR production with
entrained sand caused eros i ana 1 damage to the tubing
* Inability to reperforate the 11 C11 Sand. in as little as several days in some Kuparuk produc-
ers. Conventional steel blast joints did not provide
*Reduced stimulation flexibility for the 11 C11 Sand the desired service life (1-month failure in some
(e.g. risk of dropping fracture proppant above the cases). Injection wells may also need to be 11 back
packer). fl owed 11 on occasion which will require tubing pro-
tection. However conventional steel blast joints may
* Deposition of debris above the packer during normal be used for this limited service.
C Sand production or injection.
11 11
531
4 RECOMPLETION WORKOVER PROGRAM AT THE KUPARUK RIVER FIELD SPE 16932
Cost distributions for workovers and fracture treat- lengthy payout. However, injection workovers typical-
ments were determined using a 1987 index normalized ly provide additional reserves compared to the simple
for cost reduction trends. Distributions are shown in rate acceleration of most production workovers.
Figures 6 and 7 for workover and fracture costs, Additional recovery can result from production
respectively. Average workover cost was $613,000 with workovers where fracture treatments communicate
fracture costs averaging $49,000. previously undrained zones with the wellbore improving
waterflood conformance.
The distributions show the risk of cost over-runs for
each operation. Typical unforeseen workover problems Workovers of direct-line-drive Kuparu~ i~ectors were
include fishing of lost tools, milling on stuck analyzed using the 320-acre (1295 X 10 m ) waterflood
equipment, cement squeezes, lost circulation, and pattern shown in Figure 8. A Sand waterfl ood
11 11
other well control problems. Fracture cost over-runs recovery (% OOIP) as a function of pattern displace-
typically involved a coiled-tubing clean-out after a able hydrocarbon pore volume injected (DHPV) was
screen-out. Contingency funding should consider the determined through reservoir simulation (Figure 9)
probabilities identified in Figures 6 and 7. using a 3D areal model.
WORKOVER FLU IDS Ultimate waterflood recovery was predicted to decrease
with prolonged primary depletion as shown in Figure 9.
Early ~ecompletions using bentonite (bland mud) as a This is due to reduced waterflood sweep from an
workover fluid resulted in significant fluid loss and increase in oil viscosity and oil shrinkage during
C Sand rate damage. Hydrochloric acid treatment did primary depletion. Ultimate pattern recovery is shown
11 11
not return 11 C11 Sand rates to pre-workover levels. in Figure 10 as a function of reservoir drawdown below
11
Mud acid 11 treatments using hydrofluoric acid were not the bubble point pressure. Material balance techniques
recommended in the C Sand due to an abundance of were used to predict future pattern pressures
11 11
532
SPE 16932 G. S. WOODLING 5
533
SP-E 16 9 32
TABLE 1- Typical Gelled Diesel, 20/40 Mesh, "A" Sand Fracture Design.
GD = gelled diesel
PPG = lbs per gallon
BPM = bbls per minute
1000 ZONE
534
r
x = SINGLE COMPLETION
o = SELECTIVE-SINGLE
• = RECOMPLETJON WORKOVER
mm m
X X X X
X X X X
CPF =CENTRAL PROCESSING FACILITY
16" SURFACE CONDUCTOR 80' X X X X CPF-3
X 0 AREA
B-SURFACE SAFETY VALVE 2000' X X X X
+--+"vt-+ 9-5/8" INTERMEDIATE CASING3500'
xxoxxX
~
X X X
• LEGEND: LEGEND:
3'
~ 1500 e WORKOVER
~
~
•
•
t:,. ~~T_Ef3Jf:!J..:_
;}:
{/)
a .~----·--------·-····· t:,. [f!_A_C]fdfi£;_-
....,. ..··~' .. . ,~ .
/:,. ../:,. <: ' :.
1000 , __ J..! ................
-----·•·"'~·-----···--·--
1200 • : • •
~
'<:(
{/)
, , , , ' ' /:,. :::::>
~ I
,~
0 •:. ... -8%/YR
2: e• • :: : DECREASE
LLJ
Q::
900 '--- : : :
::::J ~ : : :
~- :~~"'tffz-
~<!""·~·"! ~---n-~----:ZS.~-.6
1-- co
(_)
~
"'l:: 100
e:I 600 -~
f-.
{/)
--···--M£.--A-.DCI IE-!:!.&---
+:;············· , , .................... .
-28%/YR
1--
(/)
0
()
---,n, 6
/:,. '0
'
, _ /:,. 6 !'
'
'
;
'
'
DECREASE
() 300 '
'
'
' .'
'
' '
Q '
'
'
''
'
'
10+---------~----------~----------+---------~
300 600 900 1200 1500 1800 2100 2400 m~ 1985 1986 1987 1988
PRE -FRACTURE RATE (STB/D)
YEAR
Fig. 4-Pre- and post-fracture "A" sand rates.
Fig. 5-Workover and "A" sand fracture cost trends.
"'
c.:>
"'
25,----------------------------------------------, 35
JO-
20-
-:---.. 25
~
"-..:.- ~
'-...:..
15-
>-
(_) >- 20-
(_)
~ ~
::::J ::::J
8 70-
8 15-1
~~
e: ~~
e: 10
(-,
5-
~
0 .
0 200 400 600 800 1000 -~
1200 7400 7600
0,
0 20 40 60 80
~
100 720
......
0'
WORKOVER COST in 1987$ (THOUSANDS $) FRACTURE COST in 1987$ (THOUSANDS $) ....0
Fig. 6-Workover cost distribution in 1987 dollars.
Fig. 7-"A" sand fracture cost distribution in 1987 dollars. ~
rv
40,-------------------------------------------~
CL'
~ 301 /?:~. ~
NOMINAL 30% RECOVERY
0
injector •
producer
0
injector •
producer
0
injector
>-
BS ~-
,~- -·························II
I
>
0
0
injector •
producer
0
iniA~tor •
producer
0
injector
<:
a:::
~
1--
10
en
""
..... 40~-----------------------------------
600~------:-----~------~--------------
LEGEND:
CL' •
I'\ '
a0 -::--. 500
a
.............. ·,· ·,·
I:\
~- ............. ·:· .................... . 0
: PRE-FRAC
30·~-=-==-=.=..:e'-=-=e- . NOMINAL 30% RECOVERY Q 1 ; '· ; .6. POST -FRAC
-QQ_f;E_i_f!~~~r~
\.f "i"j / \·\.......... j..................................
~
-.......:.-
·----==-=·----·-- ---- 0
:............... ..
X
>-
BS
>
---· ~ 400~ .......... .
Lu
1-- J I.!. ....,,.\.\. ...... .::. ................................::............... ..
~
•
-~
\ •
-~
. .
0
(_) 20 ~ 300 ..............
Lu ..._j
a::: 6
a
..._j
<:
200
/1.. ...........
~
\\. 1 \~<'t'"'''"""''''
1
.................l................ .
<: BS
1--
a::: 10 1-- '~~ ::
~
:-.;.
1--
~ 100 ... ·~'~<-- -~ .
~
0~--~----~--~----~--~----~--~--~
0 200 400 600 BOO 1000 1200 1400 1600
01---------~--------~--------~------~--------~
1980 1990 2000 2010 2020 2030 ~
PATTERN PRESSURE LOSS BELOW BUBBLE POINT (psi)
Fig. 10-Lost "A" sand oil recovery due to reservoir pressure drawdown below the bubblepoint.
YEAR
Fig. 11-Typical "A" sand oil rate prediction during an injection workover evaluation.
.....
0'
~
\.N
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