Escolar Documentos
Profissional Documentos
Cultura Documentos
Tor Ellis
Marathon Petroleum Company (Norway) LLC
Stavanger, Norway
Alpay Erkal
Houston, Texas, USA
Gordon Goh
Kuala Lumpur, Malaysia
Timo Jokela
Svein Kvernstuen
Edmund Leung
Terje Moen
Francisco Porturas
Torger Skillingstad
Paul B. Vorkinn
Stavanger, Norway
Anne Gerd Raffn
Abingdon, England
Heel
Toe
> Heel-toe effect. Pressure losses along a horizontal wellbore in a homogeneous formation cause the
flowing tubing pressure to be lower at the wells heel than at the toe. In time, and long before oil (green) from
sections near the toe arrives at the wellbore, water (blue) or gas (red) is drawn to the heel (top), resulting
in an early end to the wells productive life. Inflow control devices inside sand screen assemblies equalize
the pressure drop along the entire length of the wellbore, promoting uniform flow of oil and gas through the
formation (bottom) so that the arrivals of water and gas are delayed and simultaneous.
30
Oilfield Review
Winter 2009/2010
Nozzle-Type ICD
Helical-Channel ICD
> Leading ICD types. Fluid from the formation (red arrows) flows through multiple
screen layers mounted on an inner jacket, and along the annulus between the
solid basepipe and the screens. It then enters the production tubing through
a restriction in the case of nozzle- and orifice-based tools (top), or through a
tortuous pathway in the case of helical- and tube-based devices (bottom).
rates but higher cumulative oil recovery. However, ated wells and in several types of reservoirs.4
this simple solution generally does not work in These devices are usually part of openhole comwells drilled at high angles.
pletions that also include sand screens. In addiIn wells completed with intelligent technol- tion, ICD completions often use packers to
ogy, operators may shut off or reduce flow from segment the wellbore at points of large permeaoffending zones using remotely actuated down- bility contrast. This strategy combats water conhole valves. But horizontal wells designed to opti- ing or gas cresting through fractured zones, halts
mize reservoir exposure are often poor candidates annular flow between compartments and allows
for such strategies. Extremely long wells often for isolation of potential wet zones.
have many zones. The limit on the number of
ICDs are also effective in reservoirs where
wellhead penetrations available may render it their ability to regulate inflow rates creates a sufimpossible to deploy enough downhole control ficient pressure drop at the toe of the wellbore
valves to be effective.3 Additionally, such comple- for the reservoir fluid to flow or lift filtercake and
tions are expensive, complex and fraught with other solids to the surface.
This article describes various ICD designs
risk when installed in long, high-angle sections.
As a consequence, operators often choose to and how they are modeled to suit particular
produce these multiple-zone wells using isolating applications. Case histories from Asia, the North
devices such as swellable packers. To mitigate Sea and the Middle East illustrate how these pasOSWIN09/10Rick, story #2Figure 03
crossflow and to promote uniform flow through the sive devices enable operators to increase well life
reservoir, they have turned to passive inflow control and ultimate recovery.
devices (ICDs) in combination with swellable packers. By restraining, or normalizing, flow through Velocity Control
high-rate sections, ICDs create higher drawdown Inflow control devices are included in the hardpressures and thus higher flow rates along the bore- ware placed at the formation/borehole interface.
hole sections that are more resistant to flow. This They use a variety of flow-through configurations
corrects uneven flow caused by the heel-toe effect including nozzles, tubes and labyrinth helical
channels (above). These devices are intended to
and heterogeneous permeability.
Whether intended for injection or production, balance the wells inflow profile and minimize
ICDs have applications in horizontal and devi- annular flow at the cost of a limited, additional
31
12
10
8
6
4
2
0
Heel
Measured depth
Toe
> Reducing the influence of high-flow-rate areas. In a heterogeneous model ICDs reduced the fluid
inflow rate (blue) at the heel (within orange circle) to half that predicted for a screen-only completion
(red). However, they increased the inflow rate from the lower two-thirds of the well (within green oval)
including the toe.
32
Oilfield Review
Winter 2009/2010
Oil Rate,
bbl/d
Gas Rate,
Mcf/d
Water Rate,
bbl/d
Water Cut,
%
BHP,
psi
698
2,411
23.7
3,794
798
1,263
12.5
3,752
837
762
7.6
3,740
Open hole
7,759
3 x 4 mm, second joint
8,821
3 x 4 mm, joint
9,290
The wells were part of a second-stage development of a mature field; challenges included a
stacked sand reservoir with uncertain dips and
unconsolidated sands. The company also sought
to avoid formation damage during drilling, minimize drilling costs, and maximize production and
drainage of remaining reserves while minimizing
water cut.7
While the horizontal well option was less
costly than an alternative plan that included
drilling three deviated wells, it was technically
more challenging. It required one 2,000-ft
Gas zone
000
4,
Oil zone
Water zone
3,875
A
B
,75
750
ft
2,500
> Well placement. As part of an ongoing field expansion, this small area within a field offshore Malaysia
was targeted for development using one 2,000-ft lateral (A) and one 1,000-ft lateral (B). The thin oil rim
(green) is bounded by a strong waterdrive (blue) and a gas cap (red).Depth contours are labeled in
feet. (Adapted from Maggs et al, reference 7.)
33
Vilje
Production line
Gas lift line
East Kameleon
Alvheim FPSO
Water injection
and disposal line
Umbilical
East riser
base
West riser
base
Kneler A
South
riser base
Boa
Kneler B
Volund
> Layout of Alvheim and Volund fields in the Norwegian area of the North Sea. [Courtesy of Marathon
Petroleum Company (Norway) LLC.]
Production from both wells compared favorably with that from other deviated wells in the
area drilled conventionally through the stacked
sands of the field. However, even including costs
of the additional technologyrotary steering system, LWD and ResFlow ICDsthe overall project
cost was 15% less than it would have been using
traditional well construction methods. In addition, increased sweep efficiency gained by well
placement and ICDs has increased the asset value
by an estimated 100,000 bbl [16,000 m3] of oil.
30,000
25,000
80
70
60
20,000
50
15,000
40
30
10,000
Water cut, %
20
5,000
0
Jun 16,
2008
10
Aug 08,
2008
Sept 24,
2008
Nov 13,
2008
Jan 02,
2009
Feb 21,
2009
Apr 12,
2009
Jun 01,
2009
Jul 21,
2009
Sept 09,
2009
Date
> Production improvements. In Well 24/6-B-1CH of the Alvheim field, the 13-m oil column with an active
aquifer was produced at a higher drawdown than originally planned. As shown in the graph, the
resulting higher production volumes were achieved without significantly increasing water cut over
predicted values, which is indicative, if not conclusive, that an even inflow profile was achieved.
34
Critical Components
Besides their ability to enhance drainage efficiency and boost cumulative oil recovery, ICDs
offer the industry relatively inexpensive, low-risk
components for technology-driven strategies. They
can be easily added to development programs that
include sand control and horizontal wells.
In the Norwegian sector of the North Sea, engineers at Marathon Petroleum Company (Norway)
LLC concluded that the recoverable reserves in
the relatively thin oil columns of the Alvheim and
Volund fields were directly and consistently linked
to the amount of net pay exposed to the wellbore
(left). To establish maximum contact, Marathon
therefore drilled single-, dual- and trilateral wells
with horizontal sections ranging in length from
1,082 to 2,332 m [3,550 to 7,651ft].
The Marathon team realized that to fully
exploit the benefits of the correlation of recoverable reserves to net feet of reservoir contact, it was
important that the entire length of the completions contribute to production. Early in the project
they decided to use both ResFlow nozzle-type ICDs
and helical-type ICDs in all production wellsa
total of 10 wells at Alvheim and 1 at Volund.
As a result of this technology-based approach
and the favorable geology, Marathon has increased
its booked reserves at Alvheim from 147 million
to 201 million bbl [23 million to 32 million m3]
of oil and from 196 to 269 Bcf [5.5 billion to
7.6 billion m3] of gas.
The fields have been in production less than
two years, and the completions include numerous
technologies, making it difficult to attribute
specific results to a single methodology. However,
overall water production at the Alvheim floating,
production, storage and offloading (FPSO) facility
is less than originally expected. A good example is
the 24/6-B-1CH well, which has a 13-m [43-ft] oil
column and an active aquifer. The well has been
produced at higher rates than originally planned
without significant onset of, or increase in, water
production (left). Both these outcomes, though
their causes are inconclusive, suggest ICD success
in maintaining an even flow profile.
When one completion planned as a single lateral evolved to a trilateral, engineers also learned
a valuable lesson concerning planning for the use
of ICDs and multilateral installations. Because
the actual completion departed from the original
plan, the flow rate was different than predicted.
The ICDs chosen for these installations were of a
design type that could not be readily changed,
and thus optimized, on location. The result was
gas and water coning earlier than expected in
both laterals.
Oilfield Review
Winter 2009/2010
Heel
Toe
Measured depth
1 ICD
ICD
1 ICD
2 ICDs
Swellable packer
2 ICDs
3 ICDs
3 ICDs
4 ICDs
5 ICDs
> Inflow profile from production log measurements. After installation of ICDs and swellable packers,
production logging tools were run to acquire an inflow profile along the length of the well at low,
medium and high flow rates. The inflow profile shown was obtained with the well flowing at the
medium rate. Crossflow evident in earlier logs has been eliminated and flow contribution is evident
from the entire lateral. The actual inflow profile (green) was very close to the simulated one (red).
(Adapted from Krinis et al, reference 8.)
10,000
9,000
8,000
Production rate, bbl/d
A Clean Start
Predictably, it has been observed that the difference in pressure drops between the heel and toe
caused by friction losses in an openhole horizontal well increases with wellbore length. This
disparity can lead to the filtercake being preferentially lifted from the wellbore wall at the heel
and to poor inflow performance caused by correspondingly higher skin at the toe.
Studies have shown that in relatively highpermeability environments, the best cleanup
resultsremoval of filtercake after drilling or
completionare obtained through proper chemical treatment and extended flowback with high
rates.11 In 2006 Saudi Aramco completed two test
wells equipped with ICD systems, one in a sandstone formation and the other in carbonate rock.
In the sandstone there were concerns over water
and gas coning through high-permeability
streaks, and the operator sought to decrease the
impact of the heel-toe effect to improve cleanup
and sweep efficiency. The 8-in. openhole completion included 5-in. screens with ResFlow
ICD nozzles on every joint of tubing. For compartmentalization and better inflow control, small,
swellable elastomer packers were placed on
every second joint. The horizontal section was
2,540 ft [775 m] long.
Production, bbl/d
7,000
6,000
5,000
4,000
3,000
2,000
1,000
0
9,000
9,300
9,600
9,900
> Cleanup through higher rates. After the logging tool failed to reach TD and
log data indicated no production contribution from the toe after an initial flow
period of 4 months (red), the rate was increased to about 9,000 to 10,000 bbl/d
for 4 h and the production log was rerun. Log data yielded an improved flow
profile, and the tool was able to travel an additional 350 ft (gray). Four hours
later, the logging tool was run to within 50 ft of TD (green). The rate was
returned to about 6,000 to 7,000 bbl/d, and log data demonstrated a permanent
change had been made to the inflow profile (blue). (Adapted from Sunbul et al,
reference12.)
8. Krinis D, Hembling D, Al-Dawood N, Al-Qatari S,
Simonian S and Salerno G: Optimizing Horizontal Well
Performance in Nonuniform Pressure Environments
Using Passive Inflow Control Devices, paper OTC 20129,
presented at the Offshore Technology Conference,
Houston, May 47, 2009.
9. Krinis et al, reference 8.
35
Standard
Screen
Zone 1
800 to 1,800 mD
5,800
ICD with
ICD with
Target Rate,
Same Nozzle
Different
m3/d
Size, 1.2
Configuration
cm/joint,
in All Zones Nozzle Size
4,604
3,570
3,500
0.9 cm/joint
Zone 2
200 to 500 mD
748
1,233
Zone 3
100 to 2,000 mD
961
1,677
820
800
0.7 cm/joint
3,128
3,200
2.2 cm/joint
3
7,509
7,514
7,518
7,500
> Optimizing injector ICD design. The injection rates used in the different
completion scenarios of the Str structure demonstrate that the injectors
can be optimized based on permeability and nozzle design to obtain the
desired rates in each zone. (Adapted from Raffn et al, reference 13.)
Engineers suspected that the higher rates designing injection projects must consider perrequired to clean up the entire production interval meability contrasts, heel-toe effect, formation
had exacerbated the heel-toe effect in the tradi- damage, creation of thief zones and injectivity
tional openhole completions. Modelers matched changes at the wellbore.13
the production log data to a static reservoir simuJust as they do with inflow control, ICDs
lation and replaced the ICD completion in the address these challenges by balancing fluid outsimulation with a standard screen completion. flow along the entire length of the injection wellThey then increased the rate in the standard bore. If the well has a high-permeability streak,
screen completion to 15,000 bbl/d [2,400 m3/d].
the ICD self-regulating feature prevents a signifiThat simulation indicated an extreme heel- cant increase of local injection rate. This ability
toe effect: The toe was contributing only 25% as to automatically control fluid mobility results in
much production as the heel. By contrast, simu- better water distribution and pressure support
lated ICD completions with 15,000-bbl/d rates and thus enhanced areal and vertical sweep of oil
showed better balance of the inflow, including reserves in all zones. It also delays water breakthrough, and because ICDs can control injection
much higher contribution from the toe.12
These findings are significant in that they pressure and rate, there is minimal risk of nearshow ICD completions allow extended well wellbore fracturing.
These capabilities matched the management
lengths in both these formations without compromising the balancing effect or cleanup efficiency goals of the Statoil team planning the 2004 develin the lower sections of the wells. That result opment of the Urd fielda satellite producing to
allows the operator to contact more formation the Norne FPSO vessel in the North Sea. Placed on
with fewer wellbores without fear of sacrificing production in 2005, the Urd oil field contains two
heterogeneous structures: Svale and Str, which
cumulative production.
OSWIN09/10Rick, story
12 and 5.6 mi], respectively, from
are 4#2Figure
and 9 km [2.5
the main field. The field was developed using three
Reversing Direction
Though they are called inflow control devices, subsea templates and pipelines for oil production,
ICDs are also used to manage fluid outflow in water injection and gas lift. Management goals for
injection wells. In some cases modeling reveals the ICD injection system included
that it is more effective to place ICDs in the injec- optimizing pressure support and sweep efficiency for all zones
tor well than in the producer. And in many
instances installing the devices in both the injec- delaying water breakthrough in high-permeability connected zones
tor and producer wells is the best option.
Injector wells often penetrate and give pres- avoiding fractures that may dominate water
distribution.
sure support to several reservoir intervals with
The Str structure was completed with one
varying characteristics. To avoid water breakthrough at production wells, reservoir engineers injector containing ICDs and two horizontal oil
producers containing intelligent technology for
control of three zones. The reservoir is divided
36
Oilfield Review
Winter 2009/2010
Production history
Modeled standard completion,
high-permeability channels
Modeled standard completion,
no high-permeability channels
80
70
60
Water cut, %
50
40
30
20
10
0
200,000
400,000
600,000
Cumulative oil production, m3
800,000
1,000,000
> Water-cut models. For the most part, the actual water cut in this well was
lower than predicted by either model. Though the field is in early production,
the improved numbers may reflect enhanced sweep achieved by the use of
ICDs. (Adapted from Raffn et al, reference 13.)
In an effort to better understand SAGD production and find more efficient solutions to its
challenges, Chevron has constructed a surface
horizontal steam-injection facility at its Kern
River field near Bakersfield, California, USA.
Researchers there are focusing on evaluation and
deployment of equipment for accurate and reliable steam placement along laterals in horizontal
injection wells to improve recovery.17
Their proliferation in recent years is testimony to the effectiveness of ICDs. Use of ICDs
has allowed operators to realize full value from
the ability to drill long laterals, thereby exposing
large volumes of the reservoir to the wellbore. In
fact it can be argued that inefficient drainage
owing to uneven flow through the reservoir
threatened to impose economic limits on wellbore length that were far short of the technical
limits. Todays lengths are measured in kilomeOSWIN09/10Rick, story #2Figure 13
ters rather than in meters, as they were less than
a decade ago.
RvF
37