SPE 28836
Montrose: A case study of innovative, cost effective field rejuvenation
I.J.Andrewsand E.R.Hennington,Amoco (UK) Exploration Co.
SPE Members
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Since 1992,Montrose, a mature waterflood field, has been
rejuvenatedthrough a multi-disciplinaryfill field re-
evaluation and the innovative, cost effective applicationof
completiontechnology. Workoveropportunitiesand areas of
potentially incompleterecovery, have been identifiedby the
fill integrationof all field performance, reservoir and
geological data. Then workovers incorporating innovativecost
et%dive gaslifthelocity string completions,which addressed
the concerns of weak and potentially non gas-tight casing,
were carried out to rejuvenate the field.
This multidkciplinsry team approach to the rejuvenation of
the Montrose field, has significantly increased field wide
production rates, and dramaticallyreduced production costs
per bad, so allowing economic production in today’slow oil
price environment and the fulfillment of the fields long term
po’~iitial.
In addition the study has identified many techniques/lessons
that can be readily applied to other similar mature field
studies.
The Montrosefiel~ located approximately 130 miles East of
Aberdeen, was discovered in 1971 with the drilling of well
22/18-2, and appraised with one fbrther weii 22/i7-l in i972,
which Confined the potential for the field. An eight legged
drilling/productionplatform was later installed in 1975,
leading to fmt oil production in June 1976.Though initial
production was purely *m naturally flowing wells, risiig
held in Lc#ka, U.K., SS-27 Octcar 19S4.
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watercuts and falling reservoir pressures soon led to the
maintenanceof production with Electrical SubmersiblePumps
(ESP’s)of which 156had been installedby the end of 1992,
and afield wide policy of pressure maintenancethrough water
injection.This however has not been without significantcost
due to continuousESP changeout workovers and multiple
casing collapses.To date 83 MMBBLSof the 232 MMBBL
STOOIP,has been produced ftom 22 wells, with peak
production occumingin 1979 at rates in excess of 37000 bopd.
In 1989work commencedon platform modificationsthat
would allow the Arbroath field to be brought on-line as a
satellite of the Montrose field. As such, a strategic move was
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the Montrose field through the non-availabilityof certain
facilities (especiallycontinuous use of a full drilling/workover
rig), and open up new opportunitiesthrough lower operating
costs and the availabilityof gas compression.Although it was
tiltially anticipatedthat there would only be a minii impact
upon Montroseproduction, an ever expsndmg workacope
eventually Ied to the total loss of all rig availability fi’omApril
1989to Aug 1993 (with the exception of one short period in
early 1992).With the average mnlife of Montrose ESP
completionsbeing +/-200 days, this rapidly led to the field
becdi~ ~MV~i~ dCrm-. ..t *T
. . . . I*
. i ~~~ ~0 rn.id iW3 ,
At this stage the field had many problems largely associated
with its mature age md extended shut-down, i.e. all ESPSin
the field had fiild so all wells bar one which was flowing
naturally, were shut-in. Most of the wells also had weakened,
non-gas tight casingwhich had not been designed to ‘beused
with any artificial litt system. Further, a reduced size
replacement living qwuters meant that sustained continuous
rig operation was no longer a viable option.
319
2 MONTROSE: A CASE STUDY OF INNOVATIVE ,COST EFFECTIVE FIELD REJUVENATION
From the field managementperspective,the geological model
of the field was known to be flawed, the field databaseswere
often incomplete,and to compound the problem fiuther, low
oil prices were severely impacting the economicsof how ESP
operationswere historically handled.
Howeverthe opportunity was there and to this end, a major
field evrduationwas initiated to fimdamentallyreview the
production strategy for Montrose,to reassess all remaining
reserves, identify upside potential, and the most cost effective
manner in which to rejuvenate the field. This paper documents
the methods, procedures and techniquesthat were used to
achieve this field rejuvenation.
Initial planning for the field rejuvenation called for a full field
re-evaluationwith the following objectives/ stages:
1. A complete review, update and quality check of all
databases,thus ensuring that the data used was of known
quality and where sub standard data had to be used, due
allowancecould be made in the uncertaintiessurrounding
the interpretation.
2. Generation of a new geological field model, with the full
integrationof all geological,petrophysical,geophysical,
production and historical field data.
3. Identificationof all areas of economicallyrecoverable
hydrocmbons, inciuding areas ofpotentiai upskiehrked
oil.
4. Are-evaluation of production methods used on Montrose,
to identifi the best method for fiture production in light
of the new operating environment on Montrose.
5. Identificationof candidate wells and other value added
workover activity, to optimise recovery and long term
field value.
Database assimilation
The &abases in existence at the outset of the study varied
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rapidly showed that just because it is in existence does not
mean that it is usable. The problems were compounded by the
absenceof much of the raw data collected in early field life,
plus some incorrect interpretationand reporting. This was
typified in the reservoir pressure data which contained
ev~mg from good RFT da@ to 1 hr shut-in pressures
measured with gauges of dubious accuracy,none of which was
immediatelyidentifiable.It was obvious that no work could be
done with this dataae$which consequentlywas totally
320
SPE 28836
reworked to make the source and likely quality of all the data
identifiable. Similar exercises were carried out with all
reservoir, geological,geophysical and petrophysicaldatabases,
and though very time consuming was probably one of the most
useful and essentialparts of the study.
Lesson no 1: ensure all raw data is quality checked and stored
in a robust database.
Geological model generation
The need for an updated geologicalmodel was recognised, as
the developmentof the nearby Arbroath field had highlighted
a number of inconsistencieswithin the Montrose model.
As the dataset availableto build this model was large and of
varying quality, it was decided to use a multi-disciplinary
team approach using multiple techniques, where by
interpretationsand assumptionsmade could as far as possible
be cross checked. The key steps in building the new model for
the Montrose Field were as follows
(i) Analysis of biostratigraphicdata to correlate major
sequence boundariessuch as the Forties, Top Lists and Mid
Lista condensedhorizons. Where possible detailed quantitative
biostratigraphywas then used to further sub-divide the Forties
SandstoneMember. In wells with no biostratigraphydaw the
change in cuttings Iithologywas used (where possible)to
define the Lists/Sele formation boundary.
(ii) Repeat Formation Tester (R.FT)data and field pressure
historieswere used in conjunctionwith variances in PVT
properties, to compartmentalisethe field both vertically and
areally.
(iii) Gpen hole logs and core data (where available)were then
used to generate a lithostratigraphiccorrelation within the
constraints imposed by the pressure data and biostratigraphy.
Gne notable problem faced in incmporating the petrophysical
data at thii stage, was the regeneration of original water
saturationprofiles for post production wells with depleted
sections. While many methods were tried the most satisfactory
was found to be the regeneration of original Sw curves using a
function derived from capillary pressure data.
In this, capillary pressure data was utilised to generate a
relationshipbetween water saturation and heights above the oil
water contact. Ordinarily such an equation relates SW to
height above the oil water contact with permeability as a rock
property function. In this case though, due to a lack of core
permeabilitydata inmost wells and or a permeability function
in the MontroseFie14 such an equation was arranged with log
porosity as the rock propaty function.
 .
SPE28836 LJ.ANDREWS,
Once initially derived the equation was then calibrated in with
small adjustmentsto the contact angle, to finally arrive at the
following equation
13.872- (17.52 X@)
SW0.27 =
9.16 X I-@.07
‘where
Sw is water saturation - in fraction
@ is porosity - in fiction
H is height above oil water contact - in feet
The graphical representationof the above equation is
presented in Figure 1. Caution does need to be used in the
applicationof this function however, as it is facies sensitive.
(iv) Production data (e.g. production rates, DST%,timing of
water cut increases,water analysis results etc.) and production
logs, were added to the above lithostratigraphiccomelationto
test and further refine the establishedcorrelation, especially
within the pay section of the reservoir which is below the
resolution of present biostratigraphicmethods. For this it was
found to be especiallyusefid that all the data be presented in a
~iiigi~COiTdtitiijii paid.
(v) Maps created using the preliminary correlation above were
then further tested for accuracy by calibratingthe provisional
STOOIP figures against material balance calculations(which
are geologically independent)for each area of the field, The
material baiance figures were thus used as a final ‘checkin
balance’of the mapped volumes. If a large discrepancy
existed then the correlation was re-analysed for that area and
improvementsconsideredto achieve abetter fit.
Lesson N02: The in-depth nature of this study has highlighted
the need for quality &@ much of which can only be gathered
in early field life. i.e. it is critical to have a good distributed
core database from across the field as much of the later field
re-evaluationwork and some evolving technologies use core
da@ and so cannot be done without it. Similarly it is critical to
have good log and pressure data (NT or similar) in every
well.
Reaewe and upside identification
While reserve potential was largely assessedwith risk
weighted decline curves, upside potential was more difficult to
identiijiquantify. Tinefoiiowing two techniques‘Aoiigh-were
found to be particularly useful in identi~ing upside potential:
321
E.R.BENNINGTON 3
1. The use of material balance calculationsto provide a
geologically independentestimation of OOIP, aliowed cross-
checking and refinement of the field mapping away horn well
control, to produce high confidence volumetric. Where the
initial discrepancywas high, as in the East lobe of Montrose
with the material balance estimate some 35°%greater than the
volumetric mapping, then the presence of a field extension can
be established.Also once high confidence volumetric are
established,then high confidence recovery factors can be
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depletion policy, which merit further investigation.Through
these methods two major field extensions and one area of
particularly poor drainage were identified,with potential
additionalreserves of up to 10.3 MMSTB.
2. The close examinationof actual drive mechanismsthrough
material balance analysis and the tracking of water movemen~
to veri@consistencywith previous assumptionsand hence
previous depletion strategy, allowed wells and areas to be
examined on an individualbasis to see if all identified
hydrocarbon bearing sands were being filly depleted. In the
case of the Montrose field one well was identified as having
sands which were potentially not depleted, due to a bottom
water drive system having been historically assumed,yet no
rise in the OWC could be detected. The upside potential of this
layer if undepleted is 1.8 MMSTB.
Lesson N03: Material balance is an extremely powerfid tool
for mature field evaluation, as it is a minimum assumption
approach, is largely geologically independentand is no
respecter of previous field managementdoctrine.
Lesson lVo4: Ensure actual not assumed drive mechanismsand
there impact upon perforating/depletionpolicy are clearly
understood.
Workover candidate selection
With the installationof the Arbroath topside process plant
which included gas compressionfacilities,the oppcvtunitywas
at hand to dramaticallyreduce future operating expensesby
the conversionof Montrose wells to gaslitt and the elimination
of rdltiture ESP workovers.
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established,candkiateworkover wells with favorable
economicscould be selected.The fm primary tool used in
this process was risk weighted decline curves, which in the
absenceof a working/matchedreservoir model were used to
identi~ the potential reserves for each well in the field. ‘Ilk
could then be readily combined with provisional workover
costs to calcuiate the workover economicsfor any well, and at
the -e lime the wells be ranked in order of production/
shortestpayback as minimum payback period was an
important criterion. Secondly integrated productiotiwell
history plots (Figure 2) were closely examined for signs of

4 MONTROSE: A CASE STUDY OF INNOVATIVE,COST EFFECTIVE FIELD REJUVENATION
formation damage, layer flushing and injection breakthrough,
so that all additional value added activity i.e. water shutoffs,
could be identified and aetioned. With this approach, 11 out of
the 15 producing wells on Montrose were identified and
recommendedfor workover, although eventually due to time
constraints,only 10 wells were actually worked over.
In early 1993two Montrose wells had been identified as
having excessiveanmdus pressures. Following an engineering
review, the decision was taken to plug and abandon both
wells. This required mobilisation of the platform rig which
subsequently,made the gas-lift workovemeasier to justi~. On
the downsidethough, problems were being encounteredwith
compressoruptime, which further challengedthe operations
team to come up with a completion to maximiseproduction
under all conditions.
Lesson N05: Good integrated production/wellhistory plots are
a powerful tool, in the identificationof layer flushing, water
movement, formation damage and well potential.
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gas-lifi two primary design changes had to be implemented.A
new completion design incorporatinggas-litt had to be
installedin all of the workover candidates.Also, the top side
facilities had to be modified to rdlowhigh pressure Iitl gas to
be routed to each of the workover candidates.
+ Well Work
The workover team was tasked with providing a cost effkctive,
long term gas-lifi completion design as well as the actual
installationof the new completions, This offered several
challengesas the Montrosewells were old and not initially
designed for potential gas-lift. Design parameters included an
expected gas-lift pressure ranging tiom 1300psi to 1600psi
and individualwell rates of 3000 bpd with varying water cuts.
Also, logging accessto the perforations was considered
critical.
Both in-house and contractor nodal analysis was used to
confm correct tubing sizing. Although results indicated some
wells could potentially be restricted if 2-7/8” production
tubing was run in lieu of the field standard 3-1/2” tubing, they
also indicatedthat many of the wells would flow natarally
with the smaller size. As compressorrun time and available
lift gas were both in doub~ it was an easy decision to select the
option that provided some oil production without artificial Iifi.
This also opened other options to reduce costs in the overall
completion design.
None of the wells had 9-518”production casing strings which
incorporatedpremium connections.Also, due to numerous
ESP workovers involving multiple cleanouts and new pump
.
SPE 28836
installations,none of the wells were deemed to have
==pUble production casing integrity for gas-lifi purposes.
Therefore, a system had to be devised which would include a
new gas-lift anmdus. Due to previously anticipatedproblems
with the production casing strings, a general study had been
conductedto ensure the 7“ liners could be tied back to surface
without placing undue loads into the wellheadskonductors.
This work provided one option of isolating the unusable
9-5/8” casing. However, a simpler and less costly option
became availablewhen 2-7/8” OD tubing was selected for the
production siring. The 2-7/8” gas-lifi mandrels can be
manufacturedto an OD allowing them to fit inside 5-1/2”
tubing. Also, 5-1/2” tubing can be provided with special
clearance couplings allowing the 5-1/2” tubing to be run inside
7“ casing. A gas-liff completion design was developed to
incorporatetwo new completion strings, a gas-lift annulus
string and a production tubing string, run consecutivelyinside
the existing casing strings isolating both the unusable 9-5/8”
production casing and the ageing 7“ liner top (refer to
figure 3).
As with most modem platform gas-lift completions in the
North se% an annular safety system was deemed an important
feature to include in the design. Most of the systemsthat have
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have been run. The typical installationallows for tophole
workover capability escalatingthe complexity and purchase
price. For Montrose,the requirement was for a proven, simple,
and low cost system. Several low cost options new to the
North Sea (though many often had track records of several
hundred world wide installations)were evaluated. Key
f-tares of the final selection included packer setting
mechanismby tubing pressure, packer retrievability, and
fimctioningby dedicated control line. However,the packer
was sind for 7“ casing. This resulted in the gas-lift annulus
string incaporating T’ tubing in the top 800’ and 5-1/2”
tubing tlom 800’ down to the packer setting depth inside the
existing T liner. A 7“ permanent packer was used to anchor
●L- --- I:a unmuus
---.. a... suing
----- .-.L:-L.---- 1-—>->m:– comprcsslan
--—–--__,.–
UIC gawmt wmcn was mnaea
with a T tubing hanger in the existing tubing spool. A short
2-7/8” tailpipe assembly including a production nipple hung
beiOw the packer assembiy.
As sta@ the production tubing string incorporatedmostly
2-7/8” tubing, mandrels, and nipples. A floating seal assembly,
spaced out in the T’ packer sealbore,was used to isolatethe
gas-lift anmdus and facilitatepulling the production tubing
should a future workover be required. The 2-7/8” tubing was
crossed over to 3-1/2”tubing in the top 800’ of the completion
where the annular saf~ system and a tubing retrievable sub-
surface safety valve were located. The production tubing string
was landed in a new tubing spool raising the xmas tree height
appmxim~iy 2’. ikei%rii~hedxmas trees were utiiised as a
f!!ti_jer~Qgg~tt~qgf~h!~.
A long track record of retrieving Montrose ESP completions
(refer to figure 4 ) had been achieved. Fluid loss control had
322
.
SPE28836
been identified as a problem in previous workovers and had
been successfullyaddressedusing sized-particlesalt pills.
Additionally,the Montroserig package had been virtually idle
for over a year prior to the start-up for gas-lift conversions.
Fortunately,the rig had been maintained in reasonable
condkion and only relatively minor repairs to pipework and
valves had to be instigated.
A major problem facing the workover team was the ever-
present PGB limitationson the Montrose platform. With only
83 beds and ongoing production operations supporting both
the Montrose and Arbroath plus a compressorteam coming
and going with critical priority, every bed was a drdy
negotiation.To addressthe needs of a major workover
program it was vital to establisha multi-skilledworkforce. The
engineerswho designed the new completion and planned the
workover program were transferred offshore at rig start-up and
took on a dual role of rig supervisor and completionsengineer.
Senior toolpusherswith extensiveworkover experiencewere
selectedto oversee planned operations along with hand-picked
drillers and assistant drillers. Several within the rig crew were
—?---
aameo A--—- ——.
to operate- computer
-— —.—..A-— .- ——.
torque .- -.—.
mm quiprnent to reduce
service company presence.A core completionsteam made up
of reps from several service companieswas established,
creating a project oriented attitude that enabled much of the
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reducing PGB. At peak periods during 24 hour workover
operationsthe entire rig team included only 27 personnel.
Phase 1 of the workover program included six wells with the
scope of pulling the existing ESP completionsand installing
the new gas-lift completionswhich included the gas-lift
annulus string and the production tubing string. The estimated
time to complete a workover was 20 days at a cost of
0$96,000.
+ Facility Modifications
The Montroseplatform has gas compressionprimarily to
provide lift gas for the Arbroath wells although the high
nrmwre cm can he rnntd thrnnuh n IT valve
r. ----- e— ----- “- ..,...-” “- ~“ a- --- .-. “ .“.
NGL recovery. The Montrose wells already had a gas header
to which the low pressure annulus gas was directed when
ESP’s were in operation. Consequentlythe topside facility
modificationsto allow gas-lift to commence on Montrose
wells were relatively minor. Piping, shutdown,and
instrumenticontrolmodificationswere the primary areas
addressed.
The piping scheme included anew high pressure line to the
existing gas header which required full inspectionprior to use
as a gas-lift manifold. All redundant routing valves were
removed to eliminate any risk of misdirected high pressure
gas. ‘l’herequired number of existing 2“ valves on the
. . ..”.e..l..l
lllalllulu
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WS1 G 1CUWJU w VU1lllCVL
----- 11- 11/LP3M BUS
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--- n-...
going to each gas-lift well. The new high pressure line
supplying gas to the existing manifold was connectedby hot-
LJ.ANDREWS, E.RHENNINGTGN 5
tapping into a 6“ flowline exiting the gas dehydration plant. A
new blowdown line connecting the new system to the flare
system was also installed.As earlier stat~ each of the xmas
trees was raised approximately2’. This required that all of the
production flowlines be modified to accommodatethe new
wing valve position.
Each of the new 1-1/2”gas flow lines requires a non-return
valve and shutdown valve. Fwther a flow control valve
installed on the new high pressure gas line supplyingthe
gas-lifl manifol~ is activated during an ESD and segregates
the new gas-lifi system ffom existing facilities.All pipework
downstreamof this FCV depressurisesvia the new blowdown
line to the flare while gas upstream of the FCV depressurises
via pipework in the existing gas plant. These modifications
required significant alterations in the platform shutdown logic
and fire/gas panels. Additionally, an engineering study
confined the viability of additional gas volumes in the flare
system during a blowdown.
Modificationswere required to the existing split range
-– *–.-– .,. - e-–l –––------,–.–-.1 .-.L..-..,- ,,A
controller which regulates me mei gas supply ana muroam un
gas requirementssuch that Montrose lift gas was also
included.A new configuration was establishedbased on
priorities 1) fuel gas, 2) Arbroath lift gas, and 3) Montrose Iifi
-..” A“.. Spa!&
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removal, spare gas is flared as no export pipeline exists.
Montrosewell gas injectionrates are monitored by variable
area type flow meters fitted in each of the 1-1/2”injection
lines.
As a result of the field rejuvenation work undertaken, field
wide production rates have been restored fkomthe field
dormant state of+/- 1500bopd, to its former production level
of 5500 bopd. In all, 10wells (with a fiuther 4 wells
recompleted in phase 2), have been successfidlyand cost
fnr onhmw.d .=.4...1., .-”.,.-..4 L- m@n a-—d,... - “.”l:a ....*L
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installationof low risld low cost gaslitivelocity strings and at
a cost some 18V.below the approved budget of E7.4MM.
Fmlhermore it is anticipatedthat production costs per barrel
will decline significantlydue to the elimination of future ESP
replacementworkovers.
The field evaluationhas also shown how a properly tailored
multi-disciplinaryfield investigationon mature waterflood
fields like Montrose,can find previously unidentified
opportunitiescreated by changing circumstance,field
operating practice and even changes in field management
philosophy. This particular team effort/study, identified an
upside potential of 12.1MMSTB.
llUW
1:---
UllGS
323
6 MONTROSE A CASE STUDY OF INNOVATIVE ,COST EFFECTIVS FIELD REJUVENATION SPE 28836

The authors would like to thsnk Amoco (UK) Explomtion Co

and Co-Venturers,Amerada Hess Ltd and Entwprisc Oil Plc
for allowing us to publish this papar. In addition we extend our
thanks to H.Phillips and the many others both onshore and
offshore, who contributed significantlyto the successof the
work outlined in this paper.

aw ●S ● function of porosity ●nd height ●bovo OWC

300.00

250.00

200.00

~ 160.00
.

100.00

So.oo

0.00
0.0S 0.1 0.15 0.2 0.26 0.3 0.S6 0.4 0.46 0.S 0.S6 0.0 0.66 0.7 0.76 0.0 0.06 0.S 0.96 1
SW

i~l O% ~16% +20% ~26% ++30%1

Figure 1 Graphical representation of Sw correlation

324
 .
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A06
1000, t , —. “
/ ,, 1 1
1 1 I ! [ I
500 I I
I I I I I I
, I

7677 ”7879”8~”131”u “8j’84”8~’a6’8J’&j’ 89’$)()’91’92’ 93’

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0 — (--l--- f--r-’- . —“—r——— —“—r—— —.—l.”— w“.l.”— ~ ———l——. “.—f””. ~ v — —

0000 76, :7,78, 79,80 :8’ ,82:83: ‘4:85, 86; 67:88,89,90.91. 92.93
- Perorated L.ayers
5000 L
- Survey5Per10rmec
, - Mditional Inleres!
1000-J

Figure2 Atypieal combined productionhvell hktory plot

325
 . ,.

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ei