PAPER 2009-526

DESIGN ASPECTS TO CONSIDER DURING

DRILLING AND COMPLETION OF WELLS OF
THE PILOT TEST IN THE “IN SITU
COMBUSTION PROJECT”, BARE FIELD.,
D. VARGAS & J. GARCIA
PDVSA E&P / INTEVEP

J. RODRIGUEZ & H. REVEROL

PDVSA E&P

This paper has been selected for presentation and publication in the World Heavy Oil Congress 2009 Proceedings. All papers
selected will become the property of WHOC. The right to publish is retained by the WHOC’s Publications Committee. The authors
agree to assign the right to publish the above-titled paper to WHOC.
Proposal
The In Situ Combustion Pilot Project Test to be
implemented in the Bare Oil Field of the Orinoco Oil Belt
(OOB) to enhance the recovery of heavy oil is considering non
conventional drilling and completion techniques to warrant
wells performance during the different phases of the combustion
process.
This paper describes drilling, completion and monitoring
techniques to be implemented in the design of each well in
order to have control during the advancement of the burning
front from the injector to the producing wells.
Abstract
Drilling and completion of horizontal wells under the
design criterion currently used in the Orinoco Oil Belt (OOB)
have allowed increment of oil production rate from 200 b/d in
verticals wells to 2000 b/d in horizontal wells (Ex. Bare field).
In spite of the fact that the initial oil rate has been improved,
optimizing pumping systems and using cyclic steam injection,
the recovery factor remains still low (less than 8 %).
In Situ Combustion Technology (ISC) is considered as a
real alternative to increase the recovery factor[1] in the heavy
and x-heavy oil reservoir contained in the OOB. This thermal
process generates high temperature and combustion gases in
the reservoir creating a fireflood which moves ahead as a result
of the air injection. This reduces the crude viscosity and
improves its mobility from the injector to the producing wells.
Drilling and completion of wells arrangement for the In
Situ Combustion Pilot Project has to consider special design
criterions to ensure safe operations conditions with minor
environment impact of the affected area.
For the Bare oil field ISC Pilot Project has been proposed
non conventional drilling techniques and special mechanical
well configurations which must consider critical reservoir
conditions generated before and during the different phases of
this thermal process in order to:
Minimize formation damage during drilling operations.
Maximize pay zone contact and navigate close to bottom.
Handle High fluid production and injection rates.
Monitor wells variables in Real time.
Reduce well completion equipment corrosion.
Prevent formation sand production.
Improve cement zonal isolation.
Increase the useful life of the wells.
The implementation of these news drilling and completion
design techniques in the Bare oil field ISC project will allow to
get information to be used in the phase of development of this
technology taking into account the different oil types present in
the OOB. The analysis and implementation of these techniques
will permit the increment of the recovery factor above 50 %.

1
Introduction
Drilling and completion of wells arrangement for the In
Situ Combustion Pilot Project in the Bare Oil Filed has to
consider special design of casing, production and injection
strings capable of withstanding high temperature, high pressure
and attack of H2S and CO2 and strings with monitoring
equipment to continuously register temperature and pressure in
real time as well as production rates of the horizontal wells.
These will allow control of the burning front.
The project considers the construction of one vertical
injector well, two horizontal production, four observation and
three water wells. The construction of these wells must applied
drilling techniques, cement slurry, casing designs, production
and injection strings and real time monitoring equipments
capable of withstanding critical reservoir conditions during the
difference phases of the combustion process.
Mathematical models, laboratory tests and core samples
were considered to define wells arrangement and selection of
completion equipment.
Geographical Location
The In Situ Combustion Project Pilot Test is to be
developed in Anzoategui State in the Ayacucho block of the
Orinoco Oil Belt, which covers an area of 11300 Km2
specifically in the R0 pay sand of the MFB-52 reservoir of the
Bare Oil Field (BOF) with an area of 487 Km2 [2]. Figure No.
1.
Figure No. 1
Location of Ayacucho Block MFB-52 Reservoir in Bare Field.
This reservoir is characterized for having unconsolidated
sand of high porosity and permeability.
Pay sand depth -------------------------------------------------- 2750'.
Dip -------------------------------------------------------------- 2 - 3°.
Pay thickness -------------------------------------------------- 0' - 51'.
Initial reservoir pressure ------------------------------------ 980 psi.
Initial reservoir temperature -------------------------------- 140 °F.
Porosity ----------------------------------------------------- 27 - 30%.
Initial oil saturation ------------------------------------------- 87%.
Gas oil ratio ------------------------------------------------- 88 Scf/b.
Permeability (mD) ------------------------------- 270 - 13000 mD.
Oil °API ------------------------------------------------------------- 9.
OOIP -------------------------------------------------- 208,533 MB.
Fracture gradient ---------------------------------------- 0,68 Lb/ft.
Pore pressure Gradient -------------------------------- 0,43 Lb/ft.
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Drilling, cementing and Completion
Drilling, cementing and completions of wells in the Orinoco
Oil Belt for the In Situ Combustion Pilot Project Test to be
developed in the Bare Oil Field has to consider critical
reservoir and surface conditions before and during the
combustion process. Mathematical model were used to simulate
data obtained from combustion tube test where reservoir
conditions of pressure and temperature of the burning process
were simulated at different rates of air and steam. All these
helped to define well arrangement and completion equipment.
Initially the horizontal wells would be open to production at
different rates to help in the mobility of crude from the injector
well to the tail of the production wells. Pressure would be
register constantly. Figure No. 2.
Fig. No. 2. Simulated Reservoir Pressure Distribution
during Cold Production
Vertical straight holes as well as calibrated, deviated and
horizontal holes have to be drilled with fluids that minimize the
impact in the hydrocarbon zone. The horizontal 8 ½” hole
section will be drilled with directional and deep asimutal
electromagnetic resistivity and rotary steerable system tools to
warrant travelling along the best pay zone and close to the
bottom. Cement slurries and casing designs to be used in each
of the wells have been selected based on the high temperatures
expected and on the result of numerical simulations.
Completion, production and injection strings have been selected
to handle high volumes of crude, steam and air. The strings
design considered high temperature and pressure, and the
presence of H2S and CO2. Table No. 1.
Component Molar %
N2 80.80
CO2 15.03
CO 03.09
C4 Traces
O2 0.26
H2S 2000 ppm
Table No. 1 RO Sand Crude Combustion Test Results.
Monitoring equipment to register temperature and pressure
include thermocouples, pressure chambers y fiber optic installed
in each of the wells. Temperature and pressure generated below
the pumping system would be recorded during the cold
production phase of horizontal wells as well as during the
advancement of the burning front.
Production well designs
The horizontal production wells will be drilled with 20” bit
and completed with 16" Butts x 65 #/Ft, J-55 surface casing,
centralized and cemented to top with a 45% silica flour
Portland cement slurry. The intermediate 14 3/4" hole will be
completed with 11 3/4" STC x 75 #/Ft, P110 casing cemented
till surface with two cement slurries, a flexible thermal alumina
tail at the bottom and a lighter flexible thermal alumina lead till
surface [3]. The selection of the cement slurries proposed are
accordingly with the temperatures changes to be generated
during the advancement of the burning front. Figure No. 3.
Simulated reservoir temperature profile of production well
during the displacement of the burning front.

Figure No. 4. Production Well Completion Diagram.

Injector well design

Figure No. 3 Simulated Reservoir Temperature Distribution
of Production Well.
The injector well will be drilled with 17 ½” bit and
completed with 13 3/8" Butts x 65 #/Ft, J-55 surface casing,
centralized and cemented to top with a 45% silica flour
Portland cement slurry. The intermediate 12 ½” hole will be
completed with 9 5/8" Butts x 43 #/Ft, N-80 casing, cemented
till surface with two cement slurries, a flexible thermal alumina
tail at the bottom and a lighter flexible thermal alumina lead till
surface. The selection of the cement slurries proposed are
according with the temperatures generate during the ignition
process and advancement of the burning front. Numerical
simulation gives temperature values as high as 1250 °F. Figure
No. 5. Injection well temperature profile.

The horizontal section will be completed with 7” Butts x

0,012” SS thermal screen, L-80 base pipe to mitigate the
migration of formation sand from the reservoir to the well bore
and the effect of H2S. The screen assembly will be hanged on a
thermal packer with an expansion joint to compensate for tubing
movement. The production 5 ½” x 17 #/Ft, L-80 string and the
metal to metal insertable mechanical pump are designed to
handle high volume of crude, H2S and CO2. Pressure and
temperature sensors placed below the pumping system and
along the horizontal section, including fiber optic will
continuously register temperature and pressure values in real
time.

The optic fiber will allowed measurement of temperature

changes from top to bottom and along the complete trajectory
of the well. Registration of these temperature as well as pressure
values is essential to have a better control of the burning front.
In this way potential operational risks will be minimized. The
pay sand R0 has very viscous crude which initially will need
injection of a lighter crude oil as diluent for better displacement
of native crude to surface. Crude from R0 will also generate
H2S during the combustion process which needs to be
controlled. The production wells completion design
contemplates a flexible injection string for loading diluent and
H2S breaker at the bottom of the hole. Temperature and Figure No. 5 Simulated Reservoir Temperature
pressure sensors and the optic fiber will be assembly inside a Distribution of Injector Well
flexible string line to stop possible damage while going down
the hole and along the horizontal section of the well. This The pay zone in the injection well will be perforated with 7”
assembly could be replaced in case of incorrect functioning or x 21 spf big hole guns to allow better communication between
damage of the optic fiber and thermocouples. Figure No. 4. well bore and reservoir. The perforated area will be washed out
Production well completion diagram. to clean for debris that could affect flow rate and volume of

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steam and air injected. The injection zone will be completed
with 7” Butts x 23 #/Ft x 0,012” SS thermal screen, L-80 base
pipe, hanged on a PBR thermal packer and packed with
synthetic high temperature gravel for formation sand control.
The injector well 5 ½” air injection string with high
temperature seal assembly at the end will have attached control
lines with sensor to measure temperature and pressure in the
annular space. Inside the air injection string will be placed the 2
3/8” steam injection string and along its will be attached the
control lines for the pressure and temperature sensors which
will be placed above R0. The steam injection string will have at
the end a nipple profile that will accommodate a firing device in
case it is needed to ignite the combustion front. Figure No. 6.
Injection well completion diagram.

Figure No. 7 Observation Well Temperature Profile

Temperature and pressure sensors will be installed outside

Figure No. 6. Injector Well Completion Diagram
Observation well designs
Observation wells (Four) will be drilled with 12 ½” bit and
completed with 9 5/8” Butts x 43 #/Ft, N-80 surface casing,
centralized and cemented to top with a 45% silica flour
Portland cement slurry. The intermediate 8 ½” hole will be
completed with 5 1/2" Butts x 17 #/Ft, N-80 casing, cemented
till surface with two cement slurries, a flexible thermal alumina
tail at the bottom and a lighter flexible thermal alumina lead till
surface.
The selection of the cement slurries proposed are according
with the temperatures to be generated during the advancement
of the burning front and in line with numerical simulation
results. The observation well to be drilled close to the injector
well would be the first to made contact with the advancing
burning front and the first one to be exposed to critical reservoir
conditions. Data collected from this well would be essential to
determine ignition performance and burning front direction
inside the reservoir. This well is expected to be exposed to
temperature as high as 1250 °F. The rest of the observation
wells will see temperature below 1250 °F. Figure No. 7.
the intermediate casing across the pay zone in each observation
wells. Two of the observation wells will monitor temperature,
along the completed section and from top to bottom, using
optic fiber. One of these well will be located close to the
injector well and the optic fiber will allow a more accurate
temperature readings during ignition process and once the
burning front stars advancing toward the production wells.
Having accurate measurement of temperature as well as
pressure on time will help in defining a better control from
surface. The steam injection initially and the air injection later
would be done in a more efficient manner. Figure No. 8A. All
four observation wells proposed will have thermocouples
installed inside the casing, attached to a 2 3/8" tubing as a back
up. None of them would have direct communication with the
reservoir for safety reasons.
OBSERVATION WELLS No. 1 y 4 COMPLETION DIAGRAM.
9 5/8” BTTS x 43,5 #/Ft, N-80 CASING @ +/- 1.000’.
TEMPERATURE SENSORS CABLE INSIDE CASING
2 3/8” EUE x 4,7 #/Ft, N-80 TUBING.
1/8” x 0,035” SS-316L CAPILLARY LINE WITH 50/125 MULTIMODE
OPTIC FIBER.
TEMPERATURE & PRESSURE SENSORS CABLE OUTSIDE CASING.
TYPE K THERMOCOUPLE INSIDE CASING.
TYPE K THERMOCOUPLE OUTSIDE CASING.
RO (2.694’-2.728’).
0-3.000 PSI PRESSURE SENSOR.
U THERMAL CEMENT +/- (0’-3.000’).
BOTTOM HOLE @ +/- 3.000’.

Figure No. 8A. Observation Well Completion Diagram.

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 The second observation well completed with optic fiber for
distributed temperature recording and placed close to the end of
the horizontal section of the production wells will permit
monitoring on time of the burning front to decide when to stop
air injection in order to have a better control of the production
wells. The others two observation wells placed along side of the
reservoir will have temperature and pressure sensors but not
optic fiber. Figure 8B.
The horizontal section of the production wells must be
drilled with special directional and geo navigational tools to
perforate close to bottom and along the best section of pay
sand.
Reservoir monitoring in real time of the different variables
must be continuously registered to have a better control of the
fireflood

Acknowledgement
OBSERVATION WELLS No. 2 y 3 COMPLETION DIAGRAM.
The authors would like to acknowledge the professional
assistance of Rosa la Cruz and Danny Oliveira from PDVSA
INTEVEP, and Diogenes Lugo from PDVSA E&P.
9 5/8” BTTS x 43,5 #/Ft, N-80 CASING @ +/- 1.000’.

TEMPERATURE SENSORS CABLE NOMENCLATURE

2 3/8” EUE x 4,7 #/Ft, N-80 TUBING. OOB = Orinoco Oil Belt
ISC = In Situ Combustion
BOF = Bare Oil Field
PRESSURE SENSOR CABLE OB_1 = Observation well No. 1.
PH-01 = Horizontal well No. 1.
TYPE K THERMOCOUPLE INSIDE CASING.
TYPE K THERMOCOUPLE OUTSIDE CASING.
OOIP = Original oil in place.
b/d = Barrel per day.
RO (2.694’-2.728’). Scf/b = Standard cubic foot per barrel.
0-3.000 PSI PRESSURE SENSOR. Lb/ft = Pound per foot.
THERMAL CEMENT +/- (0’-3.000’). spf = shot per foot.
BOTTOM HOLE @ +/- 3.000’.
I_AIRE = Injector well.

Figure No. 8B. Observation Well Completion Diagram.

Conclusion
Reservoir fluid laboratory characterization, combustion tube
tests and core samples helped in the selection of material for
completion equipments.
Numerical methods were used to simulate the effects of
temperature and pressure on the well production and injection
strings.
Local and worldwide experience helped in the completion
design of the different wells.
Well completion designs allow the installation of high rate
mechanical pumping system and monitoring equipments. The
designs are flexible enough to retrieve some of the
equipments if needed.
References
1. Partha S. Sarathi., In Situ Combustion Handbook -
Principles and Practices., U.S. Department of Energy,
Batlesville, Oklahoma. USA 1999.
2. Cesar Torcat; Economic and Technical Feasibility of
Implementing In Situ Combustion in the MFB-52
Reservoir in Bare Field of the Orinoco Oil Belt.,UDO
University, Barcelona-Venezuela, May 2009.
3. R. K Meher, K. M. Suyan, D. Dasgupta, Vinod
Sharma, ONGC, India. Successful Field Implementation
of Novel Cementing Solution for ISC Well: Case
Histories SPE/DS/CHOA 117590. Paper presented in
the SPE International Thermal Operations and Heavy
Oil Symposium. Held in Calgary, Alberta 20-23 October
2008.

Selection of completion equipments must consider high

temperatures as well as production of corrosive gases
generated during the combustion process.

Cement slurries to be use in each of the wells must be

thermally stables at very high temperature to withstand stresses
generated during the different phases of the combustion process.
They as well must be capable of maintaining hydraulic and
thermal isolation.

Holes for each of the wells must be drilled in gage and

calibrated and the casings must be centralized to warrant good
cement placement and uniform cement sheath in the annular
space.