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Steam injection gravity drainage as a follow-up process for cyclic steam MARK
stimulation
⁎
Yu Baoa, Jingyi Wangb, Ian D. Gatesb,
a
Research Institute of Petroleum Exploration and Development, China National Petroleum Corporation, China
b
Department of Chemical and Petroleum Engineering, Schulich School of Engineering, University of Calgary, Canada
A R T I C L E I N F O A BS T RAC T
Keywords: Cyclic steam stimulation (CSS) is an effective method to recover extra heavy oil but it achieves a relatively low
Thermal recovery recovery factor (~26% before economic limit is reached) and is less energy efficient with higher emissions
Extra heavy oil intensity than that of conventional oil production. After it reaches its economic limit, it remains unclear what is
Cyclic steam stimulation the follow-up recovery process where the energy and emission intensities can be minimized. Here, a detailed
Liaohe heavy oil field
examination of the Liaohe extra heavy oil CSS and continuous Steam Injection Gravity Drainage (SIGD)
Steam-to-oil ratio
operations is conducted to examine their energy and emission intensities. Further analysis is conducted by using
Steam injection gravity drainage
detailed geological and reservoir models and a history match of the CSS and SIGD operations. The results reveal
that CSS is an effective thermal recovery method to initiate production from extra heavy oil reservoirs and that
SIGD using infill wells is an effective post-CSS recovery process to produce a significant fraction of the
remaining oil from the reservoir. For the reservoir studied, the steam-to-oil ratio (energy efficiency) and
emissions intensity of SIGD is slightly worse than that of the initial CSS operation.
1. Introduction provide a well-established pathway for steam injection and flow after
the horizontal wells are placed in the reservoir and gravity drainage
One of the key differences between Cyclic Steam Stimulation (CSS) starts. Here, a detailed examination of the Liaohe heavy oil operation is
operations in the Liaohe Oil Field in Northeastern China and those in analyzed by creating a geological model and then by using reservoir
Alberta in the Cold Lake oil sands deposit is that the CSS operation in simulation to history match the CSS and SIGD operations. The main
China was operated below the fracture pressure of the reservoir objective of the study is to understand the benefits of a SIGD operation
(Denbina et al., 1991; Gallant et al., 1993, Boone et al., 1995, Yang, as a follow-up process to CSS.
2006, Yang et al., 2006). This implies that when the steam was injected
into the formation, the steam was sufficient to cause dilation but no 2. Review of geology in the Liaohe oil field
fracturing of the formation occurred. As pointed out by Cokar et al.
(2012) and Bao et al. (2016), steam fracturing enables rapid transport Geological and well trajectory data from the Liaohe oil field
of heat into the formation yielding greater steam conformance. operation in the Guantao Formation were analyzed to construct the
The Liaohe heavy oil field steam operation is unique: it started with geological model. This data consists of 40 wells with 10 cores, 40 logs,
a vertical well CSS operation which after a few cycles, transitioned into and 25 fluid analysis measurements. The operation was conducted in
a continuous Steam Injection Gravity Drainage (SIGD) operation that the Shu1 area located in the middle section of the Qishu Upper Step in
used both vertical and horizontal wells (Yang, 2006; Yang et al., 2006; the Western Slope in the western depression of the Liaohe Basin. The
Yuan et al., 2010). The chambers initially established by CSS grew main structural feature of this formation is that it dips between 2° and
under gravity drainage and continuous production. Controlled and 3° to the southeast. This oil layer consists mainly of an alluvial fan
deliberate transition from CSS to a gravity drainage process has where deposits were made from flows from an ancient mountainous
benefits with respect to steam and heat transfer within the reservoir: region that drained onto a plain. The data show that the reservoir
CSS establishes thermal communication between wells by creating hot lithology of the Guantao Oil Layer mainly includes anisotropic hetero-
reservoir zones surrounding the vertical wells that eventually connect geneous sandstone where the bounding rock layers consist of conglom-
and create mobilized oil zones throughout the reservoir which in turn erates, conglomeratic sandstone, fine sandstone and a small amount of
⁎
Corresponding author.
E-mail address: ian.gates@ucalgary.ca (I.D. Gates).
http://dx.doi.org/10.1016/j.petrol.2017.04.002
Received 24 October 2016; Received in revised form 15 March 2017; Accepted 5 April 2017
Available online 07 April 2017
0920-4105/ © 2017 Elsevier B.V. All rights reserved.
Y. Bao et al. Journal of Petroleum Science and Engineering 153 (2017) 268–282
Table 1
Liaohe Oil Field CSS oil production and steam injection (expressed as cold water equivalent) data. On average, the steam injection pressure, corresponding saturation temperature, and
quality was equal to 10,000 kPa, 311 °C, and 0.76 for all wells, respectively.
Wells Number of completed Duration, days Cumulative steam (CWE) Cumulative produced Cumulative produced cSOR, m3/ CDOR, m3/ TFSR, m3/
cycles injected, m3 Oil, m3 Water, m3 m3 day m3
area of study. In the Guantao oil column, the density and viscosity of
the oil is 1.008 g/cm3 and 230,000 cP (at 50 °C), respectively.
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Y. Bao et al. Journal of Petroleum Science and Engineering 153 (2017) 268–282
Liaohe Oil Field SIGD oil production and steam injection (expressed as cold water equivalent) data. On average, during the CSS preheat period prior to SIGD, the steam injection pressure, corresponding saturation temperature, and quality was
The total fluid produced to steam injected ratio (TFSR) lies between
m3/m3
equal to 12,000 kPa, 324 °C, and 0.76 for all wells, respectively. During the SIGD period, the steam injection pressure, corresponding saturation temperature, and quality was equal to 6500 kPa, 280 °C, and 0.9 for all wells, respectively.
TFSR,
0.78 and 1.12 m3/m3. The average value is equal to 0.98 m3/m3. For
0.81
the TFSRs lower than unity, this means that less liquid was being
CDOR, m3/ produced from the reservoir than the liquid equivalent of steam
injected. This implies that steam was being lost to the reservoir beyond
44.44
72.28
93.87
47.59
the stimulated zone. For the wells with TFSRs greater than unity, this
day
implies that more liquid was being produced from the reservoir than
was injected into the reservoir, which means that a vapor steam
m3/m3
cSOR,
water, m3
produced
234,054
363,768
527,001
205,874
Beyond 2004, a continuous steam injection gravity drainage process
using a combination of the vertical wells as injectors and new
horizontal wells as producers was implemented. This recovery process
we refer to as the steam-injection gravity drainage (SIGD) to distin-
produced oil,
Cumulative
guish it from classical SAGD operation where two horizontal wells are
146,654
190,566
used. The SIGD recovery process where steam is injected into the
82,605
83,145
vertical wells and fluids are produced through the horizontal wells is
m3
wells conducted 2 cycles whereas the other two did 3 cycles. During the
pre-heat period, on average, the steam injection pressure, correspond-
1859
2029
2030
1747
heat period varies from about 3.43 m3/m3 up to 8.09 m3/m3 with the
0.20
0.46
0.62
0.36
19.52
9.78
8.77
4.53
3.43
6.66
than that of the vertical wells: they vary between 8.77 and 19.52 m3/
day (this is expected given the increased contact the horizontal wells
have with the reservoir). During the pre-heat period, the TFSR has a
Cumulative
water, m3
range between 0.2 and 0.62 m3/m3, which suggests that the leakoff of
produced
steam from the wells is much greater than the amount of liquid
1614
6324
8406
4920
equivalent produced. For heating the formation, this may have been
beneficial since the injected steam and its condensate will convect heat
produced oil,
into the oil sand establishing a pre-heated zone around the wells.
Cumulative
The SIGD operation (after the preheat period) started on about Day
2612
5741
7574
3483
horizontal production well, the overall steam, cSOR, and TFSR are
reported for the field operation for the SIGD period are listed in
steam (CWE)
Table 2. During the SIGD period, the most productive wells are the
injected, m3
Cumulative
PING-11 and PING-12 wells which were also the wells that received the
21,134
26,002
25,946
23,205
CSS Preheating period prior to SIGD
greatest amount of steam and the highest productivity with the lowest
cSORs of the horizontal wells during the pre-heat period. During the
SIGD operation, the overall cSOR achieved a value equal to 4.49 m3/
Duration, days
388
388
397
over the vertical well CSS operation. Roughly about 59% of the injected
pre-heating
CDORs for the horizontal wells are significantly larger than that of the
3
vertical wells during the CSS and the pre-heat operations demonstrat-
G-10
G-11
G-12
G-13
PIN-
PIN-
PIN-
PIN-
Well
Well
Well
Well
Well
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that of continuous steam injection and production processes such as and resistivity logs. In addition, well trajectory information was used to
SIGD. The main reason for this is that additional drive mechanisms place wells within the model domain. The geological model was
(formation recompaction, solution gas drive, steam flashing) are constructed in the PETREL geological modelling package
harnessed for oil production in CSS than that in gravity drainage (Schlumberger, 2014). Fig. 2 displays views of the distributions of
dominated recovery processes. the lithofacies in the geological model. The model shows interbedded
sand and siltstone intervals with relatively small layers of shale found
4. Geological and reservoir models predominantly at the top of the domain. Based on the log data, the
Guantao oil layer was vertically subdivided into five zones with six
To accurately describe characteristics of the reservoir including the horizons labeled from the top to bottom as Zones 1–5; the most
distributions of the lithofacies (rock types), geological and rock-fluid productive oil zones are Zones 2–4. Fig. 3 displays a horizontal plane of
properties of the lithofacies, and the thicknesses of the reservoir the geological model at depth 640 m presenting locations of vertical
intervals, a static geological model was first constructed. In the and horizontal wells (vertical wells indicated by dots and well number
geomodel constructed, three lithofacies are included: 1. sand, 2. whereas horizontal wells indicated by black lines). Also shown in Fig. 3
siltstone, and 3. shale. These lithofacies were determined from detailed is the porosity distribution and the location of two lines, AB and CD, for
analysis of 34 vertical well and 4 horizontal well logs in the area of the log cross-sections displayed in Fig. 4. The porosity-permeability trans-
SIGD operation. The well log information used to construct the static form, given by k(mD)=410451ϕ4.4108 (porosity expressed as fraction),
model consisted of neutron and density porosity logs, gamma ray logs, was constructed by using core data from 10 wells. Together with
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Fig. 3. Vertical and horizontal well placements in the geological model (distance between vertical and horizontal wells is roughly equal to 35 m, and distance between horizontal wells is
roughly equal to 70 m). Locations of cross-sections of well locations for log cross-sections presented in Fig. 5 in horizontal plane of geological model (both Lines AB and CD consist of 5
wells). The colors of the grid blocks indicate the porosity distribution. The length and width of the domain shown are equal to 538 m and 462 m, respectively. The numbered dots
indicate the locations of the vertical wells whereas the black lines mark the roughly locations of the horizontal wells.
porosity logs, permeability pseudo-logs were created by using the 5. History matched reservoir simulation model
transform. The porosity, permeability, and water saturation distribu-
tions of the geological model are displayed in Fig. 5. The water To obtain a history match of the CSS and SIGD operations, we
saturation along each of the logs was determined by using Archie's imposed the same stimulation as was done in the field on the reservoir
equation with true water resistivity derived from the top water zone model. In particular, the steam injection rates and pressure (and
(cementation factor 1.5 and saturation exponent 2). The variogram corresponding saturation temperature), and quality for each injection
parameters for geostatistical modelling, determined from well data and well were prescribed in the reservoir simulation model from the field
listed in Table 3, were used to populate data in between wells by using data. Also, the well pump rate is specified in the field operation, in
sequential Gaussian simulation. The geological model was converted other words, the total liquid production rates for each production well
for use in the STARS™ thermal reservoir simulator (CMG, 2014). This was constrained to the actual field values. The oil-water split of the
simulator solves the material and energy balances together with the production wells was matched by adjusting the relative permeability
convective-diffusion equation (for each species) as well as phase curves and in particular, the irreducible water saturation. In this case,
equilibrium (done by using K-values) in the context of multiphase flow due to the injectivity of the model at initial time, a steam quality was
(oil, water, and gas) governed by Darcy's law and relative permeability assigned for the CSS operation (at 0.76) and another value for the
curves (CMG, 2014). The finite volume method is used to discretize the continuous steam injection gravity drainage operation (at 0.9). The
partial differential equations. simulation input parameters of the final history-matched model are
The reference depth of the reservoir simulation model was set equal listed in Tables 4 and 5.
to 610 m with pressure at 6000 kPa. The average vertical to horizontal To conduct the history match, just over 30 runs were required (each
permeability ratio is equal to about 0.77. For the dilation model, the simulation run took about 24 h to run on a quad core personal
Beattie et al. (1991) model was used. computer with 3.4 GHz processors). The match was done manually
In the reservoir model, the domain was discretized into a grid with and was complete when the simulation results, specifically, the
sixty-nine 5 m dimension cells in the X-direction by fifty-seven 5 m cumulative water and oil production volumes, displayed in Fig. 6, were
dimension cells in the Y-direction and ninety-five 1.5 m dimension a reasonable match for the field data. The error of the cumulative oil
cells in the vertical direction. The total number of cells in the geological production between field history and simulation result is less than 2%.
model is equal to 373,635. The top and bottom of the geological model The results reveal that the model is an excellent representation of the
are located at depths equal to 524 and 682 m from the surface, field since the individual oil and produced water rates and cSOR
respectively. profiles match so closely as well as the data listed in Tables 1 and 2.
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Fig. 4. Log cross-sections AB and CD as defined in figure. I and Vdi represent the top and bottom horizons of the Guantao Formation. Zones 2, 3, and 4 are the most productive zones
(between horizons II and V). In the first log track, the red curve represents the caliper log; the black curve is the Spontaneous Potential log. In the second log track, the purple and blue
curves are neutron porosity and absolute permeability (obtained from porosity-permeability transform, shown in Fig. 6), respectively. (For interpretation of the references to color in this
figure legend, the reader is referred to the web version of this article.)
Even though the overall field results are well matched, the results the reservoir properties and complexity of the reservoir itself, the
for individual wells are variable. There are examples where the wells match achieved is considered to be reasonable and the model is
are well matched and others where the match is reasonable. For sufficient to evaluate both the CSS and SIGD operations.
example, Fig. 7 shows the rate matches for two wells; one with a good
match and another with a reasonable match. The key observation of the 6. Results and discussion
matches is that the simulation model re-creates a good representation
of the reservoir response to steam injection. Given the uncertainty of Fig. 8 displays the initial oil saturation distribution at the initial
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Fig. 5. (a) Porosity (average value is 28%), (b) permeability (average values in shale, siltstone, and sand are 5, 200, and 10,000 mD, respectively), and (c) water saturation (average value
is 33%) distributions of the geological model. The top and bottom of the reservoir model is 524 m and 682 m below surface, respectively.
time. Fig. 9 shows the oil saturation initially and horizontal and vertical much more extensive than that was achieved after the CSS operation.
cross-section views, respectively, of it at the end of the vertical CSS After six years of SIGD operation, the depletion zones are largely
operation. Due to the limited sweep efficiency of CSS, the oil saturation connected although horizontal Wells PING-11 and PING-13 have poor
distribution within the reservoir is not uniform with lean oil regions conformance with just over half of their lengths still surrounded by oil
surrounding the vertical CSS wells and rich oil regions remaining rich reservoir. This suggests that after a steam flow path is established
within the reservoir in between the wells. Fig. 9 reveals that the from the vertical injection wells to the horizontal production wells, then
depleted zone in the reservoirs grow to 600 and 650 m elevation by the the flow continues along this path with little transverse extension of the
end of the CSS operation. The variability of the chamber heights depletion chamber into cold reservoir. This issue is reinforced due to
reflects the heterogeneity of the formation. reservoir heterogeneity. After six years of the SIGD operation, the oil
Fig. 10 displays horizontal and vertical cross-sections of the oil saturation distribution shown in Fig. 10 and a comparison with the oil
saturation distribution in the reservoir after six years of SIGD. The saturation distribution displayed in Fig. 9 reveals that the depletion
results show that the depleted oil saturation zones in the reservoir are chambers have grown significantly under gravity drainage. Also, the
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Table 3
Parameters of the variograms for populating the porosity, horizontal permeability, and water saturation distributions (directions, 0, 90, 180, and 270 degrees represent North, East,
South, and West directions, respectively). Each zone is defined in Fig. 5.
Table 4
Key reservoir simulation input parameters.
Parameters Value
Table 5
History matched oil-water and oil-gas relative permeability curves.
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Fig. 6. Comparison of cumulative oil production, cumulative steam injection, and cumulative liquid production between field data and simulation results. The CSS operation lasted up to
Day 1228 and the SIGD operation started about Day 1588 (the period between was the preheat to the SIGD operation).
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Fig. 7. Oil rate match for a Well 45-p (top) and Well 41-p (bottom).
chamber heights have grown substantially with some of the chambers with limited merging of the chambers. By the end of SIGD, the
having reached the top of the oil column. chambers are well connected and a large fraction of the chambers
Figs. 11 and 12 display areal views of the temperature distributions have reached steam temperature. One advantage of transitioning a CSS
at 630 m depth at the end of the CSS operation and at the end of SIGD, operation to SIGD is that the reservoir around the wells is heated with
respectively. Figs. 13 and 14 show the temperature distributions in the limited connectivity between wells during the CSS operation. This
vertical plane containing the PING-11 horizontal well at the end of the means that when the system is converted to SIGD, there are semi-
CSS operation and at the end of SIGD. The results show that after the established flow zones for the steam to move through. This enables a
end of the CSS operation, there are hot zones around the vertical wells steam flood drive mechanism to move mobilized oil to production
but the hot regions are largely unconnected. The temperatures in the wells. Another advantage of infill horizontal production wells in
region of the horizontal well are elevated but are substantially lower between vertical wells is the reduced costs relative to that of putting
than that of the zones surrounding the wells. By the end of SIGD, in full conventional SAGD wellpairs. Another advantage of vertical well
greater amounts of the reservoir are now heated although ‘cold’ spots CSS operation followed by SIGD is that the degree of control in the
still remain along the horizontal well. reservoir by using vertical well injectors: the steam injection pressure
The results show that SIGD is effective at growing depletion and rate can be controlled in each vertical well to achieve improved
chambers within the reservoir consistent with the results from Miller steam conformance along horizontal production wells. In this manner,
et al. (1991) and Stark (2011). The results from the history-matched the vertical wells are acting as equivalent or better than a horizontal
simulation conducted here show that after the vertical well CSS steam injector with interval control.
operation, the steam chambers are largely separated from each other The injected enthalpy, produced enthalpy (ignoring the chemical
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Fig. 8. Original oil saturation distribution (line AB is the location of the cross-section in the lower image). Lower image has aspect ratio 1:1.
energy in the produced oil and solution gas), and average reservoir produced back during the blowdown events that occur during each
temperature is plotted in Fig. 15. The results show that during CSS (up production period of the cycles during CSS.
to Day 1500), the injected and produced enthalpies are similar whereas
when SIGD begins, the injected enthalpy far exceeds the produced 7. Conclusions
enthalpy. The thermal efficiency of the process during the CSS period is
relatively high – the chambers are small and during each production A history-matched reservoir simulation model of the Liaohe
period, the system surrounding each well undergoes a blowdown event Guantao heavy oil layer has been constructed. The static model was
where energy is recovered from the reservoir. During SIGD, the derived from log and well trajectory data. The model was tuned to
systems remains at elevated pressure and since there are no blowdown match injection and production data from CSS and SIGD operations.
events (as in CSS), then energy recovery is reduced. As the average The conclusions from this study are as follows:
reservoir temperature in the reservoir shows, it increases more
significantly when SIGD starts which means that more of the injected 1. CSS is effective at initiating recovery from the oil sands reservoir
energy is being stored in the reservoir rather than being produced from considered here. Given the distance between wells and the viscosity
it. With respect to the energy intensity of the recovery processes, the of the oil at original reservoir conditions, it would be difficult to
data show that in the CSS period, the net energy required per cubic initiate a steam flood within the reservoir. After connections
meter of oil produced is equal to about 3.6 GJ/m3. In the SIGD period, between the chambers from the CSS operation are established,
this rises to 9.0 GJ/m3. This reveals that the initial CSS operation is SIGD can be started.
more energy efficient than SIGD. This is because more energy is 2. The field data from the Liaohe Guantao extra heavy oil reservoir
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Fig. 9. Oil saturation at end of CSS operation (line AB is the location of the cross-section in the lower image). Lower image has aspect ratio 1:1.
demonstrates that a vertical well injection – horizontal well produc- heterogeneity of the reservoir and initial pattern of the vertical CSS
tion steam injection gravity drainage (SIGD) process is an effective wells.
follow-up process to vertical well cyclic steam stimulation (CSS) with 5. The use of vertical steam injection wells (former CSS wells) in
respect to oil recovery. With respect to thermal efficiency (measured combination with horizontal production wells operated in a steam
by the steam-to-oil ratio), the SIGD process as conducted in Liaohe injection gravity drainage mode illustrates that multiple recovery
is about 12% less thermally efficient than CSS. This implies that the processes are required at different stages of the overall recovery
CO2 emissions intensity (kgCO2/m3 produced oil) is slightly higher operation to maximize the recovery factor and production rates at
in SIGD than that of CSS. minimal energy intensity.
3. The net energy consumed per unit volume oil produced in SIGD is
several times that of CSS. This is because in each CSS cycle, a large
fraction of the energy injected is harvested back in each cycle during
production (essentially a blowdown event). Since SIGD operates Acknowledgements
under continuous injection and production, energy is not as readily
produced from the reservoir. Perhaps a blowdown event should be The authors acknowledge support from the Chinese National
added to the SIGD process. Petroleum Corporation in the form of data and guidance on the
4. The reservoir simulation match of the field data is reasonable and its Liaohe oil field, funding from Carbon Management Canada (Project
results confirm the outcomes of the field operation. The steam A03) and the National Science and Engineering Research Council of
chambers observed in the model reveal that the steam chambers Canada (RGPAS/477902-2015), and Schlumberger for its Petrel geo-
created during CSS are extended by using SIGD. However, the steam logical modelling software and CMG for its STARS™ thermal reservoir
conformance along the horizontal wells is non-uniform reflecting the simulator.
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Fig. 10. Oil saturation at end of SIGD operation (line AB is the location of the cross-section in the lower image). Lower image has aspect ratio 1:1.
Fig. 11. Temperature profile of CSS operation Years 1–4 (aspect ratio 1:1). Years 5 and 6 are during which the pre-heat period was conducted on the horizontal wells. Line AB is the
location of the cross-sections presented in Figs. 13 and 14.
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Fig. 12. Temperature distributions at the end of each year during SIGD operation (aspect ratio 1:1).
Fig. 13. Temperature distribution along row of vertical wells at the end of CSS operation (aspect ratio 1:1). Line AB is defined in Fig. 11. The position of the horizontal well is illustrated
in the image.
Fig. 14. Temperature distribution along row of vertical wells at the end of SIGD operation (aspect ratio 1:1). Line AB is defined in Fig. 11. The position of the horizontal well is
illustrated in the image.
Fig. 15. Cumulative enthalpy injection, production and average temperature within reservoir.
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