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Steam Pilot
".K. Dietrich, SPE, The Dietrich Corp.
Summary. Sluggish oil response in the Kern River horizontal-well steam pilot was caused by placement of the wells in a
reservoir environment unfavorable for application of either conventional oil recovery processes or novel oil-mining techniques.
Encouraging pilot operational experience and the tremendous potential for improved ultimate oil recovery shown by preliminary
simulations suggest that future pilot testing of horizontal-well steam technology is warranted in a more favorable environment.
Introduction
The Kern River vertical-shaft and horizontal-well steam pilot was Thermocouples were installed in the chamber wall near embedded
designed and installed on the basis of a geologic model that emerged strain gauges and in 'h-in. [l.3-cm] pipe positioned within the for-
from analysis of numerous closely spaced wellbores drilled on the mation about 50 ft [15 m] radially from the chamber wall.
25-acre [lO-ha] test site. Numerical simulation was used to develop
both the strategy for steamflooding operations performed at the test Lateral Holes. Eight lateral holes were rotary-drilled by men and
site during the period 1982-83 and the projections of long-term proc- equipment placed in the chamber; four of these were about 430 ft
ess performance. [130 m] in length and four were about 700 ft [210 m] in length
Eight horizontal wellbores spaced at 45° [0.79-rad] increments (Fig. 3). These laterals were drilled parallel to the base of the gently
were rotary-drilled into the base of the heavy-oil column (18 to dipping heavy-oil zone (Fig. 4). The imaginary plane containing
20° API [0.95 to 0.93 g/cm 3]) from a 500-ft [150-m] vertical shaft the laterals is located at depths between 350 and 600 ft [105 and
positioned at the center of the 25-acre [lO-ha] rectangular pilot area. 180 m] below the irregular ground surface. The maximum difference
The original concept was to use only horizontal wells for cyclic in elevation between the tip of a lateral and the point where it meets
steaming and steamflooding operations; this concept was modified the chamber wall is about 50 ft [15 m].
on the basis of simulation results that indicated the potential for Sections of 8%-in. [22-cm] preslotted steel liner (with a plug at
early steam breakthrough and poor capture efficiency of the dis- the end of the first section) were pushed to the terminus of each
placed oil. The modification involved drilling conventional vertical of the holes created by rotary drilling. An unperforated 3-in.
wells (one well within each of the eight sectors formed by the [7.6-cm] steam-injection string was then placed within the full length
horizontal wells) and injecting steam into them while producing from of the slotted liner.
the horizontal wells (Fig. 1). Fig. 5 indicates that eight separate steam-injection strings and
The pilot was terminated because of unfavorable economics after eight separate produced-fluid strings pass through the vertical shaft
21h% of the oil in place (OIP) was recovered. The oil recovery and chamber. Eight conventional beam-pumping units were posi-
rate and process efficiency were each improving at the time the tioned on the surface with rods and pumps placed within 2%-in.
pilot was abandoned. Early sluggish oil response was predicted and [6-cm] tubing.
observed owing to low vertical permeability and extensively depleted
oil saturation and pressure conditions that exist at the pilot site. Geologic Conditions
Long-term pilot operations were shown to be capable of recovering Extraordinarily dense well control C!4 acre/well [3035 m 2 /well])
significantly more oil at equivalent oil/steam ratio (OSR) than that allowed a detailed description of the reservoir for this pilot.
expected from conventional steamflood development.
The concept of using horizontal wellbores to improve thermal Structural Features. A critical element of this pilot was the drilling
oil recovery was developed by Turk, Kehle and Assocs. of Austin, of the steam-injection/oil-recovery lateral holes radially from the
TX. The concept was called the heavy-oil process (HOP) and was central shaft, parallel to and a few feet above the base of the oil
initially commercialized by Barber Oil Exploration Inc. The tech- sand that was subsequently produced. To position the lateral holes
nology is currently owned by Ladd Petroleum Corp. properly, the structural configuration of the oil sand was carefully
The HOP pilot described here was installed and operated by Fenix defined by combination of geologic data from various sources.
and Scisson Inc. on Shell Oil Co. 's D&D lease at Kern River (Fig. Drillers' logs taken in many old wells drilled within the pilot area
2) with funding provided by private-sector investors. were used with data obtained in four new wells to prepare numerous
The purpose of this paper is to describe the geologic and reservoir structural cross-sections (e.g., Fig. 4) and contour maps.
engineering features of the project; details of the construction and The base of the Interval QI sand, which was paralleled by the
drilling techniques are proprietary. lateral holes, is not a planar surface; it exhibits some irregularity,
which was allowed for during placement of the laterals. The base
Drilling and Completion Practices of the Interval Ql sand was found to strike north 15 to 45° west
Vertical Shaft and Chamber. A 7-ft [2.1-m] -diameter cutter as- and dip an average of about 4 ° [0.79 rad] southwest across the pilot
sembly and a specialized drilling rig were used to drill a hole to area. The term "horizontal well" is used here to mean a lateral
a depth of about 500 ft [150 m] at the center of the 25-acre [lO-ha] that dips about 4° [0.07 rad].
rectangular pilot area. The hole was then lined with 5-ft [l.5-m]
-diameter steel casing from the surface to the top of a heavy-oil Lithology. Zone Q consists of very porous, unconsolidated sands
accumulation at about 350 ft [105 m]. Miners were lowered into interbedded with various types of nonreservoir deposits. The reser-
the shaft where they hand-dug a 25-ft [7.6-m] -diameter chamber voir sands are moderately to well sorted, range from very fine
within the interval selected for pilot operations and pressure-grouted grained to pebble and cobble size, and contain variable but gener-
the chamber walls and floor. ally small amounts of interstitial clay. The unconsolidated sands
are uncemented except for occasional small calcite concretions and
are held together mainly by the viscous oil. Igneous rock clasts of
Copyright 1988 Society of Petroleum Engineers cobble and boulder size occupy up to 20% of the oil-sand bulk
5000'
"COl.' tl '
j PRODUCTION WELL
~~
volume in some Zone Q intervals. The presence of this coarse clastic
material was an important factor in the decision to use rotary-drilling
rather than augering techniques to place the horizontal wells. @
\
MC:::-:OPERTV
Nonreservoir deposits include clays, silts and poorly sorted sands.
These sediments are usually poorly bedded and often appear mot-
tled, as though reworked by organisms or weathering processes. Fig. 2-Locatlon of Kern River horizontal-well steam pilot.
I VERTICAL STEAM
l'\. IH"[CTOftS
o 100
I
I
INDUCTION RESISTIVITY
(ohm METERS}
DEPTH
-450' 0 25
SHAFT
WALL
MOOEL LAYERS
1'I~16'
t~~:;Z· =:::i;==i:lCCliiiIllU:mONj[E=
SAND
LAMINATED SANDSTONE
e. IjU0Nt
SAND
,.,.0
_ _ _ _ ...L..6518"SL~~ _ ~EA. -800'
_ _ _ _ _ _ _ _ _- N
3"SH: .... INJECTION
STRING
41/2" PRODUCTION
STRING -650' h:82'
''''23%
5 0.32.6%
WELL HOP /I 2
Oil
Saturation Porosity Net Pay Current OIP
Interval (%/100) (%/100) (It) (STB/NAF) (MSTB) (% Total)
01 upper 0.601 0.276 32.3 1,287 1,039 52
01 middle 0.399 0.278 17.0 861 403 20
01 lower 0.428 0.242 27.8 803 558 28
01 total 0.507 0.264 77.1 1,038 2,000 100
02 total 0.346 0.260 57.4 697 1,000 100
highly saturated upper Interval Ql oil sand was not expected to con-
TABLE 3-MEASURED OIL VISCOSITY vs. TEMPERATURE tribute significantly to production during early time. The reason
ON UPDIP KERN RIVER ZONE Q OIL SAMPLE
is that viscous oil (Table 3) in upper Interval Ql would not become
Temperature Oil Viscosity effectively mobile until heat injected into the horizontal wells was
(OF) (cp) convected and conducted upward through intervening sediments,
which consist of several claystone/siltstone lenses (Fig. 4) and the
80 5,046.8
140 302.0
bedded (laminated) series of oil sands and silts in middle Interval
180 78.7 Ql (Figs. 6 and 7).
200 44.3
250 19.9 Pilot Design Simulations
300 8.9 The feasibility of using horizontal wells in a steam process was first
Rock and Fluid Properties for Simulator Input studied with thermal reservoir simulation during 1977. 2 Horizontal
PV compressibility, psi -1 0.00025 wellbores were shown at that time to be capable of improving ulti-
Irreducible water saturation, fraction PV 0.30 mate thermal oil recovery from conventional projects. On the basis
Critical gas saturation, fraction PV 0.05 of these promising feasibility results, the simulator was used to de-
Residual oil saturation to steam, fraction PV 0.01 to 0.08 sign the Kern River pilot with a site-specific geologic model and
Initial reservoir temperature, OF 110 many alternative well geometries and operating policies. The most
Rock heat capacity, Btu/lt3_oF 35.0 promising pilot design was installed and the project was operated
Rock thermal conductivity, Btu/D-It_oF 28.0 during 1982 and 1983.
Relative permeability Temperature independent
Thermal Reservoir Simulator. The volatile-oil steamflood simu-
Oil density at 60°F, Ibm/lt 3 59.9
lator described in the Appendix was used in all the pilot design and
Oil density at 110° F, Ibmlft 3 58.9
Oil gravity at 60°F, °API 15.9 monitoring work. Since its development in 1980, this simulator has
Oil gravity at 110°F, °API 18.4 been used extensively within the petroleum industry to design and
Oil compressibility, pSi-I 0.000008 analyze field projects worldwide. 3-9 Steam distillation, steam addi-
Oil thermal expansion coefficient, of-I 0.00034 tives, hydraulically induced fractures, and reservoir compaction
Oil specific heat, Btu/lbm-oF 0.44 were important elements in many of these field applications.
Z7 HORIZONTAL
~WELL \ / ZZ
0.7
\ /
-------
------- '----
>-
------- cr 0.6
w
>
o MODIFIED HOP
o STEAM FLOOD
W
23 a: 0.5
o
...J 0.4
«
z
o
t-
00.3
«
cr
u.
I
Z •
Fig. 8-Finite-difference grid system for heavy-oil process ..... 0.2
C1
0
•
/'
simulations. Z a
..J
/'
./'
~ . / ' HOP CYCLIC
conditions; one of these is shown in Fig. 8. The grid system extends :K
./
0.1 ~
beyond the pilot area in the radial direction to represent the uncon- '"E /
fined nature of the pilot in that direction. Direction of true bed dip
0
with respect to the grid is along a radial vector 22 [0.38 rad] coun-
.
a
en
terclockwise from the direction of horizontal Well 26 (Fig. 3). °OL-~~~50~0~--I-O~O~O---'5~O-O---2-0~O-O---25~O-0---30~OO
Oil recoveries simulated with downdip pattern sectors were always DAYS FOLLOWING INITIAL STEAM INJECTION
10 to 20% higher than those simulated with updip sectors. This
0
results because gravity forces present with the 4 [0.07-rad] dip
held the steam injected downdip and the displaced oil within the Fig. 9-Simulated oil recoveries for alternative pilot designs.
pilot area; fluids were free to migrate upstructure beyond the pilot
perimeter in the simulations that used updip sectors.
The vertical dimension is described by an eight-layer grid, as A
shown in Fig. 7. Logs and cores available in many old and new
wells were used to describe both areal and vertical distributions
27
HORIZONTAL
............... ~WELL
\ 22
of rock properties and fluid saturations within the one-eighth reser- ........ \
voir prototype. Horizontal and vertical permeabilities within the
......... VERTICAL
oil sands range from 300 to 700 md and from 60 to 470 md, re- ------- lNJECTOR'A
:::
1-..... 0.1
KERN RIVER HORIZONTAL-WELL STEAM PILOT
Total Steam c~
~<n
,,~
~
/.,.,...
~a:
Q.
60 / WATER 600 : ~
27 36,620 W'
>z
.. c
/ .,;0
28
Total
34,966
181,735
-0
1-"-
c ..
~o
40
/
/ OIL
~D::
....
""020
~o
/ 200 ~~
:::1
0::: / ::
tion pressure wave with an increase in total production rate. As D~~~~~~~~~~~~~~~~~~~DIO
IJ A SON 0 1 F M A M IJ A SON ~~ J J
soon as the injection well is shut in, soaked, and put on produc- t 2nd/HALFI982 I tst/HALFI983 I 2nd/HALFI983 I
PILOT OPERATING MONTHS
tion, however, the opposing well's production rate rapidly decreases
as pressure is depleted.
To study the effect of increasing reservoir energy, a steamflood Fig. 11-0bserved pilot response-cumulative basis.
was simulated after several steam cycles (from 1,400 days). In this
case, steam was injected continuously into Horizontal Well 25 with
Horizontal Well 26 on production. Only a slight improvement in of the highly laminated middle Interval Ql (Figs. 6 and 7) that con-
oil recovery was shown as a result of steam-injectivity and capture- trols the rate at which hot oil moves downward into the horizontal
efficiency problems. The tight overlying middle Interval Ql prevent- wellbore. Although the lenses are less permeable, they are less im-
ed vertical steam-zone growth, and some displaced oil was pushed portant because they are areally discontinuous. Note that strong oil
out of the pilot acreage. Injectivity and capture efficiency were re- response was not predicted by the simulator during the first 2 years
duced by the short perforation intervals. of the pilot (Fig. 9).
Steam breakthrough was shown to occur in the modified HOP
Modified HOP. The design simulations indicate that a steamflood process at about 2,000 days when steam was injected into upper
process is necessary to provide reservoir energy at the pilot location Interval Q 1. An interesting feature of this process is that steam was
and that fully perforated horizontal wells are needed for capture shown to break through initially to a limited section of the slotted
efficiency. Because the total fluid throughput rate is set by the steam liner and subsequently to move radially along the horizontal well
generator capacity in this pilot, full length perforating was shown in both directions. Oil was shown to be severed by the steam and
to be more important to improve capture efficiency than overall to move by gravity drainage into the horizontal well in a manner
production rate. analogous to the movement of hot oil into the lower perforations
The original concept of HOP was therefore altered to a scheme of a vertical well after steam override in the conventional steam-
where conventional vertical wells were used for steam injection and flood process.
horizontal wells were used for production. In this modified program,
it was possible to produce all eight fully perforated horizontal wells
simultaneously (i.e., in phase) following their initial steam stimu- Pilot Operations
lation treatments. Steam Injection. Each of the eight horizontal wells was stimulated
The grid system shown in Figs. 7 and 10 was used to evaluate by injection of I,OOO-Btu/lbm [2326-kJ/kg] steam to initiate the
this modified process. In this case, the full steam generator capacity project using the eWE steam slugs shown in Table 4.
was allocated to the eight vertical injectors following 60,000- to These steam slugs were injected through a 3-in. [7.6-cm] tubing
80,000-bbl [9540- to 12 700-m 3 ] steam-soak treatments in each of string and placed at the radial terminus of each horizontal well (Fig.
the horizontal wells. 5). The disproportionate injection volumes were the result of differ-
Simulated oil recovery for the modified HOP process is shown ences in injectivity and the need to begin the production stage of
in Fig. 9. The slow response is caused by placement of the horizontal the project without incurring time delays. Wellbore surveys were
wells within the low-oil-saturation environment at the base of the not available in the horizontal wells; hence, the injection profiles
heavy-oil column. In this pilot, it is the low permeability (60 md) are unknown.
chamber wall were about 240°F [115°C]; thermocouples installed (A) IMBIBITION CURVE FROM MATCH
OF [NJECTIVITY.(McMANUS STEAMFLOOD)
near the vertical shaft indicate that temperatures there reached 250 (9) CURvE FROM MATCH OF KERN"A"
STEAM FLOOD PILOT.
>-
I-
:::;
0.05 -m
>- / <
a:
w
>
/ w
~
o / ~ IX 10-2
0 0 .04 Q.
w
a: / >
w
A)
(8)
...J / I-
<
-'
0 0 . 03
...J
/ w
a:
<
Z
/
~ 0.02
/ IXIO-!
t-
o
<
a: co
c
u.. :a:. - PILOT RESPONSE
I 0.01
go
-
Z
<>
Z
"'li
Ec--'
~-'
u;
- - IMBIBITION k rw
_.- DRAINAGE k rw
Fig. l3-Comparison of early pilot response-observed vs. Fig. 14-Drainage and imbibition relative permeability func-
simulated. tions for simulation.
>
~ 0.6
>
0
0
w
a:: 0.5
..J
~ 0.4
Z Fig. 16-Finite-dlfference grid systems for conventional five-
0 spot steamflood analysis.
t-
~ 0.3 injection. These low OSR values are comparable with those ob-
a::
LL
I
. served and calculated for the McManus steamflood.
The series of 2V2-acre [1-ha] five-spot patterns shown in Fig .
Z
....... 0.2
a
~
...J
16 was assumed for analysis of the conventional steamflood. The
Z fluid throughput rate for the full 25 acres [10 hal was set to the
'"c
:i'_ same level assumed for analysis of the modified HOP process. A
~ CWE steam injection rate of 280 B/D [45 m 3 /d] per full injector
E
0.1
~ was used with only Interval Ql open. When a total of 1.2 PVof
;;;
CWE (1 ,OOO-Btu/lbm [2326-kJ/kg]) steam had been injected, the
simulated injection was switched to warm water containing 128
°0~~~~~--~~----~~----~-----25~OO~--~3000 Btu/Ibm [298 kJ/kg]. The 15 producing wells were operated with
DAYS INJECTION
a 50-psia [345-kPa] minimum bottomhole operating pressure and
a maximum lift capacity of 320 BID [50 m 3 /d] per full well. The
Fig. 15-Comparison of simulated oil recovery-conventional several different prototypes or pattern elements shown in Fig. 16
five-spot vs. horizontal-well steamfloods. were simulated to develop the composite production function for
the entire 25-acre [lO-ha] area.
meability functions to display the sensitivity of the modified HOP
process to this variable. The functions shown as imbibition and Modeling Limitations
drainage 5 in Fig. 14 were used; these were obtained by history The modeling approach described here has several limitations; two
matching cyclic steam response observed for the McManus lease of these are caused by the current cost of computer processing and
at Kern River (Fig. 2). Relative permeability functions published the other relates to inadequate field data.
for the Kern "A" pilot 10 in the central portion of the Kern River Computer run times and costs currently prohibit the use of a reser-
field are similar to those developed for the McManus lease. voir model (for practical engineering analysis) that includes the en-
The slope of the observed pilot response in the dimensionless plot tire pilot area. As an alternative, the pilot acreage was subdivided
of Fig. 13 falls within the envelope of performance predicted by into one-eighth sectors or elements that were assumed to be enclosed
the simulator with the alternative relative permeability functions. by no-flow boundaries that do not move. Overall pilot project
The slope of the early pilot response curve might have been even response was developed by adding the responses from the individual,
more favorable if the horizontal wells had been preheated with the relatively high-resolution, fine-grid simulations of reservoir pro-
larger steam injection design slugs. totypes. Each pattern element or sector was assigned to one of sever-
al classes of reservoir prototype, where a prototype class represents
Modified HOP vs. Conventional Steamflood any combination geometry/geology/process description that yields
Pilot oil recovery predicted by the simulator for the modified HOP a significantly different simulation response. In this pilot analysis,
is compared with that predicted by the simulator for conventional the variation in structural dip among the various sectors yielded
steamflood development in Fig. 15. Results generated from imbi- significantly different simulation responses. Each of the eight pattern
bition relative permeabilities after 8 years of project simulation for elements was therefore assigned to one of the appropriate simulated
the modified HOP indicate a cumulative oil recovery of 0.74 of prototype responses to develop estimates for its oil-rate-vs.-time
OIP and a cumulative OSR of 0.20 bbllbbl [0.20 m 3 /m 3 ]. Results function. The overall pilot oil rate was then obtained by addition
for the conventional five-spot steamflood indicate a cumulative oil of the individual pattern elements.
recovery of 0.47 of the OIP and an OSR of 0.19 bbllbbl [0.19 Cost constraints also led to the simplified modeling technique de-
m 3 /m 3 ]. scribed here for the horizontal wellbore. A more rigorous approach
Predictions made with imbibition and drainage relative permea- would involve using a series of small gridblocks scaled to the size
bility functions are considered to provide a lower and upper limit of the wellbore. This type of treatment for modeling either well-
to process performance, respectively. The improved ultimate oil bores or hydraulically induced fractures 3 .4.6 is possible with the
recovery potential shown by the modified HOP reflects increased fully implicit formulation of the simulator. However, preliminary
vertical sweep efficiency associated with injecting at the top of the simulations of this nature were discontinued for analysis of this pi-
formation and producing from the base. Early conventional steam- lot because they were prohibitively expensive. Simulation results
flood response was shown to be strong in the simulations because presented here assume that the steam injected at the terminus of
the high oil saturations present in upper Interval Ql (Figs. 6 and each horizontal well (through the 3-in. [7.6-cm] injection string)
7) are open in the production and injection wellbores. unloads the water and oil within the 8%-in. [22-cm] slotted liner
The cumulative OSR for the modified HOP process was 0.18 and contacts the sandface along the full length of the well.
bbl/bbl [0.18 m 3 /m 3 ] after nearly 7 years, when steam injection Finally, the inability to obtain either openhole or cased-hole logs
was terminated and pressure blowdown was initiated. In the five- in the horizontal wells (particularly profile surveys taken during
spot analysis, the cumulative OSR was 0.15 bbllbbl [0.15 m 3 /m 3 ] injection and production operations) limits the engineering analysis
after 5 years, when steam injection was converted to warm water of this pilot.