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SPE 154760 Using A New Intelligent Well Technology Completions Strategy To Increase Thermal EOR Recoveries-SAGD Field Trial
SPE 154760 Using A New Intelligent Well Technology Completions Strategy To Increase Thermal EOR Recoveries-SAGD Field Trial
This paper was prepared for presentation at the SPE EOR Conference at Oil and Gas West Asia held in Muscat, Oman, 16–18 April 2012.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.
Abstract
Well segmentation and instrumentation have been used to improve steam injection and production conformance in a
completions strategy for a thermal-enhanced oil recovery (EOR) project by using intelligent well technology and interval
control valves (ICVs). The initial field trial is ongoing in the injector of a Northern Alberta steam-assisted gravity drainage
(SAGD) well pair. The development of the completion technology suitable for thermal conditions, initial field trial results
and the plans for further development are described in this paper. The application modeling shows that, depending on the
level of heterogeneity present in the reservoir, a 45% reduction in the steam-oil ratio and an almost 70% increase in recovery
can be achieved in a SAGD process when both improved injection conformance and producer differential steam-trap control
can be applied in a segmented horizontal well pair. A cost-effective, intelligent-well completion solution to achieve this
segmentation and control has the potential to add substantial value to field developments through improved steam
conformance. This will result in increased energy efficiency and oil recovery. The method under development is also
applicable to a wide range of other thermal EOR processes such as cyclic steam stimulation (CSS), steam drive, and
variations, including, for example, those involving solvent additives.
The initial field deployment in the injector well was initiated to prove the technology, to demonstrate the feasibility of
modifying the steam distribution, and to obtain best practices for future developments. A successful installation and
commissioning of the intelligent completion has validated the technology. Lessons learned are highlighted. Early injection
test results and data show a significant increase in the understanding of the injection and production behavior in the well pair.
A test program to optimize the distribution of the steam injection in the well is underway, and the results are discussed. The
intelligent completion technology under trial and proposed further developments should enable more extensive use of
downhole measurement and control in thermal EOR projects than has been possible to date.
Introduction
Bitumen is a thick tar-like hydrocarbon that is often found near the surface in sandy formations. Bitumen has historically
been produced using methods similar to strip mining. The sand/bitumen mixture was dug up and carried away in a dump
truck to a refining facility where it was heated to extract the bitumen from the sand. The bitumen then continued to a refining
process. Unfortunately, mining bitumen can have a large geographical footprint and does not allow access to deeper
formations.
The SAGD system was developed to improve the accessibility to deep bitumen as well as reduce the cost and
environmental impact involved with surface mining. It involves drilling two parallel horizontal wells, one about 5 meters
above the other. Initially, the bitumen is too thick to be produced. Therefore, there is an initial break-in period for both wells
in which a work string has been installed, and steam is either pumped down the string and back up the annulus or vice-versa.
During this time, the bitumen near the SAGD pair is heated, and the viscosity is reduced. Once the viscosity is reduced
sufficiently near the SAGD pair, production can commence from the lower well, and steam is pumped down the injection
well. As bitumen and water are produced from the lower production well, and steam injection continues in the injection well,
a steam cavern forms. (Shaw and Bedry, 2011)
The steam cavern is actually an area of high permeability sand from which the bitumen has already been extracted.
Ideally, steam rises from the injection well evenly as a result of its low density and the high permeability of the steam cavern.
The steam spreads horizontally as it rises and reaches the upper boundaries of the cavern. There, it condenses as the latent
heat of condensation is passed into the tar-like bitumen. The bitumen’s viscosity is reduced as it is heated, and it is drained
2 SPE 154760
down to the production well along with the condensed steam where it is produced by conventional means. The steam cavern
grows over time as more and more bitumen is produced.
Poor Injectability
If the steam cavern grows in a less-than-ideal manner, or the formation has poor homogeneity, the injection well can exhibit
poor injectability. The pressure is limited by reservoir stability and the pressure/temperature relationship in the steam table.
Since the pressure cannot be increased, the formation cannot receive the amount of steam that the operator may wish to
inject.
Steam Breakthrough
If steam breaks through directly from the injector to the producer, it causes a couple of serious problems. The first is the cost
and environmental impact of creating steam and pumping it into the producer where it serves no purpose. Reducing wasted
steam reduces CO2 emissions and conserves water. A more significant problem is created as the steam travels at high
velocity directly from the injector to the producer. The steam can pick up sand, which will erode the casing and production
string as well as fill the production well with sand. Sand in the production well can reduce production rates and destroy
artificial-lift equipment as well as equipment downstream of the well.
Lack of Conformance
Variations in the permeability of the formation can create scenarios in which the steam travels to areas in which it is not fully
used. This is a waste of energy, and it reduces the recovery efficiency.
Steam Injection
Well
Steam Production
Well
Barbell Shaped
Steam Cavern
Surface Deformation
There are several methods of measuring ground surface deformation. They are seismic, micro-seismic, 4D-Siesmic, GPS/
interferometric synthetic aperture radar (InSAR), satellite based, and surface deformation TILT monitoring. These
technologies vary in accuracy, frequency of measurement, and of course, cost. The main use in oil-sands projects is to
determine where injection and production have caused the surface to rise or subside. With proper analysis of these
measurements, the steam-cavern shape can be determined. This can be a fantastic tool for determining not only steam
placement, but also changes that have occurred due to active control of the well pair.
Some of these same types of surface deformation technologies are also used to monitor cap-rock integrity and catch steam
breakthrough before it happens.
Pressure Measurement
There are two main solutions for high-temperature downhole pressure measurement. The oldest technology used for these
environments is a bubble tube system. These systems have a small capillary tube that extends from the surface to the desired
depth of measurement. This tube is filled with an inert gas, typically helium. Since the density of the gas is known, the
downhole pressure can be calculated from the pressure that is measured at the surface.
4 SPE 154760
Fiber-optic pressure gauges have recently been developed that can operate in a SAGD environment. A special fiber-optic
transducer is terminated at the end of a fiber-optic cable that is run to the point of interest in wellbore. Downhole pressure
deflects a pressure-sensing diaphragm that is integrated with a fiber-optic sensor. The deflection of the diaphragm is
measured remotely where the optical signal is converted into an electronic output. A temperature sensor integrated with the
pressure transducer is used for both temperature measurement and thermal correction at elevated temperatures.
Flow Control
An interval control valve (ICV) has been developed to solve the issues with current methods of controlling steam injection
into SAGD systems (Figure 2). This ICV is a sliding sleeve that can be controlled from the surface and is optimized for the
temperatures and pressures of a SAGD environment. The operator can control each of the ICVs in real-time by pumping
hydraulic fluid down hydraulic control lines that run between each ICV and the surface.
Each ICV has its own dedicated control line as well as a common control line that is connected to each valve. This is called
an N+1 control system where N represents the number of ICVs. Typically, the ICVs are plumbed so that the common line
will move the ICV to a closed position. Using this control methodology, any sliding sleeve can be uniquely positioned by
pressurizing a specific combination of hydraulic control lines (Hodges, et. al., 2000).
Figure 3 illustrates three zones using direct hydraulics. It shows lines 1-3 connected to the opening chamber of the ICVs
and the common line connected to the closing chamber. The ICVs can be placed in any position by pressurizing and venting a
combination of the control lines. For instance, pressuring up on lines 1 and 3 with all of the valves closed will open the outer
two valves while leaving the middle valve closed. (Shaw, 2011)
SPE 154760 5
Using these ICVs, no intervention is required to isolate production or injection in a specific zone. Not only does this allow
the operator to react to anomalies in the formation, but it also allows the operator to steer the development of the steam
cavern.
Control lines
Centralizer Diverter
element
Injectivity
Since zones can be selectively opened and closed, injectivity changes can be monitored over time. Calculation of injectivity
into a certain zone consists of shutting-in all of the zones, then, each zone is opened individually, and the injection pressure at
several flow rates is measured. The injectivity at a certain section can be used to estimate the size of the steam cavern at that
section and to estimate conformance. (Figures 5a and 5b).
``
Elimination of Breakthrough
An ICV can also be used in the producer to produce from specific zones of the completion. This method can be applied in
situations when there is steam breakthrough directly from the injector to the producer. While an ICV can be shut on the
injector to eliminate the breakthrough, it does not allow for further injection into that section of the steam cavern. Closing the
corresponding ICV in the production well eliminates breakthrough while allowing steam injection into the corresponding
zone.
4500
4000
3500
Pressure (kPa)
3000
2500
2000
1500
1000
500
0
0 50 100 150 200 250
Temperature (C)
Figure 6 ─ Controllable injection and steam diversion increases injection temperatures and pressures in selected zones.
Solution Example
Description of Field in Canada
A SAGD system in the Orion field of Northern Alberta had been on line for a number of years (Clark, et.al. 2010). However,
geological heterogeneity had created conformance issues. Technologies such as OCDs had been used in the field, but the
formations’ lack of homogeneity would not allow for even cavern growth and bitumen production.
Description of Completion
The original dual tubing string completion was pulled from the injection well. The new completion is shown in Figure 7 and
consisted of:
• 3 Steam Diverters
• 4 High-Temperature Steam ICVs
• Custom Fluted Centralizers
• 3 Fiber-Optic Pressure Gauges
• 1 Fiber-Optic DTS System
• 8 Control Lines
a) 5 hydraulic
b) 3 pre-built fiber optic
• Heavy-Duty Dual-Channel Collar Protectors
• Ratcheting Mule Shoe Guide
Torque and drag modeling was performed to ensure the completion could be run into the hole without undue stress on
components, and also, to ensure the eight control lines would be intact once the completion was on bottom. Custom fluted
centralizers were added at strategic locations in the tubing string to ensure success. The fluted centralizers also acted as
control-line protection. The steam diverters isolated the completion into four separate zones (Zones A-D), and the ICVs
controlled the injection into each of those zones. The pressures in Zones B, C, and D were measured using the fiber-optic
gauges. The pressure in Zone A was measured at the surface through communication up the nitrogen-filled annulus. DTS
provided temperature reading in one-meter increments from the wellhead to the location of the gauge in Zone D. The control
lines were clamped at every tubing collar with dual-channel, heavy-duty line-protection clamps. The liner hanger in the well
had a very sharp entry angle, so there was concern of the completion running past it with ease. To mitigate this issue, a
ratcheting mule shoe was added to the end of the completion to ensure success.
SPE 154760 9
Results
There has been significant improvement in production after 6 cycles as shown in Figure 8. Selective injection into specific
zones has also allowed a temperature and pressure increase from 230° C to 260° C and 2700 to 4700 kPa. The SAGD pair
has exhibited a 45% improvement in SOR, and an almost 70% increase in bitumen production. Figure 9 shows that the
injectivity has shown over 100% increase in zones A and B. Pressure, temperature, and injection data also show significant
improvement in the steam cavern. The operator is now injecting solely into Zones A and B to further improve SOR and
maximize production. The ICVs have also proven to be highly reliable. They have each gone through approximately 50 to 60
full shifting cycles since their deployment in 2009. There have been no issues shifting the valves to date.
As published on the Alberta Energy Resource Conservation Board (ERCB) and shown in Figure 10, there has been
significant improvement in performance when comparing the six months prior to installation of the steam valve and the six
months after its installation. In that time, cumulative oil has gone from 3000 cubic meters to 5000 cubic meters, and the SOR
went from 11 to 6, which reduced the cumulative steam by 2000 cubic meters. These numbers can be used to estimate the
gain that has been realized by using the steam valve. Using the average price from October 2010 through October 2011 of
$62/barrel for the price of bitumen and $10/metric tone for steam, the savings can be calculated. (Alberta ERCB, 2011)
• 2000 cubic meters = 12,600 barrels; 12,600 barrels *$62 per barrel yields $781,000 increase in production over a six
month period.
• Assuming $10/ metric ton for steam, 1 cubic meter is 1 metric ton, 2000 cubic meters, *$10 yields $20,000 savings in
steam over a six month period
This represents an increase of $1.5 Million per year to the operator.
Future Developments
While current ICVs for SAGD service have yielded successful results, there has been ongoing development to make the
ICV’s even more versatile.
Current steam ICV designs are designed for operation in either a fully opened or a fully closed position. This allows for
control of injection and production to eliminate steam breakthrough, control steam-cavern growth, and minimize SOR.
SPE 154760 11
However, it requires frequent movements of the ICV to allow controlled injection into certain zones. A choking ICV is being
developed to allow partial flow into portions of the steam cavern.
The ICV is also being qualified for temperatures above those at which SAGD fields are currently operated. These higher
temperatures will provide solution technologies such as cyclic steam stimulation (CSS) or steam flood as well as green
energy systems such as geothermal.
Conclusion
1. The new completions strategy was successfully implemented in a SAGD steam-injection well and operated in
temperatures of up to 260°C.
2. The mechanical reliability and integrity of the surface-controlled thermal interval-control valves and thermal feed-
through diverters has been proven over the trial period.
3. The fiber-optic monitoring systems have proven themselves to be valuable to the evaluation of the completion equipment
and reservoir response.
4. The baseline data gathered during the trial and close surveillance has improved the understanding of the well pair
performance and its link to the geological heterogeneity. This has helped to identify the opportunities for conformance
improvement and the building of a more uniform steam chamber.
5. The completion is currently being used to modify the injection conformance in the well by injecting into one zone at the
heel. The initial indications are of some warming of these zones, an improvement in injectivity, and an improvement in SOR
performance of 45%. Evaluation of the possibility to develop a more uniform chamber will take a longer time.
References
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