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Saudi Aramco
THE SAUDI ARAMCO JOURNAL OF TECHNOLOGY
Journal of Technology
A quarterly publication of the Saudi Arabian Oil Company
Contents
Fig. 1. Target zone sand, mapped using Periscope HD to monitor the lower boundary (clearly shown
• Deploying PeriScope HD, a multilayer bed boundary GEOMECHANICS
maintain the maximum TVD and stay inside the target zone as planned.
detection service, to facilitate proactive geosteering and
provide more information about the reservoir geometry Workover sidetrack operations in this offshore field typically
and substructure. cut across several shale formation layers to target a shaly
• Utilizing cuttings flow meters to monitor hole cleaning reservoir sand. This sandstone reservoir could be at a low
effectiveness and wellbore stability. pressure due to depletion, meaning the virgin pressure in the
shale layers could be higher than the reservoir pressure.
All these solutions and technologies ensured safe and op- This difference makes it a challenge to design a mud weight
timum (MW) that can both minimize shear failure in the shales, which
Fig. 1.delivery
Target of zone
the wellsand,
and helped
mappedto achieve
usingthePeriscope
well’s HD to monitor the lower boundary (clearly shown) to
objectives. are at a higher pressure, and at the same time minimize differ-
maintain the maximum TVD and stay inside the target zone as planned.
ential sticking risk across sandstone reservoirs. Furthermore,
since the shale layers are drilled at a high angle before landing
the well, they are also prone to bedding plane failure.
Fig. 2. Graph showing that the cuttings recovery (red line) was maintained at around 90% throughou
drilling operation.
Fig. 2. Graph showing that the cuttings recovery (red line) was maintained at around 90% throughout the drilling operation.
Fig. 2. Graph showing that the cuttings recovery (red line) was maintained at around 90% throughout the
drilling operation.
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2016 3
The drilling history of the surrounding wells was reviewed sectioned to the planned sidetrack trajectory to construct a
to understand the shale failure mechanisms and to mitigate pre-drill MEM. Using the information gleaned from the drill-
the drilling risk. A robust mechanical earth model (MEM) was ing history of surrounding wells, a MW of 84 pounds per
constructed using logs from one well of interest, which were cubic foot (pcf) was found optimum to minimize shear and
calibrated by correlating the predictions to the drilling history bedding plane failure in the shale as well as differential stick-
of surrounding wells. The rock properties were then curtain ing risk in the sandstone. During drilling, the cuttings at the
Fig.
Fig. 3.3.
Fig. 3.Plots
Plots
Plots showing
showingshowing the
thedelicate
the delicate control delicate
of control
control
drilling operation of
ofdrilling
maintaineddrilling operation
throughoutoperation
the job. maintained
maintainedthroughout
throughoutthe
the job.
job.
Fig. 3. Plots showing the delicate control of drilling operation maintained throughout the job.
4 FALL 2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
This zone was
isolated as the
standoff from
GOC was low
Fig. 4. Permeability graph showing the completion setup and design based on the lateral’s standoff distance from the gas cap.
Fig. 4. Permeability graph showing the completion setup and design based on the lateral’s standoff
distance from
shale shaker werethe gas cap.
monitored and correlated to the downhole circulating and tripping. These meters were installed in front
logs. The well was drilled successfully with a MW of 84 pcf of each shale shaker and connected to software programmed
without any drilling issue. to process the raw data coming from the meter and compare
This zone was them to the theoretically calculated data so as to draw con-
WELL PLACEMENT
isolated as the clusions regarding the borehole condition.
standoff from This automated analysis ensures a clean hole while drill-
GOC was low
The well was landed smoothly in the target sand, and the ing and lowers the chances of cuttings accumulations in the
bottom boundary was continuously mapped, Fig. 1, to en- annulus. It also provides the foreman and engineers with
sure successful geosteering in the target zone, while main- valuable information when they have to decide if a sweep
taining the maximum planned true vertical depth (TVD) pill or short wiper trips are needed. Furthermore, it directly
until total depth (TD), and keeping to a maximum dogleg of contributes to increasing the overall rate of pick penetration
8.5°/100 ft. It is quite important toThe watch
ICD
out for the The ICD and
sand minimizes
encourages the shale
influx exposure,
for these whichwhich
intervals, is a critical
is parame-
layer’s changing dip and thickness, as losing
restricts influxtrack of the ter for wellbore stability maintenance.
farthest away from the GOC. These meters assist in
for this
Fig.
sand4. Permeability
would impact the graph showing
reservoir the completion
contact length
interval.
as well as setupdrilling
and design
the hole based on the the
and lowering lateral’s
liner tostandoff
the bottom safely
distance
raise hole from the gas
instability cap. Standoff from
concerns. as the acquisition unit allows the user to set up alarms to
GOC is low. alert the field engineers if any anomalies occur.
Zone
HOLE CLEANING has been Shale
As seen in Fig. 2, the cuttings recovery was maintained
isolated as the
standoff from at around 90%, which helped in controlling the equivalent
Cuttings analysis is a tedious
GOC is < 10 ft. and time-consuming task, but circulating density, optimizing pill frequency, monitoring
automated approaches can significantly facilitate this pro- wellbore instability and undesired shale cuttings, maintain-
cess and yield high quality results1. Cuttings flow meters ing good mud properties, and checking the average hole
were deployed to monitor the rock cuttings returning to the size with each pill pumped to ensure no hole enlargement.
surface during the different rig operations, such as drilling, This excellent hole cleaning and constant wellbore control
The ICD The ICD encourages influx for these intervals, which is
restricts influx farthest away from the GOC.
for this
interval.
Standoff from
GOC is low.
Fig. 5. The
Zoneoilhas
influx
beenfrom the lateral for the different completion scenarios: ICD cases (red, green) and
Shale
base case (blue).
isolated as the
standoff from
GOC is < 10 ft.
Fig. 5. The oil influx from the lateral for the different completion scenarios: ICD cases (red, green) and base case (blue).
Fig. 5. The oil influx from the lateral for the different completion scenarios: ICD cases (red, green) and
base case (blue).
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2016 5
throughout the job are clearly reflected in plots of the drill-
ing operation, Fig. 3.
Zone has been isolated
as standoff from the
GOC is > 10 ft.
INFLOW CONTROL DEVICE (ICD) COMPLETION DESIGN
The ICD restricts influx
of a larger field complex, which has an active gas drive. This The ICD encourages
influx for this
interval, which is
gas cap introduced another geosteering challenge, given that away from the GOC.
Fig. 7. The tubing flow profile showing pressure drop for the two ICD scenarios.
Fig. 7. The tubing flow profile showing pressure drop for the two ICD scenarios.
6 FALL 2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
7” Casing
Baker PAC 4½” MPas 4½” MPas 4½” MPas 4½” MPas GPV
TOW at
Valve Packer Packer Packer Packer Shoe
5,190 ft TD at
4½” 11.6# Casing
12,400 ft
Baker PAC 4½” MPas 4½” MPas 4½” MPas 4½” MPas GPV
TOW at
Valve Packer Packer Packer Packer Shoe6⅛” Open Hole
5,190 ft 4½” 350 Micron Resflow ICD Screen 4½” 350 Micron Resflow ICD Screen TD at
Baker ECPs Motherbore
12,400 ft
Fig. 8. The final well lower completion schematic showing the ICD screens along with the open hole isolation packers as run in the well.
Fig. 8. The final well lower completion schematic showing the ICD screens along with the open 6⅛” holeOpen Hole
completion.
isolation Figure 8as
packers is the
runfinal lower
in the completion
well.
Baker ECPs design,
4½” andICD
350 Micron Resflow drillstring
Screen 2
. In4½”
addition,
350 Micronthere
ResflowisICD
a need
Screento maintain
Motherborethe
showing the ICD screens and packer placements. integrity of the open hole swell packers and the liner’s exter-
nal casing packers, which means rotation of the completion
Fig. 8. The final well lower completion schematic showing the ICD screens along with the open hole
TORQUE AND DRAG string is not an option. Therefore, torque and drag problems
isolation packers as run in the well.
can occur. To reduce friction in any well, a good mud pro-
Drag is measured as the difference between the static weight gram design is important. In this well, the friction factor was
of the completion string and the tripping weight. In extended as low as 0.3, and the torque and drag simulation results,
reach holes, horizontal displacement usually is limited be- Fig. 9, ensured that the BHA design was suitable for this
cause of frictional forces between the drilling and comple- type of well.
tion string and the hole wall. Torque and drag modeling
therefore is critical when estimating the capability of the rig
Authors: Dr. Jinjiang Xiao, Randall A. Shepler, Yhossie S. Windiarto, Rob Fox and Stuart Parkinson
ABSTRACT 50% of the electrical failures in one key offshore field were
related to the electrical connection below the ESP packer
In high hydrogen sulfide (H2S) and high-pressure/high tem- penetrator and to the motor lead extension (MLE), Fig. 1.
perature fields, the average run life of electrical submersible Moreover, severe service environments for ESP systems are
pumps (ESPs) is still limited to three years. The dismantle generally defined as those applications where the wells have
inspection failure analysis results show that around 50% downhole hydrogen sulfide (H2S) concentrations above 5%
of ESP failures are directly or indirectly related to electrical and carbon dioxide concentrations of more than 5%. In
delivery problems concentrated at a distance of about 200 ft such applications, corrosion will also affect the run life of
between the packer and the motor. This article presents the any equipment. The rate and extension of corrosion, how-
results of a collaborative R&D effort to develop and field ever, can differ based on fluid partial pressures, bottom-hole
test a reliable power delivery system (RPDS) with the goal temperature and well history — according to the evidence of
of extending the average ESP run life from the current three previous premature corrosion.
years to 10 years. To alleviate this issue, a joint research project was initi-
The development focused on improving the reliability of ated to develop a reliable power delivery system (RPDS) as a
key power delivery components, including the packer pene- solution to prolonging ESP run life in a harsh environment.
trator, the motor lead extension (MLE) cable and the cable
connection with the motor. The design not only integrates SYSTEM DESCRIPTION
learnings from advanced completions and subsea technol-
ogy, but also includes new concepts, features and materials. The RPDS configuration provides increased reliability over
Connections that could be pressure tested in the field were im- the conventional MLE configuration. The key aspect of the
plemented to ensure the proper makeup of field connections. RPDS is the fact that all primary interfaces are field testable
Factory testing brought together a robust, highly accelerated and metal to metal, vastly reducing the potential failure
life test methodology to simulate a 10-year service life. modes caused by high H2S and rapid gas decompression. The
Prototype components were designed, fabricated and scope of development included modification of the motor
tested. These components were then integrated and subjected head to accept new feedthrough connectors, metal encased
to a rigorous system integration test. After the comprehen- cable, a splice connector below the packer, a packer adapter
sive factory tests, a field prototype system was built and and penetrator, and modification of the ESP cable connector.
installed in an offshore well. The system was put into oper- Figure 2 shows the RPDS components that were addressed in
ation and exceeded the field test’s success criteria of a mini- this R&D project.
mum run life of 180 days.
Damaged/Burned
For years, engineers and companies have battled with ESP Motor (15%) Intake and Pump Plugging (16%)
The reliability of the electrical connections in electric sub- ESP Packer Penetrator (28%)
Fig. 6. Metal encapsulated MLE cable with three connector configuration, covered with the replacement
Pressure test port Fig.or6.
625 825Metal encapsulated
alloy (orange color). MLE cable with three connector configuration, covered
Pressure test port
Pressure test port
Fig. 6. Metal
with the encapsulated
replacement MLE
625 or 825 alloy cable
(orange with three connector configuration, c
color).
625 or 825 alloy (orange color).
Individual pressure test port
Dual Dual
metal
Dual
metal
conecone
metal tocone
sealseal to
seal to Individual pressure test port
metal metal encapsulated
encapsulated
metal MLEMLE
encapsulated MLE Primary metal-to-metal seal to encased MLE cable
(3 individual terminations)
Fig.
Fig.5.
Fig. 5.Connector’s
5.5. Connector’s
Connector’s metal-to-metal seal
metal-to-metal
metal-to-metal with
seal thewith
seal
with MLE,
with
the including
the
MLE, a including
test port.port.
MLE,including
including a test a test port. Fig.
Fig.7. 7.
Splice connection
Splice added below
connection addedthebelow
packer.the packer.
Fig. Connector’s metal-to-metal seal the MLE, a test port.
10-Year Run
Life Goal
Breakdown Voltage (kV)
Fig. 10. Data from accelerated aging test plotted to produce a degradatio
Fig. 10. Data from accelerated aging test plotted to produce a degradation curve.
Fig. 10. Data from accelerated aging test plotted to produce a degradation curve.
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2016 15
connectors and is preassembled in the shop, which makes it Probability of 200 ft MLE
possible to ship the penetrator to the field with the packer Operating Voltage (kV)
Exceeding 10-Year Run Life
and splice connector already terminated, connected and 26 6.26E-4%
tested. It incorporates the same key features and sealing phi-
22 31.90%
losophy as the motor feedthrough connectors.
The upper section of the penetrator mates with the ESP 20 74.10%
power cable. Despite this, this side of the connector will be 16 98.70%
submerged in completion fluid and won’t see well fluids; it 8 99.99%
also incorporates a metal-to-metal seal at the connector in- 4 99.99%
terface to the packer penetrator.
Table 1. A 10-year run life probability vs. operating voltage
Figure 9 shows the ESP power cable connector, which is
based on subsea dry mate technology. It interfaces with the
a logarithmic scale, which best fits the expected degradation
packer penetrator and allows the ESP cable to be connected
curve, Fig. 10. This degradation curve was then extrapo-
to the penetrator. It was modified to suit the AWG #2 main
lated to 10 years, and a run life probability was established
cable by adding a new cable seal and termination sleeve.
based on the operating voltage. The result is the percent
Some specific installation tools were developed as well, in-
probability that the unit will operate for 10 years at various
cluding a detailed installation and handling procedure for
operating voltages. Table 1 shows that at operating voltages
termination and testing both at the operational base and in
equal to or less than 8 kV, there is a 99.99% probability of
the field.
exceeding a run life of 10 years.
COMPONENT LEVEL TESTING — METAL
ENCASED MLE FACTORY SYSTEM INTEGRATION TEST
Encapsulated Cable Cold Bending Test A qualification test of the RPDS was conducted in the
factory.
This test simulates the bending of the finished MLE over
the sheave — the sheave is the wheel used in the installation Endurance Testing
of the ESP. The MLE goes from the spool and through the
Operating Voltage (kV) Probability of 200 ft MLE Exceeding
sheave before it is connected to the motor during installation This test proved the connector string’s
10-Year Run Lifefunctionality as a sys-
26 6.26E-4%
at the well site. Because in some parts of the world installa- tem
22
under simulated maximum operating
31.90%
conditions. Figure
tion temperatures can be as low as -40 °C, test samples were 11 is a picture of the endurance test setup. The test ran for
20 74.10%
16 98.70%
bent after being stored at -40 °C for a minimum of 24 hours. 40
8 cycles. The number of cycles was determined per the life-
99.99%
4 99.99%
This test was performed five times around a 16” mandrel, time testing of the encapsulated cable, which was relevant to
Table 1. A 10-year run life probability vs. operating voltage
which is less than half of the 42” sheave diameter. This the connector system. Electrical verification tests were taken
small reel was used as it was able to fit inside a freezer. Even prior, during — at the start of each cycle — and after the
though this MLE was tested using a 16” mandrel, the mini- test to ensure the connector string’s performance was within
mum bending diameter recommended for this product is still the acceptance criteria. The test parameters were:
42”. Results show no damage or loss of electrical properties
because of the cold bending, so this test was considered
successful. ESP Cable Connector
Vessel (covered in
Encapsulated Accelerated High Temperature insulation) containing
connector string
Aging Test
Motor interface simulation
(hose contains oil, so
termination components
This test simulates material aging, which will occur during are immersed)
the product’s expected 10-year life at a maximum tempera-
Fig. 11.
Fig. 11.Endurance
Endurancetest
test setup.
setup.
ture of 176 °C. For this test we chose to simulate acceler-
ated aging by testing the samples at 216 °C for 5 days, 10
Cycle Voltage (Phase) Current (Phase)
days, 20 days, 40 days and 80 days. The Arrhenius model2
1 1-2 3
indicates that for every 10 °C increase in temperature, the
product life is reduced by half. Therefore, if the expected 2
Cycle Voltage (Phase) Current1-3
(Phase) 2
1 1-2 3
life is 10 years at 176 °C, the expected life is reduced to 23 1-3 2-3
2 1
0.625 years (228 days) at 216 °C. By doubling the aging 3 2-3 1
Table 2. The wiring arrangement for the thermal cycles
duration between each dataset, we could plot the results on Table 2. The wiring arrangement for the thermal cycles
Table 3. Shock and vibration test parameters SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2016 17
Fig. 12. IR profile during endurance test.
AC Breakdown Testing
Table 3. Shock and vibration test parameters Fig. 14. Motor feedthrough connectors.
Fig. 14. Motor feedthrough connectors.
18 FALL 2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
Fig. 15. Field installation of the RPDS.
Fig. 15.criteria.
acceptance Field installation
The glass transition of theof the
PEEK RPDS.
insula- CONCLUSIONS
tion material used on the connector’s contact pins is 170 °C,
whereas the highest recorded temperature during the test was The RPDS maintained electrical integrity, ensuring proper
36 °C. Contact resistance values taken after both the 4-hour ESP performance for more than 250 days. This outcome pro-
test and surge test were within acceptance criteria. This test vides enough confidence to install the system not only in this
was successfully passed. offshore field, but also in other fields with high H2S concen-
trations. The project demonstrated the successful collabora-
FIELD RESULTS tion of bringing subsea and advanced completion connector
and penetrator technologies to ESP applications.
The field test objective was to assess the performance of
the RPDS for a period of at least 180 days to determine the ACKNOWLEDGMENTS
robustness of the feedthrough connection and the usability
of the system. The idea was also to determine the challenges The authors would like to thank management of Saudi
that the field personnel might encounter during the handling, Aramco and Schlumberger/OneSubsea for their permission to
installation and operation of this MLE and motor head sys- publish this article.
tem, and to assess their effect on the short-term operational This article was presented at the SPE Saudi Arabia Section
performance of the product. Moreover, the RPDS had to Annual Technical Symposium and Exhibition, al-Khobar,
maintain good electrical readings during the test period. In Saudi Arabia, April 25-28, 2016.
case an ESP failure arose, it was important that it not be as-
sociated with the RPDS. REFERENCES
The system was installed in an offshore well in February
2015 and has successfully operated for more than 250 days, 1. Al-Sadah, H.: “ESP Data Analysis to Enhance Electrical
which exceeds the field test’s success criteria of a minimum Submersible Pump Run Life at Saudi Arabian Fields,” SPE
180-day run life. Figure 14 is a photo of the actual motor paper 173703, presented at the SPE Middle East Artificial
feedthrough connectors. Figure 15 shows the field installa- Lift Conference and Exhibition, Manama, Bahrain,
tion of the RPDS. The downhole equipment configuration November 26-27, 2014.
includes a pump with 57 stages, a LSBSB-BSBSB severe ser- 2. Spahi, S. and Parsley, P.: “Reliable High Power ESP
vice protector and a 300 HP motor. The ESP with the RPDS Tubing Hanger Connector Systems for Deepwater
was function tested in March 2015 at various speeds and an Downhole Applications,” OTC paper 24138, presented
estimated rate of 5,000 bbl of fluid per day (BFPD). at the Offshore Technology Conference, Houston, Texas,
Upon rig movement, the ESP was commissioned and is May 6-9, 2013.
running at an average of 55 Hz. During the life of the ESP,
several trips were made to the subsea well for various reasons;
however, the ESP, electrical connection system and RPDS still
indicated a healthy system. The ESP is still running and con-
tinuously producing between 5,000 BFPD to 8,000 BFPD.
Authors: Yousif M. Abu Ahmad, Rami F. Saleh, Brett W. Bouldin, Robert J. Turner and Ali Bin Al-Sheikh
posed to a cased hole completion. The Saudi Aramco drilling Saudi Aramco has many Lateral 0
team was faced with the challenge of executing a multilateral oil Lateral
producing
1 tight car- Lateral 2
well plan that involved running three open hole lateral com- bonate
Lateral 0formations that
pletions. The intent was to segment the open hole laterals respond
Lateral 2 well to horizon-
and then provide active control and monitoring capabilities tally drilled, open hole
for each segment. Such a completion requires a complex completions. Experience
power and telemetry system that can deliver electric power has shown that increased
to all the segmented lateral completions, including the ones reservoir contact with a
that are deployed through the milled windows. The open lower unit drawdown is
hole laterals also had to be conditioned properly to success- an effective way to in-
fully run the modified completion components in the open crease recovery and mini-
hole without restriction and land the completions at the pre- mize water and gas coning
7” Liner
7” Liner
cement the liner and mill the windows without intersecting km of reservoir contact, 9⅝” Casing
the cable, which would jeopardize the success of the entire Figs. 1 and 2. By 2004, in-
Fig. 1. A plan view of a typical MRC well.
completion. The team developed new procedures to properly telligent completions were
Fig.
Fig. 1.1.AAplan
planview
view of
of a
a typical
typicalMRC
MRCwell.
well.
execute these operations and succeeded in maintaining the added with the placement
integrity of the power system and landing the completions
at depth. This was confirmed by conducting tests at various
stages throughout the implementation process.
An integrated project, such as this one, requires focused
collaboration between the drilling and completion teams.
Whereas the traditional practice is to drill to total depth and
then complete the well, this unique completion design requires
a repeated drill-and-complete sequence as the well progresses.
In addition to highlighting the key factors in managing
Fig.
Fig. 2.
2. Plan of aa standard
standard trilateral
trilateralwell.
well.
and implementing such a well, where various disciplines are Plan of
isolated with swell packers. The innovative design requires location has been identified, each lateral is drilled and one
the deployment of what has been coined a “wired liner.” Manara completion, containing several stations, is installed
The liner itself is used as a power and telemetry conduit per lateral. Figure 5 shows the general makeup of the lateral
between the upper completion and Cable wrapped
the lateral around
segments, pro-the liner to
completion, with the two Manara stations compartmental-
viding a permanent path for ACallowpowerforandwindow milling without
communication. ized by a swell packer.
The liner was “wired” by adding intercepting
the followingthe cable.to
elements
the string: WIRED LINER
Fig. 5. Lateral completion showing the ICC locator, a coupler, the umbilical, and Manara Stations
separated by swell packers (figure provided by Schlumberger).
Fig. 5. Lateral completion showing the ICC locator, a coupler, the umbilical, and Manara Stations separated by swell packers (figure provided by Schlumberger).
Fig. 5. Lateral completion showing the ICC locator, a coupler, the umbilical, and Manara Stations
separated by swell packers (figure provided by Schlumberger). SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2016 23
to 9”. Enlarging the hole was necessary for several reasons During the first run, an anchor packer is run in hole, and
related to the integrity and successful deployment of the wired then oriented and spaced out in reference to the cable loca-
liner. First of all, when pumping the cement for the new liner tion. Ideally, the window should be cut 180° from the cable,
in the smaller hole, the annular restrictions created by the on the opposite side of the liner, minimizing the chances of
clamps and cable will result in high equivalent circulating den- contact with the umbilical. The whipstock is set in the sec-
sities acting on the borehole, which may result in fracturing ond run and the window milling operation is initiated.
the formation and lead to severe losses. Another reason for Once the window depth and orientation are selected, the
hole enlargement is the presence of reactive shales; enlarging window can be milled with minimal chances of intercepting
the hole will help to overcome the time dependent swelling of the cable. The challenge arises when trying to separate from
the shales during liner deployment and keep them from creat- the liner with no reliable directional readings due to the
ing an obstruction. Finally, the additional clearance between magnetic interference created by the BHA’s proximity to the
the open hole and the liner will accommodate the increase in metallic body of the liner. This essentially creates a blind
the effective diameter of the liner and its accessories. spot for the first ± 200 ft of drilling beyond the window.
In Trial 3, a two-run operation was conducted to enlarge The risk materialized in Trial 3, where the window was suc-
the 8½” hole. First, the hole was drilled, then a separate cessfully milled but separation was not achieved. The BHA
underreaming run was performed to enlarge the hole. This instead tracked the liner and intercepted the umbilical, lead-
was found to be time-consuming and provided no additional ing to aborting the project and running a conventional intel-
benefits with regards to hole quality. For the subject well, ligent completion. To address the lack of directional readings
the drilling and underreaming were performed in a single during separation, a method for monitoring the separation in
run, resulting in a more than 50% reduction in time when real time needed to be established.
compared to the two-run method.
Based on the lessons learned from previous wells, a fit-for-
The specific 9” gauge of the enlarged hole was selected
purpose procedure was implemented to ensure proper separa-
based on previous trials. When one well was enlarged to
tion from the liner without damaging the umbilical cable. At
10”, it created an excessive gap between the liner and open
the core of the procedure is the ability to qualitatively monitor
hole, resulting in poor cement distribution. The excessive ce-
the separation of the drilling BHA from the liner in real time,
ment thickness on one side of the liner may contribute to the
enabling any immediate adjustments in the directional drilling
BHA tracking the liner during window milling and subse-
BHA steering ratio as needed. This was achieved by deploying
quent lateral drilling operations. This scenario was observed
a near bit, real-time resistivity tool in the directional drilling
during Trial 3, when the BHA drilled the cement around the
BHA to monitor the resistivity trends. The tool registers the
liner, rather than the harder compressive strength rock, and
difference between the liner resistivity and formation resistiv-
so tracked the liner, which resulted in intercepting the elec-
ity as the drilling BHA progresses in depth, Fig. 6. The mon-
tric umbilical. This led to aborting the completion plan and
itoring employed a matrix to accelerate the decision making
running the contingency conventional intelligent completion.
process while drilling past the window.
Based on the lessons learned from the trials, the under-
The first point, Pt 1, shows no resistivity reading, indi-
reamed hole size was reduced to 9”, which provides enough
cating that the tool is in the liner. Once the tool exits the
clearance to run the liner with all its accessories without
window, a signature spike in resistivity is observed, Pt 2.
jeopardizing the cement quality.
This spike is the first positive indication of separation from
WINDOW MILLING AND CABLE AVOIDANCE the liner. The resistivity should then move closer to the
formation resistivity as drilling progresses. Successful sep-
The fact that an umbilical cable is wrapped around the liner aration is signaled when the resistivity reading matches the
makes it challenging to mill the window while keeping the formation readings. If a trend is observed of declining or sta-
cable intact. One of the functions of the ICCs is to permit bilizing resistivity prior to reaching the target value, several
the identification of the cable location. Dedicated cable lo-
Casing Resistivity at Formation
cating runs were conducted for each of the ICCs. Based on Resistivity Window Exit Resistivity
the information, the whipstock orientation was selected with
a contingency for each window. Because the depth restriction
of the windows limited the options of window orientation,
a proper window milling procedure needed to be developed
and followed to ensure successful drilling exit and separation
from the liner and its umbilical cable in the first milling at-
tempt. This procedure is described as follows.
Once the cable’s location behind the liner is confirmed,
Fig. 6. Real-time resistivity readings as a lateral is drilled.
window milling is carried out using a two-trip process. Fig. 6. Real-time resistivity readings as a lateral is drilled.
Fig. 7. Tripping the pipe with circulation allowed the cuttings to be carried to the surface improving the FF by about 0.025.
Fig. 7. Tripping the pipe with circulation allowed the cuttings to beJOURNAL
SAUDI ARAMCO carried to the surface
OF TECHNOLOGY FALL 2016 25
improvi
by about 0.025.
by about 0.025.
Fig. 8. Reaming trips smoothened the borehole and enabled more cuttings to be lifted to the surface, improving the FF by about 0.05.
Fig. 8. Reaming trips smoothened the borehole and enabled more cuttings to be lifted to the surfac
improving the FF by about 0.05.
Fig. 9. Increasing the fluid viscosity gave better cutting suspension, which slightly improved the FF.
Fig. 9. Increasing the fluid viscosity gave better cutting suspension, which slightly improved the FF.
practice the whipstock engineer monitors the milling oper- CONCLUSIONS
ation to ensure success. In the case of the subject well, both
the multilateral engineer and the completion engineer were One of the primary goals of the team was to establish spe-
involved in the window milling operation to ensure that cific procedures and practices that can be implemented on
the completion passed through the window. In many cases, future wells. Through the lessons learned from the subject
the completion requirements directed the drilling practices, well and the preceding trials, the team was able to produce
necessitating a new level of compromise between different an effective step-by-step methodology for drilling similar
segments within the team. This was crucial, for example, wells and set the standards that will open the door for fur-
to achieving the desired low FF in the 6⅛” open hole. The ther efficiency and optimization.
drilling practices, clean out operations and BHA design
where optimized to reduce the FF while sacrificing the rate ACKNOWLEDGMENTS
of penetration.
The stated examples represent a common theme seen The authors would like to thank the management of Saudi
throughout the project. Collaboration and alignment of Aramco and Schlumberger for their support and permission
goals and objectives among the parties was achieved with to publish this article.
effective communication involving extensive meetings and This article was presented at the Offshore Technology
correspondence. Conference, Houston, Texas, May 2-5, 2016.
ABSTRACT of these tools can only be used outside the zone of magnetic
interference once sufficient separation from the motherbore
Generally, deep gas workover and reentry wells in Saudi has been achieved. Moreover, consistent doglegs of more than
Arabia are kicked off in the Sudair formation through a 14°/100 ft were recorded using the HRSS; the maximum dog-
whipstock because the overlying base Jilh dolomite (BJD) leg was 17.44°/100 ft.
formation can flow with high pressure, which jeopardizes Since then, this concept has been applied successfully to
well control. Whipstocks are set deep in the 9⅝” casing, other vertical reentry wells and at existing inclinations in the
after which the 8⅜” and 5⅞” holes are drilled to access the 8⅜” and 5⅞” sections in Saudi Arabia and worldwide. The
targeted lower carbonate and sand reservoirs. Deeper kick- scope of the article is limited to Saudi Arabian deep gas wells
offs also avoid contact across the water-bearing Carbonate only. The average ROP across the build section showed a
A reservoir and instead aim for displacement across the 137% improvement over the ROP for conventional motor
Carbonate B or C reservoirs. Isolation from the Carbonate A bottom-hole assemblies (BHAs) across similar build sections.
reservoir is important for multistage fracturing completions Eliminating the 8⅜” section, avoiding the hazards of drilling
as they are still not proven for maintaining the long-term in the Jilh and Sudair formations, saving the motor trip to
isolation of water-bearing zones. kickoff from the whipstock and improving the ROP resulted
Regardless of the deeper whipstock setting, the high dogleg in significant savings. This step change in drilling performance
requirements of such wells exceed the capabilities of conven- was realized by acquiring a thorough understanding of local
tional rotary steerable systems (RSSs). Conventional steerable drilling conditions and conducting the in-depth analysis that
motors with a high bend housing and the capacity to achieve enabled efficient execution.
70% to 80% of the sliding mode of drilling have been the only
option to drill wells with such high dogleg severity (DLS) — INTRODUCTION
100 ft. Drilling medium radius wells with a conventional motor
assembly, however, requires multiple runs, several wiper trips Most of the deep gas wells in Saudi Arabia are drilled in the
to clean the hole and multiple reaming trips before running gigantic South Ghawar field. The main gas producing zones
are the Late Permian Carbonate B and C stacked carbonate
the liner. These operations show poor drilling efficiency due to
reservoirs1. Wells drilled here incorporate three types of cas-
their slow rates of penetration (ROP) and numerous bit trips.
ing designs, namely MK1, K1 and K2. Figure 1 shows the
A high build rate rotary steerable system (HRSS) was in-
troduced as a solution to such challenges in these workover
wells’ 8⅜” and 5⅞” sections. While the HRSS technology
has been used before, this was the first time the HRSS kicked
off vertically from a whipstock in a well in Saudi Arabia,
setting a worldwide milestone. The new technology allowed
the kickoff point to be pushed further into the Sudair for-
mation near the Sudair dolomite, reducing the costly risk
from Jilh pressure. The step change also provided the option
to slim the hole by eliminating the 8⅜” hole size, so kickoff
was done in the 7” liner.
Deployment of the HRSS, which allowed direct kickoff
from a whipstock set vertically, eliminated the need for a ded-
icated steerable motor assembly run. Direct kickoff also meant
eliminating the need for a gyro tool, used to enhance the
Fig.1.1.The
The differences between theK1
K2, K1 andcasing
MK-1designs.
casing designs.
steerability of conventional RSS tools; the steering capacity Fig. differences between the K2, and MK-1
300
weight on bit is pushed from the beginning to steer away from
250
the motherbore. The advantage of having near bit inclination
is that it provides real-time assurance of separation away
200
from the pilot hole, even though the azimuth readings are still
Time (hrs)
150
affected by magnetic interference. A proper fatigue manage-
100
ment process has to be followed prior to drilling to ensure the
50
tubulars are in good condition to resist the bending stresses
0
Well F Well G Well H Well J associated
Well K with use in a high DLS environment.
Time to kick off (hrs) Time between POOH and P/U RSS (hrs)
RESULTS
Fig.2.2.Time
Fig. Time taken
taken to drill
to drill sidetracks
sidetracks in reentry
in typical typicalwells
reentry wells
using using a conventional
a conventional motor, RSS BHAs, and
gyro tools. Time Time between Pull
motor, RSS BHAs, and gyro tools. Well Hole Size Required to Out of Hole and Comments
Kickoff Pick Up RSS
Table 1 describes the average time taken to sidetrack from
contingency plans for high mud, in case flow is encountered Well F 8⅜” 216 65.5
Gyro tool failure led to tracking 7” liner
due to channeling in the cement. A dedicated run for gamma Well G 8⅜” 30 27.5 Smooth kickoff
of Ha conventional
Well 8⅜” 19steerable motor 21 assembly Smooth and kickoff
a gyro tool;
ray and/or casing collar location is carried out before the Well J 8⅜” 43 No RSS used Difficulties kicking off
it also depicts the time taken for a round trip — pulling
whipstock setting to correlate the depth and avoid setting the Well K 5⅞” 43 No RSS used Difficulties kicking off
out of hole and picking up the RSS — to change the BHA
whipstock in front of a casing collar. A gyro tool is used to Table 1. Average time taken to sidetrack from the motherbore using a whipstock with the help of a
10.0 2000
is more than 5°. 9.0 1800
8.0 1600
with its length determined by the distance of the top stabilizer 7.0 1400
on the HRSS tool and the bit. The rathole length has to be
6.0 1200
Footage (ft)
5.0 1000
kept short enough to prevent losing TVD room, needed to 4.0
9.0
800
7.3 7.4
ease the dogleg requirement, while at the same time it has to 3.0 6.0
6.6
600
be long enough to ensure that once drilling has started, the 2.0
3.1
400
0.0 0
and casing does not cause damage to the HRSS tool. The road Well MR1 Well MR2 Well MR3 Well MR4 Well MR5 Average
Table 2. Average ROP of medium radius wells drilled using a conventional steerable motor assembly and cutting across formations from BJD to Khuff.
Table 3. Average ROP and DLS on the five reentry wells drilled using the HRSS tool across formations varying from Sudair to the Carbonate B reservoir.
17.0 1600
shows the average ROP and maximum DLS of drilling the
16.5 1400 five reentry wells using the HRSS, while Fig. 4 illustrates the
Rate of Penetration (ROP ft/hr)
Footage (ft)
800
steerable motor assembly. This represents a 137% increase
16.7
14.5
600
14.0 15.6
in ROP over the conventional steerable motor option. It
15.3
15.8 15.8 400
13.5
14.2
13.0 200
also means that an estimated 3.7 days of drilling time can
12.5 0
Well A Well B Well C Well D Well E Average be saved if the curve of the medium radius well of 1,000 ft
Fig.4.4.
Fig. ROP
ROP and footage
and footage achieved achieved in with
in wells drilled wellsthe drilled with
HRSS tool, theoffHRSS
kicking tool,a whipstock.
directly from kicking has to be drilled. In addition, direct savings of at least 40
Wells A and B were kicked off in the 5⅞” section, while Wells C, D and E were kicked off in the 8⅜”
off directly from a whipstock. Wells A and B were kicked off in the 5⅞” section,
section. hours or 1.6 days were achieved due to the quick exit di-
while Wells C, D and E were kicked off in the 8⅜” section.
rectly from the whipstock since a dedicated motor run was
time spent and average ROP of drilling five medium radius no longer needed to achieve separation from the motherbore
wells in the same set of formations using the steerable motor
Reentry Wells with Direct Whipstock Kickoff and High DLS
and move away from the zones of magnetic interference to
Well Hole Start Incl End Incl Footage ROP (ft/hr) Max DLS Runs
Size
A 5⅞” 2° 48° 579 15.8 17.4 1
B 5⅞” 19° 84° 1,187 16.7 10.7 1
C 8⅜” 32° 74.85° 1,424 14.2 6 1
D 8⅜” 3° 41° 576 15.8 10.3 1
E 8⅜” 2.2° 81.5° 1,359 15.3 9.3 1
Average ROP = 15.6 ft/hr
Table 3. Average ROP and DLS on the five reentry wells drilled using the HRSS tool across formations
varying from Sudair to the Carbonate B reservoir
Fig. 5.
Fig. 5. Results
Results achieved
achievedininWell-A.
Well-A. Fig. 6. Results achieved in Well-B.
Fig. 6. Results achieved in Well-B.
Authors: Mohammed A. Geer, Dr. Ahmed Gmira, Dr. Ali A. Yousef and Dr. Sultan M. Al-Enezi
ABSTRACT lately and has proven the efficiency of this recovery method.
Extensive research on oil-brine-rock systems has shown the
SmartWater flooding has proven to be an effective and suc- impact of ionic makeup and salinity on wettability alteration
cessful recovery method for carbonates. With SmartWater and oil recovery.
flooding, the injected water alters the carbonate rock wettabil- The consensus in the industry is that salinity affects oil-
ity to produce incremental oil. Core-scale displacement exper- brine-rock systems by rock wettability alteration. A series of
iments have demonstrated significant incremental recoveries in spontaneous imbibition tests were conducted1, 2 on carbonate
both secondary and tertiary modes. Single well chemical tracer rocks, and the results attributed the observed oil recovery
tests have demonstrated this potential in the field at a scale increase to the interplay of determining ions — magnesium
larger than that available in the laboratory. Still, the underly- (Mg2+), sulfate (SO42-) and calcium (Ca2+). SmartWater injec-
ing mechanisms responsible for the SmartWater alteration of tion in carbonates has been widely investigated in several pre-
carbonate wettability are not well understood. The objective vious studies, which showed the positive impact of seawater
of this work is to understand the effects of individual mon- dilution on oil recoveries by employing numerous techniques:
ovalent and divalent ions on brine-oil interactions, and their from measuring interfacial tension (IFT), contact angle and
role in the observed alteration of carbonate wettability. zeta potential, to coreflooding3-7 and nuclear magnetic reso-
In previous studies, we investigated liquid-rock interactions
nance techniques8. The latest fundamental research findings
and their role in wettability alteration. At fixed salinities,
concern the detrimental effects of monovalent ions, such as
monovalent and divalent ions were found to have different
sodium (Na+) and chlorine (Cl-), and the key role played by
effects on the calcite surface potential. In this study, we have
multivalent ions, such as Ca2+, Mg2+ and SO42-, in addition to
investigated the liquid-liquid interactions. We performed in-
the connectivity enhancement between micropores and mac-
terfacial tension (IFT) measurements between oil and brines
ropores due to anhydrite dissolution. It has been shown that
of fixed salinities but varying ionic compositions, and we col-
dissolved ions are temperature dependent thermodynamically
lected IFT data at different temperature conditions.
and that sulfate ions gain in efficiency at a higher temperature
That the different SmartWater recipes have exhibited differ-
ent IFT values at fixed salinities indicates the varying effects of Component Amount
ions on fluid-fluid interactions. For instance, SmartWater reci- Saturates 39.2%
pes composed exclusively of magnesium (Mg) cations exhibited Aromatics 48.3%
a remarkably low level of IFT values. Other SmartWater recipes
Resins 7%
with sodium (Na) or calcium (Ca) cations exhibited comparable
Asphaltenes 5.5%
IFT stabilization levels, while SmartWater recipes that are solely
composed of sulfate anions have resulted in higher IFT values. Total Acid Number 0.25 mg KOH/g oil
Those results will be integrated at further stages with mea- Properties Amount
surements of the zeta potentials and contact angles acquired Saturation Pressure
1,804
across brines of variant ionic compositions. This systematic (psia at 212 °F)
integration will eventually allow for a clearer distinction Stock Tank Oil Gravity
0.3
(°API at 60 °F)
of the ions’ effects, which will help to better optimize the
SmartWater recipe. Dead Oil Density at
0.545
Room Temperature (lb/cf)
Enhancing oil recovery by adjusting the ionic composition Table 1. The components and properties of the crude oil used in conducting this
experiment
and salinity of the injected water has been widely investigated
Fig. 2. IFT vs. time plot for the fluid-fluid interface between oil and the four brines composed of individual
Fig. 5.
Fig. 5. Initial
Initial values
values of
of IFT
IFT for
for the
thefour
four brine
brinecompositions.
compositions.Note
Notethat MgCl
that MgCl has
2 2 has the lowest IFT
SmartWater flooding key ions conducted at 25 ¡ C.
the lowest
across IFT values across
all temperatures, CaClall 2temperatures,
and NaCl haveCaCl and NaCl
comparable
2
have comparable
values, while Na2SO4 has the high
all constituents.
values, while Na2SO4 has the highest among all constituents.
Fig. 2. IFT vs. time plot for the fluid-fluid interface between oil and the four
brines composed of individual SmartWater flooding key ions conducted at 25 °C.
Fig. 2. IFT vs. time plot for the fluid-fluid interface between oil and the four brines composed of individual
SmartWater flooding key ions conducted at 25 ¡ C.
Fig. 6. Equilibrium values of IFT for the four brine compositions. Note that MgC
temperatures, CaCl2 and NaCl have comparable values, while Na2SO4 has the
constituents.
Fig. 6. Equilibrium values of IFT for the four brine compositions. Note that
Fig. 6. Equilibrium values of IFT for the four brine compositions. Note that MgCl2 has the lowest
MgCl2 has the lowest
temperatures, across
CaCl2 and all temperatures,
NaCl CaCl2values,
have comparable and NaCl have
while Nacomparable
2SO4 has the highest among a
values, while Na2SO4 has the highest among all constituents.
constituents.
Fig. 3. IFT vs. time plot for the fluid-fluid interface between oil and the four brines
Fig. 3. IFT vs.
composed time plot SmartWater
of individual for the fluid-fluid interface
flooding key ionsbetween
conductedoilatand the four brines composed of individual
50 °C.
SmartWater flooding key ions conducted at 50 ¡ C.
Fig. 3. IFT vs. time plot for the fluid-fluid interface between oil and the four brines composed of individual
SmartWater flooding key ions conducted at 50 ¡ C.
Fig. 4. IFT vs. time plot for the fluid-fluid interface between oil and the four Fig. 7. The brine composed of MgCl2 only showed the lowest initial and equilibrium
Fig. 4. IFT vs. time plot for the fluid-fluid interface between oil and the four brines composed of individual
brines composed of individual SmartWater flooding key ions conducted at 90 °C. Fig.
IFT7. Themeasured
value, brine composed
at 25 °C at 34ofmN/m
MgCl andonly showed
29.4 mN/m, the lowest initial and equilib
respectively.
SmartWater flooding key ions conducted at 90 ¡ C. 2
atFig.
257.¡ CThe
atbrine composed
34 mN/m andof29.4 only showed
MgCl2mN/m, the lowest initial and equilibrium IFT value, m
respectively.
at 25 ¡ C at 34 mN/m and 29.4 mN/m, respectively.
40 FALL 2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
the lowest IFT, followed by CaCl2 and NaCl with comparable
IFT stabilization levels, and then Na2SO4 with the highest IFT
values at all temperatures. Having the same sequence of stabi-
lization across all operating temperature conditions (25 °C, 50
°C and 90 °C) confirms the sensitivity of IFT to the ionic com-
position. Also, the measurement repeatability defies any sus-
picion of measurement anomalies. The results also showed a
linear trend of decreasing IFT values in the case of MgCl2 and
CaCl2, while this behavior was not seen in NaCl and Na2SO4.
In those brines, the IFT values tended to flatten at higher tem-
Fig. 8. The brine composed of CaCl2 only showed the next lowest peratures, and
initial andtheequilibrium
difference between
IFT value, these values measured at
measured at 25 ¡ C at 38 mN/m and 32.6 mN/m, respectively.50 °C and 90 °C becomes less pronounced.
Fig. 8. The brine composed of CaCl2 only showed the next lowest initial and equilibrium IFT value,
This sequence of IFT values seen across all temperature
measured atcomposed
Fig. 8. The brine 25 ¡ composed
C ofatCaCl
382 only
mN/m showed and 32.6
the next mN/m,
lowest
only respectively.
initial and
Fig. 8. The
equilibrium IFTbrine
value, measured at 25 °C of
at 38CaCl
mN/m2 and 32.6showed the next lowest
mN/m, respectively. initial and
runs highlights theequilibrium IFT of
important role value,ions when it comes to
measured at 25 ¡ C at 38 mN/m and 32.6 mN/m, respectively.designing the composition of brines used for SmartWater
flooding applications. Lower IFT values will eventually lead
to lower capillary pressure at the interface of the wetting (oil)
and non-wetting (brine) phases, leading to further interaction.
Since rock wettability alteration is the main recovery mecha-
nism in SmartWater flooding processes, this enhanced inter-
action between the wetting and the non-wetting phases will
intensify the exchange of the ions between the SmartWater
flooding and the oil at the rock surface. This in turn will lead
to further release of the carboxylic molecules adsorbed at the
rock surface and eventually result in an incremental oil recov-
ery. In all test runs, Mg2+ ions have shown the lowest level of
Fig. 9. The NaCl brine had a stabilization level at 25 ¡ C similar IFTtovalues,
that ofandthethis
CaClfact suggests
2 brine, that optimized
although its formulations
starting
Fig. 9. Thepoint washad
NaCl brine higher at 42.8
a stabilization levelmN/m.
at 25 °C similar to that of the of the SmartWater ionic content to contain more Mg ions
Fig.
CaCl29. Thealthough
brine, NaClitsbrinestartinghad
pointa stabilization
was level at 25 ¡ C similar to that of the CaCl2 brine, although its
higher at 42.8 mN/m.
starting point was higher at 42.8 mN/m. may lead to further incremental oil recovery, compared to
Fig. 9. The NaCl brine had a stabilization level at 25 ¡ C similar thetorecovery
that of achieved
the CaClwith2 brine, although
the current itscomposition of
ionic
starting point was higher at 42.8 mN/m.
SmartWater.
Reducing sulfate ions in the SmartWater ionic constituents
may also lead to optimized SmartWater flooding performance.
The obstructive role of the sulfate ions seen in these sets of
IFT measurements is in agreement with results of the zeta
potential10 and streaming potential16 measurements already
published.
The low IFT values exhibited by Mg2+ can be attributed to
its relatively low molecular weight, in addition to the weak
ionic bond in MgCl2 compared to bonds in the other tested
salts. Although Mg comes second after sodium in atomic
weight, the MgCl2 bond-dissociating energy — an indication
Fig. 10. The brine that is composed mainly of Na2SO4 had the highest
Fig. 10. The brine that is composed mainly of Na2SO 4 had theofhighest
the ionicstabilization
bond strength — when
level at 25dissolved
¡ C, withinan water is 318
stabilization level at 25 °C, with an IFT value of 44.5 mN/m, and it had a very
IFT value of 44.5 mN/m, and it had a very high starting point at 55.6
kJ/mol 17
mN/m.
measured at 298 K, which is a much weaker bond
Fig. 10. The
high starting pointbrine
at 55.6that
mN/m. is composed mainly of Na2SO4 had the highest stabilization level at 25 ¡ C, with an
IFT value of 44.5 mN/m, and it had a very high starting point at 55.6 mN/m. when compared to CaCl 2
and NaCl, with energies of 398 kJ/
Fig.
25 °C 10.similar
The brineto that that is composed
of the CaCl2 brine,mainly although of Na 2SO4 had the
its starting highest stabilization level at 25 ¡ C, with
mol and 410 kJ/mol, respectively. This weak bond will breakan
IFT
pointvalue
was of 44.5atmN/m,
higher 42.8 mN/m,and itFig. had9.aFinally,
very high the starting
brine thatpoint at 55.6 mN/m.
first, allowing Mg2+ to easily get to the oil interface, interact
is composed mainly of Na2SO4 had the highest stabilization and reach equilibrium with the oil phase, all faster than the
level at 25 °C, with an IFT value of 44.5 mN/m, and it had a other ions. This can be seen clearly — previously shown in
very high starting point at 55.6 mN/m, Fig. 10. Figs. 2 to 4 — across all operating temperature conditions.
This IFT sensitivity to the ionic composition of the brines MgCl2 establishes a flat stabilization level of IFT values vs.
was seen in the other set of measurements conducted at 50 time — a clear sign of equilibrium — much earlier than all the
°C and 90 °C. The same sequence of stabilization levels was other salts. Na2SO4, with the highest bond-dissociating energy
recorded at both temperatures, where MgCl2 came first with compared to the other brines at 1,384 kJ/mol, has the highest
This study presents the full in situ stress tensor results, i.e., ΔShmin = 0.8055*ΔPP(Pore_Pressure) + 0.3762 (1)
orientation and magnitude, for the Jauf formation at pre- and
post-production conditions, and their use to build a 4D cou- The Shmin stress average maps were generated from pre- and
pled one-way geomechanics model. These results were con- post-production conditions in three stratigraphic levels (zones)
strained by using existing data from wireline logs, downhole of the Jauf formation — Upper, Middle and Lower. This
measurements and laboratory tests. After building 1D to 3D study concluded that the Upper Jauf is relatively more stressed
Mechanical Earth Models (MEMs) using data from 27 wells, than the Middle Jauf and Lower Jauf. Breakdown pressure
the 3D model was used as input to the 4D coupled model for maps for these three stratigraphic levels were also generated
years A, B, C and D. and are presented in this study.
This study concluded that the Jauf formation in the study
area is characterized by a strike-slip-faulting regime in which INTRODUCTION
the maximum horizontal stress (SHmax) is the largest principal
stress, i.e., SHmax > vertical stress (Sv) > minimum horizontal The main objective of this study was to define the full in situ
stress (Shmin). The SHmax orientation, N75°E, was constrained stress tensors at pre- and post-production conditions for the
by using borehole image logs. Jauf formation in the North Ghawar area and to build a 4D
coupled one-way geomechanics model for the years A, B, C
The calibrated stress models were established based on
and D. 1D to 3D geomechanics models were built utilizing all
poro-elastic equations, fracture closure pressures (FCPs), core
available data for 27 wells across the study area, and the 3D
data, wellbore stability models and drilling events depicting
geomechanics model was used as a prerequisite input for the
an average anisotropy ratio of approximately 1.2 to 1.4 (max-
4D coupled one-way geomechanics model.
imum principal stress magnitude)/(minimum principal stress
The 4D calibrated model will be used to identify field-scale
magnitude). The stress model at pre-production conditions
hydraulic fracturing “sweet spots” and to optimize hydraulic
showed values for the pore pressure gradient of approximately
~0.62 psi/ft, for the Shmin gradient of ~0.71 psi/ft to 0.95 psi/ft
and for the SHmax gradient of ~1.3 psi/ft to 1.4 psi/ft.
The 3D geomechanics high resolution grid was created for
elastic properties and rock strength parameters propagation;
the latter was driven by the total porosity (PHIT) model as a
controlling parameter. The range of the estimated values are:
Well log corrections were performed for the sonic and density
logs of all 27 wells using core information and multilinear
regression equation analysis. Results from one of the wells are
illustrated in Figs. 2 and 3.
High
High
PHIT(v/v) vs Vp (m/s) / VQUA(v/v) PHIT(v/v) vs AI (Kg.m/cm3.s) / VQUA(v/v)
locities in missing data intervals. The main advantage of this
200 ft approach is that all relations between elastic properties and
AI AI PHIT PHIT
RHOB RHOBDCAL DCAL DT DTSM DTSM
DT rock quality are preserved.
The rock physics model Increasing is focused on predicting
Porosity dynamic Increasing Porosity
AI
Increasing Vshale
Increasing Vshale
compressional velocity (Vp) and shear velocity (Vs) as accu-
VP
VP
Fig. 2. rately as possible, producing results suitable for further me-
Fig. 2.Well Wellloglogcorrections
correctionswerewere performed for sonicfor
performed and density
sonic andlogs, using core
density logs, using core information and
information and multilinear regression equation analysis.
multilinear regression equation analysis. chanical modeling. Using the porosity and clay content from
Low
Low
well
Low logs, an analysis Porosity was performed High to determine
Low
0
which rock
Porosity
1
High
0 1
High
PHIT vs Vp / VQUA(v/v)
(v/v) (m/s) PHIT vs AI / VQUA(v/v)
(v/v) (Kg.m/cm3.s)
effective medium modeling described by Prasad and Nur
(2003)3 was used to estimate P and S velocities. A tangential
High
High
Increasing Vshale
Increasing Vshale
observed Vp/Vs ratios in the sandstones, since contact theory
Increasing Vshale
VP
VP
RHOB
Low
Increasing Vshale
VS
Increasing Vshale
for solid clay elasticity, assuming that all other properties are
Increasing Porosity known and that our model is correct. Calculated Vp and Vs
Fig. 3. Cross-plots were used to analyze the trends and relationship between
wererespect
then calibrated on dynamic mechanical properties de-
RHOB
Increasing Vshale
with to the PHIT.
VS
Increasing Porosity
rived from the core analysis to obtain the best fit between all
Low
Low
Quartz
Fig. 3.
Fig. 3. Cross-plots
Cross-plotswere used
were to analyze
used the trends
to analyze and relationship
the trends betweenbetween different rock parameters
and relationship
different
with rock to
respect parameters
the PHIT.with respect to the PHIT.
significant azimuthal rotation of the principal horizontal stress Low PR Dynamic High
Increasing Porosity Calcite Fig. 4. Cross-plots between the Poisson’s ratio and acoustic impedance showing
Fig. 4. Cross-plots between the Poisson’s ratio and acoustic impedance show
Low
200 ft
Fig. 5. Ultrasonic core test data was used to calibrate the dynamic rock properties derivate from sonic and density logs.
Datevs
Time Pressure Gradient
vs Pressure Gradient
Fig. 5. Ultrasonic core test data was used to calibrate the dynamic rock properties derivate from 1.200
High
density logs.
1.000
0.800
Gradient
Gradient
Low
Pressure
Low
0.000
PP≈~ 0.49 PP≈~ 0.49
PP≈~ 0.49 PP≈~ 0.49
19-Apr-2001
Low
14-Jan-2004 10-Oct-2006 06-Jul-2009 01-Apr-2012 27-Dec-2014 22-Sep-2017
High
TimeTime
9000 9000 9000 Fig. 7. Pore pressure derived from 3D simulations and FCP plotted over time,
Fig. 7. Pore
show pressuretrends.
well-defined derivedThe
fromFCP-derived
3D simulations andpath”
“stress FCP plotted over time,
is interpreted show well-defined tre
to result
The FCP-derived “stress path” is interpreted to result from depletions.
TVD (ft.)
TVD (ft.)
TVDTVD (ft.)
from depletions.
15000 15000 15000 The pore pressure model at pre-production conditions was
Fig. 6. FCP shows a wide dispersion effect (from 0.71 psi/ft to 0.98 psi/ft), which generated from direct measurements obtained through the
High
2
PP≈~ 0.62
0.4 0.6
can be due to depletions.
Shmin≈~ 0.71
0.8 01Low1.20.2
PP≈~ 0.62 PP≈~
Figure 6
Shmin≈~ 0.71
0.62 0.71
Shmin≈~
Pore
00.4 Pressure
0.6
5000 Grad
0.8
10000 1
15000 High
1.2
20000 0
modular formation Shmin≈~ 0.71
PP≈~ 0.62 dynamics
5000
tester and from bottom-hole
10000 15000 20000
Pressure Gradient (Psi/ft.) Pressure Gradient Pressure
(Psi/ft.)(Psi.) Pressure
SAUDI (Psi.) JOURNAL OF TECHNOLOGY
ARAMCO FALL 2016 47
Fig. 8. Tri-axial core, YMS and YMD relationship.
static pressure (BHSP) estimated from hydraulic fracturing in
0.6 the Jauf formation, Fig. 6. Eaton’s method was used for the
S(PSI)
(ratio) YMD(PSI) vs vsYMS
PHI (v/v) PRS (ratio)
(PSI) pore pressure estimation, and the results were calibrated with
0.5 the modular formation dynamics tester measurements, BHSP,
0.6
RS (ratio) PHI (v/v) vs PRS (ratio) mud weight (MW) and drilling events.
0.4
0.5 The BHSP estimated from hydraulic fracturing in the Jauf
PRS (ratio)PRS (ratio)
0.45
0.3 ROCK MECHANICAL PROPERTIES CORRELATIONS
0.4
0.25
0.35
0.2 Values for the YMD, shear modulus, bulk modulus and
0.3
0.15 Poisson’s ratio of the rock were generated from the compres-
0.25
0.1 sional sonic, shear sonic and density logs. Converted static
473 0.2 PRS = 1.1068*PRD
0.05 properties using empirical correlations from triaxial tests were
R² = 0.55
0.15
0 also estimated. From these triaxial tests, a relationship was de-
12000000
0.1 0 0.1 0.2 0.3 0.4 0.5
2473 PRD (ratio ) PRS = 1.1068*PRD rived between the static Young’s modulus (YMS) and YMD,
0.05
R² = 0.55
Fig. 8. A derivative of the equation is:
0
12000000
0 0.1 0.2 0.3
Fig. 9. Static Poisson’s ratio plotted
PRD (ratio ) with0.4the PHIT,
0.5
density and YMS. There are no direct relationships
YMS = 0.0001646742* YMD1.51606 (2)
identified between the parameters.
Fig. 9. Static Poisson’s ratio plotted with the PHIT, density and YMS. There are
Fig.CoreCore
–Core
Core
9. Static
Core –– Log
–Log –correlations
Logcorrelations
correlations
no direct relationships identified between the parameters.
Log correlations
Poisson’s
Log ratio plotted with the PHIT, density
correlations Theand
PRDYMS. There are
was estimated withno
the direct relationships
poro-elastic equation, and
identified between the parameters.
WELL XX_A WELL XX_B WELL XX_C
Core
Core
Core–Core–– Log
–Log
Core Log –correlations
Log
Log correlations
correlations
correlations
correlations
Density TS Density TS Density TS
DTS UCS DTS UCS DTS UCS
Gr Li thology DT PRDWELL XX_APRS F_AN PHT CAL Gr Li thology DT PRD YMDWELL
YMD YMS YMS XX_B WELL
PRS F_AN PHT CAL Gr Li thology DT PRD YMD YMSXX_C
PRS F_AN PHT CAL
200 ft
RHOB
RHOB
RHOB
RHOB RHOB
PRDPRDPRD
PRD PRD
YMDYMDYMD
YMD YMD
YMSYMSYMS
YMS YMSPRS
PRSPRS PRS PRSUCS
UCSUCS UCS UCS
PHITPHITPHIT
PHIT
DCAL PHIT
DCALDCAL
DCALDCAL
F_AngF_Ang
F_Ang
F_Ang
F_Ang
RHOB
RHOB
RHOB PRDRHOB
RHOB PRD
PRD PRD
YMDYMD YMD
PRDYMD YMD
YMSYMS YMS
YMS YMS
PRSPRS PRS
PRS
UCSUCS UCS
PRS
UCS UCS
PHITPHIT PHIT
PHIT
DCAL PHIT DCAL
DCALDCAL
F_Ang F_Ang
F_Ang
F_Ang
F_Ang
200 ft
RHOB
RHOB
RHOB
RHOB RHOB PRD
PRDPRD
PRD PRD YMD
YMDYMD
YMD YMSYMS YMS
YMDYMS PRS
YMSPRS
PRSPRS UCS
PRSUCS
UCSUCS UCS
PHITPHIT PHIT
PHIT
DCAL DCALDCAL
PHIT
DCALDCAL RHOB RHOB
RHOB
RHOB RHOB
PRDPRDPRD
PRD PRD
YMDYMDYMD
YMD YMD
YMSYMSYMS
YMS YMSPRS
PRSPRS PRS PRSUCS
UCSUCS UCS UCS
PHITPHITPHIT
PHIT
DCAL PHIT
DCALDCAL
DCALDCAL
F_Ang
F_Ang
F_Ang
F_Ang F_Ang F_Ang F_Ang
F_AngF_Ang
F_Ang
RHOB
RHOB
RHOB
RHOB PRDRHOBPRD
PRD PRD
YMDYMD YMD
PRDYMD YMD
YMSYMS YMS
YMS YMS
PRSPRS PRS
PRS
UCSUCS UCS
PRS
UCS UCS
PHITPHIT PHIT
DCALDCALDCAL
PHIT DCAL
F_Ang F_Ang
F_Ang
F_Ang
F_Ang
dynamic
48
properties and core correlations.
FALL 2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
Fig. 10. Well XX_A, Well XX_B and Well XX_C with static rock mechanics properties modeled using
Fig. 11. Vertical stress was estimated from the density log.
WELL XX_D
MW
Mineralogy
SV Shear Failure
Density UCS Shmin Kick
DTS PRS TS SHmax Losses SH/Sh
Gr SW DT YMS F_Ang PP Breakdown CAL PHIT Shmin BHI
MW MW
FCP FCP
BHSP BHSP
200 ft
BreakoutBreakout
SH/Sh SH/Sh
SV SV
RHOB RHOB
YMS PRS
YMS PRS
UCS F_Ang
UCS F_Ang
Pore Pore SHmax SHmax
Shmin Shmin DCAL DCAL
PHIT Shmin Shmin
PHIT
PressurePressure grad grad
Fig. 11. Vertical stress was estimated from the density log. Fig. 12. Stress model and wellbore stability model for Well XX_D.
Figure 11 Fig. 12. Stress model and wellbore stability model for Well XX_D.
the static Poisson’s ratio was defined based on several cor- poro-elastic and horizontal strain stress models, where the
relations from the triaxial core tests using the porosity, bulk Shmin and SHmax at each depth depended upon:
density, YMS and PRD results. No direct relationship was
inferred between these properties, Figs. 9 and 10. • Mechanical properties
• Pore pressure
Static_Poisson_ratio = 1.15*Dynamic_Poisson_Ratio (3)
• Vertical (overburden) stress
The unconfined compressional strength (UCS) was esti-
mated using the multi-correlation between the YMS and total The Shmin was also constrained by the FCP and leakoff
porosity (PHIT). The equations’ result was: test data4. The stress profiles were plotted together with
MW windows.
UCS = 0.001405728*(YMS) - 19821.21*(PHIT) + The Shmin, as estimated from the hydraulic fracture data,
5828.503 (4) was found to lie in the range of approximately ~0.85 psi/ft to
~0.98 psi/ft.
1D MECHANICAL EARTH MODEL (MEM) The SHmax was estimated using the poro-elastic model, the
wellbore stability model and drilling events. The wellbore
The Jauf formation is characterized by a strike-slip-faulting stability model was also calibrated with the borehole image
regime in which the SHmax is the largest principal stress — SHmax interpretation — identifying drilling-induced tensile fractures
> vertical stress (Sv) > minimum horizontal stress (Shmin). The and breakouts. The estimated gradient of maximum principal
orientation, N75°E, of the SHmax was inferred from borehole horizontal stress magnitude is approximately ~1.3 psi/ft.
breakouts and drilling-induced tensile fractures interpreted
from borehole images. Stress Calibrations Using Drilling Events
Vertical Stress Figure 12 shows the final wellbore stability calculation for
Well XX_D. No major drilling issues were observed in the
The overburden, or vertical stress, was evaluated using the wells drilled through the Jauf formation except for Well XX_B
density logs, which showed an average gradient of approxi- (drilled in 2009), which reported a gas kick. The MW used to
mately ~1.1 psi/ft, Fig. 11. drill through this well was 9.8 pounds per gallon. There is good
agreement between the calculated breakouts and the actual
Horizontal Stresses breakouts as interpreted from the borehole images5.
Figure 12 also shows the main results from the 1D geome-
The Shmin and SHmax profiles were estimated using the chanics process as follows:
slowness.
2.8000
20000
20000
High
2.7000
18000
2.2000
16000
14000
14000
green) and Young’s modulus (pink). UCS, [psi]
12000
12000
10000
UCS
10000
8000
6000
4000
4000
(dark blue), Shmin (green), SHmax (red), Sv (black), FCP Symbol legend
effective_Porosity vs. UCS vs. RHOBR_Cor (All cells)
effective_Porosity vs. UCS vs. RHOBR_Cor (Upscaled)
• Track 13. Ratio between SHmax/Shmin (red) and the Shmin SH/Sh:
SH/Sh 1.35 :1.35
gradient (pink).
Sh Azimuth: 165°
• Track 14. Breakout from borehole image interpretation Sh Azimuth :165 Degree
Fig. 18. Boundary conditions used on the 3D MEM.
(red).
FigureThe19
Fig. 19. SHmax tensor stress estimated from geomechanics simulations.
Slight rotation
Slight rotation
Fig. 22. Fault simulations case, showing the normal and shear stress for cells within faults.
Jauf Formation: Shedgum Field
• Fault shear stiffness: 2.35E+06 KPa/m.
9000
High
8500
8000
6500
• Cohesion: 1 Kpa.
Static Well Pressure (Psig)
6000
5500
Figure 22
Pore Pressure
5000
1500 gesting either that the influence of faults and fractures was
1000 Static Pressure (Psig)
Low
500 minimal or that there are no minor faults in the vicinity of
0
1-Jan-15
1-Jan-02
1-Jan-03
1-Jan-04
1-Sep-04
1-Jan-05
1-Jan-06
1-Jan-07
1-Jan-08
1-Jan-09
1-Jan-10
1-Jan-11
1-Jan-13
1-Jan-14
1-Aug-15
1-Sep-01
1-Sep-02
1-Sep-03
1-Sep-05
1-Sep-06
1-Sep-07
1-Sep-08
1-Sep-09
1-Sep-10
1-Sep-11
1-Sep-12
1-Sep-13
1-Sep-14
1-May-02
1-May-03
1-May-04
1-May-05
1-May-06
1-May-07
1-May-08
1-May-09
1-May-10
1-May-11
1-May-12
1-May-13
1-May-14
1-May-15
Low High
the tensor stress model for the faults, these are still inside the
Fig. 23. Pore pressure and stress steps defined for years A, B, C and D.
Fig. 23. Pore pressure and stress steps defined for years A, B, C and D.
SHmax range. The normal stress and shear stress were computed
for each cell in the faults showing stable conditions, Fig. 22.
Faults Stability Analysis High
WELL XX_J
WELL XX_J
Shmin
Upper 4D COUPLED
Shmin PP ONE-WAY GEOMECHANICS MODEL
To evaluate the fault stability6 at pre-production conditions,
WELL XX_D Middle
Low
the
PP
normal
Shmin
stiffness and shear stiffness were estimated — un- Stress Step and Pore Pressure Changes
der the same boundary conditions — using the following geo-
mechanics
FCP
fault properties: The stress step calibrations were selected from the pore pres-
FCP
sure profile to simulate the stress conditions over years A, B,
• Fault normal stiffness: 7.67E+06 KPa/m. C and D, Fig. 23.
FCP
WELL XX_D @A SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2016 53
Fig. 24. 3D cross-section showing the Shmin initialization, compared with the FCP (hydraulic fracture over year A) for year A.
Fig. 25. 3D cross-section through Wells XX_D to XX_J, showing the Shmin at pre-production conditions and over time.
Stress Variations over Time In year D, the FCPs from Well XX_Z and Well XX_K were
compared with the 3D Shmin, showing a good match, Figs. 26
The stress calibration from pre- to post-production conditions and 27.
was performed taking the FCP measured from the wells over
time7. In Figs. 24 and 25, the FCPs from Well XX_D and Reservoir Stress Path
Well XX_J were compared with the 3D Shmin simulation for
initial conditions (year A), reaching a good match. In normal depletion behavior, the effective vertical stress
Fig. 27. 3D cross-section showing the Shmin through Well XX_Z and Well XX_K at pre-production conditions and over time.
1.100
1.000
1.000
Gradient
FCPFCP
Pressure
Shmin
Shmin
0.400
0.700 Middle
Fig. 28. The pore pressure from 3D simulation results and FCP plotted over time, Fig. 29. Reservoir stress path defined by the relationship between S
hmin
/Pp and FCP
Fig. Fig.
28. The pore pressure from 3D simulation results and FCP plotted over
showing the possible trend for the reservoir stress path.
29. Reservoir
time, showing stress path defined by the relationship
the possible
through to the reservoir depletions.
between Shmin/Pp and
trend for the reservoir stress path. reservoir depletions.
Z-values: Zon
5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600 PRESSURE, [psi]
11200 TOTAL_EFFSTR_HMIN[3]_2014
Z-values: Zones (hierarchy) 5200 5600 6000 6400 6800 7200 7600 8000 8400
High Upper_Jauf
Middle_Jauf High Upper_Jauf
Middle_Jauf
13600
13600
13600
Lower_Jauf Lower_Jauf
12800
12800
12800
12000
12000
12000
Shmin_3D
Shmin_3D
[psi]
TOTAL_EFFSTR_HMIN[0]_2002,
11200
11200
10400
10400
10400
9600
9600
9600
Shmin=0.8055* Pore_ Pressure +5578 @A Shmin=0.8055* Pore_ Pressure +5578
Low Low
8800
8800
8800
Pore Pressure High Low Pore Pressure
5200 5600 6000 6400 6800 7200 7600 8000 8400
Low
5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600
PRESSURE, [psi]
Symbol legend Symbol legend
PRESSURE vs. TOTAL_EFFSTR_HMIN[0]_2002 vs. Zones (hierarchy) (All cells) TOTAL_EFFSTR_HMIN_3_2014_vs_PRESSURE
TOTAL_EFFSTR_HMIN_3_2014_vs_PRESSURE PRESSURE vs. TOTAL_EFFSTR_HMIN[1]_2008 vs. Zones (h
TOTAL_EFFSTR_HMIN[3]_2014,
5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600 5200 5600 6000 6400 6800 7200 7600 8000 8400
High
Upper_Jauf
Middle_Jauf High Upper_Jauf
Middle_Jauf
13600
13600
13600
Lower_Jauf Lower_Jauf
12800
12800
12800
12000
12000
12000
Shmin_3D
Shmin_3D
[psi]
11200
11200
TOTAL_EFFSTR_HMIN[2]_2011
11200
10400
10400
10400
9600
9600
9600
8800
8800
Low
Low Pore Pressure
5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600 5200 5600 6000 6400 6800 7200 7600 8000 8400
Fig. 30. Reservoir stress path defined by the relation between Pp 3D and Shmin 3
depletions time.
Figure 30
Fig. 30. Reservoir stress path defined by the relation between Pp 3D and Shmin 3D from simulations, over depletions time.
Fig. 31. Year A Shmin average stress map for the Upper (left), Middle (middle) and Lower Jauf (right).
Figure 31
increases at the same rate that pore pressure decreases because Stress Maps
the total vertical stress is unaffected by changes in pore pres-
sure. Subsequently, the effective horizontal stress increases more Shmin stress average maps were generated for each stress step
slowly during depletion than the pore pressure decreases. The and the three levels defined for the Jauf formation, showing
total horizontal stress decreases with pore pressure following important changes throughout the formation.
the Shmin/pore pressure coupling ratio8-10, Fig. 28. For the pre-production conditions (year A), Fig. 31, the
Figure 29 shows the relationship defined between the Shmin/ Shmin stress average map shows:
pore pressure ratio with a value of 0.805 and the FCP, which
can be considered as a normal range for a strike-slip-faulting • In the Upper Jauf section, high stress values from the
regime. It was assumed that the drop in Shmin with the pore southwest area, e.g., Well XX_L, and lower values from
pressure is nonrecoverable and that the Shmin does not increase the central part of the reservoir, e.g., Well XX_D.
with a re-pressurization process.
• In the Middle Jauf section, lower stress in comparison
In the 4D coupled one-way geomechanics model, the
with the Upper Jauf section, but still with high stress in
stresses obtained for the three stratigraphy levels defined for
the southwest area — Well XX_L.
the Jauf formation — Upper, Middle and Lower — show al-
most the same behavior regarding the pore pressure and Shmin • In the Lower Jauf section, high stress in the southwest
relationship. This can be deduced from Fig. 30, where the area but less stress in the central area, e.g., Well XX_D.
Middle and the Lower Jauf are overlapping.
During the depletion process over years A, B, C and D, the The post-production conditions for years B, C and D show
pore pressure and Shmin follow the stress path previously defined important reductions in the stress due to depletions in the
in Fig. 29, reaching in year D depleted zones where the pore Middle Jauf. The stress map over the Lower Jauf also shows
pressure values are less than the original pressures. Following significant reductions in the central part of the reservoir near
the stress path defined at post-production conditions, separate Well XX_D. The southwest part keeps the high stress values for
trends were identified for the Upper, Middle and Lower Jauf. the Upper, Middle and Lower Jauf around Well XX_L, Fig. 32.
Figure 32
Fig. 32. Year D Shmin average stress map for the Upper (left), Middle (middle) and Lower Jauf (right).
CONCLUSIONS gave a good match with the FCP over the 27 wells where data
was available, with the reservoir stress path defined over the
The Jauf formation in the study area is characterized by a grid model by the following equation:
strike-slip-faulting regime in which the SHmax is the largest
principal stress, i.e., SHmax > Sv > Shmin. The SHmax orientation, ΔShmin = 0.8055*ΔPP(Pore_Pressure) + 0.3762 (5)
N75°E, was constrained by using borehole image logs.
The calibrated stress models were established based on po- The Shmin stress average maps were generated from pre- to
ro-elastic equations, FCP, core data, wellbore stability models post-production conditions for the three stratigraphy levels —
and drilling events showing an average anisotropy ratio of ap- Upper, Middle and Lower Jauf — showing more stress in the
proximately 1.2 to 1.4 (maximum principal stress magnitude)/ Upper Jauf in comparison with the Lower and Middle Jauf
(minimum principal stress magnitude). The stress model at sections. The southwest area shows the highest stress values
pre-production conditions showed values in the pore pressure of the three levels, > ~13,000 psi, even at post-production
gradient of ~0.62 psi/ft, the Shmin gradient of ~0.71 psi/ft to conditions.
0.95 psi/ft, and the SHmax of around ~1.3 psi/ft to 1.4 psi/ft.
The high resolution 3D geomechanics grid was used to ACKNOWLEDGMENTS
propagate the elastic properties and rock strength using the
PHIT model as the main drive; the ranges of estimated values The authors would like to thank the management of Saudi
were as follows: Young’s modulus from 1.2 Mpsi to 6.0 Mpsi, Aramco for their support and permission to publish this ar-
Poisson’s ratio from 0.24 to 0.38, and UCS primarily from ticle. The authors would also like to thank Khaqan Khan,
6.0 Kpsi to 16.0 Kpsi. Jubril Oluwa and Thamer A. Sulaimani for their contributions
In the 4D coupled model, the FCP values from the hydrau- to this project.
lic fractures were used to calibrate the Shmin at post-production
conditions over years B, C and D. The predicted stress model
ABSTRACT INTRODUCTION
Drilling through total loss zones without returns at the surface Reentering old wells to access bypassed portions of the
is a common practice for operating companies in the Middle reservoir is one of the most common jobs in the workover
East. This is known as the mud cap drilling technique, a operation. Workover engineers spend a great deal of time and
“blind drilling” technique that has been used for a long time effort to come up with designs to accommodate the conditions
in the region. The lessons learned throughout these years have of the existing wellbore so the reentry well can reach the
produced well established procedures and “rules of thumb” required targets in a cost-effective manner.
for estimating the mud density, volume and pumping schedule Currently, one of the most common reentry designs applied
of the mud cap for different situations. in one of the main oil fields in Saudi Arabia is the long radius
The application of this mud cap (blind) drilling technique sidetrack. The wells following this design are initiated by
becomes more challenging when drilling through oil reservoirs cutting a window in the existing 7” casing, then drilling a
with a high hydrogen sulfide (H2S) content and through a 6⅛” curve section with dogleg severities around 5°/100 ft
combination of zones in the same hole section with pressure through the overlying formations to land the well horizontally
regimes that are significantly different. This situation is often at the top of the reservoir. Drilling continues using geosteering
the case when drilling wells used to reenter oil producer wells techniques with logging while drilling tools until the well
in Saudi Arabia fields. Under these circumstances, the main reaches the planned total depth (TD). Finally, the opened
well control strategy is to maintain enough of a mud cap to upper formations are isolated from the producing lateral by
prevent any migration of the hazardous gases and/or liquid means of a cemented off-bottom liner, Fig. 1a.
hydrocarbons to the surface. The main drilling hazards found during the workover
This approach often results in a conservative design reentries come from having different pressure regimes
requiring large mud cap densities and volumes, which in combined in the same hole section. These hazards are as-
turn generates huge expenditures in mud material and puts sociated with (1) the relatively high pressure in the water
tremendous stress on logistics and transportation. producer, Formation-A, and (2) the nature of Formation-B, an
The pressurized mud cap technique offers a safe alternative oil reservoir that is highly fractured in some zones of the field.
to blind drilling. This technique uses regular managed These two create conditions for experiencing differentially
pressure drilling (MPD) equipment to monitor the behavior stuck pipe or a total circulation loss. Moreover, dealing with
of the reservoir at all times, thereby improving the safety of total circulation loss while drilling through the oil reservoir
the operation by having accurate well control. This approach can produce dangerous well control situations, which are
also realizes substantial cost savings by optimizing the use of severely aggravated by the high hydrogen sulfide (H2S) content
drilling fluid materials and other resources associated with the found in the reservoir fluids.
mixing and pumping of the mud cap. Conventional managed pressure drilling (MPD) has been
This article describes the successful implementation of this used in the past to optimize the overbalance applied to the
technique for reentering oil wells in an onshore field in Saudi lower pressure zone and to reduce the risk of getting the
Arabia. The article also provides details on the equipment drillpipe differentially stuck. But conventional MPD is not
and procedures utilized to maintain a full column of fluid applicable once total losses are encountered. This led to the
under pressure by keeping the MPD choke fully closed while idea of using the pressurized mud cap technique, a variant
drilling without any returns at the surface. The results, when of MPD, as an alternative to the traditional blind drilling
compared with the conventional mud cap (blind) drilling to continue drilling the reentry under total circulation loss
technique, show significant improvements in safety (well conditions, all while providing accurate well control and
control), cost efficiency and logistics. minimizing fluid lost to the reservoir.
Conventional MPD, understood as the “constant” bottom- Once the total loss of drilling fluid is encountered, the
hole pressure (BHP) variation of MPD1, does not solve the pressurized mud cap technique uses MPD equipment —
challenges presented by workover reentry operations in Saudi drillpipe check valves, rotating head and choke — to maintain
Arabia. The main reason is that to maintain a constant BHP, a full column of viscous fluid with a density lighter than that
it is necessary to have a “closed system.” The regular closed required to control the pore pressure found in the highly
circulating system existing in any ordinary drilling operation fractured formation. In this way, a positive pressure is
is lost once the drilling fluid starts massively leaking into the maintained in the MPD choke at the surface.
downhole formations. Drilling continues with a sacrificial amount of fluid being
Initially, it was thought that the conventional MPD was pumped through the string to drive directional tools and lift
going to help prevent these drilling fluid losses by keeping the cuttings to the loss zone; the MPD choke remains fully
the wellbore pressure profile within the mud weight (MW) closed. The positive choke pressure permits operators to
window and walking along the line between well kicks monitor the well to detect any hydrocarbons migrating to the
and losses. This approach was attempted but failed to have surface, any increase in drilling fluid losses or any evidence
positive results. It became clear that conventional MPD was that the formation is plugged.
not the right application for this environment due to the It is important to emphasize that the pressurized mud cap
pre-existence of karst type fractures with extremely high approach will work only if the formation fracture or karst is
permeability. big enough to receive all the fluid and cuttings being dumped
Pressurized mud cap drilling is another variation of MPD1, as a result of the change in drilling technique. If the formation
and a quick literature review confirmed the suitability of the starts getting plugged, the operation will have to switch to
technique for drilling through highly fractured hydrocarbon conventional MPD.
zones with H2S content2, 3. It was decided to take a hybrid In this particular field, operators suspected that the high-
approach to the implementation of MPD in the oil reentry pressure formation, Formation-A, had started to cross
wells: start with conventional MPD and then switch to flow and to dump formation water into the oil reservoir,
pressurized mud cap drilling once total loss of the drilling Formation-B, as represented in Fig. 1b. At first, they expected
fluid is encountered. The two main objectives of this effort to use the pressurized mud cap technique only for drilling and
are to (1) reduce the frequency and severity of differentially tripping; however, as the crew became familiar with it, the
stuck pipe and well control events, and (2) minimize the total implementation was extended for the logging and completion
amount of drilling fluid used during the reentry. phases, including running and cementing the off-bottom liner.
RISK ASSESSMENT AND FINAL PROCEDURE Uncontrolled Flow to the Surface — Rotating
Control Device (RCD) Failure
The peer review and risk assessment process identified
the following main issues for the implementation of the The probability of uncontrolled flow to the surface was
pressurized mud cap technique. Some of the issues are related considered a low risk; there are no records of catastrophic
to conventional MPD, but are mentioned here due to their rotating control device (RCD) failures causing a sudden
relevance for the pressurized mud cap technique as well. For release of fluids to the atmosphere in regular MPD operations
simplification purposes, the risk scenarios listed here are based in Saudi Aramco or in the region. Obviously, the severity was
on a 3 × 3 Risk Matrix, Fig. 2. deemed as a high risk due to personnel considerations. Rig
well control equipment would take care of the situation to
Differentially Stuck Pipe in Low-Pressure and/ contain the momentary release, but to maintain the severity
or High Permeability Formations to as low a risk as was reasonably practical, it was decided to
keep the surface working pressure at a maximum of 500 psi
The concern was that once operators started implementing at any given time. It is important to mention that the pressure
the pressurized mud cap, the clear, solids-free fluid used as the rating for the RCD used is 2,500 psi, and the rig blowout
“mud” cap was going to deplete the bridging agent — regular preventer stack is rated at 5,000 psi.
calcium carbonate (CaCO3) — in the formations uphole of
Formation-A and Formation-B, promoting the tendency for Drillpipe Check Valve Failure
having the drillstring differentially stuck; the probability of
this happening was considered a medium risk. Even though In the event of a check valve failure, flow or pressure through
such depletion is not normally observed in regular blind the drillpipe would occur during the connection. Because
drilling while pumping the mud cap, in this new scenario, several failures have been associated with check valves in
the fluid acting as the mud cap would not have any of the MPD operations in the region, the probability was considered
bridging agents common in regular mud caps. a high risk. The severity was a medium risk, mainly associated
The severity was considered a medium risk as well, since with the lost time spent tripping and replacing the valves.
it was hoped that the differential sticking situation would be As a risk mitigation factor, it was decided to use the valves
managed by manipulating the pressure in the backside with provided by the MPD company, which have a better track
the MPD choke. To mitigate this risk, the decision was made record than the valves provided by the rig and/or the di-
to use resilient bridging material — graphite and gilsonite — rectional drilling company. Also, a minimum of two of these
to set a good durable cake in these upper formations. The use valves were requested in the final procedure. In the event of
of these damaging bridging agents would then be discontinued a drillpipe check valve failure, the procedure to follow was
before starting to drill the reservoir. to kill the well, switch to the conventional mud cap (blind)
drilling technique and trip out of the hole to fix the problem.
Pressure containment is lost if the drillstring fails. The The trip for conventional MPD is performed with the well
probability of this happening was considered a medium to low killed. The trip for the pressurized mud cap application can be
risk, and the severity was deemed as a medium to low risk performed using the rotating head and pressurized fluid in the
as well, mainly associated with the rig lost time and the need backside all the way to “light pipe” depth. At this point, the
to kill the well by bullheading. To mitigate the risk, it was well is controlled by bullheading kill mud, and the operation
decided to perform a full drillstring inspection to the DS-1 Cat switches to conventional mud cap (blind) drilling techniques,
3-5 level prior to beginning with the MPD and pressurized which involves frequent pumping of a certain volume of mud
mud cap operation. In the event this situation happened, the cap that is heavier than the kill drilling fluid. The empirical
contingency was to kill the well by bullheading and continue best practice, learned over the years, is to pump (for the mud
remedial operations with the conventional mud cap (blind) cap) 60 barrels (bbl) per hour of fluid that is 10 pounds per
drilling technique. cubic foot (pcf) heavier than the kill mud.
The main tripping risks — RCD failure and drillpipe
Hydrocarbons and H2S Migrating to the Surface check valve failure — have already been mentioned, as well
as their respective mitigations. Additionally, the light pipe
Preventing such a migration is actually an advantage of the depth for the drillstring would have to be calculated prior to
pressurized mud cap technique compared with the regular tripping and after any pressure change observed during the
mud cap (blind) drilling technique. The probability of having trip, making sure that the calculation included a 100% safety
hydrocarbons and H2S migrate uphole to the surface was factor. The procedure involves pumping viscosified water in
considered as a medium to high risk. The severity was deemed the backside to replace the drillstring volume being pulled out
as a medium risk since having the RCD rigged up was going of the hole.
to actually mitigate the consequences of having any gas or It is necessary to keep in mind that the operating company,
oil cut mud to surface — when compared with the regular like others in the region, has extensive experience in drilling
blind drilling. The risk mitigation strategy was basically the without returns to the surface using the conventional mud
concept of the pressurized mud cap itself. With it, the rig team cap (blind) drilling technique. Because of this, risks related to
was going to be able to monitor the behavior in the drillpipe drilling mechanics and hole cleaning were not included for
casing annulus, thereby detecting any gas or hydrocarbon this analysis since those have already been addressed in the
migration in time to take the corrective actions well before blind drilling practices.
the hazardous fluids rose to the surface. The main additional A common operational risk faced when using any of the
barrier used to reduce the chances of having gas migration MPD variations is the drilling crew’s and rig team’s lack
to the surface was the utilization of viscosified water — 25 of familiarity with MPD equipment and procedures. The
lb/100 ft2 to 30 lb/100 ft2 yield point — as the fluid in the MPD service provider thereby played a very important role
pressurized mud cap. in training all crews on-site. The numerous pre-job meetings
held with the key members of the well site management team
Formation Plugging were also crucial to explain the objectives and details of the
application. For this particular case, the footage drilled in
In the event the loss zone(s) get plugged and returns are the “dead” rock found in the formations above the high-
regained, the cuttings would be trapped in the annulus pressure zone — Formation-A — was used to get the crews
space since the choke is fully closed. This would severely familiar with the connections, tripping and directional survey
affect the hole cleaning capabilities and create a big risk of procedures as well as with the MPD equipment.
hole pack off. Also, since the pressurized mud cap — water The simplified procedure for the application of the
— would be substantially underbalanced with the higher pressurized mud cap technique for drilling through a total loss
pressure Formation-A, the pressure at the surface might zone is summarized as follows:
increase to values higher than desirable. The probability
of having this situation develop was considered a low risk, 1. Once total losses are observed during conventional MPD
based on the extensive experience with conventional blind operations, close the MPD choke fully and completely fill
drilling; the severity was deemed as a high risk, mainly for the annular space until positive pressure is observed in the
the potential stuck pipe and well control issues. As a point of casing pressure MPD gauge. Keep filling until 100 psi to
risk mitigation, the procedure included alarms set to flag any 150 psi casing pressure is reached. Continue drilling with
abnormal increase in casing pressure; two full hole volumes of the choke fully closed and pump sacrificial water through
kill mud were ready to be used at any time; and the full MPD the drillstring; also pump a 30 bbl hi-vis water pill for
package was primed to switch to conventional MPD in case every stand drilled to assist with hole cleaning.
full circulation was regained.
RCD
Main
Main flow
flow line
line
Trip tank
pump
Fig. 3. MPD equipment configuration used for the pressurized mud cap technique implementation.
Fig. 3. MPD equipment configuration used for the pressurized mud cap technique implementation.
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2016 65
TOTAL LOSSES:
Zero Returns (Red Line)
TOTAL LOSSES:
Surface Pressure to Zero
(Red Line)
Pressurized Cap:
Surface Pressure Steady
at ±300 psi. (Red Line)
Fig. 4. Actual MPD log while drilling using the pressurized mud cap technique.
Fig. 4. Actual MPD log while drilling using the pressurized mud cap technique.
down the drilling BHA and picking up the next reaming BHA. The off-bottom liner was then run with the pressurized
A pressurized mud cap was used again for the reaming trip mud cap, and returns were partially regained after stringing
and the logging run. Memory pipe conveyed logs were run the seal assemblies into the lower completion. Full returns
using the RCD and pressurized mud cap procedures. Also were obtained with MPD techniques, and the liner cementing
the lower completion, consisting of inflow control devices job was performed successfully, with full returns, keeping
and mechanical open hole packers, was run while using the control of the BHP with the MPD equipment.
pressurized mud cap.
All objectives were met and the actual results significantly Conventional drilling approaches or even conventional MPD
exceeded all expectations for this first trial of the pressurized techniques won’t work in drilling scenarios like the one
mud cap. presented in this article. When the dominant cause of the
When compared with the conventional mud cap (blind) total losses is pre-existing karst type fractures, any attempt
drilling technique, the pressurized mud cap offered a much to regain circulation before continuing drilling will require
better control of the well and provided the ability to monitor an excessive amount of time and materials and presents very
BHP and reservoir fluid behavior at all times. limited chances to succeed. The only options left are either to
The main immediate cost benefit was obtained from continue drilling with the mud cap (blind) drilling technique
eliminating the cost of the saved mud. A total of 17,000 bbl or to set a sacrificial casing if the well design allows it.
of 95 pcf mud cap were saved in this well, thanks to the Pressurized mud cap drilling was demonstrated in this trial
pressurized mud cap implementation. to be a safer and more cost-effective alternative to the con-
The value goes beyond the monetary savings of these ventional mud cap (blind) drilling technique. The main benefit
mud cap barrels themselves. The associated logistics and obtained with the application of this technique is the ability
materials for preparing the 17,000 bbl, involving about 3,500 to accurately monitor the pressure profile in the wellbore by
metric tons of calcium chloride and CaCO3, represent ±190 means of the indications seen at the casing pressure gauge,
truckloads and round trips to the rig site — approximately thanks to having a full column of mud filling the annulus
76,000 km of heavy traffic avoided on public roads. Also, space. This capability allows the drilling crew to react in time
there was a corresponding reduction in operational exposure to take the corresponding corrective actions well before any
for the rig personnel, who did not have to mix this large hazardous fluids reach the surface.
amount of drilling fluid at 60 bbl per hour. This added benefit In addition to the huge cost savings that come from
should not be understated since the mixing process involves achieving a reduction in the mud cap volumes of about
numerous heavy load movements and other hazards. 70% and the obvious operational safety improvements
In terms of the rate of penetration (ROP), there was not related to well control, there were at least three further
a noticeable improvement during the application of the important benefits observed during the implementation of
pressurized mud cap; the ROP in the lateral is very dependent this technique:
on the amount of the intersected pay zone, and the observed
ROP in the interval below the loss zone was the same as other • A dramatic reduction in the usage of fresh water for
wells drilled in the area. It is fair to say, however, that while mixing mud.
using the MPD in the upper section — when full returns were
• Improved safety at the rig site since the mud mixing
still in place — the observed ROP was about 33% higher than
requirements were significantly reduced.
in the offset wells.
With these encouraging results, the technique was applied • A significant reduction in transportation requirements,
in one more reentry well and later in three newly drilled wells. decreasing exposure to motor vehicle accidents.
The results were consistent with the observations made in the
first trial well. A diligent risk management process helped the team to
develop a robust procedure with virtually all the contingencies
FUTURE DEVELOPMENTS well covered. Many of the identified risks were easily
mitigated by having the possibility to bullhead the well due to
Currently, the pressurized mud cap technique is the operator’s the high permeability of the fractures.
preferred way to drill reentry wells in zones where total losses
are expected. The main urgency now is to bring the technique ACKNOWLEDGMENTS
to offshore rigs, where the potential savings are even higher.
During this first stage of the implementation, the operating The authors would like to thank the management of Saudi
company is keeping the full MPD setup. This definitely Aramco, Halliburton and Weatherford for their support and
permission to publish this article. The authors would also like
offers a high degree of flexibility, especially useful to obtain
to thank the operations and field personnel involved in the
all the information in the zones above the lost circulation
first implementation of the pressurized mud cap technique
zone. Currently, the operator’s engineering team and the in Saudi Arabia, especially Askar S. Al-Hajri, Gabriel M.
service providers are working on alternatives to optimize the Morava, Joshi Ainnikal and Hussain Ghazzaly.
equipment requirements. Reducing the amount of equipment This article was presented at the SPE/IADC Middle East
needed for a pressurized mud cap will help to enable an easier Drilling Technology Conference and Exhibition, Abu Dhabi,
implementation of the technique and to capture more oppor- UAE, January 26-28, 2016.
tunities for its application.
INTRODUCTION
During the production life cycle of oil and gas extraction from
reservoir fields in geological formations, certain stages follow
in a specific order: exploration, appraisal, reservoir develop-
ment, production decline and abandonment of the reservoir.
Massive amounts of data are collected in the process, such
as seismic, well logs, core data and production data, all rep-
resenting raw data1. In addition, during the life of the field
development, several disciplines develop studies to increase
Fig. 1. Cross section where the colors indicate geological properties in a reservoir.
understanding of different parts of the reservoir. For example,
Fig. 1. Cross section where the colors indicate geological prope
70 FALL 2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
model. What follows is a better prediction of gas and/or oil actions of interpreting and integrating quality controlled data
production. This tool will reduce the time spent in quality at different scales from a variety of sources and vintages are
checking simulation related data from months to days. prerequisites for preparing a comprehensive reservoir model.
Therefore, the validation of the geological model at the very
GEOLOGICAL MODEL VALIDATION beginning of the larger overall process is a very important part
of constructing the simulation model3.
The geological model aggregates all the concepts and static
measurements of reservoir properties into a full reservoir char- THE QUALITY CONTROL (QC) TOOL
acterization. The geological model not only provides the geo-
logical basis of the reservoir simulation model, but also serves As mentioned, it is time-consuming and critical work to check
to assist with well planning and volumetric calculations, among all geological parameters. This is where the idea of this tool
other uses. The geological model is constructed by integrating came from. This in-house developed system will assist in im-
the reservoir geometry with rock characterization data3. proving the model quality, enforce best practices and reduce
The geological model depicts the distribution of rock types the turnaround time required for building and conducting
and properties in the reservoir, Fig. 1. It also includes geological reservoir simulation studies. The workflow consists of nine
features, such as faults, fractures and stratiforms. Rock prop- QC steps, Fig. 2, that allow simulation engineers to easily val-
erties such as porosity, permeability, and thickness of reservoir idate the geological model, especially the data related to the
strata are described in the geologic model as well. Engineering grid and well completions, e.g., grid orientation, grid origin,
data, such as pressures, fluid densities, free water levels, satura- flipped cells, grid horizon, well trajectories and completions,
tions, etc., may also be included in the geologic model. Because and faults orientation, by using one of the pre-processing and
the model is an interpretation, and interpretation is necessarily post-processing platforms.
the result of the geologist’s judgment, knowledge and experi- The following are just a few of the aforementioned issues
ence, the geological model may have some issues4. that reservoir simulation engineers can face when checking the
Interpretation is often a step toward a more accurate and geological model:
reliable geologic model, developing further as new data is
gathered and new concepts are formulated. The geologic • When the well completions are integrated with the
model is not a final product, but a milepost on the way to model grids, they sometimes do not share the same
obtaining a description of the “actual” reservoir. The two depth zone, Fig. 3.
At every step, specific data is reviewed and validated based Grid Validation
on some well-developed QC criteria. The following discusses
these nine QC steps. Validation of the grid requires checking the origin and lo-
cation of the grid. This is the first step to performing QC of
any other data. In this first QC step, the tool validates the
Well A
reservoir grid index order automatically, and it checks the
origin of the grid by considering all possible reasons, which
is implemented to generate the grid or grid affected because
of the loading process by using a different format2. An output
result is displayed in text format showing a 3D environment
with the base horizon and the origin of the grid indicated with
a point at the cell where I=1, J=1 and K=1. The tool validates
Fig. 5. Examples of the mismatch of well trajectorie
the top left cell, whether it is (1,1,1) or not, then it validates
the grid location by importing a well-known location well.
Validating the grid location can be performed with reference
72 FALL 2016
Fig. 6. Grid origin checked with one well location in
SAUDI ARAMCO JOURNAL OF TECHNOLOGY
Well Tops Horizon
which the tool provides statistical results of how many well
Well Tops Horizon tops have a distance of more than the assigned threshold for
each grid horizon. Also, the tool displays all the well tops that
do not intersect with grid horizons in 3D, Fig. 7.
Grid Faults
Fig. 7. Horizons checked against well tops.
Fig. 7. Horizons checked against well tops. In the third QC step, the tool automatically validates the grid
Fig. 7. Horizons checked against well tops.
faults against the interpreted faults to ensure that the grid
faults are modeled correctly, Fig. 8. All the grid faults should
intersect with the imported interpreted faults. The simula-
tion engineers are allowed to select a threshold, then the tool
provides statistical results of how many grid faults have a
distance of more than the assigned threshold for imported
interpreted data. Also, the tool displays all the grid faults that
do not intersect with imported faults in 3D.
Grid
Cell Vol.
Horizons ft3
52,329 507,243,264 53,167,167 0 0 grid
0 cell are0 met. The 0 tool displays all the cells having issues
Property
Cell Angle Units
Areal
deg Total 0.00
Minimum
Total 0.64
Maximum
Total
Average
Threshold
0.150.81 Bad25
Cells
Minimum0
in
Maximum
3D,
0.00 based
Average 0.00
on the threshold
Status 0.000.52
Display
put forward by the simulation
Cell Vol. ft3 52,329 507,243,264 53,167,167 0 0 0 0
In the
Cell second
Angle degQC step, 0.09 the tool automatically
8.96 4.16 validates 25 the 0 engineers,
0.00
0
and provides
0.00 0.00 full statistics for, and the status of,
Cell Angle deg 0.00 0.64 0.150.81 25 0 0.00 0.00 0.000.52
Vertical
grid horizons against the well tops to ensure that the grid
Areal each cell’s properties, Table 1.
Cell
horizons
Dimension are ftmodeled
Cell Angle deg 0.09
635.93correctly.
8.96 This step917.70
1,916.05
4.16 determines0.00
25 0 the ac-2.295
0.00 0.00 The
635.93
properties
0.00
1,916.05
that
917.70
are generated in checking the geometry
Vertical X
X
curacy of the horizons in the grid by comparing them against of the grid cell as listed in Table 1 are discussed next.
Cell
Cell
the well tops,
Dimension
Dimension ft ft which
635.93 are 1,916.05
708.69 deemed to917.70
1,974.32 be interpreted
0.00
1,041.62 with
0.0 high
2.295 635.93
2.295 1,916.05
708.69 917.70
1,974.32X 1,041.62 X
X
Y
confidence.
Cell The tool automatically picks the horizons of the Cell Volume. This refers to the bulk grid cell block volume;
Cell Vol. 0.00 1 0.81 0.75 581 0.00 0.75 0.52 X
grid provided
Dimension
Contrast ft
for the grid
708.69
validation
1,974.32
— previously
1,041.62 0.0
described.
2.295 708.69 the porosity
1,974.32 1,041.62 and
X saturations are not accounted for in the cal-
Y
All the well tops0.00
Cell Inside
Cell should
0.00
intersect
0.00
with
0.81 the horizons.
0.00
The
0
simu- 0 culation.
0.00
0.52 The Xminimum and maximum cell volume values of
0.00 0.00
OutVol. 1 0.75 581 0.00 0.75
Contrast
lation engineers are allowed to select a threshold in feet, after the entire grid are reported in the “Total Min.” and “Total
Cell Inside 0.00 0.00 0.00 0 0 0.00 0.00 0.00
Table
Out 1. Statistics describing the results of the cell validation step
Total Total Total Bad
Property Units Threshold Min. Max. Average Status Display
Minimum Maximum Average Cells
Table 1. Statistics describing the results of the cell validation step
Cell Vol. ft3 52,329 507,243,264 53,167,167 0 0 0 0 0
Cell Angle
deg 0.00 0.64 0.150.81 25 0 0.00 0.00 0.000.52
Areal
Cell Angle
deg 0.09 8.96 4.16 25 0 0.00 0.00 0.00
Vertical
Cell
Dimension ft 635.93 1,916.05 917.70 0.00 2.295 635.93 1,916.05 917.70 X
X
Cell
Dimension ft 708.69 1,974.32 1,041.62 0.0 2.295 708.69 1,974.32 1,041.62 X
Y
Cell Vol.
0.00 1 0.81 0.75 581 0.00 0.75 0.52 X
Contrast
Cell Inside
0.00 0.00 0.00 0 0 0.00 0.00 0.00
Out
Perforations
Fig. 10. Well tops checked against horizons.
Fig. 10. Well tops checked against horizons.
Trajectories
Grids
Completions
Fig.
Well 11.
TopsQC step for the well trajectories.
In the fifth QC step, the tool ensures that the well trajecto-
ries are located correctly by comparing them with the well
tops’ locations. This step is about checking the well trajectory Fig. 12. Well completions checked against perforations.
Li
Water Injection Rate Observed
Rate
Flow Rate
Liquid Flow
Fig.
lists and displays all the wells with issues, Fig. 13, 14. Observed
showing datamade
decision checked
in theagainst the This
QC process. completion
will enhanceevents.
the com-
production log vs. completion. munication and collaboration among simulation engineers by
allowing them to save, access and review previous decisions.
Observed Data The tool also provides automatic KPIs summarizing the simu-
lation model data quality, displayed in statistical and graphi-
In the ninth QC step, the tool validates the well completion cal forms, Fig. 15.
events
Fig. 14.against the observed
Observed data.against
data checked The observed production
the completion data
events.
is imported and cross-checked against the completion data over CONCLUSIONS
time; the purpose is to highlight any production that coincides
with a closed well, Fig. 14. The tool first checks the opening and This workflow contains nine QC steps that streamline all the
closure of the wells for production against the observed data workflows that are currently being used by simulation engi-
measurement, then it issues messages with the well’s name and neers, and the QC tool automates the processes applied in the
corresponding error, e.g., flowing wells without an open flow grid and well completion workflow. The tool also highlights
section, completed wells without a flow rate, etc. all the simulation model data inconsistencies, and it issues a
warning message and specifies proper actions needed to resolve
REPORTING AND KPI the relevant errors.
Even more, this tool enforces reservoir simulation best prac-
In addition, this system provides a means of transferring tices by not allowing the user to go further without finishing
the accumulated knowledge by capturing every activity and the current QC step successfully. It gives flexibility within this
Fig. 15. KPI report sample highlighting the statistics of the well tops and cell volumes.
Fig. 15.
Fig. 15. KPI
KPI report
report sample
sample highlighting
highlighting the
the statistics
statisticsof
ofthe
thewell
welltops
topsand
andcell
cellvolumes.
volumes.
76 FALL 2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
stricture by letting the user activate the next QC step after pro- ACKNOWLEDGMENTS
viding a proper business and technical justification.
Tests and quality checks of the static model using this tool The authors would like to thank the management of Saudi
before the reservoir simulation process will ensure the consis- Aramco for their support and permission to publish this
tency and good quality of the reservoir model. It offers many article.
advantages: This article was presented at the SPE Reservoir
Characterization and Simulation Conference and Exhibition,
• Eliminates the manual effort. Abu Dhabi, UAE, September 14-16, 2015.
• Reduces the turnaround time.
REFERENCES
• Increases the accuracy.
• Reduces the history matching process. 1. Aziz, K. and Settari, A.: Petroleum Reservoir Simulation,
• Enforces reservoir simulation best practices. Applied Science Publishers, London, U.K., 1979, 476 p.
2. Shirzai, A.F., Solonitsyn, S. and Kuvaev, I.: “Integrated
Such an automated QC tool requires less work, which saves Geological and Engineering Uncertainty Analysis
a lot of time during the history match phase and significantly Workflow, Lower Permian Carbonate Reservoir,
improves the static models. It enhances the robustness of the Timan-Pechora Basin, Russia,” SPE paper 136322,
production forecasts based on these models. It must be noted presented at the SPE Russian Oil and Gas Conference and
as well that the proposed workflows can be applied in con- Exhibition, Moscow, Russia, October 26-28, 2010.
junction with any geostatistical simulation method. Therefore,
3. Aljenaibi, F.S., Salameh, L.A., Recham, R., Albadi, B.S.
the geological modeling process chosen by the geologist will
and Meziani, S.: “Best Practice for Static and Dynamic
always be preserved, as long as it is consistent with dynamic
Modeling and Simulation History Match Case — Model
data. Only the input parameters will be adjusted later to better
QA/QC Criteria for Reliable Predictive Mode,” SPE paper
account for constraints defined by the reservoir engineer.
148279, presented at the SPE Reservoir Characterization
and Simulation Conference and Exhibition, Abu Dhabi,
UAE, October 9-11, 2011.
4. Flint, S.S. and Bryant, I.D.: The Geological Modeling
of Hydrocarbon Reservoirs and Outcrop Analogues,
Blackwell Scientific Publications, Oxford, U.K., January
1993, 269 p.
Authors: Suresh Jacob, Nibras A. Abdulbaqi, Chandresh Verma and Rabih Younes
ABSTRACT sensors are powered from the surface using small diameter
control lines. An early generation of intelligent completion
Extended reach wells with thousands of feet of open hole systems relied heavily on electronics, where multiple downhole
reservoir contact and multilateral wells with eight to 10 laterals valves were operated through a single electric line from the
are becoming common practice as the industry develops tight surface1. These systems used a downhole motor or a hydraulic
and difficult reservoirs. Over the years, drilling and well pump to generate the motive force. The downhole electronics
construction technologies have made significant advances in the were later simplified by replacing the motor and pumps
field of geosteering, multilateral junctions, etc., to make these with simpler electro-hydraulic solenoid systems that uses
complicated wells not just a reality but also commonplace. The high-pressure hydraulic fluid from the surface through control
industry has recently introduced several new well completion lines. These hybrid systems had only solenoid valves downhole
technologies for the downhole monitoring and inflow control to select the valve to be operated. Both the electronic and
of these extended reach and multilateral wells. Over the last the hybrid electro-hydraulic valves had a very fast operation
10 years, Saudi Aramco has drilled and completed hundreds time and provided excellent feedback for the operation.
of multilateral wells with intelligent completions for real-time Unfortunately, the electric cable, connectors, and electronics
downhole monitoring and for remote valve operation to control used in these systems were highly susceptible to electrical
inflow from each lateral. These technologies have improved failures due to water ingress. The low reliability of such
well performance and reduced well intervention. electronics in harsh downhole conditions and the high cost of
This article presents a case study examining the design, these systems forced the industry away from electrical systems.
planning, installation, and operation of Saudi Aramco’s The industry therefore moved from electronically
first intelligent completion to be operated with a combined operated systems to purely hydraulic systems. Valves were
electro-hydraulic control system. New technologies like this operated with high-pressure hydraulic fluid supplied from
system are expected to improve the operation and inflow from the surface through small diameter lines to the valves. The
multi-zone wells by increasing the number of downhole inflow industry leveraged its experience with hydraulically operated
control zones and faster operation of downhole valves. subsurface safety valves and mechanical sliding side doors
Conventional intelligent completion systems use downhole to make highly reliable, hydraulically operated intelligent
valves that are operated by hydraulic pressure. The pressure completion valves. In addition to their high reliability,
is supplied from the surface through dedicated hydraulic lines these valves were less expensive than previous electronically
running to each of the downhole valves. The wellhead and operated valves. Over time, hydraulically operated valves
operations equipment constraints impose a maximum limit of became mainstream in intelligent completions. Currently,
five downhole valves in a well. nearly 1,000 wells have been completed in the industry with
The system in this case study uses an electro-hydraulic hydraulically operated intelligent completions.
control module at each of the downhole valves. The system The hydraulic system, while being highly reliable and more
can control up to 12 intelligent completion tools with the use cost-effective than the electronic system, had its own set of
of only two hydraulic lines and one electrical line from the drawbacks, i.e., it took a longer time to operate each downhole
surface. Technology like this allows control of inflow from each valve, and the system could operate only a limited number of
of the laterals, enhancing the performance of the completion. downhole valves. Given the hydraulic system’s complicated
downhole fluid metering and fluid directing systems, in some
EVOLUTION OF INTELLIGENT COMPLETIONS cases it took hours to operate a single downhole valve. This
TECHNOLOGY delay in valve operation created additional rig time for the
installation of an intelligent completion. In regions with high rig
Downhole inflow control valves (ICVs) and permanent sensors costs, the additional time negatively affected the economics of
are critical elements of intelligent completions. The valves and those completions. The long operating time for the valves also
Fig. 1. Schematic showing a well completion with a hydraulic intelligent completion — limited to a
maximum of five downhole valves.
Fig. 1. Schematic showing a well completion with a hydraulic intelligent completion — limited to a maximum of five downhole valves.
Fig. 1. Schematic showing a well completion with a hydraulic intelligent completion — limited to a
maximum of five downhole valves. immediate feedback of valve positions. Recently the industry
has leveraged the advances in high temperature electronics to
develop new electronically operated intelligent completions
that overcome the limitations of the previous electrical
systems3, 4.
The following sections of this article describe this new
generation electro-hydraulic system that uses a single electric
line and two hydraulic lines to operate up to 12 downhole
ICVs. The single electric line and two hydraulic lines are
connected to all the downhole valves. The two hydraulic
lines are connected, one each, to the open and closed sides
of the downhole ICV, while the electric line is connected to
a solenoid valve in the ICV. Each of the solenoid valves has
a different address, and each can be electrically activated
from the surface independently from the others. Activating a
particular solenoid valve allows the high-pressure hydraulic
pressure in the control lines to operate the ICV for the zone,
without affecting the other connected ICVs.
Fig. 2. Schematic of the electro-hydraulic intelligent completion showing
Fig. 2. Schematic
Valve B operation.
of the electro-hydraulic intelligent completion showing Valve B operation.
In summary, the electric system is used to select the specific
valve to be operated, and the hydraulic system provides the
reduced the frequency of their operation during production. motive force to operate the valve. Figure 2 shows the valve
The hydraulic intelligent completion system required a operation using the electro-hydraulic system. Valve B is being
dedicated hydraulic line for each downhole valve. The maximum operated. After the solenoid valve is energized for that zone,
number of valves in a well was five, due to the operation high-pressure fluid from the surface in open line 2 (purple),
constraints of multiple lines and the limited number of ports on flows through the solenoid valve in Unit B to Valve B. This
the wellhead and packers. This created a situation where a well high-pressure fluid operates Valve B, and the fluid from the
would be drilled with eight laterals but completed with only backside of the piston on this valve (pink) returns to the
Fig. 2. Schematic of the electro-hydraulic intelligentsurface
five downhole valves, Fig. 1. This limitation forced adjacent
completion showing Valve B operation.
through line 1. Valves A and C are not operated
laterals to be commingled through one valve2. Premature gas during this process as the solenoid valves in Unit A and Unit
or water breakthrough on one lateral would require its valve C are not activated and the ICVs are hydraulically isolated..
to be closed, thereby reducing inflow from the adjacent lateral, The solenoid is activated and kept open during the
which is produced through the same valve. New technologies duration of the ICV operation, it is de-activated and closed
were developed to increase the number of downhole valves when the ICV operation is complete. The downhole valves
while maintaining the same number of downhole cables. may be closed, opened fully or operated to an intermediate
choke setting by controlling the time period the solenoid is
NEW GENERATION ELECTRO-HYDRAULIC kept open.
INTELLIGENT COMPLETIONS Figure 3 shows a comparison of operating times for
the hydraulic and electro-hydraulic downhole valves. The
As stated earlier, the electronically operated intelligent electro-hydraulic valves’ operation is much faster.
completion offers several benefits, like faster operation and The solenoid valve unit used in the system is physically
Electro-hydraulic Zone 2
Actuation
Fig. 3. Comparison of operating times for hydraulic valves (left) and electro-hydraulic valves (right).
Fig. 4. Comparison of operating times for hydraulic valves (left) and electro-hydraulic valves (right).
Electro-hydraulic
Electro-hydraulicmodule
module
Actuation
ICV
Electro-hydraulic
Electro-hydraulic module
module (enlarged)
(enlarged)
Fig. 4. The electro-hydraulic control module and hydraulically operated ICV as separate components.
Fig. 5. Detailed drawing of the single lateral well before workover (left), and the planned well trajectory
and laterals (right).
Fig.Fig.
7. 7.
Detailed
Detailedviews
views of
of the intelligentcompletion
the intelligent completion valve
valve showing
showing the fully
the fully open open position (le
Fig.5.5.Detailed
Fig. Detailed drawing
drawing of theof the single
single lateral
lateral well well
before before(left),
workover workover
and the(left),
plannedand the
well
closed position (center) and the valve set to position 3 (right).
trajectory position (left), the fully closed position (center) and the valve set to position 3
and laterals (right).
planned well trajectory and laterals (right). (right).
Tubing Hanger
Tubing Hanger
35
Nipple Nipple
PDHMS 30
PDHMS
PDHMS 25
SSD
Packer 6
20
PDHMS
Electro-hydraulic ICV 6
15
Dual PDHMS
SSD
10
Packer 6
7” 26# Casing Shoe
Packer 5 Packer 4 Packer 3 Packer 2 Packer 1
5
5½” Liner Shoe
Electro-hydraulic ICV 6 0
L5 L4 L3 L2 L1 L0
DTS TAS and Bullnose
Fig. 8. Percentage inflow contribution from each lateral with all the downhole valves in a fu
Electro-hydraulic ICV 5 Electro-hydraulic ICV 4 Electro-hydraulic ICV 3 Electro-hydraulic ICV 2 Electro-hydraulic ICV 1
Dual PDHMS
position.
Fig. 6. Schematic of7”
the26#
intelligent
Casing completion
Shoe with the electro-hydraulic controls installed in six lateral
wells. Packer 5 Packer 4 Packer 3 Packer 2 Packer 1
Electro-hydraulic ICV 5 Electro-hydraulic ICV 4 Electro-hydraulic ICV 3 Electro-hydraulic ICV 2 Electro-hydraulic ICV 1
Fig. 6. Schematic of the intelligent completion with the electro-hydraulic controls installed in six lateral wells.
Fig.
82
6.FALL
Schematic of the intelligent completion with the electro-hydraulic controls installed in six lateral
2016 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
wells.
L-5 (Pos-10) L-4 (Pos-10) L-3 (Pos-10) L-2 (Pos-10) L-1 (Pos-10) L-0 (Pos-10)
35 18
20 10
15 8
6
10
4
5
2
0 0
L-5 (Pos-10) L-4 (Pos-10) L-3 (Pos-10) L-2 (Pos-10) L-1 (Pos-10) L-0 (Pos-10) L-5 (Pos-7) L-4 (Pos-4) L-3 (Pos-8) L-2 (Pos-8) L-1 (Pos-9) L-0 (Pos-10)
Downhole Valve Choke Setting for Each Lateral (a) Downhole Valve Choke Setting for Each Lateral (b)
Fig. 8(a). Percentage inflow contribution from each lateral with all the downhole valves in a fully open position, and (b) Balanced inflow contribution with downhole
valves in18different choke settings.
Percentage Inflow from Each Lateral
16
Saudi Aramco: Company General Use
up and14had started producing dry oil, it was extensively flow ACKNOWLEDGMENTS
tested 12
to measure reservoir pressure, gas-oil ratio, water cut
and to10estimate productivity. The authors wish to thank the management of Saudi Aramco
8 and Halliburton for their support and permission to publish
WELL PERFORMANCE
6 MODELING this article. The authors also acknowledge the valuable
4 support of Manesh Mathew, Ameen Al-Zubail, Elias Garcia
The data2 collected from the lateral flow tests was used to
and Savio Saldanha at Halliburton for their contribution to
simulate0 well and lateral inflow performance at different well
L-5 (Pos-7) L-4 (Pos-4) L-3 (Pos-8) L-2 (Pos-8) L-1 (Pos-9) L-0 (Pos-10) the successful installation.
conditions. The simulations show that due to variations in
Downhole Valve Choke Setting for Each Lateral (b) This article was presented at the SPE Saudi Arabia Section
productivity and completions geometry, some laterals will
Annual Technical Symposium and Exhibition, al-Khobar,
dominate inflow while others will have low contributions.
Saudi Arabia, April 25-28, 2016.
The results shown in Fig. 8a indicated that laterals 5 and 3
dominated the inflow when the well was produced with all the
Saudi Aramco: Company General Use REFERENCES
downhole valves in the fully open position. This dominance
prevents weaker laterals, like the mainbore and lateral 4,
from meeting the target rates. Long-term production in this 1. Shaw, J.: “Comparison of Downhole Control System
condition can cause premature water or gas breakthrough in Technologies for Intelligent Completions,” SPE paper
the laterals with the higher contribution, which can ultimately 147547, presented at the Canadian Unconventional
affect the life of the well. Resources Conference, Calgary, Alberta, Canada,
The production objective of balancing inflow from all the November 15-17, 2011.
laterals is achieved by reducing the rate from the stronger laterals 2. Jacob, S., Bellaci, I.J., Nazarenko, P. and Joseph, P.:
and increasing the rate from the weaker laterals. The rate from “Designing, Planning and Installation of an 8-Zone
the stronger laterals can be reduced by operating the downhole All-Electric Intelligent Completion System in an Extreme
choke from the fully open position — position 10 — to a smaller Reservoir Contact Well,” SPE paper 176811, presented at
position. The rate from the weaker laterals can be increased the Middle East Intelligent Oil and Gas Conference and
by keeping the ICV fully open and increasing the pressure Exhibition, Abu Dhabi, UAE, September 15-16, 2015.
drawdown of these laterals. Figure 8b shows the balanced inflow
3. Garcia, E. and Saldanha, S.: “Electrohydraulic ICV Control
from all laterals by following the above process.
System: A Novel Approach to Multizonal Control,”
OTC paper 26816, presented at the Offshore Technology
CONCLUSIONS
Conference Asia, Kuala Lumpur, Malaysia, March 22-25,
2016.
Saudi Aramco’s first electro-hydraulic intelligent completion
was successfully installed in a six-lateral multilateral well. 4. Garcia, E. and Mathew, M.: “Delivering Selective Interval
The technology performed as designed during installation and Control: Electro-Hydraulic Intelligent Completion
subsequent production. The electro-hydraulic system allows Enhances Reservoir Management for Multilateral Well,”
the number of downhole zones in a well to be increased, and SPE paper 178168, presented at the SPE/IADC Middle
it improves efficiency by reducing the time required to operate East Drilling Technology Conference and Exhibition, Abu
the valves. Dhabi, UAE, January 26-28, 2016.
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An Experimental Investigation of Performance Evaluations for Seawater and CO2 Injection Using Dual Core
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Xianmin Zhou, Fawaz M. Al-Otaibi, AlMohannad A. Al-Hashboul and Dr. Sunil L. Kokal
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In this study, a novel methodology of dual coreflooding testing was first developed and described in detail, and then applied to
evaluate the displacement efficiency and performance of seawater and supercritical carbon dioxide (sc-CO2) injection in tests of
two carbonate core plugs with different permeabilities at reservoir conditions. The dual coreflooding apparatus, which consists
of seven components, can be used for the individual or simultaneous injection of one- or two-phase fluids into core plugs of
various length arranged in a single or dual coreflooding configuration.
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The Permo-Carboniferous Unayzah Group is generally lacking in high resolution biostratigraphic control and fails to produce a
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minimal throughput. Gel-based conformance control has been successfully applied in both sandstone and carbonate reservoirs.
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Scale formation has been a persistent challenge in many producing sour gas wells from the Khuff reservoir in Saudi Arabia.
Accumulation of scale deposits on downhole tubulars and in wellhead manifolds interferes with field operation, limits well
accessibility and decreases well productivity. Extensive efforts have been devoted to understanding the scale deposition process
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