Field Lessons From Successful Application in Drilling Depleted
Transcription
Field Lessons From Successful Application in Drilling Depleted
OTC 14278 Aphron Drilling Fluid: Field Lessons From Successful Application in Drilling Depleted Reservoirs in Lake Maracaibo Julio Montilva, PDVSA; Catalin D. Ivan, M-I L.L.C.; James Friedheim, M-I L.L.C.; and Rafael Bayter, M-I L.L.C. Copyright 2002, Offshore Technology Conference This paper was prepared for presentation at the 2002 Offshore Technology Conference held in Houston, Texas U.S.A., 6–9 May 2002. This paper was selected for presentation by the OTC Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Offshore Technology Conference or its officers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Abstract Depleted reservoirs pose numerous technical challenges in both the construction and completion phases for wells in dozens of producing fields, often putting into question the economical viability of these fields. Wellbore instability, severe lost circulation, and stuck pipe are just a few of the problems encountered when drilling into these low-pressured reservoir formations. No area better illustrates the problems with depleted reservoirs than the Lake Maracaibo region. Water-wet sands that frequently triggered costly seepage losses and differential sticking typify many of these zones. Some contain microfractured sandstone formations where uncontrollable losses of whole drilling fluid previously were the norm rather than the exception. Others are characterized by laminated sand and shale sequences, which create the conditions for slow, dangerous, and unduly expensive drilling. Attempts were made with underbalanced drilling, but in addition to the extra time and equipment required, wellbore instability lead to failed well construction and thus seriously degrading project economics. Over the past two years, a specialized drilling fluid has being utilized to drill these depleted reservoirs in Lake Maracaibo. This fluid combines certain surfactants and polymers to create a system of "micro-bubbles" known as aphrons encapsulated in a uniquely viscosified system. These aphrons are non-coalescing, therefore creating a micro-bubble network for stopping or slowing the entry of fluids into the formation. The aphrons allow conventional drilling equipment to be used to successfully complete many reservoirs that previously would have been candidates for underbalanced drilling only. This paper describes the development and application of the specialized “micro-bubbles” or aphron-based drilling fluid for drilling depleted reservoirs by controlling downhole mud loss and formation damage. The authors will detail the operational procedures and the field applications of this drilling fluid, with particular emphasis on the lessons learned in the Lake Maracaibo implementation of the system. Introduction The drilling problems associated with the depleted reservoirs intrinsic to many of the mature fields throughout the world often make further development uneconomical. Uncontrollable drilling fluid losses frequently are unavoidable in the often large fractures characteristic of these formations. Furthermore, the typical laminated sand and shale sequences create conditions that can make drilling unduly expensive and dangerous when using conventional rig equipment. Consequently, these and a host of associated problems have led some operators to forgo continued development of these promising, yet problematic, reservoirs. The overbalance pressure generated when using conventional drilling fluids is to blame for the majority of the loss circulation and differential sticking problems encountered when drilling these wells. The equipment required when using aerated muds or drilling underbalanced is often prohibitively expensive and meeting safety requirements can be an exhaustive effort. Furthermore, these techniques may fail to provide the hydrostatic pressure necessary to safely stabilize normally pressured formations above the reservoir. The early wells in the Lake Maracaibo area were drilled using underbalanced drilling techniques combined with special casing designs to isolate the Miocene and Eocene formations. Yet, the hole instability problems associated with this drilling technique rendered this project unprofitable. Consequently, the operator looked for any alternative that would return profitability to this mature reservoir by reducing the drilling days and enhancing the production rate. The aphron-based system was recommended as an alternative drilling fluid to drill both the normal and subnormal pore-pressure sections, while simultaneously maintaining wellbore stability and controlling mud losses. The main challenges placed upon this drilling fluid system were solving the whole mud losses and hole instability problems associated with drilling normal and depleted pressure intervals 2 J. Montilva, C.D. Ivan, J. Friedheim and R. Bayter and attaining cost effectiveness through avoiding an extra casing run. Lake Maracaibo – Regional Geology Overview The principal plays in the northeast area of Lake Maracaibo are Miocene and Eocene sandstones sealed by interbedded shales, charged from organic rich La Luna source rocks of upper Cretaceous age. Fig. 1 is a map showing the various fields operated in Lake Maracaibo and surrounding areas, while Fig. 2 represents a geological cross-section through the lake and land formations. The API gravities of the crude in the area vary from values as low as 14° API to 35° API. The most important reservoir units are Miocene (Lagunillas, La Rosa Formations, Santa Barbara and Bachaquero Members) and Eocene sandstones (Misoa Formation B and C sands). The Miocene sandstones have the best reservoir properties and the Bachaquero Member of the Lagunillas Formation, consisting of thick channel sands, is the best producer. The thickest sands occur within the overlying, predominantly regressive Misoa B sequence, in particular the lower Misoa B beds, a distributary mouth bar complex. Deeper intervals consisted of a mainly transgressive sequence with relatively thin sandstones reservoirs (Misoa C). In general, the lower structural formations (i.e., Tia Juana, Lagunillas, and Bachaquero) were more prone to fractured formation losses, while the fields situated on the upper part of the structure (Lagomar) had specific permeable sands mud losses. The unconsolidated Miocene sands represented a better target/candidate for the aphron-based system, as fewer problems (i.e., mud losses) were recorded while drilling this interval. The deeper formations (Eocene) are characterized by localized micro-fractures that could explain the minimal lost circulation problems recorded during drilling these intervals at the beginning of this project. These problems were solved by adding sized bridging agents (i.e., calcium carbonate) to the drilling fluid system. Judging from the amount of losses recorded, the Lagomar field has shown the best results in using the solids-free version of the aphron-based system. This can be explained as the C sands (the producer in this field) have lower permeability than the B sands (drilled in Tia Juana or Lagunillas fields). Aphron Structure An aphron comprises two fundamental elements1: • A core that is commonly, but not always, spherical. Typically, the core is liquid or gaseous. • A thin aqueous protective shell The aqueous shell contains surfactant molecules positioned to produce an effective barrier against coalescence with adjacent aphrons. As illustrated in Fig. 3, the encapsulated shell protects the aphrons, which can attract one another to build up complex aggregates. It should be noted that the encapsulating soap film has both an inner and outer surface.1 This phase has oriented surfactant molecules at the surface that are hydrophilic pointing inwards and hydrophobic outwards. OTC 14278 Physically, the bubble in Fig. 3 is a sphere of gas, separated from its surroundings by a thin, soapy film. The hydrophilic head of the surfactant distributed on the molecular monolayer is oriented towards the bulk water, while its lipophilic tail is oriented towards the gas core.1 Thus, the foam (Fig. 4) has a water-wet or hydrophilic boundary as opposed to the aphron, which has a hydrophobic boundary. The advantage of gas-core aphrons is the tendency to lump together, creating large aggregates. Perhaps surprisingly, these macro-structures behave in the same manner as the individual aphron (Fig. 5). Through the meniscus that wraps all the individual colloidal gas aphrons, this macro-structure has the same liphophilic character and, to a certain degree, is believed to exhibit the same behavior when in contact with a water-wet formation.1 The “meniscus-wrapping theory” is literally endorsed by the mechanism known as “Laplace Pressure.” This theory simply states that when a flat liphophilic surface (i.e., plateau border from the aphron structure) dips into a water-wet liquid a contact angle will exist where the liquid and gas meet.1 If two such “liphophilic charges” are close together, the effect of the two contact angles will be the generation of a curvature of the liquid surface between those two liphophilic droplets. This is known as a meniscus. This mechanism may cause the aphron macro-aggregate to be wrapped with a meniscus with the liphophilic character. Aphron Structure Stability The water lamella in the aphron structure will remain stable as long as the water film is viscosified and the minimum and maximum thickness criteria is respected.1 First, a certain thickness is required for the water lamella to remain stable. According to the Thin Soap Film Thickness study by Clunie, et al,2 the water/film lamella is not stable if it is thinner than 4 microns or thicker than 10 microns. The study states in part that a minimum thickness created by the interaction between the water molecules and the hydrophilic parts of the surfactant must exist. As this “critical thickness” is altered, such as thinning due to stretching effects when the aphron volume increases, the soap film will break. Another phenomenon plays an important role in water lamella stability. This one has been described as “rate of transfer”, which can be affected by the “Marangoni effect”.1, 3 The water molecules from the lamella tend to leave the film and return to the bulk water (continuous phase). By viscosifying the water through the addition of a biopolymer, the rate of transfer is reduced to a point where the aphron structure is stabilized. Aphron as an Energized Microenvironment An aphron is much more than a “gas bubble”. The viscosified water lamella, in tandem with the surfactant layers, creates an “energized environment.” First, when an aphron is generated inside a liquid, a new surface must be created, which increases in area in proportion with the growth of the bubble.1 This expansion must be balanced by an increase in the pressure within the bubble (Laplace pressure), thus explaining why the OTC 14278 Aphron Drilling Fluid: Field Lessons From Successful Application in Drilling Depleted Reservoirs in Lake Maracaibo aphron is associated with an “energized environment” or “precompressed structure.” Aphrons contain a gas nucleus of encapsulated air and compress when circulated downhole. The internal pressure of these micro-bubbles increases at a rate proportional to the external pressure being applied (Fig. 6). The combination of increasing pressure and temperature serve to energize the individual aphrons.4 Once the drilling bit exposes a depleted formation, the aphrons immediately aggregate within the openings of lowpressure zones. There, a portion of the energy stored within each aphron is released, causing it to expand. The expansion continues until the internal and external pressures on the wall of the aphron are in balance. Fig. 7 illustrates this energizing process. As the energized micro-bubbles enter formation openings, they carry energy equal to that of the annulus. As the aphrons crowd into the openings, external Laplace forces increase dramatically, causing aggregation and an increase in Low Shear-Rate Viscosity (LSRV). The microenvironment created by this phenomenon forms a solids-free bridge.4 Aphron-Based System Composition Table 1 shows the components of a typical aphron system. As shown, the high-LSRV type fluid consists of a high-yield, stress-shear-thinning (HYSST) polymer coupled with fluidloss-control additives that create and stabilize the aphrons within the system. An aphronizer surfactant is incorporated to achieve the desired concentration of micro-bubbles, which typically range from 8 – 14% by volume. As the concentration builds, it is not uncommon to observe an increase in the Brookfield LSRV to between 120,000 and 160,000 cP.4 Once the system is circulated, the rheological properties are easily maintained to provide optimum hole cleaning, cuttings suspension, and a high degree of control in preventing whole drilling fluid invasion into the lost circulation zone. The organic and biodegradable polymers and non-caustic pH materials in the system have allowed it to meet Gulf of Mexico bioassay and Canadian micro-toxicity requirements.4 First Aphron-Based System Field Trial in Lake Maracaibo The first aphron-based system field trial was performed in the reservoir section of the VLA 1321 well. This well was characterized by a formation pressure gradient of 0.15 psi/ft to 0.30 psi/ft. The offset well data that were analyzed during the planning stage of this field trial are presented in Table 2. The aphron-based system was displaced to drill the reservoir section after the 13⅜-in. casing was set at 5,477 ft and the interval was drilled to 6,855 ft. The total section length was 1,378 ft and throughout this interval 390 ft were cored with 91% recovery. At the section total depth (TD), three logging runs were made and the 9⅝-in. casing was run without any problems. During all these operations (drilling, logging, running casing and cementing), no mud losses were experienced. The repeat formation tester data (RFT) are presented in Fig. 8. The formation gradients were ranging 3 from 0.15 psi/ft to 0.33 psi/ft while the mud gradient varied from 0.39 psi/ft to 0.41 psi/ft. Further Aphron-Based System Field Applications After the success of the first field trial of the aphron-based system, various operators used the system in several fields in the Lake Maracaibo field. Fig. 9 shows the evolution of the aphron-based system in Lake Maracaibo. The system has continuously been adjusted and fine tuned as per the lessons learned on each specific field and application. The system applications ranged from: 1. 2. 3. 4. Drilling low-pressure / low-fracture gradient sections Drilling fractured and high permeable sections Reservoir drill-in applications Drilling normal and low-pressure sections (high density applications). The low-pressure applications were mainly in the depleted reservoirs in the Miocene formations. Owing to the depleted nature of the sandstone formations, the aphron-based system was formulated to bridge the porous media and prevent lostcirculation problems. All the wells drilled for this type of application showed a pore pressure ranging from 2.5 lb/gal to 5.0 lb/gal and equivalent circulation density (ECD) between 9.5 lb/gal and 10.0 lb/gal. No mud losses were experienced. The micro-fractured, low-pressure/low-fracture gradient permeable formations applications were very typical for the depleted reservoirs in the Eocene sections. For these formations, the fracture gradient is around 9.0-lb/gal equivalent mud weight and there are several in-situ fractures (Fig. 10). The annular-pressure-while-drilling (APWD) data showed that the equivalent-circulating-density (ECD) value using the aphron-based systems was comparable with those for a polymer-based system and the effect of the aphron structures did was not significantly reduce the hydrostatic pressure. Because of this behavior and in order to drill the sections with low fracture gradient, hollow glass spheres were introduced to the original formulation to reduce the hydrostatic pressure. Calcium carbonate was used to provide a matrix in the natural fracture and to create a “bridging medium” where the aphron could work. Wells TJ 1336 and TJ 1333 were drilled using this new formulation. The recorded ECD values were around 9.0 lb/gal. No mud losses were reported. The biopolymer blend concentration was reduced from 5 lb/bbl to 3 lb/bbl to optimize rheological properties and avoid excessive ECD. The aphron-based system was introduced for drill-in applications for horizontal wells in the Lake Maracaibo area, aiming to minimize formation damage through reduced mud losses in the depleted target formations. At the same time, its unique features of solids-free bridging and using aphron-type structures for sealing the permeable zones were considered to better control potential formation damage through easier removal and smaller drop-down pressure. As a comparison, a conventional bridging agent employed by a standard drill-in fluid will not get removed from the productive formation 4 J. Montilva, C.D. Ivan, J. Friedheim and R. Bayter unless a mechanical operation or an acidization process will be performed. The main aphronizer surfactant was reduced in this application from 1.0 lb/bbl to 0.75 lb/bbl in order to minimize crude oil–mud emulsion. As previously described in this paper, most of the structures in the Lake Maracaibo field are located in the normal and low-pressure sections covering the Miocene and Eocene formations. Because of this geological structure sequence, an extra casing run was usually required to drill and case off the normal pressure section (Miocene), significantly increasing operating costs. . The aphron-based system was re-formulated to drill through both low-pressure and normal pressure formations, responding to permeable formations sealing requirements and hole stability issues. The system was formulated as a solidsfree system using NaCl or KCl as weighting agents. Several pilot tests were performed to evaluate the stability of the system in the presence of salt. The test results showed no unusual instability of the system. The maximum density used to date is 11.5 lb/gal when incorporating NaCl salt. The TJ 1349 and TJ 1348 wells were drilled using this formulation. Those wells are the first ones to drill with just one bit size/one interval diameter in both the normal and subnormal sections, thereby avoiding an extra casing run. OTC 14278 system. This could be caused by the high concentration of surfactant required to create and keep the aphron structures in the drilling fluid system. During the field trials in Lake Maracaibo, a compatibility test was performed prior to any application using crude samples from offset wells and, if emulsion was identified as a potential problem, the mud system was treated with defoaming/anti-emulsion agents. The driving forces behind using the aphron-based drilling fluid system were to increase the overall profitability of the Lake Maracaibo mature field through cost-effective drilling operations, reduce downhole losses, and improved primary oil recovery. The main achievements of using the aphron-based system can be summarized as reduced drilling days (from 33 to only 13 days), savings of one to two casing strings per well, increased cost efficiency through saving from not requiring underbalance drilling equipment and overall improved well productivity / oil recovery. Acknowledgements The authors wish to thank the management of both PDVSA and M-I L.L.C. for permission to present this paper. A special thanks goes to Mary Dimataris and Jim Redden from M-I L.L.C. for professionally revising this paper. References Lessons Learned, Special Considerations, and Conclusions Any time drilling operations are conducted in a very narrow pore pressure/fracture gradient window environment, the hydraulics calculations are of paramount importance. The aphron-based system appears to be a multiphase system, but there actually is no clear model for modeling multiphase hydraulics calculations for drilling fluid applications. However, according to the comparison between the APWD data and the single-phase hydraulics calculations performed with the modified power law model, the aphron-based system hydraulic behavior is equivalent to a polymer system. Fig. 11 presents this comparison. Regarding the bridging capacity of the system, the optimum system performance was obtained when the aphron concentration was kept between 8% to 14% by volume. However selection of the optimal aphron concentration will depend on the formation characteristics (pore or fracture size, pore pressure) and hydrostatic pressure. Until sufficient data are collected for fine tuning, a minimum of 12% will be required for any “wildcat”-type application. The aphron concentration is controlled with the aphronizer surfactant concentration and low-shear-rate-viscosity (LSRV) control (higher than 50,000 cP). Another important lesson learned from applying this technology in Lake Maracaibo was the necessity to determine and field-test the potential crude oil–mud emulsion. Even though this crude-mud emulsion has not been a problem in the field (no formation damage or production impairment related to in-situ emulsion was recorded), in laboratory conditions, the aphron-based system seemed to have a higher tendency to emulsify the crude oil as compared to a standard biopolymer 1. 2. 3. 4. Sebba, F.: Foams and Biliquid Foams – Aphrons, John Wiley & Sons Ltd, 1987. Clunie, J.S., Goodman, J.F. and Symons, P.C.: “Nature”, 216, 1203 (1967) Scriven, L.E., and Sternling, C.V.: “Nature”, 187, 186 (1960) Ivan, C.D., Quintana, J.L., and Blake, L.D.: “Aphron-Base Drilling Fluid: Evolving Technologies for Lost Circulation Control,” SPE 71377 2001 SPE Annual Technical Conference, New Orleans, Louisiana, Sept30 –Oct3, 2001. SI Metric Conversion Factors bbl x 1.5897 E-01 = m3 °F x (°F-32) x 5/9 = °C ft x 3.048 E-01 = m gal x 3.785 E-03 = m3 in. x 2.540 E-02 = m lb x 4.536 E-01 = kg lb/bbl x 2.853 E+00 = kg/m3 lb/gal x 1.198 E+02 = kg/m3 lb/gal x 1.198 E-01 = Specific Gravity (sg) OTC 14278 Aphron Drilling Fluid: Field Lessons From Successful Application in Drilling Depleted Reservoirs in Lake Maracaibo 5 Land Lake Table 1 – Formulation of a typical aphron system Component Base fluid (freshwater or brine) Soda ash Biopolymer blend Polymer blend Functions Provides continuous phase for system Formulation 0.974 bbl/final bbl Hardness buffer Viscosifier Fluid-loss control and thermal stabilization pH control Aphronizer Biocide pH buffer Surfactant Biocide 0.25 lb/bbl 5.0 lb/bbl 5.0 lb/bbl Upper Lagunillas Middle Lagunillas Bachaquero Lower Lagunillas Laguna Laguna Lower Lagunillas 0.5 lb/bbl 1.0 lb/bbl 5.0 gal/100 bbl Lower Lagunillas La Rosa Misoa Upper B Intermediate Sta. Barbara Misoa Lower B Table 2 – Offset wells general data Well no. 123 131 230 290 769 765 Target zone C-4 C-4M C-5 C-5 C-4 C-4m Depth (ft) 5,775 – 5,791 5,960 – 6,006 6,562 – 6,619 6,547 – 6,600 5,770 – 5,780 6,110 – 6,279 Pressure (psi) 1,279 1,215 1,578 1,342 1,076 864 Temperature °F 197 196 208 206 190 194 4000’ Misoa C Miocene/Eocene Unconformity Eocene Formation Miocene Formation Producing Interval Fig. 2 – Geological cross-section through the lake and land formations 6000’ 8000’ 9000’ 8000’ 10000’ 9000’ 6000’ 8000’ 5000’ 4000’ Tia Juana (TJ/LL) Lagomar (VLA) 0 40 80 Km Lagunillas (LL) La Salina (PB/TJ) Bachaquero (BA) Maracaibo Major Faults 6000’ Unconformity Datum Fig. 1 – Various fields operated in Lake Maracaibo Fig. 3 – Structure of colloidal gas aphron1 6 J. Montilva, C.D. Ivan, J. Friedheim and R. Bayter OTC 14278 Fig. 4 – Structure of standard foam1 Fig. 6 – The aphron energizing process Annulus Higher Pressure Zone Micro-environment p Formation Lower Pressure Zone Fig. 5 – The gas-core aphrons can lump together, creating large aggregates and these macro-structures behave in the same manner as the individual aphron Fig. 7 – When the bit enters a low-pressure zone, the energized aphrons aggregate instantaneously within the formation, creating a microenvironment bridge, preventing invasion of whole drilling fluid, filtrate and solids OTC 14278 Aphron Drilling Fluid: Field Lessons From Successful Application in Drilling Depleted Reservoirs in Lake Maracaibo 7 RFT Well RFTData Data -–VLA-1321 well VLA 1321 Mud Gradient 5500 5500 5500 5600 5600 5600 5600 5700 5700 5700 5700 DISCORD. 5800 5800 5800 5800 MISOA/C-4U2 5900 5900 5900 5900 C-4U3 6000 6000 6000 6000 C-4M 6100 6100 6100 6100 C-4L 6200 6200 6200 6200 6300 6300 6300 6300 C-5U2L 6400 6400 6400 6400 C-5U3 6500 6500 6500 6500 6600 6600 6600 6600 6700 6700 6700 6700 6800 6800 6800 6800 LA ROSA BASAL C-5U1 C-5U2U C-5L1 C-5L2 C-6U1 Fig. 8 – Repeat Formation Tester Data (RFT) Depleted sections Low pressure and fracture gradient intervals La Salina – Eocene (B-5-X, B-6-X etc.) Drill-in applications La Salina – Miocene (LL-03) Tia Juana – Miocene (LL-05) Solids free formulation Hollow glass spheres formulation Aphron-base system application evolution – Lake Maracaibo Depleted sections Low pressure and very low fracture gradient intervals Normal/low pressure sections – high density applications Mud weight up to 11.5 ppg La Salina – Eocene (B-5-X, B-6-X etc.) La Salina – Eocene (B-5-X, B-6-X etc.) Hollow glass spheres and CaCO3 formulation NaCl, KCl, CaCO3 Fig. 9 – Aphron-base system evolution in Lake Maracaibo 0.41 0.41 0.41 0.39 5500 0.37 Mud Gradient 0.33 0.31 0.24 0.15 Formation Gradient 7.9 7.8 7.3 7.5 2157 1981 1520 1126 846 Formation Gradient Mud Weight,ppg Mud weight (ppg) @ surface Pore Pressure (psi) 0.19 Pore Pressure 8 J. Montilva, C.D. Ivan, J. Friedheim and R. Bayter OTC 14278 Micro-fractures Field: B-6-X.25; Well TJ-872; Depth: 4345 ft Fig. 10 – The micro-fractured low-pressure/low-fracture gradient permeable formations are typical for the depleted reservoirs in the Eocene sections. These formations have the fracture gradient around 9.0-ppg equivalent mud weight and are showing several in-situ fractures Hidraulics Evaluation Mud weight Mud Weight (ppg) ppg 7 8 9 10 7,0 4.200 4.250 Mud Weight ECD Comparison APWD Vrs Calculated Data 8,0 9,0 10,0 ppg9.0 8.0 10.0 ECD Comparison APWD versus Calculated Data (ppg) surface Surface mud density readings 4.300 H Depth , ft 4.350 ECD ECD 4.400 _____APWD data ____ ECD δH Typical drill Ripiosstring assembly 4.450 APWD Data ------Calculated data - - - Calculate 4.500 Fig. 11 – Comparison between the APWD data and the single-phase hydraulics calculations performed with the modified power law model, which shows that aphron-base system hydraulic behavior is comparable with polymer system calculations.