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Potassium Formate from Addcon An Oilfield Success Story : 1995-2014
Potassium formate from Addcon
Formate brines
Potassium formate from Addcon
Sodium formate
Potassium formate
Cesium formate
Solubility in water
47 %wt 77 %wt 83 %wt
Density 1.33 g/cm3
11.1 lb/gal1.59 g/cm3
13.2 lb/gal2.30 g/cm3
19.2 lb/gal
Formates are also soluble in some non-aqueous solvents
Solubility of cesium formate in various solvents
Potassium formate from Addcon
Solvent Solvent density (g/cm3)
Cesium formate
solubility (% w/w)
Solution density (g/cm3)
Water activity of solution
Water 1.00 83.0 2.30 0.25
Monoethylene glycol 1.11 82.9 2.22 0.05
Diethylene glycol 1.12 57 1.66 0.20
Triethylene glycol 1.13 33 1.38 0.11
Glycerol 1.26 63.8 1.96 0.08
Formate brines – Discovery and qualification
1987 1988 1989 1990 1991 1992
Shell patent the use of formates as
polymer stabilisers
Shell discover cesium formate
brine
Shell R&D in UK study the effect of sodium and potassium formates on the thermal stability of drilling polymers
Shell R&D in The Netherlands carry out qualification work on formate brines as deep slim-hole (HPHT) drilling fluids
Shell publish first SPE papers on formate brines
Start of Shell’s deep slim-hole drilling
R&D programme
Potassium formate from Addcon
The main application for formate brines is in High-Pressure High-Temperature gas wells
Low-solids heavy fluids for deep HPHT gas well constructions
• Reservoir drill-in • Completion • Workover • Packer fluids • Well suspension • Fracking
Used in hundreds of HPHT wells since 1995, including some of Europe’s deepest, hottest and highly-pressured gas reservoirs
Potassium formate from Addcon
The economic benefits provided by formate brines in HPHT gas field developments
Formate brines improve the economics of HPHT gas field developments by :
• Reducing well delivery time and costs
• Improving operational safety and reducing risk
• Delivering production rates that exceed expectations
• Providing more precise reservoir definition
Potassium formate from Addcon
42 deep HPHT gas fields developed using potassium formate brine , 1995-2011*
Country Fields Reservoir Description
Matrix type
Depth, TVD (metres)
Permeability (mD)
Temperature (oC)
Germany Walsrode,SohlingenVoelkersen, Idsingen,Kalle, Weissenmoor, Simonswolde
Sandstone 4,450-6,500 0.1-150 150-165
Hungary Mako , Vetyem Sandstone 5,692 - 235Kazakhstan Kashagan Carbonate 4,595-5,088 - 100
Norway Huldra ,NjordKristin,Kvitebjoern Tune, ValemonVictoria, Morvin, Vega, Asgard
Sandstone 4,090-7,380 50-1,000 121-200
Pakistan Miano, Sawan Sandstone 3,400 10-5,000 175
Saudi Arabia
Andar,ShedgumUthmaniyah Hawiyah,Haradh Tinat, Midrikah
Sandstone and carbonate
3,963-4,572 0.1-40 132-154
UK Braemar,DevenickDunbar,ElginFranklin,GlenelgJudy, Jura, KessogRhum, ShearwaterWest Franklin
Sandstone 4,500-7,353 0.01-1,000 123-207
USA High Island Sandstone 4,833 - 177
Potassium formate from Addcon
* More HPHT fields developed in Kuwait, India and Malaysia during 2012-2013
Formate brines – Production and first field use - Milestones
1993 1994 1995 1996 1997 1998
First field use of sodium formate: Shell drills and completes first
Draugen oil wells
Start of deep HPHT gas well
drilling with formates in Germany
(Mobil, RWE, BEB)
Sodium formate powder available throughout, but no anti-caking additive. Draugen wells each produce 48,000 bbl oil /day
1995 - Potassium formate brine becomes available from Hydro Chemicals (now Addcon) in Porsgrunn – sold thru Forbrico Ltd
Potassium formate brines used in USA, Canada,
Mexico, Venezuela,
Brazil, Ecuador
First field use of potassium formate (with Micromax) : Statoil drills and
completes Gullfaks oil well
1997 - Cesium formate brine becomes available from Cabot
Potassium formate from Addcon
First use of formate brine
as packer fluid: Shell Dunlin
A-14
Potassium formate brine has been produced at Porsgrunn since 1994
Production Site ADDCON NORDIC AS
Storage tanks for raw materials
Potassium formate from Addcon
Cesium formate produced by Cabot in Canada from pollucite ore
Pollucite ore Cs0.7Na0.2Rb0.04Al0.9Si2.1O6·(H20)
• Mined at Bernic Lake, Manitoba • Processed on site to Cs formate brine• Cs formate brine production 700
bbl/month
Potassium formate from Addcon
W-Cluster
15000'
14800'
Z2Z6
Z5Z7
Z4
5000'
10000'
15000'
18000'
Germany : Potassium formate brine has been used to drill deep HPHT gas wells since 1995 First use : ExxonMobil’s Walsrode field, onshore northern Germany - high-angle deep HPHT slim hole low perm gas wells
TVD : 4,450-5,547 metres Reservoir: Sandstone 0.1-125 mDBHST : 157o C Section length: 345-650 mDrilling fluid: SG 1.45-1.55 K formate brine
Potassium formate from Addcon
Potassium formate from Norway used in 15 deep HPHT gas well constructions in Germany ,1995-99
Well Name Application Fluid Type Density s.g. (ppg) Horizontal Length(m) Angle (°) BHST (°F) BHCT (°F) TVD (metres) MD (metres) Permeability
(mD)
Walsrode Z5 W/C K Formate 1.55 (12.93) 345 26 315 na 4450 - 4632 4815 - 5151 0.1 - 125 mD
Wasrode Z6 W/C K Formate 1.55 (12.93) 420 40 315 na 4450 - 4632 4815 - 5151 0.1 - 125 mD
Walsrode Z7 Drill-In K Formate 1.53 (12.77) 690 59 315 295 4541 - 4777 5136 - 5547 0.1 - 125 mD
Söhlingen Z3A Drill-In Formix 1.38 (11.52) 855 89 300 270 4908 5600 na
Söhlingen Z3a Drill-In Na Formate 1.30 (10.85) 855 89 300 270 4908 5600 na
Volkersen Z3 W/C Formix 1.40 (11.68) 512 52 320 na na na na
Kalle S108 Drill-In Formix 1.45 (12.10) 431 60 220 na 6000-6500 6200-6600 na
Weißenmoor Z1 W/C Formix 1.35 (11.27) 634 31 300 na na na na
Idsingen Z1a Drill-In K Formate 1.55 (12.93) 645 61 321 290 4632 - 4800 5257 - 5821 0.1 - 125 mD
Söhlingen Z12 Drill-In Na Formate/Formix 1.35 (11.27) 452 28 313 285 4736 - 4937 4846 - 5166 1.0 - 75 mD
Simonswolde Z1 Drill-In K Formate/Formix 1.52 (12.68) 567 35 293 275 4267 - 4572 4236 - 4648 0.1 - 25 mD
Walsrode NZ1 Drill-In Formix 1.51 (12.60) 460 34 290 265 4632 - 4815 4541 - 4693 0.1 - 125 mD
Idzingen Z2 W/C Formix 1.40 (11.68) na na 320 na 4632 - 4800 5257 - 5821 0.1 - 125 mD
Voelkersen NZ2 W/C Formix 1.40 (11.680 na na 320 na na na na
Söhlingen Z13 Drill-In/Frac K Formate/Formix 1.30 (-1.56)(10.85) 1200 90 300 285 4724 5486 - 6400 0,1 - 150 mD
Potassium formate from Addcon
Further wells drilled for BEB and RWE-DEA in Germany with Porsgrunn’s potassium formate brines via Baroid (1997 onwards)
Summary of potassium formate brine use in HPHT gas wells in Germany,1995-99
Potassium formate from Addcon
Formate brines – Some further important milestones : 1999-2004
1999 2000 2001 2002 2003 2004
First production of non-caking
crystalline K formate at Porsgrunn
First drilling jobs with
K/Cs formate brine:
Huldra and Devenick
Formate brines used as packer fluids for HPHT wells in GOM. First well : ExxonMobil’s MO 822#7 (215oC BHST) in 2001
Use of Cs-weighted oil-based completion fluids for oil reservoirs : Visund, Statfjord, Njord, Gullfaks, Snorre , Oseberg, Rimfaks 2001 – present
First use of Cs-weighted LSOBM as perforating completion
fluid (Visund)
First use of K/Cs formate
brine : Completion
job in Shearwater well (Shell
UK)
Potassium formate from Addcon
Cs-weighted LSOBM used as OH screen completion
fluid (Statfjord)
First use of K/Cs
formate brine as
HPHT well suspension
fluid (Elgin G-3)
Individual Draugen oil wells (1993) and Visund oil wells (2003) have similar flow rates of around 50,000 bbl oil/day
First of 14 Kvitebjørn HPHT wells drilled and completed with K/Cs formate brines
The first sustained use of K/Cs formate brine was in the world’s largest HPHT gas field development
Potassium formate from Addcon
190oC1100bar
5300m
Water Depth 90m
SIWHPFWHT
830bar180oC
::
GASCONDENSATE
3-4% C0230-40 ppm H2S
320barDEWPOINT
30% O1 Darcy K
Cesium formate brine used by TOTAL in 34 well construction operations in 8 deep gas fields in period 1999-2010
Elgin/Franklin field – UK North Sea
Formate brines – Some published milestones 2005 -2010
2005 2006 2007 2008 2009 2010
OMV Pakistan
start using K formate to drill and
complete (with ESS) in
HPHT gas wells
K/Cs formate brines used as well perforating fluids in 11 HPHT gas fields in UK North Sea : Dunbar, Shearwater, Elgin, Devenick , Braemar , Rhum, Judy , Glenelg , Kessog , Jura and West Franklin1999-2011
Saudi Aramco start using K
formate to drill and complete (with ESS) in
HPHT gas wells
Potassium formate from Addcon
Gravel pack with K
formate brine in
Statfjord B
First MPD operation in Kvitebjørn with K/Cs formate
“designer fluid”
First of 12 completions
in the Kashagan field with
K/Cs formate
Total’s West Franklin F9 well (204oC) perforated in K/Cs formate
brine
Petrobras use K
formate brine for
open hole gravel packs
in Manati field
Saudi Aramco have been drilling HPHT gas wells with potassium formate brine since 2003
Potassium formate from Addcon
Saudi Aramco use of formate brines, 2003-2009
• 7 deep gas fields
• 44 HPHT wells drilled
• 70,000 ft of reservoir drilled at high angle
• 90,000 bbl of brine recovered and re-used
• Good synergy with ESS, also OHMS fracturing
Potassium formate from Addcon
Summary from Aramco’s OTC paper 19801
Potassium formate from Addcon
Pakistan - OMV use potassium formate brine for HPHT deep gas well drilling and completions
Potassium formate from Addcon
Extracts from OMV’s SPE papers and SPE presentations – note 1,700 psi overbalance, and 350oF
Potassium formate from Addcon
North Sea - K/Cs formate brines used as combined HPHT drill-in and completion fluids
33 development* wells drilled and completed in 7 HPHT offshore gas fields
•Huldra (6 ) •Tune (4) •Devenick (2) •Kvitebjoern (8 O/B and 5 MPD) •Valemon (1) •Kristin (2) – Drilled only •Vega (5)
* Except Valemon (appraisal well)
Mostly open hole stand-alone sand screen completions
Potassium formate from Addcon
Tune field – HP/HT gas condensate reservoir drilled and completed with K formate brine, 2002
4 wells : 350-900 m horizontal reservoir sections. Open hole screen completions. Suspended for 6-12 months in formate brine after completion
Potassium formate from Addcon
Tune wells - Initial Clean-up – Operator’s view (direct copy of slide) June 2003
Potassium formate from Addcon
• Wells left for 6-12 months before clean-up• Clean-up : 10 - 24 hours per well • Well performance
•Qgas 1.2 – 3.6 MSm3/d•PI 35 – 200 kSm3/d/bar•Well length sensitive
•No indication of formation damage•Match to ideal well flow simulations (Prosper) - no skin
• Indications of successful clean-up•Shut-in pressures •Water samples during clean-up
•Formate and CaCO3 particles•Registered high-density liquid in separator•Tracer results
•A-12 T2H non detectable•A-13 H tracer indicating flow from lower reservoir first detected 5 sd after
initial clean-up <-> doubled well productivity compared to initial flow data•No processing problems Oseberg Field Center
SIWHP SIDHP SIWHP SIDHPbara bara bara bara
A-11 AH 169 - 388 -A-12 T2H 175 487 414 510
A-13 H 395 514 412 512A-14 H 192 492 406 509
Before After
3350
3400
3450
3500
3550
3600
0 100 200 300 400 500 600 700 800 900 1000
Well length [m MD]
Dep
th [m
TVD
MSL
]
A-11AHA-12HT2A-13HA-14HA-11 AH plugged back
Tune – Production of recoverable gas and condensate reserves since 2003 (NPD data)
Good early production from the 4 wells - No skin (no damage)
- 12.4 million m3 gas /day - 23,000 bbl/day condensate
Good sustained production - 90% of recoverable hydrocarbon reserves produced by end of Year 7
NPD current estimate of RR: - 18.3 billion m3 gas - 3.3 million bbl condensate
Rapid and efficient drainage of the reservoir
Potassium formate from Addcon
• 6 production wells
• 1-2 Darcy sandstone
• BHST: 147oC
• TVD : 3,900 m
• Hole angle : 45-55o
• Fluid density: SG1.89-1.96
• 230-343 m x 81/2” reservoir sections
• Open hole completions, 65/8” wire wrapped
screens
• Lower completion in formate drilling fluid and
upper completions in clear brine
Huldra field – HPHT gas condensate reservoir drilled and completed with K/Cs formate brine, 2001
Potassium formate from Addcon
Huldra – Production of recoverable gas and condensate reserves since Nov 2001 (NPD data)
Plateau production from first 3 wells - 10 million m3 gas /day - 30,000 bbl/day condensate
Good sustained production - 78% of recoverable gas and 89% of condensate produced by end of Year 7 - Despite rapid pressure decline.....
NPD current estimate of RR: - 17.5 billion m3 gas - 5.1 million bbl condensate
Rapid and efficient drainage of the reservoir
Potassium formate from Addcon
• 13 wells to date – 8 O/B, 5 in MPD mode
• 100 mD sandstone
• BHST: 155oC
• TVD : 4,000 m
• Hole angle : 20-40o
• Fluid density: SG 2.02 for O/B
• 279-583 m x 81/2” reservoir sections
• 6 wells completed in open hole : 300-micron single wire-wrapped
screens.
• Remainder of wells cased and perforated
Kvitebjørn field – HPHT gas condensate reservoir drilled and completed with K/Cs formate brine, 2004-2013
Potassium formate from Addcon
Kvitebjoern well
Completion time
(days)
A-4 17.5
A-5 17.8
A-15 14.8
A-10 15.9
A-6 12.7 *
* Fastest HPHT well completion in the North Sea
“The target well PI was 51,000 Sm3/day/bar This target would have had a skin of 7”
“A skin of 0 would have given a PI of 100,000”
“THE WELL A-04 GAVE A PI OF 90,000 Sm3/day/bar (ANOTHER FANTASTIC PI)”
Operator comments after well testing (Q3 2004 )
The Well PI was almost double the target
Potassium formate from Addcon
Fast completions and high well productivity
Kvitebjørn– Production of recoverable gas and condensate reserves since Oct 2004 (NPD data)
Good production reported from first 7 wells in 2006 - 20 million m3 gas /day
- 48,000 bbl/day condensate
Good sustained production (end Y8) - 37 billion m3 gas - 17 million m3 of condensate - Produced 70% of original est. RR by end of 8th year
NPD : Est. RR have been upgraded - 89 billion m3 gas (from 55) - 27 million m3 condensate (from 22)
Note : Shut down 15 months, Y3-5 - To slow reservoir pressure depletion - Repairs to export pipeline
Potassium formate from Addcon
Economic benefits of using formate brines
• SPE 130376 (2010): “A Review of the Impact of the Use of Formate Brines on the Economics of Deep Gas Field Development Projects”
• SPE 145562 (2011): “Life Without Barite: Ten Years of Drilling Deep HPHT Gas Wells With Cesium Formate Brine”
Potassium formate from Addcon
Economic benefits from using formate brines - Good well performance and recovery of reserves
• “High production rates with low skin” * • “ We selected formate brine to minimise well control problems and maximise well productivity”*
* Quotes by Statoil relating to Kvitebjoern wells (SPE 105733)
Potassium formate from Addcon
Economic benefits from using formate brines
- More efficient and safer drilling
“ a remarkable record of zero well control incidents in all 15 HPHT drilling operations and 20 HPHT completion operations”
Better/safer drilling environment saves rig-time costs • Stable hole: see LWD vs. WL calipers in shale
• Elimination of well control* and stuck pipe incidents • Good hydraulics, low ECD
• Good ROP in hard abrasive rocks
* See next slide for details
Potassium formate from Addcon
Economic benefits from using formate brines - Improved well control and safety
• Elimination of barite and its sagging problems
• Elimination of oil-based fluids and their gas solubility problem
• Low solids brine Low ECD (SG 0.04-0.06) and swab pressures
• Inhibition of hydrates
• Ready/rapid surface detection of well influx
• Elimination of hazardous zinc bromide brine
Potassium formate from Addcon
- Drill-in and completing with formate brine allows open hole completion with screens
- Clean well bores mean no tool/seal failures or blocked screens
- Completion time 50% lower than wells drilled with OBM
“ fastest HPHT completion operation ever performed in North Sea (12.7 days)”
Economic benefits from using formate brines
- More efficicient/faster completions
Potassium formate from Addcon
• No differential sticking
• Pipe and casing running speeds are fast
• Mud conditioning and flow-check times are short • Displacements simplified, sometimes eliminated
Duration of flow back(minutes)
Fluid Gain (bbl)
30 0.8
15 0.56
20 0.44
30 0.56
Potassium formate from Addcon
Flow check fingerprint for a Huldra well
Economic benefits from using formate brines - Operational efficiencies
Economic benefits from using formate brines - Good reservoir definition if Cs present in fluid
• High density filtrate and no barite
• Filtrate Pe up to 259 barns/electron
• Unique Cs feature - makes filtrate invasion highly visible against formation Pe of 2-3 b/e
• LWD can “see” the filtrate moving (e.g. see the resistivity log on far right – drill vs ream
• Good for defining permeable sands (see SAND-Flag on log right )
• Consistent and reliable net reservoir definition
from LWD and wireline Potassium formate from Addcon
Economic benefits from using formate brines - Good reservoir imaging
• Highly conductive fluid
• Clear resistivity images
• Information provided: - structural dip - depositional environment - geological correlations
Potassium formate from Addcon
Formate brines – Summary of economic benefits provided to users
Formate brines tend to improve oil and gas field development economics by :
• Reducing well delivery time and costs
• Improving well/operational safety and reducing risk
• Maximising well performance
• Providing more precise reservoir definition
Potassium formate from Addcon
OPERATOR LOCATION Packer Fluid(ppg)
BHT (°C)
BHT (°F)
Start Date
End Date Comments
Devon WC 165 A-7 8.6 KFo 149 300 1/2005
Devon WC 165 A-8 8.6 KFo 149 300 1/2006
Devon WC 575 A-3 ST2 9.5 KFo 132 270 5/2005
WOG/Devon MO 862 #1 12.0 NaKFo 215 420 4/2005 5/2006Well P&A – H2O production – G-3 in excellent condition
BP/Apache HI A-5 #1 11.5 NaKFo 164 350 2/2002 4/2008Well P&A - Natural depletion – S13Cr in excellent condition
ExxonMobil MO 822 #7 12.0 NaKFo 215 420 2001
EPL ST 42 #1 11.5 NaKFo 133 272 2006
EPL ST 41 #F1 13.0 NaKFo 105 222 2006
EPL EC 109 A-5 11.5 NaKFo 121 250 2006
EPL ST 42 #2 12.8 NaKFo 132 270 2006
Dominion WC 72 #3 BP1 10.0 NaFo 121 250 2006
EPL WC 98 A-3 ST1 12.7 NaKFo 153 307 2006
EPL WC 98 A-3 10.8 NaKFo 154 310 2007
Formate brines as packer fluids in GOM
Potassium formate from Addcon
• 177ºC, 14,000 psi
• S13Cr tubing failed from CaCl2 packer fluid
• Well worked over and re-completed with Cs formate
• 1.4 g/cm3 Na/K formate used as packer fluid
• Tubing retrieved 6 years later
• Tubing was in excellent condition.
BP High Island – Na/K formate brine as packer fluid for 6 years
Potassium formate from Addcon