Petrotech-2010

31 October-3 November 2010, New Delhi, India

1
Paper ID : 20100395

Micro bubble based workover fluid mitigates workover problems in
highly depleted reservoirs and enhances productivity- a case study

S.K.Mishra, U.S.Sengupta
Oil India Limited,Duliajan,Assam
Email : skmishra_oil@yahoo.com

Abstract

Oil India Limited (OIL), a national oil company, has its existence for over last five decade not only in
logistically difficult and geologically complex areas in North East of India but also beyond. Most of its
reservoirs of Naharkatia and Moran oil fields in Assam, discovered in early sixties are in their
advanced stage of depletion. Few reservoirs are much below the hydrostatic pressure.

Work over operations in depleted formation is often associated with mud loss. Mud losses in
permeable depleted reservoir damages the reservoir due to fluid invasion defeating the core purpose
of work over. To select a appropriate work over fluid to carry out various work over job has become a
challenge. The choices are not many too. For normal pressured wells OIL uses clear brine, however,
OIL is using a polymeric viscosifier imparted by Xanvis to combat loss circulation in depleted reservoir
to certain extent of success during work over operations. However, for highly depleted reservoirs
having reservoir pressure 40- 200kg / cm below hydrostatic, OIL experienced much difficulties to
carry out work over jobs till a micro bubble based Invasion Control System (MB-ICS) was introduced.

This paper discusses the merits and demerits of this system over other systems available in the
market as well as the out come of using this system in OILs four depleted wells,

Introduction

Use of brines as work over fluid in depleted reservoirs invariably leads to high fluid loss into the pay
zone resulting in prolonged flow back periods for the wells to come back to their full potential.
Formulating suitable water based, easy to use, work over fluid system for wells where the reservoir
pressures have gone down much below hydrostatic pressures had been a problem for last several
years. Severe mud loss into the formation not only results in increase in cost but also, deep fluid
invasion and hence high level of formation damage. Ultimately, the exploitation becomes
uneconomical.

Polymeric high viscous pills using different polymers like CMC (HVG),XC polymer and Xanthan Gum
(Xannvis) have been traditionally used in OIL to overcome the problem of loss circulation in work over
operations with varying degree of success. Although, these polymers are bio-degradable in nature, it
takes considerably long period of time to degrade and bring the well to stream to its full potential. Due
to improper mixing and other impurities, mechanical plugging also cannot be ruled out.

To overcome the problem of workover in sub-hydrostatic, highly depleted wells, OIL searched for
some technology and provisionally selected foam as an alternative as it gives a low density and has
the ability to bridge a wide range of pore sizes. However, as foams are compressible, may lose some
or all of their structure at the bottom of the hole. Moreover, due to high cost involved as well as
additional infrastructure required to generate foam, this proposal was not considered.

Hollow Glass Spheres (HGS) was also an alternative to use in highly depleted reservoir. But the cost
involved with this system was quite high and the grinded glass spheres are potential formation
damager in work over wells.

Following, literature survey and discussion with few service providers, OIL selected micro bubble
based water based fluid to carry out work over in depleted reservoirs. Accordingly, OIL tried this
system initially in four wells. This note describes in brief the outcome of field trial of this system.
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31 October-3 November 2010, New Delhi, India

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Micro bubble Invasion control system (MB-ICS)

Micro bubble Invasion control system (MB-ICS) is based on micro-bubble technology, where air
bubbles are generated using specific surfactants. Micro bubbles in conjunction with low shear rate
viscosity (LSRV) fluid have the ability to stop or reduce losses into formation fractures. These micro-
bubbles, which differ significantly from aerated fluids and foams, do not coalesce and upon entering a
lower pressure region within the depleted reservoir agglomerate, thus creating a strong internal seal.
This seal is minimally invasive in nature and readily cleans up with reservoir flow back as production
is initiated. Surface density of this system is low due to presence of micro-bubbles in the system.
These reductions in density disappear down hole due to the hydrostatic pressure. The fluid can be
formulated with freshwater, seawater or saltwater.

MB-ICS doesnt require any of the elaborate equipment / infrastructure used in air or foam drilling.
The system uses conventional fluid mixing equipment to form tough and flexible micro-bubbles. Due
to elevated LSRV, it not only arrests loss circulation but also eliminates hole cleaning problem.

Components of Micro bubble system

Micro bubbles differ from standard foams as these bubbles are stable, thick walled, compressible, do
not coalescence. It does not require any special arrangement at rig site
Micro bubble system is generally used to drill depleted reservoir. Hence the basic ingredients of this
system is so selected that it produces a stable system at bottom hole condition. The density of the
fluid is controlled by the concentration of micro bubbles. This system requires a range of chemicals
for production and stabilization of micro bubbles. Chemicals such as Soda Ash for hardness (of mix
water) control , a biocide, a viscosifier, filtration controlling agent, pH buffer, a surfactant. Surfactant
allow air to get entrained in presence of viscosifiers to produce micro bubbles and other bridging and
shale stabilizing agents are basic ingredients of this system.
Since OIL used this product for work over operations, shale stabilizing agents are not incorporated in
the system.

Preparation of Micro bubble system in the field

This system uses conventional fluid mixing equipments in combination with bit nozzle pressure or the
circulating pressure to form tough flexible micro-bubbles. Once formed, these micro bubbles differ
from foam and other bubbles in two ways. Firstly, they do not coalesce into larger bubbles but they
agglomerate at the low pressure zone to form a solid free bridge arresting invasion / loss of fluid into
the depleted reservoir. Secondly, these micro bubbles are strong and stable. They are comprised of a
core of air surrounded by layers of polymer and a tensoactive additive. Once formed, they remain in
the drilling fluid, flow through the shale shaker and are re-circulated down hole.
After hooking up the work over infrastructure, all the tanks, suction and delivery lines are cleaned with
approximately 2 % solution of bleaching powder to minimize bacterial action. Although, Sodium
hypochlorite is recommended for tank flushing, in absence of this chemical, bleaching powder was
used.
Calculated amount of water was taken in the mud preparation tank and is treated with soda ash to
precipitate out any divalent ions such as Calcium and Magnesium. The water is then treated with
approximately 0.5ppb bactericide followed by 5ppb each of Viscosifier and filtration control additives.
These chemicals were mixed thoroughly and a PH buffer is added to it to maintain pH to around 10.5.
A surfactant was then added very slowly at a concentration of about 0.5 ppb based on the density of
the work over fluid. The surfactant produces micro bubbles on stirring. A typical structure of a micro
bubble is given in fig-1.
Petrotech-2010
31 October-3 November 2010, New Delhi, India

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Typical properties of Micro bubble based Invasion control system prepared as above is given below.


Density < 8.0 ppg
Viscosity at @120 deg F 60cp
6rpm 32
3rpm 28
Plastic Viscsity 9cp
Yield value 50 lb/100 ft
Gels 30 / 39 lb/100 ft
Ph 10.0
LSRV (Brookfield) 168,800 cP @ 0.3 rpm








Fig-1


Case study


Well A

OIL field tried this system in four highly depleted wells to see its efficacy. The well was completed in
2872m Barail 4
th
+ 5
th
sand following a work over operation in December 2002 with 2%KCL brine. The
well initially produced 5-10KLPD oil with 3% water cut till April 2003 with gas lift assistance, after
which the well ceased to flow. Before cessation of flow, the well produced at a rate of 1KLPD with
high GOR of 1679scum /KL. The well was kept shut in since then. Static Bottom Hole pressure
(SBHP) recorded before taking work over in this well found to be 131.2 kg/cm at the mid perforation
depth ( EMW of 29pcf , 3.87ppg ). It was decided to recomplete the well with Hook Wall packer and
new set of gas lift valves (GLV) in the same barail sand.

After preparation and thorough mixing of Micro bubble system, the hole was filled up with 95 bbls of
this system through both tubing and casing having average density 7.1ppg ( 8.33ppg by pressure
pyknometer). The packer was unset and the well was circulated to balance. During the process of
killing and subsequent well operations no loss into the formation was observed. The packer was
pulled out and following a rotovert trip, a new packer was run in with a newly designed GLV.

Petrotech-2010
31 October-3 November 2010, New Delhi, India

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The well was unloaded with gas shot and the well flowed at a rate of 6klpd initially and started flowing
at rate of 12klpd almost clean oil. Due to high concentration of micro bubbles, the well took some
considerable time to unload in this well.

Well B

The objective of work over in this well was to recomplete with new set of GLV after setting HW packer.
SBHP recorded before taking the job was found to be 164kg/cm ( EMW 34.5 pcf, 4.61 ppg)at mid
perforation depth of 2960m in lower Tipam sand.
The left over fluid from well A were transported to well B by tankers after some dilution. This was later
reconditioned and some fresh fluid was prepared as per earlier formulation.The well was killed and
packer was unset and the system was balanced through circulation. During the process of killing and
subsequent well operation, no loss was observed. Following a rotovert trip, a new packer was run in
along with a new set of GLV and set as planned.
From the experience gained while unloading the well A, the well fluid loaded with micro-bubbles were
diluted a bit before setting the packer. This helped in quick unloading, however, the well produced
formation water for about two months at rate of 01 klpd after which it produced clean oil. It may be
worth mention that the well was producing water at the rate of 01 klpd and was shut in since
September 1997 due to high water cut. Although, production results of this was not encouraging, it
may be concluded that Micro bubble based Invasion control system has served its purpose as no fluid
loss was noticed during carrying out well operations.

Well C

The well was producing 33klpd oil with 2 klpd water. This well had a scrapping problem and it required
daily scrapping by heavy scrapper in the range 350m to 780m. In a work over ,a flow improver
treatment was carried out and the well was put on regular production since then. Though there was
marginal increase in production after the flow improver treatment, the frequency of scrapping
remained the same. In another work over, flow improver along with demulsifier treatment was carried
out, however, the well could not be brought into production except the recycling of injection gas. It
was planned to detect the gas return point by carrying out a temperature survey. However, while
probing prior to the temperature survey, the dummy got held up at 1389m.It was observed that
unrecorded fish such as wires and gauge cutter were inside hole. Bottom Hole pressure extrapolated
at pool datum before taking work over in this well found to be 70 kg/cm at the mid perforation depth (
EMW of 15.1 pcf, 2.01ppg ). It was therefore planned to recover the fish and recomplete the well with
packer and new sets of GLVs using micro bubble ICS system.

The well could not be completed due to severe fluid loss as the well was severely depleted.

Well D

The objective of this well was to recomplete the well with Hook Wall packer and new set of gas lift
valves (GLV) in the same Barail 3
rd
sand. The mid perforation Static bottom hole pressure at 2895m
was extrapolated to be 125 kg/cm (EMW 27pcf, 3.6 ppg) prior to carry out work over operation. After
completion of work over, the well produced clean oil at a rate of 29klpd from 6klpd producing earlier.
No fluid loss was noticed during the well operation and unloading with gas shots were problem free.
The details of production behaviors of these wells before and after the operations are given in table-1.

Observations and Recommendation


Micro bubble system is primarily used in the Middle East and Mexico as a drilling fluid in
highly depleted loss prone reservoirs. However, if proper mud mixing facility is available at
work over sites, it can be used as an excellent fluid for work over operation in highly depleted
reservoir. OIL used this fluid for work over operations in highly depleted pay zones
successfully with many fold increase in productivity.
This is solid less system that forms bridging across the depleted reservoir and arrests fluid
loss.
This system does not need any elaborate arrangement for producing micro bubbles unlike
other fluids in this category such as foam and mist.
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31 October-3 November 2010, New Delhi, India

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The tanks where this system is prepared and stored must be cleaned properly and free from
bacteria.
The system needs constant stirring / gunning.
This is a very stable system but degrades soon. Hence it needs constant biocide treatment.
Though the initial cost of chemicals of this system is high, if a number of wells are lined up for
servicing with this fluid, the overall cost is minimized and cost effective. This system is
recyclable with minimum treatment.
OIL tried this system for the first time in four depleted wells. The results obtained are quite
successful so far the basic purpose of using this fluid is concerned.
Well B and C did not give expected production results possibly due to wrong selection of
candidate wells.
In highly depleted reservoir, to arrest loss, the LSRV is kept at a higher side but LSRV has to
be reduced prior to setting packers for easy flow back.
This system is quite compatible to reservoir.
Primary objective of using this system i.e. completion of work over operation without any fluid
loss into the depleted reservoir has been achieved through field trial in four highly depleted
wells. As the numbers of depleted reservoirs are increasing, Micro bubble system is one of
the most suitable cost effective systems.
Air, Foam, Mist and Hollow Glass Spheres available with some service providers are also
suitable for this purpose but these systems needs elaborate arrangements to run and are very
costly.
Polymers used in this system are compatible to both fresh water and saline environment and
are bio-degradable.


MB ICS field trial history
2895
Barail 3
rd
sand
(NHK 17+128D block)
2896
Barail 3
rd
sand
(NHK 11D + 18 block)
2960
Jaipur Lower
Tipam
(NHK 393 block)
2857.5
Barail 3
rd
sand
(NHK 17+128D block)
Mid perforation
depth (M) / pool
datum (M)
164
219
132
154
Below hyd.
head
(kg/cm
2
)
125
(pool
press.)
EMW= 27.0
pcf
70
(pool
press.)
EMW= 15.1
pcf
164
(pool
press.)
EMW= 34.5
pcf
131.2
(SBHP)
EMW=28.7
pcf
SBHP
(kg/cm
2
)
0 0 0 Completed C
23 29 06 Completed
(Successful)
D
1.0 7 kl/week
(by stop
cooki
g)
0 Completed
(successful)
B
10 11 01 completed
(successful)
A
Gain
(klpd)
Post w/o
prod. rate
(klpd)
Pre w/o
prod.
rate
(klpd)
Status Well
Table-1


Acknowledgement

The authors are thankful to OIL Management for granting permission to present this paper in
Petrotech 2010.Contribution by Sri A.K.Gogoi, Head Well Construction and Sri A.N.Singh, Deputy
Chief Chemist are thankfully incorporated in this paper.


Petrotech-2010
31 October-3 November 2010, New Delhi, India

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