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SPE FOUNDATION The Society gratefully acknowledges those companies that support the program by allowing their professionals to participate as Lecturers. And special thanks to The American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME) for their contribution to the program.

Oilfield Scale: A New Integrated Approach to Tackle an Old Foe Dr Eric J. Mackay Flow Assurance and Scale Team (FAST) Institute of Petroleum Engineering Heriot-Watt University Edinburgh, Scotland [email protected] Society of Petroleum Engineers Distinguished Lecturer 2007-08 Lecture Season

Outline 1) The Old Foe a) b) c) d)

Formation Definition of scale Water (Ba) Problems caused Common oilfield scales Mechanisms of scale formation

2) The New Approach

Injection Water (SO4) •• •• • • •••• •

Ba2+ + SO42- Æ BaSO4(s)

a) The new challenges b) Proactive rather than reactive scale management c) Effect of reservoir processes

3) Conclusions Slide 3 of 39

Outline 1) The Old Foe a) b) c) d)

Formation Definition of scale Water (Ba) Problems caused Common oilfield scales Mechanisms of scale formation

2) The New Approach

Injection Water (SO4) •• •• • • •••• •

Ba2+ + SO42- Æ BaSO4(s)

a) The new challenges b) Proactive rather than reactive scale management c) Effect of reservoir processes

3) Conclusions Slide 4 of 39

1a) Definition of Scale „

Scale is any crystalline deposit (salt) resulting from the precipitation of mineral compounds present in water

„

Oilfield scales typically consist of one or more types of inorganic deposit along with other debris (organic precipitates, sand, corrosion products, etc.) Slide 5 of 39

1b) Problems Caused „

Scale deposits z z z z z z z

„

formation damage (near wellbore) blockages in perforations or gravel pack restrict/block flow lines safety valve & choke failure pump wear corrosion underneath deposits some scales are radioactive (NORM)

Suspended particles z z

plug formation & filtration equipment reduce oil/water separator efficiency

Slide 6 of 39

Examples - Formation Damage scale crystals block pore throats

quartz grains Slide 7 of 39

Examples - Flow Restrictions

Slide 8 of 39

Examples - Facilities separator scaled up

and after cleaning

Slide 9 of 39

SPE 87459

1c) Common Oilfield Scales Name

Formula

Specific Gravity

Solubility cold water

other

(mg/l) Common Scales barium sulphate

BaSO4

4.50

2.2

calcium carbonate

CaCO3

2.71

14

acid soluble

strontium sulphate

SrSO4

3.96

113

slightly acid soluble

calcium sulphate

CaSO4

2.96

2,090

acid soluble

calcium sulphate

CaSO4.2H2O

2.32

2,410

acid soluble

sodium chloride

NaCl

2.16

357,000

(insoluble in HCl)

SiO2

2.65

insoluble

HF soluble

60 mg/l in 3% HCl

Sand Grains silicon dioxide

Some Other Scales Iron Scales:

Fe2O3, FeS, FeCO3

Exotic Scales:

ZnS, PbS Slide 10 of 39

1d) Mechanisms of Scale Formation „

Carbonate scales precipitate due to ∆P (and/or ∆T) z

wellbore & production facilities

Ca2+(aq) + 2HCO-3(aq) = CaCO3(s) + CO2(aq) + H2O(l) „

Sulphate scales form due to mixing of incompatible brines z z

injected (SO4) & formation (Ba, Sr and/or Ca) near wellbore area, wellbore & production facilities

Ba2+(aq) (Sr2+or Ca2+) + SO42-(aq) = BaSO4(s) (SrSO4 or CaSO4) „

Concentration of salts due to dehydration z

wellbore & production facilities

Slide 11 of 39

Outline 1) The Old Foe a) b) c) d)

Formation Definition of scale Water (Ba) Problems caused Common oilfield scales Mechanisms of scale formation

2) The New Approach

Injection Water (SO4) •• •• • • •••• •

Ba2+ + SO42- Æ BaSO4(s)

a) The new challenges b) Proactive rather than reactive scale management c) Effect of reservoir processes

3) Conclusions Slide 12 of 39

2a) The New Challenges „

Deepwater and other harsh environments z z z z

„

Inhibitor placement z

„

Low temperature and high pressure Long residence times Access to well difficult Compatibility with other production chemicals

Complex wells (eg deviated, multiple pay zones)

Well value & scale management costs

Slide 13 of 39

Access to Well „

Subsea wells z

z

z

z

difficult to monitor brine chemistry deferred oil during squeezes well interventions expensive (rig hire) squeeze campaigns and/or pre-emptive squeezes Slide 14 of 39

Inhibitor Placement in Complex Wells „

„

Where is scaling brine being produced? Can we get inhibitor where needed? z z

z

„

Ptubing head

wellbore friction pressure zones (layers / fault blocks) damaged zones

Pcomp 1 Presv 1 Shale

Options: z z z z

Bullhead bullhead + divertor Coiled Tubing from rig Inhibitor in proppant / gravel pack / rat hole

Fault

Pcomp N

Presv N

Slide 15 of 39

Well Value & Scale Management Costs „

Deepwater wells costing US$10-100 million (eg GOM)

„

Interval Control Valves (ICVs) costing US$0.5–1 million each to install z z

„

Rig hire for treatments US$100-400 thousand / day z z z

„

good for inhibitor placement control susceptible to scale damage

necessary if using CT deepwater may require 1-2 weeks / treatment cf. other typical treatment costs of US$50-150 thousand / treatment

Sulphate Reduction Plant (SRP), installation and operation may cost US$20-100 million Slide 16 of 39

2b) Proactive Rather Than Reactive Scale Management „ „ „

Scale management considered during CAPEX Absolute must: good quality brine samples and analysis Predict z z z z

„

water production history and profiles well by well brine chemistry evolution during well life cycle impact of reservoir interactions on brine chemistry ability to perform bullhead squeezes: • flow lines from surface facilities • correct placement

Monitor and review strategy during OPEX Slide 17 of 39

2c) Effect of Reservoir Processes EXAMPLE 1 Management of waterflood leading to extended brine mixing at producers (increased scale risk) EXAMPLE 2 In situ mixing and BaSO4 precipitation leading to barium stripping (reduced scale risk) EXAMPLE 3 Ion exchange and CaSO4 precipitation leading to sulphate stripping (reduced scale risk)

Slide 18 of 39

EXAMPLE 1

SPE 80252

Extended Brine Mixing at Producers

Slide 19 of 39

EXAMPLE 1

SPE 80252

Extended Brine Mixing at Producers

This well has been treated > 220 times!

Field M (streamline model) Slide 20 of 39

EXAMPLE 2

SPE 60193

Barium (mg/l)

Barium Stripping (Field A)

Dilution line

% injection water

Slide 21 of 39

EXAMPLE 2

SPE 94052

Barium Stripping (Theory) „

„

„

Injection water (containing SO4) mixes with formation water (containing Ba) leading to BaSO4 precipitation in the reservoir Minimal impact on permeability in the reservoir Reduces BaSO4 scaling tendency at production wells

Slide 22 of 39

EXAMPLE 2

Barium Stripping (Theory) Ba2+ (hot)

SO42Rock

FW 1) Formation water (FW): [Ba2+] but negligible [SO42-] Slide 23 of 39

EXAMPLE 2

Barium Stripping (Theory) Ba2+ (cold)

SO42(hot)

IW 2) Waterflood: SO42- rich injection water displaces Ba2+ rich FW

Rock

FW

Slide 24 of 39

EXAMPLE 2

Barium Stripping (Theory) Ba2+ (cold)

IW

SO42-

BaSO4 (hot)

Rock

FW

3) Reaction: In mixing zone Ba2+ + SO42- → BaSO4 Slide 25 of 39

EXAMPLE 2

Barium Stripping (Theory) 3000

900

Ba Ba (mixing) SO4 SO4 (mixing)

800 2500 2000

[Ba] (mg/l)

600 500

1500 400 1000

300 200

500 100 0 0

20

40

60

seawater fraction (%)

80

0 100

[SO4] (mg/l)

700

•Large reduction in [Ba] •Small reduction in [SO4] (SO4 in excess) •Typical behaviour observed in many fields Slide 26 of 39

EXAMPLE 2

Barium Stripping (Model & Field Data) 90 Field A - actual Field A - dilution line Field A - modelled

barium concentration (ppm)

80 70 60 50 40 30 20 10 0 0

20

40

60

% seawater

80

100 Slide 27 of 39

EXAMPLE 3

SPE 100516

Sulphate Stripping (Theory) „

„

„ „

Injection water (with high Mg/Ca ratio) mixes with formation water (with high Mg/Ca ratio) leading to Mg and Ca exchange with rock to re-equilibrate Increase in Ca in Injection water leads to CaSO4 precipitation in hotter zones in reservoir Minimal impact on permeability in the reservoir Reduces BaSO4 scaling tendency at production wells Slide 28 of 39

EXAMPLE 3

Ion Exchange Rock: 0.038

ˆ C Mg C Mg = 0.50 ˆ C Ca C Ca

Gyda FW (mg/l)

FW: 0.077

IW: 3.2 IW (mg/l)

CCa

Ca in solution

30,185

426

CMg

Mg in solution

2,325

1,368

ĈCa

Ca on rock

ĈMg

Mg on rock

Slide 29 of 39

EXAMPLE 3

Sulphate Stripping (Theory) Ba2+ (hot)

SO42-

Ca2+

Mg2+ Rock

FW 1) Formation water: [Ca2+] and [Mg2+] in equilibrium with rock Slide 30 of 39

EXAMPLE 3

Sulphate Stripping (Theory) Ba2+ (cold)

IW

SO42-

Ca2+ (hot)

Mg2+ Rock

FW

2) Waterflood: [Ca2+] and [Mg2+] no longer in equilibrium Slide 31 of 39

EXAMPLE 3

Sulphate Stripping (Theory) Ba2+ (cold)

IW

SO42-

Ca2+ (hot)

Mg2+ Rock

FW

3) Reaction 1: Ca2+ and Mg2+ ion exchange with rock Slide 32 of 39

EXAMPLE 3

Sulphate Stripping (Theory) Ba2+ (cold)

IW

SO42-

Ca2+ (hot)

Mg2+

CaSO4 Rock

FW

4) Reaction 2: In hotter zones Ca2+ + SO42- → CaSO4 Slide 33 of 39

EXAMPLE 3

35,000

3,500

30,000

3,000

25,000

2,500

20,000

2,000

15,000

1,500

10,000

1,000

5,000

500

0 0

20

40

60

seawater fraction (%)

80

Ca Ca (mixing) Mg Mg (mixing) [Mg] (mg/l)

[Ca] (mg/l)

Modelling Prediction: [Ca] and [Mg]

•Large reduction in [Mg] •No apparent change in [Ca]

0 100 Slide 34 of 39

EXAMPLE 3

40000

8000

35000

7000

30000

6000

25000

5000

20000

4000

15000

3000

10000

2000

5000

1000

0

0 0

20

40

60

80

100

Ca Ca (mixing) Mgl Mg (mixing) [Mg] (mg/l)

[Ca] (mg/l)

Observed Field Data: [Ca] and [Mg]

•Large reduction in [Mg] •No apparent change in [Ca]

seawater fraction (%) Slide 35 of 39

EXAMPLE 3

Modelling Prediction: [Ba] and [SO4] 900

3000 Ba Ba (mixing) SO4 SO4 (mixing)

800 2500 2000

[Ba] (mg/l)

600 500

1500 400 300

1000

200 500 100 0 0

20

40

60

seawater fraction (%)

80

0 100

[SO4] (mg/l)

700

•Small reduction in [Ba] •Large reduction in [SO4] (No SO4 at < 40% SW) Slide 36 of 39

EXAMPLE 3

300

3000

250

2500

200

2000

150

1500

100

1000

50

500

0

0 0

20

40

60

seawater fraction (%)

80

100

Ba Ba (mixing) SO4l SO4 (mixing) [SO4] (mg/l)

[Ba] (mg/l)

Observed Field Data: [Ba] and [SO4]

•Small reduction in [Ba] •Large reduction in [SO4] (No SO4 at < 40% SW) Slide 37 of 39

3) Conclusions „

Modelling tools may assist with understanding of where scale is forming and what is best scale management option… z z

identify location and impact of scaling evaluate feasibility of chemical options

… thus providing input for economic model. „

Particularly important in deepwater & harsh environments, where intervention may be difficult & expensive

„

But – must be aware of uncertainties….. z z z

reservoir description numerical errors changes to production schedule, etc.

… so monitoring essential. Slide 38 of 39

Acknowledgements „

Sponsors of Flow Assurance and Scale Team (FAST) at Heriot-Watt University: Baker Petrolite, BWA Water Additives, BP, Champion Technologies, Chevron, Clariant, ConocoPhillips, Halliburton, M I Production Chemicals, Nalco, Petrobras, Petronas, REP, Rhodia, Saudi Aramco, Shell, StatoilHydro and Total

Slide 39 of 39