1. Field of the Invention
This invention relates broadly to production of oil from formations. More particularly, this invention relates to dual completion systems and related methods for segregating oil and water downhole so that oil is produced separately from water.
2. State of the Art
At some time in the life of most wells, water is co-produced with hydrocarbons (e.g., oil). Lifting this water to the formation surface, separating it from the hydrocarbons, cleaning, and disposing it contribute to the costs of production operations. Moreover, because of issues related to two-phase flow (e.g. water and oil) in the wellbore, lifting of water along with oil may substantially reduce overall oil production. In addition, in some cases, regulatory restrictions call for treatment of water once it is brought up to the surface. Because of these considerations, various downhole oil-water separation (DHOWS) schemes have been proposed. None has been universally successful since all have technical and/or economical limitations.
One DHOWS scheme utilizes hydrocyclones. Reservoir simulation and economics studies suggest that DHOWS systems should be installed soon after water breakthrough when oil flow rates are still high and water rates low. Hydrocyclones, however, are not well-suited to situations in which the produced water fraction is small. In addition, hydrocyclones are often unreliable, particularly downhole.
In-well gravity separation is another DHOWS scheme which has been proposed. However, in-well gravity separation will not perform well at low water cuts or high water cuts, and therefore, this technique has not gained traction in the art. They also do not perform well for high flow rates due to viscous drag, and high crude oil viscosity where separation may be hindered.
Dual-drain completions that attempt to separately produce fluids that are already largely segregated by gravity within the reservoir have been proposed as a DHOWS scheme. See, e.g., co-owned U.S. Pat. No. 6,415,864 to Ramakrishnan et al. These completion systems work in conjunction with reservoir monitoring and control of the oil-water transition zone. In particular, these systems are best deployed with monitoring via a sensing mechanism for the oil-water transition around the wellbore. Because this is technologically intensive, costs are large, if not prohibitive.
A fourth proposed DHOWS scheme is disclosed in U.S. Pat. No. 4,296,810 to Price where membranes are suggested for oil-water separation. While membranes can facilitate the delay of the onset of water production, this approach is limited since naturally, a near-wellbore water-block will form and reduce oil production or allow water breakthrough to occur. Furthermore deployment of relatively fragile membranes while maintaining integrity has not been overcome.
In accord with the present invention, a dual completion wellbore is provided where the formation around part of the wellbore or an extension thereof is chemically treated to be hydrophobic and a closely spaced area of the formation around another part of the wellbore or an extension thereof is chemically treated to be hydrophilic. Perforations in the wellbore or its extensions are provided at the hydrophobic and hydrophilic formation locations and production tubing is provided so that oil and water independently flow through the perforations into the tubing and are separately produced.
In one embodiment, two closely spaced wellbore legs are drilled out from a single (main) wellbore. The formation around one of the closely spaced wellbore legs is chemically treated to be hydrophobic, and the formation around the other of the closely spaced wellbore legs is chemically treated to be hydrophilic. Separate production tubing or a dual completion is installed in order to enable independent flow from the closely spaced wellbore legs.
According to one embodiment, where closely spaced wellbore legs are utilized, the wellbore legs are horizontally oriented.
According to one embodiment, drawdown pressures in both legs are controlled to be sufficiently close to each other such that only oil flows into one leg and only water into the other.
According to another embodiment, the water produced in one leg is reinjected downhole.
The instant DHOWS invention is particularly economical when either the far-field is in a water-oil transition zone, or when an underlying water zone driven by an aquifer is likely to have a water cone advancing towards the oil-zone completion. Deployment is not recommended in what is known to be a pure hydrocarbon interval, where oil production occurs either by decompression or by a distant drive. However, for cases where a distant drive is the production mechanism, the invention becomes relevant once the water starts to rise near the wellbore.
Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
As will be described in detail hereinafter, the invention involves a dual completion wellbore where the formation (reservoir rock) around part of the wellbore or an extension thereof is chemically treated to be hydrophobic and a closely spaced area of the formation around another part of the wellbore or an extension thereof is chemically treated to be hydrophilic. Perforations in the wellbore or its extensions are provided at the hydrophobic and hydrophilic formation locations and production tubing is provided so that oil and water independently flow through the perforations into the tubing and are separately produced.
In understanding the invention, it is useful to grasp the basics of the effect of making a region of a formation hydrophobic or hydrophilic. The situation where the far-field is in a zone capable of producing water and oil, both in moderate amounts, may be taken as an example. For the sake of illustration, it is assumed that the formation is homogeneous and mildly water-wet before any treatment. In such a situation it can be anticipated that the reservoir capillary pressure will be roughly a few times higher than the entry capillary pressure (pb), but not significantly (i.e., factors of 10) higher. When there is a uniform flow of oil and water, pressure gradients in both phases occur. The pressure profiles at a single wellbore depth are illustrated in
If the near wellbore region is made hydrophobic, the relative permeability and the capillary pressure curves can be expected to go from a water-wet to a oil-wet behavior. It is difficult to precisely judge the magnitude of the change of the relative permeability curves without tracking all of the hysteresis issues. However, it can be assumed that the relative permeability to water will increase and the relative permeability to oil will decrease. Similarly, the capillary pressure curve will also shift below the pc=0 axis with pc defined as the oil pressure minus the water pressure. As a result, it can be shown that upon treatment (i.e., when the near wellbore region is made hydrophobic), a zone radially outside of and adjacent the treatment area will develop where an anomalous water accumulation will result. Water and oil will continue to flow at the same rate as before, because at steady-state, this is dictated by the far-field. However, the near wellbore hydrophobicity results in an accumulation of the non-wetting phase of the treated zone (i.e., water) to form in front of the treated zone, ultimately leading to failure unless the blocked water is removed.
The converse situation is obtained when the near wellbore region is made hydrophilic. In particular, given the above-described assumptions it can be shown that when the near wellbore region is made hydrophilic, a zone in front of the treatment area will develop where an anomalous oil accumulation results. As a result, eventually, unless the blocked oil is removed, failure results. A facility to remove the oil is needed.
One embodiment of the invention is shown in
As seen in
Production, drawdown pressures are applied to both legs. Seen from large distances this creates a pressure sink within the reservoir causing both oil and water to flow towards the wellbore legs. The combination of near-wellbore wetting modification treatments, and controlled drawdowns in each leg permits oil to flow into the hydrophobically treated rock 115a surrounding a portion of wellbore leg 110a and thence into leg 110a for production uphole, and water to flow into the hydrophilically treated rock 115b surrounding a portion of wellbore leg 110b and thence into wellbore leg 110b for appropriate disposal. The oil production from leg 110a will be all or close to all oil because the water that flows with the oil from the bulk of the reservoir is held back by the hydrophobicity and preferentially flows into wellbore leg 110a. By allowing water to be continuously produced nearby into leg 110b, an increase in the water saturation near wellbore leg 110a and consequent decrease in the relative permeability to oil is avoided. Water accumulation induced blocking of oil is thus avoided. While water from wellbore leg 110b can be lifted to the surface for disposal (as described in the embodiment of
According to one aspect, the drawdown pressures in the two legs are controlled in a manner such that the difference between them does not exceed approximately twice the entry capillary pressure for the region. Controlling the drawdown pressures in this manner limits the difference in the oil and water flow rates. If desired, the drawdown pressures in the legs may be controlled on the basis of observations. For example, the desired oil flow rate may be maintained and the water leg may be adjusted so that pressures are sufficiently close to that of the oil leg. In other words, the water rate will be determined automatically when the oil rate is fixed via pressure proximity. The limit on the oil rate that may be obtained in this manner can be determined through simulations. As previously mentioned, the pressure difference between the legs of the wells should not be allowed to become too large since this could allow a nonwetting fluid to invade into the treated region.
A second embodiment of the invention is shown in
As seen in
In production, drawdown pressures are applied to wellbore leg 210a and leg portion 210b of the mother wellbore 210. Seen from large distances this creates a pressure sink within the reservoir causing both oil and water to flow towards the wellbores. The combination of near-wellbore wetting modification treatments, and controlled drawdowns in each leg permits oil to flow into the hydrophobically treated rock 215a surrounding a portion of wellbore leg 210a and thence into leg 210a for production uphole, and water to flow into the hydrophilically treated rock 215b surrounding portion 210b of the mother wellbore 210 and thence into leg portion 210b for appropriate disposal. The oil production from leg 210a will be all or close to all oil as the water that flows with the oil from the bulk of the reservoir is held back by the hydrophobicity and preferentially flows into wellbore leg 210a. By allowing water to be continuously produced nearby into leg portion 210b of the mother wellbore, any increase in the water saturation near wellbore leg 210a and consequent decrease in the relative permeability to oil is avoided. Water accumulation induced blocking of oil, which would occur if simultaneous production of water were not undertaken, is thus avoided. While water from wellbore portion 210b can be lifted to the surface for disposal (as described in the embodiment of
According to one aspect, the drawdown pressures in the legs 210a and 210b are controlled in a manner as described above with reference to
A third embodiment dual completion system is shown in
In production, drawdown pressures are applied to wellbore portion 310a and wellbore portion 310b. Seen from large distances this creates a pressure sink within the reservoir resulting in both oil and water flow towards the wellbore. The combination of near-wellbore wetting modification treatments and controlled drawdown in each wellbore portion, permits oil to flow into the hydrophobically treated rock 315a surrounding a wellbore portion 310a for production uphole, and water to flow into the hydrophilically treated rock 315b surrounding wellbore portion 310b for appropriate disposal. The oil production from wellbore 310a will be all or close to all oil as the water that flows with the oil from the bulk of the reservoir is held back by the hydrophobicity and preferentially flows into wellbore portion 310a. By allowing water to be continuously produced nearby into wellbore portion 310b, any increase in the water saturation near wellbore portion 310a and consequent decrease in the relative permeability to oil is avoided. The blocking of oil due to water accumulation is avoided through simultaneous production of water. While water from wellbore portion 310b is shown being lifted to the surface for disposal, the production paths may be modified to the paths discussed above with reference to
According to one aspect, the drawdown pressures in the wellbore portions 310a and 310b are controlled in a manner as described above with reference to
While all of the embodiments have been described as having wellbores that are completed with perforated casings, it will be appreciated by those skilled in the art that the invention also applies to wellbores that have “barefoot completions” as well as wellbores that are completed with slotted sleeves. In fact, it is possible that completions could involve a combination of technologies; by way of example only, a slotted sleeve completion for one portion of the wellbore (or extension thereof), and a casing completion with perforations in another portion of the wellbore (or extension thereof). Regardless, for each situation, what is required is that the identified portions of the wellbore or extensions thereof be isolated so that independent production of oil from the area of the formation treated with hydrophobic agent through one portion of the wellbore (or extension) and water from the area of the formation treated with the hydrophilic agent through another portion of the wellbore (or extension) may be accomplished.
It will also be appreciated that while all of the embodiments have been described as utilizing pumps (uphole and/or downhole) to control pressures and flow rates, other means are well-known for such control. By way of example only, in certain circumstances, instead of using pumps, “intelligent completion” throttle valves may be located downhole, with the size of the opening controlled for pressure and flow. Alternatively, throttle valves may be located at the surface of the formation.
There have been described and illustrated herein downhole oil-water separation systems and methods. While particular embodiments have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. While a second embodiment was shown where a formation portion surrounding a wellbore leg drilled from the mother wellbore was treated with hydrophobic chemicals and another formation portion surrounding a portion of the mother wellbore was treated with hydrophilic chemicals, it will be appreciated that the treatment could have been reversed; i.e., with the hydrophilic treatment of the formation surrounding the deeper wellbore leg drilled from the mother wellbore and the hydrophobic treatment of the formation portion surrounding the mother wellbore. Further, it should be appreciated that various aspects of one embodiment can be used in conjunction with other embodiments. For example, water produced through the hydrophilic zone of any of the embodiments may be either produced to the surface or pumped to another location in the well (typically lower down) and reinjected into the formation. As another example, while horizontal and vertical “leg” wellbores have been described, the wellbores or wellbore portions may take any of many different orientations (e.g., angled) depending upon the geography of the formation. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
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Number | Date | Country | |
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20130025856 A1 | Jan 2013 | US |