Patent Application
20210095563
This disclosure relates to managing tubing and wellbore production operations.
Hydrocarbons trapped in underground reservoirs are produced to the surface through wellbores drilled in the ground to contact the reservoir. Wellbores can be cased or uncased. Different types of tubing can be lowered and positioned in the wellbore. One example of such tubing is production tubing through which the hydrocarbons from the reservoirs flow to the surface. Over time, any tubing in the wellbore can experience corrosion or scale buildup which can negatively affect the wellbore's capability to produce the hydrocarbons.
Implementations of the present disclosure include a method that includes receiving, from a plurality of first sensors positioned at a downhole location of a wellbore, first production stream information. The plurality of first sensors are configured to sense the first production stream information about a production stream flowing past the downhole location. The method also includes receiving, from a plurality of second sensors positioned at an uphole location with respect to the downhole location, second production stream information. The plurality of second sensors are configured to sense the second production stream information about the production stream flowing past the uphole location. The production stream flows through a tubing disposed within the wellbore. The method also includes performing, using the first production stream information and the second production stream information, a material balance to determine a first value representing a difference between a first production steam flow rate at the downhole location and a second production stream flow rate at the uphole location. The method also includes, comparing the first value with a threshold, and determining, using the second production stream information, a second value representing a critical metal ion concentration of the production stream. The method also includes, based on a result of comparing the first value with a threshold and based on the second value, determining a third value representing a risk of corrosion and scale formation at the tubing disposed within the wellbore.
In some implementations, the downhole location includes a reservoir location at which hydrocarbons entrapped in a subterranean zone enter the tubing.
In some implementations, the uphole location includes a surface of the wellbore.
In some implementations, the first production steam flow rate includes a first water vapor production rate and the second production stream flowrate includes a second water vapor production rate, where determining the first value includes 1) determining the first water vapor production rate at the downhole location and the second water vapor production rate at the uphole location and 2) determining, by subtraction, a difference between the first water vapor production rate and the second water vapor production rate. In some implementations, the first production stream information includes a pressure and a first gas production rate and the second production stream information includes a temperature, a water production rate, and a second gas production rate. Determining the first water vapor production rate includes determining, based the pressure and the first gas production rate, the first water vapor production rate, where determining the second water vapor production rate includes determining, based on the temperature, the water production rate, and the second gas production rate, the second water vapor production rate. In some implementations, the threshold represents a water vapor production rate value, where comparing the first value with the threshold includes determining that a difference between the first value and the water vapor production rate value is indicative of fluid accumulating at the wellbore. In some implementations, the threshold represents a water vapor production rate value, where comparing the first value with the threshold includes determining that a difference between the first value and the water vapor production rate value is indicative of excess fluid being produced at the wellbore.
In some implementations, determining the second value includes acidifying a sample of the production stream at the uphole location and measuring, from the sample, at least one of a critical iron concentration and a critical manganese concentration of the sample.
In some implementations, determining the second value includes determining a critical iron concentration of the production stream based on a depth of the wellbore.
In some implementations, the method further includes, after determining the second value, comparing the second value with a second threshold. Determining the third value includes, based on the result of comparing the first value with the threshold and based on a second result of comparing the second value with the second threshold, determining the third value representing the risk of corrosion and scale formation at the tubing.
In some implementations, the method further includes receiving, from a plurality of third sensors positioned at a mid-wellbore location between the downhole location and the uphole location, third production stream information. The plurality of third sensors are configured to sense the third production stream information about the production stream flowing past the mid-wellbore location, where performing the material balance includes performing, using the third production stream information and at least one of the first production stream information and the second production stream information, a second material balance to determine a fourth value. In some implementations, the method further includes analyzing, based on the third production stream information and at least one of the first production stream information and the second production stream information, the production stream to determine a fifth value representing a flow regime of the production stream. Determining the risk of corrosion and scale formation at the wellbore includes determining the third value based on the first value, the second value, and the fifth value. In some implementations, determining the fifth value includes determining, based on a fluid density difference, a gas velocity, and interfacial tension between gas and liquids in the tubing, a flow regime.
In some implementations, the method further includes notifying a user about the third value representing a risk of corrosion and scale formation at the tubing disposed within the wellbore.
In some implementations, the method further includes determining, using the second production stream information, a critical corrosion rate of the production stream, Determining the third value includes, based on a result of comparing the first value with the threshold, based on the second value, and based on the critical corrosion rate, determining the third value.
Implementations of the present disclosure also include a system that includes at least one processing device and a memory communicatively coupled to the at least one processing device. The memory stores instructions which, when executed, cause the at least one processing device to perform operations that include receiving, from a plurality of first sensors positioned at a downhole location of a wellbore, first production stream information. The plurality of first sensors are configured to sense the first production stream information about a production stream flowing past the downhole location. The operations also include receiving, from a plurality of second sensors positioned at an uphole location with respect to the downhole location, second production stream information. The plurality of second sensors are configured to sense the second production stream information about the production stream flowing past the uphole location. The production stream flows through a tubing disposed within the wellbore. The operations also include performing, using the first production stream information and the second production stream information, a material balance to determine a first value representing a difference between a first production steam flow rate at the downhole location and a second production stream flow rate at the uphole location. The operations also include, comparing the first value with a threshold, and determining, using the second production stream information, a second value representing a critical metal ion concentration of the production stream. The operations also include, based on a result of comparing the first value with a threshold and based on the second value, determining a third value representing a risk of corrosion and scale formation at the tubing disposed within the wellbore.
In some implementations, the first production steam flow rate includes a first water vapor production rate and the second production stream flowrate includes a second water vapor production rate. Determining the first value includes 1) determining the first water vapor production rate at the downhole location and the second water vapor production rate at the uphole location and 2) determining, by subtraction, a difference between the first water vapor production rate and the second water vapor production rate.
In some implementations, the first production stream information includes a pressure and a first gas production rate and the second production stream information includes a temperature, a water production rate, and a second gas production rate. Determining the first water vapor production rate includes determining, based the pressure and the first gas production rate, the first water vapor production rate, and determining the second water vapor production rate includes determining, based on the temperature, the water production rate, and the second gas production rate, the second water vapor production rate.
Implementations of the present disclosure also include a system that includes a plurality of first sensors positioned at a downhole location of a wellbore. The plurality of first sensors are configured to sense first production stream information about a production stream flowing past the downhole location. The system also includes a plurality of second sensors positioned at an uphole location of the wellbore. The plurality of second sensors are configured to sense second production stream information about the production stream flowing past the downhole location. The system also includes at least one processing device and a memory communicatively coupled to the at least one processing device. The memory stores instructions which, when executed, cause the at least one processing device to perform operations that include receiving, from the plurality of first sensors, the first production stream information. The operations also include receiving, from the plurality of second sensors, the second production stream information. The production stream flows through a tubing disposed within the wellbore. The operations also include performing, using the first production stream information and the second production stream information, a material balance to determine a first value representing a difference between a first production steam flow rate at the downhole location and a second production stream flow rate at the uphole location. The operations also includes comparing the first value with a threshold and determining, using the second production stream information, a second value representing a critical metal ion concentration of the production stream. The operations also include, bases on a result of comparing the first value with a threshold and based on the second value, determining a third value representing a risk of corrosion and scale formation at the tubing disposed within the wellbore.
In some implementations, the first production steam flow rate includes a first water vapor production rate and the second production stream flowrate includes a second water vapor production rate, where determining the first value includes 1) determining the first water vapor production rate at the downhole location and the second water vapor production rate at the uphole location and 2) determining, by subtraction, a difference between the first water vapor production rate and the second water vapor production rate.
Fluids such as water and hydrocarbons are produced through wellbore tubing (for example, production tubing in the wellbore). Such fluids along with the conditions of the wellbore contribute to corrosion and scale buildup on the tubing. Unchecked scale buildup can lead to production loss and corrosion can result in the failing of the tubing. Determining a risk of corrosion and scale buildup in the tubing followed by needed intervention can prevent the failure of the tubing.
The present disclosure relates to sampling a production stream flowing through a tubing of a wellbore to determine a risk of corrosion, scale formation (for example, iron sulfide scale formation), or other properties that compromise the integrity of the tubing. Implementations of the present disclosure include a risk detection system that is configured to receive information from sensors at different location of the tubing and to perform a volume and material balance with the information. The material balance is used to estimate water content, liquid hydrocarbon content, and water-gas ratio and condensate-gas ratio at various locations in the production tubing and wellbore. Some of the sensors can sense physical properties of the production stream such as pressure, temperature, and flow rates. Other sensors can also sense other properties of the production stream such as composition, density, viscosity, sound speed, optical transmittance, and refractive index.
Implementations of the present disclosure may provide one or more of the following advantages. Corrosion and scale buildup can be detected on the tubing without using sensors that directly measure corrosion or scale formation. The present system can rank various wells with regards to their risk of corrosion and scale formation and therefore identify wells at highest risk in order to prioritize well intervention. The present system can determine the location of the scale formation or corrosion along the tubing without the need of deploying sensors that move through the tubing or without using sensors that directly measure corrosion or scale formation.
The risk detection system 100 can also include multiple sensors 111 disposed in a first mid-wellbore location 136, multiple sensors 113 disposed in a second mid-wellbore location 137, and more sensors disposed between sensors 104 and sensors 108. The third sensors 111 and the fourth sensors 113 can also sense production stream information about the production stream flowing through the tubing 102. For example, the third and fourth sensors 111 and 113 can be disposed inside the tubing 102 to sense the production stream flowing through the tubing 102. The fourth sensors 113 can be disposed between the second sensors 108 and the third sensors 111.
The processing device 122 can be communicatively coupled to the sensors 104, 108, 111, and 113. The sensors transmit (for example, through wired or wireless connections), to the processing device 122, the production stream information sensed at their respective locations. For example, the first sensors 104 sense first production stream information about the production stream flowing past the downhole location 134. The second sensors 108 sense second production stream information about the production stream flowing past the uphole location 138. The third sensors 111 sense third production stream information about the production stream flowing past the first mid-wellbore location 136. The fourth sensors 113 sense fourth production stream information about the production stream flowing past the second mid-wellbore location 137 between the third sensors 111 and the second sensors 108. The production stream information that each multiple sensors sense include, but is not limited to: pressure of the production stream, temperature of the production stream, flow rate of the production stream (for example, hydrocarbon gas product flow rate, oil production flow rate, and water production flow rate), composition of the production stream (for example, ionic composition of water), density of the production stream, viscosity of the production stream, sound speed in the production stream, optical transmittance in the productions steam, and refractive index in the production stream. The properties at the four different locations will be different due to change in the pressure and temperature with depth. The composition of oil, gas and water will change with changes in pressure and temperature. The density of each water, oil and gas phase will also change with changes in composition and change in pressure & temperature. Change in ionic composition and pH of water many cause precipitation of solids (scale) or dissolution of solids and metal from tubing (corrosion). Change in pH and ionic composition of water between different location allows determination of corrosion & scaling between these locations.
The sensors 104, 108, 111, and 113 can include one or more of the following devices. For example, a multiphase meter can be used to sense or measure hydrocarbon gas, oil, and water production rates. A multiphase meter that can be used is the Roxar Multiphase meter by Emerson Process Management located in St. Louis, Mo. In some cases, the wet gas meter such as the Roxar Wet-gas meter also by Emerson Process Management can be used. The output of such devices can be measured to calculate hydrocarbon gas, oil, and water production rates. Devices such as thermocouples, fiber optic device, or electrical resistance devices can be used to sense temperatures of the production stream. Piezo resistive silicon devices can be used to sense pressures of the production stream. Additionally, metal ion concentrations in the produced stream can be measured using inductively coupled X-ray atomic emission spectroscopy. Electron spin resonance can also be used with inline measurements to detect iron and manganese concentrations in the production stream. Changes in ionic concentration of water phase in material balance calculations allows determination of amount of corrosion or scaling between the sensor locations. The composition of the hydrocarbon production stream can be measured using gas chromatography or other suitable instrumentation. This allows determination of locations where a liquid hydrocarbon phase may condense from otherwise gas phase. Such liquid hydrocarbon film coating on metal tubing may prevent corrosion or scaling in locations where it may occur in the absence of the liquid hydrocarbon film. The choice of a sensor depends on the location (that is, the depth) at which the sensor is installed.
Referring also to
For example, if a flow rate at the four locations is the same, then the wellbore is likely free of corrosion and scale buildup. If the mass flow rate at the four locations is not the same, then the wellbore likely has corrosion and scale buildup where water is accumulating. Similarly, if the metal ion concentration at the four locations is the same, then the wellbore is likely free of corrosion and scale buildup. If the metal ion concentration at the four locations is not the same, then the opposite is likely true. Thus, the mass balance and material balance test can be a comparison at each of the four locations.
To perform the material or mass balance tests, processing device 122 first receives production stream information form the multiple sensors 104, 108, 111, and 113 to determine a first production stream flowrate at the downhole location 134 and a second production stream flowrate at the uphole location 138. The respective production stream flowrates can be water vapor production rates or other fluid production rates. To determine the first water vapor production rate at the downhole location 134, processing device 122 can, based on a pressure and a hydrocarbon gas production rate received from multiple first sensors 104, determine the water vapor production rate at the downhole location 134. To determine the second water vapor production rate, processing device 122 can, based on a temperature, a water production rate, and a second hydrocarbon gas production rate received from multiple second sensors 108, determine the water vapor production rate at the uphole location 138.
To determine the first water vapor production rate, the processing device 122 can use information representing pressure and a hydrocarbon gas production rate (for example, gas flow rate) received from the multiple first sensors 104. The pressure can be a bottom hole pressure of the production stream at the entrance of the tubing 102. The processing device 122 can determine the first water vapor production rate based on the hydrocarbon gas production rate and on a mole fraction of water in the gas phase. To determine the mole fraction of water in the gas phase, the processing device 122 can use the following equation:
y
w
=p
vw
/p
bh
in which yw is the mole fraction of water in the gas phase, pvw is the vapor pressure of pure water (obtained using the pressure and temperature received from sensors 104 and an appropriate equation for water saturation properties), and pbh is the bottom hole pressure in the reservoir received from sensors 104. Upon determining the mole fraction of water in the gas phase, the processing device 122 can calculate, using the mole fraction of water and the hydrocarbon gas production rate, the water vapor flow rate at the downhole location. Water flow rate can be determined from gas flow-rates using the following equation:
q
w(bbl/d)=qg(MMSCF/d)*yw*C,
where, qw is water vapor flow rate in barrels per day, qg is gas flow rate in Million cubic feet per day, and C is a unit conversion factor.
To determine the second water vapor production rate at the uphole location 138, the processing device 122 can use a pressure and temperature, and a hydrocarbon gas production rate received from the second sensors 108. For example, the second production stream information includes a pressure and temperature of the production stream at the outlet of the tubing 102 where the second sensors 108 are disposed. The second water vapor production rate can be an amount of water vapor exciting the tubing 102. To determine the water vapor flowrate at the uphole location 138, the mole fraction of water vapor in the gas stream is determined using the following equation:
y
w
=p
vw
/p
108,
in which yw is the mole fraction of water in the gas phase, pvw is the vapor pressure of pure water (obtained using the pressure and temperature received from sensors 108), and p108 is the tubing pressure from sensors 108. Water vapor flow-rate is obtained from the equation listed in [0017]. The difference between the two rates allows calculation of liquid water rate some of which may be accumulated in the tubing if not produced to the surface.
In some implementations and upon determining the first water vapor production rate and the second water vapor production rate, the processing device 122 can perform the material balance. To perform the material balance, the processing device 122 can determine, by subtraction, a first value which represents a difference between the first water vapor production rate and the second water vapor production rate. Thus, to determine if fluids are accumulating or being produced in the wellbore 106, the risk detection system 100 can determine, using material balance and based on the information received from the sensors, the first value. The first value represents a difference between the first production steam flow rate (for example, the first water vapor production rate) at the downhole location 134 and the second production stream flow rate (for example, the second water vapor production rate) at the uphole location 138. The difference can be determined by subtracting the first water vapor production rate from the second water vapor production rate.
The processing device 122 can also determine, based on the information received from the multiple second sensors 108, a second value representing a critical metal ion concentration of the production stream (for example, an iron concentration and a manganese concentration of the production stream). To determine the second value representing the critical metal ion concentration in the production stream, multiple methods can be used. First, the processing device 122 receives, from multiple second sensors 108 at the surface 116 of the wellbore 106, a value representing an ion concentration of the production stream. For example, multiple second sensors 108 can help determine at least one of an iron concentration and a manganese concentration from a water sample at the surface 116 of the wellbore 106. One method to determine iron or manganese concentrations from water samples is to acidify the sample and use inductively coupled X-ray atomic emission spectroscopy to measure the iron concentration. Another method includes obtaining inline measurements for iron and manganese using electron spin resonance. With the measured pressure and temperature at locations in the surface 116, pressure and temperature gradients are used to calculate pressure and temperature at various depths of the wellbore 106. Such plots of pressure and temperature with depth are referred to herein as “pressure profile” and “temperature profile,” respectively. Pressure and temperature at each depth are used in thermodynamic calculations to determine the “critical metal ion concentration” that can be dissolved in aqueous phase at those conditions. Comparing actual metal ion concentration to “critical ion concentration” helps determine depth at which scale may form. The amount of iron required to precipitate iron sulfide scale throughout the profile can be calculated using information on the solubility product of different iron sulfides. In some examples, if the calculated iron concentration in the produced water is measured by the processing device 122 to be 10 mg/l, a portion of the wellbore 106 deeper than 5000 feet would be at risk of scaling and the interval shallower than 5000 feet would be at the risk of corrosion.
The processing device 122 can also determine a critical corrosion rate of the production stream. For example, a critical corrosion rate can be a corrosion rate at which iron sulfide precipitation can occur in the tubing 106. The amount of iron released in the tubing 106 is indicative of corrosion in the tubing. The composition of gas and oil being produced is needed for some risk assessments. The composition may be measured using gas chromatography or other suitable instrumentation. If a very small critical sour corrosion rate is needed to cause iron sulfide precipitation, the tubing 106 is at risk for iron sulfide precipitation.
To determine if the tubing 102 is at risk of corrosion and scale buildup, the processing device 122 can compare the difference between the first production stream flow rate and the second production stream flow rate, that is, the first value, to a threshold. As described earlier, to determine such difference, the processing device 122 determines, by subtraction, the difference between the first and second production stream flowrates (for example, the difference between the first and second water vapor production rates). If the difference between the first and second water vapor production rates is above or below the threshold (for example, 10% above or below), the well is deemed a risky well. The threshold can represent a water vapor production rate value. For example, the threshold can indicate a normal amount of water vapor expected to be produced by condensation or a normal amount of water vapor expected to be accumulated in the wellbore. The higher the percentage, the higher the risk of corrosion or scale formation or both. The risk of corrosion can be represented by a third value such as a value from 1 to 10, with 1 representing low risk and 10 representing high risk. Such relative ranking among various wells from lowest to highest risk can allow prioritization of well intervention for wells with highest risk of corrosion or scaling.
In some examples, if the difference between the production stream flow rates is within a certain percentage of the amount of water coming from the reservoir 101 with gas, then most of the water at the surface 116 is considered coming from the saturated gas from the reservoir 101 and the well is considered to be at a steady state that has less risk. If the amount of water produced in the wellbore 106 is significantly more than the water that is carried by saturated gas from the reservoir 101, then large amounts of water is considered being produced from the reservoir 101 as free water. In such scenario, the tubing 102 is considered to be likely at risk of corrosion and scale formation. If the amount of water produced is significantly less than the water that is carried by the saturated gas from the reservoir 101, then fresh water is considered to be accumulating within the wellbore 106. In such scenario, the tubing 102 is likely to be at risk due to both corrosion and scale formation.
Additionally, as described earlier, the second value representing a critical metal ion concentration of the production stream at the wellhead can also influence the risk of corrosion and scale buildup. Thus, based on the result of comparing the first value to the threshold and on the result of comparing the second value to a second threshold, the third value representing the risk of corrosion and scale formation at the tubing 102 can be determined. The first and second thresholds can include normalized values or percentages. As shown in
The processing device 122 can perform more than one material balance to determine areas of the tubing 102 that may be at more risk of corrosion and scale formation than other areas. For example, the processing device 122 can use the third production stream information received from multiple third sensors 111 and the first production stream information received from multiple first sensors 104 to determine a fourth value representing a second difference between the production stream flow rates at the area of the tubing 104 between the multiple first sensors 104 and the multiple third sensors 111. Thus, the processing device 122 can determine an amount of fluids being accumulated or over-produced at different areas of the tubing 102. With such information, the processing device 122 can indicate what areas of the tubing 102 are more susceptible to corrosion and risk formation.
Additionally, the processing device 122 can analyze the information received from multiple sensors 104, 108, 111, and 113 to determine a fifth value representing a flow regime of the production stream at different location of the tubing 102. The flow regime is determined based on density difference and interfacial tension between gas and liquids, and, gas velocity that is determined by the total gas flow rate and the cross-sectional area of the tubing available for the flow of gas. Flow regime determines if the liquids in the production stream can be produced to the surface or if the liquid will accumulate in the tubing thus impacting the risk of corrosion and/or scale formation. In some implementations, metal ion concentration is compared to the equilibrium concentration at the temperature and pressure of the water. A high metal ion concentration indicates scale formation. A low metal ion concentration indicates risk of corrosion.
Although the present detailed description contains many specific details for purposes of illustration, it is understood that one of ordinary skill in the art will appreciate that many examples, variations and alterations to the following details are within the scope and spirit of the disclosure. Accordingly, the example implementations described in the present disclosure and provided in the appended figures are set forth without any loss of generality, and without imposing limitations on the claimed implementations.
Although the present implementations have been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the disclosure. Accordingly, the scope of the present disclosure should be determined by the following claims and their appropriate legal equivalents.
The singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
Ranges may be expressed in the present disclosure as from about one particular value, or to about another particular value or a combination of them. When such a range is expressed, it is to be understood that another implementation is from the one particular value or to the other particular value, along with all combinations within said range or a combination of them.
As used in the present disclosure and in the appended claims, the words “comprise,” “has,” and “include” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps.
As used in the present disclosure, terms such as “first” and “second” are arbitrarily assigned and are merely intended to differentiate between two or more components of an apparatus. It is to be understood that the words “first” and “second” serve no other purpose and are not part of the name or description of the component, nor do they necessarily define a relative location or position of the component. Furthermore, it is to be understood that that the mere use of the term “first” and “second” does not require that there be any “third” component, although that possibility is contemplated under the scope of the present disclosure.
