METHOD OF PRODUCING VISCOUS HYDROCARBONS BY STEAM-ASSISTED GRAVITY DRAINAGE
A non-cemented liner (20) is introduced into an injection bore (21), steam is fed into the liner at a first bore part (24) and injected into the reservoir through holes (22, 23) in the liner distributed so that the total hole area per length unit of the liner is greater at a second part (25) than at the first part of the bore. Steam enters an annular space between liner and bore only through holes near first part of the bore and subsequently gradually travels inside the liner in direction of second bore part and gradually enters the annular space through holes nearer and nearer second bore part. Gradually liquid is displaced away from an upper liner part and an upper part of the annular space, so that steam contacts the bore along substantially the entire length of the liner in the upper part of the annular space.
The present invention relates to a method of producing viscous hydrocarbons by steam-assisted gravity drainage (SAGD), whereby steam is injected into a hydrocarbon reservoir by means of an injection well bore placed above a production well bore, so that heat is transferred from the steam to the reservoir fluids and thereby reduces the viscosity of hydrocarbons of the reservoir, thereby facilitating recovery of hydrocarbons by means of the production well bore, whereby a liner is introduced into the injection well bore so that it extends from a first part of the injection well bore to a second part of the injection well bore as a non-cemented liner, and whereby the steam is fed into the liner at the first part of the injection well bore and is injected into the hydrocarbon reservoir through a number of holes formed in a wall of the liner.
Steam injection is a common thermal recovery technique for heavy oils, particularly in Canada, Venezuela, and in Oman. The main idea is that steam injected into the well bore condenses in the reservoir and transfers its heat of vaporization to the reservoir fluids. This results in a dramatic reduction in viscosity of the reservoir oil and makes economic recovery of even extra-heavy oil like bitumen possible.
GB 2 053 328 discloses a thermal method for recovering normally immobile oil from a tar sand deposit, in which two wells are drilled horizontally into the deposit, an upper well for injection of heated fluid and a lower well for production of liquids. The injection well includes a casing having perforations along the horizontal section which are in communication with the tar sand deposit. Thermal communication is established between the wells. The wells are operated such that heated mobilized oil and steam flow without substantially mixing. Oil drains continuously by gravity to the production well where it is recovered.
According to SPE 50429, Society of Petroleum Engineers, some operators in California have tried a different completion strategy where they cement the liner and then perforate the well to provide access to the reservoir through multiple zones. In an attempt to ensure that steam is distributed to all the zones and not just the first zone, a limited-entry technique has been used, implying that the size or area of the perforations has been specifically selected to limit the flow rate into a zone at a given injection pressure. However, as most of the annulus is now covered with cement, this design provides very little access to the reservoir.
According to SPE 97922, Society of Petroleum Engineers, some operators choose a slotted liner for both oil producer and steam injector. A slot can be thought of as a rectangular hole, which does not impose any significant pressure drop. Hence, its purpose is not to divert steam but merely to provide access for the steam to reach the reservoir. Unsurprisingly, most of the heat transfer takes place at the heel of the well bore.
A common problem with the above-mentioned completion techniques is that steam distribution along the injection wells is poor. Uniform development of the steam chamber remains one of the most critical challenges of the SAGD process because of its direct impact on heavy oil recovery. This means that the wells must be short and oil recovery suffers from inadequate transfer of heat from the steam to the heavy oil.
The object of the present invention is to provide improved steam distribution even along very long injection well bores.
In view of this object, an annular space is formed between the liner and the injection well bore in which annular space steam injected through the liner may travel along the outside of the liner and contact the injection well bore along the entire length of the liner, and the holes are distributed so that the total hole area per length unit of the liner is greater at the second part of the injection well bore than at the first part of the injection well bore and so that, during a start-up phase, initially, the steam enters the annular space only through holes near the first part of the injection well bore, and subsequently the steam gradually travels inside the liner in the direction of the second part of the injection well bore and thereby gradually enters the annular space through holes nearer and nearer the second part of the injection well bore, thereby gradually displacing liquid away from an upper part of the liner and away from an upper part of the annular space, so that, during the start-up phase, finally, steam contacts the injection well bore along at least substantially the entire length of the liner in the upper part of the annular space.
Thereby, it may be ensured that liquid is eventually displaced entirely from even the second part of the injection well bore and at the same time it may be avoided that excessive quantities of steam is injected into the hydrocarbon reservoir at the first part of the injection well bore during the start-up phase, and consequently an improved steam distribution along the length of the injection well bore may eventually be achieved during the entire normal operation phase during which production of hydrocarbon takes place. Consequently, oil recovery may be increased as a result of improved transfer of heat from the steam to the heavy oil over the entire length of the well bore.
In an embodiment, an end opening of the liner located at the second part of the injection well bore is closed or at least substantially closed against the injection well bore, preferably by means of an end cap or the like. Thereby, it may better be ensured that steam exits the liner through the holes as desired. However, the end cap may itself be provided with holes for steam injection or drainage of well bore liquids. The end opening of the liner may alternatively be pressed against the end of the injection well bore, thereby at least substantially closing the end opening.
In an embodiment, steam is introduced into the liner only from the end at the first part of the injection well bore. Due to an improved steam distribution along the length of the injection well bore achieved during the start-up phase, it may be unnecessary to introduce steam from more than one end of the liner even during the entire normal operation phase, whereby complex tubing may be avoided.
In an embodiment, the first part of the injection well bore is the inner part at the heel of the injection well bore, and the second part of the injection well bore is the outer part at the toe of the injection well bore. Thereby, steam may enter the liner at the inner part of the injection well bore, whereby auxiliary tubing inside the liner for the introduction of steam at the outer part of the injection well bore may be avoided.
In an embodiment, the liner includes top holes pointing upwards for diverting the steam into the reservoir and bottom holes pointing downwards in order for condensed water and initial well bore liquids to escape from the liner. Thereby, a better separation between steam and well bore liquids may be achieved.
In an embodiment, the liner is inserted into the injection well bore by connecting a number of liner sections at random angular rotations in relation to each other, and each liner section includes at least one set of at least two holes arranged with a regular spacing in the circumferential direction of the liner section. Thereby, as a large number of liner sections may be connected, it may be ensured that generally, over the length of the liner, some of the holes will point in more or less upward direction, and some of the holes will point in more or less downward direction, so that both steam diversion into the reservoir and drainage of liquids out of the liner may be facilitated.
In a structurally advantageous embodiment, each liner section includes at least one set of two holes arranged with a spacing of approximately 180 degrees in the circumferential direction of the liner section.
In an embodiment, the holes of the at least one set of at least two holes have corresponding or equal cross-sectional area. Thereby, the cross-sectional area of the holes per length unit of the liner for top holes as well as for bottom holes may be well-controlled, even if the holes are pre-drilled before insertion of the liner sections into the injection well bore.
In an embodiment, all the holes included by each set of holes are arranged at the same length position of the liner section. This may further facilitate controlling the cross-sectional area of the holes per length unit of the liner for top holes as well as for bottom holes.
In an embodiment, the total hole area per length unit of the liner gradually increases from the first part of the injection well bore to the second part of the injection well bore. Thereby, an even better improved steam distribution along the length of the injection well bore may be achieved.
In an embodiment, the total hole area per length unit of the liner at a part of the second part of the injection well bore is at least 2 times, preferably at least 3 times and most preferred at least or about 4 times the total hole area per length unit of the liner at a part of the first part of the injection well bore. Thereby, a particular good steam distribution along the length of the injection well bore may be achieved.
In an embodiment, the holes in the liner has a diameter in the interval from about 0.5 mm to about 8 mm, and the distance between holes in the liner at the second part of the injection well bore is less than 12 metres (approximately 40 feet), preferably less than 9 metres (approximately 30 feet) and most preferred about 7.5 metres (approximately 25 feet), and the distance between holes in the liner at the first part of the injection well bore is more than 24 metres (approximately 80 feet), preferably more than 27 metres (approximately 90 feet) and most preferred about 30 metres (approximately 100 feet). Thereby, an even better steam distribution along the length of the injection well bore may be achieved.
In an embodiment, the liner has a diameter of between about 2.5 cm (approximately 1 inch) to about 18 cm (approximately 7 inches).
In an embodiment, over a length of the liner of not more than 20 metres, preferably not more than 30 metres and most preferred not more than 35 metres, at least one hole is positioned at a top position of the liner, and at least one hole is positioned at a bottom position of the liner. This may further facilitate controlling the cross-sectional area of the holes per length unit of the liner for top holes as well as for bottom holes.
In an embodiment, acid is injected into the hydrocarbon reservoir by means of the injection well bore before that steam is injected into the hydrocarbon reservoir by means of the injection well bore. Thereby, a significant advantage may be obtained, as the acid may generate long wormholes along the reservoir section of the well and thereby subsequently promote improved steam distribution.
The invention will now be explained in more detail below by means of examples of embodiments with reference to the very schematic drawing, in which
Accurate well placement is important for the success of this method. If the wells are too close to the oil-water contact, the oil production well bore will produce more water from the aquifer. On the other hand, if the well bores are positioned higher up in the reservoir, oil below the well bores will not be contacted with the steam and will therefore not be produced.
The SAGD process generally takes place in three distinct phases: start-up, or circulation; normal SAGD operation; and wind down. The start-up is aimed at mobilizing the heavy oil close to and between the injection well bore 5 and the production well bore 1 to establish communication between the well bores. The most widely used method for start-up is circulating steam in both injection well bore and production well bore for as long as 90 days. Normal operation involves injecting steam and producing heavy oil to form the steam chamber 6 above the pair of well bores. This phase provides access to the maximum amount of resources within the drainage area and lasts as many years as necessary, so that the maximum amount of oil is recovered from the drainage volume. Finally, the wind down includes a series of operations aimed at reducing the amount of steam injected and using auxiliary operating patterns to maximize recovery.
If the steam condenses before contacting the reservoir 3, the released heat will not lead to the desired oil viscosity reduction; instead it will be absorbed by the tubing steel of the open-ended tubing 8. Effective development of areally extensive reservoirs requires long horizontal well bores, and the ability to deliver steam across the entire reservoir interval is of great importance for economic development of such reservoirs. The uniform distribution of steam is a challenge because of the large mobility contrast between the injected steam and the reservoir fluid having viscosity in the range of 0.1 to 1.0 million cP. Failure to fully displace the open annulus 9 to steam will prevent a uniform SAGD process across the exposed reservoir section and the contrast will grow with time as the injected steam provide even higher mobility in the better exposed areas. Therefore, the prior art SAGD injection well bore 7 illustrated in
The method according to the present invention seeks to achieve a controlled steam distribution along the entire well bore length (the length of the injection well bore as well as the length of the production well bore) by means of a non-cemented liner 20 inserted into an injection well bore 21. The wall of the non-cemented liner 20 is provided with a limited number of holes 22, 23 for steam injection from the liner 20 into the reservoir as well as escape of condensed water and the initial wellbore fluids from the liner 20. The holes may be pre-drilled before insertion of the liner 20 into the well bore. Preferably, the well bore 21 is configured as an open hole completion; however, if special demands may occur, the wall of the bore could be provided with a slotted liner, screen or similar in order to strengthen the bore, but still providing substantially free access to the wall of the bore.
The holes 22, 23 are distributed over the length of the liner 20 so that the total hole area per length unit of the liner 20 is greater at a second part 25 of the injection well bore 21 than at a first part 24 of the injection well bore 21. This may be achieved either by providing holes regularly along the length of the liner, but larger holes at the second part 25 than at the first part 24, or by providing holes of equal size along the liner, but more holes per length unit of the liner 20 at the second part 25 than at the first part 24. The latter configuration is the one that is illustrated in
The holes 22, 23 may be drilled in pairs of two, whereby a top hole 22 pointing upwards serves to divert the steam by imposing a pressure drop whereby a choke effect is created, and whereby a bottom hole 23 drilled oppositely and pointing downwards serves to enable condensed water and initial well bore fluids to escape from the liner 20 into the reservoir. However, although the figures illustrate holes 22, 23 only at the top and bottom positions of the liner 20, holes may also be positioned at other positions. Preferably, at least some of the holes 22, 23 are positioned at the top position of the liner 20, and, preferably, at least some of the holes are positioned at the bottom position of the liner 20. Furthermore, this should preferably be the case over a reasonable length of the liner, for instance such as 30 metres, in order to ensure regular steam diversion to the top of the injection well bore along the length of the bore as well as regular drainage of the bottom of the liner 20 along the length of the bore.
The liner 20 is preferably inserted into the newly drilled injection well bore 21 by connecting a number of liner sections at random angular rotations in relation to each other. Each liner section may include at least one set of at least two pre-drilled holes arranged with a regular spacing in the circumferential direction of the liner section. Thereby, it may generally be ensured that, over a certain length of the liner, at least some holes will be positioned more or less at the top position of the liner, and that, over a certain length of the liner, at least some holes will be positioned more or less at the bottom position of the liner.
In order to control the distribution of the hole area per length unit of the injection liner, both for top holes 22 directed upwards and intended for steam diversion and for bottom holes 23 directed downwards and intended for drainage, it may in the case of pre-drilled holes be preferred that the holes are arranged in sets of holes positioned at the same length position of the liner 20, whereby all holes of a set have corresponding cross-sectional area.
On the other hand, if the holes 22, 23 would be drilled after insertion of the liner 20 into the injection well bore 21, all of the holes 22 could just as well be drilled at least substantially at a top position of the liner 20, and similarly, all of the holes 23 could just as well be drilled at least substantially at a bottom position of the liner 20. Furthermore, in this case, top holes 22 and bottom holes 23 could have different cross-sectional area.
In
It is noted that the first end 29 of the substantially horizontal injection well bore 21 is connected to a not shown substantially vertical well bore leading to the surface of the reservoir, corresponding to the prior art arrangement illustrated in
It is noted that in
The oil viscosity in the near well bore region will decrease in the area contacted by the steam as the steam transfers its latent heat of vaporization to the heavy oil.
In
After sufficient time, as illustrated in
The steam distribution along the liner during the start-up phase as illustrated in
The liner 20 may typically have a diameter of between about 2.5 cm (approximately 1 inch) to about 18 cm (approximately 7 inches). For instance, coiled tubing may be used, and for instance of a diameter of approximately 4.4 cm (1.75 inches).
An average hole area per length unit of the liner may be about 2.0 mm2/m for a length of the liner of approximately 1000 metres. For a longer liner, the average hole area per length unit of the liner may be smaller, probably around 0.5-1.0 mm2/m.
The hole area per length unit of the liner may be from 60-70% of the average hole area per length unit of the liner at the heel (inner part) of the well to 130-140% of said average hole area at the toe (outer part) of the well. Regarding the length of the wells allowed by means of the invention, an increase from about 1,000 metres to some 2,000-3,000 metres per well is envisaged.
The above-described distribution of the total hole area pr. length unit of the liner 20 in fact results in that, during a start-up phase, initially, the steam enters the annular space 26 only through holes 22 near the first part 24 of the injection well bore 21, and subsequently the steam gradually travels inside the liner 20 in the direction of the second part 25 of the injection well bore 21 and thereby gradually enters the annular space 26 through holes 22 nearer and nearer the second part 25 of the injection well bore 21, thereby gradually displacing liquid away from an upper part of the liner 20 and away from an upper part of the annular space 26, so that, during the start-up phase, finally, steam contacts the injection well bore 21 along at least substantially the entire length of the liner 20 in the upper part of the annular space 26.
An end opening of the liner 20 located at the second part 25 of the injection well bore 21 is preferably closed against the injection well bore 21 by means of an end cap 28 or the like. The end cap 28 could be provided with upper and/or lower holes for steam injection.
According to the present invention, it is preferred that steam is introduced into the liner 20 only from the first end 29 at the first part 24 of the injection well bore 21, at least during the start-up phase. However, at least during the entire normal operation phase, steam could possibly also be introduced from the second end 30 of the injection well bore 21.
Acid may be injected into the hydrocarbon reservoir by means of the injection well bore 21 before that steam is injected into the hydrocarbon reservoir by means of the injection well bore 21. Thereby, a significant advantage may be obtained, as the acid may generate long wormholes along the reservoir section of the well and thereby subsequently promote improved steam distribution.
Claims
1. A method of producing viscous hydrocarbons by steam-assisted gravity drainage (SAGD), comprising:
- injecting steam into a hydrocarbon reservoir via an injection well bore placed above a production well bore, so that heat is transferred from the steam to the reservoir fluids and thereby reduces the viscosity of hydrocarbons of the reservoir, thereby facilitating recovery of hydrocarbons via the production well bore, wherein a liner is introduced into the injection well bore so that it extends from a first part of the injection well bore to a second part of the injection well bore as a non-cemented liner, and wherein the steam is fed into the liner at the first part of the injection well bore and is injected into the hydrocarbon reservoir through a number of holes formed in a wall of the liner, wherein an annular space is formed between the liner and the injection well bore in which annular space steam injected through the liner may travel along the outside of the liner and contact the injection well bore along the entire length of the liner, and wherein the holes are distributed so that the total hole area per length unit of the liner is greater at the second part of the injection well bore than at the first part of the injection well bore and so that, during a start-up phase, initially, the steam enters the annular space only through holes near the first part of the injection well bore, and subsequently the steam gradually travels inside the liner in the direction of the second part of the injection well bore and thereby gradually enters the annular space through holes nearer and nearer the second part of the injection well bore, thereby gradually displacing liquid away from an upper part of the liner and away from an upper part of the annular space, so that, during the start-up phase, finally, steam contacts the injection well bore along at least substantially the entire length of the liner in the upper part of the annular space; and
- injecting acid into the hydrocarbon reservoir via the injection well bore before that steam is injected into the hydrocarbon reservoir via the injection well bore.
2. The method according to claim 1, wherein an end opening of the liner located at the second part of the injection well bore is closed or at least substantially closed against the injection well bore, preferably via an end cap or the like.
3. The method according to claim 1, wherein steam is introduced into the liner only from the end at the first part of the injection well bore.
4. The method according to claim 1, wherein the first part of the injection well bore is the inner part at the heel of the injection well bore, and wherein the second part of the injection well bore is the outer part at the toe of the injection well bore.
5. The method according to claim 1, wherein the liner includes top holes pointing upwards for diverting the steam into the reservoir and bottom holes pointing downwards in order for condensed water and initial well bore fluids to escape from the liner.
6. The method according to claim 1, wherein the liner is inserted into the injection well bore by connecting a number of liner sections at random angular rotation in relation to each other, and wherein each liner section includes at least one set of at least two holes arranged with a regular spacing in the circumferential direction of the liner section.
7. The method according to claim 6, wherein each liner section includes at least one set of two holes arranged with a spacing of approximately 180 degrees in the circumferential direction of the liner section.
8. The method according to claim 6, wherein the holes of the at least one set of at least two holes have corresponding or equal cross-sectional area.
9. The method according to claim 6, wherein all the holes included by each set of holes are arranged at the same length position of the liner section.
10. The method according to claim 1, wherein the total hole area per length unit of the liner gradually increases from the first part of the injection well bore to the second part of the injection well bore.
11. The method according to claim 1, wherein the total hole area per length unit of the liner at a part of the second part of the injection well bore is at least 2 times, preferably at least 3 times and most preferred at least or about 4 times the total hole area per length unit of the liner at a part of the first part of the injection well bore.
12. The method according to claim 1, wherein the holes in the liner has a diameter in the interval from about 0.5 mm to about 8 mm, and wherein the distance between holes in the liner at the second part of the injection well bore is less than 12 meters, preferably less than 9 meters and most preferred about 7.5 meters, and the distance between holes in the liner at the first part of the injection well bore is more than 24 meters, preferably more than 27 meters meters and most preferred about 30 meters meters.
13. The method according to claim 1, wherein the liner has a diameter of between about 2.5 cm to about 18 cm.
14. The method according to claim 1, wherein, over a length of the liner of not more than 20 metersmeters, preferably not more than 30 metersmeters and most preferred not more than 35 metersmeters, at least one hole is positioned at a top position of the liner, and at least one hole is positioned at a bottom position of the liner.
15. The method according to claim 2, wherein steam is introduced into the liner only from the end at the first part of the injection well bore.
16. The method according to claim 7, wherein the holes of the at least one set of at least two holes have corresponding or equal cross-sectional area.
17. The method according to claim 7, wherein all the holes included by each set of holes are arranged at the same length position of the liner section.
18. The method according to claim 2, wherein the first part of the injection well bore is the inner part at the heel of the injection well bore, and wherein the second part of the injection well bore is the outer part at the toe of the injection well bore.
19. The method according to claim 2, wherein the liner includes top holes pointing upwards for diverting the steam into the reservoir and bottom holes pointing downwards in order for condensed water and initial well bore fluids to escape from the liner.
20. The method according to claim 2, wherein the liner is inserted into the injection well bore by connecting a number of liner sections at random angular rotation in relation to each other, and wherein each liner section includes at least one set of at least two holes arranged with a regular spacing in the circumferential direction of the liner section.
Type: Application
Filed: Jun 6, 2013
Publication Date: Jun 4, 2015
Inventors: Kristian Mogensen (Kobenhavn K), Jens Henrik Hansen (Kobenhavn K)
Application Number: 14/406,008