Role of workover operations in Reservoir Management

Need for workover jobs:

• to maintain optimum production rate
• keeping the well in producing condition
• zone transfer
• gravel packing for sand control
• water shut off through cement squeeze etc.
 Different kinds of problem in well

Mechanical Problem: Bad cementation and channeling behind casing

may lead to
- production of water, gas or undesirable materials from other
layers into the producing layer
- loss of hydrocarbon of present layer to other layer
- loss of injection fluid
Casing or well head failures:
- failures of sealing elements of well head
- casing leakage/damage
- bad casing profile
Perforation problems:
- insufficient perforation
- plugging of perforation
- no communication from well to reservoir
- production of sand, paraffin scale etc
- deposition of undesirable materials in flow string/wellbore
- failure of completion of artificial lifts equipment
Reservoir problems:
- low formation permeability
- low reservoir pressure
- small productivity pay zone thickness
Fluid problem:
- improper and non-compatible injection fluid
- gas coning
- water coning/preferential mobility
- formation of precipitate and scale
- heavy viscous formation fluid
Problems around wellbore: DIRECTION OF CIRCULATION
- accumulation of formation fines ROTATING HEAD
- emulsion blocking DIVERTER LINE
BOP CASING VALVE
- water blocks DRILL PIPE
- poor perforation
- loose compaction and sand production
CASING

CASING SHOE

GRAVEL PACK VALVE

SLOTTED LINER

UNDERREAMER

BIT
 Remedial measures for the mentioned problems

Rig less way: periodical well maintenance which include

- well scraping
- steaming
- sand or bottom washing with or without CTU (Coiled Tubing Unit)
- hot or normal oil circulation
- paraffin or scale inhibitor treatment
- well stimulation treatment
- water unloading
Operation which need Rig deployment:
- removal, replacement of defective down hole equipment such as
packers, SRP, Gas lift valves, ESP, tubing etc
- removal of bottom hole deposits and perforations, well bore
blockages and damages
- capital repairs of wells are the most complicated and time
consuming.
drilling and milling of packers, bridge plug etc
detection and blocking of channeling behind casing &
recompletion
detection and repairing of casing damages & recompletion
fishing and removal of stuck tubing packers and other down
hole tools
testing of different objects and recompletion
 Planning of workover job and deployment of Rig

-Workover time is very important due to idling and high inventory of sick wells
-The planning of workover job is important step, which is jointly prepared by
reservoir engineer, geologist, workover groups
-A system approach is essential for correct interpretation of well behavior,
well problem and repairs to be taken-up to avoid needless jobs
-The system requires a several well information
- well history commencing from G. T. O.
- drilling and cementation history
- well completion and inclination profile
- log interpretation reports of different logs taken in the well
- production, bottom hole study and test data
- prediction about the well and present well

After through investigation, the workover plan is prepared. The use of workover
rig involves high cost, so its judicious utilization should be the prime motive of
every planner and execution engineer.
 Identification of completion defect

Completion defect can be identified through some of the

following method:
- pressure build-up in the outer annulus
- decline in reservoir pressure even when there is no production
- communication of applied pressure to outer annulus during high
pressure jobs
- unexpected changes in well production
- unexpected changes in tubing head pressure
- failure to activate the functional part of the valves, pumps and
dynometer survey
- problem in down hole artificial lift tools
- obstruction in production tubing detected by lowering dummy and
scrappers
 Identification of reservoir related problems

Reservoir related problems can be identified with the help of:

- inflow performance and flow rate

- production system analysis and optimization of inflow and
outflow from well
- pressure/temp gradient survey and buildup study
- decline curve method
- analysis of petro physical properties from logs/cores
- special production logging and evaluation
The WOJ begins with well preparation which include
- well site preparation (rig foundation, approach road etc.)
- closing and disconnection of X-mass tree from flow arm
- subduing the well
- erection of workover rig mast
- removal of x-mass tree and installation of BOP
The specific repair job are take –up after that
 WORKOVER JOBS

- detection and repairing of channeling behind the casing

- testing and zone transfer

- fishing, milling and stuck-up removal and recompletion

- detection and repairing of casing damage

- water/gas shut-off jobs

 CEMENTATION DURING WORKOVER JOB

Cementation is usually done through drill string

BLOCK CEMENTATION: In case cement bond is very poor over a section covering
one or more pays and in between there is no block, cement retainer is used and
circulation is established between given interval after perforating, if required
BLOCK SQUEEZE: Squeeze cementing is the process of applying hydraulic
pressure to the cement slurry to
(1) force or squeeze the slurry into the desired location and
(2) force water from the slurry after placement to create a mass which will
remain in place and harden to provide a seal
HIGH PRESSURE SQUEEZE: Placement of a cement slurry or other sealant at
pressure greater than a fracture pressure of the zone are referred as high
pressure squeeze.
USED WHEN: squeezed with solid laden fluids (drilling mud) in hole
where no void exist behind the casing- small single zone, leaking
linear tops
LOW PRESSURE SQUEEZE: It is preferred for most squeezes cementing
operation. Cement slurry designs are frequently complex but generally better
control over placement.
WHEN USED: filling the existing void behind the casing
squeezing long perforated interval
squeezing low permeability zones
squeezing when clean, solid free fluids are in the wellbores
used as injection fluid ahead of complex fluid
 Detection and repairing of channeling

• Channeling is detected by logs like CBL, VDL, Thermologs,

temperature gradient and isotope survey (if required)
• Perforation and block cementation
• Re-perforation in pay zone
• Recompletion as desired
 Testing and zone transfer

- Testing of the present pay zone for its bottom hole

pressure, temperature and fluid flow rates/influx. If the
fluid production is not in commercial quantity even after
stimulation, then transfer may be required
- Isolate the present pay zone by cement plug/cement
squeeze and bridge plug
- Perforate the desired pay zone
- Test this pay zone for pressure, temperature and flow rates
- Re completion the well as desired
 Fishing
-The exact sequence of job plan is very much dependent upon the problem

-Normal fishing operation would include

- wash over the fish top
- feeling the top and orientation of the fish in the down
hole with impression block
- design the fishing tool/tape accordingly
- carrying out the fishing job to recover it
- clean the hole and perforate the pay zone
- recomplete the well as required

-The success of each operation is quite uncertain

-It is a time consuming operation
 Detection and repairing of casing damage

- Casing damage is located by CCL, casing caliper logs and

hermetic testing with testing packer
-The repair of leakage and damage include cement squeeze
into the leaking point, re-perforation and block cementation
- Isolation of leakage by production packer completion
- Checking and cleaning the hole by perforating (if required)
- Re-completion of the well after repair
 WORKOVER JOBS

- detection and repairing of channeling behind the casing

- testing and zone transfer

- fishing, milling and stuck-up removal and recompletion

- detection and repairing of casing damage

- water/gas shut-off jobs

 WORKOVER PLAN TO REDUCE WATER CUT

PROBLEMS OBSERVED IN HIGH WATER CUT WELLS:

• Scaling
• Emulsion
• Water blocks
• Corrosion and production problem
• Decline in reservoir pressure
• The excess water production reduced fluid head in the well bore and
creates extra pressure in the formation. This in turn reduces well’s low
capability or focus an increase in artificial lift capacity as the volume of
water production increases

OBJECTIVE: To shut-off the water production in high water cut wells

To minimize the effluent generation and environmental problem
POSSIBLE SOURCE OF WATER CUT:
• Casing leakage
• Perforation in aquifer
• Channel behind casing
• Coning from an underlying aquifer
• Rise in OWC
• High permeability streak from natural water drive or
water injection drive
• Natural fractured formation connected to water
source
 Water shut-off job
- Sequence of operation
- Detection of source of entry by isotope, differential
temperature, PLT etc.
- Block cementation/cement squeeze and chemical polymer
squeeze
- Isolate by cement plug/bridge plug
- Checking and cleaning the hole and pay zone interval
- Re-perforation (if required)
- Re-completion as desired
 WATER SHUT-OFF TREATMENTS

Water encroachment in oil and gas well is responsible

for increased operating costs and generally for
premature shut-down of the wells
OBJECTIVE:
• To shut-off the water production in high water
cut wells
•To minimize the effluent generation and
environmental
problem
Injection of chemicals in the formation around the wellbore
can effectively prevent excessive water production by
creating a selective barrier to water flow which remains
permeable to oil and gas flow.
Formulation based on water solution polymers are
commonly used f or this purpose. This kind of treatment
efficiently reduces water production in different cases as
• water coning
• multilayer production with sharp permeability
contrast between the different producing zones
Polyacrylamide is used in water shut-off job. The dilute
solution of polyacrylamide approximately 2000-3000
ppm are ideal water control material for oil and gas
producing wells. The polymer are simply dissolved in
water at the surface and injected into well.
 WORKING MECHANISM OF POLYACRALAMIDE

The hydrophilic film theory:

Polyacralamide absorbs on to the rock matrix by
interacting between the reactive group of the matrix
and reactive polymer groups and remain there as a
film that attracts water. There after all water that
passes near this film is slowed by attraction to the
polymer. However, oil or gas repulsed by the
polymer, which causes oil or gas to flow through the
centers of the pores.
The dynamic entrapment theory:
Polyacralamide molecules are extremely long and being a million
to several million molecular weight. They tend to coil in a helical
shape as they relax but when sheared as they are injected
through porous media, they will elongate. If sheared too much
they may break down and become low molecular weight polymers
that are less effective.
When pumped into a formation, the molecules stretch to confirm to the
path which water is flowing. When injected into the formation, it will flow
at a relatively higher rate through the pores of the formation nearest to
the wellbore. When it continue deeper into the formation in a radial flow
pattern, the velocity is less and the polymer relaxed and resumes helical
shape. When the well is put on production, the coiled polymer molecules
bridge in pores throat and resist the flow of water.
The polymer within first foot or so around a wellbore is ineffective, as the
shear rate of produced liquid will be high enough to cause the polymer
molecule to elongate. The most effective polymer will be that injected
five foot away from the wellbore.
The polymer are shear degradable –
•some degradation may occur while pumping the polymer through pump
• in a turbulent flow through pipe and tubing
• in the perforation tunnel
• in the formation pores
The most critical location where shear degradation may occur is at
the entrance to the formation pores, so those polymers are less
effective in reducing water production. The recommended
injection rate will be controlled less than 0.05 BPM per perforation.
 The physical plugging theory:
By adding multivalent ion it is possible to cross-link a polyacralamide
solution. Commonly used cross linkage agents are aluminium citrate and
potassium dichromate. Cross-linked polymer acts as a plugging material
in the formation, thus water is physically prevented from moving through
pores. Due to relative permeability effect which allows the aqueous
polymer solution to preferentially invade the high water saturation zones
and due to the fact that water tends to swell cross linked polymers and
effectively shrinking the oil and gas phase and reduces water production.
This treatment are often done by injecting the cross-linkers and polymers
separately into formation. The cross-linking then occurs deep into the
formation, which prevents a build up of polymers near the wellbore.

P–C=O
The chromium (Cr3+) ion cross-link numerous
O – Cr – O – C
number of polymers, so that the molecular weight
O–C=O of cross linked polymer is in the billion range
P
 TREATMENT DESIGN

Pre-treatment:
• Wells are conditioned by pre-flush that consists of a slug of
biocide, weak organic acid and cross linkers. The use of biocide
assures a bacteria free environment for polymer treatment. The
cross linkers is a surface active agents which promotes polymer
absorption on formation surface if scale or iron is present.
• A small volume of weak acid treatment to be done to clean the
perforation and tubing.
• All pre-flush treatment solutions are injected into formation and
well is shut in overnight
Treatment volume:
Treatment volume is calculated from reservoir parameter, shape factor
and required
Let, radius of cross linker gel around wellbore, r = 5 m
porosity (Φ
Φ) = 0.2
water saturation = 0.3
height of formation = 8 m
cross-section of 5 m radius = Πr2 = 78.5 m2
volume of cross linker solution = 78.5 * h*Φ
Φ*(1-0.3)
= 88 m3
Polymer treatment :
After the pre-treatment the polymer solution of approx.
2000-3000 ppm in 1% KCl with oxygen scavenger is injected
at approximately 200 LPM. Polymer mixing and injection
begins while continuously monitoring the injection rate and
pressure is necessary. Treated wells are over displaced with
water free crude which helps to restore the natural increase
in relative oil permeability near the wellbore while driving
polymer solution away from the wellbore. The well is then
shut in for a minimum of 48 hours.
 BEFORE AND AFTER POLYMER TREATMENT

MULTILAYER PRODUCTION
WATER CONING WITH SHARP K CONTRAST
 RELATIVE PERMEABILITY GRAPHS
BEFORE AND AFTER POLYMER TREATMENT
 WORKOVER OPERATION FOR CONTROLLING SAND

The sand cut problem arises due to high withdrawal rate and
increase in water saturation
Related problem:
• sand fills inside hole, casing or tubing and shuts off production
• erosion damages linear, tubing and creates unsafe well condition
SAND CONTROL METHOD

CHEMICAL METHOD MECHANICAL METHOD

Plastic consolidation Slotted linears
Resin coated sand Screens
Pre-packed screens
Gravel packing
 GRAVEL PACK JOB
The process of placing gravels around a screen. The gravel stops
formation sand movement while the screen holds the gravel in
place.

ADVANTAGE:
• does not rely on chemical reaction and less subject to deterioration with
time
• less effected by varying permeability in the formation
• more effective for long intervals-intermixed shale/sand intervals
• less expensive and more effective

DISADVANTAGE:
• wellbore diameter is restricted by presence of gravel and screen
• well repair require removal of packer, screen and gravel
• difficult to isolate unwanted gas or water production
Requirements of successful gravel pack:
1. Gravel has to be sized to effectively stop formation sand
movement
2. Gravel has to be packed in tight pack, with radius of pack as
large as possible
3. Design to minimize formation damage
Carrying fluid:
Gravel pack job is carried out by polymer, water (brine) as a
carrier fluid
 SELECTION OF SUITABLE GRAVEL
Based on sieve analysis of representative sample of formation sand
The gravel will be selected based on the criteria that are 4 – 8 times of D-50.
 AN EXAMPLE

Size of the sand particles at 50 percentile point

– 0.177 mm
Selection of gravel size:
Smallest size of gravel = 0.177X4 = 0.708 mm
> 20 U. S. mesh
Largest size of gravel = 0.177X8 = 1.416 mm
=> 16 U.S. mesh
Selected gravel size = 16 + 20 U.S. mesh
Screen opening at 0.75 mm
UNIFORMITY COEFFICIENT = D40/D90 =
0.19/0.08 = 2.3

Sand volume calculated according to screen/casing capacity

 TYPE OF GRAVEL PACK
LOW RATE WATER PACK
The field brine as a carrying fluid
Rate : 2 – 5 BMP
Advantage:
• a tight annulus pack can be achieved
• does not bypass near wellbore damage
Used when:
unable to get rate due to narrow
clearness
perforations are clean and pre-pack
HIGH RATE WATER PACK
The field brine as a carrying fluid
Rate : > 5 BMP
Advantage:
• a tighter annulus pack
• more sand behind pipe and perforation
• Re-stress formation and bypass near
wellbore damage
Disadvantage:
• increased erosion effect and volume of fluid
used
• more equipment and higher cost when
compared to low rate water pack
Used when;
In all type of application
 ACIDIZING JOB
It id defined as the injection of acid into the formation porosity
(inter granular, vugular or fracture) at a pressure below the
pressure at which a fracture can be opened
Due to extremely large surface area contacted by acid in a matrix
treatment, spending time is very short. Therefore, it is difficult to
affect formation more than a few feet from the wellbore.
Removal of severe plugging in sandstone, limestone or dolomite
can result in a very large increase in productivity.
 Carbonate Acidizing Acid wash-perforation
Matrix acidizing –wellbore
TYPE OF ACIDIZING damage
Sandstone Acidizing Acid fracture stimulation

ACID USED IN ACIDIZING JOBS

Inorganic Acid Organic Acid

• HCl • Acetic Acid
• Formic Acid
• HF Usually in carbonate
• Fluroboric Acid reservoir with high T
 ACIDIZING TECHNIQUE FOR CARBONATE RESERVOIR
In a carbonate reservoir with mixed carbonate minerals, the acid used (usually
HCL) is injected at pressure low enough to prevent formation fracturing. The
goal of treatment is to achieve more or less radial acid penetration into
formation to increase the apparent permeability near the wellbore. 15% HCl
normally used, with modification as required
REACTION:
CaCO3 + 2HCl
CaCl2 + H2O + CO2

CaMg(CO3)2 + 4HCl
MgCl2 + CaCl2 + 2H2O + 2CO2

When acid is pumped into a carbonate at a pressure below the fracture

pressure, the acid flows essentially into the highest permeability regions causes
the formation of large, highly conductive flow channels called wormholes. The
creation of wormholes is related to the rate of the chemical reaction of the acid
with the rock.
 SANDSTONE ACIDIZING FOR OIL WELLS

The primary reason to acidize sandstone well is to increase well

permeability by dissolving calys near the wellbore.
This clay may be:
• naturally occurring with the rock
• may have been introduced from drilling
• may be from completion or workover fluids

SEQUENCE OF ACIDIZING TREATMENT

Pre-flush

Acid (HCl-HF) treatment

After flush
 SANDSTONE ACIDIZING FOR OIL WELLS
PRE-FLUSH treatment for oil well:
The pre-flush is usually 5-10 % HCl containing a corrosion
inhibitor and other additives as required.

The pre-flush displaces water from the wellbore and connate

water from the near wellbore region, thereby minimizing direct
contact between sodium and potassium ions in the formation brine
and florosilicate reaction products. The acid also reacts with
calcite and other calcareous minerals in the formation thereby
reducing /eliminating reaction between HF and calcite.

The pre-flush avoids waste of more expensive HF and prevents

the formation of CaF2, which can precipitate from a spent HF-HCl
mixture.
 SANDSTONE ACIDIZING FOR OIL WELLS

HF-HCl treatment for oil wells:

The HF-HCl (3% HF & 12 % HCl) is injected after pre-flush. The
HF reacts with clay sand, drilling mud or cement filtrate to improve
permeability near the wellbore. The HCl will not react and is
present to keep the pH low, preventing the precipitation of reaction
products
SiO2 + 6HF
H2SiF6 + 2H2O

Al2Si4O10(OH)2 + 36HF
4H2SiF6 + 12H2O + 2H3AlF6

(Clay) (Fluo silicic acid) (Fluo aluminic acid)

The reaction rates on sand and clay are dependent on the ratio of
the surface area of the rock to volume of acid in the sandstone
pores
HF can be generated in-situ by using ammonium-bifluoride –
fluoride mixture. It dissolves in HCl to produce

(NH4)HF + HCl
(NH4)Cl +2HF

(NH4)F + HCl
(NH4)Cl + HF

This compound offers many advantages. The mud acid based on

ammonium bifluoride –fluoride is much cheaper than that based
on commercial HF. The compound ammonium chloride formed in
the solution improves the quality of mud acid. Ammonium
bifluoride is less hazardous and easy to transport.
 SANDSTONE ACIDIZING FOR OIL WELLS

AFTER-FLUSH for oil wells:

Inject about 25 gallons after-flush per foot of sand. After-flush
may be 5-10 % HCl, clean filtered kerosene, diesel oil or crude
oil. All fluids should contain about 0.1 % water wetting non-
emulsifying surfactant. The purpose of the after-flush is to
act as a buffer between HF and the pumped down fluid.
Sufficient after-flush should be used to thoroughly displace
the HF into formation.
After acidization, it is considered good practice to withdraw
the spent acid soon after its introduction to avoid possible
plugging of the formation pores with an insoluble residue
that may result from the contact of the acid with any
impurities that may be present.
 ADDITIVES FOR OIL WELLS
SURFACTANTS:
It is commonly used with acid to reduce the surface tension
of the raw acid and spent acid solution.
Surface active agents are used in acid treating to
• to demulsify acid and oil
• to reduce interfacial tension
• to alter the formation wettability
• to speed clean up and
• to prevent sludge formation

CAUTION should be exercised when adding surfactants

to be sure that they are compatible with corrosion
inhibitor and additives.
MUTUAL SOLVENTS:
Mutual solvents also known as acid mutual solvents, are materials that have
appreciable solubility in both oil and water.
EGMBE (ethylene glycol monobutyle ether) is used in sandstone acidization for
mutual solubility.
In addition to its mutual solubility,
- reduces interfacial tension between oil and water
- acts as a solvent for solubilizing oil in water
- acts as a detergent removing oil wetting materials from surface.
CORROSION INHIBITOR:
Inhibitor effectiveness is a function of ability to form and maintain a thin film on
the steel surface. At high temperature the acid corrosion rate increases and the
ability of the inhibitor to absorb on the steel surface decreases. For this reason
the inhibitor for high strength acid at temperature above 2500 F are expensive
and difficult to formulate.
STABILIZER:
Organic acid such as acetic, citric, lactic acid are used as
stabilizers.
The main purpose of these acid is to maintain the pH of solution
below 2. By keeping this pH, it gives salt of Fe and Al in solution.
Otherwise, the rise of pH due to reaction of HCl with formation
cause the precipitation of iron and Al-hydroxide which will create
surface plugging problem.
DIVERTING OR BRIDGING AGENT:
Acid will follow the least path of resistance, unless diverting or
bridging agents are employed to allow relatively uniform acidizing
of various porous zones open to the wellbore.
Benzoic acid is one of the bridging agent used in acidizing. It is
slowly soluble in water or oil and is available as finely divided
particle and as flakes.