Understanding ESP Performance Under High Viscous Application and Emulsion Production

by Luiz Pastre, Jorge Biazussi, William Monte Verde, Jean Marins, Aline Melchuna, Mark Cowie, Luis Vergara, Ivamberg Navarro, Daniel Lemos, Antonio Alfonzo, Leudy Ramos, Antonio Bannwart, presented at OTC2022, April 2022.

Abstract

 

Although being widely used as an artificial lift method for heavy oil field developments, Electrical Submersible Pump (ESP) system performance in high viscous applications is not fully understood. A miscomprehension of challenges and equipment performance in such conditions might lead to operation inefficiencies and equipment failures. This paper presents results of single-phase and multiphase tests performed by University of Campinas (UNICAMP). It also presents operation data, lessons learnt, and failure examples gathered over 10 years of ESP operation in Peregrino field which is a heavy oil, high viscous oilfield offshore Brazil operated by Equinor.

Affinity laws commonly used for ESP simulations don’t hold true for high viscosity applications. Hydraulic performance of centrifugal pumps is affected by fluid parameters like viscosity and density; operation parameters such as flow rate and rotational speed; and specific stage design characteristics. To determine degradation in head and efficiency as well as power requirement increase in viscous applications, Equinor performs one-phase high viscosity flow loop test to qualify each stage type prior to deployment in Peregrino field.

For the qualification of ESPs, single phase qualification tests are performed using mineral oil with viscosities specifically chosen to cover the viscosity range of the specific field. Each stage type is qualified using a prototype with reduced number of stages due to flow loop limitations. Qualification tests for the Peregrino field confirmed that affinity laws are not accurate for high viscous applications and provided important insights regarding pump performance that are used in equipment specification and system surveillance.

The UNICAMP research team has designed and performed multiphase flow tests to evaluate emulsion formation inside centrifugal pump stages and effective viscosity behavior. Phase inversion phenomenon investigation was also included in studies. Studies performed using a prototype stage allowed visualization and evaluation of oil drops dynamics inside the impeller in different rotational speeds. Two phase flow loop tests investigated the shear forces influence in effective viscosity inside pump stages and downstream pump discharge. Phase inversion phenomenon was also a point of great interest during the studies. Data gathered during lab tests was used to evaluate accuracy of mathematical models existing in the literature when a centrifugal pump is added to the system. Hysteresis effect associated to catastrophic phase inversion (CPI) was confirmed and replicated during flow loop tests. Such behavior can be related with operation parameters instabilities and equipment failures noticed in actual application in Peregrino field which are also presented in this paper.

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Comparing WAG-CO 2 injection with continuous water and gas injection in separate wells for the development and management of a CO2-rich light oil fractured carbonate reservoir subject to full gas recycling

by Josias Pereira de Oliveira, Susana Margarida da Graça Santos, Antônio Alberto Souza dos Santos, Denis José Schiozer, presented at SPE EuropEC 2023, June 2023.

Abstract

 

Many projects in the Brazilian pre-salt assume the use of water alternating gas (WAG-CO2) injection as an ecologically safe carbon storage strategy, with improved hydrocarbon recovery. However, studies that compare these advantages with a simpler management plan are not common. The objective of this work is to compare WAG-CO2 injection with continuous injection of water and gas (CIWG) rich in CO2 in separate wells for the development and management of a light-oil fractured carbonate reservoir subject to full gas recycling. We employed the UNISIM-II benchmark model, a naturally fractured carbonate reservoir with Brazilian pre-salt characteristics, which enables an application in controlled environment where the reference response is known (UNISIM-II-R). We used a model-based decision analysis for production strategy selection, hierarchical optimization of the decision variables and algorithms to maximize the objective function. Representative models (RM) are selected from the ensemble of models and used to incorporate the effects of geological, reservoir, and operational uncertainties into the optimization process. The net present value is the objective function during the nominal optimization of candidate strategies of each RM and the expected monetary value and risk analysis are considered to select the final production strategy considering uncertainties. The risk analysis was quantified based on downside risk and upside potential relation to a benchmark return. We optimized two alternative development plans (one considering WAG-CO2 injection and the other continuous injection of water and gas in separate wells) and compared their performance indicators and decision variables, including design variables (number, type and placement of well, and size of production facilities) and life-cycle control rules (management of equipment over time). We then applied a cross-simulation, where the best strategy optimized for one recovery method was applied to the other and the injection strategy was optimized again. We were therefore able to assess the need to pre-define the recovery method before defining design variables to validate the flexibility of each strategy for possible future changes in the recovery mechanism. Finally, we repeated the study for different reservoir scenarios to compare the alternatives considering typical uncertainties of the Brazilian pre-salt and validated the final strategies in the reference model to quantify the real value in decision making. The strategies reached a full gas recycling in both recovery methods and allowed a comparison of their advantages and disadvantages. The operations of WAG-CO2 injection can be more complex and the equipment more expensive. The novelty of this work is the consideration of continuous injection of water and gas in separate wells as a simpler alternative to the development and management of pre-salt oil fields, since this method may also meet operators’ and environmental demands, bearing simpler operating challenges and promoting good recovery and profitability.

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A coupled PIV/PTV technique for the dispersed oil-water two-phase flows within a centrifugal pump impeller

The current work presents a framework for the simultaneous characterization of different phases in a dispersed oil-water two-phase flow. The framework is based on the coupling of the PIV and PTV techniques in raw PIV acquisition images. The PIV technique computes the water velocity fields, while the PTV technique calculates the oil drop velocities. Thus, the proposed technique allows the simultaneous measurement of the water phase and dispersed oil drop velocity from the same image. In order to present the advantages of the coupled PIV/PTV technique, the flow within a centrifugal pump impeller is completely analyzed by computing the oil and water phase-ensembled velocities.

Effects of the Random Forests Hyper-Parameters in Surrogate Models for Multi-Objective Combinatorial Optimization: A Case Study using MOEA/D-RFTS

Surrogate models are techniques to approximate the objective functions of expensive optimization problems. Recently, Random Forests have been studied as a surrogate model technique for combinatorial optimization problems. Nonetheless, Random Forests contain several hyper-parameters that are used to control the prediction process. Despite their importance, research on the effects of these hyper-parameters is scarce. Therefore, this paper performs a systematic investigation of the effects of different combinations of values for the Random Forest hyper-parameters on the approximation of well-known multi-objective combinatorial benchmark problems. The results show that the number of samples to consider when building each tree and the minimum number of samples to be at the leaf node are the two most important hyper-parameters in this context.

Impact of seismic data conditioning on the identification of structural elements: A case of study from the pre-salt reservoir, Santos Basin, Brazil

Three-dimensional seismic data provides valuable insights into structural interpretation when dealing with naturally fractured reservoirs. The faults or fractures may control the direction of fluid flow in the reservoirs, especially during the sensitive analysis in projects of carbon sequestration and reservoir development, since these features may impact the rock-fluid interaction and oil field production. However, characterizing faults and fractures in pre-salt reservoirs using conventional approaches is challenging due to a complex and heterogeneous overlying evaporitic unit which reduces the seismic-to-noise ratio. Therefore, seismic data conditioning targeted at improving the seismic image is necessary for quality subsurface investigations. This work provides a systematic series of filters to enhance and detect discontinuities in post-stack seismic volume, primarily by reducing migration artifacts and salt multiples, thereby maintaining the true geological characteristics of the data. We emphasize the delineation of the fault and potential fracture zones by computing seismic attributes in a post-stack time-migrated 3D seismic in the Santos Basin’s deep waters. Initially, the seismic signal-to-noise ratio was analyzed, and a sequence of structural-oriented filters and spectral balancing was applied to generate vertically refined images with enhanced seismic amplitudes. To assess the quality of the conditioned data, we employed the Similarity and Curvature attributes to identify the distribution of discontinuities and compare the before-and-after denoising approach. The data conditioning and analysis of seismic attributes improved our understanding of the distribution and compartmentalization of the reservoirs, highlighting predominantly NE-trending discontinuities. The systematic processing significantly improved the signal-to-noise ratio, allowing us to identify the relative direction of structural elements and insights into potential fractured zones over the reservoir.

Ensemble-based machine learning application for lithofacies classification in a pre-salt carbonate reservoir, Santos Basin, Brazil

Machine learning techniques have been widely used in the oil and gas industry to improve the qualitative and quantitative characterization of subsurface reservoirs. Because rock properties are strongly influenced by lithological and sedimentological information, lithofacies classification is an important step in 3D reservoir modeling. The aim of this study is to use supervised classification algorithms to predict the spatial distribution pattern of lithofacies classes using borehole and seismic data. In this study, lithofacies classes are distributed away from the wells using a machine-learning classifier. Seismic data attributes extracted from well locations are utilized as training data features in various supervised classification algorithms. Machine learning classifiers trained and evaluated for lithofacies classification include K-nearest neighbors, support vector machine, Gaussian naive Bayes, decision tree, Gradient Boosting, and Random Forests. A number of parameters are optimally determined in order to achieve the highest value of classification accuracy in the model. Comparing machine learning classifiers based on evaluation metrics reveals that ensemble-based decision tree approaches such as Random Forests and Gradient Boosting are the most effective for supervised classification. The results are validated using testing data and have an 80% classification accuracy. The predicted volume of lithofacies classes contributes to improved 3D reservoir modeling for the pre-salt carbonate reservoir.

An efficient construction of divergence-free spaces in the context of exact finite element de Rham sequences

Exact finite element de Rham subcomplexes relate conforming subspaces in H1(Ômega)H(curl; Ômega)H(div; Ômega), and L2(Ômega) in a simple way by means of differential operators (gradient, curl, and divergence). The characteristics of such strong couplings are crucial for the design of stable and conservative discretizations of mixed formulations for a variety of multiphysics systems. This work explores these aspects for the construction of divergence-free vector shape functions in a robust fashion allowing stable and faster simulations of mixed formulations of incompressible porous media flows. The resulting schemes are verified by means of numerical tests with known smooth solutions and applied to a benchmark problem to confirm the expected theoretical and computational performance results.

A posteriori error estimator for a multiscale hybrid mixed method for Darcy’s flows

This article presents a computable and efficient procedure for a posteriori error estimations of approximate solutions of Darcy’s flows given by a Multiscale Hybrid Mixed method. Based on a partition of the domain by polytopal macro subregions, this is a strategy for efficient simulations of problems with strongly varying solutions. The flux approximations interacting with the skeleton (subregion boundaries) are strongly constrained by a given trace space. Whilst the dimension of the piecewise polynomial trace space is expected to be as low as possible, the small-scale features of the solution are supposed to be accurately resolved by completely independent local stable mixed solvers, the trace variable playing the role of Neumann boundary data. As the method already gives an equilibrated global H(div)-conforming flux approximation, the methodology for the error estimation only requires a potential reconstruction. In addition to usual residual errors and indicators associated with the potential reconstruction, the estimation also takes into account the effect of discretizations of practical nonhomogeneous Dirichlet and Neumann boundary conditions. Based on the proposed a posteriori error estimator, ℎ-adaptive algorithms are constructed to guide a proper choice of the trace space. The performance of the error estimator and the adaptive scheme is numerically investigated through a set of illustrating test problems.

Electrofacies definition and zonation of the lower Cretaceous Barra Velha Formation carbonate reservoir in the pre-salt sequence of the Santos Basin, SE Brazil

Lower Cretaceous carbonates in the pre-salt succession in the Santos Basin, eastern Brazil, are highly heterogeneous in terms of their reservoir characteristics as a result of depositional and diagenetic factors. Electrofacies have widely been used for reservoir zonation and, when allied with computer-based methods such as neural networks, may help with the study of such complex reservoir rocks and with the identification of high-quality reservoir zones. In this work, an unsupervised artificial neural network known as a self-organizing map (SOM) was used to carry out a zonation of the pre-salt carbonates in the Aptian Barra Velha Formation, the main reservoir unit in the Santos Basin. Available data included gramma-ray, neutron porosity, resistivity deep, sonic, density, photoelectric factor, total porosity and effective porosity profiles from 21 wells together with mineralogical models. Core descriptions and thin section images were used as additional data for the lithological characterization of the electrofacies and consequently for reservoir zonation. A total of four electrofacies were defined from the SOM application, and five reservoir zones were identified.

The characterization of the reservoir zones also considered the structural locations of the wells based on the relative depth to top- Barra Velha Formation; well locations were classified as structurally high, intermediate or low. Based on the reservoir zone characteristics, the results could be correlated with zonations in previous studies. A general tendency was noted for there to be an increase of finer-grained sediments in the formation in wells located in structural lows; packstone and mudstone facies were prevalent in these wells and were in general characterized as poor-quality reservoir rocks. By contrast, the shrubstones and grainstones which were more frequent in structurally high wells comprised higher quality reservoir rocks.

The basal reservoir zone showed wide lithological variation compared to the overlying reservoir zones. Grainstone-dominated facies were identified in the middle of the formation, and the uppermost reservoir zones were characterized by an upward increase in shrubstones and reworked grainstones which in general pointed to better quality reservoirs.