IPTC 11551
Effluent Water Disposal Experiences in the Greater Burgan Field of Kuwait
Hamad Al-Ajmi, SPE, Issa Al-Jadi, SPE, Feras Al-Ruhaimani, SPE, Kuwait Oil Company; Wahyu Budiarto, SPE, Chevron
Copyright 2007, International Petroleum Technology Conference
This paper was prepared for presentation at the International Petroleum Technology
Conference held in Dubai, U.A.E., 4–6 December 2007.
This paper was selected for presentation by an IPTC Programme Committee following review
of information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the International Petroleum Technology Conference
and are subject to correction by the author(s). The material, as presented, does not
necessarily reflect any position of the International Petroleum Technology Conference, its
officers, or members. Papers presented at IPTC are subject to publication review by Sponsor
Society Committees of IPTC. Electronic reproduction, distribution, or storage of any part of this
paper for commercial purposes without the written consent of the International Petroleum
Technology Conference is prohibited. Permission to reproduce in print is restricted to an
abstract of not more than 300 words; illustrations may not be copied. The abstract must
contain conspicuous acknowledgment of where and by whom the paper was presented. Write
Librarian, IPTC, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
Abstract
This paper presents the process of candidate well selection,
design, execution and evaluation that lead to the successful
implementation of acid fracturing treatment in Marrat field.
The acid fracturing treatment is quite challenging due to
presence of high pressure/high temperature and high
asphaltene content in the crude oil which renders the situation
even more difficult because of fluid incompatibility issues.
The formation tends to produce oil with asphaltene content
when the flowing bottomhole pressure is drawn below the
Asphalting Onset Pressure (AOP). An engineering solution
was urgently needed to enhance the productivity of wells and
to mitigate the aspheltene deposition issue by allowing the
wells to produce above the AOP. The option of acid fracturing
was evaluated and found to be feasible to alleviate the
problems.
The paper details an optimization workflow and integrated
evaluation process that improve the treatment performance.
Detailed fluid system used in the treatment is discussed in
details including the application of polymer-free viscoelastic
surfactant based fluids. Also, a surveillance program was
implemented to monitor and evaluate the acid treatment.
It is anticipated that the matured giant reservoirs of
Southeast Kuwait are going to produce substantial amount of
water in future during EOR process. The Greater Burgan field
is currently producing about 250,000 barrels of effluent water
per day. Kuwait Oil Company has the mandate to achieve the
target of subsurface disposal of all produced water and zero
discharge to the environment. In long term, several enhanced
recovery projects would be implemented and the produced
water would be reinjected to the producing reservoirs for
pressure maintenance schemes. The shorter term need is to
dispose of the water into selected non-producing reservoirs.
Several non-producing reservoirs were evaluated. The
Burgan Fourth Sand, which is mainly below the oil water
contact in most part of the field, was identified as the target
disposal reservoir in view of its large capacity and connection
with the aquifer supporting the field. Disposal well was drilled
and closely monitored. Early attempt to inject untreated
effluent water in this well encountered frequent increase in the
wellhead pressures. Acid jobs were carried out to restore
injectivity. Laboratory studies confirmed the reasons of
plugging as water incompatibility and made several
recommendations for maintaining water quality. Two effluent
water treating plants have since been built based on these
recommendations.
Along with water specification team, an earth scientist
team has studied alternate option of finding a carbonate
reservoir that can handle the existing water specification. An
existing well was made deepened to Shuaiba carbonate
reservoir. The key to a successful injection in this formation
was thought to be our ability to intersect the fracture network.
Special drilling and completion techniques were used to
extend the well horizontally into the Shuaiba. It’s been two
years of injecting the untreated water to this reservoir without
any major problem in term of plugging.
From the experience of injecting in Shuaiba, it is apparent
that the formation is very forgiving in term of effluent water
quality. However, it is not known how long the Shuaiba can
take the untreated effluent water due to its smaller storage
capacity and uncertainty about connectivity with overlying
reservoirs. Therefore, the current strategy is to combine the
two options and to continue focusing on water treating prior to
disposal to meet water quality specifications and applying the
proper chemicals to control scaling and corrosion. The Fourth
Sand will remain as a back-up in case the Shuaiba is filled up
sooner than anticipated.
The paper discusses the issues associated water injection
in to clastic and carbonate reservoirs and the strategy in detail.
Introduction
Burgan Field, the world’s largest sandstone oil field, lies 35
km south of Kuwait City near Ahmadi, Kuwait. The four
main reservoir units comprising the Greater Burgan Field
complex are the Wara, Mauddud, Burgan Third Sand and
Burgan Fourth Sand. Additionally, there are several smaller
and deeper hydrocarbon reservoirs such as the Minagish and
Marrat which has limited production. In between the main
reservoir and the deeper reservoir lies the Shuaiba, this is a
non hydrocarbon bearing carbonate reservoir (Fig.1).
2 IPTC 11551
Production in the field was initiated from the Burgan Third
and Wara Sand reservoirs in early 1946. The Greater Burgan
Field is separated into three producing areas - Burgan, Magwa
and Ahmadi. These producing areas are arbitrary surface
boundaries affecting only well naming. No structural,
geologic or reservoir features distinguish these areas. The
Wara and Mauddud reservoirs are separated vertically from
the remaining reservoirs by extensive carbonate and shale
intervals. Extensive faulting does allow communication
between the various sand units and all the reservoirs share a
common original oil-water contact (4,471 feet sub-sea) and
initial pressure (2,100 psia at 4,000 ft sub-sea).
For many years the wells in the field produce dry oil and
as water production increases in any well, the perforation will
be plugged back and producing perforation moved up. But as
the field became more mature the water production continues
to increase. Since the late-80’s water production has steadily
increased from negligible amounts to over 250,000 bwpd. This
effluent water has historically been disposed of through the
use of evaporation pits. These are large size ponds where
evaporation takes place. Several issues arise as more water is
disposed to these pits. Any presence of oily layer on the water
surface will prevent evaporation. Moreover, during the cooler
months the rate of evaporation decreases significantly. With
increasing water production, we need to keep increasing the
size of the pits. Moreover, since the pits are not lined, it is felt
that there is always risk of water leaking to the ground. These
issues as well as the increased water production make the
evaporation pits rapidly become incapable of handling the
water. In response to the need for a more environmentally and
operationally acceptable water disposal alternative, Water
Disposal Team was formed in early 1995. The Objective of
the team was to evaluate a viable alternative for subsurface
disposal of the effluent water.
Fig. 1- Geological introduction for Burgan Fields
Pilot Injection
Based on the reservoir analysis, the team decided that the best
reservoir to inject water is the Burgan Fourth Sand. This sand
is below the main producer, which is the Burgan Third Sand.
The Fourth Sand has a very high permeability and is
connected directly with the productive zones. During the
review, core analysis was performed on the Fourth Sand.
Besides the routine core analysis, special core analysis such as
pore throat measurement was also conducted. This work,
together with the effluent water analysis, formed the basis for
the team’s recommendation for water quality needed. The
water criteria can be summarized in the Table (1) below.
Table 1 - Target – Settings for Water Quality Parameters:
Parameters Quality
Total Oil in Water (ppm vol.) 50 (max)
10 (max) – 10
Total Suspended Solids –
microns particle
TSS (ppm wt.)
size
Oxygen (ppb) 50
Water Quality Ratio (RWQ) 1000
Further evaluation was planned through a pilot injection
well. Well BG-502 was drilled and completed as a Fourth
Sand disposal pilot well in January 1996. Disposal of the
current effluent water commenced in September of the same
year. Rates rapidly declined until the well was suspended due
to formation plugging. Samples back flowed from the well had
very high oil content. The well was left shut in until March
1997 when another attempt to dispose untreated effluent was
made. Again, the well plugged off (after only 20 hours).
Various attempts to inject water with different water quality
took place in the field. All of them failed due to plugging of
the well. The well remained shut-in until it was back flowed
with nitrogen December 1997. Heavy viscous oil was flowed
from the well and the flowline was found to contain heavy oil.
Despite the plugging problems, valuable injectivity and water
quality data was obtained. This, along with the water quality
survey and core flood work, showed that water quality was
critical for Fourth Sand disposal. Continuous control of water
quality is critical to maintain injectivity.
Control of water quality can be achieved though effective
performance monitoring and facilities optimization using the
Water Quality Ratio method. The Water Quality Ratio (Rwq)
is a technique to measure the injectability of water. The water
quality ratio is a measure of how the contaminants in the water
interact to impair injectivity. Rwq is determined using a
standard NACE practice (TM-01-73) using a standard
Millipore slope test. The major benefit of using the water
quality ratio is that a numerical value for water quality can be
determined. This numerical value can be used as a
performance target and the Rwq used as a monitoring and
trouble shooting tool. It is important to note that the Rwq is
limited as a numerical water quality target to waters that
IPTC 11551
contain less than 100ppm of oil. Above this concentration the
reliability /error range of the numerical value varies and hence
direct comparisons of water quality are difficult. Comparison
between the water quality ratio determined by Millipore filters
and the water quality ratio determined from the injection
decline was also made. Acceptable water will have a Water
Quality Ratio of 10,000 which approximately relates to less
than 50ppm of oil and less than 10ppm of solids.
Water Treatment Facility
In order to achieve consistent good water quality, two Effluent
Water Disposal Plants were recommended. These two plants
would be able to process all of the effluent water from all of
the gathering centers as well as from the tank farms. The
plants and its process flow can be described below:
• EWDP-1&2 capacity will handle (500 MBWPD) of
effluent water collected from 14 GCs –the North
Tank Farm (NTF) and South Tank Farm (STF).
• The dispatched effluent water from individual GCs
and Tank Farms are collected through an inlet
manifold (sized to handle 750 MBWPD) to fill 6
individual Balance Tanks with 120,000 Barrels
capacity and 8” WG design operating pressure.
• In order to avoid the ingression of oxygen from
atmosphere into the effluent water handled, the
Balance Tanks are blanketed with Fuel Gas (FG) in
between 2” – 4” WG operating pressure. Any excess
quantity of blanketed gas is routed to the individual
automatic spark continuous purge type smokeless
Flare Unit.
• The effluent water from Balance Tanks is pumped
through Booster Pumps into Nut-Shell type Filters to
achieve the desired water quality / quantity at the
outlet.
• Filter-requirements will provide removal of TSS
from the effluent water down to 10-ppm maximum
(normally less than 5-ppm) with removal of particles
10-microns and larger. In addition, removal of oil in
water will be down to 50-ppm maximum (normally
less than 20-ppm) and injectivity of water – Water
Quality Ratio (RWQ) of 10,000 minimum would be
achieved.
• The effluent water quality at the injection well heads
shall be less than 10-mg/l (Max) of TSS, 50-mg/l
(Max) of Oil in Water and 50-ppb (Max) of Oxygen
Content.
• Filtered water will be injected into the Disposal
Wells, through a Well Header (designed to handle 1
MMBWPD), by way of Disposal Pumps. Each
individual well has a designed flow requirement of
60,000 BWPD. The Well Header is sized to have
1350 psig pressure at the furthest Injection Well
Head. The individual Well Head pressure is
controlled through inlet Mechanical Choke Valves.
• Individual Balance Tanks are provided with Oil –
Separation Skimmers. The separated oil quantities are
then collected in the Recovered Oil Drum (150 bbl
Capacity).
3
• Chemical Injection system is included in the Plants
where Scale Inhibitor, Corrosion Inhibitor and
Oxygen Scavenger will be injected on a continuous
basis. Biocide will be added (by shock-dosing), in
weekly slugs, corresponding to the specified / final
dosage.
Lessons Learned From Other Field
While the design and planning of the effluent water disposal
system took place, another operation in the country was
finding success disposing water to Shuaiba formation. This
formation is below the Burgan field main reservoirs so we do
not have much experience in penetrating the formation. On the
other hand, the productive formations in the southern fields
operated jointly by KOC and Chevron are mostly below the
Shuaiba. Their experience during drilling shows that drilling
through the Shuaiba very frequently encounters drilling fluid
loss. This experience led them to try disposing effluent water
into the fractured carbonate reservoir. Moreover, they were
successful in injecting high volume water in those wells (up to
80,000 BWPD).
The Shuaiba is a karstified carbonate formation. The
formation is full of vugs and fractures resulted from
dissolution due to ancient underground water movement. The
dissolution leads to collapse and the creation of fractures
around the collapse area. The drilling of the disposal wells is
targeting the karst area in order to hit those fractures. The
collapsed area and fractures are the main mechanism for the
storage and transmibility of the water away from the wellbore.
The lesson learned from other field was then integrated
with the data collected and analyzed the Burgan field itself.
The analysis from the Burgan field includes review of the 60+
Shuaiba penetration, the 3D seismic and lost circulation
statistics from Drilling in the Shuaiba. Analysis of lost
circulation data confirmed what we learned from other field.
Nearly 80% of the drilled wells in Burgan Field experienced
circulation loss in Shuaiba.
Even though, the connectivity of the fractures is still
questionable the analysis shows that the disposal in Shuaiba in
Burgan is as promising as in other fields. Therefore, it was
decided to re-drill well BG-502 into the Shuaiba. The well was
sidetracked into horizontal completion in order to increase the
chance of intersecting the fractures. Available edge image
around BG502 shows both Karst and channel like features
similar to what have been seen in UG dip image. Most
Shuaiba penetrations in SEK do not seem to have hit these
features (Fig. 2).
4 IPTC 11551
Fig. 2 - BG-502 location related to Karst features shown in
3D seismic image.
Once injection into the Shuaiba was successful, the
injection plans would be revised accordingly. The Fourth Sand
would be kept as the long-term disposal target since the sand
offers the least risk in achieving acceptable disposal rates and
long-term storage capacity. As the mechanism for accepting
high rate in Shuaiba is through fracture, one of the main risks
associated with this is how the well can hit the fractures. If a
well could not hit fracture, injection into the carbonate matrix
would be very limited. Another risk associated with Shuaiba is
the storage capacity of the formation. We do not know if
eventually the formation would be filled up and injection
ceases due to high pressure.
The Shuaiba Pilot Well Performance
Guided by the 3D seismic, the horizontal sidetrack of the pilot
well was successful in hitting the fracture near a collapse area.
The drilling encountered formation loss as soon as the bit
came close to the collapse area. After initial testing showed
promising injectivity into Shuaiba, it was decided to have long
term injectivity test. Besides collecting injectivity experience
from this formation, the long term test would also help reduce
the load of the evaporation pits. A temporary plant was
constructed to inject water into this well. The plant consists of
a balance tank and injection pumps with no filtering units.
Injection pressure and water quality was monitored on a
continuous basis.
Over two years of injecting into the well, the Shuaiba
formation shows the ability of taking water at high rates
(50,000 BWPD) with almost constant well head pressure.
During the long term injection pilot, we gain a lot of
experience. One of the most encouraging conclusions coming
out from this pilot was that the water quality is less of an issue
in the Shuaiba compared with the Fourth Sand.
Long Term Disposal Strategy
Based on the success in BG-502, the injection system was
revised. Significant revision was mostly in the well design.
The design of the wells was converted into horizontal well
targeting the Shuaiba formation. The well locations were
selected to enable the wells hit the fractures nearby a collapse
area. The risk of not encountering natural fractures was
minimized by using a new 3-D seismic data that show karst
regions
Fig. 3 - (collapse features where fractures will be more
prevalent)
The horizontal well design was also intended to increase
the probability of encountering the fractures along the edge of
the karst. Fig (3) above shows that a horizontal well placed
along the edge of a collapse area will have higher chance of
encountering one of the fractures.
Another risk associated with Shuaiba is the storage
capacity of the formation. Shuaiba’s heterogeneity (lateral
continuity) and the top and bottom shales could form
boundary that prevent water from moving to other part of the
reservoir. However, it is possible also that the karsted regions
are open flow paths up into the Fourth Sand. The Shuaiba and
the Fourth Sand are separated by a layer of shale whose
thickness varies in different area of the field. It is suspected
that the shale is not a continuous and not forming an
impermeable seal between the two reservoirs making it
possible for water injected into Shuaiba to leak into the Fourth
Sand. If this happens, the storability of the Shuaiba formation
will practically be limitless. However, if the fracture network
in which the wells are injecting into is not connected with the
overlying Fourth Sand, the storage capacity might be limited.
Injecting a half million barrels of water per day over long
duration might cause formation fill up. In this situation, the
injection will stop due to high pressure.
To overcome injection problems due to the above risks, the
wells were designed to have the Fourth Sand as a back up
target. The primary reservoir target will be the Shuaiba which
should provide large disposal capacity and less sensitive to
water quality. The Fourth Sand, which should provide long
term water disposal albeit sensitive to water quality issue, is
easily accessible should it be needed. Fig (4) below illustrates
the completion design to achieve this objective.
IPTC 11551
Fig. 4 – Completion design to be achieved
The wells will be cased through to the base of the Fourth
Sand and completed open-hole in the Shuaiba. The trajectory
of the well was maintained that in the Fourth Sand the well is
less than 60o. Initial disposal will target the Shuaiba. Should
injection to the Shuaiba face problems either in rate or
pressure due to limited storage capacity, the Fourth Sand
could be perforated easily. Since the well is less than 60o in
the sand, adding perforation in the Fourth Sand can be done
with wireline perforation.
Drilling Result
Twelve wells were planned to be drilled in this project. All of
them were placed with the help of 3-D seismic to maximize
the chance of intersecting fractures. At the end of the 12-well
program, 11 wells were successfully intersecting fractures in
the Shuaiba and had complete circulation loss during drilling.
In one of the well, we were not able to hit any fractures even
with after two additional sidetracks were drilled into different
direction. This shows that even with a good 3-D seismic and
horizontal design, there is still a risk of not able finding
fracture. This well is planned to be completed into 4th Sand
formation.
We performed injectivity tests in some of the wells where
we had circulation loss. Most were tested for a short time
using available rig pumps, while one had longer test after the
rig moved out of location. The results of those tests show
similar injection performance with the pilot well BG-502. The
figure below shows the injectivity test results (Fig. 5).
5
Fig. 5 - Short injectivity test for horizontal wells in
Shuaiba
Disposal Start Up
Injection from the two plants started earlier this year. The
water quality coming out from the plant is kept with the
specification as described in Table 1, even though the result of
the pilot disposal well shows that the Shuaiba is more
forgiving toward lower water quality. So far we have been
injecting for several months without seeing any injection
pressure increase. The plan is to continue injecting into
Shuaiba and closely monitor the performance.
Conclusions
Effluent water disposal in the Burgan field shows that the
disposal into subsurface reservoir is the most environmentally
friendly alternative. Evaporation pits is a viable alternative
when the amount of water is limited and the disposed water is
oil free. Moreover, the pits should be lined to be sure that
water does not leak into the ground.
The experience also shows that a complete understanding
of subsurface injection requirement is very critical in the
correct design of the water treatment plant. Acceptable water
quality is a very important issue for successful subsurface
disposal. Core and effluent water analysis can help determine
water treatment required to have successful disposal system.
Moreover, Pilot disposal well can help confirm the design.
Acknowledgments
The authors would like to thank PO (EK) & FD (SEK)
Managements for their support.
References
1. Various internal company reports and documetations.