SPE-169709-MS

Challenges in 'Surface Facilities Implementation' for a Full field Polymer

Flood Project

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

Premashis Bhaumik and Santosh Mohanram, Cairn India Limited

Copyright 2014, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE EOR Conference at Oil and Gas West Asia held in Muscat, Oman, 31 March–2 April 2014.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers 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 SPE copyright.

Abstract
This paper discusses the key challenges in Surface Facilities implementation for a Full Scale Polymer Flood
Project. The key challenges discussed include (a) availability of limited technology for high concentrated polymer
dissolution, (b) transfer of high viscous Polymer Mother Solution with minimum viscosity loss, (c) water quality
issues, (d) designing a feasible supply chain strategy for polymer logistics and (e) handling back-produced polymer
associated with the well fluid.

Introduction
Cairn India Ltd (CIL) is the operator of the Rajasthan Block located in the northern Barmer basin of Rajasthan
state, India on behalf of Joint Venture. The field is currently developed with hot water flood, using injection water
heated up to 75~85°C. However, due to the unfavorable mobility ratio of the crude oil with respect to water, CIL is
currently implementing Chemical EOR process (Polymer flood) to increase the oil recoveries.

Enhanced Oil Recovery (EOR) techniques are methods of increasing recovery from oil fields. Historically, EOR has
been considered as a tertiary recovery method, to be applied at the later stage of field life after primary and
secondary recovery from the reservoirs. Cairn recognized the potential for EOR at an early stage of development
for its Mangala fields. The reservoir quality, oil properties and ambient temperature make these fields ideal for the
application of chemical flooding EOR methods. Due to high viscosity contrast between oil and water, the injected
water is not able to displace the oil very efficiently, resulting in some bypassed oil under a conventional water
flooding scheme. By adding chemicals such as polymers, the injected water attains a viscosity close to that of the
oil, which improves the displacement and overall sweep.

Based on the positive response of the EOR pilot in the Mangala field, a full field polymer flood development plan
has been prepared for Mangala. The full field polymer flood when implemented will be one of the biggest polymer
projects of the world. Following positive results from the EOR polymer pilot, in FY2012, Cairn booked 70 mm bbl.
as gross proved and probable reserves.

Proposed facility

The current facility set up consists remote well pads (having both producing and injection wells) connected with the
production fluid and injection water network. Well fluid gathering, processing, oil export and injection water
pumping facility is located in a Central Processing Terminal within the proximity of the field.

To achieve polymer flood, a range of options were evaluated including dedicated polymer injection facilities per
well pad, polymer injection facilities to serve a cluster of well pads and a single Central Polymer Preparation
Facility at various levels of concentration of polymer solution. The concept of a Central Polymer Facility (CPF) was
found to be the most economic and most attractive operationally.
2 SPE-169709-MS

The Concentrated polymer solution shall be transferred from this Central Polymer Facility (CPF) to the various
existing well-pads (15 nos.) via a new pipeline distribution and once at the well pads the concentrated polymer
solution shall be diluted with the injection water at a specific dilution ratio and injected into the individual wells
through the existing injection water lines after boosting the pressure. Augmentation of some of the existing facilities
and addition of some new surface facilities are also envisaged at the Central Processing Facility for handling the
back-produced polymer associated with the well fluid. The typical scheme of the proposed facility is shown below.

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

Figure-1 – Typical Proposed Injection Facility Overview

Key Challenges in Surface Facility Implementation

a) Availability of limited technology for high concentrated polymer dissolution

Large volume of mother solution requirement for Mangala polymer project has driven the requirement of higher
concentrated mother solution. The main driver for choosing higher concentration is to reduce the plant size for the
Central Polymer Facility (CPF) and also to use the existing water injection facility.

However, the Industry has only two standard technologies for dissolving polymer into water: the eductor type or
slicing/mixing units, both of which have been used in many polymer projects around the world.

Conventional eductors work on the venturi principle and allows for the mixing of the polymer powder and water up
to certain concentrations. Slicing units on the other hand reduce the polymer particle size by a cutting head and
thereby reducing the polymer particle into a uniform size thus allowing for significantly higher polymer
concentrations without affecting the polymer molecular weight.

To address the challenge of limited full field scale application of these technologies, workshop trial from 3 polymer
equipment manufacturers was carried out at a workshop scale replicating the full field features of the polymer
dissolution. The intent of the test was to verify that the polymer dispersion equipment has the ability to prepare high
concentration solution (for minimum 2 hours) without any interruption and to subsequently verify the viscosity and
filter ratio. The results were then cross checked with lab prepared solutions

Both Slicing and Eductor arrangements were found to be suitable to produce higher concentration of polymer
solution and viscosity and dissolution matched with that of laboratory results
SPE-169709-MS 3

b) Difficulties in Design of high viscous Mother Solution transfer system

A non-Newtonian fluid is one whose viscosity at a given temperature is dependent on rate of shear. The
Concentrated Polymer Mother Solution is a non-Newtonian fluid where the rate of shear is proportional to the
power of the shearing stress, which means that its viscosity varies with shear rate.

The pressure drop equation was derived from the commonly used relation between skin friction parameters,
Reynolds number & friction factor relationship. The values of the coefficients K and n in the pressure drop equation
were determined by a lab analysis of the polymer solution (simulated to field condition) which measured viscosities
at different shear rates and plotted the values on a log-log plot. Refer to Annexure-1 for more details.

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

One of the important considerations in transporting the high viscous Polymer Mother Solution through the pipeline
system is to eliminate permanent mechanical degradation (which causes viscosity loss) by use of long radius
bends, low shear fittings, positive displacement pumps etc. These will maximize the shear thinning properties and
thus avoid avoid excessive pipeline friction losses

To validate the theoretical calculation as done above, a work shop model was made to study actual flow
parameters by using mother solution and line size pipe since there is very minimum field reference data available
globally for such flow scenario. Viscosity degradation was studied to understand likelihood of any impact of 5-7 km
transfer of high viscosity fluid. The model of the flow loop test is shown below

Figure-2 – Flow Loop Test Setup

The sample pressure drop vs. velocity curve based on the loop test is shown below.
4 SPE-169709-MS

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

Figure-3 – Flow Loop Test – Pressure Drop vs. Velocity Curve

The result removes the uncertainty with respect to the design of pipeline for intrafield pipelines for highly viscous
mother solution transfer necessary for the project.

c) Water quality issues

Maintenance of injection water quality is a primary requirement for polymer development. To sustain good well
bore injectivity with a more viscous fluid (as compared to water flood) is critical for the success of the project.
Reduction of oil in water, solid particle, oxygen content, bacteria count is critical for viscosity management. Several
initiatives including lab and field investigation has been needed to conclude specific measures. The higher chloride
in formation water and high injection temperature were two detrimental factors for maintaining viscosity at the well
head. Lab verification was done to derive high dosage of polymer for obtaining necessary well head viscosity.
Low oxygen and suspended solids level will be ensured for polymer solution preparation and injection. The
extended polymer pilot at Mangala has verified the concept suitability. For polymer mother solution preparation, it
was decided to use make up water from aquifer this will not any contamination of oil in water and TSS. However,
inlet filtration has been considered to assure feed water quality.

d) Designing a feasible supply chain strategy for polymer logistics

The full field implementation of the project warrants handling a huge amount of polymer. The sourcing polymer will
need from international supplier across the globe. Thus designing an effective supply chain for ensuring continuous
availability of the polymer is a key.

The key parameters that affect the design of the supply chain strategy include: 1. Calculation of accurate Inventory
Requirements based on Mode of Transport and Medium of Movement (finding the safer, more reliable and less
expensive option) and Port of import (capacity, infrastructure & connectivity of the same) and 2. Operating Model

1. Calculation of accurate Inventory Requirements - Economic order quantity is the optimal order quantity that
minimizes the total operating cost for the company. The sum of annual ordering cost and inventory holding cost
has minima at EOQ level thereby, optimising the supply chain operations cost.

Safety stock is the inventory maintained at warehouse to compensate for any variations in lead time of supply
and variations in consumption of the material and run seamless operations in such scenarios. Another critical
parameter is the safety factor requirement (98% is used commonly) based on which supply chain is designed.
Thus a detailed analysis of lead times, demand variations, transit time variations, number of suppliers etc. is
warranted for calculating the inventory requirements. Sample calculation of EOQ and safety stock based on
lead time and demand standard variation is shown in Figure-4.
SPE-169709-MS 5

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

Figure-4 – Sample calculation of EOQ and safety stock

Other key considerations for the supply chain design include (a) Mode of transport of Movement - evaluation
based on distance, complexity, safety, reliability, doability of service provider, cost and container turn around
(b) port of import – congestion, connectivity with port of origin, container traffic handling and CFS infrastructure

2. Operating Model - The choice between Logistics operations outsourced to a single third party logistics
provider or Logistics operations outsourced to multiple vendors or Logistics operations to be managed in-
house - parameters including cost effectiveness, performance reliability, capability, experience, supply chain
ownership & ease of management need to be analysed in detail for arriving at the correct choice.

Figure-5 – Typical Operating Model Assessment

e) Handling back-produced polymer associated with the well fluid.

While polymer flood is effective in increasing the oil production, it seriously impacts in processing of the
produced emulsion. The polymer breaks out with the production emulsion & changes its physical and chemical
characteristics. These changes affect the processing methods and the process conditions; reduce the
efficiency of the current equipment technology.

Polymer flooding makes the viscosity of the produced water increase. This increases the binding power
between oil and water and decreases the floating up speed of oil drops and the settling down speed of the
water drops. The increase in viscosity of the water phase makes the emulsifying strength of oil and water
increase, thus making demulsifying difficult.

Figure-6 – Assessment dimensions for handling back-produced polymer

6 SPE-169709-MS

Desk top study indicates that demusifier, heating and processing with higher water cut (> 60%) will manage
emulsion handling. Lab study were carried out with sheared polymer (as in case of actual field due to artificial
lift) supports this observation in general. Impact of polymer in oil has been observed to be manageable through
adequate settling time currently available in the system.

Summary of Separation Test Matrix

65 deg C 80 deg C
-1 -1 -1 -1
Water cut 42,600 s 24,000 s 24000 s 42600 s
1 minute 1 minute 5 minute 1 minute
ü

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

10 x x x

ü ü
30 x x
ü ü
50 x ü
ü
60 ü ü ü
ü
70 ü ü ü
Figure-7 – Summary of oil–water gravity separation with back-produced polymer

Analysis of individual equipment considering plant specific operating scenario and future process flow
requirement were extensively studied. Back produced polymer return fluid from polymer pilot were also
handled in a separate train to study various impacts

To achieve the low water content required for export, the oil water emulsion after bulk water gravity separation
is sent to electrostatic coalescer. A series of test was performed with varying degraded polymer concentration.

Figure-8 – Electrostatic treater performance with degraded polymer

The challenges will mostly be on the produced water processing train as inlet Oil–In-Water (OIW) is likely to go
up significantly due to the increase in the emulsion band. The current produced water deoiling set up will
underperform significantly in presence of viscofied water. Further prevailing self-buoyant FeS particle will pose
severe challenge for meeting reinjection specification.

Lab work was carried out to understand particle size distribution both on line and using a coulter counter.
Produced water skim tank with vendor proprietary design and set up were reviewed. Non Newtonian laminar
multiphase Lagrangian approach as well as conventional single phase Algebraic slip model approach was
competitively reviewed. It was found that efficient removal of 6/12/16 micron median size with a fluid viscosity
of 3 to 5 cP is feasible. It was established that a gas floatation based skim tank with long residence time will be
able to handle project specific challenges of viscofied water with high OIW and mixed with oil free suspended
solid with very fine self-buoyant particle (Fes). The required OIW specification can be achieved with a new
proposed tank and followed by a Dissolved Gas Floatation unit as a secondary treatment. The final polishing
filter will be the tertiary treatment set up.
SPE-169709-MS 7

The conceptualizing of primary and secondary treatment were a significant challenge as retrofitting changes in
process set up in an existing plant is always difficult. It was noted that the performance of deoiling will
significantly vary due to the process dynamics involving variation in particle size, viscosity, temperature, oil
ppm, velocity & retention time, gas bubble size (in floatation device), interfacial elasticity and coalescence.

During extensive analytical lab work, few brands of polymer were used to study various factors (viz, clouding
due to precipitation, shear stability, enhancement of water drop out, effect of heat exchanger and scaling,
performance in oil water separation). Chemical injection to mitigate bacterial activity, to maintain low Oxygen
level and to improve coalescing fine oil globule in produced water system will also be a key element of the
overall process.

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

Possibility of reducing the viscosity of back produced polymer have been studied. In case of Mangala,
significant shearing of polymer across reservoir and in artificial lift has been demonstrated. Thus the option of
using shearing devices or chemical injection for reducing the viscosity has been screened out. The makeup
water from aquifier (to meet the voidage requirement) will be routed upstream of water treatment train to avail
dilution benefit.

Acknowledgements:

The authors would like to acknowledge and thank the following people and organizations:

1. Ganesan Rajagopalan, Director Projects, Cairn India Limited for key business support and strategy
guidance
2. Polymer flow loop test (June 2013) - Cairn internal report carried out with SNF , France
3. Investigative study on EOR carried out by Oil Plus, UK
4. Supply Chain Strategy review , Cairn internal work with market intelligence inputs from external
consultants

References:

1. Sizing pipe for Non Newtonian flow – W.L McCabe, J.C Smith, Peter Harriot, Unit Operations of Chemical
Engineering,  Calculating liquid regimes, Blazo Ljubicic, Brown Fintube-Koch Company, USA
8 SPE-169709-MS

Annexure-1: Pressure Drop Calculation for Non-Newtonian Fluid

The Polymer fluid is a NON-NEWTONIAN FLUID for which the rate of shear is proportional to the power of the
shearing stress.

Step 1: Defining the Pressure drop equation

This equation is derived from the commonly used relation between skin friction parameters, Reynolds number &
friction factor relationship.

Downloaded from http://onepetro.org/SPEOGWA/proceedings-pdf/14OGWA/All-14OGWA/SPE-169709-MS/1544092/spe-169709-ms.pdf/1 by Kuwait University user on 14 October 2022

The equation is as follows:

ΔP - Pressure drop, Pa ; qV - Flow rate, m3/s; L - Pipeline length, m ; D - Pipe inside diameter, m ; K - Consistency
n
Coefficient, Pa·s ; n - Liquidity Index ; µ - viscosity ; ϒ – shear rate

Step 2: Calculation of Pressure Drop based on K and n from Lab

Lab analysis of the polymer solution (simulated to field condition) measured viscosities at different shear rates and
plotted on a log-log plot

The intercept of the plot is the value of K and the slope of the plot is the value of n.

By substituting the values of K and n obtained from the plot above in the pressure drop equation, the pressure drop
can be calculated.