SPE 143771

Temporary Zonal Isolation Minimizes Reservoir Damage During Workover

Operations in Ecuador
C. Del Rio, SPE, A. Boucher, SPE, F. Salazar, A. Milne, SPE, Schlumberger, and M. Robles, EP Petroecuador

Copyright 2011, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE European Formation Damage Conference held in Noordwijk, The Netherlands, 7–10 June 2011.

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
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Abstract
In Ecuador, the principal reservoirs are subhydrostatic, with permeability ranging from 100 to 2,000 mD and significant clay
content. The crude oils are prone to form emulsions in contact with completion fluids. After workover operations—pulling electric
submersible pumps (ESP) or recompleting a well—it is common to lose more than 1,000 bbls of completion fluid, resulting in a
20% to 50% reduction in production.

Fluid loss control pills containing sized particulate, such as calcium carbonate or sized salt, are frequently used to control the fluid
loss; however, a further treatment is required to remove the solids. Using this technique, 25 wells producing a total of 8,000 BPD
were worked over, after which the production decreased to 5,000 BPD.

The main challenges in developing a solids-free fluid loss control pill to control losses of completion fluid during a well
intervention are: a) the low, subhydrostatic (0.16 to 0.36 psi/ft.) reservoir pressure, b) high matrix permeability, and c) cleanup
when well is put on production. To overcome this, a highly viscous, polymer crosslinked fluid with an internal breaker was
developed to temporarily isolate the reservoirs. Using this fluid, it is possible to work over a well without losing fluid into the
reservoirs and having the associated loss of production.

In 15 wells worked over using the fluid loss control fluid combined with modified workover procedures, fluid losses were
controlled and production was maintained after the workovers. This technique also made it possible to selectively stimulate certain
intervals, increasing production. The total production prior to the interventions was 7,300 bpd. Afterward, it increased 27% to
9,250 bpd.

The fluid-loss control fluid, together with the new workover procedures, has now been adopted as a standard. It has proved an
effective means to protect the subhydrostatic reservoirs in mature fields during workover interventions.

Introduction
The loss of completion and workover fluids into productive zones is a major concern in high-permeability formations, especially
where the reservoir pressure is subhyrodstatic. This is the case in Ecuador, where the main producing reservoirs have this
condition, and production rates after workover operations are often impaired.

Fluid-loss control pills containing sized particulate, such as calcium carbonate or sized salt, have often been used. However, solids
invasion has negatively impacted the productivity of the wells and increased the costs of workover operations. Therefore, the
preferred solution in this case was to implement a low residue content fluid-loss system, which would prevent the loss of
completion fluid during the workover operation, but would break and flow back when the well is put back on production. In
addition, the fluid-loss control pill needed to be operationally simple to mix, have low friction pressure while pumping, and low
formation damage potential. Hydroxyethylcellulose (HEC) is known to have these characteristics (Parlar et al. 1995).
2 SPE 143771

The solution for this type of reservoir is the application of a non-damaging temporary gel system to isolate a producing zone, be it
a low pressure or high production well, to be able to treat other potential productive zones and/or correct problematic issues with
the well while minimizing the damage caused by completion fluid invasion into the initial pay zone. The case studies in this paper
will demonstrate the effectiveness of the HEC fluid-loss pill as a mean of isolating productive zones with little to no damage
during workover operations.

Fluid Chemistry
Transition metal ions, such as titanium and zirconium, have been used to crosslink HEC fluid systems. Difficulty in forming stable
crosslinks on HEC linear chains has limited its application in oilfield completion and stimulation operations. The titanium-
crosslinked systems suffer shear and thermal instability, leaving zirconium a better choice for crosslinker. The HEC requires a high
pH to be crosslinked by zirconium; the stability and strength depend on the pH value. In a general mixing process, an activator is
needed to raise the pH after the zirconium crosslinker is added. The gel will be more elastic and stable as the fluid pH increases. A
rubber-like crosslinked HEC gel can be achieved by adding NaOH as a crosslink activator. However, NaOH causes crosslinking to
immediately occur due to the rapid pH increase, and no delay can be obtained. To delay the crosslink, a slow OH-releasing
compound must be used. Magnesium oxide (MgO) is usually applied to accomplish the delay mechanism. Due to its low
solubility, the equilibrium pH value can reach 10.0 to 10.5 with MgO at room temperature. However, this pH level can only create
a weak crosslink for the HEC/Zr crosslinked system. The fluid-loss control capability of this system showed to be permeability-
dependent and spurt dominated leakoff, similar to crosslinked-guar systems, although the retained permeabilities in the invaded
region were significantly better than crosslinked-guar due to much lower residue content of HEC polymer. The inability of
creating a highly elastic and yet delayed crosslinked gel has been the major drawback for the usage of an HEC polymer (Chang et
al. 1998).

It was found that a pH of 12 to 13 is needed to render a crosslinked gel strong enough to stop fluid loss in high permeability
(>1000 md) formations with no indication of invasion of the pore-space (within % resolution). A chelating agent can be used to
raise pH beyond the equilibrium value that MgO can provide and still maintain the delay. The chelant rapidly dissolves in water
and raises the pH to 10.5 to 11.0. When a low MgO concentration is used, the early pH profile will be dominated by the chelant,
and the late pH profile will be dominated by the MgO dissolution. However, when a high MgO concentration is used, the chelant
has a minimum effect on the pH profile of the system, i.e., it will follow the pH profile given by the release of MgO, but the
equilibrium pH is much higher. Therefore, the delay mechanism at a high MgO concentration is not altered by the chelating agent,
and the crosslink strength is dramatically improved. The delay can be further achieved by overloading the Iigand that forms a
compound with zirconium (Chang et al. 1998).

The delayed crosslinked fluid system has excellent rigidity and elasticity. It can be used as a formation sealer or a chemical packer
for zone isolation. The gel can be broken by slowly released internal breakers as well as by external acid or an oxidizer soak.
Commonly used acid solutions, including hydrochloric, formic, acetic, and citric acids, are all effective external breakers for the
crosslinked HEC system (Fig. 1).

3.5
3
Time to break

2.5
(in hours)

2
150 F
1.5
1 200 F
0.5
0
10% HCL 10% Formic 10% Citric 10% Acetic

Fig. 1—External breaker efficiency for removal of crosslinked HEC pill. Testing results
from soaking 50 ml of pill in 250 ml of acid.
SPE 143771 3

Location, Geological and Reservoir Description

The study area is geographically located in the Eastern Basin of Ecuador, a jungle area in the Ecuadorian portion of the Amazon
basin (Fig. 2). The block studied in this paper is in the Amazon rainforest. This area has been subject to major tectonic events
related to the convergence of the South America and Nazca plates. The Ecuadorian Eastern Basin is part of the Upper Amazon
River and is contiguous with the Putumayo Basin of Colombia and the Maranon Basin of Peru (Ziritt et al. 2005)

Fig. 2—Map of Ecuador showing the Eastern Region

The Eastern basin represents a back arc sedimentary sequence where the Paleozoic and Mesozoic sediments were deposited,
overlaying the Triassic-Jurassic basement. The stratigraphic column of the Eastern basin illustrates the U and T intervals of the
Napo formation, which represents two cycles of regression and transgression (Fig. 3 and 4). The field structure is bounded
eastward by a steep north-south trending reverse fault that has 350 ft of vertical displacement at its greatest offset and dies out at
both ends. The U and T formations were deposited by fluvial/estuarine river systems near a NE-SW coastline. Incised valleys
formed and were later filled by estuarine deposits. A strong NE-SW structure inherited from the pre-Cretaceous era controlled the
location of incised valley and channel systems.

Fig. 3—Stratigraphic column of the Eastern Basin

4 SPE 143771

Fig. 4—Cycles of Regression and Transgression

The T and U formation, consisting of the Inferior and Superior flow units, are part of the big Napo formation (Ohen et al. 2004). At
depths ranging from 7,000 to 10,000 ft, the Napo formation typically has permeability estimating from 100 to 2,000 mD and
temperatures ranging from 165 to 210 degF. It is an underpressurized reservoir with average reservoir pressures in the range of
1,800 psi. The oil is typically between 22º and 35º API with a GOR of 230 to 340 SCF/STB.

Losing Completion Fluid and Production

In Ecuador, many reservoirs are low pressure (subhydrostatic) and highly permeable. The loss of completion fluid during
workover operations frequently results in fines migration and the creation of emulsions.

In a study of 23 wells from five different fields in Ecuador, it was concluded that the loss of completion brine during workover
operations damaged the reservoirs and production decreased by an average of 30% after a well was worked over, and up to 50% in
some cases (Fig. 5). It was also concluded that the use of fluid-loss control pills with sized solid particles, in many cases, damaged
the reservoirs due to solids invading the matrix.

Fig. 5—Production before and after workover operations using conventional techniques.
SPE 143771 5

Controlling Los sses and Maintaining Pro oduction

A way
w to maintaiin production byb applying ann effective soliids-free, crossllinked polymeer system that could be spottted across the
low
w pressure and//or highly perm
meable reservoir to temporariily isolate and protect them fromf the fluid invasion
i durinng a workover
opeeration—this was
w extremely im mportant for thhe success and revitalization of the fields inn Ecuador.

Prevventing the loss of completiion fluid into the reservoir minimizes

m posssible formatioon damage andd loss of produuctivity. This
soliids-free pill proovides (Parlar et
e al. 1998):

- Wide rannge of applicatiion: temperaturres of 90 to 2990 degF

- Applicabble in permeabiilities of 10 to 2,000 mD
- Long-term stability con
ntrolled by inteernal or externaal breakers
- High retaained permeabiility due to the use of low-ressidue polymer
- Compatibbility with mosst brines and foormation fluidss

Casse Histories
A series of differeent case studiess under differennt scenarios are defined below
w.

Casse 1
Thee crosslinked HEC
H pill was used in a fieldd located in thhe Ecuadoriann eastern plain.. The well is a vertical oil well
w that was
prodducing 690 bpd with 4% basic sediment annd water (BS&W W) from a formmation of arouund 10,000 ft. The
T bottomholee temperature
wass estimated to be
b 210 degF an
nd the bottomhhole pressure leess than 1,500 psi.
p

A tuubing-casing leeak repair job was required. Considerationn of using a fluuid-loss controll pill was baseed on the fact that
t excessive
fluid loss would occur
o based onn experience whhen intervening with the worrkover rig. Thee formation hadd an estimatedd permeability
valuue of more thaan 200 mD. Th herefore, whenn the well wass worked over,, a HEC fluid loss pill was used u to contol losses to the
form
mation. The syystem was desig gned to be stabble and control losses for 72 hours,
h and cleaanup was to be done afterwarrd by utilizing
an internal
i breakeer.

2 bbl pill was spotted at 3.5 bpm

A 25 b without encountering significant frictiion pressure, annd the fluid losss was successffully stopped.
Thee pill was desiggned to contro
ol losses over a 72-hour periood. The well wasw put on prooduction after thist time and produced
p 724
bpdd with 7% BS& &W and had neeither issues noor difficulties inn cleanup (Fig.. 6).

Bassed on past expperiences in th

he area, if this technique haddn’t been used,, the workoverr rig would havve taken doublle the time to
com
mplete the job.

Fig. 6—HEC
6 viscous pill spotted to repair tubing-ca
asing leak.
6 SPE 143771

Case 2
An HEC pill was used to control fluid loss in a well located in the Ecuadorian jungle. The oil well was producing 150 bpd with
2.5% BS&W when an electric submersible pump (ESP) failure required the well to be shut in and worked over. During the
workover, the pay zone was reperforated and tested at 336 bpd with 27% BS&W. The formation’s permability was estimated at
250 mD, reservoir pressure at 1,600 psi, and bottomhole temperature at 215 degF.

To avoid further losses of completion fluid to the formation while replacing the ESP, a 20 bbl of HEC viscous pill was spotted
across the perforated interval successfully protecting the zone. The system was designed to have one week of stability on fluid loss
control and cleanup afterward by pumping a hydrochloric acid soak.

When the well was put back on production after the workover, which lasted 7 days, the well produced 520 bpd with 5% BS&W.
Production after a year had stabilized at 459 bpd of fluid with no change in water cut (Fig. 7).

Fluid-loss pill
treatment

Fig. 7—HEC pill pumped during the workover operation to repair an ESP.

Case 3
An oil well was producing 504 bpd with 35% BS&W when a well maintenance issue required the well to be shut in. The well’s
depth was around 9,000 ft, estimated permeability at 150 md, reservoir pressure of 1400 psi and bottomhole temperature of 200
deg F. A 19 bbl of HEC viscous pill was spotted across the perforated interval successfully protecting and isolating the zone of
interest. The system was designed to have one day of stability on fluid loss control and cleanup afterward by internal breakers.

After the workover, the well was put back on production the next day with net production of 480 bpd with 34% BS&W (Fig. 8).

Fig. 8—HEC pill designed for 1-day stability.

SPE 143771 7

Results
The information from fifteen wells worked over using the fluid loss control system was gathered for this paper with pre- and post-
production results, where the application of HEC pills showed production increases of 1,950 bpd compared to pre-treatment (Fig.
9). Along with the increased production, the workover operation times and costs were reduced.

1000

900

800

700
Production, bbl/d

600

500
Production before WO
400
Production after WO
300

200

100

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Well

Fig. 9—Production before and after workover operations after implementing the solids-free viscous pill in 15 wells.

Conclusions
The HEC pill system has proved to be successful in controlling loss of completion fluid when working over low pressure wells.

It is possible to design solids free lost circulation pill with a controlled break time, capable of preventing losses at high
temperatures even when there is a substantial overbalance.

In many cases the loss of completion fluid when working over low pressure wells greatly increases the cost of the workover
operation and results in lost and deferred production.

To minimize the time and cost of a workover operation, there needs to be contingency plan in the program to avoid losses during
the workover operation.

Preventing losses during workover operations is most likely one the cheapest and most cost effective ways of maintaining
production in a mature field.

References
Chang, F. F., Ali, S.A., Cromb, J., Bowman, M. and Parlar, M. 1998. Development of a New Crosslinked-HEC Fluid Loss Control Pill for
Highly-Overbalanced, High-Permeability and/or High Temperature Formations. Presented at the SPE Formation Damage Control Conference,
Lafayette, Louisiana, 18-19 February. SPE 39438.

Parlar, M., Nelson, E. B., Walton, I.C., Park, E. and DeBonis, V. 1995. An Experimental Study on Fluid-Loss Behavior of Fracturing Fluids and
Formation Damage in High-Permeability Porous Media. Presented at the SPE Annual Technical Conference and Exhibition, Dallas, Texas, 22-25
October. SPE 30458

Ziritt. J.L.2005. Mature vs. Unknown, Where Are We Really? – An Ecuadorian Field Case. Presented at the SPE Latin American and Caribbean
Petroleum Engineering Conference, Rio de Janeiro, Brazil, 20-23 June. SPE 97636

Ohen, H.A., Erian, A., Ali, L., Guzman, D., Guerrero, O., Ochoa, J., and Valdivieso, L. 2004. Integrated Reservoir Study of Shushufindi Field
– Dynamic Modeling. Presented at SPE/DOE Symposium on Improved Oil Recovery, Tulsa, Oklahoma, 17-21 April. SPE 89465.