Selection and Successful Application of Jet Pumps in Mangala Oil field: A Case Study
Abstract: This paper describes the selection, field application and performance monitoring of jet pumps in the giant Mangala field situated in the Barmer basin in Rajasthan, India. The field contains more than a billion barrel of STOIIP (Stock Tank Oil Initially in Place) in high-quality reservoirs. The field was brought on production in August 2009 and is currently producing at a plateau of 150,000 bopd. Mangala field is characterized by multi-Darcy rocks with mix to oil wet characteristics. The oil is waxy and viscous… Show more
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The Mangala oil field, discovered in 2004 is one of the largest onshore oilfields in India. The field is divided into five reservoir units and contains approximately 1.3 billion barrels of STOOIP. The field currently produces around 175,000 BOPD. The oil is highly viscous, with high paraffinic content, a high pour point, high Wax Appearance Temperature (WAT), as well as high wax dissolution temperature. In addition, high CO2 content, sand production and a high water cut are some of the other notable problems. Keeping this in mind, a combination of innovative technologies had been envisaged right from the development and appraisal stage of the field. The technologies used have been reviewed from a flow-assurance point of view and possible reasons for the selection of these techniques over other methods are also investigated and presented.The waterfloods, EOR pilots, artificial lift systems as well as surface facilities have been designed and implemented keeping in mind the nature of the crude. From a flow assurance point of view, techniques such as hot water injection, coiled tubing heater string, jet pumps etc. have been used extensively. A 670 km long pipeline has been laid from the field to Bhogat in Gujarat for transporting the crude. This pipeline is the world's longest independent heated section pipeline and makes use of another innovation called Skin Effect Heat Management System (SEHMS). A careful examination of these techniques can help us gauge whether they can be put to use to handle similar crudes in other parts of the world. This being a review paper, the working methodologies of flow assurance techniques used for the Mangala crude and the reasons for their success are studied. The Mangala Field and the Mangala crudeThe Mangala field, located in the Barmer basin was discovered in 2004 and is estimated to have around 1.3 Billion barrels of Stock Tank Oil in Place. It is one of the most prolific oil fields of India. There are 5 reservoir units, with the Upper formation dominated by sinuous, meandering, fluvial channel sands and the Lower formation consisting of well-connected sheetflood and braided channel sands. The five units have been named FM1-FM5 from the top down.The sand properties are excellent, with porosities in the range of 21-28% and an average permeability of ~5 Darcy. Fig. 1 shows the Barmer Basin.The Mangala structure is a simple tilted fault block dipping at ~9° to the southeast. Fig. 2 shows the major faults. This structural interpretation is based on a 3-D pre-stack time migrated (PSTM) seismic volume and well data. The structural crest is at ~600mSS and the oil-water contact at ~960mSS. This gives a total oil column of ~360mSS.The Mangala crude is a waxy, sweet crude with an average API gravity of 27°, an in-situ oil viscosity of 9-22cp and live oil wax appearance temperature (WAT) ~6°C lower than average reservoir temperature of 65°C. Another major point that influences all aspects of process design is the high pour point of 40-45°C. The wax dissolution temperature (WDT) of this crud...
The Mangala oil field, discovered in 2004 is one of the largest onshore oilfields in India. The field is divided into five reservoir units and contains approximately 1.3 billion barrels of STOOIP. The field currently produces around 175,000 BOPD. The oil is highly viscous, with high paraffinic content, a high pour point, high Wax Appearance Temperature (WAT), as well as high wax dissolution temperature. In addition, high CO2 content, sand production and a high water cut are some of the other notable problems. Keeping this in mind, a combination of innovative technologies had been envisaged right from the development and appraisal stage of the field. The technologies used have been reviewed from a flow-assurance point of view and possible reasons for the selection of these techniques over other methods are also investigated and presented.The waterfloods, EOR pilots, artificial lift systems as well as surface facilities have been designed and implemented keeping in mind the nature of the crude. From a flow assurance point of view, techniques such as hot water injection, coiled tubing heater string, jet pumps etc. have been used extensively. A 670 km long pipeline has been laid from the field to Bhogat in Gujarat for transporting the crude. This pipeline is the world's longest independent heated section pipeline and makes use of another innovation called Skin Effect Heat Management System (SEHMS). A careful examination of these techniques can help us gauge whether they can be put to use to handle similar crudes in other parts of the world. This being a review paper, the working methodologies of flow assurance techniques used for the Mangala crude and the reasons for their success are studied. The Mangala Field and the Mangala crudeThe Mangala field, located in the Barmer basin was discovered in 2004 and is estimated to have around 1.3 Billion barrels of Stock Tank Oil in Place. It is one of the most prolific oil fields of India. There are 5 reservoir units, with the Upper formation dominated by sinuous, meandering, fluvial channel sands and the Lower formation consisting of well-connected sheetflood and braided channel sands. The five units have been named FM1-FM5 from the top down.The sand properties are excellent, with porosities in the range of 21-28% and an average permeability of ~5 Darcy. Fig. 1 shows the Barmer Basin.The Mangala structure is a simple tilted fault block dipping at ~9° to the southeast. Fig. 2 shows the major faults. This structural interpretation is based on a 3-D pre-stack time migrated (PSTM) seismic volume and well data. The structural crest is at ~600mSS and the oil-water contact at ~960mSS. This gives a total oil column of ~360mSS.The Mangala crude is a waxy, sweet crude with an average API gravity of 27°, an in-situ oil viscosity of 9-22cp and live oil wax appearance temperature (WAT) ~6°C lower than average reservoir temperature of 65°C. Another major point that influences all aspects of process design is the high pour point of 40-45°C. The wax dissolution temperature (WDT) of this crud...
This paper discusses the performance monitoring and optimization of large scale jet pumping in Mangala field, one of the biggest onshore fields in India. Mangala field is characterized by multi-Darcy sandstones, containing waxy and viscous crude oil. Currently, the field is producing at plateau of 150,000 BOPD. The base development plan for the field included hot water flooding; this also makes water heated up to 80 °C available at the well pads as power fluid for jet pumping. Jet pump was selected as the preferred artificial lift method in deviated wells, as it addresses all flow assurance issues arising due to high wax appearance temperature of Mangala crude. Jet pumps provide the required drawdown for sustained liquid production both at low and high water cut. With significant number of wells operating on jet pump, it has become crucial to monitor the performance and optimize for maximum efficiency application by varying operating parameters, changing the nozzle throat combinations and making other adjustments. Currently, Cairn is monitoring the real time jet pump operating parameters on a daily basis by virtue of DOF (Digital Oil Field). DOF has not only eased the tedious task of jet pump monitoring in bulk but also has reduced the response time to any failures/damage in the pump. Liquid handling capacity of the processing plant has become crucial with increasing field water cut and more jet pump installations. Jet pump performance optimization for maximum efficiency has now started to play an important role in not only reducing the burden of the processing facility but also in improving the production profile of the wells. This paper will discuss the use of a methodology based on an in-house developed algorithm for monitoring the efficiency of the pumps, with supporting field examples. This paper will also make an attempt to analyze the effect of different operating conditions on the pump performance curves published in the literature.
Chemical Qualification and Field Application of a Nondamaging Scale Squeeze Treatment in the Mangala Field
Significant production rate decline and a few ESP failures were observed in the Mangala field, onshore India, due to scaling. Scale inhibitor squeeze treatments were required to arrest the production decline and prevent additional ESP failures. The Mangala crude oil is extremely waxy, with a wax appearance temperature (WAT) of 62 o C and a reservoir temperature of 65 o C. This meant that prior to chemical application, fluids would have to be pre-heated to prevent wax formation and potential damage to the near wellbore area. The produced water chemistry included iron concentrations in the region of 5 -15 mg/l, which was related to the presence of significant quantity of siderite within the formation and which could have resulted in potential formation damage due to iron dissolution when applying pre-selected acid-phosphonate inhibitors. Additionally, the two main producing formations FM3 and FM 4 are produced from long horizontal wells completed with stand-alone screens. Chemical placement in the wells therefore proved to be a significant challenge, and treatments were designed to achieve placement across the water producing zones. This paper describes the squeeze chemical selection for minimisation of formation damage risks associated with treatments in this particularly challenging case study, with WAT close to reservoir temperature and the presence of reactive iron minerals. The impact that these factors had on both chemical performance and on the potential applicability of the selected chemicals is discussed. The paper also discusses pre-conditioning treatments pumped in these wells to regain productivity. The work also demonstrates how a combination of laboratory testing and treatment modelling has been used to minimise the potential for formation damage while at the same time maximising chemical treatment of the water producing zones. The detailed mineralogy and heterogeneity of the reservoir formations, the impact of production conditions and elevated iron on the performance of the selected chemicals are all described as well as the selection of alternative generic chemicals which were not poisoned by the increased iron. Initial field treatments have been conducted and preliminary results will also be presented which concur with the chemical qualification and treatment design Overview of Mangala FieldThe onshore Mangala field is located in the north-west part of India in the Barmer Basin (Figure 1). The field was discovered in January 2004. The main reservoir unit in Mangala field is the Fatehgarh group, which is a very high quality quartzose sandstone reservoir, with high net to gross, high porosity and multi-Darcy permeability. The Fatehgarh sand has been subdivided into the Lower Fatehgarh formation dominated by well-connected sheet flood and braided channel sands, and the Upper Fatehgarh formation dominated by sinuous, meandering, fluvial channel sands. Five reservoir units are recognized, named FM1-FM5 from the top downwards. FM1 and FM2 comprise the Upper Fatehgarh formation and FM3, FM4 and FM5 form ...
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