Encapsulated Scale Inhibitor Treatment

Abstract

Scale formation and deposition (CaCO3) in production facilities is a problem

encountered in the Ghawar Field in Saudi Arabia. The scale deposition causes
production loss and safety hazards. Downhole scale inhibitor squeeze
treatments have proven successful in controlling this scale accumulation.
However, weak producers (low oil rate and high water cut wells) could not be
squeezed due to the difficulty anticipated in re-starting production from these
wells because of the high volume of water normally needed to squeeze the
inhibitor into the formation. Starting in 1994, an alternative method (the
encapsulated inhibitor treatment) was tried for selected weak wells.

This paper presents the design of the encapsulated inhibitor treatment,

treatment procedure, a field case history with scale inspection results,
economical analysis of this treatment versus the regular downhole treatment
and the future plans. To-date, more than ten treatments have been performed in
Saudi Arabia. Regular visual inspection of selected wells revealed no scale
accumulation up to 24 months after the treatment. Current plans are to treat
more wells for further evaluation.

Introduction

Calcium carbonate CaCO3 scale is the most common scale encountered in the
Ghawar field production wells. Its deposition in surface and subsurface
equipment causes loss in oil production and major operational problems. The
scale control program was started in the Ghawar Field in 1986, and since then,
conventional scale inhibitor squeeze treatments have been successful in
controlling scale accumulations. Saudi Aramco field experience has shown that
weak oil producers, especially high water cut wells (WC >70%), when treated
using a conventional scale inhibitor squeeze, require several reviving attempts
before the wells can be put back on production and in some cases the wells
might remain dead. This is mainly due to the hydrostatic head created by the
large treatment fluid volumes normally pumped during a conventional
treatment where the inhibitor is squeezed into the formation to a predetermined
radius.
In 1994, a new scale inhibitor treatment "Encapsulated Inhibitor Treatment"
was introduced to Saudi Aramco. The main advantage of this treatment is the
placement of the treatment fluids in the rathole rather than squeezing it into the
formation. Therefore, the encapsulated scale inhibitor treatment is suitable for
the weak wet oil producers with high water cut. To-date, more than ten wells in
the Ghawar Field and an offshore field have been treated with the encapsulated
inhibitor, without any difficulty in bringing the wells back on production. Some
of these wells are being closely monitored for rescaling by performing regular
visual inspections. To date none of these treated wells have shown scale
redeposition after up to two years following the treatment of the first well.

Abstract

An alternative scale inhibition method using encapsulated scale inhibitor has

been successfully used to control calcium carbonate scaling in the Ghawar
Field oil wells of Saudi Aramco, Saudi Arabia. Field tests indicate that the
Ghawar Field requires a low threshold scale inhibitor concentration for scale
mitigation. The encapsulated phosphonate scale inhibitor treatment procedure
is thus ideally suitable for scale control in such fields. Since 1994, a total of 89
wells have been treated with this procedure. After more than five years of
treatment, there has been no reappearance of scale deposit on the treated wells
except for two instances of scaling. Low treatment cost and the resulting long
treatment life have provided an excellent incentive to treat more wet producers
using the encapsulated scale inhibitor treatment method instead of treatment by
conventional scale inhibitor squeezes. An additional benefit is realized from
this encapsulated inhibitor method when treating marginal high water cut wells
and wells located in low pressure areas by ensuring that the wells sustain flow
after the treatments without the need for extensive livening work.

This paper presents the results of a field case study where calcium carbonate
scaling was controlled using the encapsulated scale inhibitor treatment
procedure. Treatment design, job procedure, inhibitor return monitoring,
economic analysis and comparison with conventional squeeze treatments as
well as future applications are presented.

Introduction

Calcium carbonate is the most commonly encountered scale in the Ghawar

Field of Saudi Arabia. Due to the presence of high reservoir pressure (>2700
psi) with reservoir fluid containing 5-20% dissolved acidic gases (CO2 and
H2S), there is no CaCO3 scaling problem in the reservoir and at the bottom-hole
of the tubing. However, as the fluid moves up the production tubing, the
dissolved gases flash out of the brine as pressure is reduced. The loss of
CO2 results in an increase in fluid pH. This shifts the thermodynamic balance,
and results in the brine being supersaturated with respect to CaCO3. By the time
the nucleation and kinetics of crystal growth favor the scale formation, the
brine has reached the top 1000 feet and higher of the production tubing. The
CaCO3 scale formation is represented by the equation:

Ca2++2HCO3- CaCO3+H2O+CO2

Calcium carbonate scale formation has resulted in production loss and severe
field operational problems in the Ghawar Field oil producers. Since 1987,
conventional scale inhibitor squeeze treatments have been used to control this
scaling problem. All wet producers in the Ghawar Field require scale inhibitor
treatments to avoid production loss as well as expensive scale removal from the
producing tubing string, wellhead, manifold and flow-lines. Initial squeeze
treatment costs were very high due to high pumping cost, particularly since a
large number of wells had to be treated. An alternative scale inhibition method
was therefore sought to reduce the treatment costs. The first trial of an
encapsulated scale inhibitor treatment was performed in 1994 with encouraging
results. Consequently, more wells were treated using the encapsulated scale
inhibitor method in 1997 and subsequent years.

Low MIC

After monitoring residual inhibitor levels of the squeezed wells, it was

recognized that a low threshold scale inhibitor concentration or MIC (minimum
inhibitory concentration) requirement existed for the Ghawar Field.

ABSTRACT The Cerro Dragon field in Comodoro Rivadavia, Argentina

produces 42,000 m3/day (264,000 bbl/day) of oil and 590,000 m3/day (3.7
million bbl /day water) in 9 different districts. The field contains 3950
producing wells with more than 1000 ESP wells being treated for mostly scale
and some for corrosion. Due to a high bottom hole temperature 120C (~250F)
and moderate calcium levels, many wells have a tendency for downhole
calcium carbonate formation. More than 1000 wells are treated for
scale/corrosion and to minimize the complexity of logistics and cost factors, the
preferred control method is via the use of an innovative technology of a micro-
encapsulated product. This product is applied downhole via batch treatments
where it slowly dissolves offering long term scale or corrosion protection. This
paper will describe the chemical management system that reviewed such
factors as: statistical interpretation of the results, laboratory methodologies for
screening the products, software simulations to calculate (a) the amount of
encapsulated materials to be used per well, (b) the frequency of treatment, (c)
the economic analysis of this methodology. This paper will also describe the
iterative improvement process in comparing field results with the calculated
theoretical values. INTRODUCTION The Cerro Dragn is the main producing
oil field in Argentina. From the point of view of the production engineer, the
challenge of maintaining the integrity and flow assurance of these wells is not
in the severity of the problems, but rather the complexity of the operation and
the logistics of treatments. There are 3950 producing wells dispersed over an
area of 4000 km2 (1500 mi2) For many years there has been the need for
corrosion inhibitors and scale inhibitors technologies that would control the
problems of integrity and flow assurance in the producing wells. The treatments
needed to be both efficient and low logistics costs associated with the chemical
applications. Faced with these challenges, scale inhibitors, corrosion inhibitors
and biocides were developed as microencapsulated materials and had to meet
the following criteria: reach bottom hole, release slowly and be efficient in
controlling the different problems.

Abstract

This paper describes the development and testing of a solid, encapsulated scale
inhibitor for use in fracturing treatments. Data from laboratory and field tests
are reported. Laboratory testing with a continuous flow apparatus has yielded
inhibitor release rates under dynamic conditions. The inhibitor was tested to
determine the minimum inhibitor concentration required to inhibit the
formation of CaCO3, CaSO4, and BaSO4 scales in brine. Laboratory data were
used to determine the parameters of a mathematical model to predict the long-
term release rate of the inhibitor. Data from a treated well are compared with
predictions of the model.

Release-rate testing in a continuous-flow apparatus shows that an encapsulated

solid derivative of a phosphonate inhibitor has a sustained release profile.
Temperature (100 to 225 F) and brine strength have a small effect on the
release-rate profile. Coating the solid derivative makes it compatible with
metal-crosslinked fracturing fluids. The coating has a short-term effect on the
release-rate profile. The composition of the solid derivative has the greatest
effect on its long-term release-rate profile.

A comparison between the mathematical model proposed to describe the long-

term release rate of the inhibitor and actual data collected from a treated well
shows a large discrepancy, likely because most of the inhibitor is not in contact
with the water being produced from this well.
Introduction

A variety of scale inhibitors are available for use in oilfield applications,

including polyphosphate phosphate ester, phosphonate polyacrylic acid, and
polyacrylic acid derivative inhibitors. Most of these inhibitors are available as
liquids and can be applied by continuous addition or in squeeze treatments.
Polyphosphate inhibitors appear to be one of the few types available in a solid
form that can be combined with a hydraulic stimulation treatment. A solid
inhibitor that can be applied in conjunction with a fracturing treatment allows
two treatments to be combined, saving the operator time and possibly expense.

The objective of this paper is to describe our work in developing and testing a
solid scale inhibitor for use in fracturing treatments for wells with BHSTs up to
225 F. Several inhibitors were screened before three candidates were chosen.
These three inhibitors were tested to determine (1) their effectiveness to inhibit
commonly occurring oilfield scales and (2) their release-rate profiles in
continuous flow-release experiments.

A mathematical model was used to describe the release-rate profiles and to

predict the long-term behavior. Compatibility testing showed that solid
derivatives of these inhibitors interfered with metal-crosslinked fracturing
fluids. To abate this interference, a semipermeable membrane was used to coat
the solid derivatives. The following data is presented for the solid derivative
chosen for field testing:

- effect of the coating on a release-rate profile

- effect of brine strength on a release-rate profile

- minimum effective dosage of inhibitor required to inhibit scale formation for

calcite, gypsum, and barite scales

Results for one field trial are reported and compared to the mathematical
model.

Experimental

Equipment. The test system used to determine the release rate of inhibitors is
shown in Fig. 1. The system consists of an isolated reservoir of brine that
supplies the test column. The reservoir is made from Ampcoloy , and all tubing
in the system consists of stainless steel or nylon tubing. Several 12-in. columns
of 0.75-in. OD stainless tubing were used for testing. Nitrogen was used to
maintain the system pressure at approximately 200 psi.