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Potassium Formate from Addcon An Oilfield Success Story : 1995-2014 Potassium formate from Addcon
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Potassium formate from addcon

Sep 06, 2014

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John Downs

Potassium formate brine and powder production by Addcon, 1995-2014
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Page 1: Potassium formate from addcon

Potassium Formate from Addcon An Oilfield Success Story : 1995-2014

Potassium formate from Addcon

Page 2: Potassium formate from addcon

Formate brines

Potassium formate from Addcon

Sodium formate

Potassium formate

Cesium formate

Solubility in water

47 %wt 77 %wt 83 %wt

Density 1.33 g/cm3

11.1 lb/gal1.59 g/cm3

13.2 lb/gal2.30 g/cm3

19.2 lb/gal

Formates are also soluble in some non-aqueous solvents

Page 3: Potassium formate from addcon

Solubility of cesium formate in various solvents

Potassium formate from Addcon

Solvent Solvent density (g/cm3)

Cesium formate

solubility (% w/w)

Solution density (g/cm3)

Water activity of solution

Water 1.00 83.0 2.30 0.25

Monoethylene glycol 1.11 82.9 2.22 0.05

Diethylene glycol 1.12 57 1.66 0.20

Triethylene glycol 1.13 33 1.38 0.11

Glycerol 1.26 63.8 1.96 0.08

Page 4: Potassium formate from addcon

Formate brines – Discovery and qualification

1987 1988 1989 1990 1991 1992

Shell patent the use of formates as

polymer stabilisers

Shell discover cesium formate

brine

Shell R&D in UK study the effect of sodium and potassium formates on the thermal stability of drilling polymers

Shell R&D in The Netherlands carry out qualification work on formate brines as deep slim-hole (HPHT) drilling fluids

Shell publish first SPE papers on formate brines

Start of Shell’s deep slim-hole drilling

R&D programme

Potassium formate from Addcon

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The main application for formate brines is in High-Pressure High-Temperature gas wells

Low-solids heavy fluids for deep HPHT gas well constructions

• Reservoir drill-in • Completion • Workover • Packer fluids • Well suspension • Fracking

Used in hundreds of HPHT wells since 1995, including some of Europe’s deepest, hottest and highly-pressured gas reservoirs

Potassium formate from Addcon

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The economic benefits provided by formate brines in HPHT gas field developments

Formate brines improve the economics of HPHT gas field developments by :

• Reducing well delivery time and costs

• Improving operational safety and reducing risk

• Delivering production rates that exceed expectations

• Providing more precise reservoir definition

Potassium formate from Addcon

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42 deep HPHT gas fields developed using potassium formate brine , 1995-2011*

Country Fields Reservoir Description

Matrix type

Depth, TVD (metres)

Permeability (mD)

Temperature (oC)

Germany Walsrode,SohlingenVoelkersen, Idsingen,Kalle, Weissenmoor, Simonswolde

Sandstone 4,450-6,500 0.1-150 150-165

Hungary Mako , Vetyem Sandstone 5,692 - 235Kazakhstan Kashagan Carbonate 4,595-5,088 - 100

Norway Huldra ,NjordKristin,Kvitebjoern Tune, ValemonVictoria, Morvin, Vega, Asgard

Sandstone 4,090-7,380 50-1,000 121-200

Pakistan Miano, Sawan Sandstone 3,400 10-5,000 175

Saudi Arabia

Andar,ShedgumUthmaniyah Hawiyah,Haradh Tinat, Midrikah

Sandstone and carbonate

3,963-4,572 0.1-40 132-154

UK Braemar,DevenickDunbar,ElginFranklin,GlenelgJudy, Jura, KessogRhum, ShearwaterWest Franklin

Sandstone 4,500-7,353 0.01-1,000 123-207

USA High Island Sandstone 4,833 - 177

Potassium formate from Addcon

* More HPHT fields developed in Kuwait, India and Malaysia during 2012-2013

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Formate brines – Production and first field use - Milestones

1993 1994 1995 1996 1997 1998

First field use of sodium formate: Shell drills and completes first

Draugen oil wells

Start of deep HPHT gas well

drilling with formates in Germany

(Mobil, RWE, BEB)

Sodium formate powder available throughout, but no anti-caking additive. Draugen wells each produce 48,000 bbl oil /day

1995 - Potassium formate brine becomes available from Hydro Chemicals (now Addcon) in Porsgrunn – sold thru Forbrico Ltd

Potassium formate brines used in USA, Canada,

Mexico, Venezuela,

Brazil, Ecuador

First field use of potassium formate (with Micromax) : Statoil drills and

completes Gullfaks oil well

1997 - Cesium formate brine becomes available from Cabot

Potassium formate from Addcon

First use of formate brine

as packer fluid: Shell Dunlin

A-14

Page 9: Potassium formate from addcon

Potassium formate brine has been produced at Porsgrunn since 1994

Production Site ADDCON NORDIC AS

Storage tanks for raw materials

Potassium formate from Addcon

Page 10: Potassium formate from addcon

Cesium formate produced by Cabot in Canada from pollucite ore

Pollucite ore Cs0.7Na0.2Rb0.04Al0.9Si2.1O6·(H20)

• Mined at Bernic Lake, Manitoba • Processed on site to Cs formate brine• Cs formate brine production 700

bbl/month

Potassium formate from Addcon

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W-Cluster

15000'

14800'

Z2Z6

Z5Z7

Z4

5000'

10000'

15000'

18000'

Germany : Potassium formate brine has been used to drill deep HPHT gas wells since 1995 First use : ExxonMobil’s Walsrode field, onshore northern Germany - high-angle deep HPHT slim hole low perm gas wells

TVD : 4,450-5,547 metres Reservoir: Sandstone 0.1-125 mDBHST : 157o C Section length: 345-650 mDrilling fluid: SG 1.45-1.55 K formate brine

Potassium formate from Addcon

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Potassium formate from Norway used in 15 deep HPHT gas well constructions in Germany ,1995-99

Well Name Application Fluid Type Density s.g. (ppg) Horizontal Length(m) Angle (°) BHST (°F) BHCT (°F) TVD (metres) MD (metres) Permeability

(mD)

Walsrode Z5 W/C K Formate 1.55 (12.93) 345 26 315 na 4450 - 4632 4815 - 5151 0.1 - 125 mD

Wasrode Z6 W/C K Formate 1.55 (12.93) 420 40 315 na 4450 - 4632 4815 - 5151 0.1 - 125 mD

Walsrode Z7 Drill-In K Formate 1.53 (12.77) 690 59 315 295 4541 - 4777 5136 - 5547 0.1 - 125 mD

Söhlingen Z3A Drill-In Formix 1.38 (11.52) 855 89 300 270 4908 5600 na

Söhlingen Z3a Drill-In Na Formate 1.30 (10.85) 855 89 300 270 4908 5600 na

Volkersen Z3 W/C Formix 1.40 (11.68) 512 52 320 na na na na

Kalle S108 Drill-In Formix 1.45 (12.10) 431 60 220 na 6000-6500 6200-6600 na

Weißenmoor Z1 W/C Formix 1.35 (11.27) 634 31 300 na na na na

Idsingen Z1a Drill-In K Formate 1.55 (12.93) 645 61 321 290 4632 - 4800 5257 - 5821 0.1 - 125 mD

Söhlingen Z12 Drill-In Na Formate/Formix 1.35 (11.27) 452 28 313 285 4736 - 4937 4846 - 5166 1.0 - 75 mD

Simonswolde Z1 Drill-In K Formate/Formix 1.52 (12.68) 567 35 293 275 4267 - 4572 4236 - 4648 0.1 - 25 mD

Walsrode NZ1 Drill-In Formix 1.51 (12.60) 460 34 290 265 4632 - 4815 4541 - 4693 0.1 - 125 mD

Idzingen Z2 W/C Formix 1.40 (11.68) na na 320 na 4632 - 4800 5257 - 5821 0.1 - 125 mD

Voelkersen NZ2 W/C Formix 1.40 (11.680 na na 320 na na na na

Söhlingen Z13 Drill-In/Frac K Formate/Formix 1.30 (-1.56)(10.85) 1200 90 300 285 4724 5486 - 6400 0,1 - 150 mD

Potassium formate from Addcon

Further wells drilled for BEB and RWE-DEA in Germany with Porsgrunn’s potassium formate brines via Baroid (1997 onwards)

Page 13: Potassium formate from addcon

Summary of potassium formate brine use in HPHT gas wells in Germany,1995-99

Potassium formate from Addcon

Page 14: Potassium formate from addcon

Formate brines – Some further important milestones : 1999-2004

1999 2000 2001 2002 2003 2004

First production of non-caking

crystalline K formate at Porsgrunn

First drilling jobs with

K/Cs formate brine:

Huldra and Devenick

Formate brines used as packer fluids for HPHT wells in GOM. First well : ExxonMobil’s MO 822#7 (215oC BHST) in 2001

Use of Cs-weighted oil-based completion fluids for oil reservoirs : Visund, Statfjord, Njord, Gullfaks, Snorre , Oseberg, Rimfaks 2001 – present

First use of Cs-weighted LSOBM as perforating completion

fluid (Visund)

First use of K/Cs formate

brine : Completion

job in Shearwater well (Shell

UK)

Potassium formate from Addcon

Cs-weighted LSOBM used as OH screen completion

fluid (Statfjord)

First use of K/Cs

formate brine as

HPHT well suspension

fluid (Elgin G-3)

Individual Draugen oil wells (1993) and Visund oil wells (2003) have similar flow rates of around 50,000 bbl oil/day

First of 14 Kvitebjørn HPHT wells drilled and completed with K/Cs formate brines

Page 15: Potassium formate from addcon

The first sustained use of K/Cs formate brine was in the world’s largest HPHT gas field development

Potassium formate from Addcon

190oC1100bar

5300m

Water Depth 90m

SIWHPFWHT

830bar180oC

::

GASCONDENSATE

3-4% C0230-40 ppm H2S

320barDEWPOINT

30% O1 Darcy K

Cesium formate brine used by TOTAL in 34 well construction operations in 8 deep gas fields in period 1999-2010

Elgin/Franklin field – UK North Sea

Page 16: Potassium formate from addcon

Formate brines – Some published milestones 2005 -2010

2005 2006 2007 2008 2009 2010

OMV Pakistan

start using K formate to drill and

complete (with ESS) in

HPHT gas wells

K/Cs formate brines used as well perforating fluids in 11 HPHT gas fields in UK North Sea : Dunbar, Shearwater, Elgin, Devenick , Braemar , Rhum, Judy , Glenelg , Kessog , Jura and West Franklin1999-2011

Saudi Aramco start using K

formate to drill and complete (with ESS) in

HPHT gas wells

Potassium formate from Addcon

Gravel pack with K

formate brine in

Statfjord B

First MPD operation in Kvitebjørn with K/Cs formate

“designer fluid”

First of 12 completions

in the Kashagan field with

K/Cs formate

Total’s West Franklin F9 well (204oC) perforated in K/Cs formate

brine

Petrobras use K

formate brine for

open hole gravel packs

in Manati field

Page 17: Potassium formate from addcon

Saudi Aramco have been drilling HPHT gas wells with potassium formate brine since 2003

Potassium formate from Addcon

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Saudi Aramco use of formate brines, 2003-2009

• 7 deep gas fields

• 44 HPHT wells drilled

• 70,000 ft of reservoir drilled at high angle

• 90,000 bbl of brine recovered and re-used

• Good synergy with ESS, also OHMS fracturing

Potassium formate from Addcon

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Summary from Aramco’s OTC paper 19801

Potassium formate from Addcon

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Pakistan - OMV use potassium formate brine for HPHT deep gas well drilling and completions

Potassium formate from Addcon

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Extracts from OMV’s SPE papers and SPE presentations – note 1,700 psi overbalance, and 350oF

Potassium formate from Addcon

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North Sea - K/Cs formate brines used as combined HPHT drill-in and completion fluids

33 development* wells drilled and completed in 7 HPHT offshore gas fields

•Huldra (6 ) •Tune (4) •Devenick (2) •Kvitebjoern (8 O/B and 5 MPD) •Valemon (1) •Kristin (2) – Drilled only •Vega (5)

* Except Valemon (appraisal well)

Mostly open hole stand-alone sand screen completions

Potassium formate from Addcon

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Tune field – HP/HT gas condensate reservoir drilled and completed with K formate brine, 2002

4 wells : 350-900 m horizontal reservoir sections. Open hole screen completions. Suspended for 6-12 months in formate brine after completion

Potassium formate from Addcon

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Tune wells - Initial Clean-up – Operator’s view (direct copy of slide) June 2003

Potassium formate from Addcon

• Wells left for 6-12 months before clean-up• Clean-up : 10 - 24 hours per well • Well performance

•Qgas 1.2 – 3.6 MSm3/d•PI 35 – 200 kSm3/d/bar•Well length sensitive

•No indication of formation damage•Match to ideal well flow simulations (Prosper) - no skin

• Indications of successful clean-up•Shut-in pressures  •Water samples during clean-up

•Formate and CaCO3 particles•Registered high-density liquid in separator•Tracer results

•A-12 T2H non detectable•A-13 H tracer indicating flow from lower reservoir first detected 5 sd after

initial clean-up <-> doubled well productivity compared to initial flow data•No processing problems Oseberg Field Center

SIWHP SIDHP SIWHP SIDHPbara bara bara bara

A-11 AH 169 - 388 -A-12 T2H 175 487 414 510

A-13 H 395 514 412 512A-14 H 192 492 406 509

Before After

3350

3400

3450

3500

3550

3600

0 100 200 300 400 500 600 700 800 900 1000

Well length [m MD]

Dep

th [m

TVD

MSL

]

A-11AHA-12HT2A-13HA-14HA-11 AH plugged back

Page 25: Potassium formate from addcon

Tune – Production of recoverable gas and condensate reserves since 2003 (NPD data)

Good early production from the 4 wells - No skin (no damage)

- 12.4 million m3 gas /day - 23,000 bbl/day condensate

Good sustained production - 90% of recoverable hydrocarbon reserves produced by end of Year 7

NPD current estimate of RR: - 18.3 billion m3 gas - 3.3 million bbl condensate

Rapid and efficient drainage of the reservoir

Potassium formate from Addcon

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• 6 production wells

• 1-2 Darcy sandstone

• BHST: 147oC

• TVD : 3,900 m

• Hole angle : 45-55o

• Fluid density: SG1.89-1.96

• 230-343 m x 81/2” reservoir sections

• Open hole completions, 65/8” wire wrapped

screens

• Lower completion in formate drilling fluid and

upper completions in clear brine

Huldra field – HPHT gas condensate reservoir drilled and completed with K/Cs formate brine, 2001

Potassium formate from Addcon

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Huldra – Production of recoverable gas and condensate reserves since Nov 2001 (NPD data)

Plateau production from first 3 wells - 10 million m3 gas /day - 30,000 bbl/day condensate

Good sustained production - 78% of recoverable gas and 89% of condensate produced by end of Year 7 - Despite rapid pressure decline.....

NPD current estimate of RR: - 17.5 billion m3 gas - 5.1 million bbl condensate

Rapid and efficient drainage of the reservoir

Potassium formate from Addcon

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• 13 wells to date – 8 O/B, 5 in MPD mode

• 100 mD sandstone

• BHST: 155oC

• TVD : 4,000 m

• Hole angle : 20-40o

• Fluid density: SG 2.02 for O/B

• 279-583 m x 81/2” reservoir sections

• 6 wells completed in open hole : 300-micron single wire-wrapped

screens.

• Remainder of wells cased and perforated

Kvitebjørn field – HPHT gas condensate reservoir drilled and completed with K/Cs formate brine, 2004-2013

Potassium formate from Addcon

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Kvitebjoern well

Completion time

(days)

A-4 17.5

A-5 17.8

A-15 14.8

A-10 15.9

A-6 12.7 *

* Fastest HPHT well completion in the North Sea

“The target well PI was 51,000 Sm3/day/bar This target would have had a skin of 7”

“A skin of 0 would have given a PI of 100,000”

“THE WELL A-04 GAVE A PI OF 90,000 Sm3/day/bar (ANOTHER FANTASTIC PI)”

Operator comments after well testing (Q3 2004 )

The Well PI was almost double the target

Potassium formate from Addcon

Fast completions and high well productivity

Page 30: Potassium formate from addcon

Kvitebjørn– Production of recoverable gas and condensate reserves since Oct 2004 (NPD data)

Good production reported from first 7 wells in 2006 - 20 million m3 gas /day

- 48,000 bbl/day condensate

Good sustained production (end Y8) - 37 billion m3 gas - 17 million m3 of condensate - Produced 70% of original est. RR by end of 8th year

NPD : Est. RR have been upgraded - 89 billion m3 gas (from 55) - 27 million m3 condensate (from 22)

Note : Shut down 15 months, Y3-5 - To slow reservoir pressure depletion - Repairs to export pipeline

Potassium formate from Addcon

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Economic benefits of using formate brines

• SPE 130376 (2010): “A Review of the Impact of the Use of Formate Brines on the Economics of Deep Gas Field Development Projects”

• SPE 145562 (2011): “Life Without Barite: Ten Years of Drilling Deep HPHT Gas Wells With Cesium Formate Brine”

Potassium formate from Addcon

Page 32: Potassium formate from addcon

Economic benefits from using formate brines - Good well performance and recovery of reserves

• “High production rates with low skin” * • “ We selected formate brine to minimise well control problems and maximise well productivity”*

* Quotes by Statoil relating to Kvitebjoern wells (SPE 105733)

Potassium formate from Addcon

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Economic benefits from using formate brines

- More efficient and safer drilling

“ a remarkable record of zero well control incidents in all 15 HPHT drilling operations and 20 HPHT completion operations”

Better/safer drilling environment saves rig-time costs • Stable hole: see LWD vs. WL calipers in shale

• Elimination of well control* and stuck pipe incidents • Good hydraulics, low ECD

• Good ROP in hard abrasive rocks

* See next slide for details

Potassium formate from Addcon

Page 34: Potassium formate from addcon

Economic benefits from using formate brines - Improved well control and safety

• Elimination of barite and its sagging problems

• Elimination of oil-based fluids and their gas solubility problem

• Low solids brine Low ECD (SG 0.04-0.06) and swab pressures

• Inhibition of hydrates

• Ready/rapid surface detection of well influx

• Elimination of hazardous zinc bromide brine

Potassium formate from Addcon

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- Drill-in and completing with formate brine allows open hole completion with screens

- Clean well bores mean no tool/seal failures or blocked screens

- Completion time 50% lower than wells drilled with OBM

“ fastest HPHT completion operation ever performed in North Sea (12.7 days)”

Economic benefits from using formate brines

- More efficicient/faster completions

Potassium formate from Addcon

Page 36: Potassium formate from addcon

• No differential sticking

• Pipe and casing running speeds are fast

• Mud conditioning and flow-check times are short • Displacements simplified, sometimes eliminated

Duration of flow back(minutes)

Fluid Gain (bbl)

30 0.8

15 0.56

20 0.44

30 0.56

Potassium formate from Addcon

Flow check fingerprint for a Huldra well

Economic benefits from using formate brines - Operational efficiencies

Page 37: Potassium formate from addcon

Economic benefits from using formate brines - Good reservoir definition if Cs present in fluid

• High density filtrate and no barite

• Filtrate Pe up to 259 barns/electron

• Unique Cs feature - makes filtrate invasion highly visible against formation Pe of 2-3 b/e

• LWD can “see” the filtrate moving (e.g. see the resistivity log on far right – drill vs ream

• Good for defining permeable sands (see SAND-Flag on log right )

• Consistent and reliable net reservoir definition

from LWD and wireline Potassium formate from Addcon

Page 38: Potassium formate from addcon

Economic benefits from using formate brines - Good reservoir imaging

• Highly conductive fluid

• Clear resistivity images

• Information provided: - structural dip - depositional environment - geological correlations

Potassium formate from Addcon

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Formate brines – Summary of economic benefits provided to users

Formate brines tend to improve oil and gas field development economics by :

• Reducing well delivery time and costs

• Improving well/operational safety and reducing risk

• Maximising well performance

• Providing more precise reservoir definition

Potassium formate from Addcon

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OPERATOR LOCATION Packer Fluid(ppg)

BHT (°C)

BHT (°F)

Start Date

End Date Comments

Devon WC 165 A-7 8.6 KFo 149 300 1/2005

Devon WC 165 A-8 8.6 KFo 149 300 1/2006

Devon WC 575 A-3 ST2 9.5 KFo 132 270 5/2005

WOG/Devon MO 862 #1 12.0 NaKFo 215 420 4/2005 5/2006Well P&A – H2O production – G-3 in excellent condition

BP/Apache HI A-5 #1 11.5 NaKFo 164 350 2/2002 4/2008Well P&A - Natural depletion – S13Cr in excellent condition

ExxonMobil MO 822 #7 12.0 NaKFo 215 420 2001

EPL ST 42 #1 11.5 NaKFo 133 272 2006

EPL ST 41 #F1 13.0 NaKFo 105 222 2006

EPL EC 109 A-5 11.5 NaKFo 121 250 2006

EPL ST 42 #2 12.8 NaKFo 132 270 2006

Dominion WC 72 #3 BP1 10.0 NaFo 121 250 2006

EPL WC 98 A-3 ST1 12.7 NaKFo 153 307 2006

EPL WC 98 A-3 10.8 NaKFo 154 310 2007

Formate brines as packer fluids in GOM

Potassium formate from Addcon

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• 177ºC, 14,000 psi

• S13Cr tubing failed from CaCl2 packer fluid

• Well worked over and re-completed with Cs formate

• 1.4 g/cm3 Na/K formate used as packer fluid

• Tubing retrieved 6 years later

• Tubing was in excellent condition.

BP High Island – Na/K formate brine as packer fluid for 6 years

Potassium formate from Addcon