A Strategy for Attacking Excess

Water Production
R.S. Seright, SPE, New Mexico Petroleum Recovery Research Center, R.H. Lane, SPE, Northstar Technologies Intl.,
and R.D. Sydansk, SPE, Sydansk Consulting Services
Summary
This paper describes a straightforward strategy for diagnosing and
solving excess-water-production problems. The strategy advocates
that the easiest problems should be attacked first and that diagnosis
of water production problems should begin with the information
already at hand. A listing of water-production problems is pro-
vided, along with a ranking of their relative ease of solution. Al-
though a broad range of water-shutoff technologies is considered,
the major focus of the paper is when and where gels can be ef-
fectively applied for water shutoff.
Introduction
In the United States, on average, more than seven barrels of water
are produced for each barrel of oil.
1
Worldwide, an average of
three barrels of water are produced for each barrel of oil.
2
The
annual cost of disposing of this water is estimated to be U.S. $510
billion and approximately $40 billion worldwide.
2
Many different causes of excess water production exist (see
Table 1). Each problem requires a different approach to find the
optimum solution. Therefore, to achieve a high success rate when
treating water-production problems, the nature of the problem first
must be identified correctly.
3
Many different materials and meth-
ods can be used to attack excess-water-production problems. Gen-
erally, these methods can be categorized as chemical or mechani-
cal (see Table 2). Each of these methods may work very well for
certain types of problems but are usually ineffective for other
problems. Again, for effective treatment, the nature of the problem
first must be identified correctly.
Four problem categories are listed in Table 1 in the general
order of increasing treatment difficulty. Within each category, the
listing order is only roughly related to the degree of treatment
difficulty. Category A, Conventional Treatments Normally are
an Effective Choice, includes the application of water-shutoff tech-
niques that are generally well established, use materials with high
mechanical strength, and function in or very near the wellbore.
Examples include Portland cement, mechanical tubing patches,
bridge plugs, straddle packers, and wellbore sand plugs.
A few comments may be helpful to clarify some of the listings
in Table 1. First, the difference between Problems 1 and 4 is
simply a matter of aperture size of the casing leak and size of the
flow channel behind the casing leak. Problem 1, involving casing
leaks without flow restrictions, describes a leak occurring through
a large aperture breach in the piping (greater than roughly
1
8 in.)
and a large flow conduit (greater than roughly
1
16 in.) behind the
leak. The use of Portland cement is favored for treating Problem 1.
Problem 4, involving casing leaks with flow restrictions, is when
the leak occurs through a small aperture breach (e.g., pinhole
and thread leaks) in the piping (less than roughly
1
8 in.) and a
small flow conduit (less than roughly
1
16 in.) behind the leak. Gel
is favored to successfully treat Problem 4. In this paper, the gels
under discussion may include those formed from chemically
crosslinked water-soluble organic polymers, water-based organic
monomers, or silicates.
The difference between Problems 2 and 5 again is simply a
matter of aperture size of the flow channel behind the pipe. Prob-
lem 2, involving flow behind pipe without flow restrictions, refers
to fluid flow occurring through a large aperture flow conduit be-
hind the pipe (greater than roughly
1
16 in.). Portland cement is
favored to treat Problem 2. This problem is often manifested by a
total lack of primary cement behind the casing. Problem 5, involv-
ing flow behind pipe with flow restrictions, describes flow behind
pipe occurring through a small aperture flow conduit (less than
roughly
1
16 in.). Gel is favored to treat this problem. Problem 5 is
often exemplified by microannuli flow behind the pipe. This prob-
lem often results from cement shrinkage while curing during the
wells completion.
The recognition, importance, challenge, and necessity of suc-
cessfully treating Problems 2 and 5 recently have become much
more prominent with the advent of regulatory-required mechanical
integrity (hydro-) testing of petroleum well tubing and cas-
ing strings.
Logically, identification of the excess-water-production prob-
lem should be performed before attempting a water-shutoff treat-
ment. Unfortunately, many (perhaps most) oil and gas producers
do not properly diagnose their water production problems. Conse-
quently, attempted water-shutoff treatments frequently have low
success rates. Several reasons exist for the inadequate diagnosis of
excess-water-production problems. First, operators often do not
feel that they have the time or money to perform the diagnosis,
especially on marginal wells with high water cuts. Second, uncer-
tainty exists about which diagnostic methods should be applied
first. Perhaps 30 different diagnostic methods could be used. In the
absence of a cost-effective methodology for diagnosing water-
production problems, many operators opt to perform no diagnosis.
Third, many engineers incorrectly believe that one method (e.g.,
cement) will solve all water production problems or that only one
type of water production problem (e.g., 3D coning) exists. Finally,
some service companies incorrectly encourage a belief that a
magic bullet method exists that will solve many or all types of
water production problems.
A number of excellent papers have addressed candidate selec-
tion and various aspects of treating specific types of excess-water-
production problems.
214
A common theme of many of these
papers is the need for proper diagnosis of the excess-water-
production problem. However, for the reasons mentioned previ-
ously, such diagnosis frequently is not obtained. This paper fo-
cuses on a cost-effective strategy and methodology for diagnosing
and solving excess-water-production problems. The objective of
this paper is to provide a straightforward strategy and methodology
for performing effective problem diagnosis so the practicing en-
gineer does not forgo problem diagnosis and, in turn, implement
ineffective water-shutoff treatments.
Proposed Strategy
Our proposed strategy for attacking excess-water-production prob-
lems advocates that the easiest problems should be attacked first
and that diagnosis of water production problems should begin with
information already at hand. To implement this strategy, a priori-
tization of water production problems is needed. Based on exten-
sive reservoir and completion engineering studies and analyses of
many field applications, the various types of water problems were
prioritized and categorized from least to most difficult, as shown in
Table 1. The first three listings are the easiest problems (Category
Copyright 2003 Society of Petroleum Engineers
This paper (SPE 84966) was revised for publication from paper SPE 70067, first presented
at the 2001 SPE Permian Basin Oil and Gas Recovery Conference, Midland, Texas, 1516
May. Original paper received for review 10 December 2001. Revised paper received 30
January 2003. Paper peer approved 3 February 2003.
158 August 2003 SPE Production & Facilities
A, Problems 1 through 3), and their successful treatment generally
has been regarded as relatively straightforward. Of course, indi-
vidual circumstances can be found within any of these problem
types that are quite difficult to treat successfully. For example, for
Problem 3, impermeable barriers may separate water and hydro-
carbon zones. However, if many water and oil zones are inter-
mingled within a short distance, it may not be practical to shut off
water zones without simultaneously shutting off some oil zones.
The ranking of water production problems in Table 1 is based on
conceptual considerations and issues related to the ease of treating
each type of problem. We realize that operational and practical
issues can make even the easiest problems in Table 1 very difficult
to solve.
Nevertheless, the first three problem types in Table 1 are gen-
erally easier to treat in practice than the others on the list. There-
fore, one should look for these types of problems first.
In contrast, the last three problems (Category D, Problems 11
through 13) are difficult, with no easy, low-cost solution. (Gel
treatments will almost never work for these problems.) The inter-
mediate problems (Categories B and C, Problems 4 through 10) are
caused by linear-flow features (e.g., fractures, fracture-like struc-
tures, narrow channels behind pipe, or vug pathways). Certainly,
much work remains to optimize the treatment of these problem
types. However, substantial theoretical, laboratory, and field prog-
ress has been made in recent years toward solving these problems,
especially with gels. As will be discussed shortly, Problems 4
through 7 (Category B in Table 1) normally are best solved using
gelants (i.e., the fluid gel formulation before significant crosslink-
ing occurs). Problems 8 through 10 (Category C) are best solved
with preformed or partially formed gels (i.e., crosslinking products
that will not flow into or damage porous rock).
A key element of the proposed strategy is to look for and solve
the easiest problems in Table 1 before attempting to attack the
more difficult problems. In many cases, engineers initially as-
sumed that 3D coning (Problem 11 in Table 1) caused the problem,
whereas a small amount of subsequent diagnosis and analysis re-
vealed that the true source of water production was either flow
behind pipe (Problem 2) or 2D coning through a fracture (Prob-
lem 6). This knowledge could have substantially reduced the cost
of solving the problem (because Problems 2 and 6 can be solved
with relatively low-cost methods, whereas Problem 11 cannot).
Also, by correctly identifying the problem first, the most appro-
priate method can be identified, and the probability of successfully
treating the problem increases significantly.
To help implement the proposed strategy, the following ques-
tions should be addressed in the following order.
1. Is there a problem?
2. Is the problem caused by leaks or flow behind pipe?
3. Is the problem caused by fractures or fracture-like features?
4. Is the matrix-flow problem compounded by crossflow?
Is There a Problem? An important first question when attack-
ing a water production problem is: Do significant volumes of
mobile oil remain in the pattern or in the vicinity of the well of
interest? Three types of observations are commonly used to make
this assessment. First, a pumper may notice that certain well(s)
exhibit a sudden increase in water cut. Second, a well or pattern of
wells may be noted as producing at significantly higher water/oil
ratios (WORs) than other, similar patterns. Third, plots of fluid
production vs. time may show an abrupt increase in the WOR at a
certain point. Results from reservoir simulation studies constitute
a fourth, less common method sometimes used by large oil pro-
ducers to analyze water production problems in large reservoirs.
The oilfield operator should recognize that two distinct types of
water production exist. The first type, usually occurring later in the
life of a waterflood, is water that is coproduced with oil as part of
the oils fractional flow characteristics in reservoir porous rock. If
production of this water is reduced, oil production will decrease
correspondingly. The second type of water production competes
directly with oil production. This water usually flows to the well-
bore by a path separate from that for oil (e.g., water coning or a
high-permeability water channel through the oil strata). In these
latter cases, reduced water production can often lead to greater
pressure drawdowns and increased oil production rates. Obviously,
159 August 2003 SPE Production & Facilities
the second type of water production should be the target of water-
shutoff treatments.
Understanding and conceptualizing the reservoir plumbing is
a key to:
Distinguishing between the previous two types of water
production.
Successfully diagnosing the water production problem.
Successfully implementing and designing water-shutoff
treatments.
Is the Problem Caused by Leaks or Flow Behind Pipe? Once
the operator decides that the water cut is too high (considering the
remaining reserves) and that the water is produced via a flow path
separate from that of the oil, the operator should ask whether the
excess-water-production is caused by a relatively easy problem (as
listed in Table 1), particularly by unrestricted casing leaks or by
flow behind pipe. Some of the common methods used to diagnose
these problems include:
Leak tests/casing integrity tests (e.g., hydrotesting).
Temperature surveys.
Flow profiling tools (e.g., radiotracer flow logs, spinner sur-
veys, production logging tools).
Cement bond logs.
Borehole televiewers.
Noise logs.
Refs. 15 and 16 provide detailed descriptions of these methods.
Many of these methods are used during routine surveillance of
wells. Therefore, consistent with our proposed strategy, one should
begin the diagnostic process by examining information already at
hand. If this type of information is not available, then the previ-
ously listed methods comprise a list of the first diagnostic methods
that should be considered for implementation.
If a problem with unrestricted casing leaks or flow behind pipe
(as defined in Table 1 and the subsequent paragraphs) is identified,
that problem should be addressed before attempting to solve ad-
ditional, more difficult problems that may exist. Some engineers
disagree with this suggestion, arguing that they wish to apply a
water-shutoff method that solves multiple types of problems at
once. While this fortuitous circumstance occasionally occurs, the
optimum solution for treating the different types of problems usu-
ally varies considerably. For example, the optimum solution for an
unrestricted-flow-behind-pipe problem and that for a fracture that
leads to an aquifer may differ considerably in desired properties of
the blocking agent, volume of blocking agent placed, and place-
ment method. Thus, although a chosen treatment method may be
effective in treating one of these two excessive-water production
problems, the chosen treatment will most likely be ineffective in
treating the other water production problem.
Is the Problem Caused by Fractures or Fracture-Like Fea-
tures? A critical aspect in diagnosing most excess-water-
production problems is deciding whether fluid flow around the
wellbore is radial or linear. Flow behind pipe, fractures, and frac-
ture-like features are associated with linear flow, while radial flow
generally occurs in matrix reservoir rock when these features are
absent. [We recognize the special case of radial flow in fractures
(e.g., for vertical fractures that cross horizontal wells). This case
will be treated separately later. In this section, our consideration of
radial flow is confined to flow in matrix, while linear flow refers
to the presence of extremely permeable fracture-like features.]
Simple calculations with the Darcy equation reveal that the ap-
proach for solving these linear flow problems must be fundamen-
tally different from solving radial flow problems in matrix reser-
voir rock or sand.
17
Especially for gel treatments, linear vs. radial
flow problems differ radically in gel properties desired, placement
procedures required, and optimum volume of the gel placed. In
particular, hydrocarbon productive zones must be protected during
gelant placement for radial flow problems.
17
For linear flow, an
acceptable gel placement (without mechanically isolating zones) is
much easier to achieve than with radial flow.
A number of methods are available to judge whether flow
around a wellbore is linear (in fracture-like features) or radial (in
matrix rock or sand). One simple method
4
uses the Darcy equation
for radial flow.
qp = kh141.2 ln r
e
r
w
. . . . . . . . . . . . . . . . . . . . . . . . (1)
If the actual injectivity or productivity for a well (i.e., the left
side of Eq. 1, q/p, in BPD/psi) is five or more times greater than
the injectivity or productivity calculated with the Darcy equation
for radial flow (i.e., the right side of Eq. 1), the well probably
suffers from a linear flow problem.
Linear Flow:
qp kh141.2 ln r
e
r
w
. . . . . . . . . . . . . . . . . . . . . (2)
On the other hand, if the left side of Eq. 1 is less than or equal
to the right side, radial flow becomes likely.
Radial Flow:
qp kh141.2 ln r
e
r
w
. . . . . . . . . . . . . . . . . . . . . . . (3)
In the previous equation, k effective rock permeability in
md. If the zone contains water at residual oil saturation (S
or
), k
should take this into account. Typically, the water relative perme-
ability at S
or
is between 5 and 30% of the absolute permeability,
with 10% being a good estimate if k at S
or
is not known. If the zone
is producing only oil, k can be taken as the absolute permeability
without incurring much error in the calculation. The permeability
used in Eq. 1 should be taken from core analyses, log data, or
pressure transient analyses. It should not be taken from production
data. Net pay, h, in Eq. 1 has units of feet, while viscosity, , is
measured in cp. If the well is a water injector or is producing a very
high water cut, then the viscosity of water can be used (at the
appropriate temperature). If the oil cut is significant, there may be
value in performing two calculations with Eq. 1one using water
viscosity and one using oil viscosity. The natural log term in Eq.
1 can be assumed to have a value of 6 or 7. The pressure drawdown
or buildup (p, in psi) in Eq. 1 must be reasonably current and
applicable to the specific well of interest. It is a mistake to take this
value from another well or to use a value that is too old. This
pressure difference indicates a great deal about the problem of the
specific well and is extremely important to measure both before
and after (and even during) a gel treatment.
Of course, uncertainty exists for a significant range of condi-
tions that do not satisfy either Eq. 2 or Eq. 3. Thus, injectivity/
productivity calculations will not always distinguish between ra-
dial and linear flow. Nevertheless, they frequently do provide a
definitive indication of the flow geometry near the wellbore. Be-
cause the calculations are easily performed with data often at hand,
they provide a low-cost diagnostic method that should be consid-
ered when diagnosing any excess-water-production problem.
In addition to the injectivity/productivity calculations discussed
previously, several other methods can be used to determine if
fractures or fracture-like features are the source of the water prob-
lem. These other methods include core and log analyses (especially
from highly deviated or horizontal wellbores), pulse tests/pressure
transient analyses, and interwell tracer studies.
Various logging methods have been used to detect and charac-
terize fractures (see Chap. 3 of Ref. 18). However, these methods
must be used with caution because they usually measure properties
at or near the wellbore. The value of these methods can be in-
creased if the wellbore is deviated to cross the different fracture
systems (i.e., fractures with different orientations).
Pressure transient analyses often have been used to characterize
fractured reservoirs (see Chap. 4 of Ref. 18). Reportedly, these
methods can estimate the fracture volume; the fracture permeabil-
ity; and, under some circumstances, the minimum spacing between
fractures. Pressure interference tests can also indicate fracture ori-
entation. In addition to unsteady-state methods, steady-state pro-
ductivity indices also were suggested as a means to estimate frac-
ture permeability.
Interwell tracer studies provide valuable (and often relatively
inexpensive) characterizations of fractured reservoirs, especially
for use in judging the applicability of gel treatments to reduce
channeling.
19,21
Interwell tracer data provide much better resolu-
160 August 2003 SPE Production & Facilities
tion of reservoir heterogeneities than pressure transient analyses.
20
Tracer results can indicate the following.
Whether fractures or fracture networks are probably present
and if those fractures are the cause of a channeling problem.
The location and direction of fracture channels.
The fracture volume.
The fracture conductivity.
The effectiveness of a remedial treatment (e.g., a gel treat-
ment) in reducing channeling.
21
For operators producing from mature, highly fractured oil res-
ervoirs, low-cost and operationally easy tracer techniques exist that
can help diagnose excess-water-production problems.
Is the Matrix-Flow Problem Compounded by Crossflow? Once
fractures and fracture-like features are eliminated as possibilities,
the problem is deduced to be radial in nature (i.e., radial flow exists
in the matrix rock around the wellbore). Next, the possibility of
crossflow between reservoir strata must be addressed. If fluids can
crossflow between adjacent water and hydrocarbon strata (and
flow is radial), a gel treatment should not be attempted.
22
Even if
gelant is injected only into a single zone, it will crossflow into and
damage the oil-producing zones away from the wellbore. Thus, no
matter how much gelant is injected, the treatment will be ineffec-
tive in promoting conformance.
22
In contrast, if fluids cannot
crossflow between zones and sealing Portland cement exists that
prevents vertical flow immediately behind the casing, a gel treat-
ment can be effective if gelant injection is placed only in the
offending water zones.
17
Several methods are used to assess whether crossflow exists
between strata, including pressure tests between zones; various
logs for determining fluid saturations, permeability, porosity, and
lithology; injection/production profiles; simulation; and seismic
methods. The most straightforward method tests pressure differ-
ences between zones. A packer is commonly placed between two
zones, and one of the zones is allowed to pressure up. If a signifi-
cant pressure can be maintained across the packer, effective bar-
riers to crossflow exist between the zones. If a pressure difference
cannot be maintained, crossflow between the zones can occur. If
the operator does not know whether crossflow occurs, he should
assume that crossflow exists. Ref. 23 describes an interesting
case in which pressure testing was used to assess the presence
of crossflow.
WOR History Plots. Plots of the WOR vs. time can provide a
valuable indication of when an excess-water problem develops.
2,24
Along with other information, such plots also can aid in identifying
the cause of the problem. However, these diagnostic plots (of
WOR or WOR-derivative vs. time) should not be used alone to
diagnose excess-water-production mechanisms and problems.
25,26
This method was said to be capable of distinguishing whether a
production well is experiencing premature water breakthrough
caused by water coning or channeling through high permeability
layers.
24
According to this method, gradually increasing WOR
curves with negative derivative slopes are unique to coning prob-
lems, and rapidly increasing WOR curves with positive derivative
slopes are indicative of a channeling problem. As far as we are
aware, this method has not been used to distinguish between linear
(fracture or flow behind pipe) and radial flow for either channeling
or coning. As mentioned previously, the linear/radial distinction is
extremely importantmuch more so than whether the problem is
caused by generic channeling or coning.
Recently, reservoir models were built for water coning and
channeling, respectively, and a sensitivity analysis was performed
with numerical simulation.
25,26
Reservoir and fluid parameters
were varied to examine WOR and WOR-derivative behavior for
both coning and channeling production problems. The results from
this study demonstrated that multilayer channeling problems easily
could be mistaken as bottomwater coning, and vice versa, if WOR
diagnostic plots are used alone to identify an excessive-water-
production mechanism. Hence, WOR diagnostic plots easily can
be misinterpreted and, therefore, should not be used alone to di-
agnose the specific cause of a water production problem.
Solutions to Specific Types of Problems
After diagnosing the cause(s) of the excess-water-production, what
approach should be taken to solve the problem? As mentioned
earlier, each problem type usually requires a different approach,
including choice of treatment method, properties of the conform-
ance or blocking agent, volume of conformance or blocking agent
used, and placement method. The remainder of this paper will
focus on the use of gelant or gel treatments and will address
whether and how these treatments should be applied to success-
fully treat each problem type listed in Table 1.
Casing Leaks (Problems 1 and 4 in Table 1). The most common
methods to repair casing leaks (i.e., for Problem 1) involve either
cement
27,28
or mechanical patches.
2,29
However, these methods
generally have not been very successful when treating small casing
leaks, such as pinhole or thread leaks (Problem 4). In particular,
cement has difficulty penetrating through small leaks. With luck,
cement may lodge in and plug the leak, but small mechanical
shocks often dislodge the cement plug. Gel treatments can be more
successful for these applications.
3032
Appropriately designed ge-
lants flow easily through the small casing leaks and some distance
into the formation surrounding the leak. Thus, the gel treatment is
directed at stopping flow in the porous rock around the vicinity of
the casing leak, rather than solely attempting to permanently plug
the casing leak itself. If the resultant gel (placed in the matrix
reservoir rock) can withstand the near-wellbore pressure gradients,
a small radius of penetration (e.g., 1 ft) may be adequate to stop
flow. Consequently, gelant volumes can be quite small. Of course,
greater gel volumes and/or other treatment methods may be needed
if flows behind pipe or fractures exist in the vicinity of the casing
leak.
What placement and permeability reduction properties are de-
sired for gels used to plug casing leaks? Because the objective is
to achieve total water shutoff from the leak and because small gel
volumes are often used for this application, the gel plug should be
relatively strong and must have a very low permeability. Rigid gels
can be prepared from several materials that yield permeabilities in
the low microdarcy range.
33,34
Gels for this application often have
been formulated with relatively high concentrations (4 to 7%) of
acrylamide polymers that have a relatively low molecular weight
(on the order of 25,000 to 500,000 daltons).
35
Gelants for this
application should be of relatively low viscosity and should expe-
rience essentially no polymer crosslinking during gel treat-
ment placement.
Refs. 30 through 33 provide field examples in which gels
showed superior behavior vs. cement when treating leaks.
Flow Behind Pipe (Problems 2 and 5 in Table 1). Problems with
unrestricted flow behind pipe are usually treated with cement.
27
Cement can perform extremely well for this type of application if
the channel to be plugged is not too narrow (i.e., Problem 2). When
narrow channels are encountered (Problem 5, such as microannuli
between cement and the formation or the pipe), cement often can-
not be placed effectively through small or constricted flow paths.
Gels provide a better solution for this case, because they can flow
or extrude readily through narrow constrictions.
3638
The ability of
gels to withstand high pressure gradients increases with decreasing
channel width.
39
Therefore, gel alone cannot be expected to plug
large voids behind pipe. In some cases, gelants or gels were in-
jected first (to penetrate into narrow constrictions), and cement
was injected subsequently to fill and plug larger near-wellbore
voids and to prevent gels from washing out from their strate-
gic locations.
40
When treating flow-behind-pipe problems in which a substan-
tial drawdown pressure (i.e., >100 psi) exists, gelants often are
employed rather than preformed or partially formed gels. Three
reasons support favoring gelant injection when treating this prob-
lem type. First, flow constrictions in small flow channels behind
pipe may prevent full penetration of preformed gel into the of-
fending channels. These constrictions do not significantly impede
placement of gelant solutions. Second, gelant invasion into per-
161 August 2003 SPE Production & Facilities
meable matrix rock adjacent to the channel behind pipe is usually
beneficial when treating this type of problem. In contrast, pre-
formed gels will not penetrate appreciably into the permeable ma-
trix. Third, because of relatively high near-wellbore drawdown
pressures, gel in the channel probably will wash out much more
easily than gel formed in the permeable matrix. Methods of siz-
ing gel treatments for these applications have been strictly empiri-
cal to date.
In certain circumstances, properly formulated gels of pre-
formed or partially formed, crosslinked, organic polymer gels may
be favored when treating long intervals of microannuli between the
primary cement and the formation.
Refs. 36 through 38 provide field examples in which gels showed
superior behavior vs. cement when treating flow behind pipe.
Unfractured Wells With Effective Barriers to Crossflow
(Problem 3). Often, when radial flow exists around a well (i.e.,
fractures are not important), impermeable barriers (e.g., shale or
anhydrite) separate hydrocarbon-bearing strata from a zone that is
responsible for excess-water-production. When the water zone is
located at the bottom of the well, cement or sand plugs are most
commonly used to stop water production. Historically, when the
water zone is located above an oil zone, the most common water-
shutoff methods include cement or carbonate squeezes (into per-
forations) or mechanical packers or patches
27
(i.e., the conven-
tional treatments of Category A).
However, gels involving gelant injection also have been used
frequently to treat these problems.
7,32,36,41
In these instances, the
problem solution falls into Category B of Table 1. Gels have two
advantages vs. cements and carbonates for some applications.
36
First, gelants can flow into porous rock, whereas cements and
particulate blocking agents are filtered out at the rock surface.
Cements (including microfine cement) will not invade porous
rock or sands with normal permeabilities (e.g., sandstone and
sands of <10,000 md) to any significant distance unless the porous
medium experiences fracturing, parting, or very high pressure gra-
dients. If the cement does not adhere adequately to the rock in the
perforation or other large void (e.g., because of chemical incom-
patibility or mechanical shock), the zone may not seal sufficiently.
In contrast, gels (i.e., after gelation) can form an impermeable
rubbery mass that extends past the rock surface and well into the
porous rock. Second, gelants and gels can penetrate into and plug
narrow channels (e.g., microannuli) behind pipe in the vicinity of
the zone to be shut off.
36
Therefore, in some cases, gels can pro-
vide a more effective seal in the zone to be plugged.
When treating radial flow problems with gels or similar block-
ing agents, hydrocarbon zones must be protected during gelant
placement. Otherwise, the blocking agent probably will also dam-
age the hydrocarbon zones.
17
Mechanical isolation of zones is the
most obvious method to protect oil zones during gelant placement.
However, other methods existnotably, dual injection.
7,23,42
As
an example of dual injection, gelant might be injected down coiled
tubing into the water zone while nondamaging water or hydrocar-
bon fluid is injected simultaneously down the annulus into the oil
zone (while the two zones are in fluid communication). Downhole
pressure gauges in the tubing and annulus are carefully monitored
to maintain a very delicate pressure balance. Near the wellbore,
this balance minimizes gelant crossflow into the oil zones and
protective-fluid crossflow into the water zone. This method is of
particular interest and value for wells in which mechanical zone
isolation is impractical, especially gravel-packed wells and wells
with flow behind pipe. The method and its associated gel treatment
will not be effective in cases in which laterally extensive barriers
(e.g., shale or anhydrite layers) are not present away from the
wellbore.
26
The dual-injection technique is considered to be an
advanced zone-isolation technique that must be carefully designed
and tailored to individual well problems and often requires com-
puter simulation support for successful implementation. Refs. 23
and 42 describe field applications of the dual-injection technique.
For gel applications in unfractured injection or production
wells in which crossflow does not occur, how much gel should be
injected and what properties should the gel have? This question is
easily answered by considering Fig. 1, which was generated using
the Darcy equation for radial flow.
43
This figure applies to gel
treatments in both injection and production wells.
Fig. 1 plots the fraction of original injectivity or productivity
retained after a polymer or gel treatment as a function of the
residual resistance factor (i.e., the permeability reduction provided
by the polymer or gel). This figure applies to a waterflooded
reservoir with a 40-acre, 5-spot pattern with a unit-mobility dis-
placement. The wellbore radius was 0.33 ft. Two cases of radii of
gelant penetration (r
gel
) are presented5 and 50 ft. A comparison
of these two curves reveals that for a given residual resistance
factor, the injectivity or productivity losses are not strongly de-
pendent on the radius of gelant penetration. Therefore, the perfor-
mance of the gelant treatment is not sensitive to the volume of
gelant injected. A 5-ft radius of penetration often will be adequate
for many applications if the gel can withstand the high pressure
gradients near the wellbore. Fig. 1 also indicates the desired prop-
erties of the gel. For typical gelant penetrations in the water zones,
residual resistance factors of 20, 50, and 100 will provide water
productivity losses of 80, 90, and 95%, respectively. These values
are adequate for most radial flow problems.
In some cases in which cold water is injected into wells in hot
reservoirs, thermal fractures may develop and extend a significant
distance (e.g., 10 to 100 ft or more) from the wellbore.
44,45
In these
circumstances, the gel treatment should plug both the matrix and
the fractures in the offending zone.
Many polymers and gels can reduce permeability to water (k
w
)
more than that to oil (k
o
) or gas (k
gas
). For the credible experi-
mental data reported to date, polymers and gels, however, always
reduce k
o
to some extent. In the best cases, Zaitoun and Kohler
46
reported that adsorbed polymers significantly reduced k
w
at any
given water saturation, while the oil relative-permeability curve
was basically unaffected by the polymer. However, the polymer
increased the irreducible water saturation, thus lowering the end-
point relative permeability to oil. Therefore, for all practical pur-
poses in zones with high oil saturations, the polymer treatment
reduces the effective permeability to oil to some extent.
For gel treatments applied to water injection wells, the dispro-
portionate permeability reduction is of no value. However, in pro-
duction wells, the property is critical to the success of gel treat-
ments if hydrocarbon zones are not protected during gelant place-
ment. Even then, the property is of value only when zones with
high hydrocarbon saturation are distinct from the offending water-
producing zones.
47
In other words, this disproportionate perme-
ability reduction will not mitigate water production from a res-
ervoir that effectively has only one zone. When a single zone
exists, even if the polymer or gel can significantly reduce the
permeability to water without affecting the permeability to oil, the
average fractional flow of water and oil from that zone must re-
main the same. If the polymer or gel near a production well allows
oil to pass but not water, the water saturation will increase near and
just beyond the gel bank, thus decreasing the relative permeability
Fig. 1Fraction of original injectivity or productivity retained
vs. residual resistance factor.
162 August 2003 SPE Production & Facilities
to oil until the fractional water and oil flows match the values that
existed before the polymer or gel treatment. Therefore, unless a
particular zone is at its irreducible water saturation, a polymer or
gel treatment will always cause some loss in oil productivity, even
if the polymer or gel reduces k
w
without affecting k
o
. This loss of
oil productivity will be in direct proportion to the water-
productivity loss caused in that particular zone.
A common misconception is that the disproportionate perme-
ability reduction will be of value mainly in treating unfractured
production wells in which fluid flow is radial around the wellbore.
However, two technical obstacles currently impede this type of
treatment from being commonly successful. First, if zones are not
isolated during gelant placement, then generally, the residual re-
sistance factor (permeability reduction value) in the oil zone must
be less than 2, while the residual resistance factor in the water zone
must be greater than 10. The reason for this requirement can be
appreciated by considering Fig. 1. For radial flow, relatively small
residual resistance factors (F
rr
) can cause significant injectivity or
productivity losses. For example, for a gel radius of 50 ft, an F
rr
value of 2 causes a 27% loss in productivity, while an F
rr
value of
10 causes a 75% loss. Both losses might be considered unaccept-
able if these are oil zones. Thus, in unfractured wells, oil residual
resistance factors (F
rro
) provided by the gel must be small.
A second technical obstacle also thwarts the disproportionate
permeability reduction from being usable in practice when treating
radial flow problems. Especially for gels and/or products of gela-
tion reactions, F
rro
values of less than two may be difficult to
achieve in a predictable and controllable manner.
33,48
Low F
rro
values usually mean that gelation was incomplete and that the
products of the gelation reaction were small gel particles that be-
come trapped in pore throats. These particles occupy a small frac-
tion of the aqueous pore space. Gelation reactions are usually
sensitive to pH, salinity, and other factors, which are influenced by
the rock lithology and resident fluid composition.
33,48
Conse-
quently, small differences in rock lithology and reservoir condi-
tions may significantly change the concentration and size of par-
ticles formed during the early stages of gelation, ultimately re-
sulting in residual resistance factors that are unpredictable
and uncontrollable.
As will be discussed in the next section, the disproportionate
permeability reduction is currently of much greater value in treat-
ing linear flow problems (i.e., fractured production wells) than
radial flow problems.
When treating water production problems in unfractured reser-
voirs with barriers to crossflow, gel treatments can be applied in
either injection or production wells. Refs. 23, 32, 49, and 50 dem-
onstrate field applications of gel treatments for solving this type
of problem.
2D Coning: Hydraulically Fractured Production Wells (Prob-
lem 6). When production wells are hydraulically fractured, the
fracture often unintentionally breaks into water zones, causing
substantially increased water production. Gelant treatments have
significant potential to correct this problem. These gelant treat-
ments rely on the ability of the gels to be placed in the rock matrix
adjacent to the fractures and to reduce permeability to water much
more than that to hydrocarbon (disproportionate permeability re-
duction). An engineering-based method was developed for design-
ing and sizing gelant treatments in hydraulically fractured produc-
tion wells.
51
This design procedure was incorporated in user-
friendly graphical-user-interface software that can be downloaded
from the Internet at http://baervan.nmt.edu/randy.
In these matrix rock treatments, gelants flow along the fracture
and leak off a short, predictable distance into the matrix rock of all
the zones (water, oil, and gas). Success for such a treatment re-
quires that the gel reduce permeability to water much more than
that to hydrocarbon in the treated matrix rock. The ability of the
gel to stop water entry into the fracture is determined by the
product of gelant leakoff distance (from the fracture face) and the
residual resistance factor (permeability reduction factor) provided
by the gel. For example, consider the case in which the gelant leaks
off 0.2 ft into both water and oil zones, and in the gel-contacted
rock, permeabilities to water and oil are reduced by factors of
50,000 and 50, respectively. (These properties have been reported
for a gel formulation.
52
) In this case, the gel adds only the equiva-
lent of 10 ft of additional rock that the oil must flow through to
enter the fracture (i.e., 0.2 ft 50). In contrast, for the water zone,
the water must flow through the equivalent of 10,000 ft of addi-
tional rock to enter the fracture (i.e., 0.2 ft 50,000). Thus, in this
circumstance, the gel can substantially reduce water production
without significantly affecting oil productivity.
In this method, fluid entry into the fracture is controlled by gel
in the rock next to the fracture.
51
Ideally, fracture conductivity is
not reduced significantly, because it allows a conductive path for
oil flow into the wellbore. To some extent, gravity segregation of
the gelant (between placement and gelation) will mitigate damage
to the fracture when the excessive water production originates
from an underlying aquifer. However, to minimize fracture dam-
age, an oil or water post-flush could be used to displace gelant
from the fracture.
From a rigorous viewpoint, the method assumes that imperme-
able barriers (e.g., shale or calcite) separate adjacent zones.
51
However, the method frequently should provide acceptable out-
comes, even if crossflow can occur between the water- and oil-
bearing zones. For example, consider the case in which oil lies on
top of water in a single formation (a common situation in which
coning becomes a problem). Previous works
47,52
showed that
gravity alone can retard water influx into oil zones much more
effectively when the water must cusp to a linear pressure sink
(i.e., a vertical fracture or a horizontal well) than when the water
cones to a point pressure sink (i.e., a partially penetrating ver-
tical well). For the type of gel treatment we propose for application
in hydraulic fractures, in many cases, gravity may be sufficient to
minimize water invasion into the hydrocarbon zones of a single
formation. Of course, the degree of water invasion (coning) into
hydrocarbon zones increases with increased production rate, pres-
sure drawdown, vertical formation permeability, and hydrocarbon
viscosity, and decreases with increased water-hydrocarbon density
difference, horizontal formation permeability, and oil column
thickness.
47,52
If water invades too far into the hydrocarbon zone,
a water block could form that reduces hydrocarbon productivity.
To use this procedure to reduce water production from a hy-
draulic fracture, field data coupled with results from two simple labo-
ratory experiments are needed.
51
The necessary field data include:
Fluid production rates before gel treatment.
Downhole static and flowing pressures before gel treatment.
Permeabilities, porosities, and thickness of the rele-
vant zones.
Water and oil viscosities at reservoir temperature.
Well spacing or distance between wells.
These parameters often are available during conventional gel treat-
ments. The downhole pressure drops are critically important for
this method. They must be reasonably current and measured spe-
cifically for the well to be treated.
Use of the procedure also requires oil and water residual resis-
tance factors from laboratory core experiments.
51
These experi-
ments must be conducted with the gelant, oil, brine, rock, and
temperature that are representative of the intended application. In
the absence of laboratory oil and water residual resistance factors,
the model can use field data to back-calculate these values in situ
after a gel treatment. This information may be useful when de-
signing similar treatments in nearby wells. These calculations have
also been incorporated into the software. For cases in which re-
sidual resistance factors are calculated from field data, three pa-
rameters (from a similar, previous gelant treatment) are required in
addition to the five items listed in the previous paragraph. These
three parameters are:
Fluid production rates after the gel treatment.
Accurate downhole static and flowing pressures after the
gel treatment.
The volume of gelant injected.
Although somewhat challenging to properly design and ex-
ecute, strong and/or rigid gel treatments involving the injection of
163 August 2003 SPE Production & Facilities
partially formed gels can be used to treat 2D water coning in
hydraulically fractured production wells. In this treatment strategy,
gravity is exploited to selectively place a partially gelled solution
in the lower portion of the fracture.
9
Natural Fracture System Leading to an Aquifer (Problem
7). Several operators reported impressive (but often short-lived)
results from polymer and gel treatments in production wells in the
Arbuckle, Ellenberger, and Madison formations.
4,53,54
These treat-
ments were applied to reduce excessive water production emanat-
ing via natural fractures from underlying aquifers that provided
strong waterdrives.
Phillips applied 37 treatments in Arbuckle formations using
eight different organic polymer and polymer-crosslinker combina-
tions.
53
In their treatments, the average incremental recovery was
1.9 STB/lb polymer, with a range from 1 to 13 STB/lb. The
average time for the well to return to the pretreatment WOR and
oil production rate was 12 months, with a range from 2 to 43
months. The treatments typically reduced the total fluid produc-
tivity by a factor of 2. Interestingly, Phillips found that the incre-
mental oil recovery, treatment lifetime, and WOR reduction did
not correlate with the mass of polymer injected (390 to 1,400
lb/well), the type of polymer or gel treatment (eight types used),
the productivity reduction induced by the treatment (1 to 5), the
structural position of the completion, completion type, the fluid
level before the treatment, or the Arbuckle reservoir.
53
(Treat-
ments were applied in several Arbuckle reservoirs.)
A review of 274 water-shutoff treatments applied between
1970 and 1990 focused on gel treatments in two naturally fractured
carbonate formations (Arbuckle and Ellenberger).
4
For the results
published, the median WOR was 82 before gel injection, 7 shortly
after gel treatment, and 20 after 1 to 2 years following the treat-
ment. The median oil productivity increased by three shortly after
treatment and returned to pretreatment levels after 1 to 2 years.
The positive effects of these treatments were generally short-
lived in the Arbuckle and Ellenberger formations. However, for
several gel applications in the Madison formation in Wyoming,
reductions in the water cut were sustained for many years.
54
Chro-
mium(III)-carboxylate/acrylamide-polymer gel water-shutoff
treatments also were applied to 14 economically marginal produc-
tion wells of the mature Big Lake field in Texas.
9
On average,
water production was decreased from 3,410 to 993 barrels of water
per day (BWPD), and oil production increased, on average, from
2 to 14 barrels of oil per day (BOPD). The main producing zone
of these 14 oil wells was the dolomitic Grayburg formation that
was naturally fractured. Excess water production was believed to
be coning up through vertical fractures from the underlying active
aquifer.
9,55
During successful gel treatments in the Madison and
Grayburg formations, partially formed gels were injected. Thus,
the gel solution to these two excess-water-production problems
(Problem 7) shifts into Category C of Table 1.
Results from treatments applied to Problem 7 raise a number of
important questions. First, what is the water shutoff mechanism for
these treatments? Do the treatments work primarily because gelant
penetrates into the porous rock and provides disproportionate per-
meability reduction? Or do the treatments work because gels se-
lectively plug the lower parts of the fracture system more than the
upper parts? Is it better to inject a gelant that forms a strong gel or
a weak gel? Is it better to inject gelant, fully formed gels, or
partially formed gels, and when and where? Why were the benefits
from the treatments temporary in most cases? How should these
treatments be sized? Should preformed gels be injected instead of
gelants? Although many of these questions remain to be answered,
Ref. 56 describes engineering calculations for determining gel
properties, volume requirements, and treatment impact for gelant
treatments in the naturally fractured Motatan field in Venezuela.
Individual Fractures That Cause Channeling From Injectors
to Producers (Problem 9). Gel treatments currently provide the
most effective means to reduce channeling through frac-
tures.
4,5759
Except in narrow fractures (i.e., fracture widths of less
than 0.02 in.), extruded gels have a placement advantage vs. con-
ventional gelant treatments when treating channeling through frac-
tures. To explain, during conventional gel treatments, a fluid gelant
solution typically flows into a reservoir through both the porous
rock and the fractures. After placement, chemical reactions (i.e.,
gelation) cause an immobile gel to form. During gelant injection,
fluid velocities in the fracture are usually large enough that viscous
forces dominate gravity forces.
60
Consequently, for small-volume
treatments, the gelant front is not greatly distorted by gravity dur-
ing gelant injection. However, after gelant injection stops, a small
density difference (e.g., 1%) between the gelant and the displaced
reservoir fluids allows gravity to rapidly drain gelant from at least
the upper part of the fracture.
60
Generally, gelation times cannot be
controlled well enough to prevent gravity segregation in the time
between gelant injection and gelation.
Alternative to conventional gelant treatments, formed (pre-
formed) gels can be extruded through fractures. Because these gels
are 10
3
to 10
6
times mores viscous than gelants, gravity segrega-
tion for gels is much less important than for gelants. For some of
the most successful treatments in fractured reservoirs, formed
gels were extruded through fractures during most of the place-
ment process.
11,5759
The extrusion properties of a Cr(III)-acetate-HPAM [chro-
mium(III)-carboxylate/acrylamide-polymer] gel have been charac-
terized as a function of injection rate and time and fracture width
and length.
39
Gels concentrate or dehydrate during extrusion
through fractures. During flow in a fracture, the dehydration rate
for these gels varies inversely with the square root of time. This
fact allows gel propagation along fractures to be predicted.
39,61
[See Figs. 2 and 3 for propagation of a Cr(III)-acetate-HPAM gel
in a vertical fracture of fixed height.] To maximize gel penetration
along fractures, the highest practical injection rate should be used.
However, in wide fractures or near the end of gel injection, gel
dehydration may be desirable to form stronger and more rigid gels
that are less likely to wash out after placement. In these applica-
tions, reduced injection rates may be appropriate. In single, wide
(i.e., >0.5 in.), vertical fractures (of fixed height) where short
penetration distances are needed, the gel volume required increases
roughly with the distance of penetration. In single vertical fractures
(of fixed height) with narrow to moderate widths (i.e., 0.02 to 0.5
in.), the required gel volume increases roughly with the penetration
distance raised to the 1.5 power. A rule of thumb derived from this
latter behavior is that doubling the distance of penetration along a
given fracture (of narrow or moderate width) requires tripling the
volume of injected gel.
A minimum pressure gradient is required to extrude a given gel
through a fracture.
39
After this minimum pressure gradient is met,
the pressure gradient during gel extrusion is insensitive to the flow
rate. The pressure gradient required for gel extrusion varies in-
versely with the square of the fracture width.
39
The volume of gel
that can be injected depends critically on fracture width and gel
Fig. 2Gel propagation predictions in long two-wing fractures.
Fracture width=0.04 in.
164 August 2003 SPE Production & Facilities
properties (i.e., gel composition and rigidity). For a typical Cr(III)-
acetate-HPAM gel (containing 0.5% polymer), a 2 psi/ft pressure
gradient was noted during extrusion through a 0.1-in.-wide frac-
ture.
39
Therefore, in field applications, knowledge and/or estima-
tion of fracture widths is important for deciding the composition
and properties of the gel to be injected.
For interwell channeling, the effective average width of the
most direct fracture can be estimated from interwell tracer
tests.
62,63
Tester et al.
62
suggested that the best estimate of the
volume of a fracture path is provided by the modal volume (i.e.,
the volume associated with the peak concentration in the produced
tracer distribution). The interwell tracer time (t in days) associated
with this peak concentration can be used to estimate effective
average fracture width (w
f
in inches)
63
:
w
f
= 5.4 10
5
L
f
tp
12
, . . . . . . . . . . . . . . . . . . . . . . . . . . (4)
in which L
f
the injector-producer well separation (in feet),
tracer fluid viscosity (in cp), and p the downhole interwell
pressure drop (in psi).
For some applications in which wide fractures or large vugs are
present, gels alone may not provide sufficient mechanical strength
and flow resistance to plug the channel. In these cases, particulate
matter (sand, cellophane, fibers, nut shells, etc.) can be added to
increase the mechanical strength and plugging characteristics
of the gel.
6466
Gel jobs to treat individual fractures that cause channeling from
injectors to producers can be applied in either injection or produc-
tion wells.
Faults or Fractures That Cross Deviated or Horizontal Wells
(Problem 8). Deviated and horizontal wells are prone to intersect
faults or fractures. If these faults or fractures connect to an aquifer,
water production can jeopardize the well.
59
Often, the completions
of these wells severely limit the use of mechanical methods to
control fluid entry. In contrast, gel treatments can provide a viable
solution to this type of problem. However, conventional gelant
treatments are not the desired form of remediation in this case. In
a conventional gelant treatment, a fluid gelant solution is injected
that flows down the well into the target fracture or fault and also
leaks off into the porous rock around the wellbore and the fracture
or fault. The resultant gel may plug or severely restrict water entry
into the fracture or fault. Unfortunately, the gelant also will flow
into the exposed hydrocarbon-bearing rock all along the well dur-
ing the placement process. Consequently, after gelation, oil pro-
ductivity can be damaged as much as water productivity. Alterna-
tively, a formed gel can be pumped down the well and selectively
placed in the fracture.
39,59,61
The gel formulation may exist as an
uncrosslinked fluid at the wellhead, so long as significant gelation
occurs before the gelant reaches the oil zone. Then, because
formed gels do not enter or flow through porous rock,
67
damage to
oil productivity can be minimized. In contrast, the gel can extrude
selectively into and plug the fracture or fault. When the well is
returned to production, gel remaining in the wellbore often can
flow back to the surface. If designed properly, gel in the fault or
fracture will remain in place because the fracture width is much
smaller than the diameter of the wellbore. (The pressure gradient
required to mobilize formed gels varies inversely with the square
of fracture width or tube diameter.
39
) Alternatively, coiled tubing
can be used to circulate gel out of the wellbore.
36
(In practice,
water, oil, or an uncrosslinked polymer solution often is injected
immediately after the gel in an attempt to displace gel from the
wellbore into the fracture.
59
Because this displacement is unstable,
its effectiveness is questionable.)
If the water production problem is caused by a single fracture
or fault that intersects the horizontal wellbore, the distance of gel
penetration into the fracture need not be particularly large.
68
In this
case, the benefit gained varies approximately logarithmically with
the distance of gel penetration.
61
However, this conclusion is spe-
cific to one particular scenario (i.e., a single fault or fracture in-
tersecting a horizontal well). The conclusion may not be valid for
vertical wells, if multiple fractures or faults intersect a horizontal
well, or if a natural fracture system is present. Furthermore, even
for the case of a single fault or fracture that intersects a horizontal
well, some value may be realized by injecting a significant amount
of gel to mitigate the possibility of gel washout after the well is
returned to production.
For horizontal wells that cross individual faults or fractures,
simple calculations based on productivity data can give at least a
rudimentary indication of the width of the fracture that causes the
excess-water-production.
61
The calculations also can give an idea
of how far the gel should penetrate to provide a beneficial effect.
39
Using laboratory data coupled with field data collected before,
during, and after injection of similar gel treatments, the calcula-
tions also can give an indication of how far the gel actually pen-
etrated into the fracture.
61
To successfully make these determina-
tions, accurate flowing and static downhole pressures are critical
measurements that must be obtained during field applications of
these gel treatments.
In vertical fractures that cut through vertical wells, gel flow in
the fracture is generally linear. However, in vertical fractures that
cut through horizontal wells, the flow geometry is radial (at least
near the well). During gel extrusion through fractures of a given
width, the pressure gradient and degree of gel dehydration were
nearly independent of position and velocity during both radial and
linear flow.
69
Because the pressure gradient during gel extrusion is
almost independent of injection flux, the pressure gradient is
nearly independent of the radial position from the wellbore. Thus,
the distance of gel penetration from the wellbore (L
gel
or r
gel
) can
be estimated regardless of whether flow in the fracture is linear
or radial.
L
gel
or r
gel
= p
gel
p
water
dpdl
gel
, . . . . . . . . . . . . . . . . . . . (5)
in which p
water
the pressure drawdown (i.e., the downhole pres-
sure difference between the wellbore and the formation) during
water injection, p
gel
the pressure drawdown during gel injec-
tion, and (dp/dl)
gel
the pressure gradient required for gel extru-
sion through the fracture of interest. As mentioned earlier, the
pressure gradient for gel extrusion varies inversely with the square
of fracture width.
39
For one Cr(III)-acetate-HPAM gel (with 0.5%
HPAM) that is commonly used in field applications, the pressure
gradient (in psi/ft) for gel extrusion is related to fracture width (in
inches) with Eq. 6.
dpdl
gel
= 0.02w
f

2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6)
Of course, the coefficient in Eq. 6 (i.e., 0.02) depends on gel
composition. More rigid gels exhibit greater coefficients and pres-
sure gradients during extrusion.
Ref. 61 describes the application of the previous methodology
and equations for fractures and faults in the Prudhoe Bay field.
Refs. 59 and 68 provide additional discussion of field applications
Fig. 3Gel propagation predictions in long two-wing fractures.
Injection rate=1 BPM.
165 August 2003 SPE Production & Facilities
of gel treatments that were directed at faults that crossed deviated
or horizontal wells in Prudhoe Bay and Qatar.
Injector-Producer Channeling in Naturally Fractured Reser-
voirs (Problem 10). Some of the most successful gel treatments
were applied to reduce water and gas channeling in naturally frac-
tured reservoirs.
11,5558,68,70
The primary objective of these gel
treatments was to improve sweep efficiency and to promote incre-
mental oil production. A secondary benefit of the gel treatments
was the substantial reduction of excessive water and gas produc-
tion at the offsetting production wells. During these injection well
applications, the time required to inject large volumes (e.g., 10,000
to 37,000 bbl) of gel was typically greater than the gelation time by
a factor around 100.
11,57,58
Thus, formed gels extruded through
fractures during most of the placement process. Several operators
reported that oil recovery increased with an increased volume of
gel injected per treatment.
11,57,58
However, sizing of these treat-
ments to date has been empirical, dictated primarily by perceived
economic and operational limitations. Engineering-based sizing
methods are under development for this type of problem.
63
Theoretical work indicates that gel treatments have the greatest
potential when the conductivities of fractures that are aligned with
direct flow between an injector-producer pair are at least 10 times
the conductivity of off-trend fractures.
63
Gel treatments also have
their greatest potential in reservoirs with moderate to large fracture
spacing. Produced tracer concentrations from interwell tracer stud-
ies can help identify reservoirs that are good candidates for water
shutoff using gel treatments. The average width of the most direct
fracture between an injector-producer pair can be estimated with
Eq. 4 from the breakthrough time from an interwell tracer study.
Because the ability of a gel to extrude through a fracture depends
critically on the fracture width or conductivity,
39,67,69
this knowl-
edge is important when selecting an appropriate gel formulation
for the treatment.
Simulation studies indicate that the potential for successful ap-
plication of a gel treatment becomes greater as the peak produced
tracer concentration increases to more than 20% of the injected
tracer concentration.
63
When produced tracer concentrations are
low (i.e., less than 1% of the injected tracer concentration), gel
treatments are unlikely to be effective. However, results from a
poorly designed tracer test can mislead one to believe that a gel
treatment has little potential. For example, if the tracer bank is too
small, dispersion can reduce produced tracer concentrations to
very low values in a fracture system even though a gel treatment
has excellent potential.
Ref. 55 discusses a field example in which tracer testing was
conducted in conjunction with the application of injection-well
chromium(III)-carboxylate/acrylamide polymer (CC/AP) gel treat-
ments to the Tensleep sandstone formation of the Pitchfork Field
in Wyoming.
Gel treatments to reduce injector-producer channeling in natu-
rally fractured reservoirs can be applied in either injection or pro-
duction wells. Well documented field applications involving in-
jector-producer channeling in naturally fractured reservoirs can be
found in Refs. 11, 55, 57, 58, and 70.
3D Coning and Cusping (Problems 11 and 12). Gelant or gel
treatments have an extremely low probability of success when
applied toward cusping or 3D coning problems occurring in un-
fractured matrix reservoir rock. When treating coning problems, a
common misconception is that the gelant will enter only the water
zones at the bottom of the well. In reality, this situation will occur
only if the oil is extremely viscous and/or the aqueous gelant is
injected at an extremely low rate (to exploit gravity during gelant
placement). In the majority of field applications to date, the crude
oils were not particularly viscous, and gelant injection rates were
relatively high. Consequently, one must be concerned about dam-
age that polymer or gel treatments cause to hydrocarbon-
productive zones.
Even if a polymer or gel reduces k
w
without affecting k
o
, gel
treatments have limited utility in treating 3D coning problems.
Extensive numerical studies using a variety of coning models in-
dicate that gel treatments can provide improvement only if the
desired production rate is less than 1.5 to 5 times the pretreatment
critical rate.
47,52
This circumstance rarely occurs.
In contrast to the very limited potential of polymers and gels in
successfully treating 3D coning, these treatments have much
greater potential for successfully treating 2D coning in which
vertical fractures cause water from an underlying aquifer to be
sucked up into a well. Whereas gel treatments will only raise the
critical rate by factors from 1.5 to 5 in unfractured wells, they
can raise the critical rate by a factor of more than 100 in frac-
tured wells.
47,52
A number of literature reports suggested that gel or foam
treatments were effective in mitigating 3D coning. A critical ex-
amination of these reports
71
revealed that they fall into one of
three categories:
Evidence suggests that flow behind pipe or fractures or frac-
ture-like features were the actual cause of the coning.
Results were not convincing that the treatment reduced the
WOR, gas/oil ratio, or water/gas ratio.
Insufficient evidence was presented to determine whether the
problem was caused by 3D coning, flow behind pipe, or flow
through fractures or fracture-like features.
The experience of Shell/Petroleum Development Oman in the
Marmul field provides an interesting exception to the previous
observations.
72
Out of 14 gel treatments, 5 were quite successful in
reducing the water cutup to 45% in one case. Convincing evi-
dence was presented that flow behind pipe and fracture-like fea-
tures were not important. Gelant (0.4 to 0.5% cationic polyacryl-
amide with glyoxal as a crosslinker) was bullheaded into the wells,
using 700 to 2,500 bbl per treatment (11 to 19 bbl per ft in gravel-
packed completions). The key question is, why were five of the
treatments successful, when basic reservoir engineering calcula-
tions indicate a very low probability for success for gel treatments
in 3D coning applications? The answer may be tied to two special
characteristics of this field. First, Shells simulation work suggests
that effective barriers to vertical flow are present.
72
These barriers
were not recognized when the first treatments were applied. Sec-
ond, the oil viscosity was approximately 80 cp. Thus, viscous
fingers of water may have arrived at a given well much earlier in
some of the discrete zones than others. Because the oil was much
more viscous than the gelant (10 cp), the gelant may have fol-
lowed these water fingers and preferentially reduced flow in the
water zones to a much greater extent than if a light oil was present.
This scenario is consistent with basic reservoir engineering calcu-
lations.
17,47
Of course, this scenario suggests that the real problem
in this reservoir was not 3D coning, but rather viscous fingering
through discrete high-permeability pathways. Thus, consistent
with our original contention, gelant treatments are unlikely to be
effective against 3D coning.
Gel treatments also are expected to be ineffective when treating
cusping. In cusping, like 3D coning, the well is produced so rap-
idly that viscous forces overcome gravity forces. For cusping in
particular, water from an aquifer follows an inclined zone up to the
well. The only practical method to stop water production from the
zone (other than decreasing the production rate) is to plug the zone.
Unless extraordinary circumstances exist (as in the previous Mar-
mul case), hydrocarbon-productive zones in radial flow must be
protected during gelant placement. (For the Marmul treatments,
one wonders whether the success rate might have been 14/14 in-
stead of 5/14 if hydrocarbon zones had been protected during
gelant placement.)
Injector-Producer Channeling in Unfractured Reservoirs
With Crossflow (Problem 13). Gelant and gel treatments are
expected to be ineffective for treating injector-producer channeling
in unfractured reservoirs where fluids can crossflow between
zones.
22
For many years, engineers recognized that near-wellbore
blocking agents are ineffective in these applications.
73
Even if the
blocking agent could be confined only to the high permeability
channel, water quickly crossflows around any relatively small
plug. The only hope for blocking agents in these applications exists
if a very large plug (i.e., that plugs most of the channel) can be
166 August 2003 SPE Production & Facilities
selectively placed only in the high permeability zone.
73
Unfortu-
nately, existing gelants (including the so-called colloidal disper-
sion gels) enter and damage all open zones in accordance with the
Darcy equation and basic reservoir-engineering principles.
22
Pen-
etration and damage caused to the less-permeable zones is greater
for viscous gelants than for low-viscosity fluids. Also, penetration
and damage caused to the less-permeable zones is greater when
crossflow can occur than when crossflow cannot occur.
22
Al-
though an admirable attempt was made to devise a sophisticated
process in which gelant treatments might be effective in treating
this type of problem,
74,75
traditional polymer floods provide a
more cost-effective and reliable solution.
22,7679
Refs. 76 through
79 provide illustrative examples of polymer floods in various
fields throughout the world.
Conclusions
1. When addressing excess-water-production problems, the easiest
problems should be attacked first, and diagnosis of water pro-
duction problems should begin with information already at
hand. To facilitate implementation of this strategy, a prioritiza-
tion of water production problems was provided (Table 1).
2. Conventional methods (e.g., cement and mechanical devices)
normally should be applied first to treat the easiest problems,
(i.e., casing leaks and flow behind pipe where cement can be
placed effectively and unfractured wells where flow barriers
separate water and hydrocarbon zones).
3. Gelant treatments are normally the best option for casing leaks
and flow behind pipe with flow restrictions that prevent effec-
tive cement placement.
4. Both gelants and preformed gels have been successfully applied
to treat hydraulic or natural fractures that connect to an aquifer.
5. Treatments with preformed or partially formed gels are nor-
mally the best option for faults or fractures crossing a deviated
or horizontal well, for a single fracture causing channeling be-
tween wells, or for a natural fracture system that allows chan-
neling between wells.
6. Gel treatments should not be used to treat the most difficult
problems (i.e., 3D coning, cusping, or channeling through strata
with crossflow).
Nomenclature
dp/dl pressure gradient, psi/ft (Pa/m)
F
rr
residual resistance factor
F
rro
oil residual resistance factor
h height, ft (m)
k permeability, darcys (m
2
)
k
gas
permeability to gas, darcys (m
2
)
k
o
permeability to oil, darcys (m
2
)
k
w
permeability to water, darcys (m
2
)
L distance along a fracture, ft (m)
L
f
fracture length, ft (m)
L
gel
distance of gel penetration along a fracture, ft (m)
q total injection or production rate, BPD (m
3
/D)
r
e
external drainage radius, ft (m)
r
gel
radius of gel penetration, ft (m)
r
w
wellbore radius, ft (m)
S
or
residual oil saturation
t time, days
w
f
fracture width, in. (m)
p pressure drop, psi (Pa)
p
gel
pressure drop during gel injection, psi (Pa)
p
water
pressure drop during water injection, psi (Pa)
viscosity, cp (mPas)
Acknowledgments
Financial support for this work is gratefully acknowledged
from the Natl. Petroleum Technology Office and NETL of the
U.S. Dept. of Energy, BP plc, ChevronTexaco, China Natl. Petro-
leum Corp., Chinese Petroleum Corp., ConocoPhillips, Marathon,
and Shell.
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SI Metric Conversion Factors
acre 4.046 873 E+03 m
2
bbl 1.589 873 E01 m
3
cp 1.0* E03 Pas
ft 3.048* E01 m
in. 2.54* E+00 cm
lbm 4.535 924 E01 kg
psi 6.894 757 E+00 kPa
*Conversion is exact.
Randy Seright is a senior engineer at the New Mexico Petro-
leum Recovery Research Center at New Mexico Tech in So-
corro. e-mail: [email protected]. He was an SPE Distin-
guished Lecturer for 199394. Robert Lane heads Northstar
Technologies Intl. and previously worked for Arco. e-mail:
[email protected]. He was an SPE Distinguished Lec-
turer for 19992000 and now serves on the Distinguished Lec-
turer Selection Committee and the Oilfield Chemistry Program
Committee. Robert Sydansk heads Sydansk Consulting Ser-
vices after working 33 years at Marathon Oil Co. in chemical
IOR R&D. e-mail: [email protected]. He is an SPE Distin-
guished Member, was an SPE Distinguished Lecturer for
199798, is cochairperson of the SPE EOR/IOR Technical Inter-
est Group and serves as a Technical Editor on the SPE Produc-
tion & Facilities Editorial Review Committee.
169 August 2003 SPE Production & Facilities