Thermal EOR Conformance – A New Frontier for Asset Optimization: Steam Shutoff Pilot in Oman

Over the last 50 years, thermal EOR has been an effective method for reducing the viscosity of and recovering heavy oil from deep reservoirs. In mature thermal EOR projects, conformance is one of the main challenges for maximizing reserves and meeting long-term production expectations. In this paper, Occidental presents a novel pilot to address thermal conformance in the Mukhaizna field in Oman. This is a thermal EOR operation in deep reservoirs (> 2,000 ft) with extremely high viscosity (>10,000 cp) in harsh desert conditions with temperatures exceeding 500°F. The pilot area is a mature thermal area with 15 years of continuous steamflood operations. The novel conformance technique, based on a combination of chemical and zonal mechanical isolation systems, was developed in-house in a low oil price environment. The pilot area consists of multiple reservoir zones that have undergone vertical steam injection since 2005. Thermal conformance has emerged as a challenge because more than 60% of the injected steam has been preferentially entering the high-permeability zones, with only 40% of the steam entering the other zones, which hold a larger amount the remaining oil. The subsurface and well engineering teams collaborated to design a rigless operation using dual coiled tubing units, one for cooling water and one pumping a chemical gelation recipe that gels at a certain trigger gelation temperature at the target zone. Zonal isolation of the reservoir is achieved using a novel inflatable packer triggered mechanically by ball gravitation through coiled tubing at 500°F and retrieved after the temporary zonal isolation. The well and reservoir surveillance included gathering data for injectivity assessment, vertical injection logging, temperature profiles, tracer tests in offset producers, and well testing for determining water cut. The pilot improved vertical conformance, as injection logging showed 40% steam reduction was achieved in the target zone, and more steam was re-allocated to the shallow zones. In addition, there was a water cut reduction of more than 20% in offset producers, and oil production tripled over a period of 3 months, which paid back the cost of the pilot and generated positive cash flow. To our knowledge, based on an SPE literature search, this is the first successful thermal conformance operation conducted with the following combination of technologies: 1) Placing a novel chemical recipe through temporary zonal isolation with an inflatable packer, and 2) Using rigless operation of coiled tubing units at harsh conditions of >500°F and high pressure >1000 psi. The outcomes open a new frontier for thermal EOR development in multi-stack reservoirs, offering better utilization of steam injection and improving mobility control over the field life cycle. The cost of the pilot project was paid off in the first 6 weeks, and all chemicals used were developed in an eco-friendly system.