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Ultrasonic automated oil well complex and technology for enhancing marginal well productivity and heavy oil recovery
Accepted Manuscript Ultrasonic automated oil well complex and technology for enhancing marginal well productivity and heavy oil recovery M.S. Mullakaev, V.O. Abramov, A.V. Abramova PII:
S0920-4105(17)30724-6
DOI:
10.1016/j.petrol.2017.09.019
Reference:
PETROL 4262
To appear in:
Journal of Petroleum Science and Engineering
Received Date: 26 March 2017 Revised Date:
9 September 2017
Accepted Date: 11 September 2017
Please cite this article as: Mullakaev, M.S., Abramov, V.O., Abramova, A.V., Ultrasonic automated oil well complex and technology for enhancing marginal well productivity and heavy oil recovery, Journal of Petroleum Science and Engineering (2017), doi: 10.1016/j.petrol.2017.09.019. This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.
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Ultrasonic Automated Oil Well Complex and Technology for Enhancing Marginal Well Productivity and Heavy Oil Recovery M. S. Mullakaev*, V. O. Abramov, and A. V. Abramova Kurnakov Institute of General and Inorganic Chemistry, Russian Academy of Sciences, Leninskii pr. 31, Moscow, 119991 Russia *E-mail: [email protected]
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Abstract An ultrasonic automated oil well complex is developed that includes an ultrasonic oil well module MSUM based on magnetostrictive transducers, an ultrasonic oil well module MSUP based on piezoceramic transducers, and a workstation. The developed complex makes it possible to control and record the parameters of ultrasonic modules MSUM and MSUP and to collect information on the parameters of the near-wellbore area during the sonochemical treatment of oil formations under different geological and technical conditions. The field tests of the complex in the wells of the Samotlor oil field (Western Siberia) have shown that after sonochemical stimulation of the nearwellbore region the average increase in the daily production rate of oil wells is 5.2 tons per day, the increase in the well productivity index is on average 107%, and the decrease in the water cut of the well fluid is on average 28%. The fundamentally new advantages of the technology are as follows: the simplicity of application (it is not more complex than the geophysical study of wells), the possibility of introducing the reagents of various chemical natures into the near-wellbore area, the selectivity of treatment, the absence of a negative effect on the production string and the cement sheath, environmentally friendly, and the absence of a negative impact on the health of operators. The developed oil well complex and sonochemical technology are offered to oilfield service companies for stimulating low-productivity wells and heavy oil production.
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Keywords: Enhanced oil recovery (EOR); Heavy oil recovery enhancement; Acoustic well stimulation; Ultrasonic oil well stimulation; Sonochemical technology; Ultrasound.
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1. Introduction Evaluating the prospects of crude oil production in the world, it can be stated that the epoch of low-cost and easily produced oil has come to an end. In Russia, as in the entire world, the discovered reserves of light oil are being depleted, and the production of heavy oil with a high paraffin, resin, and asphaltene content increases. From the standpoint of rational nature management, the development of new combined environmentally safe and effective technologies for enhanced oil recovery will ensure substantial saving in material resources, a decrease in environmental impact, and an increase in the cost efficiency of crude oil production. The basis for this is the intensive development of basic and applied research. At present, the possibility of using acoustic methods for enhancing processes in the oil and gas industry is extensively studied. Due to the effect of ultrasonic vibrations in crude oil production, there are an increase in the permeability of the near-wellbore region of formations, dewaxing, acoustic degassing, a decrease in the viscosity of oil, etc. [1–14]. The early use of sound to revitalize oil wells involved sonic waves of a much longer wavelength than ultrasound (often termed seismic waves) which were used to restart the flow. One of the oldest patents was taken out in 1939 [15]. The theory behind this was that when such a wave passes through porous media it will be dispersed into higher harmonics (ultrasonic waves) producing a series of effects that include: the disruption of the surface film, the coalescence of oil drops together with oscillation, and the excitation of oil drops trapped in capillaries. The theory underlying the use of ultrasound for oil recovery continues to be of interest [16]. The mechanisms responsible for improving the flow of oil through porous media under the effect of an ultrasonic field were reported in [17–19], and they are as follows: 1
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• An increase in the relative permeability of phases takes place [20, 21]; • Arising nonlinear acoustic effects in pores (cavitation, acoustic streaming, and sound pressure) decrease capillary forces due to the destruction of surface films and increase the rate of fluid flow through porous media [19, 20]; • The surface tension, density, and viscosity of the fluid are reduced due to ultrasonic heating [22, 23]; • The peristaltic transport of the fluid occurs due to the mechanical vibration of the pore walls by which the fluid is forced through pores [24]; • The microemulsification of oil in the presence of natural or introduced surfactants takes place, the solubility of surfactants increases, and the adsorption of surfactants decreases [21, 25]; • The coalescence of oil droplets occurs due to the Bjerknes forces [26, 27]; • The permeability and porosity of rocks are increased due to the deformation of pores, the perforation channels and pores of a reservoir are cleaned from asphaltene, resin, and paraffin deposits and other inclusions, and the skin effect is decreased [19]; • The origination of interstitial convection leads to a change in the thermal conductivity of fluid-saturated media, a decrease in the skin effect, and, as a consequence, an increase in the productivity of oil wells [19]; • Sound pressure reduces the shear viscosity of the fluid, which leads to an increase in the rate of fluid flow through porous media [19, 28]. In this study, we provide practical evidence obtained directly from oil well experiments which show conclusively that the use of ultrasonic downhole stimulation of oil wells is a viable process [29]. The efficiency of acoustic well stimulation can be substantially increased due to the mathematical modeling of physical processes that occur in the near-wellbore area [30, 31], the correct selection of candidate wells for acoustic treatment, and the development of high-efficiency equipment and technology for increasing the productivity of oil wells [30–38]. The present work is the continuation of our studies dealing with the development of an ultrasonic oil well module MSUM based on magnetostrictive transducers [39] and an ultrasonic oil well module MSUP based on piezoceramic transducers [40]. The objective of this work is to improve technologies for restoring or enhancing the productivity of oil wells using the developed ultrasonic modules MSUM and MSUP as part of an automated oil well complex for combined ultrasonic and chemical treatment (sonochemical stimulation) of oil formations under different geological and technical conditions. The development of the automated complex has made the implementation of sonochemical technology considerably easier: the simplicity of application due to process automation; the continuous control of treatment; the possibility of introducing the reagents of various chemical natures into the near-wellbore area; the selectivity of treatment; and the possibility of high-viscosity and heavy oil recovery. 2. Development of ultrasonic automated oil well complex The complex performs the combined ultrasonic and chemical treatment (sonochemical stimulation) of oil wells and provides automated control, diagnostics of its state, and documentation and visual image of the occurrence of processes in the near-wellbore area of the well. The technical characteristics of the complex are given in Table 1.
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Value 4000 1020 0–135 0–45 45 1 No less than 95 No less than 1.6
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Table 1. Technical characteristics of the complex Characteristics Maximum depth of well treatment, m Maximum density of the fluid in the near-wellbore area, kg/m3 Range of temperature measurement in the near-wellbore area, °C Range of pressure measurement in the near-wellbore area, MPa Maximum pressure of chemical injection, MPa Maximum flow rate of chemicals, m3/min Efficiency of ultrasonic generators TS6M and TS10W, % Output power of the transducers of downhole tools PSPK and PSMS, kW Power supply (number of phases х voltage, V / frequency, Hz) Power consumption, kW
3 × 380 / 50, 60 No more than 15
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The developed ultrasonic oil well complex consists of the following equipment (Fig. 1): • magnetostrictive ultrasonic oil well module MSUM; • piezoceramic ultrasonic oil well module MSUP; • workstation; • package of maintenance documentation; • package of technical documentation on the modes and parameters of the treatment of the near-wellbore zone; • set of spare parts, tools, and accessories.
Fig. 1. Block diagram of the ultrasonic automated oil well complex (UAOWC). The magnetostrictive ultrasonic oil well module MSUM consists of surface equipment, which includes an upgraded ultrasonic generator TS10W, and downhole equipment, which includes 3
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downhole tools with magnetostrictive transducers with a diameter of 42 mm (PSMS-42) and a diameter of 102 mm (PSMS-102). In contrast to previous-generation generators, the controller of the developed generator includes a unit that ensures the receipt of data on pressure and temperature in a well from a downhole tool, their processing and transmission to an external computer. The detailed description and technical characteristics of the ultrasonic oil well module MSUM are given in [39]. The piezoceramic ultrasonic oil well module MSUP consists of surface equipment, which includes an upgraded ultrasonic generator ТS6Р, and downhole equipment, which includes downhole tools with piezoceramic transducers with a diameter of 44 mm (PSPK-44) and a diameter of 52 mm (PSPK-52). The possibility of varying the frequency and intensity of radiation, depending on the geological and technical conditions of the near-wellbore region, makes it possible to achieve a high efficiency of its treatment. The detailed description and technical characteristics of the ultrasonic oil well module MSUP are given in [40]. The workstation of the complex has been developed that makes it possible to operate the complex in the automatic mode. The workstation issues control instructions and receives the controlled and recorded parameters of ultrasonic modules MSUM and MSUP and a device for chemical dosing, controls the operation of ultrasonic generators, controls and diagnoses the technical state of the complex, and records and archives the operating modes and parameters of the complex. The workstation includes an industrial panel computer with a touch screen and a printer, which is connected via RS-232 ports to an ultrasonic generator, a log recorder, and a setup for chemical well treatment. A layout for an ultrasonic generator, which is arranged on a special rack, an industrial computer, and a workstation in the laboratory compartment of the well logging truck hoist PKS-5GT has been developed. The software runs under Debian GNU/Linux or Ubuntu (Kubuntu, Xubuntu) with the x86 architecture (32-bit PC). The software creates a low computational load, does not impose special requirements on a hardware platform, and can be installed on any up-to-date personal computer. A personal computer with an Intel Atom 1.8 GHz processor, a 1 GB random access memory, and a 60 GB hard disk can be used as a hardware platform. A well-logging system YUGRA with a printer, which operates together with a downhole tool SOVA D-42 and ensures the study of the geophysical parameters of the near-wellbore region and a tie-in to the perforated interval of the well, is located in the lower section of the rack (Fig. 2а). The general appearance of the workstation is shown in Fig. 2b.
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(b) Fig. 2. (a) Arrangement of ultrasonic generators TS6P and TS10W and a workstation in the well logging truck hoist PKS-5G-T and (b) general appearance of the workstation.
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3. Field testing of ultrasonic automated oil well complex The field testing of the ultrasonic automated oil well complex was performed in oil fields in Western Siberia (the Samotlor oil field) and Samara Region, which are on the late stage of development and the main reserves are concentrated in highly nonhomogeneous, partially waterflooded reservoirs. In each specific case, the technological arrangement of ultrasonic equipment in wells depended on the chemical composition of oil and such geological factors as net and gross pay zones, permeability, compartmentalization, areal and sectional inhomogeneity, elastic properties of the formation, and the sizes of impermeable shields, as well as the operating modes of the field as a whole: the closeness of injection, the state of formation pressure, etc. Criteria for the selection of wells for the ultrasonic treatment of the near-wellbore region were as follows: • the operating mode of a candidate well for the past period from the beginning of operation was analyzed; • the density and composition of a well-killing fluid during repairs were studied;
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• all forms of action on the near-wellbore area of the candidate well for the entire operating period (physical, chemical, acoustic, etc.) and the results of these actions on well performance parameters were investigated; • the effect of formation pressure on a decrease in the production rate of the candidate well was evaluated using data on formation pressure and operating modes of adjacent wells with a similar geological structure; • the principal cause of a decrease in the production rate for the operating period was determined. More detailed information on the selection criteria and the cutoff values for ultrasonic treatment during major repair is given in [40]. The operation of the complex on site is provided with the following standard equipment, which is not part of the complete set of the complex: • well logging truck hoist PKS-5G-T with an umbilical cable TG-15/44-100-(2х2.5+4х0.75) for the placement of ultrasonic modules MSUM and MSUP and the deployment of workstations; • pumping unit SIN-32; • tank truck ATs-10 with service water; • geophysical complex SOVA D-42 in the well logging truck hoist PKS-5G-T; • recorder of geophysical parameters YUGRA in the well logging truck hoist PKS-5G-T; • lubricator; • feeder for an umbilical cable; • device for chemical dosing UDPKh-LOZNA with a control unit in a truck-mounted block box for the preparation of a mixture of chemical reagents from dry and liquid components and its supply at a flow rate of up to 1 m3/min and a pressure of up to 45 MPa; • umbilical cable with a length of no less than 4100 m, a breaking load of no less than 7.0 t, and a channel that is capable of withstanding pressure up to 45 MPa. The operating modes of the complex are as follows: Mode 1. Ultrasonic treatment of the near-wellbore area. Mode 2. Sonochemical treatment of the near-wellbore area. Mode 3. Treatment of the near-wellbore area in heavy oil recovery. Mode 4. Emergency operation: automatic safe shutdown condition. A technology for treating the near-wellbore region by the complex in modes 1 and 2 is described in detail in [39]. Let us dwell upon a technology for treating the near-wellbore zone in heavy oil production (mode 3). Figure 3 shows the arrangement of equipment during ultrasonic oil well stimulation by the downhole tool PSMS-102, which is mounted on the tubing and powered through a cable with a length of up to 4000 m. The technology of round-trip operations for the downhole tool PSMS-102 in heavy oil recovery is similar to the technology used to lower submersible pumps [13, 14]: • a well is killed (during the major or scheduled repair of wells), and a pump is dismantled; • operations are performed for lowering the tubing with a cable for the power supply of submersible pumps; • the downhole tool PSMS-102 is mounted on the tubing with a power cable; • the downhole tool PSMS-102 is lowered into the perforated zone; • the pump is mounted on the tubing depending on the dynamic fluid level in the well; • the pump is switched on, and well performance is brought to the production rate that was prior to mounting operations; • based on an analysis of the geological and technological characteristics of wells, the operating parameters of the downhole tool PSMS-102 (power and operating time) are determined, and the tool is switched on.
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Fig. 3. Ultrasonic stimulation of the near-wellbore region by the downhole tool PSMS-102: 1 – anchor, 2 – ultrasonic generator, 3 – downhole tool PSMS-102, 4 – casing, 5 – tubing, 6 – producing formation, 7 – ultrasonic field, 8 – perforated zone, 9 – sucker-rod pump, and 10 – power cable for the downhole tool.
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In the case of a high gas–oil ratio, a separator was installed ahead of the pump. In heavy oil production, the plugging of formation pores occurs rather rapidly; therefore, the downhole tool PSMS-102 mounted on the tubing was located in the perforated zone on a permanent basis. Depending on the specific features of wells, the treatment of the near-wellbore region was performed intermittently during a day in order to prevent the blocking of channels. The field tests of the complex using the ultrasonic oil well module MSUM based on magnetostrictive transducers and the technology of its use for the treatment of the near-wellbore area were performed in the Samotlor oil field in Western Siberia and in the oil fields of Samara Region (Russia) and are described in detail in [39]. They have shown that after ultrasonic well treatment the average increase in the oil production rate was 4.4 tons per day for Western Siberia and 10.2 tons per day for Samara Region, the increase in the well productivity index was on average 33%, the decrease in the water cut of the well fluid was on average 4%, and the percentage of successful treatments was up to 90%. The field tests of the complex using the ultrasonic oil well module MSUP based on piezoceramic transducers and the technology of its use for the treatment of the near-wellbore area were performed in the Samotlor oil field in Western Siberia (Russia) and are described in detail in [40]. An analysis of the results of ultrasonic well stimulation in 27 production wells has shown that the average increase in the oil production rate was 5.4 tons per day (75%), the increase in the well productivity index was on average 40%, and the decrease in the water cut of the well fluid was on average 8.2%. The field tests of the complex using sonochemical technology were performed in the formations that fall into the BC group (the permeability is lower than 20 mD, and the porosity is less than 15%). The efficiency of the ultrasonic treatment of these formations is not high due to the imperfection of the technology of well completion and the negative factor of well killing after the 7
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treatment of the near-wellbore region, since the negative effect of well killing increases with an increase in the depth. Inorganic gel-forming compositions GALKA and polymeric gel-forming compositions METKA were used as gelling agents, and compositions IKhN-60, IKhN-100, and NINKA were used as oil-displacing agents [41]. Treatment by these reagents is applicable for oil fields with various geological and physical conditions (the permeability is in the range of 0.005–0.5 µm2, and the temperature is in the range of 20–120°C), and it is the most effective for nonhomogeneous lowpermeability reservoirs (Jurassic and Cretaceous deposits) [42]. The cancellation of the use of acid reagents is dictated by the fact that they reduce one of the strongest advantages of ultrasonic technologies, i.e., environmental safety. Nine wells (six production wells and three injection wells) in the Samotlor oil field (Western Siberia) were treated within the framework of field tests [31, 38]. In all of the cases, treatment was effective, and the duration of the effect after treatment is from six months to one year. The averaged results of treatments for all of the wells are given in Table 2.
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Table 2. Averaged parameters before and after treatment Parameters Before treatment Oil production rate, tons per day 2.9 Water cut, % 48.5 Well productivity index 0.14
After treatment 8.1 35.1 0.29
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The efficiency of the sonochemical method can also be clearly seen from the results of the treatment of three injection wells, two of which (wells nos. 51240 and 51220) were subjected to sonochemical treatment, and one (well no. 5550) was only subjected to ultrasonic treatment (Fig. 4). As is seen from the figure, there is a clear synergistic effect under the conditions of combined treatment with ultrasound and chemicals.
Fig. 4. Change in the intake capacity of injection wells in the formations that fall into the BC group after sonochemical treatment. 4. Conclusions 1. An ultrasonic automated oil well complex is developed that includes an ultrasonic oil well module MSUM based on magnetostrictive transducers, an ultrasonic oil well module MSUP based on piezoceramic transducers, and a workstation. The developed complex makes it possible to control and record the parameters of ultrasonic modules MSUM and MSUP and to collect 8
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information on the parameters of the near-wellbore area during the sonochemical treatment of oil formations under different geological and technical conditions. 2. The field tests of the complex in the wells of the Samotlor oil field (Western Siberia) have shown that after sonochemical stimulation of the near-wellbore area: • the average increase in the oil production rate is 5.2 tons per day; • the average well productivity index increases from 0.14 to 0.29 (by 107%); • the decrease in the water cut of the well fluid is on average 28%. 3. The fundamentally new advantages of the technology are as follows: • the simplicity of application (it is not more complex than the geophysical study of wells); • the possibility of introducing the reagents of various chemical natures into the nearwellbore area; • the selectivity of treatment; • the absence of a negative effect on the production string and the cement sheath; • environmental safety; • the absence of a negative impact on the health of operators. 4. The developed oil well complex and sonochemical technology are offered to oilfield service companies for stimulating low-productivity wells and heavy oil production.
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5. References 1. Caicedo, S., 2009. Feasibility study of ultrasound for oil well stimulation based on waveproperties considerations. SPE Prod. Oper. 24, 81–86. 2. Hamidi, H., Rafati, R., Junin, R.B., Manan M.A., 2012. A role of ultrasonic frequency and power on oil mobilization in underground petroleum reservoirs. J. Pet. Explor. Prod. Technol. 2, 29–36. 3. Amro, M.M., Al-Mobarky, M.A., Al-Homadhi, E.S., 2007. Improved oil recovery by application of ultrasound waves to waterflooding. SPE 105370. 15th SPE Middle East Oil and Gas Show and Conference, Kingdom of Bahrain, 11–14 March 2007, pp. 1015–1022, doi: 10.2118/105370-MS. 4. Mason, T.J., Collings, A., Sumel, A., 2004. Sonic and ultrasonic removal of chemical contaminants from soil in the laboratory and on a large scale. Ultrason. Sonochem. 11, 205–210. 5. Kobayashi, T., Kobayashi, T., Fujii, N., 2000. Effect of ultrasound on enhanced permeability during membrane water treatment. Jpn. J. Appl. Phys. 39, 2980–2981. 6. Hamida, T., Babadagli, T., 2007. Fluid-fluid interaction during miscible and immiscible displacement under ultrasonic waves. Eur. Phys. J. B. 60, 447–462, doi: 10.1140/epjb/e2008-000055. 7. Tunio, S.Q., Tunio, A.H., Ghirano, N.A., El Adawy, Z.M., 2011. Comparison of different enhanced oil recovery techniques for better oil productivity. Int. J. Appl. Sci. Technol. 1, 143–153. 8. Watkins, G.C., Chant Sharp, K., 1985. Enhanced oil recovery: retrospect and prospect. J. Can. Pet. Technol. 24, article ID 85-01-04, doi: 10.2118/85-01-04. 9. Mullakaev, M.S., Abramov, O.V., Abramov V.O., 2008. Development and study of operating efficiency of technological ultrasonic installations. Chem. Pet. Eng. 44, 433–440. 10. Abramov, O.V., Abramov, V.O., Mullakaev, M.S., Artemev, V.V., 2009. The efficiency of ultrasonic oscillations transfer into the load. Acoust. Phys. 55, 894–909. 11. Mullakaev, M.S., Abramov, V.O., Pechkov A.A., 2009. Ultrasonic unit for restoring oil wells. Chem. Pet. Eng. 45, 133–137. 12. Mullakaev, M.S., Abramov, O.V., Abramov, V.O., Gradov, O.M., Pechkov, A.A., 2009. An ultrasonic technology for productivity restoration in low-flow boreholes. Chem. Pet. Eng. 45, 203– 210. 13. Mullakaev, M.S., 2011. Ultrasonic Intensification of Oil Production, Oil Refining, and Purification of Oil-Contaminated Water and Soil. Sc.D. Dissertation. Moscow State Univ. of Environmental Engineering, Moscow. 14. Mullakaev, M.S., 2014. Ultrasonic Enhancement of Oil Production and Refining. VNIIOENG, Moscow. 9
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15. Brammer, G.R., 1939. Well flow stimulator. US Patent 2184809. 16. Hamida, T., Babadagli, T., 2007, Analysis of capillary interaction and oil recovery under ultrasonic waves. Transp. Porous Med. 70, 231–255. 17. Beresnev, I.A., Johnson, P.A., 1994. Elastic-wave stimulation of oil production: a review of methods and results. Geophysics. 59, 1000–1017. 18. Hamida, T., Babadagli, T., 2008. Displacement of oil by different interfacial tension fluids under ultrasonic waves. Colloids Surf., A. 316, 176–189. 19. Dyblenko, V.P., 2008. Wave Methods for Stimulating Oil Reservoirs with Hard-To-Extract Reserves: Review and Classification. VNIIOENG, Moscow. 20. Nikolaevskii, V.N., 1989. Mechanism of vibroaction for oil recovery from reservoirs and dominant frequencies. Dokl. Akad. Nauk SSSR. 307, 570–575. 21. Mikhailov, D.N., Nikolaevskii, V.N., 2000. Dynamics of flow through porous media with unsteady phase permeabilities. Fluid Dyn. 35, 715–724. 22. Fairbanks, H.V., Chen, W.I., 1971. Ultrasonic acceleration of liquid flow through porous media. Chem. Eng. Prog., Symp. Ser. 67, 108–116. 23. Maximov, G.A., Radchenko, A.V., 2005. Modeling of the intensification of oil production by an acoustic action on the oil pool from the borehole. Acoust. Phys. 51, suppl. 1, S102–S114. 24. Aarts, A.C.T., Ooms, G., Bil, K.J., Bot, E.T.G., 1999. Enhancement of liquid flow through a porous medium by ultrasonic radiation. SPE J. 4, 321, doi: https://doi.org/10.2118/57720-PA. 25. Abismaı̈ l, B., Canselier, J.P., Wilhelm, A.M., Delmas, H., Gourdon, C., 1999. Emulsification by ultrasound: drop size distribution and stability. Ultrason. Sonochem. 6, 75–83. 26. Bjerknes, V.F.K., 1906. Fields of Force. Columbia University Press, New York. 27. Mettin, R., Akhatov, I., Parlitz, U., Ohl, C.D., Lauterborn, W., 1997. Bjerknes forces between small cavitation bubbles in a strong acoustic field. Phys. Rev. E. 56, 2924–2931. 28. Mullakaev, M.S., Volkova, G.I., Gradov, O.M., 2015. Effect of ultrasound on the viscositytemperature properties of crude oils of various compositions. Theor. Found. Chem. Eng. 49, 287– 296. 29. Abramov, V., Abramova, A., Bayazitov, V., Saltikov, Yu., 2012. Some applications of ultrasonic technology in the oil industry. 13th Meeting of the European Society of Sonochemistry. Lviv, Ukraine, July 2012, pp. 22–23. 30. Prachkin, V.G., Mullakaev, М.S., Asylbaev, D.F., 2015. Improving the productivity of wells by means of acoustic impact on high-viscosity oil in the channels of the face zone of a well. Chem. Pet. Eng. 50, 571–578. 31. Abramov, V.O., Mullakaev, M.S., Abramova, A.V., Esipov, I.B., Mason, T.J., 2013. Ultrasonic technology for enhanced oil recovery from failing oil wells and the equipment for its implemention. Ultrason. Sonochem. 20, 1289–1295. 32. Abramov, O.V., Abramov, V.O., Pechkov, A.A., and Mullakaev, M.S., 2010. A method for cleaning the near-wellbore area and apparatus for its implementation. RF Patent 2396420. 33. Abramova, A.V., Bayazitov, V.M., Mullakaev, M.S., Pechkov, A.A., 2011. A complex of equipment for high-viscosity oil production. RF Patent 2450119. 34. Apasov, T.K., Abramov, V.O., Mullakaev, M.S., Saltikov, Yu.A., Apasov, G.T., Apasov, R.T., 2011. Integrated schemes for ultrasonic well stimulation in the Samotlor oil field. Sci. FEС, 80–84. 35. Mullakaev, M.S., Abramov, V.O., Pechkov, A.A., Eremenko, I.L., Novotortsev, V.M., Bayasitov, V.M., Esipov, I.B., Baranov, D.A., Saltikov, A.A., 2012. Ultrasonic technology for productivity increase of low production wells. Oilfield Eng., 25–31. 36. Abramov, V.O., Mullakaev, M.S., Kalinnikov, V.Т., Abramova, A.V., Bayazitov, V.M., Esipov, I.B., Saltykov, A.A., Saltykov, Yu.A., 2012. A complex of equipment and ultrasonic technology for restoring the productivity of oil wells. Oilfield Eng., 25–30. 37. Abramov, V.O., Mullakaev, M.S., Bayazitov, V.M., Timashev, E.O., Kuleshov, S.P., 2013. Experience in the application of ultrasonic irradiation for restoring the productivity of oil wells in Western Siberia and Samara Region. Oilfield Eng., 26–31. 38. Mullakaev, M.S., Prokoptsev, V.O., 2014. Development of an ultrasonic automated oil well 10
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complex and a sonochemical technology for enhancing the productivity of wells. Equip. Technol. Oil Gas Complex, 37–45. 39. Mullakaev, M.S., Abramov, V.O., Abramova, A.V., 2015. Development of ultrasonic equipment and technology for well stimulation and enhanced oil recovery. J. Pet. Sci. Eng. 125, 201–208. 40. Mullakaev, M.S., Abramov, V.O., Abramova, A.V., 2017. Ultrasonic piezoceramic module and technology for stimulating low-productivity wells. J. Pet. Sci. Eng. Accepted. In Press. 41. Altunina, L.K., Kuvshinov, V.A., 2007. Enhancing oil recovery from high-viscosity oil fields by physicochemical methods. FEС Technol., 46–52. 42. Altunina, L.K., Kuvshinov, V.A., 2007. Physicochemical methods for enhancing oil recovery from oil fields. Russ. Chem. Rev. 76, 971–988, doi: 10.1070/RC2007v076n10ABEH003723.
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Highlights • Automated oil well complex for sonochemical enhanced oil recovery is developed. • Average increase in the oil production rate is 5.2 tons per day. • Increase in the well productivity index is on average 107%. • Decrease in the water cut of the well fluid is on average 28%. • Advantages are the possibility of using various chemicals and selective treatment.
S0920-4105(17)30724-6
DOI:
10.1016/j.petrol.2017.09.019
Reference:
PETROL 4262
To appear in:
Journal of Petroleum Science and Engineering
Received Date: 26 March 2017 Revised Date:
9 September 2017
Accepted Date: 11 September 2017
Please cite this article as: Mullakaev, M.S., Abramov, V.O., Abramova, A.V., Ultrasonic automated oil well complex and technology for enhancing marginal well productivity and heavy oil recovery, Journal of Petroleum Science and Engineering (2017), doi: 10.1016/j.petrol.2017.09.019. This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.
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Ultrasonic Automated Oil Well Complex and Technology for Enhancing Marginal Well Productivity and Heavy Oil Recovery M. S. Mullakaev*, V. O. Abramov, and A. V. Abramova Kurnakov Institute of General and Inorganic Chemistry, Russian Academy of Sciences, Leninskii pr. 31, Moscow, 119991 Russia *E-mail: [email protected]
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Abstract An ultrasonic automated oil well complex is developed that includes an ultrasonic oil well module MSUM based on magnetostrictive transducers, an ultrasonic oil well module MSUP based on piezoceramic transducers, and a workstation. The developed complex makes it possible to control and record the parameters of ultrasonic modules MSUM and MSUP and to collect information on the parameters of the near-wellbore area during the sonochemical treatment of oil formations under different geological and technical conditions. The field tests of the complex in the wells of the Samotlor oil field (Western Siberia) have shown that after sonochemical stimulation of the nearwellbore region the average increase in the daily production rate of oil wells is 5.2 tons per day, the increase in the well productivity index is on average 107%, and the decrease in the water cut of the well fluid is on average 28%. The fundamentally new advantages of the technology are as follows: the simplicity of application (it is not more complex than the geophysical study of wells), the possibility of introducing the reagents of various chemical natures into the near-wellbore area, the selectivity of treatment, the absence of a negative effect on the production string and the cement sheath, environmentally friendly, and the absence of a negative impact on the health of operators. The developed oil well complex and sonochemical technology are offered to oilfield service companies for stimulating low-productivity wells and heavy oil production.
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Keywords: Enhanced oil recovery (EOR); Heavy oil recovery enhancement; Acoustic well stimulation; Ultrasonic oil well stimulation; Sonochemical technology; Ultrasound.
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1. Introduction Evaluating the prospects of crude oil production in the world, it can be stated that the epoch of low-cost and easily produced oil has come to an end. In Russia, as in the entire world, the discovered reserves of light oil are being depleted, and the production of heavy oil with a high paraffin, resin, and asphaltene content increases. From the standpoint of rational nature management, the development of new combined environmentally safe and effective technologies for enhanced oil recovery will ensure substantial saving in material resources, a decrease in environmental impact, and an increase in the cost efficiency of crude oil production. The basis for this is the intensive development of basic and applied research. At present, the possibility of using acoustic methods for enhancing processes in the oil and gas industry is extensively studied. Due to the effect of ultrasonic vibrations in crude oil production, there are an increase in the permeability of the near-wellbore region of formations, dewaxing, acoustic degassing, a decrease in the viscosity of oil, etc. [1–14]. The early use of sound to revitalize oil wells involved sonic waves of a much longer wavelength than ultrasound (often termed seismic waves) which were used to restart the flow. One of the oldest patents was taken out in 1939 [15]. The theory behind this was that when such a wave passes through porous media it will be dispersed into higher harmonics (ultrasonic waves) producing a series of effects that include: the disruption of the surface film, the coalescence of oil drops together with oscillation, and the excitation of oil drops trapped in capillaries. The theory underlying the use of ultrasound for oil recovery continues to be of interest [16]. The mechanisms responsible for improving the flow of oil through porous media under the effect of an ultrasonic field were reported in [17–19], and they are as follows: 1
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• An increase in the relative permeability of phases takes place [20, 21]; • Arising nonlinear acoustic effects in pores (cavitation, acoustic streaming, and sound pressure) decrease capillary forces due to the destruction of surface films and increase the rate of fluid flow through porous media [19, 20]; • The surface tension, density, and viscosity of the fluid are reduced due to ultrasonic heating [22, 23]; • The peristaltic transport of the fluid occurs due to the mechanical vibration of the pore walls by which the fluid is forced through pores [24]; • The microemulsification of oil in the presence of natural or introduced surfactants takes place, the solubility of surfactants increases, and the adsorption of surfactants decreases [21, 25]; • The coalescence of oil droplets occurs due to the Bjerknes forces [26, 27]; • The permeability and porosity of rocks are increased due to the deformation of pores, the perforation channels and pores of a reservoir are cleaned from asphaltene, resin, and paraffin deposits and other inclusions, and the skin effect is decreased [19]; • The origination of interstitial convection leads to a change in the thermal conductivity of fluid-saturated media, a decrease in the skin effect, and, as a consequence, an increase in the productivity of oil wells [19]; • Sound pressure reduces the shear viscosity of the fluid, which leads to an increase in the rate of fluid flow through porous media [19, 28]. In this study, we provide practical evidence obtained directly from oil well experiments which show conclusively that the use of ultrasonic downhole stimulation of oil wells is a viable process [29]. The efficiency of acoustic well stimulation can be substantially increased due to the mathematical modeling of physical processes that occur in the near-wellbore area [30, 31], the correct selection of candidate wells for acoustic treatment, and the development of high-efficiency equipment and technology for increasing the productivity of oil wells [30–38]. The present work is the continuation of our studies dealing with the development of an ultrasonic oil well module MSUM based on magnetostrictive transducers [39] and an ultrasonic oil well module MSUP based on piezoceramic transducers [40]. The objective of this work is to improve technologies for restoring or enhancing the productivity of oil wells using the developed ultrasonic modules MSUM and MSUP as part of an automated oil well complex for combined ultrasonic and chemical treatment (sonochemical stimulation) of oil formations under different geological and technical conditions. The development of the automated complex has made the implementation of sonochemical technology considerably easier: the simplicity of application due to process automation; the continuous control of treatment; the possibility of introducing the reagents of various chemical natures into the near-wellbore area; the selectivity of treatment; and the possibility of high-viscosity and heavy oil recovery. 2. Development of ultrasonic automated oil well complex The complex performs the combined ultrasonic and chemical treatment (sonochemical stimulation) of oil wells and provides automated control, diagnostics of its state, and documentation and visual image of the occurrence of processes in the near-wellbore area of the well. The technical characteristics of the complex are given in Table 1.
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Value 4000 1020 0–135 0–45 45 1 No less than 95 No less than 1.6
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Table 1. Technical characteristics of the complex Characteristics Maximum depth of well treatment, m Maximum density of the fluid in the near-wellbore area, kg/m3 Range of temperature measurement in the near-wellbore area, °C Range of pressure measurement in the near-wellbore area, MPa Maximum pressure of chemical injection, MPa Maximum flow rate of chemicals, m3/min Efficiency of ultrasonic generators TS6M and TS10W, % Output power of the transducers of downhole tools PSPK and PSMS, kW Power supply (number of phases х voltage, V / frequency, Hz) Power consumption, kW
3 × 380 / 50, 60 No more than 15
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The developed ultrasonic oil well complex consists of the following equipment (Fig. 1): • magnetostrictive ultrasonic oil well module MSUM; • piezoceramic ultrasonic oil well module MSUP; • workstation; • package of maintenance documentation; • package of technical documentation on the modes and parameters of the treatment of the near-wellbore zone; • set of spare parts, tools, and accessories.
Fig. 1. Block diagram of the ultrasonic automated oil well complex (UAOWC). The magnetostrictive ultrasonic oil well module MSUM consists of surface equipment, which includes an upgraded ultrasonic generator TS10W, and downhole equipment, which includes 3
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downhole tools with magnetostrictive transducers with a diameter of 42 mm (PSMS-42) and a diameter of 102 mm (PSMS-102). In contrast to previous-generation generators, the controller of the developed generator includes a unit that ensures the receipt of data on pressure and temperature in a well from a downhole tool, their processing and transmission to an external computer. The detailed description and technical characteristics of the ultrasonic oil well module MSUM are given in [39]. The piezoceramic ultrasonic oil well module MSUP consists of surface equipment, which includes an upgraded ultrasonic generator ТS6Р, and downhole equipment, which includes downhole tools with piezoceramic transducers with a diameter of 44 mm (PSPK-44) and a diameter of 52 mm (PSPK-52). The possibility of varying the frequency and intensity of radiation, depending on the geological and technical conditions of the near-wellbore region, makes it possible to achieve a high efficiency of its treatment. The detailed description and technical characteristics of the ultrasonic oil well module MSUP are given in [40]. The workstation of the complex has been developed that makes it possible to operate the complex in the automatic mode. The workstation issues control instructions and receives the controlled and recorded parameters of ultrasonic modules MSUM and MSUP and a device for chemical dosing, controls the operation of ultrasonic generators, controls and diagnoses the technical state of the complex, and records and archives the operating modes and parameters of the complex. The workstation includes an industrial panel computer with a touch screen and a printer, which is connected via RS-232 ports to an ultrasonic generator, a log recorder, and a setup for chemical well treatment. A layout for an ultrasonic generator, which is arranged on a special rack, an industrial computer, and a workstation in the laboratory compartment of the well logging truck hoist PKS-5GT has been developed. The software runs under Debian GNU/Linux or Ubuntu (Kubuntu, Xubuntu) with the x86 architecture (32-bit PC). The software creates a low computational load, does not impose special requirements on a hardware platform, and can be installed on any up-to-date personal computer. A personal computer with an Intel Atom 1.8 GHz processor, a 1 GB random access memory, and a 60 GB hard disk can be used as a hardware platform. A well-logging system YUGRA with a printer, which operates together with a downhole tool SOVA D-42 and ensures the study of the geophysical parameters of the near-wellbore region and a tie-in to the perforated interval of the well, is located in the lower section of the rack (Fig. 2а). The general appearance of the workstation is shown in Fig. 2b.
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(b) Fig. 2. (a) Arrangement of ultrasonic generators TS6P and TS10W and a workstation in the well logging truck hoist PKS-5G-T and (b) general appearance of the workstation.
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3. Field testing of ultrasonic automated oil well complex The field testing of the ultrasonic automated oil well complex was performed in oil fields in Western Siberia (the Samotlor oil field) and Samara Region, which are on the late stage of development and the main reserves are concentrated in highly nonhomogeneous, partially waterflooded reservoirs. In each specific case, the technological arrangement of ultrasonic equipment in wells depended on the chemical composition of oil and such geological factors as net and gross pay zones, permeability, compartmentalization, areal and sectional inhomogeneity, elastic properties of the formation, and the sizes of impermeable shields, as well as the operating modes of the field as a whole: the closeness of injection, the state of formation pressure, etc. Criteria for the selection of wells for the ultrasonic treatment of the near-wellbore region were as follows: • the operating mode of a candidate well for the past period from the beginning of operation was analyzed; • the density and composition of a well-killing fluid during repairs were studied;
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• all forms of action on the near-wellbore area of the candidate well for the entire operating period (physical, chemical, acoustic, etc.) and the results of these actions on well performance parameters were investigated; • the effect of formation pressure on a decrease in the production rate of the candidate well was evaluated using data on formation pressure and operating modes of adjacent wells with a similar geological structure; • the principal cause of a decrease in the production rate for the operating period was determined. More detailed information on the selection criteria and the cutoff values for ultrasonic treatment during major repair is given in [40]. The operation of the complex on site is provided with the following standard equipment, which is not part of the complete set of the complex: • well logging truck hoist PKS-5G-T with an umbilical cable TG-15/44-100-(2х2.5+4х0.75) for the placement of ultrasonic modules MSUM and MSUP and the deployment of workstations; • pumping unit SIN-32; • tank truck ATs-10 with service water; • geophysical complex SOVA D-42 in the well logging truck hoist PKS-5G-T; • recorder of geophysical parameters YUGRA in the well logging truck hoist PKS-5G-T; • lubricator; • feeder for an umbilical cable; • device for chemical dosing UDPKh-LOZNA with a control unit in a truck-mounted block box for the preparation of a mixture of chemical reagents from dry and liquid components and its supply at a flow rate of up to 1 m3/min and a pressure of up to 45 MPa; • umbilical cable with a length of no less than 4100 m, a breaking load of no less than 7.0 t, and a channel that is capable of withstanding pressure up to 45 MPa. The operating modes of the complex are as follows: Mode 1. Ultrasonic treatment of the near-wellbore area. Mode 2. Sonochemical treatment of the near-wellbore area. Mode 3. Treatment of the near-wellbore area in heavy oil recovery. Mode 4. Emergency operation: automatic safe shutdown condition. A technology for treating the near-wellbore region by the complex in modes 1 and 2 is described in detail in [39]. Let us dwell upon a technology for treating the near-wellbore zone in heavy oil production (mode 3). Figure 3 shows the arrangement of equipment during ultrasonic oil well stimulation by the downhole tool PSMS-102, which is mounted on the tubing and powered through a cable with a length of up to 4000 m. The technology of round-trip operations for the downhole tool PSMS-102 in heavy oil recovery is similar to the technology used to lower submersible pumps [13, 14]: • a well is killed (during the major or scheduled repair of wells), and a pump is dismantled; • operations are performed for lowering the tubing with a cable for the power supply of submersible pumps; • the downhole tool PSMS-102 is mounted on the tubing with a power cable; • the downhole tool PSMS-102 is lowered into the perforated zone; • the pump is mounted on the tubing depending on the dynamic fluid level in the well; • the pump is switched on, and well performance is brought to the production rate that was prior to mounting operations; • based on an analysis of the geological and technological characteristics of wells, the operating parameters of the downhole tool PSMS-102 (power and operating time) are determined, and the tool is switched on.
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Fig. 3. Ultrasonic stimulation of the near-wellbore region by the downhole tool PSMS-102: 1 – anchor, 2 – ultrasonic generator, 3 – downhole tool PSMS-102, 4 – casing, 5 – tubing, 6 – producing formation, 7 – ultrasonic field, 8 – perforated zone, 9 – sucker-rod pump, and 10 – power cable for the downhole tool.
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In the case of a high gas–oil ratio, a separator was installed ahead of the pump. In heavy oil production, the plugging of formation pores occurs rather rapidly; therefore, the downhole tool PSMS-102 mounted on the tubing was located in the perforated zone on a permanent basis. Depending on the specific features of wells, the treatment of the near-wellbore region was performed intermittently during a day in order to prevent the blocking of channels. The field tests of the complex using the ultrasonic oil well module MSUM based on magnetostrictive transducers and the technology of its use for the treatment of the near-wellbore area were performed in the Samotlor oil field in Western Siberia and in the oil fields of Samara Region (Russia) and are described in detail in [39]. They have shown that after ultrasonic well treatment the average increase in the oil production rate was 4.4 tons per day for Western Siberia and 10.2 tons per day for Samara Region, the increase in the well productivity index was on average 33%, the decrease in the water cut of the well fluid was on average 4%, and the percentage of successful treatments was up to 90%. The field tests of the complex using the ultrasonic oil well module MSUP based on piezoceramic transducers and the technology of its use for the treatment of the near-wellbore area were performed in the Samotlor oil field in Western Siberia (Russia) and are described in detail in [40]. An analysis of the results of ultrasonic well stimulation in 27 production wells has shown that the average increase in the oil production rate was 5.4 tons per day (75%), the increase in the well productivity index was on average 40%, and the decrease in the water cut of the well fluid was on average 8.2%. The field tests of the complex using sonochemical technology were performed in the formations that fall into the BC group (the permeability is lower than 20 mD, and the porosity is less than 15%). The efficiency of the ultrasonic treatment of these formations is not high due to the imperfection of the technology of well completion and the negative factor of well killing after the 7
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treatment of the near-wellbore region, since the negative effect of well killing increases with an increase in the depth. Inorganic gel-forming compositions GALKA and polymeric gel-forming compositions METKA were used as gelling agents, and compositions IKhN-60, IKhN-100, and NINKA were used as oil-displacing agents [41]. Treatment by these reagents is applicable for oil fields with various geological and physical conditions (the permeability is in the range of 0.005–0.5 µm2, and the temperature is in the range of 20–120°C), and it is the most effective for nonhomogeneous lowpermeability reservoirs (Jurassic and Cretaceous deposits) [42]. The cancellation of the use of acid reagents is dictated by the fact that they reduce one of the strongest advantages of ultrasonic technologies, i.e., environmental safety. Nine wells (six production wells and three injection wells) in the Samotlor oil field (Western Siberia) were treated within the framework of field tests [31, 38]. In all of the cases, treatment was effective, and the duration of the effect after treatment is from six months to one year. The averaged results of treatments for all of the wells are given in Table 2.
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Table 2. Averaged parameters before and after treatment Parameters Before treatment Oil production rate, tons per day 2.9 Water cut, % 48.5 Well productivity index 0.14
After treatment 8.1 35.1 0.29
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The efficiency of the sonochemical method can also be clearly seen from the results of the treatment of three injection wells, two of which (wells nos. 51240 and 51220) were subjected to sonochemical treatment, and one (well no. 5550) was only subjected to ultrasonic treatment (Fig. 4). As is seen from the figure, there is a clear synergistic effect under the conditions of combined treatment with ultrasound and chemicals.
Fig. 4. Change in the intake capacity of injection wells in the formations that fall into the BC group after sonochemical treatment. 4. Conclusions 1. An ultrasonic automated oil well complex is developed that includes an ultrasonic oil well module MSUM based on magnetostrictive transducers, an ultrasonic oil well module MSUP based on piezoceramic transducers, and a workstation. The developed complex makes it possible to control and record the parameters of ultrasonic modules MSUM and MSUP and to collect 8
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information on the parameters of the near-wellbore area during the sonochemical treatment of oil formations under different geological and technical conditions. 2. The field tests of the complex in the wells of the Samotlor oil field (Western Siberia) have shown that after sonochemical stimulation of the near-wellbore area: • the average increase in the oil production rate is 5.2 tons per day; • the average well productivity index increases from 0.14 to 0.29 (by 107%); • the decrease in the water cut of the well fluid is on average 28%. 3. The fundamentally new advantages of the technology are as follows: • the simplicity of application (it is not more complex than the geophysical study of wells); • the possibility of introducing the reagents of various chemical natures into the nearwellbore area; • the selectivity of treatment; • the absence of a negative effect on the production string and the cement sheath; • environmental safety; • the absence of a negative impact on the health of operators. 4. The developed oil well complex and sonochemical technology are offered to oilfield service companies for stimulating low-productivity wells and heavy oil production.
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complex and a sonochemical technology for enhancing the productivity of wells. Equip. Technol. Oil Gas Complex, 37–45. 39. Mullakaev, M.S., Abramov, V.O., Abramova, A.V., 2015. Development of ultrasonic equipment and technology for well stimulation and enhanced oil recovery. J. Pet. Sci. Eng. 125, 201–208. 40. Mullakaev, M.S., Abramov, V.O., Abramova, A.V., 2017. Ultrasonic piezoceramic module and technology for stimulating low-productivity wells. J. Pet. Sci. Eng. Accepted. In Press. 41. Altunina, L.K., Kuvshinov, V.A., 2007. Enhancing oil recovery from high-viscosity oil fields by physicochemical methods. FEС Technol., 46–52. 42. Altunina, L.K., Kuvshinov, V.A., 2007. Physicochemical methods for enhancing oil recovery from oil fields. Russ. Chem. Rev. 76, 971–988, doi: 10.1070/RC2007v076n10ABEH003723.
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Highlights • Automated oil well complex for sonochemical enhanced oil recovery is developed. • Average increase in the oil production rate is 5.2 tons per day. • Increase in the well productivity index is on average 107%. • Decrease in the water cut of the well fluid is on average 28%. • Advantages are the possibility of using various chemicals and selective treatment.