Heavy Oil Production Challenges and Solutions in North Kuwait Pilot Project Illustrated through Case Examples

Abstract

Heavy oil production is becoming standard for the industry as demand continues to increase. The first pilot, in the South Ratqa area of North Kuwait, experienced challenges related to producing such low API production in 6 heavy oil production facilities. The manuscript will focus on the challenges faced during initial set up, solutions executed during the trial phase, and the preventive measures taken to assure smooth daily operations and production of heavy oil.

Well surveillance, field development, and field operations teams met to agree on the operation structure and the daily resources, equipment, and facility requirements to run the field. Full time surveillance resulted in a complete picture of well performance and allowed a deeper understanding of the challenges in this unique formation. The main challenges were low API production, sand production, different gas production rates, the remote location, and thermal production issues that occurred after steaming.

Sand production is a major challenge to producing as it affects pump performance and flowline and production facility operation. Producing such low API oil, especially in harsh winter temperatures, resulted in plugging the flowline and made oil shipment more difficult. In order to handle high gas production rates, relieving and flaring systems were installed. This solution positively affected the down-hole pump performance and production facility tanks. Deploying the pilot in a remote area of Kuwait resulted in delayed support, equipment, diesel, water, and power supplies required for daily operations.

Using steam as an enhanced oil recovery method resulted in solving most of the above challenges while increasing oil productivity. Based on the challenges faced, data collected, researches executed and different solutionsapplied, the objective of the pilot to understand the reservoir behavior and operational requirements have been fulfilled.

This successful pilot is the main reference for heavy oil applications and field development in Kuwait. It is the first project applied to increasing production in the South Ratqa field. After the pilot's success, an additional 28 wells were successfully deployed. Another project, with over 1,000 sucker rod pump wells, has been planned for the same field.