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Produced Water White Paper 48 DOWS and downhole gas/water separators for DOE and try to identify the types of geological formations in which DOWS perform most effectively. One of the applications for which DOWS could be used is to improve the water handling and production rate on a field-wide basis. To date, DOWS have not been used for this purpose. The following examples lead in that direction. In 1999, DOE awarded a large grant to Venoco, Inc., a southern California offshore producer, to conduct a pilot application using downhole water separation units attached to electric submersible pumps. The goal was to improve field economics and minimize water disposal in the South Ellwood Field, offshore from Santa Barbara, California. Venoco continues to work on reservoir and fracture characterization but does not plan to install a DOWS until one of its wells receives a workover about the first quarter of 2004 (Horner 2003). A second application involves an innovative approach to recover more oil from a field in a shorter amount of time. The so-called π-mode production strategy (Ehlig-Economides and Economides 2000; Guerithault and Ehlig-Economides 2001) relies heavily on the use of downhole oil/water separators to reinject water into the same formations from which the fluids originated and maintain formation pressure. This process accelerates the rate of recovering the available oil. Chachula (2003) discusses use of a DOWS as part of a “smart well” system that would control real-time choking, plugging, isolation, and monitoring. He acknowledges that this is an expensive, complex, and unproven technology. 5.1.2.3 Downhole Gas/Water Separators Several companies have marketed devices similar to DOWS for gas wells. These are known as downhole gas/water separators. The Gas Research Institute (now known as Gas Technology Institute) funded Radian International Corporation to prepare a “consumer guide” to downhole gas/water separation. The study was released in CD format in 1999 (GRI 1999). GRI found 53 commercial field tests involving 34 operators in the U.S. and Canada. Sixty percent of the tests used modified plunger rod pumps, while another 32% used bypass tools. Gas production rates were increased in 57% of the tests with 47% of the field tests termed successful, confirming that there is still significant risk. Half of the 42% failures were attributed to water cycling or poor injectivity issues. Produced water rates and well depth exert the primary influence on which the DWGS tool is appropriate. Bypass tools are appropriate for water volumes from 25 to 250 bpd and depths in the 2,000 to 8,000-foot range. Modified plunger rod pumps can handle 250- 800 bpd at depths in this range. Fully burdened costs for bypass tools and modified plunger rod pumps are about the same, in the $0.30 to $1.10/bbl range. For higher water rates above 800 bpd, electric submersible pumps are typically the most cost effective ($0.20-0.40/bbl), especially at depths greater than 6,000 ft.PDF Image | Produced Water from Production of Crude Oil
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