PRACTICAL ASPECTS OF STEAM INJECTION PROCESSES

A HANDBOOK FOR INDEPENDENT OPERATORS

BY
Partha S. Sarathi
David K.. Olsen

October 1992

Performed Under Cooperative Agreement No. FC22-83FE60149

IIT Research Institute

National Institute for Petroleum and Energy Research
Bartlesville, Oklahoma

Bartlesville Project Office

U. S. DEPARTMENT OF ENERGY
Bartlesville, 0 klahoma
 DISCLAIMER
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This report has been reproduced directly from the best available copy.

Available to DOE and DOE contractors from the Office of Scientific and
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 NIPER-580
Distribution Category UC-122

Practical Aspects of Steam Injection Processes

A Handbook for lndependent Operators

BY
Partha S. Sarathi
David K Olsen

October 1992

Work Performed Under Cooperative Agreement No. DE-FC22-83FE60149

Prepared for
U.S. Department of Energy
Assistant Secretary for Fossil Energy

Thomas B.Reid, Project Manager

Bartlesville Project Office
P. 0.Box 1398
Bartlesville, OK 74005

Prepared by
IlT Research Institute
National Institute for Petroleum and Energy Research
P. 0.Box 2128
Bartlesville, OK 74005
 TABLE OF CONTENTS

Pag.e
Abstract ....................................................................................................... 1
Acknowledgments.......................................................................................... - 2
CHAPTER 1 . Fundamentals of Steam Injection Processes ........................................3
Introduction ...........................................................................................3
A

Basics of Steam Injection ....................................................................... 3

Steam Quality ......................................;.............................................- 5
Steam Injection Process ......................................................................... 5
Steam Injection Process Mechanisms...................................................... 10
Steam Distillation .......................................................................... 10
Gas Stripping .............................................................................. 10
In Situ Solvent Drive ...................................................................... 10
Viscosity Reduction ............................................................................11
Thermal Expansion ............................................................................12
Solution Gas Drive ............................................................................ 12
Gravity Segregation ............................................................................12
Emulsion Drive .................................................................................13
Cydic Steam Injection ......................................................................... 13
Process Description .......................................................................13
Mechanism of Cyclic Steam Process ........................................................ 16
References...........................................................................................16
TABLES
Properties of saturated steam .......................................................................- 4
Heat content of wet steam. B t d b .................................................................. 6
Approximate contribution of various steamflood mechanisms to overall recovery
of 13' to 15' API gravity oil .......................................................................10
ILLUSTRATIONS
Heat content of wet steam. Btu/lb ..................................................................6
Schematic of stearnflood process ...................................................................7
Schematic of steamflood temperature profile ......................................................8
Schematic of steamflood saturation profile .......................................................- 9
Effect of temperature on oil viscosity ............................................................12
Schematic of cyclic steam process ................................................................ 14
Schematic of push-pull cyclic steam process .................................................... 15
CHAPTER 2 . Criteria for Evaluating Steam Injection Prospects ................................18
Introduction ......................................................................................... 18
Rock and Fluid Properties .................................................................... 18
Rock Type ..................................................................................18
Pay Zone Thickness ........................................................................... 18
Depth and Reservoir Pressure ................................................................ 18

iii
 TABLE OF CON,TEWTS-Continued

Parre
Permeability and Transmissibility ............................................................. 21
Stratification .................................................................................... 23
Anisotropy ...................................................................................... 23
Gas Cap or Aquifer ............................................................................ 24
Dip Angle ......................................................................................... 24
Porosity ......................................................................................... 24
Oil Saturation ................................................................................... 24
Clay Content ..................................................................................... 25
Crude Oil Charactektks...................................................................... 25
Gravity ...................................................................................... 25
Viscosity .................................................................................... 25
Field History and Status ........................................................................... 26
Primary and Secondary Production IIistoty ., ............................................. 26
Well Spacing and Condition ................................................................... 26
Pattern Configuration.......................................................................... 26
Water and Fuel Supply ......................................................................... 27
Water Disposal ................................................................................. 2'7
Summary ............................................................................................ 28
References........................................................................................... 28
TABLES
2.1 Cyclic steam screening criteria ..................................................................... 19
2.2 Steamflooding screening criteria.................................................................. 20
ILLUSTRATIONS
2.1 Estimated heat hss as function of depth .......................................................... 22
n an anisatropic reservoir ............................... 23
2.2 Typicit pilot pattern c ~ ~ g u r a t i ofor
2.3 Unconfined steamflood pattern with peripheql injectors ...................................... 27
CI-HFCER 3 . Project Planning ........................................................................ 29
.......................................................................................... 29
] I ? I ~ ~ Q ~ u c ~
Resemir Sdection ....................................................................... 29
Depth ............................................................................................. 29
Oil-In-Place ...................................................................................... 29
Reservoir Segregation and Inhomogeneities................................................. 30
. Prehinaty Evaluation ........................................................................ 30
Laboratory Analysis ........................................................................... 30
Comprehensive Investigation................................................................. 30
. Comprehensive Performance Investigation.................................................. 31
. Comparison with Conventional Praclees; .................................................. 31
Pilot Test ........................................................................................ 36
Summary ............................................................................................36
. Reference .........*...............................*.................................................*. 37
 TABLE OF CONTENTS-Continued

TABLES
List of major initial expenses to be included in the steam injection project economic
evaluation ............................................................................................32
Steps for steam injection prospect evaluation process selection. and field
implementation ...................................................................................... 32
Initial investigation .................................................................................33
Laboratory analysis and data processing .......................................................33
Comprehensive pilot feasibility study and design .............................................. 34
Field pilot irnplementation .........................................................................35
Expanded field operation .......................................................................... 35
CHAPTER 4 . Economics of Steam Injection ......................................................38
Introduction .........................................................................................38
Economic Factors in Steam Injection Operation............................................38
Estimation of Economically Recoverable Oil ................................................................43
Steam Injection Project Costs.................................................................44
Cost Estimate ................................................................................... 45
Development Costs ............................................................................45
Well Costs ..................................................................................
... 45
Water Treatment FaciIitles .....................................................................45
Steam Generation .............................................................................. 48
Steam Distribution System ....................................................................49
Other Surface Facilities.. ......................................................................50
Free Water Knockout Unit ....................................................................50
Heater Treater ................................................................................... 50
Well-Testing Unit .............................................................................. 50
LACT Unit ......................................................................................50
Tank Battery ....................................................................................50
Operating Costs ................................................................................50
Raw Water Production and Transportation Costs ..........................................50
Water Treatment................................................................................50
Steam Generation Operation Costs ........................................................... 51
Power ............................................................................................51
Well Pulling and Workover Costs ...........................................................51
Other Operating Costs .........................................................................51
Financial Costs .................................................................................51
Summary ............................................................................................52
References ........................................................................................... 55
Appendix 4-A-Rkview of Department of Energy Steam Drive Predictive Models ........ 57
Background .....................................................................................57
Review of Available Steamflood Models from BPO ..................................57
Model Recommendation .................................................................. 58
References for Appendix 4-A .................................................................58
Appendix 4-B--Calculation of Capital Charge Rate ........................................... 61 .
 TABLE OF CONTENTS-Continued
TABLES

Parze
4.1 Kern County. CA. new steam injection well costs. excluding well head injection
equipment ............................................................................................40
4.2 Kern County. CA. new production well costs. excluding downhole pump ................. 46
4.3 Cost to drill and equip a 1.000 ft steam injection well .........................................46
4.4 Cost to drill and equip a 1.000 foot production well ........................................... 47
4.5 Index of drilling and equipping wells unadjusted for depth ...................................48
4.6 Characteristics of conventional lease crude fued steam generator ....,........................ 49
4.7 Conventional oil fued surface steam generator costs ........................................... 49
4.8 Comparisons of economic factors affecting oil production from selected oil
production states.................................................................................... 53
4.9 Capital Charge Rates ............................................................................... 54
4.10 Suggested average life tables for oilfield related equipment ................................... 54
CHAPTER 5 . Water Treatment for Steam Generation ............................................ 62
Introduction ......................................................................................... 62
Water for Steam Generation ....................................................................... 62
Sources of Water for Steam Generators..................................................... 62
Water Treating Consideration ................................................................. 63
Total Hardness ............................................................................. 65
Alkalinity ...................................................................................65
Oxygen ......................................................................................65
Sulfides.. ...................................................................................65
Dissolved Solids ...........................................................................65
Suspended Solids ..........................................................................65
Iron ..........................................................................................65
Oil. ........................................................................................... 66
Silica .......................................... -..............................................66
pH ...........................................................................................66
Biological Growths ........................................................................ 66
Feedwater Treating Equipment ....................................................................66
Ion Exchange Units............................................................................66
Sodium Zeolite Softener ....................................................................... 68
Principles of Operation ........................................................................68
Salt Requirements
. ................................,............................................ 69
Softener Equipment and Operation ........................................................... 71
Brining System ................................................................................. 74
Sofkner Operation ............................................&............................... 75
Backwash ...................................................................................76
Brining ...................................................................................... 76
Slow Rinse .................................................................................77
Fast Rinse ..................................................................................77
Limitations of Strong Acid Resins ...........................................................77
Weak Acid Resins .............................................................................. 79
Regeneration ...............................................................................79
Neutralization .............................................................................. 79
Weak Acid Cation Exchange Resin Equipment and Operation ........................... 80
Limitation of Weak Acid Cation Exchange Resins ......................................... 80
Ion Exchange Unit Operation Problems ..................................................... 80
Resin Stability .................................................................................. 81
 TABLE OF CONTENTS-Continued

Page
Varying Water Quality .........................................................................81
Poor Operational Practices ....................................................................82
Mechanical Problems .......................................................................... 82
Fouled Resins ..................................................................................83
Hardness Leakage ......................................................................... 83
Water Treatment for Steam Injection Projects .............................................. 85
Steam Injection Water Softening System .................................................... 85
Selection of Ion Exchange Resins ..........................:.................................86
Ion Exchange Calculations ....................................................................$8
Use of Chelating Agents ...................................................................... 88
Hardness Monitors ............................................................................. 91
Overview of Other Water Treatment Equipment............................................91
0 2 and Solid Removals ....................................................................... 92
Gravitv Se~aration.............................................................................93
d A

Flotation .........................................................................................93
Induced Gas Flotation .........................................................................95
Operation Principle ............................................................................. 95
Filtration ........................................................................................ 98
Choice of Filters ................................................................................98
Pressure Filters .................................................................................98
Diatomaceous Earth (DE) Fiters .............................................................99
Selection of Diatomite ........................................................................101
Diatomite Filter Problems ...................................................................-101
Deaeration .........................................................................................-102
Oxygen Exclusion ............................................................................. 102
Oxygen Removal ..............................................................................103
Mechanical Deaeration ........................................................................103
Vacuum Deaeration ...........................................................................104
Steam Deaeration .............................................................................. 105
Gas Stripping................................................................................. -107
Chemical Deaeration .......................................................................... 109
Oxygen Scavenging by Sulfur Oxide .......................................................110
Reclamation of Produced Water For Steam Generation .................................-113
Silica Scaling................................................................................... 114
Disposal of Excess Produced Water ........................................................116
Water Treating Costs ......................................................................... 117
Guidelines td water Treatment System Design and Operation........................... 118
Design Concept ................................................................................ 120
Source Water Properties and Problems .....................................................121
Equipment Consideration ...................................................................-122
Operation of a Water System ................................................................122
Summary ...........................................................................................123
References .......................................................................................... 124
General References ................................................................................126
Appendix 5.A .............................................................................................129
Water Chemistry ..................................................................................-129
Definition ....................................................................................... 129
Ions, Valence and Radicals ..................................................................130
pH ...............................................................................................131
Water Analysis ...............................................................................-131

vii
 TABLE OF CONTENTS-Continued

Paee
Appendix 5.B.. ..........................................................................................-133
Oilfield Steam Operator Water Quality Requirements .........................................133
Introduction ...................................................................................-133
Total Hardness ............................................................................ 133
Total Dissolved Solids (TDS)..........................................................-134
Alkalinity ..................................................................................134
Suspended Solids.........................................................................135
Oxygen ..................................................................................... 135
Sulfides .................................................................................... 136
Iron ........................................................................................ -136
Oil ..........................................................................................137
pH ..........................................................................................137
Silica ...................................................................................... -137
Biological Growths ....................................................................... 138
Turbidity ................................................................................... 139
Carbon Dioxide ..........................................................................-139
Appendix 5-C. Feedwater Treatment Equipment and Chemical Vendors.........................141
TABLES
Typical analysis of raw waters used in the San Jaoquin Valley. California. steam
injection projects ....................................................................................64
Approximate total dissolved solid (TDS) content and hardness of California oilfield
produced water ......................................................................................64
Steam generator feedwater requirements ....................................................... 65
Methods for removal of common raw water impurities ........................................67
Effects of salt level on the performance of a typical synthetic sodium zeolite exchanger . . 7 1
Zeolite softener seiection chart ....................................................................72
Rules-of-Thumb for selection of ion exchange resins for oilfield steam generator
feedwater softener ..................................................................................88
Ion exchange softening system calculations.....................................................89
Concentration of EDTA and its sodium salts necessary to complex 1 ppm of hardness
ion .................................................................................................... 90
5.10 Induced gas flotation cell selection chart .........................................................96
5.1 1 Feedwater oil reduction achievable using a depurator ..........................................97
5.12 Summary of advantages and disadvantages of water deoxygenation systems .............104
5.13 Oxygen towers selection chart ...................................................................109
5.14 Typical SO2 scrubber waste analysis ............................................................113
5.15 Typical water analysis for water treatment cost estimation ...................................118
5.16 Fresh water treatment costs ....................................................................... 119
5.17 Produced water treatment costs .................................................................. 119
ILLUSTRATIONS
5.1 Effect of feedwater hardness and salt dosage on resin capacity ...............................70
5.2 Effect of brine hardness and salt dosage on water softening costs ........................... 72
5.3 Schematic of a typical ion exchange water softener ............................................73
5.4 Schematic of the internals of a typical zeolite softener unit ....................................74

viii
 Page
5.5 Schematic of a bulk salt storage facility ..........................................................75
5.6 Effect of water hardness and salt dosage on hardness leakage from primary beds ........- 7 8
5.7 Resin exchange capacity as a function of water hardness and salt dosage ...................78
5.8 Schematic of steam injection water softener piping arrangement ............................. 86
5.9 Flow schematics of steamflood ion exchange softener regeneration cycle................... 87
5.10 Schematic of an automatic hardness monitor ....................................................92
5.1 1 Schematic of a typical dissolved gas flotation unit........................................... 94
5.12 Schematic of an induced gas flotation cell ....................................................... 96
5.13 Schematic of a typical up-flow sand filter ...................................................... 100
5.14 Schematic of a vacuum deaerator ............................................................... -106
5.15 Schematic diagram of a spray type steam deaerator ........................................... 106
5.16 Schematic of a counter current gas stripping unit .............................................. 108
5.17 Schematic of sulfur burner process for oxygen deaeration ...................................111
5.18 Flow diagram for Kern River, CA, steamflood produced water reclamation plant ........ 116
CIWF'TER 6 . Steam Generation ...................................................................145
Introduction ........................................................................................ 145
General Features of Oil Field Steam Generators .........................................-145
Generator Selection ...........................................................................147
Design Requirements For Oilfield Steam Generators ....................................-152
Steam Generator Components ..........................................................152
1. Feedwater System ....................................................................152
2 . Feedwater Preheater .................................................................152
3 . Fuel System ........................................................................... 153
4 . Combustion Air System ............................................................. 153
5 . Convection Section .................................................................. 153
6 . Radiant Section ....................................................................... 154
Steam Generator Controls ....................................................................155
Process Description ..........................................................................-155
Fuel System ....................................................................................157
Combustion Air System ...................................................................... 158
Steam Generator Specifications .............................................................159
Fuels For Oilfield Steam Generators........................................................ 161
Natural Gas ...................................................................................-162
Liquified Petroleum Gas (LPG)............................................................. 162
Lease Crude ...................................................................................1 6 2
Steam Generation Operations and Problems ...............................................163
Tube Failure ...................................................................................163
Other Operation Problems ....................................................................164
Steam Generation System Maintenance ....................................................165
Daily Maintenance and Inspection ...................................................... 165
Monthly Maintenance and Inspection ....................................................... 166
Annual Inspection .............................................................................167
Operational Problems Because of Poor Maintenance .....................................167
Steam Generator Efficiency ..................................................................169.
Flue Gas Scrubbers...........................................................................173
System Description ........................................................................... 173
Other Types of Steam Generation Equipment .............................................175
 TABLE OF CONTENTS-Continued
Ba9.e
Vapor Tech Steam Generator ............................................................... -175
Fluidized Bed Combustion (FBC) Steam Generator...................................... 176
The Wet Air Oxidation Boiler ................................................................ 176
Wet Oxidation Concept .................................................................. 176
WAO Boiler .............................................................................. -177
Vapor Them System .........................................................................179
Downhole Steam Generator ................................................................ 179
Low Pressure DSG .......................................................................... -182
High Pressure DSG .......................................................................1 8 4
Cogeneration .................................................................................. -188
Summary ........................................................................................... 190
References......................................................................................... -191
Bibliography ...................................................................................... -193
Appendix 6-A. API recommended fuel oil analysis specification sheet ..................197
Appendix 643. API recommended fuel gas analysis specification sheet ................. 198
Appendix 6.C . API recommended water analysis specification sheet .................... 199
Appendix 6.D . API recommended maintenance practice for oilfield steam generator ..200
Table 6-D- .
1 Steam generator safety inspection check sheet ............................201
Appendix 6.E . Steam generator annual check list ......................................... -203
Appendix 6.F . Steam generator vendors ....................................................206
TABLES
6.1 O i e l d steam generator selection chart ......................................................... 148
6.2 Oilfield steam generator fuel requirements .....................................................1 4 8
6.3 Oilfeld steam generator electrical requirements. kw .......................................... 149
6.4 API recommended steam generator daily log...................................................166
6.5 API recommended steam generator monthly maintenance and inspection check list ...... 168
6.6 Advantages and disadvantages of downhole steam generators..............................1 8 1
6.7 Typical operating parameters for a low pressure DSG ........................................ 184
6.8 Typical operating parameters for a high pressure DSG ....................................... 185
6.9 Comparison of surface and downhole steam generators cost ................................187
6.10 Capital cost itemization of a California cogeneration project (all costs are in 1989
dollars) .............................................................................................. 189
6.1 1 Economic summary for a skid-mounted cogeneration unit ...................................191
ILLUSTRATIONS
6.1 Iosmetric view of a skid-mounted oifield steam generator...................................146
6.2 Schematic of oilfield steam generator ..........................................................-147
6.3 Approximate steam generator output (lbslhrlbhp) at various pressures, steam quality
and feedwater temperature........................................................................149
6.4 Daily fuel (lease crude) costs for operating various capacity steam generators............. 150
6.5 Daily fuel (natural gas) costs for operating various capacity steam generators ............. 150
6.6 Tubing arrangementsin the steam generator flue gas convection section ................... 154
6.7 Layout of a typical oilfeld steam generator burning lease crude ............................-156
6.8 Approximate flue gas dewpoints for heavy oils.............................................. 171
6.9 Thermal efficiency versus flue gas temperature for 10' API crude ..........................171
6.10 Thermal efficiency versus flue gas temperature for 15' API crude .......................... 172
6.1 1 Thermal efficiency versus flue gas temperature for natural gas (1,000 BWSCF) .........172
 TABLE OF CONTENTS-Continued
Pag.e
6.12 Schematic of a typical steamflood flue gas scrubber system ................................. 174
6.13 Schematic of a fluidized bed combustion steam generator .................................... 177
6.14 Schematic of a wet air oxidation boiler arrangement for steamflood application ........... 178
6.15 Schematic of Vapor Them system .............................................................. 180
6.16 Schematic of a downhole steam generation system............................................ 182
6.17 Low pressure downhole steam generator.......................................................183
6.18 High pressure downhole steam generator ......................................................184
6.19 Downhole steam generator selection chart ...................................................... 185
6.20 Cost of energy injected into reservoir versus reservoir depth ................................187
6.2 1 Schematic layout of a cogeneration facility .....................................................188
CHAFTER 7 . Steam Distribution ..................................................................207
Introduction ........................................................................................ 207
Components of a Steam Distribution Network ............................................207
General System Pressure and Temperature Design Requirements ......................209
Main Steam Headers ..........................................................................212
Lateral Steam Lines ...........................................................................213
Steam Flow Rates and Pressure Drop .................................................. 213
Steam Shut-off Valves ................................................................... 213
Expansion of Steam Lines ................................................................... 214
Expansion of the Steam Headers............................................................ 217
Wellhead Connection ........................................................................ -217
Support of Steam Lines .....................................................................-217
Insulation and Heat Loss ....................................................................-220
Effects of Branching on Steam Quality .....................................................223
Wellhead Equipment......................................................................... -224
Wellhead Steam Rate Control Devices ...................................................... 229
Static Chokes in Critical Flow .......................................................... 229
Adjustable Chokes Operated in the Subcritical Flow Regime ....................... 232
The Effect of Steam Quality on Injection Rate Control............................... 234
Control of Individual Well Steam Quality .................................................. 234
Steam Disvibution System Maintenance and Monitoring ................................ 235
Summary .......................................................................................... -235
References.........................................................................................-236
Appendix 7-A. Steam distribution network components suppliers .........................237
TABLES
Design properties and allowable working pressures for piping ..............................210
Pressure-temperature ratings for low carbon forged steel pipe flanges ................... 211
Thermal expansion of steel pipe ................................................................. 211
Loop size vs. spacing ............................................................................. 216
Heat losses from pipes Btu/hr/ft length (steady state) ........................................-221
ILLUSTRATIONS
Schematic of a typical steam distribution system layout ...................................... 208
Typical expansion loops used in steam injection operations to relieve steam flow line
thermal stresses .................................................................................... 215
 TABLE OF CONTENTS-Continued
Page
7.3 Schematic of different expansion methods for steam injection lines.........................215
7.4 2-bend expansion loop sizing chart .............................................................216
7.5 Schematic of a typicd swivel joint used at the steam injection wellhead ....................218
7.6 Schematic of expansion manifold connection to steam injection well Christmas tree .....218
7.7 Steam injection line heat loss versus cash loss ................................................-221
7.8 Schematic of insulated pipe for heat loss transfer estimation.................................222
7.9 Schematic of pipe tee installations in steam injection lines....................................224
7.10 Schematic of typical steam injection wellhead arrangement ................................. -225
7.1 1 Schematic of steam injection wellhead details ..................................................226
7.12 Schematic of a typical steam injection well casing stuffing box ..............................226
7.13 Schematic of a typical steam injection well tubing stuffing box ..............................227
7.14 Schematic of steam injection wellhead assembly showing casing and tubing stuffing
box arrangement ...................................................................................227
7.15 Schematic of steamflood production wellhead arrangement showing the facilities
for pump hookup .................................................................................. 228
7.16 Schematic of acceptable and nonacceptable choke inserts for steam injection rate
control choke bean .................................................................................230
CHAPTER 8 . Steam Quality ....................................................................... -238
Introduction ....................................................................................... -238
Surface Steam Quality Measurement ............................................................239
Separator Method ............................................................................-239
Orifice Metering Method ....................................................................-240
Total Dissolved Solids Method .............................................................. 242
Electric Conductivity Method ................................................................243
Stack Gas Analysis Method ..................................................................244
Fixed Heat Rate Method ...................................................................... 245
Enthalpy Determination Method .............................................................245
Wellhead Steam Quality .....................................................................-246
Vibrating Densitometer ....................................................................... 247
Gamma Ray Absorption Technique ......................................................... 249
Neutron Densitometer Steam Quality Measurement System .............................250
Downhole Steam Quality Measurement ....................................................252
Summary .......................................................................................... -252
References.........................................................................................-252
Appendix 8-A. Steam quality measurement system vendors ................................255
TABLES
8.1 Steam injection wellhead steam quality .........................................................247

8.1 Schematic of equipment arrangement for steam quality measurement by the vapor-liquid
separation technique ..............................................................................-240
8.2 Schematic of a vibration densitometer for steam quality determination .....................248
8.3 Schematic of gamma ray steam quality measurement technique ............................. 249

xii
 TABLE OF CONTENTS-Continued

l23-S
8.4 Schematic of the principles of operation of a neutron densitometer .........................251
8.5 Arrangements for steam quality measurement using a neutron densitometer ...............251
CHAFER 9 . Thermal Well Com~letionPractices............................................... 256
Introduction ........................................................................................ 256
Casing Design ...................................................................................... 256
Temperature Effects on Casings and Tubings ............................................. 256
Thermal Well Casing Design ................................................................ 261
Tubing Strings Consideration ..............................................................-263
Thermal Well Completion................................................................... -263
Drilling Fluids ............................................................................. 264
Cementing ................................................................................ -266
Perforating ................................................................................ -266
Well Completion and Workover Fluids ................................................267
Open-Hole Completion .................................................................. 267
Screens..................................................................................... 267
Pre-Packs .................................................................................. 268
Open-Hole Gravel Packing ..............................................................268
Consolidated Pack .......................................................................-269
Case-Hole Completion ...................................................................269
Clay Stabilization ........................................................................-270
Well Workover Practices ...............................................................-271
Screening ................................................................................. -272
Suggested Steam Injection and Production Well Drilling and Completion
Procedures .................................................................................273
Downhole Equipment ............................................................................. 276
Thermal Packers ...............................................................................276
Packer Installation. ............................................................................279
Seal Systems................................................................................... 279
Packerless Completion ...................................................................... -280
Summary .......................................................................................... -280
References.........................................................................................-280
Appendix 9-A. Thermal well completion tools and accessories suppliers ................. 283
TABLES
Recommended operating temperature range for thermal well tubular goods ...............258
Tensile Properties of various grades of seamless casing and tubing .......................-259
Typical casing completions in California thermal wells .......................................262
ILLUSTRATIONS
Tensile strength of casing versus temperature..................................................258
Yield strength of casing versus temperature ....................................................260
Elastic limit of casing versus temperature.......................................................260
Schematic of a typical steam injection well completion .......................................264
Schematic of a typical steamflood production well completion ..............................265
Schematic of a typical steamflood observation well completion ............................-265

xiii .
 TABLE OF CONTENTS-Continued

rats
9.7 Schematic showing retrievable and permanent packer position in steam injection we11 ...277
9.8 Schematic detailing packer installation for mu1tizone completion ............................277
9.9 High-pressure steam injection well packer details .............................................278
CHAPTER 10. Thermal Well Cementing Practices ................................................ 284
Introduction ....................................................................................... -284
Steam Injection Well Cementing Requirements ........................................... 284
Thermal Cement Chemistry ...................................................................... 284
Portland Cement ............................................................................... 284
High Alumina Cement........................................................................ -288
Steamflood Cementing Practices ................................................................. 288
Steam Well Problems ........................................................................-288
Cementing Practices ......................................................................... -292
Summary ........................................................................................... 293
References ......................................................................................... -293
Appendix 10.A . Thermal well cementing service vendors.................................. 295
ILLUSTRATIONS
Compressive strength of neat Portland cement at 400' F .................................286
Permeability behavior of neat Portland cement at 400' F .................................286
Compressive strength of Portland cement stabilized with 3 5 8 silica flour at various
temperatures ...................................................................................287
Permeability behavior of Portland cement stabilized with 35% silica flour at various
temperatures ................................................................................... 287
Compressive strength of conventionally extended Portland cement at 400' F .........290
Permeability performance of conventionally extended Portland cement at 400' F.....290
Compressive strength of conventionally extended Portland cement at 600' F .........291
Permeability performance of conventionally extended Portland cement at 600' F.....291
CHAPTER 11. Thermal Well Lifting Equipment .................................................. 296
Introduction ........................................................................................ 296
Thermal Well Pumping Problems ............................................................... 296
Rod Fall and Rod Drag ......................................................................-296
Sanding ........................................................................................ -297
Steam Breakthrough .......................................................................... 298
Production Conditions Variations ........................................................... 298
System Operations Problems ................................................................ 299
Solutions to Heavy Oil Thermal Well Pumping Problems.................................... 299
Novel Pump Jacks ............................................................................300
HEP Pump ....................................................................................-301
PC 3000 System .............................................................................-301
Variable Speed Beam Pump .................................................................302
Diluent Pump ..................................................................................302
U.S.Thermal Well Pump Systems .........................................................304
Use of Pump-Off Controls in Thermal Well ............................................... 304
Summary ...........................................................................................305
References .......................................................................................... 306
Appendix 11-A. Thermal well lifting equipment suppliers ..................................309

xiv
 TABLE OF CONTENTS-Continued
ILLUSTRATIONS
Pa~e
11.1 Schematic of a diluent pump used in the Cat Canyon field of California to produce the
'6 API oil ........................................................................................... 303
CHAPTER 12. Use of Insulated Tubulars in Thermal Projects .................................. 310
Introduction ........................................................................................ 310
Wellbore Heat Losses ........................................................................ 310
Benefits of Using Insulated Tubing ......................................................... 311
Insulated Tubing Design Requirements ....................................................311
Insulated Tubing Types and Selection Criteria ............................................314
Insulated Tubing Installation Procedures ................................................... 316
Insulated Tubing Performance ...............................................................318
Insulated Tubing Cost Effectiveness ........................................................318
Summary ........................................................................................... 318
References .......................................................................................... 320
Appendix 12-A. Downhole insulated tubing suppliers.......................................321
TABLES
12.1 Cost effectiveness of insulated pipe ............................................................. 319
ILLUSTRATIONS
12.1 Heat loss in the wellbore and casing temperature during steam injection ...................312
12.2 Variation of overall heat transfer coefficient (U) with tubing temperature for
different tubing surfaces and annulus pressure ...............................................-313
12.3 Estimated heat loss as function of depth ........................................................313
12.4 Schematic of basic insulated tubular design .................................................... 315
12.5 Typical insulated tubing construction ........................................................... 315
12.6 Exploded view of a field installed insulated tubular ...........................................317

CHAPTER 13. Sand Control Problems ............................................................. 322

Introduction ....................................................................................... -322
Occurrence and Identification of Problems-Causing Sands..............................322
Prevention of Problems in Producing Wells ...............................................323
Use of Open-Hole or Gravel Pack Completion............................................324
Screens ......................................................................................... 325
Gravel Packing ................................................................................. 326
Design of Gravel Packs for Thermal Wells ................................................329
Chemical Methods of Sand Control .........................................................333
Summary ..........................................................................................-333
References .......................................................................................... 334
Appendix 13.A . Sand control and gravel pack system vendors.............................337
TABLES
13.1 Sanding problems encountered in U.S. steam stimulation projects .........................325
13.2 Use of screens on Canadian oil sands...........................................................326
13.3 Sand sieve sizes....................................................................................328
13.4 Most common grades of gravel used for sand control ........................................329
 TABLE OF CONTENTS-Continued
ILLUSTRATIONS
eaee
13.1 Types of screens ..................................................................................-327
13.2 Gravel size selection .............................................................................. -328
13.3 Schematic of a thermal well gravel pack completion .......................................... 330
13.4 High-temperature screen ......................................................................... -331
CHAPTER 14. Steam Injection Profile Control ...................................................338
Introduction ....................................................................................... -338
Distribution of Steadwater in Tubing .....................................................338
Measurement of Steam Injection Profile.................................................... 339
Spinners ...................................................................................340
Temperature Surveys ..................................................................... 341
Radioactive Tracer Surveys ............................................................. 343
Methods of Altering Profiles.................................................................347
Concentric Tube Method ..................................................................... 348
Parallel Tubing Injection ....................................................................-348
Limited E n q Injection ...................................................................... -350
Use of Monitoring Wells ....................................................................-353
Summary .......................................................................................... -354
References......................................................................................... -354
Appendix 14-A. Steam injection profile control service vendors ...........................357
TABLES
14.1 Procedure for determining steam injection profile using a spinner .......................... 341
14.2 Properties of tracers ..............................................................................-344
14.3 Procedure for running radioactive tracer survey with sodium iodide........................344
14.4 Procedure for running radioactive tracer survey using inert gas tracers.....................345
14.5 Calculation of the critical pressure ratio ........................................................ -351
ILLUSTRATIONS
Mist and annular flow regimes for two-phase flow ......................................... 339
Diagram of spinner tool ......................................................................... 340
Steam spinner surveys ..........................................................................342
Survey points for different tubing tail configurations.......................................346
Survey results: well configuration. vapor phase profile by krypton. liquid phase
profile by sodium iodide. and heat profile ....................................................347
Schematic of concentric tubing completion ...................................................349
Schematic of parallel tubing completion ......................................................349
Three steam injection well completion designs ..............................................350
Steam deflector design .......................................................................... 352
Schematic of limited entry completion ........................................................353

xvi
 TABLE OF CONTENTS-Continued
Pane
CHAPTER 15. Emulsion Problems in Steam Injection Projects.................................358
Introduction ........................................................................................ 358
Definition of an Emulsion....................................................................358
Emulsion Formation and Stability...........................................................359
Methods Used to Break Emulsions ......................................................... 360
Emulsion Breaking ............................................................................361
A. Oil-in-Water Emulsions ................................................... 361
B. Water-in-0i-l Emulsions ............................................................ -363
Summary ..........................................................................................-364
General References................................................................................364
Appendix 15-A. Emulsion treatment chemical suppliers.....................................365
CHAFER 16. Surface Production Facilities ......................................................366
Introduction ........................................................................................ 366
Production Gathering System ....................................................................366
Automatic Well Test (AWT) Units ..........................................................369
The AWT System ............................................................................-370
Treatment of Produced Fluids .................................................................... 371
Freewater Knockout (FWKO) Vessels ....................................................-372
Settling Tanks ................................................................................ 375
Heater Treater ..................................................................................377
Vertical Treaters..............................................................................-378
Horizontal Heater Treater ....................................................................378
Electrostatic Treaten........................................................... ...............383
Emulsion Breaker Treatment ................................................................ -383
Lease Automatic Custody Transfer (LACT) Unit .........................................384
Tank Bottoms Cleaning ......................................................................385
Cyclone Desanders............................................................................ 386
Operation, Maintenance and Monitoring Considerations.................................386
Automation of Dehydration Plant ........................................................... 386
Summary .......................................................................................... -387
References.......................................................................................... 389
Appendix 16-A. Steam injection production facilities vendors .............................. 391
TABLES
16.1 Specifcations for horizontal freewater knockouts ............................................. 375
16.2 Specifications for vertical freewater knockouts ................................................375
16.3 Computerized automation of oilfield productions-c osts and benefits...................... 388
ILLUSTRATIONS
Schematic of a steamflood surface production facility ...................................... 367
Schematic of a typical steamflood production gathering network .........................368
Schematic of steamflood automatic well testing system ....................................371
Typical horizontal freewater knockout ........................................................ 374
Typical vertical freewater knockout ........................................................... 374
Schematic of an oilfield wash tank ............................................................ 376
Schematic of a vertical heater water .......................................................... 379
Schematic of a second type of vertical heater treater ........................................380

xvii
 TABLE OF CONTENTS-Continued
Pane
Schematic of a third type of vertical heater treater ........................................... 381
Schematic of one type of horizontal heater treater ........................................... 382
Schematic of a second type of horizontal heater treater .....................................382
Schematic of an electrostatic treater .......................................................... -384
Schematic of a LACT system .................................................................. 385
CHAPTER 17. Steam Injection Project Performance Monitoring Tools........................ 392
Introduction ....................................................................................... -392
Physical Data Monitoring Tools ............................................................. 393
Automated Well Testing ................................................................. 393
Steam Generator Fuel Usage Report ................................................... 393
Steam Distribution-4 team Injection Rates ...........................................393
Water Treatment System ............................................................393
Electrical Power Consumption Report ............................................ 394
Comments on Physical Data Monitoring Tools................................... 394
Economic Data Monitoring Tools ........................................................... 394
Monitoring Capital Expenses............................................................ 395
Monitoring Tools Improvement......................................................... 395
General Reference ................................................................................ -395
CHAPTER 1 8 . Environmental Issues .............................................................. -396
Introduction ....................................................................................... -396
Obtaining an Environmental Permit ............................................................ -396
Federal Regulatory Framework ............................................................. 402
Enforcement Agencies.......................................................................-403
Air Resources Board (ARB) ............................................................ 403
Air Pollution Control and Air Quality Management Districts (APCDIAQMD) ....403
Stae Water Resources Control Board (SWRCB) ....................................403
Regional Water Quality Control Boards (RWQCB).................................. 403
Department of Health Services (DHS) ................................................ -403
Air Quality Regulations Impacting Steam Injection Operations ..................... 408
National Ambient A. Quality Standards............................................... 408
State Implementation Plans (SIP)....................................................... 411
Emission Limitations ......................................................................... 411
Prevention of Significant Deterioration (PSD)............................................. 412
Nonattainment Areas (NAA) ................................................................. 413
Best Available Control Technology (BACT) for Steam Injection Operation
Pollutants ....................................................................................... 414
Lowest Achievable Emission Rate (LAER)................................................ 414
The Clean Air Act (CAA) Amendments of 1990......................................... -415
Water Quality Regulations Impacting Steam Injection Operadons ......................415
Federal Clean Water Act (CWA) ............................................................ 415
Safe Drinking Water Act (SDWA) .......................................................... 416
Miscellaneous Regulations Governing Oil and Gas Wastewaters .......................417
Spill Prevention Regulations ................................................................. 417
Classification of Injection Wells in California ............................................. 417

xviii
 TABLE OF CONTENTS-Continued

Paee
Waste Management Regulations Impacting Steam Injection Operations................418
Resource Conservation and Recovery Act (RCRA) ...................................... 418
Noise Quality Regulations Impacting Steam Injection Operations ......................418
Sources of Pollution in Steam Injection Field Activities..................................420
Air Quality .................................................................................... -420
Water Quality .................................................................................. 420
Waste Management ...........................................................................422
Summary .......................................................................................... -423
References ......................................................................................... -423
Appendix 18.A . Thermal EOR environmental Consultants..................................425
TABLES
State EOR Environmental Regulatory Agencies .............................................404
Abbreviations used in the text ..................................................................409
Current national primary and secondary ambient air quality standards ...................410
Permitted airquality increments for prevention of significant deterioration ..............413
Typical emissions from an oil-fired steam generator ........................................ 413
EPA list of exempt and nonexempt oilfield wastes from RCRA hazardous
management requirements......................................................................419
Estimated air emissions from a typical steam injection project during site preparation
activities ......................................................................................... -412

xix
 PRACTICAL ASPECTS OF STEAM INJECTION PROCESSES
A HANDBOOK FOR INDEPENDENT OPERATORS

BY
Partha S. Sarathi and David K. Olsen

ABSTRACT
More than 80% of the total steam injection process operating costs an for the production of
steam and the operation of surface and subsurface equipment. The proper design and operation of
the surface equipment is of critical importance to the success of any steam injection operation.
However, the published monographs on thermal recovery have attached very little importance to
this aspect of thermal oil recovery; hence, a definite need exists for a comprehensive manual that
places emphasis on steam injection field practices and problems. This handbook is an attempt to
fulfill this need.
This handbook explores the concept behind steam injection processes and discusses the
idormation required to evaluate, design, and implement these processes in the field. The emphasis
is on operational aspects and those factors that affect the technology and economics of oil recovery
by steam. The intended purpose of this handbook is twofold: (a) to provide operators with a
ready reference, a starting point when searching for information to engineer a steam injection
project; and (b) to provide a bibliographic source on the subjects discussed in the handbook. It
should, however, be emphasized that this handbook is not a detailed "trouble shooter" manual on
field problems. Steam injection process problems and solutions are field specific, and only
experienced field personnel or consultants can solve these specific problems.
The fust four chapters describe the screening criteria, engineering, and economics of steam
injection operation as well as discussion of the steam injection fundamentals. The next four
chapters begin by considering the treatment of the water used to generate steam and discuss in
considerable detail the design, operation and problems of steam generations, distribution and steam
quality determination. The subsurface aspects of steamflood operations are addressed in chapters 9
through 12. These include thermal well completion and cementing practices, insulated tubulars,
and lifting equipment. The next two chapters are devoted to subsurface operational problems
encountered with the use of steam. Briefly described in chapters 15 and 16 are the steam injection
process surface production facilities, problems and practices. Chapter 17 discusses the importance
of monitoring in a steam injection project. The environmental laws and issues of importance to
steam injection operation are outlined in chapter 18.
 The handbook is organized in the above manner so that the reader will have a good
understanding of the engineering and financial requirements of a steam injection project before he
reads the steam injection field practices, problems and solutions.

ACKNOWLEDGMENTS
This work was sponsored by the U.S. Department of Energy (DOE)under Cooperative
Agreement DE-FC22-83FE60149 and performed within project BE1 1B as outlined in the IT91
Annual Research Plan (DOE Report NIPER-465). The work of this nature could not have been
completed without the help and cooperation of various personnel. Many people have made
significant contributions to the preparation of this report. In particular, the authors wish to offer
their thanks to John Ball, consultant, for his assistance in the preparation of chapters 12, 13, and
14; Bruce Ramzel, and Summer DOE Interns, Heather Horstman, Yesh Tyagi, William Lucas,
Johnathan Grigsby and Robert Pendergrass II, all of NIPER, for their help in preparing the
figures; and Rex Thomas, Consultant, for his assistance in gathering materials for the report. We
offer our thanks to Michael Madden for his assistance in preparing chapter 18 and Arden Strycker
and Min Tharn, all of NIPER, and Thomas B. Reid of the U.S.Department of Energy, Bartlesville
Project Office, for their critical reviews of the manuscript We also extend our appreciation to Bill
Linville and Ron Kendall of NE'ER for their editorial review. We also thank the American
Petroleum Institute for permission to reproduce portions of RPl 1T report and various technical
journals and equipment manufacturers for permission to use their illustrations, tables, and charts.
 CHAPTER 1
FUNDAMENTALS OF STEAM INJECTION PROCESSES

INTRODUCTION
Steam injection is a thermal drive process that adds heat to the reservoir to expand the oil-in-
place, reduce its viscosity, provide drive energy and thereby improve the displacement efficiency
of injected fluid. For more than 100 years, steam has been used in attempts to solve the problems
of low recovery from heavy oil reservoirs. Its full potential was not realized until the early 50s
when field testing of the steam injection process began. In the United States in 1990,
steamflooding recovered 520,000 barrels of oil per day (BOPD) or 73% of all enhanced oil
recovery.1
This manual explores the concepts behind steam injection processes and discusses the
information required to evaluate, design, and implement these processes in the field. The emphasis
is on the practical aspects of steam injection. Details of equations and calculation methods for
estimating steam injection performance are not discussed in this manual. Other p~blications2~
cover these subjects in detail. There is a heavy emphasis on surface and subsurface facilities, field
practices, and operational problems which are not discussed in sufficient detail in other
publications. The material presented is directed toward engineers and independent operators who
have become familiar with routine waterflood operations but have had no exposure to thermal
operations.
This chapter reviews the steam injection process and recovery mechanisms. In subsequent
chapters, various aspects of steam injection are discussed in detail.

Basics of Steam Injection

Although in situ reservoir energy is responsible for the displacement of oil through porous
rock into wellbores, it is not always sufficient for oil displacement, especially in shallow heavy oil
reservoirs. Hence, energy needs to be imparted to the reservoir to allow the oil to flow toward a
wellbore. This usually takes the form of mechanical displacement such as pushing the oil with
water or gas. In steam injection, steam is used as the displacing fluid. Steam augments the
reservoir energy by parting its heat content as well as mechanical energy because of pressure
differential,
Steam is an ideal fluid for adding energy to a reservoir because of its high heat content per
pound. For example, water at 400' F contains 375 Btu/lb, but saturated steam at 400O F has 1,201
Btu/lb, or over three times the heat content of water.
To fully realize why steam is effective in producing oil, one needs to understand the
properties of steam as well as what happens in a reservoir when steam is injected. Some properties
of saturated steam for a few selected temperatures and pressures are listed in table 1.1.
 TABLE 1.1. - Properties of Saturated Steam

Saturation Heat of Latent Heat Weight Vdume Vdume

Abso1ute temperature, lif.@d, heat of content of 1 cuft of 1 Ib of 1 1b
pressure, O F Bhlnb vaponzat~on, of steam, of steam, of steam, of liquid,
psia Bhlnb Bt& 0 cufi aft

Note that the heat content of steam is considerably higher than the heat content of liquid
water. This difference is the latent heat and represents the amount of additional energy required to
convert boiling water at a given pressure into steam at the same pressure and temperature. Latent
heat is large at lower pressure and decreases with increase in pressure and becomes zero at
705.47' F temperature and 3,208.2 psia pressure. This temperature and pressure is known as the
critical point of water. Above this point, water exists only as a single phase. Also, note that steam
saturation temperature increases with pressure and the rate of increase is greatest at lower
pressures. This rate of change in temperature becomes smaller at higher pressure. For example,
when the steam pressure increases from 100 to 200 psia, the saturation temperature changes from
328' to 381' F or an increase of 53' F. On the other hand, when the pressure of steam increases
from 1,000 to 1,100 psia, the corresponding increase in saturation temperature is only about 12' F.
The other important characteristic of steam is the change in volume. The volume of 1 lb. of
saturated steam at various pressures and temperatures is depicted in Table 1.1. At 400 psia and
444' F, 1 lb of water occupies 0.0193 cu ft, but 1 lb of saturated steam at the same conditions has a
volume of 1.161 cu ft. Therefore, the saturated vapor occupies about 60 times the volume of
water. Naturally, this ratio decreases wib3 an increase in steam pressure but still is significant at
the pressure range where most thermal projects operate. For example, at 1,500 psia, the upper
limit for many steamflood projects, the ratio is 12. This is one of the reasons why steam heating
has had such success in the thermal process. A given amount of reservoir heating can be
accomplished with a much smaller unit weight of steam than hot water.

Steam Quality
Another term frequently encountered in the steam injection processes is steam quality. This
term refers to the degree of dryness of steam. For example, an 80% quality steam refers to a steam
water mixture containing 80% steam and 20% water by weight. A 100%quality steam refers to
steam containing no water and is known as dry saturated steam. The heat content of a wet steam
(mixture of steam and water) is always lower than that of a dry saturated steam. For example, a
70% quality steam at 200 psia contains about 946 Btuflb, and dry steam at the same pressure
contains 1,200 Btu/lb, or about 1.3 times as much heat as the wet steam. At higher pressures, this
ratio becomes smaller since the effect of s t e m quality becomes less predominant. This is because
the enthalpy of water increases with pressure and the latent heat of vaporization decreases with
pressure.
In table 1.2, the heat content of several qualities of steam is presented. The heat content of
various quality steam is also shown graphically in figure 1.1. Most oilfield steam generators are
designed to give 80% quality steam. Nevertheless, in the I00 to 1,500 psia pressure range, where
most steam injection projects operate, wet steam carries more heat than hot water. For example, 1
lb of an 80% quality steam at 200 psia canies 674 Btu more heat than 1 lb of boiling water at the
same temperature. This allows an operator to introduce more heat in a reservoir per pound of
injected fluid.

Steam Injection Process

What happens in a reservoir when steam is injected? Obviously, steam moves through the
reservoir and in the process it heats the oil and displaces it towards a producing well. Figure 1.2
depicts schematically a steamflood process.
 TABLE 1.2. - Heat Content of Wet Steam Btu/lb
Heat content, Btuflb
Absolute Temperature, Steam quality. percent
pressure, 9:
Psi 100 90 80 70 60 50 40 20 0

O.F
WF

OQC
loo+?

0 10 20 30 40 50 60 70 80 $0 IOC

PERCENT VAPORlZED (STEAM QUALITY)

FIGURE 1.1. - Heat content of wet steam, Btdlb.

 FIGURE 1.2. - Schematic of steamflood process?

As steam moves through a reservoir between injector and producer, it creates several
temperature fluid-flow regions. These regions are designated as the steam zone, hot condensate
zone, oil bank, and initial zone (figure 1.3).
The hot condensate zone is further divided into a solvent bank and a hot-water bank. Even
though there is no clear-cut boundary between these regions, they serve to describe the various
processes occurring during a steamflood.
The temperature decreases from steam temperature at the injection well to the initial reservoir
temperature at the producer. As steam enters the reservoir, it forms a steam zone around the
injection well. As more steam is injected, this zone expands. As steam moves away from the
injection well, it contacts the cooler portions of the formation causing the steam to condense into
water. Thus, a hot condensate zone is formed ahead of the steam zone. As this condensate zone
progresses through the formation, it gradually loses its heat to the rock and reservoir fluids and
eventually reaches reservoir temperature.
 Ts = STEAM TEMPERATURE
T, = ORIGINAL RESERVOIR TEMPERANRE
1 = STEAM ZONE
2 = HOT CONDENSATE ZONE
3 = OIL/COLD WATER ZONE
4 = INITIAL ZONE

DISTANCE -
FIGURE 1.3. - Schematic of steamflood temperature ~rofile.5

Figure 1.4 is a typical oil-saturation profile for a linear steamflood. Since the oil-
displacement mechanisms in each region are different, oil saturation varies characteristically
between injector and producer.
The major mechanisms - hence the oil saturation - in different regions depend upon the
type of oil and formation properties. Steamflood mechanisms are closely associated with the heat
and temperature effects on the reservoir rock and fluid.
W U identified
~ the principal steamflood mechanisms as follows: (1) steam distillation
(including gas stripping), (2) steam drive, (3) viscosity reduction, (4) thermal expansion,
(5) gravity segregation, (6) relative permeability and capillary pressure variation, (7) solution gas
drive, (8) oil phase miscible (in situ solvent) drive, and (9) emulsion drive.
Wu further suggested that an oil reservoir undergoing steam drive can be divided into the
following temperature-fluid regions: (1) steam zone, (2) hot condensate zone (including solvent
and hot water bank), (3) oil bank, and (4) initid zone.
In the steam zone, the major steamflood mechanisms are steam distillation and steam
displacement. In the hot condensate zone, viscosity reduction, thermal expansion, thermal
permeability variation, gravity segregation, and in situ solvent drive occur. In the initial zone, the
main mechanisms are conventional water dive and gravity segregation.
 1 = STEAM ZONE
2 = HOT CONDENSATE ZONE
3 = OIL/COLD WATER ZONE
4 = INITIAL ZONE

DISTANCE -
FIGURE 1.4. - Schematic of stearnflood saturation profile?

Table 1.3 shows the approximate contribution of each mechanism to overall recovery by
stearnflooding a heavy oil reservoir.
The dominant mechanism in any steamflood depends on the type of oil. For example, in
heavy oil reservoirs viscosity reduction and steam distillation may be the most important recovery
mechanisms; whereas in light oil reservoirs thermal expansion, steam distillation (with
accompanying solvent bank formation), and gas stripping are the chief mechanisms that cause light
oil to flow. However, the effectiveness of gas stripping and steam distillation are primarily
controlled by oil composition, system pressure, and steam injection rate.7 Further, it should be
pointed out that formation thickness, steam quality, and temperature greatly affect the dominance of
a particular steamflood mechanism. In thick, permeable heavy oil reservoirs, gravity segregation is
the most important producing mechanism.*
The following section discusses major steamflood mechanisms in more detail.
 TABLE 1.3. - Approximate Contribution of Various Steamflood Mechanisms to Overall
Recovery of 1 3 O to 15' API Gravity O@
Temperature, O F
300

Viscosity reduction. %
Thermal expansion, %
Steam distillation, %
Solution gas drive. %
Sdvent & emulsion drive, 96

Steam Injection Process Mechanisms

Steam Distillation
Steam distillation, the principal oil recovery mechanism in the steam zone, recovers reservoir
fluids in the following manner. When steam contacts the crude, a portion of steam condenses and
provides heat to the crude. The mixture of heated crude and hot condensate begins to boil when
the vapor pressure of the mixture (equal to the sum of the partial pressure of water and crude) is
equal to or exceeds the system pressure. The mixture will always boil at a temperature lower than
either of the constituent's boiling point at the system pressure. The degree of boiling point
lowering depends on vapor phase composition, since this composition influences total system
pressure.
Steam distillation results in the rapid vaporization of oil and water. This rapid boiling
disturbs and partially redistributes oil from a dead end pore to a connecting pore. This phenomena,
known as the "chipping effect,"6 results in a more efficient displacement of the crude oil by the
injected steam.
The chipping effect is more pronounced in a heavy oil reservoir than in a light oil reservoir
because the low volatility of the heavy oil inhibits effective separation of the lighter components
from the crude. As the volatility of a crude increases, the chipping effects diminishes and the
importance of distillation increases. Depending upon the volatility of crudes, up to 70% of oil-in-
place has been recovered in laboratory 2-D steamfloods.9 However, in the field the contribution of
steam distillation to overall recovery is expected to be lower.
Gas Stripping
Along with steam distillation, gas stripping also occurs in the steam zone.6 Gas stripping
occurs because in the steam zone, steam selectively desorbs light fractions from the crude.
However, this process is less efficient than steam distillation.
In Situ Solvent Drive
A substantial portion of the light oil fraction and the carrier steam condenses in the cooler
region ahead of the steam zone and forms the hot condensate zone.
 The condensed steam (hot water) being more viscous than steam, reduces steam fingering.
The degree of reduction of steam fingering depends on the oil-water mobility ratio. The steam
condensate flows along with the oil to form a hot water drive.
In the hot condensate zone, the lighter fractions of the oil mix with the in situ oil and dilute it.
This dilution reduces the overall density and viscosity of the oil. As the steam front pushes further
towards the producers, the Light ends accumulate and extract additional light fmtions from the oil
with which it comes in contact. Thus, the volume of the light oil solvent bank grows as it moves
through the reservoir. The result is a miscible displacement of the oil phase. The amount of
additional oil recovery due to this miscible displacement has been estimated at 3 to 5% of the initial
oil-in-place for some heavy oils.10
The net effects of dilution and extraction of oil in the hot water flood region are (a) decrease
in residual oil saturation and (b) reduction in the amount of heavy fractions at the trailing edge of
the hot water flood region. Since the oil left behind in the hot water flood region is likely to be
steam distilled by the advancing steamfront only a small amount of the heavy oil fraction will be
left behind by the steamflood.

Viscosity Reduction
The most obvious effect of heating a heavy oil reservoir is reduction of oil viscosity.
Figure 1.5 shows this pronounced change in viscosity. This plot shows the effm of temperature
on the viscosity of a 14' AH gravity oil. It is evident that the viscosity improvement is greatest at
lower temperatures and tends to be marginal after reaching a certain temperature. Greater viscosity
reductions are experienced in the more viscous low API gravity crudes than in higher API gravity
crudes. Note that the viscosity of a typical 14' AH crude at 80' F is reduced from 1,445 to about
47 cP at 175' F; more than thirty-fold. In the case of a low viscosity crude, viscosity reduction
with temperature is not as dramatic as with the more viscous crude. The plot clearly indicates the
advantage of temperature in making viscous crude more "flowable" in the reservoir rock. Thus,
the net result of increasing temperature is to improve the mobility ratio. With the oil viscosity
lowered, the displacement efficiency and sweep efficiency are improved.
The change in oil viscosity with temperature is reversible, i.e. the oil viscosity returns to its
original value when the temperature decreases to the initial value. This reversibility of the change
in oil viscosity with temperature explains the formation of an oil bank.
When a steamfront moves through a reservoir, the temperature immediarely ahead of the front
increases, thereby decreasing the oil viscosity. Oil is readily displaced from this high temperature
region to a region where the temperature may be considerably lower. In this low temperature
region, the oil regains its viscosity; thus, retarding the oil flow. Consequently, a large amount of
 0 50 100 15Q 200 250 300 350
TEMPERATURE, " F

FIGURE 1.5. - Effect of temperature on oil viscosity.

oil accumulates as an oil bank. This bank, often observed in steamflooding heavy oils, is
responsible for high oil production rates and low water-oil ratios.
Thermal Expansion
Crude oil, Wre most liquids, increases in volume when heated. This change in volume,
increases its saturation and fluidity. The amount of swelling of an oil because of temperature rise
depends on the composition of the oil. Light oils expand more than heavy oils; thus, thermal
expansion is more effective in recovering light oils than heavy oils. Thermal swelling is an
important oil recovery mechanism in a hot water drive. Depending upon the type of oil and initial
saturation, as much as 10%of initial oil-in-place can be recovered by thermal expansion.
Solution Gas Drive
As the temperature ahead of a steamfront increases, the heated crude expels the dissolved
gases. These liberated gases expand, push the oil, and aid in oil recovery.
Gravity Segregation
Gravity segregation occurs because steam is lighter than oil or water. This difference in
density causes steam to rise to the top of a sand and spread out areally. The oil heated by steam
expands and becomes lighter and less viscous, permitting the steam to move quickly in the upper
part of a producing zone. Thus, the reservoir becomes divided into two layers, a steam-invaded
override zone at the top and a noninvaded zone at the bottom (see figure 1.2).
At fit, the overriding steam spreads areally, but as steam injection continues, the steam zone
grows downward forcing the hot water in front of it. Thus, the oil at the interface between the
steam and hot water can be stripped from the reservoir rock and transported towards producing
wells along with the hot water condensing from the steam zone. With time, and at the expense of
recycling steam, an entire resemoir could be heated this way. However, with very viscous oil, this
process would not be economical because of inordinate amounts of time needed to achieve good
areal coverage.
Emulsion Drive
Emulsions are an integral part of the produced fluid in heavy oil steamfloods. Both oil-in-
water emulsions and water-in-oil emulsions are observed. The high specific volumes and
velocities of steam in the steam zone, coupled with the energy released by the condensing steam,
provide the agitation needed to form emulsions in situ.
Viscosity of an emulsion, often higher than either oil or water viscosity, depends upon the oil
viscosity and the type of emulsion formed. In a high-permeability, unconsolidated formation, a
viscous emulsion may plug the high-permeability streak, divert the steam to a lower permeability
region and improve oil recovery by reducing steam fingering in the hot condensate region.
Cyclic Steam Injection
Process Description
Cyclic steam injection, also known as "huff-'n-puff," or steam soak, involves the injection of
steam into a producing well for a short time. The well is then shut in for several days to permit the
soaking of the reservoir by steam, and then placed on production (see figure 1.6).
The cyclic steam process is similar to hydraulic fracturing. However, instead of increasing
the flow capacity of the reservoir, the viscosity of the oil is reduced. The result is the same. The
producing capacity of the well is increased whether the permeability is increased or the viscosity
reduced. Although the terms are sometimes used interchangeably, steamflooding has the same
relationship to the cyclic steam process as waterflooding does to hydraulic fracturing with water.
There is one difference, in that the heat injected is not produced except as sensible heat in the
produced fluids. The injected heat is expended in heating and decreases the viscosity of the oil in
the reservoir. After repeated cyclic steam treatments, it is possible to displace some of the oil
between wells.
 a. Steam Injection

b. Fluid Production Cycle

FIGURE 1.6. - Schematic of cyclic steam process.

In an alternative process known as the "push-pull" method, steam is circulated around a

packer. As shown in figure 1.7, steam is injected down the annulus and into the formation above
the packer. The steam heats the oil and allows it to flow into the bottom of the hole where it is
pumped to the surface. The advantage of this method is that the well is never shut down. A thick
and homogeneous reservoir with good vertical permeability is required for this process.
Cyclic steam injection is often used to boost primary recovery from viscous heavy oil
reservoirs. It boosts the primary recovery through viscosity reduction and wellbore clean-up
effects. The process can increase recovery by an additional 3 to 5% OIP. Since the steam soak
process permits immediate oil production, it provides an opportunity to observe and evaluate many
of the variables early in the life of the project when using steam, among which is treating the
problem of produced fluids. The steam soak process is used as a precursor to steam drive and is a
process for which field application has been a predecessor to theory.
A frst step in the cyclic steam process is the injection of a certain volume (5,000-20,000
bbl/cycle of cold water equivalent) of high-pressure steam over a period of 2 to 10 days. The
amount of steam injected per cycle varies with the thickness of the pay zone. To prevent excessive
heat loss, the steam is usually injected at the highest practical rate, approaching the formation
fracture pressure.
 STEAM

PACKER
\

FIGURE. 1.7. - Schematic of push-pull cyclic steam process.

The well is then shut in for several days to permit the soaking of the reservoir by steam.
During this soaking period, injected steam condenses as it distributes heat to a larger volume of the
reservoir. After the steam is soaked for several days, the well is allowed to flow under primary
production and is later pumped.
Cyclic sttam process performance depends on existing reservoir pressure. Heat is needed to
make the heavy crude mobile, but energy is required for it to flow into a wellbore. Where some
reservoir pressure exists, injected steam can reinforce natural reservoir energy, increase the
pressure differential, and allow oil to flow naturally at economic rates and volumes.
Both injection and soak times generally increase as the total volume of steam injected
increases. During the production period, which may range from 1 to 7 months, the well pressure
decreases and some of the steam condensate vaporizes, driving heated oil toward the producer.
The well is produced until the &cline in production warrants another treatment with steam.
When economical amounts of oil an no longer being produced, the whole cycle is repeated.
Usually three complete cycles are used in a single well. Response to cyclic steam injection
depends on formation thickness, oil-in-place, volume of steam injected, and the number of
preceding cycles. Regardless of reservoir type, cyclic injection becomes less efficient as the
number of cycles increases. With each succeeding cycle, oil production declines, water cut
increases, and the cycle becomes longer.
After many cycles, large fractions of injected steam are produced as water, making water
handling important. From an economic standpoint, a good indicator of performance is the
produced oil to injected water ratio. When this ratio falls below 1, the project becomes marginal
and the cyclic steam process is frequently converted to steamflood.
Mechanism of Cyclic Steam Process
Mechanisms that increase oil production rates during cyclic steam injection are diverse. They
include reduction in crude oil viscosity in the heated zone near the wellbore, thermal and solution
gas expansion which produces the driving force, gravity drainage, and wellbore cleanup.
The injected steam loses its heat to the formation and causes the reservoir temperature to rise.
This temperature increase, in turn, lowers the oil viscosity and allows it to flow much more readily
into the wellbore.
The increase in temperature also causes the oil to expand and become less dense. The lighter
oil then flows toward the wellbore by gravity drainage. Gravity drainage is the dominant recovery
mechanism in California's thick, steeply dipping reservoirs containing low-gravity crudes. In
these reservoirs, many cycles are possible because the heated, less viscous oil continues to flow
downdip to the producers with each cycle. In low-dip reservoirs, where the displacing mechanism
is solution gas drive rather than gravity drainage, only a few cycles ate possible due to rapid
reservoir energy depletion.
Finally, the cyclic steam process contributes to oil recovery by dissolving organic deposits
near a wellbore. This wellbore cleanup effect significantly reduces the pressure drop between a
reservoir and a wellbore and assists natural reservoir energy in expelling oil.

REFERENCES
1. Pautz, J. F. and R. Thomas. Applications of EOR Technology in Field Projects-1990
update. DOE Report, NIPER-5 13, November 1990.
2. Prats, M. Thermal Recovery. SPE Monograph Series No. 7, SPE of AIME, Dallas,
TX, 1982.
3. Burger, J., P. Sourieau and M. Combarnous. Thermal Methods of Oil Recovery. Gulf
Publishing Co., Houston, TX,1985.
4. Boberg, T. C. Thermal Methods of Oil Recovery, John Wiley & Sons, New York,
1988.
5. Goodlett, G. O., M. M. Honarpour, H. B. Carroll and P. S. Sarathi. Diverse
Mechanisms Add to Increased Oil Production in Thermal and Gas Projects. Oil & Gas J., v. 84,
NO. 26, July 28, 1986, pp. 98-102.
 6. Wu, C. H. and A. Brown. A Laboratory Study on Steam Distillation in Porous Media.
Pres. at the SPE Annual Tech. Conf. and Exhib. of the Soc. of Pet. Eng., Dallas, TX, Sept. 28-
Oct. 1, 1975. SPE paper 5569.
7. Wu, C. H. A Critical Review of Steam Flood Mechanisms. Pres. at the Annual
California Regional Meeting of the Soc. of Pet. Eng., Bakersfield, CA, Apr. 13-15, 1977. SPE
paper 6550.
8. Chu, C. State-of-the-& Review of Steamflood Field Projects. J. Pet. Tech., v. 37,
No. 10, October 1985, pp. 1887-1902.
9. Sarathi, P., D. Roark and A. Strycker. Light Oil Steamflooding A Laboratory Study.
Soc. of Pet Eng. Reservoir Engineering, v. 5, No. 2, May 1990, pp. 177-184.
10. Willman, B. T., V. V. Valleroy, G. W. Runberg, A. J. Cornelius and L. W. Powers.
Laboratory Studies of Oil Recovery by Steam Injection. J. Pet. Tech., v. 13, No. 7, July 1961,
pp. 681-690.
 CHAPTER 2
CRITERIA FOR EVALUATING STEAM INJECTION PROSPECTS

INTRODUCTION
Several factors must be taken into consideration when evaluating candidate reservoirs for
steam injection operation. These include reservoir rock and fluid properties, crude oil
characteristics, field history and current well status. Tables 2.1 and 2.2 summarize the criteria that
must be considered in evaluating a prospect for cyclic steam and steamflood. Note that these
recommendations are general guidelines with which to identify target reservoirs for further study,
and the use of engineeringjudgment in the application of these criteria is advocated.
This chapter discusses each of these criteria and their relative importance to a reservoir
engineer evaluating the properties for a particular steam injection project. Although the screening
criteria for cyclic steam treatment and steamflooding are slightly different, the following discussion
is applicable to both processes.

Rock and Fluid Properties

Rock Type
Any fornation that permits the injection of steam at an acceptable rate should be considered
for additional study. Since sandstone generally has high permeability and limestone and dolomite
have low permeability, steamflooding has mainly been applied to unconsolidated sandstone
reservoirs. However, steam has been injected successfully into a fractured consolidated sandstone
reservoir in wyomingl and in a fractured dolomite reservoir in Southwest ~rance.2

Pay Zone Thickness

Pay zone thickness criterion is important, since heat losses from thin reservoirs may be quite
significant. This will lower the heating efficiency of the thermal process and may also adversely
affect its economics.
Pay zones from 30 to 150 ft thick are desirable for steamflooding. However, steamflood
pilots have been carried out successfully in Edison Groves (CA) field? which has a pay thickness
of only 12 ft. Larger areal patterns, combined with high initial steam injection rates, are offered as
the means to recover oil economically from reservoirs with thin pay sections. If the pay zone is
thicker than 150 ft, steam would have difficulty sweeping the formation uniformly.

Depth and Reservoir Pressure

Reservoir pressure and depth are interrelated screening criteria; their importance arises from
the difficulty they present to the injection of steam into a reservoir.
 TABLE 2.1 - Cyclic Steam Screening Criteria

Viscosity > 40 cP (centipoise) at reservoir conditions

Gravity is not critical by itself, but 12' to 20' API oil is preferred
Water
Reservoir connate water properties are not critical. Water for s t e m generator should be chemically
treated so it is, soft, slightly alkaline, and free of oxygen, solids, oil, H2S (hydrogen sulfide), and
dissolved iron.

Low clay content

Reservoir
Thickness > 20 ft
Depth < 3,000 ft
Porosity > 25%
Oil-in-place > 1,000 bbl/acre-ft
Permeability > 250 m D (millidmy)
Favorable Factors Factors Which Increase Ri&
1. Existing wells adaptable to steam injection 1. Strong water drive
2. Available fuel supply for steam generation 2. Gascap
3. Available water which is cheap, slightly 3. Low net to gross pay fraction
alkaline, and free of H2S, oil, dissolved iron, 4. Extensive fractures (not as
and turbidity serious as in other injection
4. Adequate reservoir pressure in thinner sands methods)
5. Homogeneous formation
Laboratory Screening Tests
1. Oil analysis (gravity, viscosity at formation temperature)
2. Oil atmospheric-vacuum &itillation
3. Water analysis
4. Mineral analysis of reservoir cores
 TABLE 2.2 - Stearnflooding Screening Criteria

Viscosity (PO) is not critical, but less than 10,000 cP (centipoise) oil is preferred.
Gravity is not critical by itself, but 10 to 20° API oil is preferred.

Fornation water properties are not critical.

Water for steam should be chemically treated so that it is slightly alkaline and free from factors
such as hardness, oxygen, solids, oil, HzS (hydrogen sulfide), and dissolved iron.

Low clay content

Reservoir
Thickness (h) > 15 ft
Depth < 4,500 ft
Porosity (@>25%
Oil Saturation (So) > 0.4
Oil-in-place > 600 bbllacre-ft ($SO ) 0.08)
Permeability (k)is not critical by itself, but a value > 300 mD (millidarcy) is preferred.

Transmissibility,
kh >5()mD&
CP

F l 2 tors Which Increase Risk

1. High porosity 1. Strong water drive
2. High net to gross pay 2. Large gas cap
3. High well density 3. Extensive fractures
4. High quality water
5. Low fuel costs
6 . Uszble existing wells
5. Homogeneous formation
Laboratory Screening Tests
1. Oil analysis (gravity, viscosity)
2. Oil atmospheric-vacuum distillation
3. Water analysis
4. Mineral analysis of reservoir cores
5. Predicted SOR from gravity and distillation properties
6. Steamflooding tests for SOR determination
 Steam is normally injected into shallow reservoirs. With increasing depth, heat losses in the
wellbore as well as to the overburden and underburden of the formation increases. However, the
incorporation of insulated downhole steam injection tubulars in planned project operations will
reduce the thermal losses to the overburden soil and therefore improve the process efficiency.
Normally, depths less than 4,500 ft are preferred for steamflooding. The deepest steam
injection to date has been in an 8,500 ft well in the Boscan reservoir in the Lake Maracaibo Basin
of ~enezuela.4The use of insulated tubing at this field maintained heat losses at the design value
of 5%of the injected heat Figure 2.1 shows the wellbore heat loss accompanying steam injection
through a 2 7/8-in. uninsulated tubing and an insulated tubing in a 7-in.casing. The well depth
was 3,000 ft, and the steam injection rate was 950 bbUd of cold water equivalent. The steam
injection pressure was chosen as 1,800 psig. The overall heat losses were estimated using
Ramey's method5 for both insulated and uninsulated tubing. From this plot, it is clear that there is
no technical justification to use depth as a criterion of ineligibility for steam injection. Rather, it
may be that the injection of steam into a deeper formation will violate an economic constraint.
Economic computations which consider the extra cost of insulated tubulars versus the savings in
fuel will have to be carried out.
The high pressures associated with deep reservoirs will also prohibit the use of steam. With
increasing depth, steam injection pressure generally increases with a corresponding increase in
steam temperature. If the reservoir pressure is higher than 3,200 psig, the critical pressure of
steam, steam injection is nearly impossible. Even at reservoir pressures close to 2,000 psig, the
operating pressure would be close to 3,000 psig. Additionally, with increase in pressure the total
heat of steam (sum of latent heat and sensible heat of steam) decreases.
Further, a high reservoir pressure may bring about a low steam injection rate. This will
affect the economics of the process because of increased wellbore heat loss, lower production
volumes, longer project life, and resulting increased heat losses to adjacent strata. ideally,
reservoir pressure should be less than 500 psig.

Permeability and Transmissibility

Although a permeability greater than 100m D is acceptable, an air permeability of greater than
300 mD is desirable for steamfloods. Low permeabilities would result in lower injection rates and
hence in a longer flood life. This slow injection would increase heat losses to the formation
overburden and underburden as well as to the surrounding air during steam generation. Such heat
losses would mean that more oil must be consumed in the steam generators to recover the same
amount of oil as a shorter steamflood in a more permeable reservoir.
 3600 C 2-?/8"0.D TUBING IN 7" CASING (UNINSULATED)

0 0.5 1 1.5 2 2.5 3

WElL DEPTH ( THOUSAND OF FEET )
ESTIMATED HEAT LOSS AS FUNCTION OF DEPTH

FIGURE 2.1. - Estimated heat loss as function of depth.

The effective transmissibility, Ti, of a reservoir to a fluid phase "i" is defined by the equation

where lq is the permeability to the fluid phase i and Pi, is the fluid viscosity, and hi is the pay
thickness. The ratio ki/pi is called the fluid mobility.
The fluid mobility is a function of the fluid, fluid saturation, and the displacement
temperature. Adverse transmissibilities of the injected and reservoir fluid render the stearnflood
process inefficient. A low reservoir permeability and/or a very high oil viscosity results in low oil
mobility. The effect of low permeability on the process efficiency was discussed in the previous
paragraph. Scaled physical model studies of steamflooding for different oil viscosities indicate a
strong negative influence of oil viscosity on the efficiency of the steam drive process.
The problem of low oil mobility and reservoir transmissibility has been addressed by some
operators by injecting steam above the formation pressure and allowing the fractures to provide a
path between injector and producer. An example of this is the Saner Ranch fractures assisted
steamflood proceu.6 In summary, adverse fluid mobility and reservoir transmissibilities can be
modified by tailoring the process to the reservoir. As long as these modifications are economically
sound, there can be no restrictions on these parameters.
Stratification
Steamflooding generally works best in a massive sand with no stratification. However,
reservoirs with shale stringers are frequently encountered.
If the shale stringers are very thin (4-ftthick) and continuity of the sand can be traced from
injector to producer, the formation can still be used for steam injection. If the shale breaks are
thick, the pay sands should be flooded separately. In such cases, a packer is used to separate the
steam injection for the upper and lower sands, thus avoiding injection into the shale break. If the
shale break is greater than 4 0 4 thick, flood the two zones separately.

Anisotropy
An anisotropic reservoir is one in which the reservoir properties vary areally. The most
common anisotropic effect is preferential permeability, which causes fluid to flow nonradially from
the injection well. As long as the injection and producing well are in communication, anisotropy
will not hinder steam injection.
If the preferential permeabilities have been found, the project can be designed to account for
this effect. For example, an inverted seven-spot pattern can be rotated and stretched (see
figure 2.2) along the major high permeability axis of an anisotropic reservoir to achieve uniform
steam breakthrough at the producing wells.

FIGUFE 2.2. - Typical pilot pattern configuration for an anisotropic reservoir.

 Gas Cap Or Aquifer
Normally, formations with a gas cap should be avoided for steam injection. If steam is
injected near a gas cap, the gas cap could act as a sink, i.e., steam might enter the gas cap rather
than the reservoir. A small gas cap, which could be waterflooded to residual gas saturation prior to
steam injection, may be tolerated.
Since oil reservoirs with an underlying aquifer (often calkd bottom water) are quite common,
they cannot be ruled out for steam injection, However, if steam enters the aquifer, all the injected
heat will be dissipated. Steam injection projects should be carefully designed to avoid this
possibility, in most cases.
Steam may be injected into the aquifer if the aquifer is much thinner than the pay zone (for
example, a 5 to 10-ft aquifer below a 30 to SO-ft pay zone, as in Slocum Field, Anderson County,
~exas).7The thin aquifer is heated by steam and conducts heat to the pay zone. Oil in the pay
zone is mobilized and will drain to the aquifer to be produced.

Dip Angle
Although most steam injection projects to date have been in low dip reservoirs, dip angle is
not a restriction in selecting steam injection candidates. The Brea ~ i e l and
d ~ the Mid-Way Sunset
Fields of California are the best examples of dipping reservoirs where steam has been successfully
injected.

Porosity
As porosity increases, the amount of heat energy needed to heat the reservoir rock decreases.
Also, a greater porosity will hold more oil per unit volume of reservoir rock. Ideally, a reservoir
king considered for steamflood should have a porosity of at least 0.2 from an energy usage
standpoint; a lower porosity will not have a sign%cant impact on overall process efficiency because
part of the heat stored in the rock could be recovered through scavenging operations, such as
conversion of a steamflood to waterflood. The main impact of porosity will be in its oil content.
Porosity lower than 0.2 is acceptable only if oil saturation is greater than 0.65.

Oil Saturation
A minimum oil content (the product of oil saturation and porosity) is necessary in order to
offset the energy requirements of a steamflood process. A rule-of-thumb in the oil industry says
that the product of oil saturation and porosity (O x SO;) must be at least 0.13 or 1,000 bbl/ac-ft, for
steamflooding. Thus, if porosity is 0.2, the oil saturation should be at least 0.65. For light oils
that can be flooded to a lower residual saturation, the oil content must be greater than 0.08 or 600
bbllac-ft.
 This combination of porosity and oil saturation implies that the reservoir should have enough
recoverable oil to cover the energy requirements of the process, and to supply additional
production to rnake the process economically attractive. Dugdale and ~elgravegperformed a
detailed energy analysis and concluded that it is possible to perform steamflood at oil content
values below 0.1 in heavy oil reservoirs. Thus, no general guidelines on the minimum oil content
requirement for a feasible steamflood project can be given. Individual reservoirs must be analyzed
independently. The only valid guide line for oil content is that it should be high enough to furnish
the energy needs of the process and supply sufficient additional oil production to make the process
economical.

Cluy Content
Clay content of a reservoir is not a restriction in selecting a steam injection candidate.
Reservoirs with or without nonswelling clays can be used for steam injection projects. Some
resewoirs contain water sensitive clays, such as montmorillonite clays which swell when contacted
with injected steam or water. The swollen clays greatly reduce the formation permeability.
Nevertheless, this type of reservoir can also be used for steam injection if the clays are properly
stabilized. For example, in a California reservoir containing swellable clays, swelling was
prevented by injecting a saturated potassium chloride (KCl) slug near the wellbore. In addition, a
0.5% (wt) KC1 solution was continuously injected into the generator feedwater downstream of the
water softener. This approach was effective in treating swellable clays so that steam injection rate
could be maintained. If the reservoir contains swelling clays which cannot be controlled and the
effective permeability would be reduced to less than 100 md, this reservoir should be excluded
from steam injection.

Crude Oil Characteristics

Gravity -Crude oils with gravities from 6" to 50' API are amenable to steam injection.
Steamflooding has usually been successful in heavy oils of 8' to 25' API gravity. In the range
between 26O to SO0 API, steam distillation is the major recovery mechanism. Most fields producing
oil with gravity higher than 40' API are deeper than 5,000 feet, a depth that was once impractical
for injecting steam. However, with the development of insulated tubing, it is now possible to
recover light oils from these very deep formations.
Viscositv - Since a minimum oil mobility is required at reservoir temperature for a
displacement process to operate, an upper limit is usually imposed on oil viscosity for the steam
injection process. These values are in the range of 15,000 cP for stearnflood. For steamflooding,
Yan et al? reported a decrease in recovery from 32 to 29% when viscosity was increased from
500 cP to 4,000 cP for a 15-ft thick reservoir. The corresponding steam oil ratios were 6.6 and
8.8, respectively. Doscher,ll on the basis of scaled physical model studies, concluded that very
viscous crudes could not be recovered economically. However, steam injection has been
successfully canied out in Canadian reservoirs containing highly viscous crudes. These include
Cold Lake, Primrose, Peace River, etc.

FIELD HISTORY AND STATUS

Primary and Secondarp Production History

Steamflooding can be implemented at any stage in the life of the reservoir. However, it is
usually used as a secondary process in heavy oil reservoirs. A field which produces during
primary production is most likely to be a good steamflood prospect. The primary or secondary
production history also provides a production decline curve which can be used as a baseline for
assessing the effectiveness of steam injection. Any oil production above the extrapolated decline
curve can be attributed to steamflooding. Only this stearnflood oil should be used in calculating the
economics of the flood.

Well Spacing and Condition

Usually, the primary recovery or waterflood oil wells are drilled at 40-acre well spacing.
This spacing is not suitable for most reservoirs in steamflooding because excessive heat will be lost
between the injectors and the producers. Although steamflood pattems can be as large as 20 acres
(10-acre spacing), smaller spacing will improve areal and vertical sweep efficiency. Ideally, a
2.5-acre spacing or less is preferred.
During steamflooding, both the injection and producing wells will be subjected to high
thermal stress from exposure to either live steam or hot produced fluid. Any old well or wells not
equipped to handle this stress should be worked over. Wells with holes in the casing should be
repaired prior to a steamflood. A later chapter will discuss equipping wells for use in a
steamflood.

Pattern Configuration
While a producing well in a confined pattern can capture all movable fluid inside a pattern,
such patterns have an unfavorable producing to injection well ratio. On the other hand, an
unconfined pattern has a favorable producing to injection well ratio, but it loses a large portion of
movable fluids outside the pattern. Therefore, if possible, multiple patterns with more than one
injector and producer (such as the pattern shown in fig. 2.3) are preferred.
 3.75 ACRES

FIGURE 2.3. - Unconfined steamflood pattern with peripheral injectors.

Wafer and Fuel Supply

The successful operation of a stearnflood project depends upon the availability of good
quality feed water in sufficient quantity. River water, lake water or produced water from different
formations can be used. Produced water from the formation being flooded can also be used as
generator feed water, if correctly treated. The quality of the raw water dictates the amount of
treating required. The requirements for treating source water for steam generators and the
equipment necessary for the treatment will be described in detail in a subsequent chapter.
Enough fuel must be available to fire the steam generator so that high quality steam can be
generated continuously. Fuel such as natural gas or diesel oil can be used. After oil production
reaches a steady level, part of the produced crude could be used as the generator fuel.

Water Disposal
As mentioned previously, produced water can sometimes be used as generator feedwater
after treatment. The rest of the produced water, after the removal of the oil particles must be
disposed of properly. The produced water after treatment, for example, can be disposed by
injecting into a disposal well completed in a diflerent formation. If water disposal is a problem in
the area, the field should not be considered for steam injection.
 SUMMARY
Guidelines for selecting candidate reservoirs for steam injection are presented. These are
general guidelines that reflect the current technology and economic climate. The criteria presented
should not be regarded as sacred, i.e., that all criteria must be met before the process can be
considered for a particular reservoir. Each reservoir should be examined closely on an individual
basis and engineering judgment applied before a decision can be made to pilot testa reservoir.
REFERENCES
1. Chappelle, H. H., G. P. Emsurak and S. L. Obernyer. Screening and Evaluation of
Enhanced Oil Recovery at Teapot Dome in the Shannon Sandstone: A Shallow, Heterogeneous
Light Oil Reservoir. Pres. at the Soc. of Pet. EnglDOE Symposium on Enhanced Oil Recovery,
Tulsa, OK. Apr. 20-23,1986. SPyDOE paper 14919.
2. Sahuquet, B. C. and J. J. Femer. Steam Drive Pilot in a Fractured Carbonate Reservoir
-Lacq Superior Field. J. Pet. Tech., v. 34, No. 4, pp. 873-80, April 1982.
3. Doscher, T. M. and M. A. El-Arabi. Steamflooding Strategy for Thin Sands. Pres. at
the 1983California Regional Meeting, Ventura, CA. SPE paper 11679.
4. Chacin, E., I. Gomez, 0.Erdaneta and P.Colonornos. Feasibility of Steam Injection at
8200 ft. Pres. at the 4th UNTT'ARNNDP Conference on Heavy Crude and Tar Sands, Edmonton,
Alberta, Canada, August 1988. Paper 192.
5 . Ramey, H. J. Wellbore Heat Transmission. J. Pet Tech., v. 14, No. 4, pp. 427-435,
April 1962.
6. Stang, H. R. and Y. Soni. The Saner Ranch Pilot Test of Fractured-Assisted Steamflood
Technology. Pres. at the Soc. of Pet. Eng. Annual Tech. Conf. and Exhib., Houston, TX,Sept.
16-19,1984. SPE paper 13036.
7. Hall, A. L. and R. W. Bowman. Operation and Performance of the Slocum Thermal
Recovery Project. J. Pet. Tech. v. 25, pp. 402-408, April 1973.
8. Volek, C. W. and J. A. Pryor. Steam Distillation Drive, Brea Field California. J. Pet.
Tech., v. 24, No. 8, pp. 899-906, August 1972.
9. Dugdale, P. J. and J. D. M. Belgrave. Thermal Screening Criteria - Should They
Exist? Paper pres. at the 6th Annual Heavy Oil and Oil Sands Tech. Symp., Calgary, Canada,
March 8,1989.
10. Yan, C., 2. Jianhua and 2. Mengyi. Effects of Oil Viscosity on the Steam Recovery
Efficiency. Paper 20 pres. at the China-Canada Heavy Oil Tech. Symp., Zhuo Zhuo, China,
October 1987.
11. Doscher, T. M. Limitations on the Oil-Steam Ratio for Truly Viscous Crudes. Pres. at
the California Regional Meeting, Ventura, CA, March 1983. SPE paper 11681.
 CHAPTER 3
PROJECT PLANNING
INTRODUCTION
Steam injection is typically a high cost, low profit operation-hence proper planning is
important to achieve maximum economic benefits. The success depends on proper selection of
reservoirs for injection, sound program planning, consideration of capital expenditures and high
operating costs involved, and an awareness of the degree of success which can reasonably be
expected.
The objective of this chapter is to appraise operators of the various steps which must be
considered when planning a steam injection pilot
Reservoir Selection
In selecting a reservoir for the steam injection process, all readily available information must
be taken into consideration. These factors must then be carefully appraised and the prospect
selected. Criteria for evaluating steam injection prospects are discussed in detail in Chapter 2.
Some of the parameters involved include depth, oil-in-place, porosity, inhomogeneities, sand
thickness, oil mobility, and special conditions that may influence steam injection mechanisms such
as gas cap and bottom water.
Depth
While depth is a controlling factor costwise, there i s no trend or concentration of projects in
any particular depth range. Projects have been successfully implemented at depths from a few
hundred to over 4,500 ft. A deeper depth requires a higher injection pressure, which means that
high-pressure steam-injection equipment may be required. Also, since the temperature is
determined by steam pressure, higher steam pressure translates to higher temperature.
Disadvantages of high steam temperature include greater heat losses, lower recovery, casing or
tubing failure in older wells, and accelerated corrosion of well equipment.
On the favorable side, increased depth means that a greater pressure drawdown can be
applied to producing wells. This will yield higher producing rates for a given crude in a specific
formation.
Oil-In-Place
Oil-in-place at the time of steam injection initiation is another important consideration. One of
the most frequently asked questions is: How much oil must be in place to support a steam injection
operation? There is no simple answer to this question. The only thing that can be said about oil-
in-place is that it should be high enough to sustain a cash flow sufficient to pay for high operating
costs and provide an acceptable return on the capital invested. Chances for an economically
successful steam injection operation increase as oil-in-place increases above 600 bbYacre-ft.
 Reservoir Segregation and Inhomogeneities
Reservoir segregation and inhomogeneities must be considered when appraising a prospect
for steam injection. Reservoirs initially produced by solution gas drive, and in which some gravity
segregation of oil and gas (gas cap) has occurred, can present problems to steam injection
operators. A gas cap can be a thief zone. Steam might channel across the top of the sand resulting
in early breakthrough of the injected fluid.
Although situations of this type are not ideal, they can be tolerated. The presence of gas cap
may enhance areal coverage and gravity segregation, so that a significant portion of the reservoir
can be heated. An example of this situation is the Phillips Petroleum Co. successful Smackover,
Arkansas steamflood project2
Preliminary Evaluation
Once a reservoir has been selected, all geological data pertaining to the reservoir should be
gathered and carefully studied. An estimate of in-place resource should be made. Consideration
should be given to the site and the amount and condition of surface and well equipment. Suitability
of the existing wells for steam injection should be established. If the existing wells were found
unsuitable for steam injection, the cost of drilling and completion of wells for steamflood use
should be estimated. At this stage, maximum use of applicable correlations and rules-of-thumb
should be made.
Laboratory Analysis
Assuming favorable results and no known significant deterrents, the next step is to undertake
laboratory investigations. The extent and type of laboratory analysis needed will depend on the
amount of data already available. Cores should be obtained and subjected to flooding at selected
temperatures and pressures to determine the residual oil saturation and recovery. Using these data,
a preliminary estimate of recovery on a barrels-per-acre-foot basis should be made. Reservoir
fluids should be obtained, and the viscosity-temperature characteristicsof the crude oil determined.
Steam distillation characteristics of the crude must be established. These test data, together with
data from logs, core analysis, and past production history, should be used to estimate recovery
efficiencies and life expectancy of the project. Results from these studies will usually establish the
viability of the process.
Comprehensive Investigation
If the steam injection process still appears attractive, a decision should be made to go further
into a comprehensive investigation. This involves the undertaking of a complete economic study
and a more thorough performance investigation for new projects.
 A complete economic study should consider both capital investment and operating costs,
equipment and completion problems, and the cost of complying with regulatory requirements.
Factors that must be considered in the planning stage include: type and quality of available fuel;
water availability; required water treating and sizing of water handling equipment; necessary steam,
injection and production facilities to handle anticipated volumes of injection and production fluids;
condition of existing wells and equipment; additional well equipment; drilling and remedial costs;
safety precautions; availability of market outlets for the produced fluid; and waste disposal costs.
These and other equally important points must be carefully evaluated to arrive at an economic
justification for starting a project Table 3.1 lists major capital and operating costs that must be
considered in the preliminary economic evaluation. Economic analysis should also include the cost
of regulatory compliance expenses.
Loss of revenue dm to operational problems should be included in the projected annual cash
flow. The likely operational problems include: mechanical failure of steam generation equipment,
sand production and attendant pumping problems, emulsion problems, casing failure in old wells,
surface equipment malfunction, etc. Finally, in making economic evaluation, the operator should
consider special tax breaks given for enhanced oil recovery projects. If the economic analysis is
improperly done, the profitability of the project is jeopardized and the possibility of obtaining
adequate fmancing is materially reduced.
Comprehensive Performance Investigation
In addition to economic analysis, a more comprehensive performance investigation must be
carried out during the evaluation stage. Additional reservoir data such as capillary pressure,
relative permeability, and PVT fluid analysis data must be obtained. An estimate of the quantity
and volume of heat required for a pilot project should be made. More displacement tests over a
broader temperature and pressure range must be made. A detailed computer simulation study
should be undertaken to predict steamflood performance. Many variations of spacing and injection
patterns and rates should be investigated.
If results of a comprehensive engineering and economic analysis are favorable and meet the
necessary profitability criteria, a pilot operation should be planned. The various steps for thermal
prospect evaluation are summarized in table 3.2. These steps are amplified in tables 3.3 through
3.7.

Comparison With Conventional Practices

Conventional practices in an enhanced recovery sense are defined as waterflooding, pressure
maintenance by gas injection, or liquids recovery by gas cycling. The major difference between
TABLE 3.1. - Major Initial Expenses to be Included in a Steam Injection Project
Economic Evaluation

Steam generators
Steam lines to injection wells and production lines to tank battery
Fuel lines to steam generators
Flow lines to steam generators (include expansion loops and anchors)
Electrical systems
Water supply equipment (supply pump, chemical pump, chemical tank, and water storage tank)
Water treatment equipment (ion exchange unit, filters, treated water storage tank, deoxygenator)
Satellite stations (test headers and separators)
Pumping installations (electric motors, controllers, rod strings, and pumps)
Tank battery (treating tank, storage tank and transfer pump)
Water disposal equipment (collection tank, transfer pump, disposal pump, dispersed oil extractor, etc.)
Injection and production wellhead equipment and downhole facilities

Costs and I n w b l e
.. CoSfS

1. Injection wells
2. Producing wells
3. Water disposal wells
4. Water supply wells

Costs
1. Water treatment costs (include production or purchase price of raw water, transportation cost, chemicals
necessary for treatment to generator quality, and labor to accomplish all of this)
2. Steam production wsts (include fuel wst, power for generators and fuel oil heating, and labor to operate
equipment and system)
3. Well preparation cost (include cost of pulling or downhole workover)
4. Water disposal well (include waste water treatment cost)
5. Emulsion treatment cost

TABLE 3.2. - Steps for Steam Injection Prospect Evaluation Process

Selection and Field Implementation

1. Application of screening criteria

2. Initial investigation and selection
3. Laboratory analysis and data processing
4. Comprehensive pilot feasibility study and design
5. Field pilot implementation
6. Expansion to full-scale field development
Economics must be considered in every step.

A decision point should be built-in at each level, i.e., study can be dropped or
continued based on the results at that point.
 TABLE 3.3. - Initial Investigation
This step is essentially a preliminary evaluation based on existing information. It involves selection and appraisal of the
better prospects based on the following considerations.
Geographic Location
- Topography
- Fuel and water availability
- Market availability
- Availability of oilfield services, supplies, and equipment
- Federd, state, and local restrictions
Geological Information
- Reservoir depth and thickness
- Structure
- Competence of overburden strata
- Formation dip
- Federal, state, and local restrictions
Reservoir Data
- Rock and fluid properties
- Pressure, temperature, and saturations
- Fluid withdrawals
- Recovery mechanisms
Feasibility Study (Idealized Conditions)
- Computer analysis based on existing or readily-available information
- Determine expected producing rates and fuel consumption versus time

Surface and Well Equipment

- Size and location of present equipment
- Suitability of existing wells
- Storage and transportation facilities
- Disposal of unwanted p r o d u d fluids
Economic Factors
- Preliminary evaluation based on expected producing rates, crude oil selling price, capital and operating costs,
and taxes.

TABLE 3.4. - Laboratory Analysis and Data Processing

* bill core holes to get samples of reservoir rock and fluids, and obtain logs.
* Laboratory measurement of rock and fluid properties
- Porosity, permeability, and compressibility
- Water-oil and g a s 4 relative permeabilities at elevated temperatures
- Rock composition (swelling or dispersible clay material)
- Effect of salinity on permeability
- API gravity of crude oil
- Oil viscosity versus temperature
- Distillation characteristics (light oiIs)
- Chemical composition of oil (sulfur content)
- Analysis of produced water and other source waters
* Geological studies and log analysis
* Compile all available data and make estimate of target reserves
 TABLE 3.5. - Comprehensive Pilot Feasibility Study and Design
* Site selection(s)
* Initiate environmental studies
* Detailed reservoir performance study with thermal simulation model
- Study the main operator-controlled variables:
Pattern type
-
Pattem size well spacing
Steam injection rate and steam quality
Injection pressure (temperature)
Completion intervals
Steam stimulation of production wells
- Primary information obtained.
Production rate history - oil, water, steam
Estimation of project life
Steam requirements
- Sensitivity analysis with respect to uncertainty of fixed variables
Reservoir parameters
* Design facilities
- Steam generators
Fuel
Pollution control
- Steam distribution system
Surface lines
Insulation
- Oil gathering system
Flow lines
Production tanks
De-emulsification equipment
Upgrading if necessary
- Water treating system
Collection tanks
Flotation cells
Filtration equipment
Softening equipment

- Monitoring system
Process Monitoring
Environmental Monitoring
* Economic analysis
- Drilling and completion costs:
(New vs existing wells)
- Initial investment:
Steam generators (lease or buy)
Facilities
Pumping equipment
Wellhead and downhole equipment
- Operating costs:
Fuel for generators
Water plant operation
Electrical power
Wages
- Repair and maintenance costs:
Sand production workovers
Equipment repair
System leak repair

- Taxes
- Estimated gross revenue
 TABLE 3.6. - Field Pilot Implementation

* Obtain necessary permits

* Pilot install ation
- Drilling and completion
- Injection system
- Production gathering and treating system
- Metering and monitoring system
- Waste disposal system
- Pollution control system
* Operation and monitoring
- Data gathering and processing
Rates, pressures, temperatures of injection and production fluids
- Identification of special problems
+ Evaluation
- Economic appraisal of pilot

TABLE 3.7. - Expanded Field Operation

* History-match pilot reservoir performance

* Make recovery predictions for undeveloped parts of the field
* Select best prospects for pilot expansion or for new pilots
* Consider design changes based on pilot performance
- Process design
- Equipment
* Plan annual expansions based on available investment capital, manpower, required resources, and other constraints
* Consolidate scattered properties

these more or less conventional practices and the enhanced recovery processes being developed
today are a s follows:
1. More detailed and exacting laboratory screening tests to determine process applicability.
2. More specialized and costly equipment, some of which may have to be designed. New
well completion procedures and materials may be required.
3. Proper project evaluation requires the taking of more detailed and complex data,
necessitating the installation of specialized and more costly monitoring equipment.
4. All of the above requires more and better trained field personnel in order to evaluate and
cope with operating problems and environmental considerations.
These differences, along with many others such as special chemicals and storage facilities,
etc., dictate the need for a carefully controlled and monitored field pilot test
One of the most difficult phases in developing any new oil recovery process is the design,
implementation, and interpretation of field pilot tests. They are expensive, yet represent only one
of many possible sets of operating conditions. One must take every possible precaution to choose
an optimum set of conditions and to design a pilot that provides maximum opportunities for
interpretation. l To summarize:
Pilot Test
~ll0t -
a. An experiment where the field is the laboratory
b. A simulation of the larger field effort
c. A place for making mistakes before they become too costly
d. A place for working bugs out of equipment
e. A place for developing needed controls and data to ensure the success of a project
f. A place for putting available engineering talent to the test and for training engineers
g . A place for intensive planning
h . A place for open minds and compromise
i. A place for finding every problem imaginable and many not yet thought of with their
atkndant delays
pilot test ISnot -
a. A money making proposition in the short run
b . A total field simulation
c. Usually a great place to demonstrate "theory in action"
d . A hallowed shrine
e. A place where deadlines set 6 months earlier are proved correct

Performance of a pilot test will give the f i s t practical understanding of the reservoir
performance under a steam injection. Upon completion of a pilot test, most of the questions
pertaining to the feasibility of a steam injection project will have been answered. Again, an
economic appraisal must be made, and a decision on an enlarged operation should be made only
when enough data from the pilot operation have been obtained to indicate favorable economic
benefits. Size of the enlarged operation will be determined primarily by economic considerations.
Management must indicate desired flood-out time, amount of capital available to invest, and
expected rate of return on investment

SUMMARY
Steam injection is a practical, tried and proven method of increasing both rate d recovery and
ultimate recovery from certain types of reservoirs under particular conditions. A successful
application of the steam injection process requires a systematic investigation starting with
preliminary screening and culminating with full-scale field development. Economics must be
considered in each step. Rewards from a successful steam injection project will be substantial.
Unsuccessful projects can be avoided if proper consideration is given to all aspects of the
operation.
A good understanding of the reservoir and recovery process is essential for successful
implementation of a steam injection project. Before starting a steam injection project, an operator
should have a good estimate of the capital money required, have access to it, and be willing to
spend it. The operator should keep in mind that all investments involve a certain degree of risk,
and steam injection projects are no exception. The risk of failure of a steam injection project is
minimized if highly reliable and unbiased data are used in preparation and evaluation. In the final
analysis, experience, judgement, and knowledge of the reliability of the input data should be used
as a guide in deciding whether the proposed economic gains from a project justify the expected
risk.

REFERENCE
1. Pursley, S. A., R H. Healy and E. J. Sandvik. A Field Test of Surfactant Flooding,
Loudon, Illinois, I. Pet. Tech., v. 25, No. 7, July 1973, pp. 793-802.
2. Smith, R. V., A. F. Bertuzzi, E. E. Templeton and R. L. Clampitt: Recovery of Oil by
Steam Injection in the Smackover Field, Arkansas, J. Pet. Tech., v. 25, No. 8, August 1973,
pp. 883-889.
 CHAPTER 4
ECONOMICS OF STEAM INJECTION

INTRODUCTION
The basic advantage of steam injection over that of other recovery methods is increased
ultimate recovery of lower gravity viscous oil in a shorter period of time. Steamed wells are
usually allowed to produce to their maximum ability; hence, rapid payouts are possible. In
addition, the process can be contained within a small area, thus making unitization unnecessary.
Steam injection has evolved into a mature process over the past 30 years. This advancement in
technology has removed many of the unknown factors associated with the process and has
improved production forecasting. From the lending institution prospective, this has lowered the
risks associated with the process and has permitted better evaluation of steam injection projects for
loan purposes.
In spite of the technological advancements, steam injection projects are still considered as
high-cost, low-profit operations. The production of heavy oil by steam injection is a more
complex and expensive undertaking than conventional oil recovery practices. Steam injection
requires high capital investments, and operating costs are high. Maintenance costs are generally
high since reservoirs that make good steam injection candidates are usually very unconsolidated
and lend themselves to sand production and require above normal workovers. Furthermore, the
market price realized for the produced crude oil needs to be reduced for the lower quality product
and any costs incurred for delivery to refineries. The very best steam recovery fields in California
are barely profitable operations at current heavy oil prices. Hence, a careful analysis of the
economics of the proposed project must be performed to determine feasibility. Assuming that the
feasibility of a project had been established and that a flood has been started, many other factors
will constantly arise that must be balanced against each other. Thus, a steam injection project
requires a constant study of engineering and economics, and the task is not completed until the
project is ready to be terminated.
The purpose of this chapter is to present an overview of the economics of a steam injection
project. Some of the factors which govern the economics of a steam injection operation are
outlined. Costs of steam injection operations are presented.
Economic Factors in Steam Injection Operation
An economic analysis of any injection operation whether it is watemood or steam injection is
largely a balancing of the costs for such an operation against the value of the additional oil
recovery. The factors that govern the economics of individual steam injection operations are often
numerous and varied. Many of these factors are peculiar to individual areas or operators, and it is
not the purpose of this discussion to consider such factors and how they might affect economic
conditions of steam injection. Likewise, there are factors that more or less frequently impact the
economics of individual steam injection operations, and these will be presented briefly. These
factors include (a) cost of the prospect, (b) reservoir depth, (c) oil content of the reservoir, (d) net
production pay, (e) demand and price for the crude, ( f ) abandonment, (g) availability and quality of
raw water, (h) availability and cost of fuel and power, (i) oil transportation facilities,
(j) location, (k) size, 0) existing lease terms, (m) water disposal facilities, (n) local environmental
regulations, and (0) availability and cost for labor and field s e ~ c e .
The order of importance of these factors is not necessarily the order of their listing. To
illustrate how these factors influence the economics of an individual operation, a brief discussion
of the related factors is in order.
The value of a thermal recovery prospect often is difficult to determine and may vary greatly.
The effect of this factor is often disregarded in considering the economics of a steam injection
operation. In areas where the possibilities of thermal recovery are not well established, stripper
well properties can be acquired at little more than salvage value. Under such conditions, the cost
of acquisition is of no significant importance, even though the true value of the prospect may be
great. Conversely, in an area where steam injection operations are well established, and where the
cost of such prospects more nearly reflect their true economic value, the cost of acquiring desirable
steamflooding acreage is likely to be very high, almost prohibitive, to the average operator
interested only in the production of oil. The thermal acreage of San Joaquin Valley is a good
example of this later condition. Thus, the economic values of thermal recovery prospects may vary
from salvage values to values representing a significant portion of the profit that is to be realized
from the development of the prospect. This value should always be included in the economics of
any steam injection operation.
In the development of a steam injection operation, perhaps the most important of all factors
that affect the economics are: (1) the oil content of the reservoir-measured in terms of barrels of
oil per acre-foot of reservoir; (2) the depth to the producing formation; and (3) the demand and
wellhead price for the oil. The economic effects of these factors are interrelated, and one can
hardly be considered without the others.
The oil content at the beginning of a steam injection operation is a key indicator of the
likelihood of the economic success of the project Steam injection recovery operations are energy
intensive, and approximately one-third of the produced oil is used to generate steam. Total oil
recovery must be sufficient to pay all costs of recovering that oil, at the prevailing oil price, plus
provide an acceptable rate of return on the investment. Hence, minimum amounts are needed to
permit significant incremental recovery and to exceed fuel requirements. Chances for an
economically successful steamflood increase as oil-in-place increases above 600 barrels per acre-
foot.
 The cost and efficiency of steam injection processes are strongly depth dependent. The
average 1990 Kern County, California, steam injection project well completion costs are shown as
a function of depth in table 4.1. From this table, it is clear that well costs are largely controlled by
depth. Deeper depths require higher injection pressures which means that high-pressure steam-
injection equipment may be required. Also, the higher pressures required for deeper reservoirs
may lead to higher steam temperatures and, therefore, higher reservoir heat losses. Furthermore,
the latent heat content of high-pressure steam is low. Other disadvantages of high-pressure, high-
temperature steam include casing or tubing failure in older wells and accelerated corrosion of well
equipment. These factors increase operating and maintenance costs. Inasmuch as development,
operation, and maintenance costs for intensive steam injection operations increase with depth, then
is a minimum recovery per acre of oil for a given price that can be considered profitable. As the
depth increases or the price of oil decreases, higher recoveries per acre are necessary to offset
increased costs. In the same fashion, as the depth decreases or the price of oil increases, the
minimum recovery per acre to obtain profit decreases. These are general relationships, the other
factors being equal. In any proposed steam injection operation, however, these factors must be
considered and carefully weighed to determine the probable economics of the operation.
Other factors encountered in the proposed development of a steam injection operation can be
as important to the economics of the operation as the factors just described. In many old
properties, particularly extremely old properties, many of the wells have been improperly plugged
and long abandoned. The condition of the= abandoned wells can be of major importance to a
thermal operation. The old Midcontinent fields are good examples of this later condition. Geysers
of steam, hot water and hot oil were formed at the surface after implementation of a steam

TABLE 4.1. - Kern County, California, New Steam Injection Well Costs, Excluding
Well head injection equipment'

Well depth, Eastern Western

ft Kern County Kern County
inj. well cost. $ inj. well cost, $

l ~ e r nCounty Assessor's appraised value for the year 1991-92

process at shallow depths in Missouri and Oklahoma as a result of communication to the surface
via improperly plugged and abandoned wells. These unfortunate occurrences can be remediated at
added cost by drilling new wells and changing injection patterns. Poorly plugged and
undocumented abandoned wells are sources of tremendous loss of valuable oil and steam. Such
losses reduce expected recovery and add materially to costs. When an operator is planning steam
injection process implementation in old fields, a thorough investigation is necessary, with
documentation, to try to locate all old abandoned wells for the prevention of surface contamination
and loss of recovery. With the increasingly stringent environmental regulations, such surface
contamination materially affects the economics of an operation due to cleanup costs and penalties.
While far from being universally practiced, it is recommended that any and all wells drilled within
the area to be flooded, be reopened and replugged even the so called "dry holes," in order to
prevent escape of oil andlor injected steam to the surface. Such a strategy in the long run will be
less costly than cleanup and surface restoration costs. In view of the added costs of locating and
replugging abandoned wells in older fields, it is obvious that the oil recovery per acre from such
fields must be higher than that of younger properties for the process to be economical.
The availability of an adequate supply of good quality water at a reasonable cost for steam
generation is important to steam injection operations. Large-scale steamflood operations require
large volumes of good quality water, and usually a shortage of water seriously affects the rate of
oil recovery and the economics of a operation. The cost of furnishing suitable water for steam
generation varies considerably, depending upon the source of water and the amount of water
treatment required. This varies not only from field to field but also from day to day, particularly if
produced water is recycled. When sufficient volumes of water can be acquired at reasonable cost,
the total cost of furnishing feed water for steam generation is usually small compared to steam
generator fuel cost and has minimal effect on the economics of steam injection operations. In areas
where water is scarce and extremely valuable, its cost could be prohibitive.
Steam injection operations are energy intensive, and fuel costs greatly affect the economics of
an operation. Natural gas and lease crude are the most common types of fuels used to fire thermal
EOR steam generators. In a typical California steam injection operation, fuel costs account for
more than 50% of operation and maintenance costs. Gas-fired steam generators are less expensive
to install and operate than oil-fied steam generators. In many areas, gas is not readily available,
and lease crude is burned to generate steam. This reduces the volume of fuel available for sale.
Since improvement in steam generator thermal efficiency reduces fuel requirements and reduces
cooling loads of flue gas scrubbers, generator efficiency has an appreciable effect on the economics
of an operation. For example, the fuel requirements of an oil-fued 50 MM Btu/hr steam generator
(the standard oil field unit) can be reduced roughly by 5,300 barrels of oil per year by increasing
the thermal efficiency by about 5%. Thus, even a marginal improvement in thermal efficiency can
materially affect the economics of an operation and may result in prolonging its economic life.
The location and size of a steam injection operation also can affect overall economics. There
are many factois inherent to the location of the property which affect development and operating
costs. It is more expensive to implement a steamflood project in urban areas such as Los Angeles,
California, than in rural area such as rural Kern County, California. Availability and cost of labor
and oilfield services often depend on location. Oil pipeline outlets or other means of oil
transportation often have an influence on the price received for oil at the wellhead. The size of the
operation alone may have considerable effect. Usually, a large operation can be developed and
operated for lower unit costs than a smaller operation. The shape and size of the area often affect
development and operating costs. A square area usually is less expensive to develop than a long
narrow area, such as that of the shoestring sands of eastern Kansas. Well spacing also affects
development costs. Spacing controls the number of injection and production wells to be drilled
and this, in turn, largely controls the development and operation cost per acre. In thermal
operations, wells are closely spaced to minimize heat loss between injectors and producers and to
improve areal and vertical sweep efficiency. In selecting the well spacing, the improvement in
recovery must be balanced against development and operating costs.
Existing wells may or may not be used. One should not hesitate to use an old well as a
producer, provided it is located not more than 10% off the desired geometrical location and
provided, of course, that it is in good physical condition and can handle thermal stresses resulting
from exposure to hot produced fluid. In most instances, old wells are not in good physical shape
and require either cleaning out, replacement of tubing and casing, or some other major remediation.
Since steam injection wells are subjected to high thermal stresses due to exposure to live steam, old
wells should not be used as injection wells, unless they are worked over. The cost of this work
seldom justifies the expense involved, even if it is very close to a proposed pattern input Usually,
it is less costly to drill and complete a new injection well than to convert an old exiting well to an
injector.
Existing primary lease terms and obligation to non-operating interests are also important in
thermal operations. Obviously, if royalty interests are high or nonoperating interests do not
participate in the cost of the operation, the profit is materially reduced. Geology of the reservoir or
field also significantly impact the economics of the thermal operation. For example, the shoestring
reservoirs of southeast Kansas, though very high in oil saturation, unfortunately are highly
compartmentalizd and discontinuously bedded, allowing very little movement of steam through
the producing formation. Such floods will seldom be a financial success. Steamflood is seldom
economically viable in formations with a gas cap or in reservoirs with an underlying aquifer.
Steam injected near the gas cap almost invariably moves preferentially through the gas cap,
allowing little movement of steam through the zone of oil saturation. Similarly, in oil reservoirs
with an under-lying aquifer-if steam enters the aquifer-all injected heat will be dissipated and the
steam process may not be economical. Integrated engineering and geologic analysis prior to
process implementation will improve the chances for success.
 Federal and local environmental regulations and requirements also significantly impact the
economics of thermal operations. For example, in California the air emission standards are so
stringent that the cost of compliance with the state air quality standards is becoming increasingly
prohibitive for many steam injection operators. Obtaining necessary permits to operate the steam
generators is the single most difficult and costly aspect of thermal recovery operations in
California. Disposal of project-generated wastes such as scrubber liquor, scrubber sludge, water
softener regeneration brine, etc. calls for special measures and can materially impact the economics
of an operation. The cost of compliance with environmental regulations must be taken into
consideration in any analysis of the economics of steam injection operations.
The brief factors which have been presented, not only control the economics of steam
injection operations in general but also offer a sound basis for determining the profitability of the
proposed operations. A thorough analysis of these and other factors, individually and collectively,
not only determines the merit of thermal EOR in general but also the extent to which these
operations are justified. Today, thermal recovery of oil is based on sound engineering and proven
practices. It is usually possible to determine approximately how much oil can be recovered by a
thermal method from a given reservoir. With this information on hand, thermal recovery is largely
a problem of economics, i.e., balancing the total cost of recovery against the estimated value of the
oil to be recovered. However, predicting the economics of thermal recovery is quite complex and
requires extensive knowledge and experience. Although the literature on the theoretical and
reservoir aspects of steam injection operation is voluminous, steam injection recovery costs are not
as well documented. The published economic studies?-5 of necessity, generally present overall
costs rather than specific costs. In this report, an attempt is made to present a more detailed
breakdown of equipment costs.
Estimation of Economically Recoverable Oil
It is obvious that the economics of any steam injection project are based on the simple
formula:
Gross Profit = Gross Revenue - All Costs
Estimation of gross revenue requires a reliable estimate of production. Several steamflood
recovery models have been developed for use in estimating incremental ultimate oil recovery and
potential producing rates under various operating conditions. The U.S.Department of Energy
(DOE),through the DOE Bartlesville Project Office (BPO), has made available to interested
operators and others four steam-drive enhanced oil recovery models that may be acquired free of
charge.* The four models include algorithms for calculating oil and water production rates,
optimum steam injection rates, surface and wellbore heat losses, and a basic economic analysis
package. A brief description of the features of these models and their limitations is presented in
appendix 4-A.
Steam Injection Project Costs
The total cost of steam injection operations includes many items, and the magnitude of each
item varies between individual properties and operators. Steam injection project costs can be
classified into two groups. The first group includes all costs pertaining to the development of a
project and the second, all costs pertaining to the operation of a project.
Development costs should include not only all costs or investments for the installation of all
equipment and facilities necessary for the successful operation of a steam injection project, but also
all costs on investments made in the acquisition of a property. The acquisition cost should include
the cost of a complete economic study of the thermal recovery possibilities of a property. This
normally requires consultants or other experienced personnel to analyze all factors affecting the
proposed operation including the cost of acquisition of necessary reservoir data, simulation costs,
etc. The information-acquisition cost, although not large, is necessary and important in
determining the magnitude of thermal recovery reserves and their economic value.
The direct developments for steam injection recovery represent the major portion of the total
costs of such an operation. These costs are usually considered capital costs, and they include the
drilling of wells, installation of injection and production systems, steamgeneration and water-
treatment equipment, and all additional equipment or facilities required for the successful operation
of a project. These costs vary with location and many other factors, as previously discussed. The
cost of acquiring necessary permits to implement a project is also included in the development
costs.
The operating costs involved in steam injection operations include costs for water-treatment,
fuel, operation and maintenance of injection and production wells, handling of oil, waste water
disposal, administrative overhead, and taxes. These costs vary in different areas in relation to the
size of the projects. The controlling portions of the operating costs are for fuel, labor, and
supplies. The operating costs for steam injection operations are high and are paid out of current
production and, to a considerable extent, are controlled by the amount of current production. On a
per barrel basis, thermal operations require more engineering supervision and special services than
primary or waterflooding operations. Intensive thennal recovery is a highly specialized operation,
and good engineering supervision is a necessity for a successful operation.
 Cost Estimate
To determine whether a project will be economically successful, the costs specific to steam
injection operation need to be analyzed in detail. These costs are grouped into development costs,
operational costs, and acquisitiodlease costs. Administrative costs are excluded. Steam injection
project costs are detailed in the following. All costs are for a typical 1,000-ft, shallow, heavy oil
well in California. Unless otherwise noted, all costs are in 1991 dollars.
Development Costs
Well Costs
The cost estimates for injection and production wells are shown in Tables 4.3 and 4.4.
These cost estimates are based on the Kern County, California, assessors1estimation of the cost of
drilling and equipping new steam injection and production wells (see Tables 4.1 and 4.2), and the
Independent Petroleum Association of America (IPAA) Cost Study Committee' Index of Drilling
and Equipping ~ e l l s . 6The IPAA Drilling Index for the years of 1983 through 1989 is shown in
Table 4.5.
Other capital costs associated with a steam injection project include: (1) source water wells
and distribution lines; (2) water treatment facilities; (3) fuel supply facilities; (4) steam generator;
(5) flue gas scrubber system; (5) steam distribution system; (6) wellhead injection facilities; and
(7) surface facilities. The capital costs presented in the following section were gathered from
various sources including equipment vendors and California stearnflood operators.
Water Treatment Facilities
Water treatment facility costs are contingent upon the quality of source water. Depending on
the raw water source, the system ranges from a simple zeolite ion exchange unit to a facility that
includes clarifiers, filters, skimmers, oil separators, depurators, softeners, and deaerators. As a
general rule, the poorer the water quality the more elaborate will be the treatment requirements and
the higher will be the capital costs. For the purpose of this cost estimation, the source water is
assumed to be fresh subsurface water containing less than 500 ppm total hardness. Softening of
such water, requires nothing more than a simple zeolite water softening unit. A packaged unit
capable of softening about 3,500 bbl of water (capacity of a 50 MM Btdhr steam generator) would
cost $100,000. In Kern County, California, a source well drilled to about 300 ft and completed in
200 ft of water sands and equipped with a submersible pump and related equipment will cost
$25,000. The cost of a 5,000-bbl raw water storage tank with gas blanket will cost $40,000.
Two-thousand feet of water distribution line; transfer pumps and drive will cost $20,000.
 TABLE 4.2. - Kern County, California, New Production Well Costs, Excluding
Downhole pump1

WeU Depth, Eastern Western

ft Kern County Kern County
prod well cost, S prod. well cart, $
0-250 35.000 40,
m
251-750 58,000 63,000
751-1,250 78,000 85,000
1.251-1.750 9WMO l00,ooo
1,751-2,250 130,000 146,000
2.251-2,750 153,000 180,000
2,751-3,250 180,000 225,000
3,251-3.750 210,000 270,000
3,7514,250 242,000 315,000
4.251-4.750 283,000 360,000
4,751-5,250 322,000 416,000

' ~ e r nCounty Assemx's appraised value for the year 1991-92

TABLE 4.3. - Cost to Drill and Equip a 1,000-ft Steam Injection Well (in 1991Dollars)
Drillinn:
Payment to drilling contractor
Site preparation
Transpottation and setup of rig
Fuel
Drilling mud ~d additives
Other expencbtures
Total drilling costs
LoPninn:
Logs and wireline evaluation services
Carinn:
Side waIl sampling, base charge
Sarnplin 36Wsample
8
f a 50 zone, samplelJ ft 10sunpler
Transport
supervision
Overhead

Cement and cementing setvices

Tool rentals
Perforation and formation treating
Supervision
Overhead
Casing .'7 threaded and coupled, $12+3fft1,000 ft
Tubing and attachments 2-3/8", $4.O/ft 1,000ft'
Downhole qupment
Casing and tubing centralizers, expansionjoints,high
temperature safety joints, permanent thermal packers, retrievable packer etc.)
Total cost of injection well
Steam injection well injection equipment (stuffimg box,
casing head, choke, nipples, ball joint assembly, valves,
line pipe. tubing,union, ells, etc)
Total drilling, completion, and equipment costs for the
steam injection well
TABLE 4.4. - Cost to Drill and Equip a 1,000-ft Production Well (in 1991 Dollars)

Payment to drilling contractor

Site preparation
Transportation and setup of rig
Fuel
Drilling mud and additives
Other expenditures

Total drilling c a t s
a $35.3/ft

b g s and wireline evaluation services

Side wall sampling, base charge

Sampling, $60/sample
for 50 ft zone, sample45 ft, 10 samples
Transport
supervision
Overhead

Cement and cementing services

Tool rentals
Perforation and formation treating
supervision
Overhead
I"
Casing trea* and cou led, $12.3/ft 1,000 ft
Producuon tubrng 2-318". %.0/ft 1.000 ft

Telescoping expansion joints, production packers

centralizer, gravel pack

Total cost of production well

Subsurface rod pump assembly with gas ancha, 3/4" API class C sucker rod
228,000 in Ib-torque API 228-213-86pumping unit

Total oost of production well

 TABLE 4.5. - Index of Drilling and Equipping Wells Unadjusted for ~ e p t h 6(1984 = 100)

Weight 1983 1984

Payments to drilling cootractors 29.8 114.3 100.0
Purchased Items:
Road site preparation
Transportation
Fuel
Drilling mud and additives
Mud coring, coring and monitoring
system 1.6
All other physical tests
Logs and wiretine evaluation
services
Directional drilling services
Perforate
Formationtesting
Cement and cementing services
Casing and tubing
Casing hardware
Special tool rentals
Drill bits and reamers
Wellhead equipment
Misc. equipment and supQZies
"ugs;ng
Supervtsion and overhead
Other expenditures

SubTotal Purchased Items

Source: IPAA Cost Study Committee

$20,000. A 1,000-bbl soft water storage tank with gas blanket will cost $30,000. Produced water
treatment and disposal cost will total $80,000.

Steam Generation
The operating characteristics of a steam generator are given in Table 4.6. Steam generator
and accessories costs, excluding that of pollution control equipment, are given in Table 4.7. The
steam generation operation cost, including water and fuel costs, are also shown in Table 4.7.
Labor costs are taken from reference 7. A typical 50 MM Btu/hr steam generator burns
approximately 7 gpm (gallons per minute) of crude oil and will require approximately 17 scf/min
(standard cubic feet per minute) of air (52,280 l b m h air) for complete combustion. A flue gas
scrubber (pollution control equipment) to handle approximately 25 scfm flue gas costs $360,000.
The operations and maintenance cost of the scrubber is approximately $200,000 per year ($0.2 per
barrel of produced stearn)?
 TABLE 4.6. - Characteristics of Conventional Lease Crude Fired Steam ~eneratofl
Heat inrtut 62.5 MM Btu/hr
Heat &tput 50.0 M M Btu/hr
Design capacity 3,500 bbl-steadday
Average daily output 2,800 bbl-steam (80% capacity)
Annual output 1,022,000 bbl-steam
s-qu;tlity 80%
Steam conditions 1,000 psi, saturated temperature
Water requirement 1*022,ooobbVyr
Electricity requirement 320,000 kwhfyr
Fuel requirement 10.2 bbVhr of lease crude/hr
or 74,000 bbVyr8

TABLE 4.7. - Conventional Oil-Fired Surface Steam Generator costs4 (1991 Dollars)
--

Item
Steam Generator (50 MM Btu/hr unit)
Steam piping, valves, imlation
Total
rn G w a-Y Costs
Power (7$/kwhr)
Maintenance (4% of capital investment)
Operating labor (1.5 aperatalshift 8 $ 1 7 h )
Overhead
Water (including purchase and treatment cost) 8 W l
Fuel (74,000 bbVyr @ 914hbl)
Total steam generator operating cost
Steam generation cost = $1.49 per bbl-steam

Steam Distribution System

Steam distribution lines include a main steam header and lateral lines. Steam headers m g e in
size from 12 to 24 in. diameter depending on the steam generating capacity of the site and steam
requirements in the area. Steam is transported from a steam header to individual injector wells by
steam lateral lines. Typically, these lines range from 3 to 10 in. in nominal diameter. Diameter of
lateral lines depends on injection rates of wells.
For cost estimation, the steam header was assumed to be constructed of 12-in. schedule 160
pipe and the lateral lines of 4-in. grade B seamless schedule 40 pipe. The pipes were assumed to
be supported on pedestals and guided to control direction of expansion. Expansion loops and
anchors were also installed at required intervals. Pipelines were insulated with magnesium silicate
insulation and covered with aluminum jacket for weather proofing. The steam lines, including
insulation, cost approximately $1 1.OO per ft plus installation.
A complete 600 series flanged wellhead hookup, including chokes, master valve, 1500 series
tubing valve, fittings, casing expansion flange, and swing joint would cost about $40,000.
 Other Surface Facilities
Other surface facilities used in a typical steam injection project include free water knockout
unit, heater treater, well testing unit, LACT unit, tank battery, pumps, etc.
Free Water Knockout Unit
An &ft-long unit capable of handling up to 27,000 bbUday of water would cost about
$30,000.
Heater Treater
A 6-ft horizontal heater treater, capable of handling 500 bbVday of produced fluid, would
cost about $60,000.
Well-Testing Unit
A well-testing unit is used to record the gravity of oil, gasfoil ratio, water/oil ratio, and t o t .
volume of fluid produced. A computerized automatic well testing unit costs about $35,000.
LACT Unit
Lease automatic custody transfer (LACT) units are used to measure the volume of oil sold to
a pipeline. A 2,000-BOPD LACT unit with 125 psi working pressure costs about $25,000.
Tank Battery
Tanks of different sizes, six to eight in number, will be required for storage of produced
fluids, treatment and storage of produced water, etc. These costs depend on the size of the units
and accessories. For example, a 2,000-bbl(16 ft-dia. by 30-ft-high) 10-gauge, gas-tight, bolted
steel tank would cost about $56,000 installed.
Other costs should include production lines, miscellaneous pumps, valves, fittings, power
line, sewer line, site office, etc.
Operating Costs
The operating costs for a typical steam injection project include costs for (1) raw water
production and transportation, (2) water treatment, (3) fuel, (4) fuel heating and pumping (where
lease crude is used), (5) power, (6) well pulling and repair, (7) aggravated oil treating problems,
(8) waste disposal, and (9) labor.
Raw Water Production and Transportation Costs
These costs are usually included in the water treatment costs. In Kern County, California, it
costs approximately 1cent to produce 100 gallons of water from a subsurface well.
Water Treatment
The water treatment operational costs depend on the quality of raw water and generally
include costs of salt for the regeneration of spent ion exchange resins, sodium sulfite for oxygen
removal, pH control chemicals, and other chemicals as required. In Kern County, California, it
costs approximately 4 cents to treat 1 bbl of raw water containing 1,000 ppm (parts per million)
total dissolved solids. Details of water treatment costs can be found in Chapter 5.
Steam Generation Operation Costs
These costs include fuel costs, fuel heating and pumping costs (if needed), and labor. Details
of steam generation operation costs are given in Table 4.7.
Bower
Steam projects need electric power for lighting, controls, the burner blower, water and brine
transfer pumps, chemical injection pumps, feedwater injection pumps, and operating various other
miscellaneous equipment. Power requirements for operating steam generators are shown in
Table 4.6. Purchased power in California costs about 7 cents per kilowatt hour.
Well Pulling and Workover Costs
Sand production problems associated with thermal recovery production wells require well
repair costs. These costs depend on the severity of sand production and frequency of well pulling.
No definite costs can be given. One California thermal EOR operator estimates about $10,000 per
well per year as the well workover costs for his operation.
Other Operating Costs
Apart from the water treatment and steam generation costs, a steam injection project incurs
numerous other costs such as surface facilities operational and maintenance, emulsion treatment,
well servicing, produced water disposal, sand disposal, and steamflood monitoring costs (such as
monthly temperature logs, miscellaneous other logs, tracer analysis, transient well testing, etc.),
produced fluids analysis costs, well testing costs, etc. These costs vary with the size of the project
and fluid produced. Detailed costs breakdowns are usually not possible.
Financial Costs
Royalties and taxes (federal and state income taxes) make up a substantial portion of the cost
of thermally produced oil. Hence, they must be properly accounted for in economic analysis.
Income and severance taxes vary from state to state. The current federal tax code must be
consulted for federal income taxes, investment tax credits, intangible drilling costs (IDC), and
depreciation on capital equipment
Though royalties may range from 10 to 25%, most steam injection projects are on old leases
where a royalty rate of 12.5% on gross revenue usually applies. As previously mentioned, the
profit potential of a steam injection project is severely impacted by a high royalty rate.
 The various oil-production-specific state taxes are shown in Table 4.8. These can be used to
arrive at oil production economics on a state-specific basis. The federal corporate income tax for
the year 1990-91 is 34%. The current federal tax law permits domestic independent producers to
fully deduct intangible drilling costs (IDC).
An IDC is any cost that is necessary for the drilling and completion of a well but which in
itself has no salvage value (e.g., wages, fuel, repairs, supplies, transportation, etc.)
Other charges that must be included in the financial analysis of a steam injection project
include (a) cost of borrowing the necessary capital and (b) depreciation of capital equipment.
Approximately one-third of the wellhead costs goes toward the financial costs of the operation.
The suggested average life for steam injection operation related equipment is given in Table 4.10.
Capital charge rates, as arrived at by Rand ~ o r ~ o r a t i for
on~ steamflood projects, are given in
Table 4.9. The annual capital charge rate accounts for (1) the cost of capital, (2) depreciation, and
(3) federal and state income taxes including investment tax credits. This table is based on 1982 tax
rates and presented here for illustration purposes only. The details of its calculation are presented
in Appendix 4-B. This appendix should be consulted for estimating capital charges for new
projects.
Table 4.9 is based on the following assumptions: (a) combined federal and state income tax
assumed to be 50%, (b) production and local tax rate assumed to be 10% of gross revenue. All
investments are assumed to use 100%equity financing with 10% minimum acceptable real rate of
return. Equipment life (book life) is assumed to be equal to project life. The tax life is assumed to
be 5 years with straight line depreciation. A 10% investment tax credit is assumed in the
calculation.
SUMMARY
Thermal recovery operations require a sizeable capital investment, and most components
require much more maintenance than nomal oilfield equipment. The success of an individual
steam injection operation is affected by several factors. However, the principal factors are the
o i l h a m ratio (barrel of oil produced per barrel of feedwater injected as steam), the depth to the
producing formation (deeper formations have larger heat losses and, at the same time, less latent
heat content in the injected steam), and the price and demand for the oil. Other factors may become
extremely important and affect the economics of the operation. As examples, in certain mas the
quality of feedwater is so poor that the cost of water treatment may be excessive; or the cost of
furnishing fuel for steam generation tends to make total operating costs higher. Hence, an
evaluation of the different factors which could influence costs must be made before any steam
injection operation is undertaken. A complete engineering and economic study of a prospect will,
to a large extent, determine the probable degree of success of the operation.
 TABLE 4.8. - Comparisons of Economic Factors Affecting Oil Production From Selected
Oil Producing States

New North
~ a n s a s l Oklahomal Missouri2 h4exico1 Illinois1 ex as ' cdol ~akotal

Land owner royalty. 9b 12.5 12.5 12.5 12.5 12.5 125 12.5 12.5
Land surface disruption, Site Site Site Site Site Site Site Site
specific specific specific specific specific specific specific specific

Direct state tax, 8 4.333 7.0~ None 3 . 7 ~ ~ None 4.64 2-55 53.6
Emergency school tax 3.1 s3
State Severance Pcoduction tax

Produdvity 1. Variable None one^ None None None Stripper 1. Variable

stripper wells stripper
Vintage 2 New oil None None None 2. New oil
& gas
Osher 3. Tertiary oil Incremental 50% for None 3. Workovers
prod. EOR
Secondary
& Deep &
tertiary tight gas
only
Ad Valorum Tax yes8 None None yes8 Yes Yes Yes None

Corporate Income Tax yes9 yes8 Yes yes9 Yes None Yes Yes

Corporate Franchise Tax ~esll yes12 None yes lo Yes yes12 None Flat
Sl5Wy-r

Effective Average Tax Rate, % 9.7 7.4 Variable 8.9 1.3 8.4 6.4 10.2
on oil & gas production

Percent of Total Wells in State

-Stripper Oil for 1988 99 83
Percent of Total Production
- as StripperOil 92 64 99 20 89 18 24 4

Kansas Inc., Strategic Analysis of the Oil and Gas Industry in Kansas, Arthur D. Little, Inc., Cambridge, Mass., April 1990.
P e d m u n i c a t i o n with K. Deason, Missouri Dept. of Natural Resources, and S. Evers, Missouri Dept.of Revenue, July 1990.
Gross Lease Revenue (F4.B.- Does not discount transportation and marketing costs).
Gross Lease Revenue less Marketing and Transport Costs.
Less than $25,000 at 2%,$25,000-$100.000 at 34, $100,000-$300,000 at 4%, $300,000 and over at 5%on corporatefindividwf oNgas revenues.
An extraction tax is assessed at the rate of 6.5% for old wells and 4% for new wells.
Each state is attempting to mitigate declining oil production and declining revenues to the state and have or are considering economic
incentives for enhanced oil recovery.
Ad valorurn tax levied on the economic value of each producing unit. Appraisal value calculated by applying present worth factor to
future revenue to derive a net worth for each lease.
Tax basis derived from apportioned revenue derived within state as determined by three factor formula that is equally weighted. A tw*
- facta formula is available for qualifying companies. Rates are $0 - $25,000 at 4S%, > $25,000 at 6.75%.
lo Separate accounting for oil and gas income on all taxable income.
Of shareholder equity 0.18, minimum of $20 and maximum of $2,500.
Of business aod investment capital 0.12596, minimum of $10 and maximum of $20,000.
 TABLE 4.g4 - Capital Charge Rates
Project life, Capital charge
a rate

TABLE 4.10. - Suggested Average Life Tables for Oilfield Related Equipment1

computers
Injection System
Cdledon System
Scrubber
Water Softener
Fiks
Reheaters
Steam Generators
OB[ice Furniture and Equipment
Heater Treater
Free water Knock Out
Oil Treating
Transformers
Heat Exchanger
Casing Blow System
Dehydration Unit
separa-
Shipping, Booster and Otber Pumps
LkCT. Units
Compr~s
Automatic Well Testing (AWT) Unit
Oil Analyzer
Vapor Recovery
Gauging Equipment
Flow split@
B.S. & W. Monitor
Air Exchanger
Electronic Paneis
Waste Water Plant
Boiler Piant
Gls Plant
CogenemionPtaDt
Tanks over 5,000 bbl

The economic feasibility of thermal operations has been proved over and over again in
~aliforniaand other parts of the world for many years. In spite of higher capital and operating
costs, thermal operations have proved profitable in these areas and have recovered large volumes
of heavy oil which otherwise might have been abandoned. Successful steamflooding under a
favorable geological setting is entirely dependent upon the three basic factors: engineering,
economics, and experience.

REFERENCES
1. Maples, J. W. Kern County Assessor-Oil and Gas Properties Appraisal Parameters,
1991-92-Assessor, County of Kern Oil and Gas Division, Bakersfield, CA, March 1991.
2. Lewin and Associates-Economics of Enhanced Oil Recovery. U.S. Dept. of Energy
Report No. DOElETl12072-2, May 1981.
3. Dowd, W. T., V. A. Kuuskraa, and M. L. Godec. A Technical and Economic
Assessment of Domestic Heavy Oil. U.S. Dept. of Energy Report No. DOE/BC/10840-1,
January 1988.
4. Nehring, R., R. Hess and M. Kamionski. The Heavy Oil Resources of the United
States-A report prepared for the U.S. Dept. of Energy by the Rand Corporation. Report No.
R-2946-DOE, Rand Corporation, Santa Monica, CA, February 1983.
5. Norton, J. F., I. D. Rouge, S. N. Husband, P. K. Beekley and W. R. Hearn. The
Options for Increasing California Heavy Oil Production. A report to the California Energy
Commission-Radiant Corporation, Sacramento, CA. Report No. DCN 81-250-008-07,
November 1981.
6. IPAA Cost Study Committee-Index of Drilling and Equipping Wells. Oil & Gas
Investor, v. 9, No. 10, May 1990.
7. Trends and Statistics-Petroleum Independent, November-December 1990, p. 49.
8. Bartlesville Project Office, U.S. Department of Energy, P.O.Box 1398, Bartlesville, OK
74005 (Phone: 9 18-337-4293).
 APPENDIX 4-A
REVIEW OF DEPARTMENT OF ENERGY
STEAM DRIVE PREDICTIVE MODELS

BACKGROUND
Estimating the amounts of economically recoverable heavy oil requires the use of a sound,
yet simple, thermal EOR model. For this, the Department of Energy (DOE) Bartlesville Project
Office (BPO) currently maintains four steamdrive enhanced oil recovery models and one in situ
combustion oil recovery model
This appendix reviews the publicly available thermal recovery DOE models and recommends
the model most suitable for estimating oil production by steam injection.

Review of Available Steamflood Models from BPO

The four steamdrive thermal recovery models available through the BPO contain several
common features. These features include algorithms for the determination of surface and wellbore
heat losses, engineering costing algorithms, and a basic economic analysis package. The common
technical features include a correlation for estimating residual oil saturation to steam, an optimum
steam-injection rate calculation, and a method for calculating oil and water production rates, which
includes fluid shrinkage and the presence of free gas. The models also use common routines for
handling data input, data verification, and data output
Each of the BPO steam drive models is discussed in more detail as follows:
1. SUPRI Model. The SUPRI model, also called the Williams et al. rnode1,l-2 utilizes the
Man: and ~angenheim3method to predict the growth and volume of a steam zone created by
continuous steam injection. These calculations assume that the growth of a steam zone and the
volume of oil displaced by steam are controlled by heat losses to the adjacent overburden and
underburden.
2. Jones Model. The Jones model4 is a steamdrive performance predictive model based on
work by van ~ookerensand by Myhill and Stegerneier.6 This model uses a steam-injection-rate
optimization function based on a vertical conformance factor and a steamdrive algorithm based on
the Marx and ~angenheim3equations as modified by Mandl and ~olek.7The model delays the
arrival of the oil bank at the producing well and maintains ultimate oil recovery to less than the
mobile oil in-place.
7. Gomaa Model. The Gomaa model8 predicts steamflood performance by utilizing a set of
empirical correlations. These correlations are based on observed field performance data from the
California Steamflood (notably Kern River) projects. The key correlation variables include vertical
heat losses, vertical sweep, and fractional oil recovery as functions of reservoir thickness, heat
injection rate per acre-foot of reservoir, bottomhole steam quality, and mobile oil saturation. The
correlation curves are developed by regressing the results of a finite-difference steam drive
reservoir simulator. A simple method of estimating water production rates has been added to the
original Gomaa model by BPO.
4. Intercomp Model. The Intercomp model provides a more complex and thus more realistic
description of steamdrive performance. The model utilizes the reservoir and injected steam
properties to predict stearnflood performance. The model calculations allow for the development
and eventual production of three fluid banks created during steamflooding: (1) the cold liquid
bank, (2) the hot oil, condensate, and water banks, and (3) the steam zone.
The cold liquid bank, created by the displacement of unheated oil and water by the steam and
hot liquid banks, represents the initial response of a reservoir to steamdrive. The hot liquid bank
contains heated oil and water and exists just ahead of the advancing steam zone front. The steam
bank follows and generally overrides the hot liquid fluid bank. The model varies the densities,
viscosities, residual saturations, and relative permeabilities of these banks with temperature. Heat
losses from the reservoir to the overburden and underburden are calculated from simple heat
balances, and heat is produced when the heated zone reaches the producing well. Initially the
reservoir rock is assumed to be homogeneous, isotropic, and incompressible, in thermal
equilibrium with the adjacent strata, and with uniform oil, water and gas saturations. A detailed
description of this model is presented in references 9 and 10.

Model Recommendation
A comparative assessment of these models by Dowd et al." indicated that all of the models
display reasonable and expected sensitivity to the steam injection rate, steam quality, and grosshet
pay ratio. However, the simple Gomaa model exhibits no sensitivity to reservoir permeability or
crude oil viscosity. Based on the model's ability to match simulation results and history match of
field data, Dowd et al. recommend that the Intercomp model be used to predict steamflood
recovery. However, it must be pointed out that the algorithm used in the Intercomp model to
calculate residual oil saturation after steamflood often leads to an overprediction of oil recovery.
Since this significantly affects the project economics, model results should be used with caution.

REFERENCES FOR APPENDIX 4-A

1. Williams, R. L., H. J. Ramey, Jr., S. C. Brown, and S. K. Sanyal. An Engineering
Economic Model for Thermal Recovery Methods. Pres. at the 50th Annual California Regional
Meeting of Soc. of Pet. Eng., Los Angeles, California, Apr. 9-1 1, 1980. SPE paper 8906.
2. Williams, R. L., S. L. Brown, and H. J. Ramey, Jr. A Method to Evaluate the
Economics of Thermal Recovery Projects. Stanford University Petroleum Research Institute
Technical Report No. 18 (SUPRI-TR- 18), June 1980.
 3. Marx, J. W. and R. N. Langenheim. Reservoir Heating by Hot Fluid Injection. Trans.
AIME, 216, 1959, pp. 312-315.
4. Jones, J. Steam-Drive Model for Hand-Held Programmable Calculators. J. Pet. Tech.,
v. 33, No. 9, September 1981, pp. 1583-1589.

5. Van Lookeren, J. Calculation Methods for Linear and Radial Steam Drive in Reservoirs.
Pres. at the 52nd Annual Fall Meeting of the Soc. of Pet. Eng., Denver, Colorado, 1977. SPE
paper 6788.
6. Myhill, N. A. and G. L. Stegemeier. Steam Drive Correlation and Prediction. J. Pet.
Tech., v. 30, No. 2, February 1978, pp. 173-182.
7. Mandl, G. and C. W. Volek. Heat and Mass Transport in Steam Drive Processes. Soc.
Pet. Eng. J., March 1969, pp. 59-79.
8. Gomaa, E. E. Correlations for Predicting Oil Recovery by Steamflood. J. Pet. Tech., v.
32, No. 2, February 1980, pp. 325-332.
9. Aydelotte, S. R., C. W. Paul, and R. M. Ray. Development and Verification of
Simplified Prediction Models for Enhanced Oil Recovery Application: Steam Flood Predictive
Model. U.S. Dept. of Energy, October 1984.
10. Aydelotte, S. R. and G. A. Pope. A Simplified Predictive Model for Steamflood
Performance. J. Pet. Tech, v. 35, No. 5, May 1983, pp. 991-1,002.
11. Dowd, W. T., V. A. Kuuskraa and M. L. Godec. A Technical and Economic
Assessment of Domestic Heavy Oil-Final Report. U.S. Dept. of Energy Report No.
DOE/BC/10840-1, January 1988.
 APPENDIX 4-I3
CALCULATION OF CAPITAL CHARGE RATE^
The methodology used to calculate the capital charge rate is as follows:
1. After-tax cost of capital (r):
r = ( 1 -taxrate)xrbfb+r,fs
2. Capital recovery factor based on r and book life (CltFr,~):

r( 1 + r)booklife
CRFr,~
=
(1 r) book life
+

-1
3. Capital recovery factor based on r and tax life (CRFG~):

4. Levelized depreciation factor (a)based on straight-line depreciation method:

5. Levelized investment tax credit factor (5):

5= investment tax credit ,C R F , , ~
(1 + r)
6. Capital charge rate (CCR):

C
CCR =

where rb = required rate of return on debt (bonds)

fb = fraction of capital that is debt
rs = required rate of return on equity (stock)
fs = fraction of capital that is stock
 CHAPTER 5
WATER TREATMENT FOR STEAM GENERATION

INTRODUCTION
Successful operation of steam generation equipment depends primarily upon a good source
of feedwater combined with an effective water treating system. Quality of steam generator
feedwater is of critical importance in steam injection projects. Field experience indicates that most
steamer downtime is caused by water treating problems. Although a once-through steam generator
can tolerate relatively high amounts of total dissolved solids (TDS), strict adherence to feedwater
quality requirements is essential. Operating outside a design quality range can result in scale
deposition in the water sides of steam generator tubes. Deposition of scale reduces heat transfer,
reduces flow though the tubes, and results in tube failure through formation of localized hot spots
on the tube walls. Corrosive components of the water also may cause tube failure. Therefore, it is
imperative that the feedwater be properly conditioned to minimize downtime and costly
maintenance.
Those embarking on steam injection projects should have an understanding of water quality
requirements and the reason these requirements must be met for optimum operation of the steam
equipment. Furthermore, since water provides a medium for trouble causing chemical reactions
such as scaling and corrosion, it is essential that the operator at least have a rudimentary knowledge
of water chemistry. In Appendix 5-A, oilfield water chemistsy is briefly discussed.
In this chapter, the steam injection process water quality requirements, problems, and
remedies are presented. Since the availability of fresh water for steam generation is becoming
increasingly scarce in many locations, treatment and use of produced water as steam generator
feedwater should be considered. A discussion on the treatment of produced water is also
presented.
A list of feedwater treatment equipment and chemical vendors is included in Appendix 5-C.
This list is included to serve as a reference and is not intended to be the recommended list of
suppliers.
WATER FOR STEAM GENERATION
Sources of Water for Steam Generators l
Successful operation of conventional oilfield s t e m generators requires an adequate supply of
good quality water. Depending upon the location, water for steam generation may be procured
from many different sources. Some of the potential sources include: (a) municipal systems in the
area, (2) freshwater wells, (3) lakes, rivers, creeks, dams, etc. In some fields where the potable
fresh water sands are reserved for local community or agricultural use, brackish groundwater is
used for steam generation. Produced water is another common source in many areas.
 The main point to consider before undertaking a steam injection pilot is that the available
water supply is adequate to sustain a full-scale steamflood operation for a considerable length of
time. It would be expensive to undertake a pilot program based on a limited supply of fresh water
because if the pilot proved successful (and it should be favorable on paper before it starts) the
ultimate need may be 20 to 30 times the rate required by the pilot for several years to come. The
pilot design should be based on the use of inferior quality water to assure the availability of an
adequate supply of water for future expansion.
Naturally occurring water supplies contain considerable quantities of impurities. Water is
such a superb solvent, that it has the power to dissolve virtually all inorganic substances to some
extent. The impurities found in the water result from dissolving the various gases and mineral with
which it comes in contact. Some of the typical impurities found in water sources are related to the
origin of these sources. Moving supplies such as rivers and creeks generally contain mud, silt and
other suspended matter, dissolved gases and minerals as well as bacteria, algae, and other organic
matter. Because of natural settling, static sources are usually low in suspended matter. However,
shallow lakes are easily disturbed by storms and are likely to contain higher amounts of suspended
solids than deeper lakes.
Well waters, in general, are richer in dissolved mineral content, but poorer in suspended and
organic matter and algae due to the filtration effect of the earth. As a rule, the mineral content of
well water increases with depth. Typical analyses of subsurface waters used in California
steamflood operations are shown in Table 5.1. Finally, produced water is usually contaminated
with oil and contains extremely high amounts of dissolved solids and organic matter. The
dissolved mineral content of these waters often exceeds 20,000 ppm (see Table 5.2).
Since the type and amount of impurities found in ground and surface water supplies are
considerably different, methods to produce the same end purity will vary with the source of water.
Further, it is highly unlikely that water from any two surface sources in the same area would
contain the same kind or amount of impurities. Therefore, it is essential that a specific water
analysis be conducted before developing any water weatment plans. Additionally, source water
should be monitored periodically to assure that changes which occur in a water supply due to usage
are compensated by a water treating plant.
Water Tretrting Considerution
Although the impurities present in raw water are not necessarily troublesome, field
experience indicates the use of poor quality feedwater results in frequent downtime and costly
maintenance. In Table 5.3, oilfield steam generator feedwater requirements are presented.
Primary constituents most troublesome in steam generators are: (1) total hardness,
(2) alkalinity, (3) oxygen, (4) sulf des, (5) dissolved solids, (6) suspended solids, (7) iron, (8) oil,
(9) silica, (10) pH, ( I 1) carbon dioxide, and (12) biological growth. The following will discuss
briefly how these impurities can affect steamflood equipment performance. For a more complete
discussion, please refer to Appendix 5-8.

TABLE 5.1. - Typical Analysis of Raw Waters Used in the San Jaoquin Valley, California, Steam
Injection project&

Water analysis
-
Impurities Midway Kern Coalinga
in water Sunset River
-
Total Hardness (CaC03) 50 60 460 480
Caldum Hardness (CaC%) 45 40 240 320
Silica (Si%)* 10 15 20 35
Iron (Fe)* ~1.0 <I.o < I .o <I .o
Chloride (CL-) 40 200 20 350
Alkalinity 45 110 360 120
Sulfate (SOq--) 80 50 200 2,m
Total dissolved solids 200 400 600 3,000
Total suspended solids <1 .o <1 .o <1 .o <1 .o
Oil* None None None None
pH* 7.9 7.8 7.7 7.5
oxygen* 2.0 10 3.0 <o. 1 3.0 to 5.0 <o. 1
Sulfides* None None None None

* Note: All values are in parts per million as CaC03 except those indicated with an asterisk.

TABLE 5.2. - Approximate Total Dissolved Solid (TDS) Content and Hardness of California
Oilfield Produced water10

Hardness
PP"'
Area-Field (as CaC03)

L a Angela. Inglewood
Long Bead (Wilmington)
Ventura
Santa Maria
Kern River
Belridge
Taft
Huntington Beach
Coalinga
Tulare
 TABLE 5.3. - Steam Generator Feedwater Requirements
l2xlmml m s i b l z imwit~
Hardness 4 ppnl
Total dissolved solids (TDS) <4,OOO ppnl
Alkalinity ~ 1 . 5 0 0ppm
Silica 4 0 ppm
Dissolved oxygen c0.01 ppnl
Chlorine <1 ppm
pH 9-1 1
Iron ~ 0 . 0 ppnl
5
Hydrogen sulfide 0
Turbidity
oil

Total Hardness: The hardness is the measure of the amount of calcium and magnesium ions
contained in water. These ions are responsible for the steam generator scaling and their
concentration in the boiler feedwater should be held below I part per million (pprn) to prevent
scaling. This is normally accomplished with the aid of an ion exchange resin bed.
Alkalinity: Natural water contains carbonate and bicarbonate ions which, under the influence
of heat, breakdown into hydroxide (OH-) and cabon dioxide causing the water to become alkaline.
Although excess hydroxide alkalinity can result in caustic embrittlement, a moderate alkaline
environment helps to reduce corrosion and keeps silica in solution. Therefore, alkalinity levels of
less than 1,500 pprn need not be treated.
Oxygen: Dissolved oxygen is the primary contributor to corrosion and should be excluded
from feedwater. API recommends that the maximum amount of dissolved oxygen in the feedwater
be kept below 0.01 pprn and preferably at 0.0 ppm.
Sulfides: Sulfide is usually present in the feedwater in the form of dissolved hydrogen
sulfide (H2S) gas. H2S is both corrosive and toxic and hence must be removed from the
feedwater. H2S is generally removed from the feedwater by deaeration, but chemical means such
as chlorination may have to be used for complete removal.
Dissolved Solids: Dissolved solids will cause problems only if their concentration in the
liquid phase exceeds their solubility limit. The practical limitation of dissolved solids generally
comes as a result of water softener operating limitations. A dissolved solid concentration of less
than 4,000 pprn in the feedwater is acceptable.
Sus~endedSolids: The raw water should be free of suspended solids since they contribute to
softener fouling and formation of steam generator sludge. If the concentration of suspended solids
in the raw water is high, the water must be filtered to reduce the suspended solid levels to an
acceptable level (usually less than 5 ppm) before softening.
Iron: The iron content of the feedwater should be less than 0.05 pprn to avoid contaminating
the ion exchange resins. Iron can also precipitate as scale on the generator tube and cause hot spots
to form.
 m: The presence of oil in the feedwater contributes to film formation and coking in the
generator tube and results in their eventual failure. Oil also fouls the water softener resins.
Therefore, the feedwater should be fsee of oil.
Silica: Silica is troublesome in oilfield steam generators because of its scaling tendency.
However, the presence of hardness ions such as calcium and magnesium is necessary for the silica
to form scale. Since these ions are usually removed by ion exchange process, silica removal is not
necessary. Satisfactory operations with silica contents of 150 ppm are possible in the absence of
hardness ions.
m: The pH of the feedwater should be maintained between 9 and 11 to keep silica in
solution and to avoid corrosion of the steel parts of the system.
Biolo~icalGrowths: If the total dissolved solids content of the raw water is high, bacteria
may grow in the feedwater. Since bacteria and algae will foul the ion exchange system, their
growth must be controlled. The most common method of controlling bacterial growth in oilfield
water is by means of chlorine or other biocide agents. Chlorine will attack only the exposed
organisms and will not penetrate slime. Biocides are effective in eliminating slime forming
bacteria. Biocides should be chosen with the help of a vendor representative, since the type needed
will depend on the organism, contact time, and temperature of the water to be treated, etc.
Table 5.4 summarizes the various methods of treating common feedwater impurities.
FEEDWATER TREATING EQUIPMENT
As noted previously, a wide variety of equipment is used in steamflood operations to treat
and produce water of desired quality. The water source dictates the type of treatment equipment
required. Some of the more common water treatment equipment used in steam injection operations
include depurators, sedimentation basin, skimmers, filters, ion exchange units, and mechanical
deaerators. Not all units are used in every operation. For example. only a few operations use
deaerators to reduce oxygen. Almost all operations use "catalyzed" sodium sulfite to scavenge
oxygen. However, in all steam injection projects, ion exchange systems are used to soften the
water. Finally, all operations use automation to monitor the quality of treated water. The ion
exchange units and their operational problems are discussed in detail in the following segments of
this report. The difference between conventional cation exchange systems and those used in steam
injection operations is outlined. A summary of the operation of other steam injection water
treatment equipment is also provided.

Ion Exchange Units

In almost all steam injection operations, water is softened by ion exchange. As the name
implies, an ion exchange system simply exchanges more of the desirable ions for the less desirable
 TABLE 5.4. - Methods for Removal of Common Raw Water impuritiesi

Impurities Methods for removal or reduction

H2S Gas Aeration, gas stripping, chemical reaction with chlorine

CO;!Gas Aeration, vacuum deaeration, demineralizer
0 2 Gas Vacuum deaeration. chemical scavenging, hot deaeration, sulfur
burner
Sediment, Turbidity Sand or anthracite filtration, precoat filtration
Bacteria Chlorination, bactericide
Oil Sand or anthracite filtration, diatomaceous eanh filtration, flotation
Hardness Strong acid and weak acid cation ion exchangers
Chlorine Deaeration. chemical scavenging
Iron Coagulant

ions without reducing the total solids content. Inexpensive to purchase, operate, and maintain, the
system consists of either a cation exchange resin which removes cations (such as calcium,
magnesium, iron, and manganese) or an anion exchange resin which removes anions (such as
carbonate, bicarbonate, chloride, and silica). For steam operations, most commonly used ion
exchange system for softening water is the synthetic sodium zeolite cation exchange unit. The
synthetic sodium zeolite resins are derivatives of sulfonic acids and are commonly referred to as
strong acid resins. Strong acid resin softeners efficiently reduce the calcium and magnesium
content of a raw water, but they do not affect the alkalinity, silica, or the total dissolved solids
content of the water.
Many different types of ion exchange materials are used in water softening operations. The
ion exchange material and method used to soften water will depend largely on the quality of raw
water and the quality of water required for a particular use. For example, the water quality
required for steam generation calls for almost zero hardness, and a sodium zeolite softener alone is
not satisfactory if the TDS content of raw water is greater than 2,000 pprn.10 Depending on the
TDS content of raw water, other types of resins are used alone or in conjunction with sodium
zeolite resins to obtain water of the required quality. The raw water quality and economics will
dictate the resin choice. Weak acid resins are also used in steam injection operations. These resins
exhibit a much greater capacity than conventional zeolite resins, are highly selective, and offer
more efficient regeneration. Weak acid resins are discussed more fully in a later section.
Before discussing the details of ion exchange equipment, four terms describing resin
efficiency are very important and should be remembered.
1. Capacity of an exchanger is defined as the amount of a specified ion that a given volume
of resin can remove from a raw water at stated conditions. Exchanger capacities are used
in characterizing ion exchange materials and in numerical calculations pertaining to ion
exchange operations. The capacity of an ion exchange resin is expressed as 'grains per
cubic foot' (1 grain CaCOgIcu ft = 2.29 ppm; see Appendix 5-A for definitions). For
 example, a resin is said to have a capacity of 2,500 grains per cubic foot, if 1 cubic foot
of this resin upon saturation contains 2,500 grains (5,725 ppm) of cations expressed as
calcium carbonate. The capacity of ion exchange resins varies greatly. The capacities of
naturally occurring zeolites vary between 2,500 and 5,000 grains per cubic foot. The
capacities for synthetic zeolites range between l5,OW and 35,000 grains per cubic foot.
In comparison, weak acid resins typically have a capacity as high as 70,000 grains per
cubic foot, but the operating capacity is usually in the range of 20,000 to 40,000 grains
per cubic f o d o
2. Leak= is the quantity of unwanted ions present in the treated water, after its passage
through the resin bed. Leakage is a function of raw water composition, resin capacity,
regenerant concentration, and the condition of the lower levels of the exchanger bed.
Leakage, as applied to an oilfield water, is discussed in a later section.
3. Flow Rate is expressed as the volume of water passing per square foot of cross-sectional
area of resin bed per minute. Flow rate must be regulated so as to allow proper contact
time between the water and resin. Since the flow rate can significantly effect the
operating capacity of the resin beds, it should be limited to about six to eight gallons per
square foot of resin beds.
4. Rate of Exchange is affected by resin type, flow rate, temperature, and resin particle size.
For a given resin, a decrease in particle size results in increased rate of exchange and
increased leakage. Higher temperatures increase the rate of exchange. For a given
particle size, different resins exhibit different rates of exchange.
Sodium Zeolite Softener
Zeolite water softening is the oldest and simplest of the ion exchange processes. Zeolites are
cation exchangers. Though in reality the name zeolite refers to naturally occumng alkali or alkaline
earth aluminosilicates, in practice any synthetic organic or inorganic cation exchange resin is called
a zeolite. Sodium cation exchange resins (sodium zeolites) used in the oilfield operations are
organic cation exchange resins of the polystyrene variety. These are derivatives of strong sulfonic
acids and are also commonly known as the strong acid resins. These resins are effective, durable,
inexpensive and operable over virtually the entire pH range.

Principles of operation4
In the sodium zeolite water softening process, the hard water is passed through a bed of
active sodium cation exchange resins. As the water flows through the resin bed, the resins replace
the objectionable calcium and magnesium ions in the water with the nonobjectionable sodium ions.
Using the symbol Z for the zeolite radical, the softening process can be summarized as follows:
 C1
Na2Z + Ca (or Mg) + Ca (or Mg) + 2Na
{ HC03
so4
The resin now contains calcium and magnesium ions and a few residual sodium ions.
When the ability of the zeolite bed to remove hardness has been exhausted, the softener is
temporarily taken out of service and backwashed for regeneration. The regeneration consists of
passing sodium chloride brine through the units, replacing the calcium and magnesium ions with
sodium ions. The regeneration step may be represented as follows:

Ca (or Mg)Z + 2Na C1 + Ca (or Mg) C12 + Na2 Z (2)

The regenerating solution, along with water used to rinse the softener after regeneration, is
discharged to waste. The process of regeneration of spent resins with sodium chloride is called
"brining .'
It should be mentioned at this point, that no chemical reaction is involved in the ion exchange
process. The softening or regeneration proceeds only because there is great excess of one ion in
the water compared to the resin. Although sodium zeolite treated water is nearly free of calcium
and magnesium ions, some hardness leakage is inevitable. The term "leakage' implies a slipping
of some of the unwanted ions into the effluent. Leakage occurs because the ion exchange process
is in dynamic equilibrium, i.e., reactions 1 or 2 are reversible. The sodium ion in the raw water,
plus the sodium ion released from the ion exchange bed by exchange of hardness ion, has a
regenerating effect on the resin as it is removing hardness. This results in hardness leakage
through the bed and into softened water. Hardness leakage increases with increasing TDS in the
raw water.
The frequency of regeneration needed depends on the flow rate, the hardness content of the
raw water, the exchange capacity of the resin, volume of resin in the bed, and amount of salt used
per regeneration. Of these, the operator can exercise control only on the quantity of salt used per
regeneration. The other parameters are fixed by the system design and raw water hardness.

Salt Requirements1 I
Zeolites have a greater affinity for divalent cations such as ~ a + +and M ~ + +than monovalent
. divalent cation affinity increases with an increase in atomic weight.
cations such as ~ a + The
Thus, during the softening cycle, ~ a + +ions are more readily removed from raw water than
M ~ + + . Therefore, magnesium hardness predominates in the softened water than calcium
hardness.
 Since the zeolite more readily releases sodium in exchange for calcium and magnesium, an
excess sodium chloride must be used for regeneration. This mea& the amount of sodium in the
brine must exceed the total amount of equivalent calcium and magnesium in the exhausted resins.
The amount of salt needed for regenention is determined by the acceptable effluent quality
limit and plant capacity. By using greater quantities of salt for regeneration, the capacity of the
softener can be increased. In figure 5.1, the effect of raw water hardness and salt dosage on resin
capacity is depicted. However, capacity increase is not proportional to regenerant increase. The
effect of salt level on the performance of a typical zeolite softener is shown in Table 5.5.
Capacities in this table are stated in grains of CaC03 per cubic foot of zeolite and salt consumptions
in pounds per cubic foot of resin and also in pounds per kilograin of hardness. From this table, it
is apparent that an increase in salt usage is out of proportion to the increase in softener yield. For
example, increasing the salt dosage from six pounds per cubic foot of resin to 15 lb/cu ft of resin (a
160%increase in salt usage) will result in about only a 50% increase in softener capacity. Thus,
the higher the salt level, the less efficient is the exchange process and greater is the operating and
waste handling costs. The effect of feedwater hardness and salt dosage on water softening costs is
shown in figure 5.2.

0 1000 2000 3000 4000 5000

BRINE HARDNESS IN ppm AS Ca CD3

FIGURE 5.1. - Effect of feedwater hudness and salt dosage on resin capacity. l l
 TABLE 5.5. - Effects of salt level on the performance of a typical synthetic sodium
zeolite exc:changer12
hesin c a t
Pounds per cubic foot Pounds (Grains of CaC03 per
of resin per kilograin cubic foot of resin)

Table 5.6 is a zeolite water softener sizing chart provided by one manufacturer. This chart
provides a perspective on the relative size of the equipment and choice between salt dosage and
capacity.
Softener Equipment and Operation
Although the sodium zeolite softener design features vary with vendor, in general the
softener system consists of a vertical steel tank holding the ion exchange bed, piping and valves to
permit the operations of softening, backwashing, brining, and rinsing. The system is usually
instrumented to automate the operation. A typical softening unit is shown in figure 5.3.
The softener tank is a vertical pressure vessel with dished heads. The diameter of the tank
depends on the flow rate and usually ranges from 2.5 to 10 ft. The height ranges between 6 and 8
ft. The internal components of the tank include a raw water inlet distributor, a regenerant
distributor, ion exchange resin bed, and an underdrain system. Ample room is also provided for
the free expansion of the resin bed during backwash.
The raw water inlet distributor is housed in the top portion of the tank. It also serves as the
rinse water inlet distributor, and wash water collector. It consists of a baffled arrangement which
serves to introduce and deflect the incoming feed and rinse water. Deflection of the incoming
water is necessary; otherwise the water will impinge on the bed and hollow out a portion of the
upper part of the resin bed. Hollowing would cause the flow to channel and reduce the softener
capacity.
The portion of the tank below the inlet distributor and above the resin bed is called the rising
or free board space. The free board space permits the resin bed to expand freely during
backwashing without loss of resin to the backwash drain. This expansion space is expressed as a
percentage of the resin bed volume and ranges from 75 to 80%.
The regenerant or the brine distributor is usually located about 6 in. above the resin bed. It
usually consists of a header distribution system designed to distribute the salt solution evenly over
the entire surface of the bed.
 Ibs NaCI I ft3 OF RESIN 15

0 1 000 2000 3000 4000 5000

BRINE HARDNESS in ppm as CaC03

FIGURE 5.2. - Effect of brine hardness and salt dosage on water softening costs.

TABLE 5.6. - Zeolite Softener Selection Chart l2

Total Resin

primary
tank
Polisher
tank
remn
capacity,'
kilograins
volume,
cubic feet

dimension dimension Service CaC% Primary Polisher Salt

Dia x side, Dia x side, flow rate, @ 30" bed. dosagc2
inches inches GPM depth lb

Based on a TDS of 800 ppm and 66 Ibdft resin.

Based on 15 Ibdfi primary bed.
 HlGHRATE
INLETDIFFUSER

-
AND BACKWASH\
OOLLECX)R
ACCESS MANHOLE
f-- RAW WATER INLET

UNDER DRAW TREArCD

EwslBVl WATER
olmJ3

FIGURE 5.3. - Schematic of a typical ion exchange water softener?

The resin bed contains a strong acid cation resin. The bed is leveled and hydraulically graded
so that the coarse particles are in the bottom of the bed and the finest at the top. This arrangement
permits even flow of water through the bed. The quantity of resin used will depend upon the
exchange capacity of the resin, the hardness of the water being treated, and the amount of water to
be softened between regenerations. The bed must also be of sufficient size to allow proper contact
time between the water and the resin. A minimum depth of 30 in. is recommended for all systems.
The softened water is collected by the underdrain system, located at the bottom of the
softener. This system also collects the waste brine and rinse water and distributes the backwash
water during the backwashing operation. A well-designed underdrain system permits the even
collection of softened, rinse, and salt waters from all portions of the bed and distributes the
backwash water so that it flows evenly upward through all portions of the bed. An uneven
distribution will lead to channeling and hardness leakage and cause loss of capacity. Uneven
backwash can also result in loss of resin through carryover.
Although the underdrain system design varies with the vendor, most vendors use either a
deflector plate type or a header-lateral type design. In the deflector plate design, a specially
designed deflector plate housed inside a false bottom permits the even collection or distribution of
water.
 Either a multiport valve or a valve nest is used to direct the flow of water and brine in and out
of the softener. The valve nest is comprised of six valves: raw water inlet and outlet valves, brine
inlet valve, rinse water outlet valve, and the backwash water inlet and outlet valves. In most
installations, air, water, or motor-operated automatic valves are used to control the flow. Very few
iktallations utilize manually operated gate valves. In large installations, a single multiport valve is
used instead of a valve nest to control the flow of water through the softeners during the various
cycles of operation. As the name implies, the multiport valve is comprised of several ports, and
they are positioned precisely at the desired location by manipulating the valve motion. The
positioned port then directs the flow of water in the same manner as the opening and closing of six
separate valves. Automation is usually used in the operation of a multiport valve. Although more
expensive, multiport valves are preferred over valve nests due to the elimination of operational
errors caused by opening or closing the wrong Lakes. The internal details of a typical ion
exchange water softener are shown in figure 5.4. -.

Brin ing System

The brining system usually is comprised of an epoxy-lined salt storage tank in which
saturated brine is formed. The saturated brine is then transferred to a small-diameter brine

LOCATION OF
MANHOLE n

wPLAN VIEW
AIR VENT COLLECTOR DISTRIBUTOR
HANDHOLE
DISTRIBUTOR r STRAINERS
BACKWASH
1

BO~OM VIEW
UNDER DRAIN SYSTEM

UNDER DRAIN SYSTEM

COARSE G CEMENT
1" ABOVE
LATERALS ADJUSTABLE
JACK SUPPORTS

FERRULED
OPENING

FIGURE 5.4. - Schematic of the intemals of a typical zeolite softener unit.

measuring tank where the brine is diluted to the desired concentration. The small-diameter
measuring tank allows a deeper drawdown and gives a more accurate measurement.
In large steamflood operations, where considerable amounts of salt are being used to
regenerate the spent resin, it is more cost-effective to purchase salt in truck loads than purchasing it
bagged. A reduction in handling costs is another economic advantage of bulk salt usage. A typical
design of a bulk salt storage facility for steamflood operation is shown in figure 5.5. It consists of
a large subsurface concrete brine pit, usually located adjacent to a railroad track or roadway, where
salt can be brought to the plant in bulk and simply dumped into a salt storage and brine preparation
tank. An auger is usually available to unload the shipment of salt from the truck into a pit. This
tank usually has a float-operated valve to control the addition of water into the tank. The saturated
brine is pumped at intervals into a brine measuring tank from which it is pumped to the softener
after dilution. Plastic pipes are usually used to transfer brine from the tank to softener.
Softener Operation
A sodium zeolite softener operates through two cycles: softening and regeneration. During
the softening cycle, the raw water enters the softener through the inlet distributor and percolates

FLOAT
VALVE BEAM

TOP
OF
RAIL

0'
GRAVEL

FIGURE 5.5. - Schematic of a bulk salt storage

through the zeolite bed. As it flows through the resin bed, the hardness-causing ions-calcium
and magnesium-are taken up by the resin, and an equivalent amount of sodium is given up by the
resin to the water. The softened water is collected by the underdrain system and transferred to the
point of use.
When a softener is exhausted, it is regenerated. Several different approaches are used to
signal the end of a softening cycle. Some plants regenerate after a fixed number of hours in
operation. Others monitor the hardness of the sample-softened water and initiate regeneration
when the hardness exceeds the desired level. Another common technique used to establish the
need of regeneration is to monitor the quantity of water softened between regeneration. A metering
device is used to initiate regeneration automatically when the preset numbers of gallons have been
softened.
The regeneration cycle involves the following four steps: (1) backwash, (2) brining,
(3) brine displacement and slow rinse, and (4) fast or final rinse.
Backwash-The purpose of backwash is to cleanse the resin bed of filtered particulates and
resin fmes and regrade the bed. Backwashing is accomplished by sending a strong flow of water
through the underdrain system into the resin bed. As the water flows upward through the bed, it
expands, cleanses, and hydraulically regrades the bed. The waste water is discharged to the waste
through a raw water distributor.
The backwash regrades the bed by bringing the coarsest particles to the bottom of the bed and
the finest to the top. This assures proper water distribution through the bed. Expansion fluffs the
resin bed and improves the brine resin contact efficiency. Channeling and high pressure drop
through the resin bed are eliminated through the removal of fines. Backwash must be carried out
for a minimum of 15 minutes or until the backwash water effluent is clear.
The backwash flow rates depend on the water temperature, resin type, and height of the free
board space. The rate should not be excessive to cause resin loss, yet should be sufficient to
produce a minimum of 50% bed expansion. Backwash rates usually vary from 6 to 8 gpm at
ambient temperature; however, manufacturers' recommendations should be carefully followed. A
clear, suspended, matter-free water should be used for backwashing.
Brining-The purpose of the brining operation is to regenerate the spent resin. A strong
salt solution enters the softener through the resin bed. As the brine trickles down through the bed,
it removes the calcium and magnesium ions from the resin and simultaneously replaces them with
an equivalent amount of sodium ions.
The brine flow rate must be slow enough to provide sufficient brine-resin contact time, yet
fast enough to prevent channeling of the brine. To ensure optimum contact time and regeneration
efficiency, one vendor recommended that a 10% brine be added at a rate of 1 gpm per cubic foot of
resin in the softener.
 low R i n s e T h e purpose of the slow rinsing operation is to displace the remaining brine
through the resin bed and to wash out the excess salt. The rinse water enters the softener through
the regenerant distributor and flows through the bed. The rinse water must flow through the bed at
the same rate as the brine in the previous step. This ensures proper regeneration of the entire bed.
Fast Rinse-The final step in the regeneration cycle is fast rinse. Fast rinse is carried out
to remove any residual brine from the resin bed and to eliminate the residual calcium and
magnesium ions. A flow rate of 1.5 to 2 gpm per cubic foot of resin bed is usually employed
during the fast rinse.
At first, the fast rinse water will contain large amounts of calcium and magnesium chloride
together with excess salt. Once the hardness ions are eluted and the excess salt is washed out by
the rinse water, the bed is ready for operation. The unit is usually returned to service when the
rinse water hardness falls below a desired value.

Limitations of Strong Acid ~ e s i nlso

Conventional strong acid resins do not hold the hardness ions very tightly, and a raw water
containing sufficient sodium chloride will regenerate the resin while the resin is trying to remove
calcium and magnesium. The result is hardness leakage even with a freshly regenerated resin bed.
Thus, increased salinities affect strong acid softener performance by reducing the resin ion
exchange capacity. Further, the hardness leaks through a strong acid resin bed are a function of
TDS content of the feed and increase with the increase in raw water TDS. The hardness leakage
from a conventional strong acid resin softener is shown in figure 5.6, as a function of raw water
TDS for three different types of water. In figure 5.7, the capacity of strong acid resin is shown as
a function of raw water TDS. From these it is clear that conventional strong acid resins cannot
effectively soften water to zero hardness and that hardness leakage will occur even at low TDS.
Because of these limitations, regardless of added costs, other types of resins known to have
sufficient affinity to remove hardness from high TDS water are increasingly being used in TEOR
operations. These include weak acid resins and. to a lesser extent, chelating resins. Selectivity of
chelating resins for hardness ions is several orders of magnitude higher than strong acid resins.
However, unless the raw water is of such poor quality (highly brackish) that it is not possible to
soften these waters economically using other resins, the use of chelating resins to soften water is
not recommended. This is because these resins are very expensive, and their operating capacities
are extremely low. These resins are not discussed in this report.
The selectivity of weak acid resins for divalent ions, though not as high as chelating resins,'is
much higher than the sodium zeolite resins. They are ideal for softening high TDS, high-hardness
water such as the oilfield produced water. Weak acid resins. however. are relatively more
 0 1000 2000 3000 4000 5000

BRINE HARDNESS in ppm as CaC03

FIGURE 5.6. - Effect of water hardness and salt dosage on hardness leakage from primary
beds.11

BRINE HARDNESS
8 ppm as CaCO

4000
Ibs NaCVft OF RESIN

I
0.1 0.2 0.3 0.4 0.5 0.6
lbs NaCl/kg HARDNESS REMOVED

FIGURE 5.7. - Resin exchange capacity as a function of water hardness and salt dosage."
expensive than the conventional strong acid resins and can be regenerated only with a strong acid
such as hydrochloric or sulfuric acids. However, weak acid resins can be operated near 100%
efficiency, and this will lower the regenerant requirements which generally results in a savings of
regenerant and waste-handling costs. Since the goal is to obtain the most complete softening at
minimum cost, raw water and softened water quality requirements usually dictate the resin choice.

Weak Acid ~ e s i n s *
Weak acid resins are derivatives of weak carboxylic acids such as acetic acid (vinegar) and
are widely used in water-softening operations either in the sodium form or in the hydrogen form.
The weak acid resins exhibit an immense selectivity preference for divalent (hardness) ions over
monovalent (sodium) ions. The weak acid resins hold the hardness cations so tightly that they
cannot be replaced by sodium. Since the most concentrated sodium chloride solution cannot
dislodge the hardness ion from the resin, weak acid resins are vely effective in removing hardness
ions even in the presence of large quantity of sodium ions. Calcium and magnesium ions
associated with a highly alkaline feedwater can be removed almost completely by weak acid resins.
Though both hydrogen and sodium forms of weak acid cation exchange resins are used in the
water-softening industry, the sodium forms are preferable in oilfield water treatment applications
because of their higher exchange capacity and selective preference for hardness ions. The weak
acid cation exchange resins exhibit much higher affinity for hydrogen ions than for hardness ions;
and hence, the hydrogen form of the resin is not as effective in lowering hardness ions from water
as the sodium form. However, if the water is highly alkaline, it is possible to remove the hardness
ions with the hydrogen form of the resin.
The hardness removal with the sodium form of weak acid cation resin can be expressed as
follows:
2 RCOO Na + CaC12 c-4 (RC00)2Ca+ 2NaCI
The exhausted weak acid resins are usually regenerated with a strong acid such as hydrochloric
acid or sulfuric acid. The resulting hydrogen form of the resin is then neutralized with sodium
hydroxide to convert the resin to its sodium form. The regeneration reaction with hydrochloric
acid and neutralization with sodium hydroxide is as follows:

Neutralization

RCOOH + NaOH + RCOONa + H20

Because of its strong preference for hydrogen ions, weak acid resins can be regenerated even with
a very low acid concentration.
Hydrochloric acid is preferable to sulfuric acid as the regenerant. When sulfuric acid is used
to regenerate the resin bed, calcium sulfate will precipitate. Because of the extreme insolubility of
calcium sulfate, the cleaning will take considerable time. Calcium sulfate precipitation can be
avoided by using a very dilute acid (below 1%)and maintaining a very high flow rdte. Regenerant
efficiency, however, is rapidly lost at low concentration. Further, a high flow rate results in higher
pressure drop and considerable force is exerted on the resin. The resin must have physical strength
to withstand this force. Since most metal chlorides are water soluble, a high concentration of
hydrochloric acid can be used in regenerating the bed. This not only eliminates the problems
associated with sulfuric acid, but also lowers the regenerant storage and handling costs.

Weak Acid Cation Exchange Resin Equipment and Operation

The weak acid cation exchange unit is identical to the standard sodium zeolite unit. The only
difference is that the weak resin system uses materials suitable for acid services. The resin tank,
valves, piping, and fittings are fabricated out of acid resistant materials. The regenerant system is
designed to handle acid, and several arrangements are provided for diluting the acids.
The operation of the weak acid resin bed is very similar to the sodium zeolite unit. The only
major differences are the methods for determining the end of softening cycle and the use of
hydrochloric (sulfuric) acid, rather than brine, as the regenerant.

Limitation of Weak Acid Cation Exchange Resinslo

Weak acid resin softeners are not very effective in removing the hardness from low alkaline
water. The treated water will contain hardness if the raw water hardness exceeds the alkalinity.
For example, when a raw water containing 100 ppm alkalinity and 150 ppm hardness is softened
using weak acid resins, it will contain nearly 50 ppm hardness.
The sodium zeolite softener performance is not affected by the alkalinity of the raw water and
is very effective in lowering the raw water hardness level. It is a common practice in steam
injection operations for the sodium zeolite column to be followed by a weak acid softener to
achieve total hardness removal. Since the hardness-to-alkalinity ratio of a sodium zeolite-treated
water is much less than 1.0, it is possible for complete hardness removal with a weak acid resin
bed.

Ion Exchange Unit Operation Problems '3 -

A properly designed and well-engineered ion exchange system normally operates trouble-
free, but problems can arise during the course of operation of the system. An abnormal loss of
capacity of the resin bed, poor effluent quality, and decreases in chemical utilization efficiency are
all indicative of ion exchange system operations problems. There are many possible causes for
these problems, and corrective actions must be taken to alleviate them. In this section, ion
exchange system-related operational problems and solutions are briefly reviewed.
The ion exchange system-related problems can be broadly grouped into the following classes:
(a) ion exchange resin stability; (b) problems arising from changes in raw water quality;
(c) problems associated with poor operational practices such as those resulting from the use of
offspec regenerant and improper regeneration schedule; (d) mechanical problems; and (e) resin
capacity failure due to fouling. Although hardness leakage is not an operational problem, it is
discussed in this section because many of the operational problems result in hardness leakage.
Resin Stability
Cation exchange resins are highly stable and experience very little capacity loss during the life
of an exchanger. Their useful life varies from 5 to 15 million gallons treated per cubic foot of
resin. The resin degrades either due to physical breakdown by attrition or oxidation. Resin
degradation will result in poor quality, treated water. In such cases, the resins must be replaced.
The life of the resins can be prolonged by minimizing or eliminating the oxidative conditions.
The most frequently encountered oxidant in raw water is chlorine. When lake or river water is
used as the feed, chlorine is usually added to the water to control slime and bacterial growth.
Excess chlorine in raw water will oxidize the cation resin, causing the resin to become jelly-like.
While oxidation does not affect the exchange sites, the mushy resins result in severe channeling
and increased pressure drop. Excessive pressure drop through the bed or flow channeling results
in significant reduction in ion exchange capacity and increased operational costs. Free chlorine in
supply water should be measured and controlled to prolong resin life. Free chlorine concentration
must be reduced to less than 1 pprn by deaeration or chemical means. Resin breakdown can be
minimized by avoiding excessive backwash. It is a good psactice to replace annually about 10% of
the resin bed to ensure trouble-free operation.
Varying Water Quality
It should be realized that the quality of raw water, particularly surface water (such as lake or
river water), varies considerably between summer and winter and before and after rainfalls. These
changes can affect the perfdnnance of an ion exchange unit. It is possible that the hardness of the
water may have increased or a new troublesome ionic species has entered the raw water.
The resin capacity of each ion exchange system is determined by factors such as raw water
hardness, resin volume, volume of water to be treated, and allowable hardness leakage. Hence,
any change in the raw water hardness will disturb the hardness equilibrium between water and
resin and affect the resin pel-formance. For example, assume that a resin bed is designed to handle
low hardness water of less than 500 ppm as CaC03. If the incoming raw water hardness is
increased to 5,000 ppm, this would result in 10% loss in resin capacity. Otherwise, the hardness
leakage through the bed would be increased by lo%, and an expensive aftertreatment would be
required to avoid generator tube scaling. Alternatively, by reducing the throughput in the bed or by
increasing the salt dosage, the lost capacity can be restored. Hence, a periodic chemical analysis of
the incoming water to the resin bed should be made for these difficulties to be anticipated.
Poor Operational Practices
Many times a loss of exchanger capacity can be traced to the use of poor quality regenerant
chemical or incorrect chemical application. For example, use of mined. salt containing less than
98% sodium chloride as regenerant will lower the exchanger capacity. The use of a caustic soda
containing high levels of iron in the neutralization step of the weak acid resin regeneration will
result in chemically degraded resin. Specifications for regenerant chemical quality are given by the
equipment manufacturer or the resin supplier. Only chemicals that meet these specifications should
be used as regenerant.
Raw water flow rates and regenerant flow rates both influence the quality and quantity of
water treated by ion exchange. Sometimes operators reduce the amount of salt used during the
regeneration step to save a few dollars. This is poor economics and will result in high hardness
leakage and generator tube scaling. There is an optimum concentration for each application, and
manufacturers' recommendations should be followed.
Mechanical Problems
Mechanical failure or malfunctioning of ion exchange equipment may result in poor
performance. Some of the more common mechanical problems are discussed in the following text.
Leaky valves are common sources of trouble in ion exchange system operation. Normally,
raw water is used to backwash the system. Backwash water is introduced into the bed from the
bottom at the same point where the effluent is normally withdrawn. An improperly seated
muhiport vdve or a leaky backwash inlet valve could result in a bleeding of raw water into the
effluent.
A broken or clogged distributor system is another trouble spot. Clogged distributors result in
channeling and uneven distribution of water or regenerant. Poor water distribution results in
premature breakthrough and off-quality effluent.
Underdrain system strainers and nozzles must be periodically inspected to ensure that they
are not clogged or plugged. A clogged underdrain will restrict the backwash flow rate. A low
backwash rate results in inadequate bed expansion and a dirty exchanger bed. The accumulated
dirt will cause the bed to compact. Compaction results in severe channeling and increased pressure
drop. High pressure drop across the unit will result in resin breakage. This problem compounds
itself because the broken particles will further reduce bed permeability, causing additional
compaction and more resin breakage and loss of capacity. A broken underdrain nozzle will result
in excessive backwash flow and loss of resin.
The exchanger unit must be periodically inspected for mechanical deficiencies and corrective
measures taken if needed. Since steamflood operation water treatment plant shutdown can be very
costly, periodic checkouts are an insurance against trouble.
Fouled Resins
Ion exchange materials, at times, lose their effectiveness because of the accumulation of
materials on their surfaces and in their pores. This accumulation of material, or fouling, is a result
of an adsorption of contaminants present in the raw water, which is not completely removed during
the normal backwash and regeneration steps. The substances that frequently foul ion exchange
resins in oilfield operations include iron, oil, bacterial growth, and oxidants. The effects of these
fouling agents on exchanger performance have been discussed in detail in a previous section.
Fouling problems are best handled by good preventive measures.
Oxidant fouling agents such as free oxygen and chlorine can be eliminated at the source by
adding a chemical scavenger such as sodium sulfite as far upstream as possible. Bacterial slime
and algae can be controlled by closing the system to air and sunlight and adding a bactericide to the
raw water. By eliminating oxygen pickup at the source, the iron pickup can be minimized.
Injection of sodium sulfite will keep the iron in reduced form and eliminate iron fouling. Water
containing excessive amounts of suspended matters must be filtered before softening. This is
because the softening system has a limited ability to filter suspended matters and may be difficult to
backwash. Fouled softener must be taken out of service periodically and backwashed several
hours at the maximum permissible rate to dislodge and remove the adherent fouling agents. Iron
fouled resins can be cleaned by washing the fouled resins with dilute hydrochloric acid or sodium
hydrosulfite. Proper prewater treatment is the best insurance against fouling agent troubles.

Hardness ~eakage5.7
In the operation of a water softener, one of the first things that must be dealt with is the
leakage of hardness ions through the ion exchange bed. As previously defined, the term hardness
leakage implies a slipping of some of the hardness ions present in the feedwater into the softened
water. Because of the nature of the sodium zeolite process, a certain amount of hardness leakage is
inevitable; however, the leakage must be kept to a minimum. A small amount of hardness ion in
boiler feedwater is acceptable because in the temperature range at which a steam generator operates,
these ions remain in solution in the liquid phase of the wet steam. However, the degree of
solubility of hardness ion varies according to the specific feedwater, and no generalization can be
made. In some water, only 0.2 ppm hardness leakage can be tolerated, while in others a 3 ppm
hardness can be tolerated. Reasons for these variations are unclear. Each feedwater must be
checked to determine what hardness is tolerable at a given steam quality. A safe bet is to use zero
hardness water, but complete elimination of hardness may not be economical in some installations.
Several factors are responsible for hardness leakage through a resin bed. Because of the
need for the use of uneconomical excess regenerating chemical (salt) to completely regenerate the
resin bed, the bed is never completely regenerated. Therefore, there is always some hardness ions
present in the bed. These ions probably will leak during the subsequent softening cycle. Further,
if the feedwater contains considerable sodium ion, the sodium will displace some of the calcium
(hardness) ion previously removed from the feedwater. Consequently, the displaced calcium will
be picked up by the softened water and hardness leakage occurs.
Sloppy operation and equipment malfunctioning also contribute to hardness leakage. Less-
than-satisfactory rinsing after regeneration will leave substantial amounts of hardness ions in the
bed. These will show up in the effluent for a short time after regeneration. Additional rinsing is
one way to solve this problem. A malfunctioning brine pump or meter can cause insufficient brine
to flow through the bed during the brining operation and result in incomplete regeneration and
hardness leak. A fouled resin bed will reduce the resin capacity and contribute to leakage. Poor
backwash leads to bed compaction and channeling and results in hardness leakage.
Leakage is inevitable in the ion exchange system. Leakag~,however, can be minimized by
following prudent operating practices and improved design. By automating the zeolite water
softener operation, operator errors can be eliminated, and the danger of hard water getting into the
soft water lines can be avoided. Automation also permits each cycle to perform exactly the same
way each time and eliminate insufficient backwashing or rinsing by maintaining proper flow rate
and quantity. The system can also be made to shut down in the event of an equipment
malfunction. In most large steam injection projects, the water softening plant is fully automated
and requires very little attention.
Leakage can also be minimized substantially and effluent quality improved by utilizing multi-
stage units and by using strong acid-weak acid exchangers in tandem. Further, the resin bed
should never be exhausted completely. The bed capacity begins to drop off and hardness leakage
begins to increase as a greater fraction of the theoretical capacity of the bed is exhausted.
Consequently, insofar as efficiency of regeneration is concerned, the bed should be operated only
at a fraction of its designed capacity. While this will seduce hardness leakage, it also will increase
the regeneration frequency and hence the operating cost. Therefore, a compromise must be
reached between operating costs and the amount of hardness leakage that can be tolerated. It is
recommended that the bed be exhausted to about 60% of its total capacity. This not only improves
the performance and lowers regeneration chemical requirement but also prolongs the resin life.
Also, by operating the exchanger below its rated capacity, the system will be able to accommodate
a wide variation in the raw water quality. Pretreatment of saw water to remove suspended matter
and to reduce soluble foulants will also improve resin capacity and reduce leakage.
Water Treatment fur Steant Injection Projects
Source water determines the complexity of steam injection project water-treatment systems.
Depending on the raw water source, systems range from a simple sodium zeolite ion exchange unit
to a facility that includes clarifiers, coapulators, filters, skimmers. oil separators, coalescers,
depurators, softeners, and deaerators. As a general rule, poorer water quality requires more
elaborate treatments and higher treating costs.
The water sources and the water quality requirements for steam injection operations are
discussed in previous sections. The general principles, operational techniques, and problems of
ion exchange softeners, are outlined. The principal objectives of this section are (1) to explain the
operational differences between the conventional cation exchange system and the one used in steam
injection operations and (2) to summarize features of some other common water treating equipment
and to offer some guidelines to their operation. Other topics discussed include: description of
processes for the reclamation of produced water for steam generations, water treatment monitoring
equipment, and water treatment costs.

Steam Injection Water Softening System l

The oilfield cation exchange water softening system differs from the previously described
conventional cation exchange system in two ways. Because of the stringent water quality
requirements in steam injection operations, oilfield water-softening systems utilize a primary-
secondary softener setup and a special upflow-downflow countercurrent regeneration technique to
produce water with less than 0.25 ppm hardness for stem generation. The steamflood water
softening system consists of a primary exchanger which removes the bulk of the hardness from the
water, followed by a polisher (secondary) unit which scavenges the last traces of hardness.
Depending on the water requirements, two or more such trains (primary and polisher) are used to
control water hardness. Oilfield water-softener systems are offered as fully self-contained, skid-
mounted units complete with two trains of softener vessels (2 primary and 2 polishers), brine
meter, regeneration meter, valves and piping, control panel, and pumps.
The two trains are installed in parallel so that a conthuous supply of softened water for steam
generation is assured. Raw water passes through one of the prima~yexchangers and one of the
polishing units in series to some point short of exhaustion of the resin in the primary bed. Then
the used pair is regenerated automatically as the feed water is diverted through the other pair. This
operation is automated either by hardness-sensing devices or through an automatic time cycle. A
schematic of the softeners and piping arrangement is shown in figure 5.8. The primary softeners
 RAW WATER

= = = ( t i
POUSHlNG

t
FIGURE 5.8. -Schematic of steam injection water softener piping arrangement.

produce into a common manifold. The polishing softeners receive the water from this manifold.
Each primary and polisher train is regenerated independent of other trains. Flow schematics of the
softening regeneration cycle is shown in figure 5.9. Note that soft water is used for backwashing
and brining of polisher to minimize hardness leakage. Note also that countercurrent regeneration is
used in the polisher to ensure complete regeneration at the bottom of the bed. Since portability is
an important design factor, the softener train is usually oversized to cope with unexpected raw
water quality changes. The softened water is usually stored in a galvanized or plastic-coated tank
under a blanket of nitrogen to keep oxygen out. Water is usually gravity fed from this tank to a
generator feed pump.
Selection of Ion Exchange ~ e s i n s l o
Several factors influence the selection of ion exchange resins to be used in softening waters
for thermal operations. These include the hardness and total dissolved solid contents of the raw
water, the exchange capacity of the material, and the cost of regeneration. Both strong acid and
weak acid cation exchange resins are used in a thermal operation water softening system.
 f7
DILUTIONWATER
,
BRINE

SOFTENING

RAW WATER RAW WATER

BRINE DISPLACEMENT PRIMARY RINSE POLISHER RINSE

AND SLOW RINSE

FIGURE 5.9. - Flow schematics of steamflood ion exchange softener regeneration

cycle. l2

Experimental studies indicate that the strong acid cation exchangers are not satisfactory to soften
waters containing greater than 5,000 ppm TDS. Weak acid cation exchange resins have much
higher capacity and can be used to soften water containing up to 20,000 ppm TDS. Water
containing up to 10,000 ppm TDS can be softened using a strong acid cation resin in the primary
unit, followed by a weak acid cation resin in the polisher. Because of the effectiveness of the weak
acid polisher, a higher than normal hardness leakage from the primary unit can be tolerated without
sacrificing the quality of the final product from the polisher. The amount of salt, hydrochloric acid
and sodium hydroxide (regenerant chemicals) required will depend on the extent of hardness
breakthrough from the primary. Table 5.7 shows a general rule-of-thumb for selecting ion
exchange resins for thermal EOR operations. This table can be used as a guideline in selecting a
system.
 Ion Exchccnge Calculations
The basic calculations which will be needed for sizing an ion exchange system for a steam
injection operation are given in Table 5.8.

Use of Chelating ~ ~ e n t s ~ , ~
The present day ion exchange systems used in steam injection operations can reduce the total
hardness below 0.1 ppm. However, even with this low hardness there is danger of scale
formation in a steam generator, especially if silica is present (the problem of silica scaling is
discussed in a later section). Some operators, who prefer zero hardness, use a chelating agent to
pick up any remaining calcium or magnesium ions to assure a scale free operation, while others use
nothing beyond the ion exchange.
Chelation is an equilibrium reaction between a metal ion and a complex organic chemical to
form a soluble complex of metal ions in the presence of anions that would normally cause the
cation to precipitate. The chelation reaction is generally referred to as sequestration and the
chelating chemical, a sequestering agent Many chemicals are known to form soluble complexes
with calcium and magnesium ions. In steam injection operations, the most common chelating agent
used to prevent the hardness ions from forming scales is the sodium salt of ethylenediamine-tetra

TABLE 5.7. - Rules-of-Thumb for Selection of Ion Exchange Resins for Oilfield Steam
Generator Feed water Softener

TDS Hardness Resin

~2,000 ~700 Strong acid resin (no polisher)

700-5,000 <700 Strong acid resin with polisher unit
5,000-10,000 400 Weak acid resin (no polisher)
5,000- 10,000 500- 1,500 Primary strong acid resin bed with weak acid
polisher unit
50-15,000 1,500-3,000 Weak acid resin (with polisher)
 TABLE 5.8. - Ion Exchange Softening System Calculations

1. Sodium to hardness ratio (NalH)

NaIH = 2.17 N& mq/L
Hardness, mg/L as CaC03

2. Exchange capacity (EC), kgr/ft3

where FWV = feedwater volume, gallons

TH = total hardness in feedwater,mg/L as CaC03
LH = leakage hardness in softened water, mg/L as CaC03
RV = resin volume, ft
and 5.8 1x 10'3 is a conversion factor

3. Regeneration cost (RC) $/bbl for both 100% strong acid resin systems and
100% weak acid resin systems.
CR (TH-LH)
RC = RC = 0.00244
EC

when CR = cost of regenennts, e/ft3

TH = totid hardness in feedwater, mg/L as CaC03
LH = leakage hardness in softened water, mg/L as CaC03
EC = exchange capacity, kgr/ft3
arrd 0.00244 is a conversion factor

4. Regeneration Cost (RCC), ebb1 for combined strong acid resirdwe,ak acid resin
.systems.

RCC, $/bbl = Cost for Strong Acid Resin + Cost for We,& Acid Resin

= 0.00244 CRS (TH-LH) + 0.00244 CRW (LH)

ECS ECW

where CRS = cost of strong acid resin regenerant, $/ft3

TH = total hardness of feedwater mg/L as CaC03
LH = hardness leakage from strong acid resin, mg/L as CaC03
ECS = suong acid resin excllrulge capacity kgr/ft3
CRW = cost of weak acid resin regenerate, $/ft3
ECW = weak acid resin exchange capacity, kgr/ft3
and 0.00244 is a conversion factor.

where EC = exch'mge capacity, kgrIft3

TH = total hardness of feedwater, mg/L as CaC03
LH = leakage hardness in softened water, m g L as CaC03
and 409 is a conversion factor.
acetic acid (EDTA). EDTA does not eliminate hardness, but only prevents it from forming scales.
EDTA is preferred to other chelating agents because of its thermal stability.
The amount of EDTA necessary to complex 1 pprn of calcium ion depends on which sodium
salt of EDTA is used. The amounts of various EDTA salts necessary to complex 1 pprn of
hardness ion and the solubility of the EDTA salts in water are shown in Table 5.9. Even though
the amount of tetra sodium EDTA necessary to complex 1 pprn of the cation is higher than the other
varieties, it is used almost exclusively in the steam injection applications because of its higher
solubility.
A 38% solution of these salts is most commonly used in the steam injection application. To
ensure complete chelation of the hardness ions, an excess (10 to 15 pprn) of the chelating agents is
canied in the process water. The EDTA is diluted and stored in a 55-gallon polyethylene drum. A
reciprocating metering pump is used to inject the EDTA directly into the waterline immediately
upstream of the steam generator feedwater pump.
One important consideration in EDTA use is its effect on corrosion. EDTA, at generator pH
and reducing conditions, will chelate iron and corrode boiler tubes. Hence, addition of EDTA
should be closely controlled to prevent excess. It should be added to the feedwater line so that it is
well diluted before reaching the generator.
California steam injection field experience indicates that complete hardness removal is not
necessary, and a small amount of hardness in the feedwater is acceptable. Unfortunately, the
maximum acceptable level of hardness in the feedwater without scaling the generator varies with
the feedwater and must be established for each feedwater. Chelating agent such as the EDTA
should be used only if the acceptable level of hardness cannot be achieved economically with the
ion exchange process.
TABLE 5.9. - Concentration of EDTA and its Sodium Salts Necessary to Complex
1 pprn of Hardness Ion42

Chelatiag agent Solubility ppm necessary to complex

in water 1 pprn hardness ion
@ 80' F
gm/100 cm3 1-120

Ethylenediamine tetra acetic acid

Disodium ethylenediaminetetra acetate
dihydrate
Trisodium ethylenediaminetetra acetate
monohydrate
Tetra sodium ethylenediaminetetra acetate
dihydrate
 Hardness Monitors l 7
Monitoring hardness is essential for successful treatment. Tests for hardness should be run
at least once each shift. Ideally, hardness should be monitored continuously, in addition to
periodic manual tests.
A number of different approaches are used to monitor and control hardness. The most basic
and inexpensive is the analytical approach. The simplest hardness monitoring tool samples the
softened water at frequent intervals (10 minutes or so) and indicates whether the measured
hardness is above or below the setpoint. In most models, 1, 3, 5 and 7 pprn are used as the
setpoints.
Since this instrument is basically a titration apparatus, practically no maintenance is needed.
However, technician must periodically check the instrument to assure its proper operation. The
capacity of the reagent reservoir is sufficient to perform about 1,500 analyses and can be refilled in
a matter of minutes.
A more useful hardness monitoring instrument is the one that not only monitors hardness,
but also takes appropriate action to control it. A number of manufacturers market hardness
monitors that are designed to regulate hardness. These instruments are basically automatic titrators
fitted with an actuating mechanism designed to take appropriate action in the event the hardness
exceeds the preset value. Depending on the model, the actuator will sound an alann and/or actuate
automatic regeneration equipment for zeolite softener. Some models will also shut down the steam
generator. Units are usually calibrated for setpoints from 0.25 to 3.0 ppm hardness.
A more sophisticated hardness regulator uses colorimetric principles to control hardness.
These are simple single reagent colorimetric analyzers designed to measure the intensity of the
color developed by the addition of reagent to the sample. The intensity is proportional to the
hardness and is indicated on a direct reading meter as ppm hardness. A schematic of one such
colorimetric analyzer is shown in figure 5.10. These instruments usually analyze and record
hardness every 2 minutes. Most models are also equipped with a signal generator (pneumatic or
electrical) to start automatic zeolite regeneration or to shut down the generator.

Overview of Other Water Treatment ~ q u i p r n e d 8 - 1 9

Besides ion exchange vessels, a wide variety of water-treating equipment is used in steam
injection projects. The types of equipment depend very much upon the type of operation. Not all
steam injection operators separate produced oil and water. A small operator may merely choose to
produce the oil on his lease by steam injection and transfer the produced fluids for further
processing to a facility equipped to handle the produced fluids. In such cases, no equipment other
than an ion exchange system will be needed if the operator chooses to produce his own steam
 DRAIN

FIGURE 5.10. - Schematic of an automatic hardness monitor.17

using fresh water. On the other hand, in most larger steam injection operations, the produced
water is usually reclaimed and used as the generator feed. Even when the produced water is not
used as the generator feed, it must be processed and rendered suitable for disposal. In either case,
an assortment of equipment will be needed to remove the impurities from the water.
The usage and operation of various water-treating equipment is summarized according to the
process. Factors which must be considered in the equipment choice and/or design are enumerated.
Processes covered include gravity separation, flotation, filtration, and dissolved gas removal.
Oil and Solid Removals
Produced water usually contains oil and suspended solids. These must be removed before
the watcr can be properly disposed of. Oil removal is basic to all disposal processes involving
oilfield water, although the necessary completeness of oil removal may vary widely depending on
the end use. In California's San Joaquin Valley, much of the produced water is fresh enough that
it is used as generator feedwater after proper treatment. Also, in Kern River oilfield, part of the
produced water after treatment is used for inigation of farm crops.
 Like the conventional waterflood operation, the produced fluids from the wellhead in the
steam injection operations is sent to the oil dehydration plant for separation into oil and water. The
separated water is sent to the water treatment plant for further processing. This discussion begins
at this point, as this section is concerned with the treatment of produced water, not oil dehydration.
Oi
l dehydration operations are discussed elsewhere in this report.
The degree to which the oil and solids must be removed from produced water depends on the
end use water quality requirements. If the water is to be used as steam generator feed, total
removal of oil and solid is a must. If the waters are to be disposed of or used as imgation water,
complete oil and solid removal is not necessay. Depending on the local regulations, the oil content
of treated water is permitted to vacy from a low of 10 ppm to as high as 40 ppm.
There are three practical methods of removing oil and solids from water. Each has its distinct
place in water treatment. The three methods are gravity separation, flotation, and filtration.
Gravity Separation
When a mixture of oil and water is allowed to stand, it will separate into two distinct phases
because of the differences in density between oil and water. This process is highly effective with
low-density (high API gravity) oils but becomes less effective with low API gravity oils. This is
because the density difference between water and oil determines the driving force causing
separation of oil and water into two phases.
Oil and water are separated in settling basins. Settling basins were used in large California
steam injection projects in the early 1970s to clarify produced water from dehydration plants. The
introduction of highly effective induced gas flotation cells (depurators) in 1970 for the removal of
suspended oil from produced water practically eliminated the need for settling basins in steamflood
operations. Unlike the settling basins, flotation cells require only a minimum of space for large-
capacity throughput and can handle emulsions. Settling basins are rarely used in present day steam
injection operations. However, it is advisable to use a small skid-mounted API type oil-water
separator or skim tanks upstream of the depurator to handle any unexpected oil load in feedwater
because of dehydration plant upsets.
The subject of gravity separation of oil and water has been covered in detail in an API
publication.*0 This publication sets forth clearly the design and operational requirements of
settling basins and should be consulted for details.
Flotation
Flotation is a process in which a gas is used in a mechanical system to give a lift to
suspended oil or solids. Two types of flotation machines are used in the oilfield: (a) dissolved gas
(or air) flotation (DGF) machine and (b) induced gas (or air) flotation (IGF) machine.
 Dissolved Gas ~1otation:~l The dissolved gas tlotation (DGF) process has been used in the
oilfield for a number of years in the removal of oil and suspended solids from produced water.
The process involves contacting the water in a pressurized chamber with air or nitrogen. The
volume of gas dissolved in the water is directly proportional to the applied pressure. Chemicals are
usually added to the water to facilitate higher degrees of removal. Adequate retention time must be
provided in the dissolving tank for the gas to dissolve in water. The operating pressure usually
varies from 40 to 90 psi, depending on the application. Schematics of a typical DGF unit are
shown in figure 5. I 1.
After water has been saturated with gas, the gas-water mixture is transferred to the flotation
chamber through a pneumatic pressure relieving valve. When the pressure is relieved, gas comes
out of solution, forming minute bubbles. These bubbles then attach themselves to the suspended
oil or solid particles. Adhesion of gas bubbles to the suspended particles results in the reduction of
their specific gravity. This reduction of the effective specific gravity causes the particles to rise to
the surface of the flotation cell. The accumulated surface mass is removed by rotating scraper arms
into a launder for removal. The clarified water is discharged into an effluent tank. The efficiency
of a DGF machine is of the order of 75 to 80%.
Though DGF machines are very efficient in removing suspended oil from water, their
efficiency suffers when the oil load exceeds 100 ppm and emulsion exists. As the incoming oil
load increases, increasing amounts of oil are left in the water. The disposal of sludges created by
the DGF machine is a problem in itself. Since the maximum flow capacity of these types of
machine is usually limited to about 2.0 gpm/ft2of surface area, they require large real estate.

VARIABLE

'
~ C D 1 RETENTION

AIR OR
GAS
INJECTiON

BOTTOM DRAIN
HOPPER
FIGURE 5.1 1. - Schematic of a typical dissolved gas flotation unit.a
 Once popular in the oil patch, DGF machines are increasingly being replaced by induced gas
flotation (IGF) machines, which are much more efficient than DGF machines and can handle much
higher contaminant levels. The IGF machines do not create sludge and require much smaller space
compared to DGF machines because of larger throughput.

Induced Gas ~lotation22-~3

The shortcomings of the dissolved gas flotation cell, necessitated the need for a process that
clarifies an emulsion-containing oilfield water efficiently and economically. This led to the
development of the induced gas flotation process. An IGF cell is basically a froth flotation cell
(used in the benefication of ore in the mining industry) modified for oilfield application. The
induced gas flotation machine is a natural aspirating shear force flotation cell designed to lower the
oil content of water efficiently. Since its introduction in late 1969 in a California steam injection
operation, the IGF machine became the primary treatment unit for the clarification of produced
water in steam injection operations. The induced gas flotation cells are commonly referred to as
'depurator' in the oil patch. The depurators are very effective in the removal of emulsified oil and
suspended solids from produced water. They also lower the oxygen content of the water, if gas
other than air is used in their operation. The depurator, together with a chemical flotation reagent,
can remove oil and suspended solids from the water quickly and economically. Present day
depurators can process in excess of 170,000 barrels of water per day containing up to 1,500 ppm
oil.
Operation ~rinciple24
The depurator typically consists of four flotation cells connected in series, with each cell
having 1 minute retention time; 4 minute retention time for the entire machine. A schematic of a
machine developed by WEMCO Corporation (the most popular IGF machine in the United States)
is shown in figure 5.12. Table 5.10 shows the specifications and dimensions of these machines.
These are included here to illustrate the range in capacities and overall dimensions of these units,
but their inclusion does not necessarily imply endorsement.
Each cell is equipped with a motor-driven, self-aerating rotor mechanism. As the motor-
driven rotor spins rapidly, it acts as a pump and draws in gas from the gas blanket above the water,
and the water from below and forces them through a dispenser at high velocity. This creates a
shearing force and causes the gas to be broken up into a myriad of minute bubbles. As these
bubbles rise to the surface, oil particles and solids attach to the interface of the gas bubbles. The
oil and suspended solids gather in a dense froth at the surface and are removed from the cell by
skimmer paddles into a float flume for collection and treatment.
FIGURE 5.12. - Schematic of an induced gas flotation cell.24

TABLE 5.10. - Induced Gas flotation Cell Selection

Rotor, Total Approx. Approx.

rpm horsepower dimension Wt, lb
 A polymer or other flocculation enhancer is often added upstream of the depurator to improve
its efficiency. These compounds also break oil-in-water emulsions, gather suspended solids, and
stabilize the gas bubbles to promote froth flotation. In thermal operations, nitrogen or natural gas
instead of air are used to form the bubbles. A pressure of 0.5 to 1.0 ounce maintains a gas blanket
between water level and the air-tight cover. The absence of oxygen prevents the bactcnal growth
and retards corrosion. The gas is recycled, requiring only about.0.l to 0.2 cu ft/bbl makeup gas.
The depurators are highly efficient in cleaning the oily water. The efficiency of an IGF
machine is of the order of 95% and stays at that level even at high contamination levels. The oil
concentration of the inlet water is usually lowered from about 400 ppm to less than 20 ppm.
Table 5.1 1 gives the oil reduction achieved in selected California steam injection operations using
the depurator. These machines, however, do lose efficiency as the oil concentration in the coater
exceeds 1,500 ppm and may fail completely if considerable amounts of oil (greater than 5,000
ppm) come through. This is because the free oil inhibits the formation of foam which, of course,
destroys the flotation action. If the produced water contains dissolved iron, it can be removed in
the flotation process by using air in the first cell and nitrogen in subsequent cells. Methane is
usually used to purge the air and maintain a positive gas pressure in the freeboard area of
subsequent cells. The air will oxidize the dissolved iron and remove it as ferric hydroxide.
Since the IGF machines are very efficient in removing the oil from the produced water, they
should be considered by operators contemplating the use of produced water for steam generation,
or for surface discharge. Depurators offer maximum cleaning ability with minimum space
requirement. However, before a depurator can be recommended for a specific application,

TABLE 5.1 1. - Feedwater Oil Reduction Achievable Using a ~ e ~ u r a t o r ~ ~

Oil con tent of Amount

Inlet water Exit water of
Depurator Feedwater PPm PPm chemical
capacity, flow rate. added,
Field location bbl/d b blld PPm

Ventura, CA 300 9,000 75-100 10-15 12

Wilmington, CA 750 25,000 81-175 6-10 5
Kern River, CA 450 13,000 60-350 2-15 0
Midway Sunset, CA 77,175 70,000 100-400 5-10 15
carefully monitored laboratory tests should be carried out to arrive at the proper size of machine
and preferred flotation chemical. There are laboratory-size flotation cells available for bench
testing, and often vendors of the depurators can conduct such tests and make recommendations.
Filtration
Filters are commonly employed in those steam injection operations that utilize surface or
produced water for steam generation. Surface waters generally c m y considerable amounts of
suspended solids and must be removed before the water is softened. In such cases, primary
fdtration is necessary. Produced waters usually contain oil and no filterable solids. Oil and solids
from such water can be removed more economically using flotation cells. In such cases, filtration
should be viewed as a cleanup or polishing operation.
Choice of Filters
The choice of a filter should be based on a number of factors, which must be evaluated in
each case. These include: (1) quality of effluent desired, (2) amount of suspended solids,
(3) nature of the suspended solids, (4) capital cost vs. operational cost, (5) space available,
(6) flexibility of operation, (7) variability in quality of incoming water, and (8) degree of reliability
of operation required.
A wide choice of filters is available for the removal of suspended solids and other impurities
from the water. These include: (1) slow sand filters. (2) gravity filters, (3) pressure filters, and
(4) diatomaceous earth (DE) filters. Each has various characteristics limiting them to specific
applications; therefore, the selection should be based on specific project requirements. In steam
injection, both conventional pressure filters and precoat (diatomaceous earth) filters are used.
Pressure filters are installed in operations handling waters containing large amounts of suspended
solids. Precoat fdters are very effective in removing suspended solids and oils. They are widely
used in operations that recycle produced water for s t e m generation. They are usually installed
downstream of depurators to remove the last traces of oil and solids from produced water prior to
softening.

Pressure ~ i l t e r s * S
These filters use sand, antharcite or garnet, or a combination of the above as the filter media.
Pressure filters are normally operated by forcing water down through a column of filter media such
as sand. As the dirt builds up in the filter sand, the flow rate through the filter will decrease (or the
pressure drop will increase). At some point, the flow is reversed and the accumulated solids are
flushed to waste. As the filter is backwashed, the finest sand tends to accumulate at the top of the
filter.
 During filtration, only the top inch or so of the sand acts as a filter. The remaining medium
acts only as a support. Most modem filters operate at higher flow rates and pressures to drive the
dirt down into the bed and make more use of the bed depth for filtration.
To improve the filtration efficiency, multimedia filters are increasingly being used in some
steam injection operations. In these filters a combination of sand, anthracite, and garnet is used.
The filter media is graded, so that the lightest and coarsest particles are at the top, and the finest and
heaviest medium is at the bottom. With this type of arrangement, the coarsest particles are retained
at the top of the filter, and the finer particles are driven deeper into the filter bed to be collected on
the finer and more dense filter media. Thus, the whole filter bed takes part in the filtration
operation and results in higher throughput and longer filtration cycles.
Both upflow and downflow arrangements are used in the operation of the multimedia filters.
In the upflow arrangement, the flow is from bottom to top. The rated capacity of the upflow filter
is 6 to 8 U S G P M / ~and ~ ~the backwash rates vary from 15 to 20 U S G P M / ~for ~ ~a period of about
10 minutes. Figure 5.13 shows an upflow filter arrangement. Upflow filters can remove particle
sizes up to 10 microns without the use of a coagulant aid. Particle up to 2 microns in size can be
removed with the help of a coagulant aid such as alum. Though upflow filters can be used to filter
particles up to 2 microns, they are inherently unstable. A change in flow rate, pressure fluctuation,
or vibration can result in channeling and poor filtration.
In the downflow filters, the raw water enters at the top and flows downward. The capacity
of downflow filters are much higher than in upflow filters and are much more stable operational
wise. Downflow filters are usually rated at 15 to 20 U S G P M / and ~~~ are backwashed at a rate of
15 usGph!L/ft2for 10 minutes. Particles size up to 1 micron can be effectively filtered out with the
help of a filter aid. Because of its inherent stability and higher throughput, downflow
arrangements are more popular in the oil patch.

Diatomaceous Earth (DE) ~ i t t e r s ~ 6

Diatomaceous earth (DE) filters, also known as a precoat filter, are extensively used in major
steam injection operations to remove very fine particles and oil from the recycled water. These
filters are much more efficient than the pressure filters and are capable of removing particles down
to 0.2 microns, along with all of the oil droplets.
Diatomite earth is nearly pure silica formed from fossilized, one-cell marine plants. In
filtration, the diatomite forms a layer which contains about 90% void. The DE filters used in the
oilfield are generally leaf-type pressure filters. The leaves consist of wire-wrapped screens housed
inside a 4.5-ft-diameter by 10-ft-long horizontal pressure vessel. The vessel is equipped with
retractable pressure casing for easy leaf access.27
 RELIEF VAlVE

SIGHT GLASS

. . .. .- ..
.. .. .
:.-..: ..::-...
GRID - .* . -
.._:.
;I:..;

FINE SAND

COARSE GRAVEL
/ & FLUSHWATER
DISTRIBUTION PLATE
INLET NOZZLES
INLETS - MAIN

INLET MANIFOLD
CHEM.& D/P CONN.

FIGURE 5.13. - Schematic of a typical up-flow sand filter.40

The DE earth filtration operation consists of three steps: (1) precoat, (2) body feed, and
(3) sluicing.
The precoat is the first step in the filtration and involves coating the screens with a thin cake
of fiber and diatomite. The fiber, which serves as a filter aid, is a finely ground cellufose and is
circulated fist to establish initial permeability and to aid in the quick release of the filter cake once
the filtration cycle is completed. The fiber also serves to absorb the insoluble oil. The amount of
fiber used depends upon the volume of water filtered. One stem injection operator employs about
800 lb of fiber per 500,000 bbl of water fi~tered.~T The fiber is supplied in bagged quantities and
mixed in the precoat slurry tank. The slurry then flows through the screen and the circulation
stopped when the water passing through the screen is clear. A slurry of diatomite is next circulated
through the filter, and the diatomite is added to the screen as a precoat. About 1 lb of diatomite per
10 ft2 of filter area is used as precoat concentration.
Once the screen is completely coated, the filter is placed in service. During filtration the raw
water is pumped through the filter, to be cleaned by the precoat on the screen. When the filter is in
service, the diatomite is continuously added to the incoming raw water line. This addition of
diatomite is known as a 'body feed.' The amount of diatomite added to the raw water varies with
the nature and quantity of solids and oil to be removed and with the operating characteristics of the
system. Normally, it ranges from 0.01 and 0.05 lblbbl of water to be filtered. The body is
essential to maintain a loose pack in the filter cake and to prevent premature plugging of the filter
cake. Without the body feed, the filtration efficiency will suffer. The higher the body feed rate,
the greater is the filtration rate and higher will be the operating costs. Hence, an optimum body
feed rate that results in highest filtration rate at the lowest cost should be used. In a typical thermal
EOR operation, the filtration rate is maintained at about 2 ga~midft2of filtration area. The body
feed concentration is maintained at about 0.7 part diatomite per part of suspended solid and oil.
Usually, a material handling system consists of storage silos, shakers. and screw feeders are used
to handle the volume of diatomite used in treating the raw water.
When the filter cycle is completed, the sluicing or washing cycle is initiated. The diatomite is
cleaned by the use of high-velocity water jets to remove the cakes. After sluicing, the filter casing
is opened, inspected and manually cleaned if necessary. The amount of backwash water needed to
clean the DE filter is much less than the pressure filters.
Selection of Diatomite
Several grades of diatomite are available for use as a filter aid. The choice of grade depends
entirely on the size and characteristics of the impurities to be removed and the effluent clarity
requirements. The finest diatomite should be used for removing tight emulsions, ultra fine
colloids, etc. The finest diatomite, however, has the lowest flow rate. The coarsest grade of
diatomite yields the highest flow sate and should be used to filter water containing coarse particles.
The final selection of fitter aid (diatomite) should be made on the basis of field trials to avoid costly
misapplications. Filter companies and diatomite suppliers can conduct such tests at small cost to
prospective users and make recommendations.
Diatomite Filter Problems
Diatomite earth filters are very efficient in removing oil from water and have the advantage of
high flow rate and low space requirements. They are capable of reducing the oil content of water
from 20 to 0 ppm. Unfortunately, an improperly operated filter can be the biggest source of
trouble. Diatomaceous earth filters require more closely monitored operator's attention than other
types of filters. This is because an improper or inattentive operation will result in a poorly coated
screen that results in holes, causing impurities and slurry feed to go through the filter and plug the
ion exchange resin beds. Past experience indicates that most operational problems can be traced to
poor operational practices. Some of the causes of DE filter failure in the past include the
following:269%
1. Operator leaves backwash valve open partially or completely after backwashing filter,
resulting in partial or complete bypassing of the filter. This is worse than no filter at all, because in
addition to bypassing the filter, diatomite is continuously fed to the water.
 2. Malfunctioning of the body feed devices will result in inadequate precoating of the
screens and loss of filtration efficiency.
3. Temporary shutdown on a momentary pressure surge may cause part of the precoat to
drop off the screen. Subsequent operation of filter will result in all slurry feed and all suspended
solids to go through the filters and plug the lines.
4. Failure to flush the lines containing slurry (body feed) during backwash will cause lines
to plug and filter to fail.
Diatomaceous earth filters are very efficient in removing the oil from water and have the
advantages of high flow rate and low space requirements. However, if the filter cake becomes oil
saturated, some oil will leak through the filter. Hence to prevent the leakage the filtration is never
carried to completion. This increases the cost of a filter run. It is sometimes necessary to install
strainers or in-line filters downstream of a DE filter to strain out any solids going through the filter
because of malfunction.
A properly designed and operated DE filter will produce high quality effluent consistently.
Several filter companies offer a highly automated and packaged DE filter system that eliminates
most of the operator related problerns.41 Such a system, however, is not cheap; and the savings
resulting from the reduction in labor, and cost of continuous attention, must be compared in a
decision made against initial capital expenditure.
Diatomaceous earth filters are not recommended for use in small steam injection operations
because of the logistics involved in the supply of diatomite and high cost of disposal of used
diatomite and the associated filtered solids.
IDEAERATION
Deaeration of raw feedwater is critical to the control of corrosion of oilfield steam generators,
piping, and equipment. The primary source of corrosion in steam injection operation is probably
dissolved oxygen in raw water. Oxygen removal before water is heated is very important; its
importance is second only to the removal of hudness.
Oxygen Exclusion
The fmt step in controlling oxygen is to eliminate it at the source, if possible. Subsurface
source water does not contain oxygen; however, it is aerated inadvertently through improper
handling. By taking the necessary steps, oxygen pickup from the surface can be eliminated.
These steps include the use of a sealed type wellhead (with gas blanket) and use of packers to seal
water wells. Since raw water is usually stored prior to treatment, storage tanks should be roofed
and gas blanketed. The inlet to a tank must be submerged. An inlet (above water level) without a
gas blanket can pick up 5 ppm or more of oxygen. Submerging entrance piping to a storage tank
without gas blanket, while lowering the oxygen pickup, can still result in an oxygen pickup of
about 2 ppm. The entrance piping must be equipped with check valves to prevent oxygen pickup if
water wells are not operated continuously. Oxygen may also be picked up by a surface pump if the
pressure is low enough for a vacuum to be created in the pump. If there is no water pressure on
the seals, the pump will suck air making it necessary to have the water pump checked periodically.
Oxygen Removal
When every possible precaution is taken to exclude oxygen, small amounts of oxygen still
are present in the water when the source water is other than subsurface water (for example,
municipal or produced water). Water from such sources is usually oxygen saturated and the
oxygen must be removed.
There are generally three methods of removing oxygen from softened waters. These include
mechanical deaeration, chemical scavenging, or a combination of these two methods. Depending
on the process, mechanical deaeration can remove the oxygen to about 0.1 ppm. Chemical
scavenging is necessary to remove the trace residuals. Chemical scavenging can remove the
oxygen completely, but an excess amount must be used.
Chemical scavenging is the most widely practiced oxygen-removal technique in steam
injection operations and is recommended for smaller operations. However, in large operations,
where large volumes of water are handled through a central plant, it may be more economical to
use a deaerator followed by chemical scavenging to reduce chemical costs. Because of their higher
operating costs and low efficiency, mechanical deaerators are not widely used in steam injection
operations except in very large operations. The advantages and disadvantages of various
deoxygenated systems are presented in Table 5.12.
Mechanical Deaeration
Several different processes are used to mechanically deaerate the water. They include
(1) vacuum deaeration, (2) steam stripping, and (3) countercurrent gas stripping. The mechanical
removal of oxygen from water is governed by (a) Dalton's law of partial pressures and
(b) Henry's law.
Dalton's law states that the total pressure of a mixture of several gases is equal to the sum of
the pressures which each gas would exert were it alone present in the volume occupied by the
mixture.
Henry's law states that the concentration of the dissolved gas in the solution is directly
proportional to the partial pressure of that gas in the free space above the liquid.
In accordance with the basic principles of Dalton's and Henry's laws, the dissolved oxygen
from water can be removed by lowering the partial pressure of the oxygen in the surrounding
atmosphere. This can be achieved by either (a) diluting water with a scrubbing gas or (b) by
 TABLE 5.12. - Summary of Advantages and Disadvantages of Water Deoxygenation Systems

System Advantages

A. Natural Gas Stripping 1. Mechanically simple and easy to operate. 1. Gas evolved is water saturated,
2. Flexible and reliable. at low pressure, and must be
3. Capable of reducing residual oxygen to flared genedIy.
low levels. Some chemical scavenging 2. Requires "sweet" gas free of
is necessary. sulfur compounds.
4. Low operating cost if non-commercial gas 3. Amount of tolerable C02 in
is used. the gas is limited by pH,
scaling and associated problems.

B. Vacuum 1. Capable of reducing residual oxygen to 1. Slightly more complex than gas
very low levels. stripping and normally more
2. Chemical scavenging may be needed. expensive.
3. May be used to overcome disadvantages 2. More susceptible to operating
of gas stripping in (A) above. problems than gas stripping.
4. Reliable (witb careful design). 3. Removal of C02 along with 02
and N2 may introduce scaling
problems.

C. Chemical Scavenging 1. Mechanically simple. 1. On large systems, cost of

2. Capable of reducing residual oxygen to chemical is very large.
essentially zero. 2. On large systems, logistics of
3. Minimum initial capital cost. supplying and handling chemical
may be costly and present
difficulty.
3. The chemical may present
problems with sulfate reducing
bacteria.
4. Scavenger interaction with
other chemicals may present
some problems.
5. Adequate contact time for
reaction must be provided,

lowering total pressure of the system. In the countercurrent gas stripping technique, the
concentration of dissolved oxygen in the surrounding atmosphere is reduced by dilution with the
scrubbing gas. In steam deaeration, the solubility is decreased by raising the water temperature.

Vacuum ~eaeration29
In the vacuum deaeration process, the partial pressure of oxygen, and hence its solubility in
the water, is lowered by decreasing the system's total pressure.
It is well known that water boils at different temperatures, depending on the pressure which
is maintained in the vapor space above the water. For example, water will boil at 60' F, if the
pressure reading is 0.5214 inches of mercury (0.256 psia) which corresponds to a vacuum of
about 29.4 inches of mercury. It is usually assumed that the solubility of any gas is zero at the
boiling point of the liquid. Therefore, by maintaining a vacuum of 29.5 inches of mercury,
oxygen can be completely removed from the water. Since it is not economical to maintain water at
boiling condition, complete removal of oxygen by vacuum deaeration is not possible. To maintain
an oxygen content of about 1 ppm in water at 60' F, approximately 28 inches of vacuum must be
maintained in the system.
For deaeration to be effective, two conditions must be met: (1) water must be kept in an
agitated state and (2) a very large surface area should be available. In the vacuum deaeration
operation, the water is sprayed onto a packed column maintained at about 28 inches of vacuum.
As the water droplets cascade through the packing, it forms a thin film over the packing. It
requires only a short distance for oxygen to travel for release in a thin film.
A properly designed and operated vacuum tower can reduce the oxygen content of water
down to about 0.8 ppm. A schematic of a vacuum deaerator setup used in a steam injection
operation is shown in figure 5.14. The dimensions of the tower will vary, depending on the
volume of water to be deaesated and the flow rate desired. For example, the dimension of a typical
tower used in one oilfield deaeration operation is 4 ft diameter by 55 ft high and is rated for 30,000
barrels of water per day.
Vacuum deaeration is seldom used in steam injection operations because of its high operating
expenses and complexity of operation. Fusther, the deaerated water must be chemically treated to
remove the residual oxygen.

Steam Ileaeration 30
Steam czn be used to remove oxygen from source water. The principle of removal is to
(1) increase the temperature of the water (decreasing the oxygen solubility) and (2) put water vapor
(steam) into the gas space over the water (which decreases the partial pressure of oxygen). The
advantages of steam are as follows:
(1) It is readily available;
(2) it heats the water and reduces the oxygen solubility;
(3) does not contaminate the water; and
(4) most of the steam used to scrub the water is recovered as condensate and only a small
portion of the steam utilized to remove the noncondensible gases is vented to the
atmosphere.
Steam deaerators are widely used in power plants to deaerate boiler feedwater. The two major
types of steam deaerators are the tray-type and spray-type. Only spray-type deaerators are used in
the oilfield. Figure 5.15 is a schematic of a typical oilfield spray-type deaerator.
 Z UNE TO VACUUM PUMP

24' X l2'
A E u W u T O F I TANK

WATER
ma
SOURCE
WaLS

L.4 TR)IP

FIGURE 5.14. - Schematic of a vacuum d e a e r a t ~ r . ~ ~

DIRECT CO(ICTACT
V E M CONDENSER 7 1- SPRAY NOZZLE
L P RETURNSCONNECTION

STUM INLET
CONNECTION

C l E I N OUT PWG

PUMP SUPPLY

FIGURE 5.15. - Schematic diagram of a spray type steam deaerator.7

 The major components of a spray-type steam deaerator include a carbon steel shell, spring-
Loaded inlet spray valve, direct contact vent condenser and a steam scrubber for final deaeration.
The inlet spray valve and direct contact vent condenser section are fabricated out of stainless steel.
The incoming feedwater is sprayed in a finely divided state into an atmosphere of steam in the
preheating section. The mist of water, upon coming into contact with the steam, is heated to near
steam temperature. Most of the noncondensible gases are released to the steam and the heated
water falls into a reservoir and drains to the lowest section of the steam scrubber. The heated water
is then directed into the path of the incoming steam.
Steam enters the deaerator through the steam inlet nozzle and is directed to the scrubbing
section via baffles. Here the large volume of steam scrubs and heats the water from the preheat
section to the saturation temperature. The intimate contact between steam and water in the scrubber
section results in the release of the remaining noncondensible gases. The deaerated water drops
into the storage section below for pick up by the feedwater pump.
The steam, after flowing through the scrubber, passes into the preheating section and heats
the incoming spray of water. Most of the steam condenses in the preheating section and becomes
part of the deaerated water output. Finally, the noncondensible gases are expelled through a vent
in the top of the deaerator, along with small amounts of steam into the atmosphere.
Though steam deaerators are capable of reducing the oxygen content of water to about 0.01
ppm, they are not widely used in steam injection operations because of capital equipment needs and
operational and maintenance problems. Some of the operational problems include clogging of
spray valves and the inlet distributors and scaling problems. Further, these units require constant
operator's attention to ensure that the noncondensible gases are properly vented to keep the partial
pressure of oxygen to a minimum. Use of large amounts of steam to deaerate the water increases
the process steam demand and decreases the net steam available for injection because of fixed
stearn generation capacity. Further, the size and cost of the apparatus increases sharply with the
volume of water to be deaerated. Since it is not physically possible to completely deaerate the
water using a steam deaerator, the need for a chemical oxygen scavenging system is not eliminated;
however, the scavenger requirements will be considerably less otherwise.

Gas Strippin$
Use of natural gas to strip oxygen from water is practiced in large waterflood operations, but
no steamflood operation using this technique has been reported. The underlying principle behind
this deaeration technique is the reduction of the concentration of the dissolved oxygen in water by
diluting it with the stripping gas. This reduces the partial pressure of oxygen in the gas mixture
and causes oxygen to come out of the water.
 A schematic of a countercurrent gas stripping unit is shown in figure 5.16. Gas stripping is
normally performed in bubble tray column. Bubble tray column promotes intimate contact between
the water and gas by providing a large surface area.
O~eration:The water enters near the top of the column and flows down through the trays
passing across each tray and then down the staggered downcomers to the next tray. The stripping
gas enters the column near the bottom and passes upward through the bubble caps on the trays. As
it flows up the column, the gas bubbles go up through the downflowing water and remove a good
portion of the oxygen. The gas leaves the top of the vessel through a stainless steel wire mesh mist
extractor, through a gas outlet line, and a gas backpressure valve. The deaerated water collects in
the bottom of the column. The discharge is controlled by a liquid level control and a large capacity
diaphragm dump valve.
These columns are usually designed to operate at 50 psig or less. With higher operating
pressure, more trays are required, and the cost will increase rapidly. Typical specifications for
oxygen desorption towers are shown in Table 5.13. Gas stripping operations are not as efficient
as vacuum deaeration and can lower the oxygen content of water to about 0.9 ppm. Gas stripping
units, however, are less expensive to operate than a vacuum tower. Chemical scavenging must be
used to remove the residual oxygen.

OXYGEN
DESORPTION
TOWER

FIGURE 5.16. - Schematic of a counter current gas stripping unit25

lo8
 TABLE 5.13. - Oxygen Towers Selection ~ h a n * S

Tower Tower Working No. and Water capci tv? hhl/day Gas
diameter, beight,l pressure, type of 12" tray 18"tray 24" tray cons~rn~tion,~
in. ft psi trays spacing spacing spacing MSCF/day

10 single pass
10 single pass
10 single pass
10 single pass
10 single pass
10 single pass
10 single pass
10 single pass
- -- - -

Based on using 10 trays on 24" tray spacing.

2 Capacities based on 3Wo downcomer area, 80% of flood, and 4 second rctcatioa time in downcorners.
3 Gas consumption based on 5 cu ft/bbl of water and maximum water capacity.

Mechanical deaeration systems may be cost-effective in operations handling large volumes of

water. In such operations, mechanical deaention followed by chemical scavenging will reduce the
total chemical requirements.

Chemical ~eaerationd
Removal of oxygen from water by chemical means is the most popular and widely practiced
technique in steam injection operations. Several methods of chemical scavenging exist. These
include catalyzed sodium sulfite treatment, hydrazine treatment, and sulfur dioxide method.
The use of catalyzed sodium sulfite is cheaper than other chemical treatment methods and is
the chemical of choice with steam injection operators. It is inexpensive and is very effective in
removing oxygen from water. Theoretically, 8 ppm of sodium sulfite is needed to remove each
1 ppm of dissolved oxygen. The oxygen scavenging reaction is given by

The above reaction is very slow at ambient temperature. For rapid removal of oxygen at ambient
temperature, a small amount of catalyst (about 10 parts per billion, ppb, in the water) such as
cobalt sulfate must be added to the sulfite solution. Catalyzed sodium sulfite will remove the
oxygen in a matter of seconds as compared to minutes with the uncatalyzed compound. To be
certain that all of the oxygen is removed, an excess sulfite is added to the water so that a sulfite
residual of 20 to 30 ppm is carried into the process water. It is recommended 10 lb of catalyzed
sodium sulfite be used per pound of oxygen.6
The sodium sulfite is usually added to the water at a point downstream of water softener.
Some operators inject the sodium sulfite solution upstream of the softener to provide adequate time
for the chemical to react. The advantage of injecting ahead of the softeners is that ir will protect the
steel parts of the softeners and the steel piping against oxygen corrosion. However, addition of
sodium sulfite ahead of the softener will increase the load on the softeners from the added sodium
and will cause extra hardness leakage. Further, the excess may not be available to scavenge any
oxygen that may enter the system due to leaky valve, pump failure, etc.
Both catalyzed and uncatalyzed sodium sulfite are readily available from water treatment
chemical companies. Since uncatalyzed sodium sulfite is less expensive and the amount of catalyst
needed (0.001 ppm of cobaltous ion in water) is very small, it is recommended that uncatalyzed
sodium sulfite be purchased in bulk from chemical supply companies and the catalyst be added in
the field. The catalyst, cobaltous hexahydrate, can be purchased and fed with sodium sulfite as a
catalyst without materially increasing the cost of sulfite. The equipment needed for sodium suKte
treatment includes storage vessels, mixing tanks, and chemical feed pumps.
Although sulfite is inexpensive and generally satisfactory for removing oxygen from the
feedwater, there are times when hydrazine is used in preference to sulfite. If the oxygen content of
the source water is consistently low, hydrazine may be economical to use because little excess is
required for complete oxygen removal at high temperature. Only 3 ppm of hydrazine is needed to
remove 1 pprn oxygen from the water. Further, at temperatures above 500' F, the sulfite may
decompose to give sulfur dioxide which is corrosive. Hydrazine is stable at these temperatures.
Also, hydrazine does not require mixing or large storage vessels and is easy to feed.
Hydrazine is considerably more expensive and the reaction rate is very slow at room
tempera- but can be increased somewhat by using a catalyst. Even with the use of a catalyst, the
rate of hydrazine-oxygen reaction is not fast enough to make use of hydrazine practical in many
steam injection applications. Also, hydrazine is a hazardous chemical, and certain precautions in
handling should be observed. In most thermal operations, the cost of hydrazine prevents it from
being used where high concentrations of oxygen are present in the feedwater.

Oxygen Scavenging by Sulfur oxide3 *

When sulfur dioxide is absorbed into water, sulfurous acid is formed according to the
reaction
S@ + Hz0 + H2 SO3
The sulfite ion (sulfurous acid) thus formed can then be reacted with the dissolved oxygen to form
sulfuric acid.
2M2 SO3 + 0 2 3 2H2 SO4
Cobalt solution is usually fed into the solution as a catalyst. The economics favor this scavenging
technique, provided sulfur dioxide could be produced on-site and a large volume of water can be
treated at a central point.
 A large California steam injection operator utilizes this method to scavenge oxygen from
feedwater. Theoretically, 4 lb of sulfur dioxide is required to scavenge 1 lb of oxygen from water.
A sulfur burner is used to generate sulfur dioxide for scavenging oxygen. The sulfuric acid and
the excess sulfurous acid is neutralized by the natural bicarbonate alkalinity of the water as follows:

The use of a sulfur burner to generate sulfur dioxide for scavenging oxygen from boiler
feedwater is well known and practiced since the early 1940s by the chemical process ind~stries.3~
However, this technique was not adopted by the oil industry until the early 1960s, when the first
such unit was installed in a West Texas waterflood project to deoxygenate the process ~ a t e r . 3A~
schematic of the sulfur burner process used in the West Texas field is shown in figure 5.17.

FIGURE 5.17. - Schematic of sulfur burner process for oxygen deaeratiod2

 The sulfur burning method of scavenging oxygen from feedwater was adopted by California
steam injection operators in the early 1980s. The overall process scheme used in steam injection
operations is similar to those used in waterflood operations, but differs in the specifics because of
the special needs of the steam injection operation. In this process, the sulfur is supplied to a sulfur
burner as required to produce the sulfur dioxide necessary to scavenge oxygen in the incoming
water. The hot sulfur dioxide is cooled to about 150" F by passing it through a water-cooled heat
exchanger. The cooled sulfur dioxide is then introduced to the bottom of an absorption tower
composed of ceramic packings. A side stream of source water taken from the source water storage
tank is introduced into the top of the tower at the desired rate. The process water is sprayed onto
the packing through the spray nozzles. The water reacts with the upflowing sulfur dioxide and
converts it into diluted sulfurous acid which falls to the bottom of the tower, This solution is then
pumped into the main stream of water. A dilute solution of cobalt chloride is added to the water to
speed the reaction of sulfurous acid with the dissolved oxygen.
The absorption tower design, operation, and problems are similar to those of the generator
flue gas scrubber. According to the operator, the installation costs for such a system were slightly
over $175,000 (199 1 dollars), and the operating costs were about 1$/barrel of water treated.
Another inexpensive source of sodium sulfite is the generator flue gas scrubber liquor?
Depending on the sulfur content of the fuel oil burned in the generator, the scrubber liquor contains
between 3% and 5% sodium sulfite which can be used to scavenge oxygen from the feedwater.
The use of scrubber liquor to scavenge oxygen not only eliminates chemical requirements, but will
also lower the spent liquor disposal cost. According to one California steam injection operator
who utilizes scrubber wastes to scavenge oxygen, the total capital investments needed to implement
such a system is slightly over $35,000 (1991 dollars) and includes a 200-bbl fiberglass holding
tank for scrubber liquor; a chemical feed pump; two 650-gprn cartridge filters; and associated
pipes, valves, and fittings.
The requisite volume of scrubber liquor is transferred from the scrubber waste tank into the
fiberglass holding tank. This allows the heavy metal precipitates and other debris to fall to the
bottom of the holding tank. The clear supernatant liquor then flows through the canridge filter and
introduced into the upstream of the ion exchanger units. According to the operator, between 1 and
2 bbl of scrubber effluent (containing 5% sodium sulfite) was required to remove 4 ppm oxygen
from 1,000 bbl of feedwater. The net savings in the operating and chemical costs were such that
the operator was able to recover his investment in less than 6 weeks.
It should be realized, however, the benefits of using scrubber waste to scavenge oxygen may
not be realized in all operations. This is because the scrubber waste contains high amounts of
sodium (as high as 105,000 ppm in some liquor) which makes an additional sodium load on the
ion exchange resin and may cause increased hardness leakage. The scrubber liquor is also high in
iron, which is harmful to the resin. Also, if the amount of oxygen in the steam generators is
restricted in the burn process, sulfur, sodium sulfide, thiosulfate and hydrogen sulfide may also be
Sulfur, sodium sulfide, and thiosulfate are known to inhibit the ability of sodium
sulfite to remove oxygen from the generator feedwater.6 Hence efforts should be taken to ensure
that generators operate with sufficient oxygen to minimize the harmful effects of oxygen
deficiency. Also, a complete analysis of the scrubber waste must be performed and its oxygen
scavenging potential established prior to its use as an oxygen scavenger. A typical SO2 scrubber
waste analysis is shown in Table 5.14.
Reclamation of Produced Water For Steam Generation
As discussed earlier steam injection operation requires large volumes of good quality water
for steam generation. The availability of sufficient quantities of inexpensive, good quality water is
becoming increasingly difficult in many parts of the country. This is especially true in the San
Joaquin Valley, CA, the hub of U.S. steam injection activities. Steam injection operations also
produce large volumes of water, with the crude oil creating a significant disposal problem. To
solve the problems of fresh water requirements and waste water disposal, alternate water handling
practices must be followed. Recycling represents the most efficient use of oilfield waters,
practically eliminating waste water disposal and fresh water supply needs.

TABLE 5.14. - Typical SO2 Scrubber Waste Analysis

Constituent Concentration, ppm

Sodium lO5,OOO
Calcium less than I
Iron 35
Chloride 2,400
Carbonate 0
Bicarbonate. 44,000
Sulfate 53,000
Sulfite 84,000
Bisulfite 33,000
Silica 160

Total dissolved solids

Total suspended solids
 However, before the produced water can be used for feedwater, the residual oil, suspended
solids, and hardness must be removed. The required waste water treatment operations are more
complex than conventional fresh water treatment techniques. The complexity and corresponding
higher costs of produced water treatment have made reclamation uneconomical in many small
operations. However, in larger operations, recycling is a viable alternative to conventional water
handling practices due to high fresh water requirements and high disposal costs.
Before designing the treatment facility, the geochemical analysis of the produced water and
its scaling tendencies must be investigated. Oilfield produced waters show a wide variance in the
TDS and hardness content and contain significant amounts of oil and suspended matter.
Experience indicates that conventional sodium zeolite softeners are not effective at a TDS level
above 20,000 ppm, and weak acid softening resins must be utilized to remove the hardness. The
TDS of oilfield produced water from thermal EOR fields in California varies from 1,500 ppm in
the valley to more than 30,000 ppm near the coasts. The TDS and hardness of the produced water
can usually be lowered, and the softening costs reduced, by blending it with municipal or city
water. The favorable economics depend on the ready availability of large volumes of city water at
cheaper costs. Most major operators in California blend the produced water with city water before
softening to reduce costs. Because of their high TDS content, produced waters are more likely to
cause plugging problems in the generator tubes, if the steam quality is allowed to exceed the
solubility limits of sodium salt. The use of produced water does require monitoring steam quality
more closely.
Silica Scaling
Another major area of concern regarding produced water use has been the possibility of silica
scaling. The produced water from a steamfiood usually contains between 100 and 400 ppm silica
as S i q . This silica is dissolved from the quartz present in the formation by the unvaporized and
condensed water that has a pH >9. Silica foi-ms scales at high pressure in the presence of metal
ions such as iron, aluminum, calcium, and magnesium. Although API recommendations permit up
to 150 ppm silica in generator feedwater, fields studied indicated that up to 9.9% of inlet dissolved
silica will precipitate in one form or another in the convection and radiant sections of generators?'
Even a trace mount of metal ion will result in silicate scale formation in boiler tubes. Factors that
contribute to silicate precipitation include not only the silica level but also salinity, alkalinity
(HC03-), pH, and trace amounts of metal ions.
Depending on the vapor velocity, entrained liquid droplet, and water film thickness, silicate
scale can be mobilized and cause erosion and eventual failure of the tube~.~O Field studies
indicated that irrespective of the steam quality, silica precipitation will occur, and the metal loss is
higher at higher quality steam due to greater rate of transport of the deposit present. Further,
neither the acceptable level of silica concentration in the feedwater required to produce 75% or
higher quality steam, nor a water treatment process to achieve this concentration, is known.
Since the solubility of silica increases rapidly above pH 10, it is suggested that silica
deposition can be prevented by pH modification; however, adding caustic to buffered waters is
difficult to con~-01.~ If soda ash is used to increase pH of the water, it may decompose in the
generator and release carbon dioxide to accelerate corrosion.
To mitigate silicate scale problems, high silica waters should generally be avoided in steam
generation processes. If the use of high silica water cannot be avoided, silica must be removed by
precipitation or by total demineralization (anion exchangers) to avoid scaling problems. Since the
formation of silica scales requires the presence of metal ions such as iron, calcium, and
magnesium, complete removal of these ions is technically and economically more attractive than
silica removal.
Reclamation of produced water for steam generation involves the following steps:
(a) Flotation Process: The induced gas flotation process further reduces the oil and
suspended solids to about 20 ppm and 80 pprn, respectively.
(b) Filtration: DE Nters reduce the oil and suspended solids in the produced water to 0
PPm-
(c) Oxygen Scavenging: Chemical scavengers are used to eliminate the dissolved oxygen.
(d) Ion Exchange Softener: Softening is done in two stages-primary and polisher-to
reduce the hardness to 0 pprn.
Figure 5.18 summarizes the sequence in which the unwanted constituents of the produced
water are removed. Operational details of the equipment used in these steps were discussed in a
previous section.
Daily monitoring should form an integral part of produced water reclamation plant operation.
Monitoring provides adequate warning of possible upset conditions. The following components of
the produced water must be monitored constantly.l*
Oil concentration in incoming water
Filter pressures
Dissolved oxygen and iron
Water hardness
Plant inflow and outflow volumes.
The oil concentration is probably the most critical factor since high concentrations will increase
filter differential pressure and reduce filter cycle length. A significant reduction in filter cycle
would curtail generator feed supply and may result in generator shutdown.
 .
PRODUCED WATER
INLET

DEPURATOR
UNIT
CHEMICAL
TREATMENT

SEDIMENTATION
BASIN
OXYGEN
SCAVENGER

NITROGEN

DIATOMCEOUS
FEEDWAT EARTH
CAKE FILTER

CATION
EXCHANGE
I rLu4n1
CELL
SOFTENER

DISCHARGE TO I

IFIREGATION CANAL DEPURATOR

UNIT

FIGURE 5.18. - Flow diagram for a Kern River, CA, steamflood produced water reclamation
plant. 18

Higher filter pressure is an indication not only of high oil concentration but may also indicate
bacterial growth in the settling tanks. High oil concentrations are controlled by ensuring proper
operation of the upstream dehydration plant. Bacterial growth is controlled by periodic biocide
treatment of the holding tanks.
Dissolved oxygen and iron are monitored as co~sosioncontrol indicators.
Monitors are utilized for identifying hardness leakage and to indicate when corrective action
is warranted.
Plant inflow and outflow volume monitoring is needed to ensure efficient plant operation.
Disposal of Excess Produced Water
The excess produced waters are usually disposed of by subsurface injection. Federal and
most state environmental regulations require that the produced fluid be disposed of in an
environmentally safe manner. Underground injection wells represent a safe environmental practice
for disposal of produced water and hydrocarbon-containing wastes. Underground injection of
produced fluids is subject to state and federal underground injection control regulations.
Underground injection wells associated with the disposal of oilfield produced waters are classified
by the U.S. Environmental Protection Agency (EPA) as Class I1 wells.
Produced water must be treated before its disposal. For example, current federal regulations
require that the oil content of produced water not exceed 48 ppm. The methods of treatment and
equipment used for produced water disposal are similar to those used in the reclamation of
produced water for steam generation. Treatment of produced water need not be elaborate. The
opemior's objective should be to provide only sufficient treatment to meet the regulatory
requirements and render the water suitable for injection into formations without decreasing the
injective capacity of disposal wells. It is essential that thorough laboratory studies be conducted on
the proposed injection water, thereby determining the minimum water treatment requirements;
scrubber wastes must be neutralized and filtercd before injection. If the produced water is to be
discharged to a surface facility such as a canal, a more thorough treatment may be in order.
The treatment and disposal of steamflood produced water in a pollution-free manner is an
essential part of operational expenses and must be so recognized. With proper planning, design,
and operation, produced water may be disposed of at a minimum cost. Produced water disposal
system design, operation, and economics are beyond the scope of this repon. Steam injection
produced water treatments are covered in a previous section of this report. Disposal of the
produced water by underground injection is similar to that for oilfield produced brines and is
covered thoroughly in an API publication34 which should be consulted.
Water Treating Costs
The cost of treating water depends on the quality of the feedwater. Good quality fresh waters
containing minimum amounts of hardness ions and other impurities require the least amount of
treatment and hence, the treatment costs will be nominal. At the other extreme, if the feedwater is
brackish or the produced water is to be recycled, the treatment costs will be much higher. The
chemical costs associated with the treatment of produced water increases with TDS concentration.
At any given TDS level, costs become a function of hardness concentration.30 The chemical costs
account for nearly half the water treatment expense. ~ e c k e t t allocated
3~ the expenses as follows:
Chemicals.. ................................................ 49.2%
Power ...................................................... 7.6%
Supervision and labor.. .................................. 37.0%
Repair and maintenance.. ................................ 6.2%
Elias et d.19concluded that although the chemical costs associated with softening raw water are
substantial, they are small compared with steam generation fuel costs. The chemical costs
associated with softening the high TDS feedwater amounts to about 5% of the fuel costs. Fresh
 TABLE 5.15. - Typical Water Analysis for Water Treatment Cost ~stirnation~g

Impurities Fresh water (ppm) Produced water (ppm)

Dissolved solids (TDS)

Bicarbonate
Hardness as CaCe
Calcium
Magnesium
S ilia
Sulfate
Chloride
Sodium
Iron
pH
Oil,ppm
Fresh and produced water treatment costs are based on the following chemical prices:
Diatomaceous earth, ton
Chlorine gas, ton
Oxygen scavenger, 1b
(25%sodium sulfite solution)
Sodium chloride (salt), ton
Hydrochloric acid (HCI), ton
Sodium hydroxide (NaOH), ton

* 35% HCl by wt solution.

water chemical costs amount to about 1% of the steam generation fuel costs. A typical water
analysis for the water treatment cost estimations (in 1991 dollars) are shown in table 5.15.
In Tables 5.16 and 5.17, published water treatment costs are shown. Most of the data were
published in 1980-83. These data have been updated to 1991 dollars using the U.S. Producer
Price Index. From this, it is clear that softening produced waters is more expensive than softening
fresh water. However, recycling of produced water will substantially reduce the cost of acquiring
fresh water and will result in a decrease in cost of waste water disposal. One California steam
injection operator indicated that waste water recycling will result in a savings of about 1.5 cents per
barrel over that of conventional water handling practices.36 However, this savings can be realized
only in large operations. For small operations, waste water recycling may not be economical and
efforts should be made in acquiring good quality feedwater for steam generation.
Guidelines to Water Treatment System Design and Operation
Proper planning, design, and operation of the water-handling system is a very important part
of the overall picture in a steam injection project. Because of the usually uneventful operation of a
water treatment plant, coupled with the fact that water acquisition and treatment costs constitute a
very small percentage of total operating costs, there has been a tendency on the part of operators to
minimize the importance of water-handling systems to the success of a project. Yet the economic
 TABLE 5.16. - Fresh Water Treatment Costs
(AUcosts are for processing 1 bbl of fresh water containing impurities shown in Table 5.15)

Chemical Chemical
Chemical usage requirement costs, $
Process Chemical rate per bbl water per bbl water

Bacteria control Chlorine 0.34 mg/lb water 0.1 grn

Oxygen removal Sodium sulfite 9 mg/ppm 0 2 10 gm
Strong acid
sofiening & Sodium chloride 15 1b/ft3 resin bed 0.7 lb
regeneration

Total chemical cost

Power
Operational (labor)
Repair and maintenance

Total fresh water treatment costs per barrel

TABLE 5.17.- Produced Water Treatment Costs

(All costs are for processing 1 bbl of produced water containing impurities
showr. in Table 5.15.)

Chemical Chemical
Chemical usage requirement COSiS, $
Process Chemical rate per bbl water per bbl water

Filtration Fiber and DE 0.7 part DE 0.03 Ib

Oxygen sodium sulfite 9 mghpm 0 2 10 gm
removal
Strong acid NaCl 15 lb/ft3 resin bed 0.3 lb
softening &
regeneration
Weak acid HCI 8 lb/ft3 resin bed 0.16 lb
Softening &
regeneration NaOH 9 lb/ft3 resin bed 0.17 lb

Total chemical cost

Power
Labor
Repair & maintenance
success of a steam injection project can be just as dependent on water handling practices as on such
items as steam generation, reservoir performance, and sweep and displacement efficiency. As
previously mentioned, a problem-plagued water treatment system will result in costly steamer
downtime and loss of production. A properly engineered and operated water treatment system can
result in a more profitable operation than otherwise. The purpose of this section is to outline what
needs to be considered in the design and operation of water treatment system to ensure maximum
benefits from the installed equipment.
Design Concept
Design of a water treatment system for steam injection requires careful planning and
engineering. It may require more technical effort initially, but will assure relatively trouble-free
operation over the life of the project. There is no such thing as a standard water system design.l
Each project is unique and has its own water processing requirements. A treatment facility must be
tailored realistically to meet anticipated needs, with provision for addition or expansion when
required. In designing the process, the objective should be to keep it simple. The simpler the
system, the better chance it will be operated successfully. During the planning and design stage,
major potential problems should be identified and taken into account. Since everything cannot be
foreseen, no attempt should be made to anticipate all problems and provide for all contingencies.
The approach to the planning and designing of a water treatment system for steam generation
can be broken into three steps, and certain minimum information is required for each step. In
general terms, the timing of items that need to be considered are as follows:
(a) Fewibilitv Studies: The planning of the water treatment system should coincide with
other early work on the project. At this stage, identify all water sources capable of meeting the
project's water requirements. More often than not there is only one adequately sized water source
existing at a given site. In cases where multiple water sources exist, it is necessary to consider
them separately to determine the procurement (either drilled, purchased, or piped in) and
processing costs for each source. The main objective at this step is to select the most likely water
source and rough-in expected treatment equipment requirements and order-of-magnitude costs.
The quality of feedwater will determine the equipment requirements and operating costs. The
analyses of several typical source waters used in the California steam injection projects are shown
in Table 5.2. Each type of water presents a different set of problems.
(b) Preliminary Desim: In this step, water quality data are refined, and comparative
economics of alternatives are made using firmer numbers. More exact determination of equipment
requirements, materials, and operating costs should be considered.
(c) Final Design: This step must cover such items as exact equipment sizing, location, and
brand names. Installation drawings should be reviewed to locate sampling and coupon monitoring
points, drain and flushing locations, etc. While these details may seem insignificant, they are
extremely important to the profitable operation of the project.
Source Water Properties and Problems
Water treatment system design must be tailored to both the source water characteristics and
steam generator feedwater requirements. The source water may be surface waters from streams or
lakes or subsurface fresh water, or it may be produced water from the field operation. Whatever
the source may be, the water treatment system must be able to take the supply water and improve
its quality to meet steam generator feed specifications. The method of treatment and equipment
needed to process these waters depends on the feedwater characte1-istics.
Surface waters tend to have a high concentration of suspended solids and dissolved oxygen
and often contain bacteria. It is usually necessary to employ flocculation, coagulation, and
sedimentation upstream of filtration to achieve a quality suitable for an ion exchange process. The
water must be rendered noncorrosive by utilizing oxygen-scavenging,chemical, or other processes
designed to remove oxygen from the water. Bacterial activity can be controlled through the use of
biocide on an intermediate basis. Treatment of surface water involves relatively high initial costs.
Subsurface water is rich in dissolved solids but contains reduced amounts of suspended and
organic matters. It is also lean in dissolved gases, but oxygen leakage into a source well annulus is
a frequent problem. Subsurface source water requires relatively fewer pieces of equipment to treat
and is preferred over surface water.
Produced waters are high in dissolved solids and rich in oil and suspended solids. The total
dissolved solids in steam injection produced waters can vary from a low of about 500 ppm to as
high as 30,000 ppm (see Table 5.3). Produced waters are more difficult and expensive to treat
than water from other sources. The amount of hardness and TDS in the feedwater dictates the type
of ion exchange resins employable in the softener.
The complexity of the water treatment system depends on the quality of the source water.
The better the quality of raw water the less complex the system will be. Subsurface sources of
water usually require less equipment to treat and are preferred over other sources. Steam injection
demands the handling of large volumes of water. For various reasons, a single source may not be
able to meet a project's water demand, and it is a poor practice to design a water handling system
based on a single source. Overall plans should include the handling of water from different
sources. Flexibility should be built into the initial design to provide for the handling of less than
desirable water. As a generality, the water treatment system should be designed to treat the readily
accessible and inexpensive water that is available in sufficient quantities, with provisions for
addition of supplementary equipment if and when necessary. Most water can be treated with a
reasonably simple system, if sufficient emphasis is placed on careful planning during design.
 Equipment Consideration
At each step prior to the final plans of a steam injection project, the type of equipment
believed necessary to produce water of acceptable water quality should be reviewed. Since it is not
possible to predict with certainty all of the possible problems which can arise in a
15- to 20-year steam injection project, provisions should be made for possible future additions of
water-handling equipment. Only that equipment needed to start plant operation should be installed
initially. If additional problems arise regarding water quality after a plant is in operation, a detailed
study must be conducted to identify the causes and possible solutions. If the study indicates the
need for new equipment andfor chemical treatment to achieve the desired boiler feedwater quality,
then the system should be modified accordingly. Installation of each piece of new equipment must
be justified economically.
In the design of pipelines, consideration should be given to the possibility of hydraulic shock
and surge which may damage pipes of low tensile strength. Provisions should be made for the use
of cleanout pigs for removal of scale and other fouling materials. Air pocket vents should be
included. Leak-testing equipment should be available. If separators are to be used, they should be
selected based on the volume of suspended solids and type of oil that must be removed, the
reactivity of the water, and the value of the land on which they would be located. Separators,
however, should be used only if the amount of free oil is expected to exceed the handling capacity
of the depurators. This can occur when the dehydration equipment malfunctions. Efforts shou!d
be made to prevent upsets of dehydration equipment. Installation and operation of deaeration
equipment is very expensive. Before considering deaeration equipment, other methods of control
of oxygen should be thoroughly evaluated. In the case of dissolved oxygen, elimination of the
source of oxygen can be the most profitable approach. Even the shallow water sands do not
contain dissolved oxygen, and the oxygen found in these waters is from the surface. Oxygen
pickup from the surface can be eliminated by proper design and gas blanketing of the supply well.
All chemicals, which may include bactericide, oxygen scavengers, de-emulsifiers etc.,
should have a mix hopper provided with a transfer arrangement to a feed tank. In the case of
sodium sulfite, the tanks should be closed and blanketed to prevent oxygen contamination. All
chemicals should be fed into the system through a variable metering type injection pump. Materials
should be selected for corrosion resistance to chemicals in the concentrated and dilute states.
Operation of a Water System
The objective of a water treatment system is to obtain and/or maintain the water at the quality
suitable for steam generation. Certain operating techniques are required to achieve this goal, and
specific monitoring procedures must be used to assure the success of the operation.
 Frequently, once a system is installed, put on stream, and 'debugged,' the operation and
maintenance of the water-handling system is relegated to the backburner until trouble develops-
softener resin deterioration, equipment scales, corrosion failures etc. Considerable amounts of
money are usually spent on remedial work that often destroys a project's profit picture.
As with other preventive maintenance, water-treatment system monitoring can go a long way
towards reducing such problems. A few thousand dollars spent on monitoring has a large potential
payout in decreased operating costs. A systematic review and evaluation of water quality will help
detect changes and conditions before serious problems develop. Automatic and manual hardness
and oxygen monitoring should be made to periodically determine and follow water treatment plant
performance. Oxygen content at the discharge of each piece of equipment should be checked
periodically. Performance of the ion exchange bed should be monitored carefully. Excessive
pressure-drop through the bed and poor quality treated water are indications of resin degradation.
As a rule, about 10% of the resin bed should be replaced annually. Using such a systematic
approach, the efficiency of water treatment equipment and its operation may be monitored. Such
information, in conjunction with the steam generator performance and the injection well
performance data, can be utilized to evaluate the flood performance.
Apparently, insignificant items can greatly influence water quality. In a well designed and
operated water-handling system, most of these can be classed as "good housekeeping" items. Yet
the importance of good maintenance programs cannot be over-emphasized. Routine maintenance
schedules and reporting procedures should be set up and periodically reviewed. Last, but certainly
not least ,is the importance of operator's training. Many operating problems can be avoided or
minimized by personnel who understand the what, why, and how of good maintenance
management.
Finally, it should be kept in mind that the steam injection process is, above all, an oilfield
operation. Each project is unique and has its own problems. Circumstances, when fully
understood, will dictate the best course of action.

SUMMARY
Quality of boiler feedwater is of critical importance in steam injection projects. Past field
experience indicates that the majority of steamer downtime is caused by water treating problems.
Therefore, it is imperative that feedwater problems be examined with care. This chapter discusses
in detail the feedwater treating requirements for a single-pass steam generator and the effect of
specific impurities on steamflood equipment performance. Guidelines to water treatment system
design are also provided. Water treatment softening-unit operations and problems are detailed.
Process requirements for reclaiming produced water for steam generation are also detailed.
 REFERENCES
1. Burns, W. C . Water Treatment for Once Through Steam Generators. J. Pet. Tech.,
V. 17, NO. 4, April 1965, pp. 417-421.
2. Hagist, F. C. and D. R. Fincher. What You Ought to Know About Water Treatment for
Thermal Recovery. Oil & Gas J., v. 63, No. 46, Jan. 11, 1965, pp. 64-70.
3. Fincher, D. R., F. C. Hagist and D. L. Gallaher. How to Treat Feedwater on Steam
Injection Projects. World Oil, v. 166, No. 1, January 1968, pp. 53-57.
4. Fieber, C. E. How to Treat Water for Steam Flooding. Pet. Engineer, v. 36, No. 11,
November 1964, pp. 94- 100.
5. Fincher, D. R. and F. C. Hagist. Handling Water Treating Problems in Steam Injection
Projects. Pres. at the 40th Ann. Fall meeting of the Soc. of Pet. Eng., Denver, CO, Oct. 3-6,
1965. SPE paper 1265.
6. Walker, C. L. The Chemical Treatment of Water Used in Steam Injection Systems.
J. Can. Pet. Tech., v. 4, No. 2, April-June 1965, pp. 107-110.
7. Bums, W. C. What Kind of Water Treatment for a Successful Steam Flood? Pres. at
the 39th Ann. Fall meeting of the Soc. of Pet. Eng., Houston, TX, Oct. 11-14, 1964. SPE paper
1000.
8. Roberts, J. C. and J. W. Williams. Steam Injection, Oil Recovery Techniques and Water
Quality. J. Water Pollution Control Federation, v. 42, No. 8, Part 1, August 1970, pp. 1437-
1445.

9. Haseltine, N. G. and C. M. Beeson. Steam Injection Systems and Their Corrosion

Problems. Materials Protection, v. 4, No. 10, October 1965, pp. 57-61.
10. Reyes, R. B. Softening of Oilfield Produced Water by Ion Exchange for Alkaline
Flooding and Steamflooding. Pres. at the California Regional meeting of the Soc. of Pet. Eng.,
Ventura, CA, Mar. 23-25, 1983. SPE paper 1 1706.
11. Bradley, B. W. Influence of Salt Dosage and Hardness on Series Softener Performance.
Pres. at the 42nd Ann. Fall Tech. meeting of the Soc. of Pet. Eng., Houston, TX, Oct. 1-4, 1967.
SPE paper 1% 1.
12. Serck Baker-Water Softener Systems-Oil Field Steam Generation and Other Enhanced
Recovery Techniques. Tech. Bulletin, Serck Baker Inc., Huntington Beach, CA, 1982.
13. Owens, M. E. and B. G. Bramley. Performance of Equipment Used in High Pressure
Steam Floods. J. Pet. Tech., v. 18, No. 12, December 1966, pp. 1525-1531.
14. Brusset, M. J., A. N. Edgington and R. F. Gilmour. Equipment Performance in an
Alberta High Pressure Steam Injection Project. Paper pres. at the 18th Ann. Tech. meeting of the
Pet. Soc. of CIM, Banff, Alberta, Canada, May 24-26, 1967.
15. Bealessio, M. Sources of Fresh Water for Steam Generators. Producers Monthly,
v. 32, No. 9, September 1968, pp. 8-10.
 16. Bradley, B. W. and L. K. Gatzke. Stearnflood Heater Scale and Corrosion. J. Pet.
tech.,^. 27, No. 2,February 1975, pp. 171-178.

17. Welder, B. Q. Automation Does Well in Steam Injection: The Oil & Gas J., v. 63,
No. 46, NOV.15, 1965, pp. 164-173.
18. Carrell, M. A. Reclaiming Produced Water for Steam Generation in the Kern River
Field. Pres. at the 54th Ann. Fall Tech. Conf. of the Soc. of Pet. Eng., Las Vegas, NV, Sept. 23-
26,1979. SPE paper 8411.
19. Elias, R., J. R. Johnstone, J. D. Krause, J. C. Scanlan, and W. A. Young. Steam
Generation With High TDS Water. Pres. at the 50th Ann. California Regional meeting of the Soc.
of Pet. Eng., Los Angeles, CA, Apr. 9- 11, 1980. SPE paper 8819.
20. American Petroleum Institute. Manual on Disposal of Refinery Wastes-Volume on
Liquid Wastes--Chapter 6-Construction Details of Gravity-Type Separators. 1st Edition, 1969,
American Petroleum Institute, Washington, D.C.
2 1. Katz, W. J. Dissolved Air Flotation as Applied to the Treatment of Oil-Production Water
and of Refinery Wastes. API Drilling and Production Practices, 1960, pp. 140-144.
22. Bessett, M. G. WEMCO Depurator System. Pres. at the Rocky Mountain Regional
meeting of the Soc. of Pet. Eng., Billings, MT, June 2-4, 1971. SPE paper 3349.
23. Eddins, W. N. Induced Gas Flotation Process Performance. Pres. at the 26th Ann.
Southwestern Petroleum Short Course, Lubbock, TX, Apr. 19-20, 1979, pp. 37 1-375.
24. WEMCO. WEMCO Depurator 1+ 1 Flotation Machine. Bulletin F8-B6 (5188 6500M),
1987. WEMCO, Sacramento, CA.
25. Sivalls, R. C. Water Treating Equipment Design Manual. Sivalls Inc., Tech. Bulletin,
Sivalls Inc., Odessa, TX, 1969,
26. Olmsted, B. C. and G. R. Bell. Diatomite Filtration of Water for Injection. Paper
presented at the Third Biennial Symp. on Microbiology, sponsored by API Pacific Coast District
Study Committee on Treatment and Control of Injection Waters, Nov. 29-30, 1964, Anaheim,
CA, pp. 201-219.
27. Smith, M. L. Waste Water Reclamation for Steam Generator Feed, Kern River Field,
California. Pres. at the 42nd Ann. California Regional meeting of the Soc. of Pet. Eng., Los
Angeles, CA, Nov. 4-5, 1971. SPE paper 3689.
28. Baumann, E. R. and R. L. LaFrenz. Optimum Economical Design for Municipal
Diatomite Filter Plants. J. of American Water Works Association, v. 55, January 1963, pp. 48-
58.
29. Adams, G. H. Vacuum Deaeration In Waterflood Operations, Paper No. 851-51-H,
pres. at the API Mid-Continent District's Spring meeting, Division of Production, Oklahoma City,
OK, May 1967. API Drilling and Production Practices, 1967, pp. 159-163.
30. Fanaritis, J. P. and J. D. Kimmel. Review of Once-Through Steam Generators, J. Pet.
Tech., v. 17, No. 4, April 1965, pp. 409-416.
 3 1. Weeter, R. F. Desorption of Oxygen From Water Using Natural Gas for Countercurrent
Stripping, J. Pet. Tech., v. 17, No. 5, May 1965, pp. 515-520.
32. Perry, L. N. and W. J. Frank. Sulfur Burning Method of Scavenging Oxygen From
Water. Paper 906-1 1-E, pres. at the API Southwestern District Spring meeting, Division of
Production, Hobbs, NM, March 1966. API Drilling and Production Practices, 1966, pp. 70-73.
33. Williams, R. L. and A. Harris. Use of Scrubber Waste as an Oxygen Scavenger in
Thermal Water Plant Operations. Pres. at the California Regional meeting, Ventura, CA, Apr. 8-
10, 1987. SPE paper 16368.
34. American Petroleum Institute. Subsurface Salt Water Disposal. Book 3 of the
Vocational Training Series. American Petroleum Institute, Division of Production, Dallas, TX,
1960.
35. Beckett, J. K. Low-Cost Water Treatment Solves Disposal Problems. World Oil,
v. 173, No. 6, November 1971, pp. 64-67.
36. Burton, R Waste Water Recycling in Steamflood Operations. Pres. at the California
Regional meeting of the Soc. of Pet. Eng., Ventura, CA, Mar. 23-25, 1983. SPE paper 11710.
37. Khatib, 2. J., E. E. Olson and M. C. Place Effect of High Silica Content on Scale
Deposition and Pipe Wall Loss in Oilfield Steam Generators. Pres. at the 64th Ann. Tech. Conf.
and Exhib. of the Soc. of Pet. Eng., San Antonio, TX, Oct. 8-11, 1989. SPE paper 19760.
38. BET2 Handbook of Industrial Water Conditions, 8th Ed., Chapter 8: Ion Exchange,
p. 54. BET2 Laboratories Inc., Trevoise, PA, 1980.
39. Kemmer, F. N.: The NALCO Water Handbook-Chapter 12: Ion Exchange, pp. 11,
McGraw Hill Book Company, New York, 1979.
40. Battle, J. L.: Salt Water Disposal. Pres. at the 15th Ann. Southwestern Petroleum Short
Course, Lubbock, TX, Apr. 18-19, 1968, pp. 193-206.
41. Maloney, G. F.: Diatomite Filters-Methods of Automation. Paper pres. at the Third
Biennial Symp. on Microbiology, sponsored by API Pacific Coast District Study Committee on
Treatment and Control of Injection Waters, Nov. 29-30, 1964, Anaheim, CA, pp. 170-186.
42. Ostroff, A. G.: Introduction to Oilfield Water Technology, pp. 88, Prentice-Hall Inc.,
Englewood Cliffs, NJ, 1965.

GENERAL REFERENCES
BET2 Laboratories. BETZ Handbook of Industrial Water Conditioning, 8th Ed., Chapters 6 , 8
and 9. BET2 Laboratories, hc., Trevoise, PA, 1980.
Crawford, P. B. Water Processing For Thermal Oil Recovery Programs. Producers Monthly, v.
29, No. 4, April 1965, p. 18.
Crawford, P. B. Water Treatments For Steamfloods-Part 11-Hardness Removal by Ion
Exchangers. Producers Monthly, v. 29, No. 11, November 1965, p. 28.
Crawford, P. B. Regeneration of Ion Exchangers Used in Steam Recovery Programs. Producers
Monthly, v. 29, No. 11, November 1965, pp. 16-17.
Crawford, P. B. Effect of ion Exchange Properties on Thermal Water Treatment Quality.
Producers Monthly, v. 29, No. 1, January 1965, pp. 8-9.
Crawford, P. B. Importance of pH in Treating Water For Thermal Recovery Programs.
Producers Monthly, v. 29, No. 6, June 1965, p. 4.
Crawford, P. B. Water Deionization for Steam Injection. Producers Monthly, v. 28, No. 10,
October 1964, pp. 21-22.
Crawford, P. B. Silica Removal in Thermal Recovery Water Treatment Programs. Producers
Monthly, v. 29, No. 5, May 1965, p. 2
Crawford, P. B. Catalyzed Sodium Sulfite For Oxygen Removal From Injection Water.
Producers Monthly, v. 30, No. 1, January 1966, pp. 12-13.
Crawford, P. B. Water Deaeration With Steam Ejectors. Producers Monthly, v. 25, No. 8,
August 1961, p. 10.
Gras, E. H. Portable Steam Generating Equipment. Pres. at the 40th Ann. Fall meeting of the
Soc. of Pet. Eng., Denver, CO, Oct. 3-6, 1965. SPE paper 1169.
Kemmer, F. N., Editor. The NALCO Water Treatment Handbook, Chapters 3, 12 and 14.
McGraw Hill Book Company, New York, 1979.
 APPENDIX 5-A
WATER CHEMISTRY
Definition
The purpose of this appendix is to define terms frequently encountered in oilfield water
chemistry. The treatment by necessity is very simplistic, but sufficiently accurate for our
purposes.
Elements are chemical substances which cannot be chemically decomposed to give two or
more simpler substances. Examples of elements of importance in oilfield water chemistry (and
their symbols) include: hydrogen (H), sodium (Na), calcium (Ca), magnesium (Mg), oxygen (0),
and carbon (C).
Elements are made up of matter caIled g o . An atom is the smallest particle of an element
that can enter into a chemical reaction.
An atom is made up of electrons, protons and neutrons. An electron carries a negative
electrical charge and has negligible mass. The proton carries a positive electrical charge and has a
unit mass. The neutron cames no charge and also has unit mass.
The nucleus of an atom is made up of protons and neutrons. Thus, the nucleus is positively
charged. In an atom the electrons move about the nucleus. The positive charges in the nucleus are
balanced by the negatively charged electrons orbiting it. Thus, an atom is electrically neutral.
Since the mass of an electron is negligibly small, for all practical purposes, the mass of an atom is
considered to be the mass of its nucleus. The mass of an atom is equal to the sum of the number of
protons and neutrons in the nucleus.
The number of electrons in an atom is always equal to the number of protons in the atom, but
the number of neutrons in the nucleus of an atom may or may not be the same as the number of
protons in it. When the number of protons and neutrons in an atom are different it is called an
isotope of an element.
For the purpose of this report, the number of protons and neutrons in a nucleus are assumed
to be the same. An exception to this is the nucleus of the hydrogen atom. The nucleus of the
element hydrogen contains one proton and no neutron. Only the electrons in an atom take part in a
chemical reaction.
Atoms are identified by name, atomic number and atomic mass. The atomic number is the
number of electrons moving around the nucleus of an atom. It is also the number of protons in the
nucleus. The mass of an atom is the sum of protons and neutrons in the nucleus. The atom
hydrogen has one electron orbiting about a nucleus made up of one proton and no neutron. Thus,
its atomic number is 1 and its atomic mass is also 1. The nucleus of a calcium atom is composed
of 20 protons and 20 neutrons. Thus, its atomic number is 20 and its atomic mass is 40.
 The atomic wei~htof an element is the ratio of the mass of an element to that of an arbitrary
standard element, the carbon atom. The atomic mass of a carbon atom is 12. Therefore, when we
say that the atomic weight of hydrogen is 1, it actually means that a hydrogen atom weighs 1112 as
much as an atom of carbon.
Molecules and com~ounds:Elements combine to form molecules . For example, an oxygen
molecule is comprised of two oxygen atoms. Molecules made up of a number of different atoms
are called compounds. A compound is formed by chemically combining two or more elements in
definite proportion by weight. It is not possible to identify individual elements in a compound,
unless the compound is chemically separated.
Molecular wei~htis the weight of a single molecule and is equal to the sum of the weights of
its constituent atoms. Molecular weights, like atomic weights are also relative weights. When we
say that the molecular weight of water is 18, we mean that a molecule of water weights 18/12 times
the weight of a carbon atom.
When the molecular weight of a substance is expressed in grams, it is termed as gram
molecular weinht or simply gram-mole or mole.
Ions, Valence and Radicals
As previously stated, an atom has an equal number of electrons and protons and is therefore
electrically neutral. However, if an atom is allowed to gain an electron, it will have net negative
c h a r g ~since the number of protons in the nucleus remains the same. On the other hand, if an
atom loses an electron, it will have a net positive chargc. Thus, whenever an atom loses or gains
an electron, it becomes electrically imbalanced. An electrically imbalanced atom is called an h.
Thus, an iQn is defined as an atom or group of atoms containing an electric charge.
A positively charged ion is called a cation and a negatively charged ion is called an anion.
The amount of charge an ion carries is called a valance. Valance is a measure of an element's
chemical combining power.
A radical is a group of atoms found in certain compounds that react as a unit as if it were a
single atom or ion. For example, if the compound calcium carbonate (CaCO3) were ionized, we
would find the group of atoms CO3 behaves as an ion and carries two negative charges. Thus, the
anion ~ 0is called ~ a radical.
~ -
uivalent wei~htof an element is given by:
Equivalent weight = Atomic weight
Valance
For a radical
Equivalent weight = Molecular wei.gg
Valance
 The elements and radicals present in water combine with each other on an equivalent basis to
form a salt. For example, one equivalent weight of Na+ combines with one equivalent weight of
S O 4 to form the salt sodium sulfate Na2S04.

A pH of solvent such as water is the measure of its acidity or alkalinity. A pure water
molecule dissociates itself into hydrogen ions (
H') and hydroxyl ions (OH-) according to the
equation
H 2 0 w H+ + OH-
The extent to which water dissociates is given by the dissociation constant k. The dissociation
constant is defined as the product of the number of hydrogen and hydroxyl ions present in one liter
of water. Thus,

Thus, there are 10-7 moles of H+ ions present in 1 liter of water. Since this is such a small
number, it is more convenient to express the hydrogen ion concentration in terms of a logarithmic
function. This expression is called a pH and defined as

pH = log [ l =]- log [Hi]

H+
Thus, pH is a measure of the hydrogen ion concentration of a solution and is a number between 0
and 14. A solution is said to be acidic if its pH is less than 7 and basic if its pH is greater than 7.
A pH of 7 indicates neutrality. The pH is measured using a pH meter.
Since pH is a logarithmic function, a solution having a pH of 6.0 is 10 times more acidic than
one with a pH of 7.0. Similarly, a solution having a pH of 8.0 is 10 times more alkaline than one
with a pH of 7.0.
Water Analysis
Water Analpis is merely a listing of the concentration of various chemical species present in
the water. The results of the water analysis are expressed in several ways. Some of the more
common ways of reporting water analysis include: parts per million (pprn); milligram per liter
(mglL), milliequivalent per liter (meq/L), and ppm as CaCO3. These are defined as follows:
Parts m r million (ppm) means one part in a million part, for example, 1 gram in a million
grams of water, or 1 pound in a million pounds of water.
Millieram per liter (mg/L) expresses the weight of an ion or radical in 1 liter of water. For
fairly fresh water, 1m a is approximately equal to 1 ppm. In water analysis, the units mg/L and
ppm are often used interchangeably.
 Millieouivalents per liter (meq/L) - Some laboratories report water analysis results in
milliequivalent per liter:
m e q L of an ion = mg/L t equivalent weight of the ion

PPM as CaCO3
Steamflood water analysis reports are frequently expressed in this unit. When the
concentration of a species is expressed in ppm as CaCO3, it means that the concentration of the ion
(or radical) is given as though it were calcium carbonate (CaC03). For example, ppm Mg++
expressed as CaC03 is given by
equivalent weight of CaC03
pprn Mg* as CaC03 = pprn Mg++ X
equivalent weight of Mgu
 APPENDIX 5-B
OILFIELD STEAM GENERATOR WATER QUALITY REQUIREMENTS

INTRODUCTION
Oilfield steam generator water quality requirements are much more stringent than those
required for the conventional power boilers. Poor quality feedwater can result in steam generator
tube failure. The following discussion is directed toward how specific impurities can affect steam
generator performance.
Total Hardness 6- '7
Hardness is a measure of the amount of calcium and magnesium salts contained in water.
The salts of calcium and magnesium are the most common source of scale in steam generator tubes
because the solubility of many calcium and magnesium salts in water decreases with increases in
temperature. Probably the most common source of scale is a breakdown of calcium bicarbonate
with heat to form calcium carbonate, illustrated as:
calcium bicarbonate + Heat + calcium carbonate + water + carbon dioxide
Other calcium salts that may deposit are calcium sulfate and calcium silicate. The most common
magnesium salts expected to scale are magnesium hydroxide and magnesium silicate.
Since the solubilities of these scale-forming salts are so low at tube wall temperatures, they
tend to precipitate at tube walls and plug the tubes. This results in reduced heat transfer and flow
through the tube causing hot spots to develop. Hot spots result in localized overheating and
subsequent tube rupture. The breakdown of bicarbonates also releases carbon dioxide which can
react with steam condensate to form carbonic acid and cause metal corrosion and tube failure.
The most trouble-free steam generator operation is achieved by maintaining boiler feedwater
hardness to near zero level. This is critical because, at typical steamflood operations temperatures
of 400" to 600' F, the solubility of calcium carbonate in distilled water is from 4 to 7 ppm. At 70%
steam quality, the hardness would be concentrated three and one-third times. At 80% steam
quality, there will be a fivefold concentration, and at 90% a tenfold concentration. Thus,
theoretically the solubility of calcium carbonate in 80% steam ranges between 0.8 and 1.4 ppm,
and at 90% the solubility reduces to 0.4 to 0.7 ppm. Obviously, the higher the steam quality
desired, the more carefully must feedwater hardness be controlled. Operating a steam generator
with hardness values exceeding these limits for as little as 5 hours can result in tube scaling.
Therefore, it is important to monitor the feedwater hardness level continuously to detect any
hardness leakage. Since the solubility limits given above vary according to the chemical
composition of the feedwater, each feedwater must be analyzed to determine what hardness level is
tolerable for a given steam quality .
 By far, the most common method of removing hardness for steam generation is through
sodium cation exchange. In the ion exchange method, all of the objectionable calcium and
magnesium ions in the feedwater are replaced by nonobjectionable sodium ions. The sodium salts
are highly soluble in water and contribute to the total dissolved solids (TDS) content of the
feedwater.
Total Dissolved Solids (TDS)
The TDS content of feedwater becomes a cause for concern only when their level is
extremely high. California steam injection operators have satisfactorily utilized feedwater
containing 6,000 ppm of TDS in steam generators without any problem. The practical limitation
on TDS generally comes as a result of water softener operating limitations. The resins used in most
oilfield water softeners Limit the feedwater TDS to about 7,000 ppm. However, newer resins
permit TDS levels up to 30,000 ppm, but their operating costs are several times that of the older
resins.
However, the operator should ensure that the TDS content of the feedwater does not exceed
their solubility limits in the liquid phase. Therefore, a generator producing 80% quality steam
should be able to tolerate feedwater salts in concentrations approaching 20% of their solubility
limits.1
Alkalinity
In feedwater, alkalinity may exist in several forms-carbonate, bicarbonate, and hydroxide.
Silicate, borate, and phosphate ions are also sometimes classed as alkaline. In natural water, the
bulk of alkalinity is usually carbonate and bicarbonate. Under the influence of heat, the alkaline
water in a steam generator decomposes to form carbonate and hydroxides, as illustrated by

2HCOy+Heat -t c@- + COz + H20

Bicarbonate carbonate carbon water
dioxide

+ H20
~032- + Heat + 20H' + CO*
hydroxide
The carbonates and hydroxides will combine with hardness and other divalent ions to form scale
deposits. However, since the ion exchange system removes all hardness, scale formation will not
be a problem.
With pressures above 600 psi, a feedwater containing 2,000 ppm of sodium bicarbonate
could theoretically form nearly 5,000 ppm of sodium hydroxide in the water phase of 808 quality
steam, and corrosion or caustic embrittlement of tubes would be likely. However, for this to
occur, the following three conditions must exist at the same time?
 (1) Metal must be under stress;
(2) generator water must contain hydroxide; and
(3) there must be a crevice, seam, etc. permitting the generator water solids to concentrate
on the stressed metal.
Since the presence of all of these three conditions at the same time is unlikely, high alkalinity of the
feedwater is of little concern. However, as a matter of precaution, feedwater containing greater
than 2,000 ppm alkalinity should be avoided.
Moderate levels of hydroxide alkalinity in feedwater; however, are beneficial because they
tend to keep silica in solution and reduce corrosion. Further, the free C02 formed during the
decomposition of bicarbonates and carbonates dissolves in the unvaporized water and forms
carbonic acid. However, since this carbonic acid is neutralized by the sodium hydroxide present in
water, condensate corrosion is unlikely. In light of the above factors, alkalinity less than 2,000
ppm need not be treated.
Suspended Solids
Common suspended solids found in an oilfield water include mud, silts, and corrosive
products. The presence of these materials can cause plugging and fouling of steam generator
tubes, water treating plants and injection wells. In most field operations, filtration is all that is
required to control suspended solid buildup. Suspended solid levels in the feedwater should be
maintained below 5 ppm and preferably below 1 ppm.2
Oxygen
Dissolved oxygen can exist in surface waters as a result of contact with the atmosphere and in
subsurface waters as a result of equipment suction leaks as well as pulling a vacuum on a well
because of falling water levels. Dissolved oxygen can be extremely corrosive in steam generators.
Field experience shows that even a small amount of oxygen (less than 1 pprn) can cause
nonuniform pitting.3 Therefore, as for hardness, the dissolved oxygen content of the feedwater
must be reduced to zerQ.
Since improper handling of an initially oxygen-free water source can result in aerated water,
monitors should be utilized to detect oxygen leakage. To minimize the treatment necessary to
remove dissolved oxygen, the operator should take steps to eliminate unnecessary oxygen pickup.
Unnecessary oxygen pickup can be avoided by using packers to seal water wells, gas blanketing
storage tanks as well as water wells, submerging entrance piping to storage tanks and by
maintaining adequate pressure on the suction side of the pumps.3 Oxygen from feedwater can be
removed either by a deaerator andlor by chemical means.
 Sulfides
Sulfide is unacceptable in steam generator feedwater because of the high rate and severe
nature of the corrosion it produces. Sulfides also cause plugging problems upstream of a
generator. The presence of hydrogen sulfide (H2S) in the steam phase could cause corrosion and
perhaps plugging of injection wells because of precipitation. For these reasons, as well as the
hazardous nature of HzS, sulfides should be reduced to nearly zero (less than 0.1 ppm). The
presence of bacteria in many freshwater sources is the cause of H2S in these waters. If the source
of sulfide is indigenous to the water source and another source cannot be located, treatment could
be very expensive and the process quite complex. Hydrogen sulfide is generally reduced with
deaeration, but chemical means such as chlorination have to be used for complete removal. If
chlorination is used, it must be carefully controlled to avoid added corrosion potential and to avoid
oxidizing effects of chlorine on ion exchange resin.

The natural iron content-of feedwater is quite low. Its presence is usually indicative of
corrosion. Feedwater picks up iron either from a gathering system as a result of corrosion of steel
piping or can acquire it through contact with formation minerals. Irrespective of its origin, the
presence of iron in feedwater is troublesome and should be kept below 0.05 ppm.
Iron may exist in solution as a ferric ( ~ e + + +or
) ferrous ( ~ e + +ion.
) Depending upon the
form in which it exists, iron in feedwater can cause difficulties in the ion exchange process by
fouling the resin bed or can form scale deposits in the generator tubes. To prevent scale deposits in
steam generator tubes, the iron content of feedwater should be kept below 0.05 ppm. The ion
exchange systems are extremely efficient in lowering the feedwater iron content to this level. Both
the ~ e + +and ~ e + + +ions are removed by the resin in a manner analogous to calcium and
magnesium ions. The ferrous ions can be removed from the resin bed by backwash. However,
the ferric ion fouls the resin bed by forming a gelatinous precipitate on or in the resin. This results
in capacity loss and makes the unit difficult to backwash. Special backwash and regeneration
techniques must be employed to restore the exchange capacity of the bed. These techniques are
expensive and increase water treatment costs?
The ferric ion is formed by the oxidation of ferrous ion. Hence, iron should be kept in the
reduced form (ferrous form) as water is being softened. Oxidation of ferrous ion can be avoided
by removing dissolved oxygen with a reducing agent (such as an excess amount of sodium sulfite)
upstream of the resin bed. This will act to reduce the ferric ion to ferrous ion and, thus, keep the
resin unfouled. The reducing agent should be added to the water before caustic is added for pH
control. After the iron has been removed, it is highly desirable to avoid iron pickup in long
pipelines between a softener and a steam generator. One way of accomplishing this would be to
keep residual sodium sulfite in the water to avoid oxygen contamination and iron pickup. Another
method of avoiding iron pickup is to use plastic pipes or inteimally plastic coated pipes.

oil4
The presence of free oil in feedwater can result in the formation of hard asphaltic scales on
steam generator tube walls. Deposition of scale reduces heat transfer and causes tubes to fail
through formation of localized hot spots on tube walls. Oil is especially troublesome in the fouling
of ion exchange resins. From the viewpoint of the resin bed, the oil content should be reduced to
zero ppm. Coarse media filtration can remove oil up to 50 ppm. Above this limit, pretreatment by
induced clarification, air flotation, and diatomaceous earth filtration may be required.

pH5
The pH of feedwater plays a very important role in thermal recovery operations. The
solubility of many common ions vates greatly with the pH of water. The concentration of calcium
ion in water goes through a minimum at a pH of 9 to 10. Above a pH of 10, the concentration of
calcium ion in water increases rapidly due to the formation of soluble calcium hydroxide. The
concentration of magnesium ion in water decreases wpidly with increase in pH and approaches
zero at a pH of around 10.6. The solubility of iron in water also decreases with increase in pH and
approaches zero at a pH of 9. Thus, at a pH of approximately 10, both magnesium and iron ions
would precipitate out. Since calcium, magnesium, and iron ions are the most troublesome
impurities in feedwater, problems resulting from these ions can be minimized by assuring that the
steam generator feedwater is slightly alkaline.
Field experience indicates satisfactory operations can be obtained by maintaining the pH of
feedwater between 9 and 11. This alkaline environment also keeps silica dissolved and reduces the
corrosion of steel. However, higher operation pressure will lower the optimum operating range to
between 10 to 10.5. The pH control is usually done by adding sodium hydroxide (NaOH) into the
water systems at some point between the softener and feedwater injection pump. This is done to
prevent the neutralizing of oxygen scavengers which may have also been added.

Silica6
Silica is present in most water supplies and is s much greater problem in power boilers than
in oilfield steam generation systems. Silica is tsoublesome in oilfield steam generators because of
its scaling tendency. Silica can produce scaling, both directly and as a constituent of complex
mineral scales. However, formation of complex scales requires the presence of metal ions such as
iron, calcium, and magnesium. Elimination of these ions will effectively prevent the formation of
complex silicate scales.
 Control of silica problems in steam generator systems consists primarily of maintaining silica
solubility. Silica solubility is a function of temperature, alkalinity, and concentration of other ions
with which silica forms complex scales. By maintaining the hardness of the feedwater near zero
level and pH around 11, silica can be kept in solution. Satisfactory operations have been
maintained with silica content of as much as 150 ppm. Steam generated by the system must
contain enough liquid to prevent silica from precipitating. Tolerable limits of silica in feedwater
vary from 100 ppm at pressures to 50 psi to 50 pprn at pressures up to 1,500 psi. It is
recommended that the silica concentration in feedwater be maintained around 40 ppm.
Suspended or colloidal silica can be effectively eliminated by a coagulation process. Soluble
silica can be removed by a strong base anion exchange to almost any level. Since silica content of
fresh water is much less than the tolerable limit, no silica removal is required. However, it is
suggested that before any equipment expenditures are made for silica removal, a very critical look
at all operating conditions and water analysis data be made to decide if such expenses are justified.

Biological Growths7-8
Feedwater used for steaming operations are usually rich in total dissolved solid content and
are conducive to growth of organic matter. If left untreated, these organic growths can foul and
plug an ion exchange resin bed.
Some of the common bacteria found in oilfield waters include sulfate-reducing bacteria, iron
bacteria, and slime-forming bacteria.
Sulfate-reducing bacteria are anaerobic bacteria. However, they are quite capable of thriving
in oxygenated systems, provided they find some scale to congregate under. These bacteria reduce
sulfate ions in water to sulfide ions and produce H2S as a by product. They cause corrosion, and
the iron sulfide produced as a byproduct of corrosion reaction is an excellent plugging material.
Iron bacteria are aerobic bacteria and grow well even with only trace amounts of oxygen.
Iron bacteria precipitate a sufficient quantity of ferric hydroxide to cause severe plugging problems.
As discussed previously, fenic ions foul ion exchange resins readily and are expensive to remove.
Slime-forming bacteria are aerobic bacteria and produce dense masses of slime on solid
surfaces. They are magnificent pluggers and contribute to corrosion.
One method of controlling aerobic bacteria is to seal and gas blanket water supply wells. The
other and the most common method of controlling bacterial growth in oilfields is by chemical
means. Chlorine is the most widely used inorganic chemical to kill bacteria. Chlorine, however,
attacks only exposed organisms and will not penetrate slime or scale masses which often hide
sulfite-reducing bacteria. There are other biocides (a chemical which kills other forms of life, in
addition to bacteria) available which will control sulfate-reducing bacteria.
 Since chlorine is a very strong oxidizing agent, it will oxidize iron and hydrogen sulfide.
Once it reacts, it is no longer available to kill bacteria. Hence, to determine the total amount of
chlorine needed it is necessary to establish how much chlorine will be used by reaction with other
materials. The amount used by the system is called the chlorine demand. The amount of chlorine
in excess of that required to control bacteria and meet chlorine demand is the excess chlorine. The
excess chlorine concentration in the feedwater must be less than 1 ppm because chlorine can
oxidize ion exchange resins and reduce its effectiveness. Excess chlorine concentration in
feedwater can be reduced to less than 1 ppm by chemical deaeration upstream of an ion exchange
unit.
Other biocides should be chosen with the aid of vendor representatives, since the type needed
will depend on contact time, pH, and temperature of the water treated. These biocides should be of
the nonionic type as others will clog filters and softeners.
Turbidity
The turbidity of water being fed into steam generators should be zero. Softening systems
have a limited ability to filter out turbidity. If the turbidity is high, a separate means must be used
for its reduction. A combination of coagulation, flocculation, and sludge removal is generally
required.

Carbon ~ i o x i d e ~
Although fresh sources of water contain carbon dioxide (COz), its major corrosive effect, as
far as steam generation is concerned, comes from the decomposition of sodium bicarbonate. In
theory, the bicarbonates break down at high temperatures and release carbon dioxide. The C 0 2
then reacts with steam condensate to form carbonic acid and cause of the metal condensate system
to corrode. In a typical oilfield steam generator, the tubes carry both steam and water not flashed
to steam. The water phase is usually highly alkaline due to sodium carbonate and hydroxide in
solution. On the other hand, the steam phase carries free CO;! which redissolves in the condensate
forming carbonic acid. If the velocities in the boiler tubes are high and if there is a lot of turbulence
in the flow stream, then the two phases are intimately mixed, the acid is neutralized by the
alkalinity, and minimal corrosion occurs. However, if the velocity is low, the vapor can condense
without intimate contact with the alkaline water and cause corrosion.
There is much disagreement among operators as to which situation actually occurs. This led
to two different approaches to handle the C02 problem. One group feels that treatment is not
necessary because C02 will eventually be neutralized by the alkaline water. This group, however,
carefully excludes oxygen (which can accelerate CO2 corrosion) from the system and closely
monitors corrosion rates. The other group feels that treatment for CO2 corrosion is necessary.
One method of treatment is to use sodium hydroxide or volatile filming amines (such as
cyclohexylamine) to neutralize C 0 2 as it is formed. The other approach would be to use a
nonvolatile filming mine (such as octadecylamine) which establishes a water insoluble protective
film on metal surfaces and, thus controls corrosion. In either case, the treatment chemical should
be injected into the system immediately downstream of the water softening equipment to protect as
much of the system as possible.
 APPENDIX 5-C
FEEDWATER TREATMENT EQUIPMENT AND CHEMICAL VENDORS

A. P a c h e d Ion Exchange 1Jnit~ 9. Daniel En-Fab Systems Inc.

3905 Jensen Drive
1. LA Water Treatment Corporation P.O. Box 21361
17400 T. E. Chestnut Street Houston, TX 77226-1361
City of Industry, CA 91749 Telephone: (713) 225-4913
Telephone: (818) 912-5411
B . Ion Exchange Resins and Water
2 . Serck Baker Inc. Treatment Chemical Sup~liers
5352 Research Drive
Huntington Beach, CA 92649 1. Betz Labs Inc.
Telephone: (714) 898-3474 4636 Somerton Road
Trevoise, PA 19047
3. Saltech Corporation Telephone: (215) 355-3300
1035Diesel Drive
P.0. Box 26872 2. Nalco Chemical Company, Visco
El Paso, TX 79907 Division
Telephone: (915)592-7982 485 1 Stine Road
Bakersfield, CA 93313
4. Perrnutit Company Telephone: (805) 834-6590
30 Technology Drive
Warren, NJ 07059 3. LA Water Treatment Colpmtion
Telephone: (908) 668- 1700 17400 T.E. Chestnut Street
1-800-631-0878 City of Industry, CA 91749
Telephone: (818) 912-5411
5. Graver Water
2720 U.S. Highway No. 22 4. Rohm and Hass Company
Union, NJ 07083 Independence Mall West
Telephone: (908) 964-2400 Philadelphia, PA 19105
Telephone: 1-800-338-1205
6. Illinois Water Treatment Company
4669 Shepherd Trail 5. Wolcott Water System Inc.
P.O.Box 560 2007 Wolcott Court
Rockford, IL 61105 Columbia, MO 65202
Telephone: (815) 877-3041 Telephone: (314)4-49-0011
l/8OO-325-O 104
7. Culligan Industrial Water Company
119 Paulson 6. Culligan Commercial Industrial
San Antonio, TX 78219 Systems
Telephone: (512) 227-9729 1 Culligan Parkway
Northbrook, IL 60062
8. NATCO
' Telephone: 1-800-451-3260
Division of National Tank Company
P.O.Box 1593 7. Techni Chem Inc.
4550 Pierce Rd. 6853 Indy Drive
Bakersfield, CA 93308 Belvidese, IL 61008
Telephone: (805) 325-4146 Telephone: (805) 547-5900
C. Emulsion Treatment and Corrosion Saltech Corporation
Control Chemicals 1035 Diesel Drive
El Paso, TX 79907
1. Nalco Chemical Company, Visco Telephone: (915) 592-7982
Division
485 1 S h e Road WEMCO
Bakersfield, CA 93313 1796 Tribute Road
Telephone: (805) 834-6590 P.O.Box 15619
Sacramento, CA 95852
2. Petrolite Corporation Telephone: (916) 929-9363
Chemical Group
16010 Barker's Point Lane Graver Water
Suite 600 2720 U.S. Highway No. 22
Houston, TX 77079 Union, NJ 07083
Telephone: (7 13) 558-5200 Telephone: (908) 668- 1700
3. Champion Chemicals Inc. Daniel En-Fab Systems Inc.
Oilfield Chemicals Division 3905 Jensen Drive
6321 District Blvd. P.O. Box 21361
Bakersfield, CA 93308 Houston, TX 77226-1361
Telephone: (805) 834-0454 Telephone: (7 13) 225-49 13
4. Champion Chemicals Inc. Permutit Company
Oilfield Chemicals Division 30 Technology Drive
11000 Richmond, Suite 400 Warren, NJ 07059-0920
Houston, TX 77042 Telephone: (908) 668- 1700
Telephone: (7 13) 782-3333 1-800-631-0878
D. Produced Water Reclamation Plant Precoat Filters (Diatomaceous Earth
Filters)
1. Modulur Production Equipment Inc.
P.O.Box 690965 1. LA Water Treatment Corporation
Houston, TX 77269-0965 17400 T. E. Chestnut Street
Telephone: (7 13) 320-8796 City of Industry, CA 91749
Telephone: (818) 9 12-5411
2. Daniel En-Fab Systems Inc.
3905 Jensen Drive 2. Celite Corporation
P.O. Box 21361 P.O.Box 519
Houston, TX 77226- 1361 Lornpoc, CA 93438
Telephone: (7 13) 225-49 13 Telephone: 1-800-654-3103
Other Water Treatment Equipment 3. Liquid-Solid Corporation
185 Le Grand Avenue
E. Pressure and Multimedia Filters P.O. Box 9
North Vale, NJ 07647
1, LA Water Treatment Corporation Telephone: (20 1) 784- 1570
17400 T. E. Chestnut Street
City of Industry, CA 91749 Chemical Feed Svstem
Telephone: (8 18) 9 12-5411
1. Saltech Corporation
2. Serck Baker Inc. 1035 Diesel Drive
5352 Research Drive El Paso, TX 79907
Huntington Beach, CA 92649 Telephone: (915) 592-7982
Telephone: (7 14) 898-3474
 2. Pennutit Company 2. ACS Environmental
30 Technology Drive 303 Silver Spring Road
Warren, NJ 07059 Conroe, TX 77303
Telephone: (908) 668-1700 Telephone: (409) 856-4515
1-800-631-0878
3 . AFL Industries Inc.
3. Graver Water 366 1-B West Blue Heron Blvd.
2720 U.S. Highway No. 22 Riviera Beach, J?L 33404
Union, NJ 07083 Telephone: (407) 844-5200
Telephone: (908) 964-2400
J. Dissolved and Induced Gas Flotation
4. Daniel En-Fab Systems Inc. Cells
3905 Jensen Drive
P.O. Box 21361 WEMCO
Houston, TX 77226- 1361 P.O. Box 15619
Telephone: (7 13) 225-49 13 1796 Tribute Road
Sacramento, CA 95852
H . Clarifier. haerators Telephone: (916) 929-9363
(Mechanical, Vacuum, Steam)
Modulur Production Equipment Inc.
1. Permutit Company P.O.Box 690965
30 Technology Drive Houston, TX 77269-0965
Warren, NJ 07059 Telephone: (713) 320-8796
Telephone: (908) 668- 1700
1-800-631-0878 Serck Baker Inc.
5352 Research Drive
2. Graver Water Huntington Beach, CA 92649
2720 U.S. Highway No. 22 Telephone: (714) 898-3474
Union, NJ 07083
Telephone: (908) 964-2400 Permutit Company
30-T Technology Drive
3. LA Water Treatment Corporation Warren, NJ 07059
17400 T. E. Chestnut Street Telephone: (908) 668- 1700
City of Industry, CA 91749 1-800-631-0878
Telephone: (818) 912-5411
K . Water Treatment Plant Controls
4. Sivalls Inc. (Multi Port Valves, Hardness
P.O.2792 Monitors,Oxygen Monitor, etc.)
Odessa, TX 79760
Telephone: (9 15) 337-3571 1. Saltech Corporation
1035 Diesel Drive
5. Daniel En-Fab Systems Inc. El Paso, TX 79907
3905 Jensen Drive Telephone: (915) 592-7982
P.O. Box 21361
Houston, TX 77226- 1361 2. Permutit Company
Telephone: (7 13) 225-4913 30 Technology Drive
Warren, NJ 07059
I, Oil-Water Separator. Skimmers, Telephone: (908) 668- 1700
Hvdrocvloncs. etc, 1-800-631-0878
1. Modulur Production Equipment Inc.
P.O. Box 690965
Houston, TX 77269-0965
Telephone: (7 13) 320-8796
L. Diat0maceous Earth and Filter Aids
Suppliers
1. Universal Diatoms Inc.
1024, 1st Street N.W.
Albuquerque, NM 87107
Telephone: (505) 247-3999
2. Celite Corporation
P.0. Box 519
Lompoc, CA 93438
103
Telephone: 1-800-654-3
M. md Water Treatment Plants Supplier
1. Virgles Steam Service
Renfro Road
Bakersfield, CA 933 12
Telephone: (805) 589-2597
 CHAPTER 6
STEAM GENERATION

INTRODUCTION
Steam for thermal recovery is usually generated in direct-fired, forced-circulation, once-
through generators. Since a typical steam injection operation requires large quantities of steam for
continuous injection, the cost of treating the feedwater for steam generation must be kept low. The
once-through design permits the use of low quality feedwater that is essentially free of hardness
and suspended solids, but of relatively high level of total dissolved solids (TDS). Oilfield steam
generators are usually rated in millions of BTU s per hour of heat output. Some manufacturers also
rate them in terms of pounds per hour of steam output, or in terms of boiler horsepower.
Typical oilfield steam generators range in size fsom 10 to 180 million BTUlhr (MM BTU/hr)
heat output. The smaller size generators are generally used in pilot projects and in steam soak
applications, whereas the larger units are used in continuous steam injection operations. In fact,
the 50 MM BTUhr unit has become the industry standard for steamflood applications. While all
oilfield steam generators are offered as skid-mounted units. smaller units (up to 40 MM BTU/hr)
are also offered as fully self-contained trailer-mounted units. The size of a fully-assembled skid-
mounted 50 MM BTU/hr unit is about 11 ft by 80 ft and its weight ranges from 170,000 to
230,000 pounds.2?19 The 50 MM BTUlhr unit is the largest skid-mounted unit that can be
transported easily by rail to an oil lease. A list of steam generator vendors is included in Appendix
6-F.
General Features of Oil Field Steam Generators
The oillield steam generator, also known as the wet steam generator, thermal recovery heater,
oil field heater, etc., differs from conventional power boilers, in that is specifically designed to
produce low quality steam from saline feedwater with minimum tseatment. Oilfield steam
generators can handle zero hardness feedwater containing up to 6,000 ppm TDS an3 generate up to
80% quality steam. The cap on the quality is set to prevent the precipitation and deposition of
dissolved solids on the boiler tubes.
Basically, in a generator of this type, water enters one end of a heated tube and leaves the
other end as wet steam. This type of construction permits a great deal of flexibility in operation,
allows quick response to load changes, and does not require constant supervision. Further, since
the water storage capacity of the generator is small, only a small amount of steam-water mixture is
released if the heating coil fails. Thus, these units are safe to operate under continuous operating
conditions. However, in order to respond to quickly to changing load conditions, it is important to
control precisely the rate of flow of water through the tube. the fuel injection rate, and the air flow.
Figure 6.1 is an isometric view of a skid-mounted oiltleld steam generator showing the major
 CONVECTION SECTION

RADIANT SECTION

FEED WATER
HEAT EXCHANGER

ELECTRiC FUEL OIL HEAT EXCHANGER

FUEL OIL STEAM/WATER HEAT EXCHANG

COMBUSTION AIR BLOWER

FIGURE 6.1. - Iosmetric view of a skid-mounted oilfield steam generator.'

cornpo nts on the supporting skid.1 The generator is fully self-contained and equipped with
necessary controls and instrumentation to monitor operating pressures, flows, temperatures, etc.
The standard oilfieid steam generator flow c h a t is shown in figure 6.2.
A self-contained unit is ready for operation, and the only field work required to prepare a
generator for operation after transportation consists of connecting unit's discharge pipe to the well,
connecting feedwater to pump, connecting electrical power. and connecting fuel supply to the
generator.
 WATER I SEPARATOR

DOUBLE-PIPE
A1R

BURNER
ASSEMBLY

FUEL

FIGURE 6.2. - Schematic of oilfield steam generator.

Generator Selection
Generator capacity must be carefully chosen for each application to avoid idle steam capacity.
Oilfield steam generators are available with pressure ratings of 1,000, 1,500 and 2,500 psig, based
on coil pressure capability. They come in a range of standard sizes from 10 to 150 MM BTU/hr
heat output (approximately equivalent to 650 to 9,864 bbl of water (as steam) per day) and are
designed to burn both gas and oil.
Steam rates in the United States are normally reported in barrels of steam per day (BSPD)
regardless of steam pressure or quality. This is also the 'cold water equivalent' (CWE) rate. The
CWE rate is much smaller than the actual volumetric rate for wet steam and is equivalent to the
mass flow rate. The term BSPD originates from the early day steam injection practice when the
generator feedwater meter indicator was calibrated in barrels and it was the most convenient place
to measure the amount of steam injection.
Table 6.1 is a generator selection chart provided by one manufacture? Table 6.2 presents the
capacities and fuel requirements for these units. The electlical requirements for selected units are
depicted in table 6.3. The capacity and fuel requirements in these tables are based on feedwater
temperature of 100' F and 80% quality steam at 1,000 psig. The approximate steam generator
 TABLE 6.1. - Oilfield Steam Generator Selection chart2

Size
of the
unit BTU x lo6 r>wncl\. Ikirrcls Barrels
boiler, hp. per hour per hour per hour per day

a Feedwater Temperature = 100° F.

Steam Pressure = 1,000 psig.
Generator Efficiency = 90%.

TABLE 6.2. - Oilfield Steam Generator Fuel ~equirements2

Size Fuel oila.b.c
o f the I0 BTUfGAL
unit Gallons Barrels
D ner hour mr dav

314 79 44.8

553 141 80.6

657 172 98.5

747 196 112.0

8% 235 134.4

1,195 314 179.1

1,494 392 223.9

2,100 549 3 13.5

3,000 784 447.8

4,500 1,176 67 1.8

a Feedwater Temperature = 100"F.

Steam Pressure = 1,000psig.
Generator Efficiency = 90%.
 TABLE 6.3. - Oilfieid Steam Generator Electrical ~equirements,lkw

Size
of the
unit
Oil fired, psi
I Gas fired, psi

boiler, hp

480V.3-phase, 60 cycles with 110 V control circuit.

output in pounds of water evaporated per hour for other operating pressures, steam quality, and
feedwater temperatures is shown in figure 6.3. The approximate fuel cost for operating various
capacity generators by burning 10' to 20' API California crudes is shown in figure 6.4. This
figure is based on Table 6.2 and can be used to estimate approximate fuel cost for the generation of
steam. In figure 6.5, the cost of steam generation by burning natural gas (1,000 Btdscf) is
depicted.
ACTUAL EVAPORATION-LBS./HRS./B.H.P.
26 30 34 38 42 46 50 54 58 62 66

2400 2000 1600 1200 800 400

OPERATING PRESSURE-PSIG

FIGURE 6.3. - Approximate steam generator output (lb/hr/bhp) at various pressures, steam
quality and feedwater temperature.
 I I 1
70 mm BTUIH
-

30 mm BTUIH
- 25 m m BTU/H

- 22 mm BTU/HR
18 mm 8TU/HR

0 10 20 30 40
CRUDE OIL PRICE, $/BBL

FIGURE 6.4. - Daily fuel (lease crude) cost for operating various capactiy generators.

0 1 2 3 4 5 6
NATURAL GAS PRICE, $/MCF

FIGURE 6.5. - Daily fuel (natural gas) costs for operating various capacity steam generators.
 Figure 6.3 assumes steam generator efficiency as 908. The following procedure is
employed to graphically determine the steam generator capacity from Fig. 6.3. To determine the
capacity of a 50 MM Btulhr generator delivering 80% quality steam at 1,500 psig (feedwater
temperature assumed to be 100' F), enters the chart at 1,500 psi and proceeds vertically to 80%
quality line. Then proceeds horizontally to locate the 100' F feedwater temperature line and then
goes vertically to read off the evaporation capacity as 33 lb/hr/bhp. From Table 6.1, the boiler
horsepower corresponding to a 50 MM Btu/hr generator is 1,494 and hence generator output in
lbs/hr is approximately 49,300 lb (= 33 x 1,494) per hour.
Since the steam requirements for thermal operation are not unifo~mand vary with time, it is
important to size steam generators properly, especially for small projects. It is important to bear in
mind that in any operation there will be downtime for maintenance, and it is unlikely that all
injectors will be in service at any given time. Hence, to avoid idle stem capacity, selection should
be based on maximum expected steam injection rate per injector and the number of injectors
expected to be in service at any given time. A minimal size generator that fulfills this requirement
with some spare capacity to meet unexpected demands should be specified. Selection based on the
steam requirements to start an entire project at one time should be avoided. Further, in small
projects where steam requirements are small, consideration should always be given to having two
or more smaller units instead of one large unit. This permits more flexibility in operation as steam
demands change by bringing in or removing from service one or more units. This strategy also
ensures that at least some steam is available all the time, in the event of failure of one or more units.
In steam stimulation projects, excess steam capacity can be avoided by steaming the wells in
rotation. For example, consider a steam soak operation involving 20 wells to be steamed at the rate
of 3,200 barrels of equivalent steam per cycle, two cycles per year. Also, assume that the duration
of each injection cycle is 3 weeks. If all of the wells are to be steamed simultaneously, this
operation will need about 3,050 barrels of steam per day. From table 6.1, to satisfy this
requirement, the operator must specify a 50 MM B t u h unit. On the other hand, if only 5 wells are
to be steamed at a time, the maximum steam requirement reduces to 763 barrels of steam per day,
and*smaller18 MM Btulhr unit would be sufficient to meet the peak demand with ample spare,
capacity. Such a generator is also small enough to be trailer-mounted and can be moved from well
to well; thus, minimizing heat losses in distribution lines. Another advantage of adopting a
staggering steaming policy in steam soak operations is that the production decline from the wells
steamed fist is offset by the production rise from wells steamed lates.
In large steamflood operations, due to continuous steam injection requirements, steam
demand is large and several steam generators are employed. Since steam requirements decrease
with time as injected steam reaches producers, steam demand fluctuates, and the operator must bear
this in mind while sizing steam generiting capacity. Choice of steam generator size should be
based primarily on the overall expected oil-steam ratio? As noted previously, generators should
not be sized based on total project steam requirement, but should be based on the desired steam
injection rate per injector and the number of injectors to be used at any one time. For this reason, it
is preferable in steamflood operations to undersize steam generation capacity relative to total project
requirement. Also, it is preferable to have a few standby portable units to take care of any
unexpected surge in demand or to provide steam to peripheral wells that are too far away from the
main unit.

Design Requirements For Oilfield Steam Generators2

A well-designed oilfield steam generator must meet the following minimum criteria:

Must handle zero hardness feedwater containing an appreciable amount of TDS without
significant scale deposit on the tubes.

Must operate largely unattended with a minimum of operator attention.

Must lend itself to outdoor installation with minimum of weather protection required in
the more severe climates.

Must be readily portable for ease in relocation at other sites.

Must have the ability to operate over a wide range of thermal efficiency.

Must operate efficiently over a wide steam pressure range up to the design pressure.

Must have the ability to deliver steam of any desired quality.

Steam Generator Com~onents
A standard oilfield steam generator has the following basic components:
1. Feedwater System
The feedwater system of a single-pass steam generator consists of positive displacement
pumps, a bypass system, and controls to record and regulate the flow of water to the
generator. The positive displacement pump boosts the water from the softener operating
pressure to the pressure required by the steam distribution system.
2. Feedwater Preheater
Feedwater preheaters are usually a double pipe heat exchanger, whose function is to
preheat the incoming feedwater using the hot effluent from the convection section. The
purpose of preheating is to elevate the inlet feedwater to a temperature slightly above the
 predicted flue gas dewpoint temperature, thus eliminating the condensation of acid gas
components of the flue gas.
3. Fuel System
Modern oilfield steam generators are designed to burn different fuels including natural
gas, fuel oil, lease crude, compressed natural gas (CNG), etc. The lease crude (fuel oil)
fuel system normally includes fuel oil strainer, steam-fuel oil heat exchanger, electric oil
heater, fuel oil temperature controller, pressure regulators. bypass system, air and steam
atomizing systems, burner assembly, and safety shut-off valves.
4. Combustion Air System
The combustion air system provides the air needed for the combustion and includes a
high-pressure, forced draft-type air blower and associated controls to regulate the
discharge of the blower.
5 . Convection Section
Flue gas exiting the radiant section contains a large amount of heat. The purpose of the
convection section is to capture the bulk of this heat and thereby improve the thermal efficiency of
the generator. The convection section is essentially a heat exchanger designed to transfer the heat
from the flue gases to the feedwater.
The convection section is made of two parts: the lower base tube section and the upper
finned tube section. The preheated feedwater enters the convection section at the top through the
finned tubes and travels to the bottom section. The hot flue gases from the radiant section enter the
convection section at the bottom and leaves from the top. This countercurrent flow results in
efficient heat transfer from the hot gases to the water. Since the bare tubes are the first to be
exposed to hot flue gases, they are subjected to thermal shock and hence known as the shock
tubes.
Typically, in a 50 MM BTUlhr unit, there are six to ten rows of shock tubes. In each row
there are 12 tubes, each 12 ft long. The principal function of the shock tube is to reduce the flue
gas temperature and to shield the finned tubes from exposure to direct radiant heat. Usually there
are six to ten rows of finned tubes in the upper section. In each row, there are nine tubes located
on 6-in. centers.
In oil burning units, the convection sections are equipped with removable side panels to
facilitate cleaning of the soot that accumulates. A drain is usually located at the bottom of the
transition zone (a zone where the bare tube is replaced by finned tube) to drain away wash water
from the desooting operation. The tubing arrangements in a typical convection section are shown
in figure 6.6.
 FLUE GAS TO
ATMOSPHERE

REFRACTORY
BAFRES TO
/ MINIMIZE
FLUE GAS
BY PASSING

REFRACTORY
LINING \

/ 9-ROWS
FINNED
STEEL TUBES
CASING

FLUE GAS FROM 3-ROWS OF BARE

RADIANT SECTION SHOCK TUBES

FIGURE 6.6. - Tubing arrangements in the steam generator flue gas convection section?

6.Radiant Section
The radiation section is comprised of a cylindrical1y shaped combustion chamber housing the
radiant section tubes, tube hanger support systems and the burner assembly. The dimensions of a
50 MM BTU/hr unit radiant section as provided by one manufacturer is 11 ft in diameter and 40 ft
long. The tubes within the radiant section are 3 in. in diameter and are held in place by primary
hangers in the endplate and by three or four rows of secondary hangers attached to the curved wall.
Depending on the outlet pressure ratings, schedule 40,80, or 160 pipes are used. These tubes are
arranged in rows and travel the length of the generator. In most cases, they penetrate the two ends
of the radiant section. The burner is located in the center of one flat end. On the other end, the
transition section connects the radiant section to the convection section. The radiant section shell
wall is lined with light-weight refractory bricks to protect it from the high-temperature corrosive
combustion gases. The type of refractory used depends upon the nature of fuel burned and the
environment.
Steam Generator Controls
Controls and instruments are integral parts of a steam generator that ensure its safe operation.
These include pressure relief and safety valves, alarms of various types, such as a high and low
steam discharge pressure alarms, low and high steam discharge temperature alarm, flame failure
alarm, low fuel oil pressure alarm, low burner blower pressure alarm, low fuel oil temperature
alarm, low feedwater flow alarm, high tube wall temperature alarm, and low and high atomizing
pressure alarm. These temperature, pressure, and flow monitoring devices are designed to ensure
safe operation of a generator and to keep steam generator failure to a minimum. In addition,
controls to monitor steam quality, exhaust stack oxygen content, combustion air dampers, etc. are
also provided.
Process Description
Figure 6.7 is a typical oilfield steam generator layout showing the feedwater system, fuel-
combustion air system, and associated controls and instrurnentati~n.~~
The feedwater system of a single-pass steam generator consists of a triplex or quintaplex
positive displacement pump and a bypass system to control water flow rate and to proportion the
water flow rate with fuel input. The positive displacement pump boosts the water from the
softener operating pressure to the pressure required by the steam distribution system. The bypass
loop around the pump connects the pump discharge with pump suction. A motor valve on this line
controls the fraction of total pump discharge to be routed back to pilmp suction, and thereby
controls the feed rate to the steam generator. The orifice in the feedwater line measures the flow
and is connected to a differential pressure cell that supplies the control signal for the f i n g rate. In
this way, the fuel injection rate and air flow are adjusted to correspond with water flow rate.
The feedwater under pressure is first forced through a feedwater preheater. The preheater is
a double pipe heat exchanger where the feedwater is heated to about 260' F by water on its way
from the convection section to radiant section. Preheating the feedwater assures that the outside
tube temperature in the convection remains above the dewpoint temperature of the sulfur trioxide
andlor sulfur dioxide in the flue gases. Condensation of these gases along with the moisture in the
flue gas will result in the formation of corrosive sulfuric acid and leads to rapid corrosion of
convection section tubes and fins.
The dewpoint temperature of the flue gas and, therefore, the required feedwater preheat
temperature, is a function of the sulfur content of the fuel burned in the generator. In general, a
low-gravity, high-sulfur-content crude will have a high dewpoint temperature; thus requiring
higher feedwater preheat temperature.
 FEED PUMP a BURNER A U R ~ ~ S
(FIRSTOUT INDICATION TYPE)
W. FUK;IK)WS NMUTOD AT OPERATORSW-E
1 LOWPMSHRE
2 44- WESURE
3.LO# SEAM MSCl44ROETDIPERATURE
4 STEAM OlSCCuRGE TWPERITUW
5. LOWWATER ROW
6 LOYY FEEOWATER RMPOL P R W R E
7 LOW -1RVUWT U R P R E S U R
E HIGH W M E R THRC*TTWPETUTME

FIGURE 6.7. - Layout of a typical oilfield steam generator burning lease crude. l9

The preheated feedwater enters the top of the convection section and flows downward and
countercurrently to the hot flue gases from the radiant section. The 1,600° F hot flue gases from
the radiant section enter the convection section at the bottom and contact the lower, most-bare tubes
of the convection section. These bare tubes are chosen to withstand the hot flue gas temperatures
and are located 4.5 in. apart. The flue gas, after losing pan of its heat to the bare tube, then
contacts a series of finned tubes at the upper section at a reduced temperature. The flue gas then
exits the top of the convection section at a temperature of 300' to 600' F.
The finned tubes, which increase the heat transfer rate between the feedwater and flue gas,
cannot be used in the bottom section because of increased con-osion at the high temperature. The
transition between finned tubes and bare tubes is carefully chosen to ensure that the maximum
permitted fin tip temperatures are not exceeded. Since burning of lease crude results in an
accumulation of soot in the convection section heat transfer suifaces, operation of the generator at
optimum performance will require regular cleaning of the convection section tube surfaces. The
cleaning cycle varies from 3 weeks to 3 months, depending on the fuel oil.
After supplying the heat requirements of the feedwater preheater, and usually the heat needed
to preheat the fuel oil, the effluent from the convection section enters the radiant section of the
steam generator. The tubes within the radiant section are heated by direct radiation from the
combustion gases and radiation from the refractory lining behind the tubes. The heat transfer
process at work in the radiant section is not simple. To guarantee that the correct heat flux is
delivered to the tubes, manufacturers use sophisticated computer programs to calculate tube
spacing and tube placement from the refractory wall. Heat flux rates of 20,000 B T U / ~ ~ - fare t*
typical in oilfield steam generators. Failure to model correctly the heat flux rates can result in poor
generator efficiency and premature tube failures.
Design and construction practices, which are common for oilfield steam generators, include
closely spaced tubes to minimize heat absorbed by the sefractory, and reducing tube size to
minimize the heat release in the event of a tube failure. The feedwater leaves the radiant section as
80% quality steam.
Since some formations are susceptible to swelling, it is not possible to inject wet steam into
such reservoirs. For these, the effluent steam and water fsom the generator must be separated and
only dry steam injected. The separated water can be utilized to preheat feedwater.

Fuel System
Although only the fuel oil system is shown in figure 6.7, oilfield steam generators are
designed to bum different fuels, including lease crude, natural gas, liquefied petroleum gas (LPG),
etc. To provide efficient combustion of fuel oil, they must be pumped into the burner, divided into
small droplets and intimately mixed with air before burning. The process of dividing the fuel oil
into small droplets is called atomization.
Steam or compressed air is generally used as the atomizing agent. The atomization takes
place in the burner nozzle. The atomization is accomplished by forcing the crude through the fuel
oil nozzle at sufficient pressure to guarantee a well-dispersed pattern. An atomizing air compressor
and/or an atomizing steam system is used to atomize the fuel. To assure the formation of proper
droplet size and spray pattern shape at the nozzle exit, the oil must enter the nozzle at correct
viscosity. Most nozzles are designed to function correctly at an oil viscosity of 100 to 150 Saybolt
Second Unit (SSU).
A typical 14' API Kern River, CA, crude must be preheated to about 250' F to reach the
proper nozzle viscosity. Hence, oilfields are equipped with a fuel oil preheater to preheat the fuel
oil. Electricity, hot water, or steam is used to preheat fuel oil. In figure 6.7. both electricity and
steam are used to preheat fuel oil. In many leases, produced oil is hot enough to fue a generator.
 Close control of the temperature of the oil pumped to the burner is critical. Close temperature
control is needed to provide oil at constant pressure and viscosity. If the oil were to overheat and
become less viscous, the burner could overfire. If the oil were too cool and become more viscous,
it would be difficult to handle and impossible to atomize and burn. The oil pump and piping
between oil storage tank and steam generator must also be insulated to maintain correct oil
temperature. For proper nozzle operation, the fuel oil must be delivered to the nozzle at the correct
pressure. For a 50 MM BTU/hr generator, the fuel oil must be delivered to the nozzle at 100 psi at
the rate of about 6.5 gpm.
The basic components of a generator fuel system burning lease crude include fuel pressuring
pump, fuel oil heater, atomizing equipment, and heated fuel storage. A fuel oil system supplied by
the generator manufacturer usually includes a bypass system to bypass any fuel in excess of that
required by the nozzle. Gear pumps are often used for fuel oil service. However, the lubricity of
the fuel oil should be considered before specifying the fuel pumping equipment.
When natural gas is used as the fuel in an oilfield steam generator, a separate fuel system is
used. Instead of a fuel nozzle, a pipe ring is used at the transition from the burner throat to the
radiant section. Natural gas is supplied to this ring at approximately 10 inches of water column.
The natural gas is released into the combustion chamber through small nozzles (holes) in the ring,
where they mix with combustion air and burn. The flame pattern of the gas flame is more stable
than the oil flame and hence are more easily controllable. Typical gas fuel requirements for a 50
MM BTUIhr genentor are about 1,000 standard cubic feet per minute (SCFM) of 1,000 BtdSCF
gas.
Combustion Air System
The air needed for the combustion of the fuel is provided by a high-pressure air blower. A
typical 50 MM BTUhr generator burning 6.5 gpm of crude will require approximately 17 SCFM
or 52,280 lblhr of air. This air is not filtered unless the atmosphere is dust laden. Filtering will
entail additional blower horsepower.
The combustion air system includes a forced-draft type air blower and associated controls to
regulate the discharge of the blower. The air blower system must be designed for local operating
conditions. The BTU output of a stem generator at sea level is higher than that of higher altitudes.
Also, if the generator is installed inside an ill-ventilated building (to protect it from harsh winter),
the blower is likely to suck hot air from inside the building, resulting in efficiency degradation.
Hence, the blower must be located in a well-ventilated area.
The blower delivers air to the radiant section of the generator through the burner nozzle
throat. The air and the atomized fuel are turbulently mixed at the transition from the throat to the
radiant section, and combustion is initiated.
 The rate of air delivery to the combustion process is detelmined by the 'shutters' placed at the
blower discharge. The amount of excess oxygen in the flue gas, as it leaves the radiant section,
controls the position of these shutters. Excess oxygen concentration for normal operations is
between 1.5% and 3%. Excess oxygen outside this range causes the shutter controller to take
appropriate action.
To assure complete combustion, steam generation equipment has to be operated with about
3% excess air. Any excess air above this amount will lower the steam generator efficiency,
because the additional excess air robs the heat from the combustion process that otherwise could be
used to generate steam. Otherwise, the use of less than 1.58 excess air will probably cause
incomplete combustion.
As part of the efficient operation of the unit, the stack gases released by the generator should
be monitored to assure that complete combustion is occurring and no undue air is being used. The
quantitative determination of total air (100% + excess air) admitted to an actual combustion process
requires a complete flue gas analysis for COz, 0 2 , CO and N2. However, N2 is usually
determined by difference. No oxygen in the flue gas indicates incomplete combustion with
resultant fuel wastage. Too much excess oxygen indicates needlessly high stack losses. By
performing these analyses and adjusting generator operation when necessary, the operator can save
fuel.

Steam Generator Specifcations4

Since steam injection operations are site specific, oilfield steam generators must be custom
designed to meet the requirements of a specific site. Operators must provide certain minimum
information to steam generator vendors, to assure that minimum design, safety and environment
considerations are met. The American Petroleum Institute (API) recommends that steam injection
operators include the following minimum information in steam generator specification sheets:
(a) Fuel oil analysis (see appendix 6-A for fuel oil analysis specification sheet)
(b) Fuel gas analysis (see appendix 6-8 for fuel gas analysis specification sheet)
(c) Other fuels analysis (if any)
(d) Feedwater analysis (see appendix 6-C for feedwater analysis specification sheet)
(e) Utilities specification
(i) Electric power: -V -Ph -Hz
(e.g.,. 440 V, 3 Ph, 60 Hz)
(ii) Compressed air: -SCFM -Psig O F dewpoint

(iii) Pilot fuel: -Type -SCFM -Psi

(0 Site conditions:
(i) Ambient Air Temperature,' F: -Max -Min -Design
 (ii) Wind velocity, MPH: -Max -Min -Design
(iii) Elevation, ft Above mean sea level -
(iv) Seismic zone: -
(v) Rainfall, in./yr: -Avg.
(vi) Humidity, 5%: Max -Min -Design
(vii) Atmospheric conditions: List unusual condition, such as H2S, sand, dust, salt,
air, etc.
(g) Environmental consideration:
(i) S& emission limits
PPM: -current -future
(ii) N& emission limits:
Lb/hr: -current -future
(iii) Particulate emission limit:
GrISCF: _ current -futuse
Lbhr: -current -future
(iv) Waste liquid discharge limits.
(h) Transportation
Operators must list any unusual transportation problem that vendors may encounter
while transporting a generator from the shop to the site. These may include such
obstacles as tunnels, narrow or weak bridges. restrictive roads, etc. Any special local
permits required for the transport of heavy equipment on county roads must also be
spelled out.
(i) Safety Instrumentation and Equipment:
Operators must spell out any desired special safety features that have to be included
with the generators to assure maximum safety of operating personnel and equipment.
Any special safety equipment required to comply with state and local codes must also
be listed. At the minimum, generators have to be equipped with the following safety
instrumentation to meet the code standards.
ASME code required safety valves.
Electronic flame monitoring device and combustion controller. This includes
prepurge, proof-of-pilot, proof-of-main flame, and postpurge sequence.
Steam pressure controller
Feedwater flow rate transmitter and controller
Feedwater pump relief valve
Burner fuing rate controller
Temperature and pressure indicating devices
 (j) Safety Limit Devices:
API recommends that oilfield steam generators be equipped with the following safety
shutdown switches. Upon malfunction, one or more of these devices should shut
burner fuel valve(s) and require manual restart. Many of these switches are also
required by Federal and most State Codes.
(i) Flame failure
(ii) High steam pressure
(i) High tube temperature
(iv) High stack temperature
(v) High burner throat temperature (oil fired only)
(vi) HigMow atomizing pressure switch (oil fired only)
(vii) High fuel gas pressure switch (gas fised only)
(viii) Low fuel oil pressure switch (oil Fired only)
(ix) Low fuel oil temperature switch (oil fired only)
(x) Low feedwater flow rate control
(xi) Low combustion air pressuse switch
(xii) Low instrument air pressure
(xiii) Low steam pressure
(xiv) Power failure
(k) Hook up
If special design considerations are required for connections, operator should
specify service, size, rating and locations for the following:
(i) Feedwater inlet
(ii) S t e m outlet
(iii) Fuel inlets
(iv) Electrical connection
(v) Any other special requirements.

Fuels For Oilfield Steam Generators

Oilfield steam generators burn a vasiety of fuels, the most common being natural gas and
lease crudes. Other genentor fuels include industsial fuel oil and LPG. The main criterion for the
selection of a fuel or fuels is the availability at a particular site and at u reasonable cost. Because of
the fluctuating nature of costs of delivered fuel due to price, freight rates, seasonal variations in
availability and temporaiy shortages, an operator must plan for the use of more than one fuel to
ensure continuous operation at a reasonable cost.
 Natural Gas
If natural gas is readily available, it is the most convenient fuel because it can simply be
metered to the burner at a pressure that assures the desired volume feed rate. Other advantages of
gas are cleanliness of operation, relative simplicity of heat input control and fewer operating
problems. However, if the gas is allowed to accumulate in faulty valves or fittings which are not
readily detectable, explosions can occur. The explosion hazard can be minimized with well-trained
operators. Some of the problems associated with the use of natural gas as generator fuel are:
water in gas supply lines, inadequate gas pressure, and flow rate as well as excessive pressure
drop under maximum demand operations. Typical pas consumption rates for different sizes of
steam generators are shown in table 6.2.

Liquefied Petroleum Gas (LPG)

Light hydrocarbons such as propane and butane are distributed and stored under pressure as
liquefied gas. When the pressure is released, the liquid boils producing gaseous fuels. Use of
LPG has most of the advantages of natural gas, but does require storage capacity and vaporizers to
convert LPG into gaseous form for combustion. Liquefied petroleum gases are more expensive
than natural gas. Typical consumption rates for propane range from about 1,500 gallons per day
(2,520 BTWSCF) for 5 MM BTU/hr heat release rate to 15,000 gallons per day for 50 MM
BTUkr units.

Lease Crude
Lease crude is the most commonly used steam generator fuel in the oil patch. However, the
operating difficulties and hence the costs associated with burning lease crude are significantly
higher than those associated with burning natural gas. Lease crudes contain water which is
corrosive and susceptible to sludge formation upon storage. Additives must be added to the crude
to minimize these problems.
The following requirements must be met before crude oil can be used as generator fuel.5
1. Oil properties such as the API gravity at 60° F, viscosity from 100' to 300' F, percentage
of basic sediment and water (BS & W), and flash point must be known to successfully
control burning. The flash point is defined as the temperature at which the oil begins to
vaporize. These vapors will flash when ignited.
2. The burner control system must be evaluated to ussure that it is compatible with the oil
pump*
3. The atomizing medium must be able to vaporize the oil.
 Steam Generation Operations and Problems
The oilfield steam generation system is a complex web of many interconnected mechanical
devices that are outfitted with various instruments and safety devices to ensure the safe and
efficient delivery of steam. As with any mechanical device, breakdowns are inevitable, and steam
generator failure can be kept to a minimum by adopting good operational practices and mechanical
maintenance schedules. In this section, steam generator related opesation problems and solutions
are reviewed. Maintenance practices will be discussed in the next section.
Tube Failure
Even though steam generator tubes decay and fail with use and require periodic replacements,
premature tube failures can be prevented by knowing the causes of tube failures and avoiding
them. Some of the causes of tube failure are direct impingement of flame on tubes, improper
feedwater temperature, improper water-to-fuel ratio, and poor burner operation resulting from a too
high or too low fuel preheat temperature.
Direct impingement of flame on tubes or tube hanger results in hot spots and eventual tube
burnout. This problem can be avoided by adjusting the flame to minimize impingement on tubes or
tube hangers. A clean fuel nozzle, proper air-fuel ratio and correct radiant section pressure all
contribute to a good flame pattern. In an oil-fired steam generator, good flame pattern can be
achieved and maintained by ensuing correct fuel pressure and viscosity and employing right quality
steam at suitable pressure for atomization.
Use of improperly heated feedwater to generate steam will also result in tube failures. When
cold feedwater is used to generate steam in a generator designed for preheated feedwater, it will
result in increased heat load on the unit. This increased load causes hot spots to develop and lead
to eventual tube failure. Further, if the temperature of the feedwater entesing the convection section
is low, the tube temperature can become less than the dewpoint temperature of the hot flue gases.
This will produce acid precipitation on the tubes and results in premature fouling of their heat
transfer surfaces, as well as corrosion of tubes and fins. These, in turn, will result in premature
tube failures.
Tube failures can also occur through the formation and buildup of scales inside the tubes.
Scale buildup will occur if the feedwater and fuel tlow rate are not marched. If the water-to-fuel
ratio is low, it will cause concentration of the dissolved solids in the liquid phase to increase and
result in scale formation. Scale formed inside the water tubes will lower the overall heat transfer
rate and cause hot spots. If left unchecked, scale buildup will diminish the life expectancy of the
tubes. Often, formation of scale can be detected by keeping a careful record of feedwater pressure.
By checking and adjusting the water-fuel ratio periodically, scale buildup can be minimized and
tube life prolonged.
 Tube failure can also occur as a result of improper burner operation. In oil-fired generators
burning lease crude, the fuel oil must be preheated to the right temperature before burning. Too
high or too low a preheating temperature can result in erractic busner operation and poor flame
pattern. Hampton6 has pointed out that the following problems can result from too high or too low
a preheating temperature.
1. Poor atomization will result in poor combustion.
2. Too high a preheat temperature will result in preignition and emtical firing of burner.
3. Too low a preheat temperature makes ignition of fuel almost impossible, especially on a
cold start.
4. Improper preheating of fuel oil will result in soot and carbon formation on burner
throats and in the combustion area.
5 . Improper preheating also will result in oil pump cavitation.
6 . Fuel oil pump cavitation will result in reduced fuel input to burners and poor burner
pressure regulation.

Other Operation Problems

Modern oilfield steam generators are highly instrumented to ensure safe operations and to
shut down if an unsafe condition exists. Because of this high degree of automation, steam
generators experience frequent shutdowns and reactivation. Such frequent shutdowns and restarts
result in cyclic thermal stresses on the refractory material and tubes? As a result, the refractory
lining of the inner surface of a generator will decay and fail. The loss of the insulating properties
of the refractory will permit the corrosive combustion gases to come in contact with the outer shell
of a generator and can result in skin failure due to corrosion. Further, the expansion and
contraction of radiant section tubes will cause tube sealing packings in the tube hanger to fail. In
addition, the tubes within the radiant section of a generator will suffer material loss from their outer
surface because of the erosive action of the hot combustion gases. Tubes within the convection
section will deteriorate with time due to aging and corrosive attack by the products of combustion.
Hence, steam generators must be rebuilt periodically.
California field experience has shown that on an average a 50 MM BTUlhr steam generator
burning lease crude must be rebuilt once every 7 years. In general, the first rebuilt requires the
replacement of all the refractory and a portion of the tubes. The second rebuilt requires the
replacement of refracto~yand all tubes.
Other mechanical components of the steam generation system will also fail, mostly as a result
of poor maintenance. The rotating parts of the blower will fail prematurely, if it is not aligned
properly. Accumulation of soots on generator tubes will cause blower motors to overload and
eventually fail. Presence of excessive water in the lease crude will result in burner failure. The
fuel oil nozzle is another troublesome area requiring frequent cleaning. The seals of the fuel and
feedwater pumps also fail frequently and require repair. Field experience will better define other
areas of frequent repair. Most of the steam generation system problems, however, can be kept to a
minimum with good and well thought out maintenance.
Steam Generation System Maintenance
Field experience has indicated good maintenance is a key to the technical and economic
success of a steam injection project. It is recommended that a routine maintenance schedule be
established and maintenance and inspection be performed daily. monthly, and yearly. All repairs
and maintenance should be documented. Forms should be designed for each specific application.
API recommended formats are shown in appendix 6-D. The manufacturer's recommendations
should be an integral part of the maintenance and inspection schedules. The environment in which
a generator operates dictates certain types of checks and maintenance.
Based on field experience, the A P I ~recommends the following maintenance schedules:

Daily Maintenance and Inspection

Routine inspection and recording of all instrument readings once each shift are
recommended. The instrument readings that should be recorded include: feedwater pump
discharge pressure, feedwater flow rate, feedwater inlet temperature, steam outlet temperature,
steam outlet pressure, radiant tube skin temperature, stack temperature, radiant section pressure,
fuel nozzle pressure, fuel rate, and excess air.
In addition, the operator must visually inspect all flames during each shift to ensure that the
flame is clean, bright, and smokeless and cen ti-ally placed in the radiant section. This is done to
detect bumer malfunction and take corrective action. The following comments are offered as a
guide for better bumer operation in oil-fued steam generaton.6
(i) A properly adjusted and operated oil burner will result in a clean bright yellow flame
with no tsace of smoke and will verge on whiteness.
(ii) Insufficient combustion air andlor insufficient atomizing steam will result in a long
smoky flame.
(iii) Too much atomizing steam and/or too much combustion air will result in a dazzling
white flame.
(iv) Too much atomizing steam will also lead to a thin fluttery flame.
(v) Insufficient combustion air will result in a reddish dusty looking flame with flocks of
smoke over the bright part of the flame.
(vi) Presence of too much water or solid in the fuel will cause the flame to spark or flutter.
(vii) A plugged fuel valve or too low a fuel pressure will sesult in an uneven flame.
(viii) A plugged fuel valve or too low a fuel pressure will cause the flame to be put out.
 (ix) Since conditions such as too cold a fuel oil temperature, too wide a flame angle, too
much excess air, or too much fuel supply will all result in excessive flame
impingement on tubes and rapid coke formation, they should be avoided.
In addition, the operator must monitor and record daily those parameters needed for
calculations and efficient operation of the steamflood. These include: water quality, steam quality,
lubricating oil levels of the feedwater pump and air compressors, and filter and strainer conditions.
The API recommended steam generator daily log is shown in table 6.4. Also, since the single
most expensive activity in steamflood operation is the production of steam by burning fuel, a daily
record of fuel use should be part of every steamflood operations. This will be discussed in some
detail in a subsequent chapter on tools for monitoring stearnflood performance.

Monthly Maintenance and Inspection

In addition to the daily maintenance log, monthly maintenance schedules should be
established. The API recommends that the operator adopt the following monthly maintenance and
inspection schedules:
The operator should follow the manufacturer's recommended maintenance procedures
and inspect feedwater pump and drive systems once a month. The crankcase oil
should be inspected and replaced.
All motors should be inspected and lubricated as specified by the manufacturer.
Fuel, water, and air filters and stsainers should be cleaned and serviced.
Steam generator should be shutdown and the condition of the convection section and
radiant section tubes should be noted and recorded. Any fouling, soot buildup, or fin
deterioration and the condition of the refractory sulfaces should be recorded.

TABLE 6.4. - API Recommended Steam Generator Daily ~ o g ~

Date Water Feedwater Radiant Fuel Radiant

or Inlet Feedwater pumpdisch. Steam Steam Stack tube nozzle Section Fuel Excess
time temp. flow rate pressure outlet press. outlet temp temp. skin temp. press. pressure rate O2

1 , I

(v) The condition of the burner tip, burner throat, fuel nozzle, flame diffuser, and air
blower vanes should be inspected and cleaned as required.
 (vi) It is also recommended that the convection section heat transfer surface (inside and
outside) be cleaned regularly to reduce stack temperature and improve generator
efficiency. Soots should be removed from the outside surface and any scale buildup
inside the tubes must be removed by circulating a weak solution of hydrochloric acid
through the tubes at room temperature.
The API recommended monthly steam generator inspection checklist is shown in table 6.5.
Annual Inspection
In addition to the monthly inspection, all components of steam generation systems (water,
fuel, instrument, air, safety devices, etc.) should be thoroughly inspected once a year and
permanent records should be kept. External inspection should include calibration and replacement
of pressure and temperature instruments; inspection of safety relief valves for the accumulation of
rust, dirt, or foreign matter; and inspection of electrical equipment, damaged insulation, broken
wires, and corrosion. Internal inspections should include inspection of all tube surfaces for
erosion, corrosion, deformation, bulging, cracks and sagging, and inspection of tube hangers,
yokes and hanger bolts for cracks and stress defolmation and inspection of refractory material for
cracks. The API recommended annual steam generator inspection list is included in appendix 6-E.
The above recommended practices should be considered only as the starting point for a good
and thorough maintenance schedule. Assistance of the manufacturer of steam generation
equipment must be enlisted in developing a good flexible and optimum maintenance schedule.
Operational Problems Because of Puor Maintenance
Failure to follow manufacturer's recommended maintenance schedules may cause several
operational problems and result in costly downtime. Some of these problems are detailed in the
following paragraphs.
A trouble-free steam injection operation begins with the use of good quality feedwater for
steam generation. Ideally, the feedwater must have less than 1 ppm hardness, less than 0.05 ppm
dissolved oxygen, a pH value between 9 and 1 1 , and less than 4.000 ppm TDS. Failure to use a
good quality feedwater will result in formation of scales inside the tubes and cause tubes to
corrode. Scale formed inside the tubes can cause a variety of problems in addition to lowering the
overall heat transfer rate and formation of hot spots. Feedwater should be free of oil. Oil
contamination of the feedwater may lead to asphaltene deposition inside the tubes. Oil and other
suspended matter are removed from the feedwater by flowing it through a mechanical filtering
system. Such filters should be backwashed every 24 hours to minimize cake buildup and prolong
their life.
TABLE 6.5. - API Recommended Steam Generator Monthly Maintenance and Inspection Check

Inspected Condition

Description of item Yes Faulty Replaced Date of service Inspector Comment!

or ins~ection --
Feedwater pump
crankcaseArain and
refill as specified by
manufacturer.

Feedwater pump motor l

lubricate as specified by
manufacturer.

Convection coil2

Radiant coil

Fuel oil filters and

strainers3
Water filters
Air filters

Burner blower motor1

MisceIlaneous motors
Burner stabilizerldiffuser

I Keep all motors clean and ventilation openings clear of dust, dirt and other debris. Do not over grease. WARNING:
Disconnect all power sources to the unit and discharge all parts which may retain an electrical charge before attempting
any maintenance or repair. Screens and covers must be maintained in place when unit is in operation.
Some small motors have sealed-for-life type bearings which require no relubrication.

Motors that do require lubrication, can be regreased by stopping the motor. rcrnoving thc drain plug and pumping new
grease into fillhole. Run the motor with the drain plug removed, for a short period. to discharge excess grease. Replace
the drain plug.

Motors &at operate at speeds greater than 1,800 RPM should be lubricated on a more frequent maintenance schedule
depending on duty cycle.

2. On occasion it may be necessary to remove deposits from between the fins on the tubes in the convection section. The
frequency of cleaning the fin tubes wilt be determined by the type of fuel oil being used.

The convection section fin tubes may require cleaning when increase in backpressure of approximately 2 in w.c., above
new and clean condition, is indicated on the radiant section manometer.

3. The frequency of service required for the filters and strainers is determined by operating time using fuel oil and the
quality of the fuel oil being used. One indication of a dirty element is a drop in oil pressure to the burner (as indicated on
pressure gauge).

Every effort should be made to burn only clean fuel in the generator. If field gas is used as
fuel, it should be oil-free. Oily gas will cause a gas pilot solenoid valve to become sticky and
result in solenoid pilot valve failure.
 When firing lease crude, the oil should be filtered to remove sand. sludge, and other solid
material. Dirty fuel causes nozzle plugging and contributes to erratic flame pattern and eventual
tube failure. Presence of sand in the fuel will lead to excessive wear of the pump, pressure
regulators, and nozzle. Heavy sludges give rise to erratic burning and eventual flame failure.
Sludge problems can be alleviated by adding additives to the crude. Lease crude should also be
free of excessive free water. Up to 3% water, as long as it is dispersed in the oil, is not detrimental
to combustion. ~xcessivewater can lead to burner failure and refractory deterioration.
Thus, good maintenance practices should be an integral part of a steam injection operation not
only to lower operating costs and increase thermal efficiency, but also to ensure the safety of field
personnel.
Steam Generator Efficiency
Typical thermal efficiency of an oilfield steam generator ranges between 80 and 8 5 8 and
with special design can exceed 90%. The oilfield steam generator thermal efficiency is given by:
Generator thermal efficiency =
(Heat released by burning of the fuel) - (Heat loss to the surroundin&
(1)
Heat released by burning of fuel
The above definition is the most widely accepted and most reliable procedure for the determination
of oilfield steam generator thermal efficiency.
The API recommends that steam generator thermal efficiencies be based on the higher heating
value of the fuel. However, it also allows the efficiencies to be based on the lower heating value of
the fuel. It is the accepted practice in the oilfield to base the generator's thermal efficiency on the
lower or net heating value of the fuel. The difference between the higher and lower heating values
of a fuel is the heat necessary to vaporize the water formed in the combustion reaction. This heat
can be recovered only by cooling the combustion gases to a temperature at which the water formed
during combustion will condense. Since it is not practical to cool the flue gases to this
temperature, it is standard practice to base steam generator efficiencies on the lower or net heating
value of the fuel.
The basic heat losses to the surroundings from an oilfield steam generator consist of the heat
lost in the flue gases exhausted to the atmosphere, plus the heat lost by radiation from the steam
generator setting. The thermal efficiency of the oilfield steam generator is affected by the amount
of excess oxygen (air) used in the combustion process and the flue gas exit temperature (stack
temperature). The temperature and excess air content of the flue gases are determined by actual
measurement during the operation of the generator. The net heating value of the fuel can be
determined by using a calorimeter or by a calculation based on the chemical composition of the
fuel.
 Since the flue gases heat content accounts for the major portion of generator heat losses,
steam generator efficiency can be improved by reducing the stack heat losses. The amount of heat
lost via flue gases is proportional to the temperature of the flue gases and to the mass flow rate of
the vented gases. To the extent possible, flue gas heat is recovered in the convection section and
indirectly in the feedwater preheater.
Since steam generators are mostly fired with sulfur bearing fuels, such as the California
crude oils, the flue gases contain corrosive sulfur oxides. The amount of heat recoverable from the
flue gases is limited by the dewpoint temperature of these corrosive acid gases. If cooled below
the dewpoint, these gases condense and form highly corrosive sulfuric acids. Thus, the exhaust
gases cannot be cooled below the acid dewpoint which is about 400' F under typical operating
conditions. Therefore, steam generator thermal efficiencies are limited by stack gas dewpoint
temperatures.
The approximate flue gas dewpoints for heavy oils are shown in figure 6.8 as a function of
percent sulfur in the fuel oil and percent excess air used for combustion. As can be seen for a
given amount of sulfur in the fuel, the stack gas dewpoint increases with percent of excess air.
Further, the greater the excess air used in the combustion process, the lower will be the thermal
efficiency because the additional air traveling through the generator robs heat from the combustion
process that otherwise could be converted to steam energy. Typical net thermal efficiencies (as
defined by equation 1) for three different fuels are shown in figures 6.9 through 6.11, as a
function of the flue gas temperature and percent excess air.2 These charts assume a 2% radiation
heat loss. As can be seen from these plots, the thermal efficiency increases as stack gas
temperature and percent excess air decrease.
A knowledge of thermal efficiency is essential for the proper operation of a steam generator.
A drop in thermal efficiency is usually an indication that either the tubes are fouled and/or too much
excess air is being used for combustion. A stack gas analysis for C02 will give an indication of
excess air being used. Steam generation equipment is not normally operated with excess air above
7%. Any amount greater than that will result in greater heat losses and lower thermal efficiency.
Otherwise, if too little excess air is used for combustion, it will result in incomplete combustion
and smoking and soot deposition on the surface of the tubes. In gas-fired steam generators, where
soot should not be a problem, loss in thermal efficiency generally indicates that scale has formed
inside the tubes. The presence of scale is indicated by an increase in flue gas temperature. Scale
buildup is also indicated by an increase in the feedwater pump outlet pressure. Accumulation of
soot on the external surfaces of the tube also reduces the heat transfer rate to the feedwater and
increases the flue gas temperature.
 0 1 2 3 4 5
BY WEIGHT SULFUR IN FUEL OIL

FIGURE 6.8. - Approximate flue gas dewpoints for heavy oils?

i: gens=
reducedjby 2% to al!ow for steam
..**..-.-..--.*......~.-.-- *r se~ng.rapia~on.~OSS.: a
........
.....--..
..-...... ,

300 400 500 600 700 800 900 1000

FUEL GASTEMPERATURE, OF

FIGURE 6.9. - Thermal efficiency versus flue gas temperature for 10' API crudee2
 I I I I I
78
100 150 200 250 300 350 400

FUEL GAS TEMPERATURE. OC

FIGURE 6.10. - Thermal efficiency versus flue gas temperature for 15' API crude?

I
I- 100 160 220 280 340 400
F U R GAS TEMPERATURE, OC

FIGURE 6.1 1. - Thermal efficiency versus flue gas temperature for natural gas (1,000 B~UISCF).~

172
 Any increase in the steam generator thermal efficiency reduces the fuel requirements of the
steam generator and sharply reduces the cooling load on the sulfur dioxide scrubbers (where they
are used). For example, the fuel requirements of an oil-fired 50 MM BTU/hr steam generator can
be reduced roughly by about 5,300 bbl of oil per year by increasing the thermal efficiency 5%.
For this reason, one manufacturer offers steam generators equipped with special add-on convection
sections. Corrosion-resistance, plastic-coated heat exchange tubes are used in this section to
capture heat from the corrosive flue gases. This arrangement pelnits the cooling of sulfur oxide
containing flue gases to about 150' F (well below their dewpoint temperature) and increases the
thermal efficiency by about 8%.

Flue Gas Scrubbers

In the United States, most steam generators are fired with lease crudes. These crudes contain
sulfur which is converted to sulfur oxides during combustion in a steam generator. Environmental
regulations prohibit the discharge of these flue gases without lowering their sulfur content. For
example, in Kern County, California, the emissions of sulfur from a standard 50 MM BTU/hr
steam generator is limited to less than 1 lblhs. Wet scrubbers are used in the oilfield to remove
sulfur oxides from steam generator flue gases. The sulfur oxides in the flue gases exist principally
as sulfur dioxide, with traces of sulfur trioxide. The sulfur dioxide (and trioxide) from the flue
gases is removed by passing through a wet scrubber where it is absorbed into an aqueous
. scrubbing liquor followed by reaction with the active alkaline constituents of the liquor. The
reaction products are sulfur-containing salts. These are puged from the scrubber in small batches
and sent to disposal.
Different types of internals ase used in the scrubbes tower to aid the absorption and reaction
of sulfur oxides with scrubber liquor. These include tray towers, packed towers, spray towers,
and ejector venturi. Each of these has its own advantages and disadvantages, and in designing a
scrubber system a compromise must be made between absorption efficiency, operating reliability,
and cost. Most of the scrubbers in current use in oilfields are made of packed bed and bubble cap
tray to yield very good mass transfer and turndown char-actesistics. A good turndown character
dictates that the scrubber should be capable of operating efficiently over a relatively wide range of
gas flow rate.
System Description
Figure 6.12 shows the basic components of a most commonly used oilfield flue gas scrubber
system. These include a forced draft fan, scrubber tower, caustic feed system, recirculation tank
and pump, blowdown pump and tank, pH meter control system and makeup water system.
 RECIRCULATION
LIQUID FLOW

I STEAM
GENEWTOR
I FAN I I SCRUBBER

BLOWDOWN ,l&,,,mW
PUMP
TANK

FIGURE 6.12. - Schematic of a typical steamflood flue gas scrubber system.

Flue gas from the generator, instead of being exhausted directly into the atmosphere, is
ducted to the inlet at the bottom of the scrubber via a forced draft fan. Flue gases pass upward,
fist through a humidification section, where it is cooled by a spray of water. The water also
removes the larger particles from the gas stream. The cooled gas then passes through the
absorption section where it comes in contact with scrubbing liquor. The absorption section
consists of one 316 stainless steel bubble cap tray and a packed column. The scrubbing liquor
(aqueous sodium carbonate) is passed over the bubble cap tray as the gas is .forced upward. The
scrubbing liquor reacts with the sulfur dioxide in the flue pas and converts it to water soluble
sodium salts of sulfur (sodium sulfite, sodium bisulfite and sodium sulfate).
As a result of the vigorous liquid-gas contact in the absorption section, some of the liquor is
entrained in the gas. Prior to exiting to atmosphere, the gas passes through a mist elimination
device to remove the entrained droplets. Failure to remove these droplets could not only corrode
and scale downstream equipment, but also result in particulate pollutants such as sodium salts left
after evaporation of the scrubbing liquor mist. The two most common mist eliminators are the wire
mesh pad, and the chevron mist eliminator. The chevron mist eliminator is a set of slats set in such
a way to impart a zigzag flow to the gas over a distance ranging from a few inches to few feet.

Other Types of Steam Generation Eqa ipment

While once-through type steam generators are used almost exclusively in oilfields, steam
generators with special design features are also available for oilfield use. These include generators
having the capability to handle feedwater with a very high TDS content (up to 24,000 ppm),
generators with a capability to bum low BTU or sour gas as fuel in conjunction with crude oil,
generators that work on solid fuel such as coal or petroleum coke, generators that utilize an
intermediate heat transfer fluid to provide heat necessary to produce steam from treated water in a
shell, and tube type heat exchanger and generators that are designed to bum any fossil fuel and to
generate steam from brackish water. Although these types of steam generators have not gained
wide acceptance, they may find application in unusual situations. The key features of a few such
generators are described in the following section.

Vapor Tech Steam ~enerator8

Vapor Tech steam generators are small, light-weight, inexpensive, trailer-mounted steam
generators developed to generate steam using brackish or untreated water. This steam generator is
designed to burn any type of fossil fuel including pulverized coal, lease crude, natural gas, low
BTU gas, or biomass.
The key feature of the vapor tech steam generator is a resonant burner that creates a sonic
resonance at a temperature of about 2,500' F. As a result of the burner resonance, the combustion
gases are pulsed. This pulsating action of the combustion gases results in a scrubbing effect on the
surface of the free-floating steam coil and homogenizes the steam-water mixture inside the tube.
This homogenization prevents the formation of the insulating steam layer on the inside surface of
the tubes and results in higher heat transfer. Also, the scrubbing action of the combustion gas
prevents the formation of a cooled gas insulating layer outside of the tube. As a result of the
absence of any insulating boundary layer, a steep temperature gradient across the metal wall is
achieved and makes it possible to reduce the length of steam coil necessary to achieve a given heat
transfer rate. This, in turn, reduces the size and weight of the unit.
The pulsating flue gas also results in the resonance and vibration of the free-floating steam
coil. This vibrating coil keeps the salt precipitates and other scale-foning chemicals in suspension
in the pulsating steam. As a result, the generator successfully operates on brackish water or
oilfield brine without any buildup of scale. The largest u n i t offered by the manufacturer is a 10
MM BTUIhr trailer-mounted unit. Since the unit is modular in nature, a number of such units can
be manifolded together to achieve the desired output capacity.
These units are light-weight, portable, inexpensive, and need no water treatment. According
to the manufacturer, a 10 MM BTU/hr unit costs less than $40,000.

Fluidized Bed Combustion (FBC) Steam ~ e n e r a t o f i

Conventional oilfield steam generators use oil or gas as fuel. In fields where a coal source is
readily accessible, it may be more economical to use inexpensive and more plentiful coal as fuel.
One vendor offers a steam generator whose design features a fluidized bed combustion with an in-
bed steam generating coil and economizer section. These generators permit the burning of high
sulfur coal and various solid fuels to generate steam in an oilfield environment. The fluidized bed
design has the potential for providing uniform and low heat fluxes, minimum heat retention and
quick response to load changes and low fouling tendencies. This type of steam generator was field
tested in a South Texas steamflood project where steam was injected into a tar sand to recover a
heavy -2' A H gravity t a d 0 This type of generator was a natural fit for this project due to the
existence of an abundance source of low Bnl coal and limestone in the project vicinity.
Operation Principle: Figure 6.13 is a schematic of the FBC steam generator. The crushed
solid fuel (coal, lignite, petroleum coke, waste wood, etc.) is mixed with limestone and fed into the
combustion chamber, where air is circulated at high velocity to agitate and suspend the burning
solids. The limestone reacts with the sulfur in the coal to limit the production of sulfur dioxide.
Feedwater is pumped through the heat exchanger coils in the combustion chamber where it is
heated and converted to steam. The operating conditions of the combustion are such that
production of nitrogen oxides and carbon monoxide are also minimized. Emissions from the FBC-
type steam generator are kept within stringent environmental standards without using external
cleanup equipment.
The economics of the FBC steam generator depends upon the cost of solid fuel and the
capacity of the generator. It is unlikely that the generator will be economical to operate at capacities
less than 50 MM BTU/hr. This system should be considered only if a ready and reliable source of
inexpensive solid fuel is assured and stringent air quality standards have to be met.

The Wet Air Oxidation Boiler

Wet Oxidation Concepll
The tern wet oxidation as used here refers to a flameless combustion process capable of
releasing enormous amounts of heat under certain conditions. Around the turn of the century, it
was discovered that dissolved oxygen will attack water-wetted fuels directly from the liquid phase
 1. Water Storage
2. Preheater
3. Economizer
4. Cyclone
5. Bag House
6. Fly Ash Collector
7. Dust Collector
8. Ash Collector
9. Coke
10. Limestone
11. Fuel Injection System
12. Forced Draft Fan
13. External Boiler
14. Forced Draft Fan
15. Injection Well
16. Spent Solids

FIGURE 6.13. - Schematic of a fluidized bed combustion steam generator?

if the materials are pressurized to 300 to 3,000 psi. Under these conditions the flameless oxidation
process generates temperatures of 300' to 700" F as compwed with conventional combustion which
produces flame of 1,800' F at atmosphere pressure. However, the total number of BTUs released
by wet oxidation is the same as that released by conventional combustion. The principal reaction
products are also the same: carbon dioxide and water.

WAO Boiler12
Although wet air oxidation reactors generate enormous amounts of heat and are used
extensively in the waste disposal industry for the treatment of aqueous wastes and sludges, they
have not been used in the oil patch. Their inherent chancteristics. however, make them ideal for
thermal EOR applications.
Figure 6.14 shows the schematic of one WAO arrangement for steam injection application.
The feed to the WAO boiler consists of fuel slurry, water, and compressed air (or oxygen). It
oxidizes the fuel and produces steam, C02. and N2 which can then be injected into the reservoir.
The rational behind the suggestion to use WAO process in steam injection application is that steam
contributes thermal energy to the reservoir, while the gas phase (C02 and N2) contributes both
thermal energy and gas drive/solubility effects to the process. Since by its inherent nature, the
process does not produce any S02, NO,, or particulate, and no emission control is necessary, and
the process can be used at locations where stringent air quality standards have to be met.
 .
. FUEL

PREPARATION
I
REACTOR

WATER
PRoDUCED. I t
BLOWDOWN
I 1-

AIR COMPRESSED
AIROR02
I I
+
I GENERATION I

FIGURE 6.14. - Schematic of a wet air oxidation boiler atmngement for steamflood application.12

Other advantages of a WAO boiler for steam injection application are as follows:
(a) Inexpensive fuels such as high sulfur petroleum coke, high sulfur coal, lignite, high
sulfur crude-water emulsion, wood wastes, or any other solid waste product can be
used as feed to the reactor.
(b) Feedwater requires no treatment. Brackish or oilfield brine or produced water can be
used as the source of water. Dissolved feedwater solids are concentrated and removed
in the blowdown.
(c) The steam produced in the WAO unit is essentially 100% quality; hence, the water
requirement per unit heat injected into the reservoir is significantly lower.
The major disadvantages of the WAO boiler are that it requires the use of an air compressor or a
compressed oxygen source to generate steam, and the process is corrosion prone. Hence, it is
more expensive to generate steam using the WAO boiler than a conventional boiler. Another
disadvantage of the WAO boiler is the problem of the disposal of reactor blowdown sludge.
The WAO process is a well-developed technology. However, the present economic situation
and the absence of field performance data are apparently the compelling reasons for the lack of
interest in WAO boilers. Because of increasing costs of meeting stringent air and water quality
regulation requirements, WAO boilers with their emission and water usage advantages may prove
to be cost-effective in steam injection applications.

Vapor Therm System 3

Like the WAO process, the 'Vapor Therm' system also involves the generation and direct
injection of combustion gases and steam into heavy oil bearing formations. Unlike WAO boilers,
Vapor Therm generators are designed to bum high pressure liquid fuels or natural gas and utilize
prefiltered but untreated water to generate steam.
Figure 6.15 is a schematic of the Vapor Therm process showing the major equipment and
process flow. The Vapor Therrn generator is composed of (1) a high pressure air compressor
system, (2) a high pressure combustion chamber, and (3) a steam drum where steam is formed,
harmful combustion products are removed, and solids removed. In addition, there are water and
chemical injection pumps, fuel feed pumps, and attendant instrumentation and control systems.
The air is compressed to the desired operation pressure (900 psig maximum) and mixed with
a fuel source at the entrance to the combustion chamber. The combustion reaction takes place in
excess of 2,500' F in a refractory lined combustion chamber. The hot combustion gases flow from
the combustion chamber into a steam generation drum where the hot combustion gases are
quenched with high pressure water, producing a mixture of steam and inert gases. In addition to
its function as a steam generator, the drum also acts to scrub the combustion gases. The scrubbing
action of water absorbs the acid gases such as SO2 and NO, which, in turn, are neutralized by
addition of chemicals to the drum. The effluents from the steam drum, steam, C02,and N2 are
then carried to the wellhead through the insulated pipes and injected into the reservoir. The steam
drum is periodically blown to remove aqueous concentrate of acid salts and other solids.
The Vapor Therm process requires water filters. air compressors, liquid fuels, and chemicals
to operate. The process has been successfully field tested in two different and distinct reservoirs.
The process is currently available on the masket. Vapor Therm works best in a dipping reservoir,
where a gas cap can be formed, adding drive eneqy to the reservoir.
Both WAO and Vapor Therm processes have the potential of producing more oil than a
conventional steam generator. However, they cost more than a conventional steam generator and
do not eliminate the inherent limitation of a surface steam generation facility: heat losses in surface
lines and wellbores. The major competitor to these process is the downhole steam generator which
will be discussed in the next section.

Downhole Steam Generator

The downhole steam generator was developed to overcome the two major limitations of
conventional steam operations: (1) line and wellbore heat losses and (2) exhaust emissions. Steam
 r""""""""'
LEVEL CONTROL VALVE
h

WATER SYSTEM

WATER PUMP
OuRGE PUMP
NEL CON'TROL VALVE
t-I ItUECTlOtJ LINE
TO WELLS
4
v
FUEL SYSTEM
Fua

AWHERK:
AIR IN NR SYSTEM

n
A R COMmESSORS
AND WllVERS

, CHEMICAL SYSTEM I CODE:

$ RELIEF VALES

CARMEL ENERGY INC.

VAPOR THERM. PROCESS 0 FILTERS

-£I--
CHECK VALES

FIGURE 6.15. - Schematic of Vapor Therm system.l 3

generated in conventional surface steam generators loses a significant portion of its heat as it flows
through surface piping and into injection wellbores. Wellbore heat losses have limited the
applicability of conventional steam generators to formations shallower than 3,000 ft with
uninsulated tubing and not much deeper than 5,000 ft with insulated tubing.
Downhole steam generators (DSG) are designed to eliminate surface and wellbore heat losses
and to deliver high quality steam at the sandface with high thermal efficiency. In addition, certain
DSG design permits the reinjection of combustion gases with steam, thereby eliminating the
emission problems associated with surface generation and provides some of the advantages of a
steam additive process. Further, for the same heat injection rate into an oil-bearing formation, a
DSG will require less generator fuel and combustion air than a surface level generator. However,
this reduction is achieved at the expense of the air compressor and its associated energy utilization.
Some of the advantages and disadvantages of DSG are listed in table 6.6. A schematic of a
downhole steam generation system arrangement is shown in figure 6.16.
 TABLE 6.6. - Advantages and Disadvantages of Downhole Steam Generators

Advantages Disadvantages

1 . Significantly minimize heat losses. 1. Their output capacity is limited.

2. Reduction of air pollution. 1. Not well suited for cyclic steam injection
appIication. since it adds significantly to
3 . Has potential to extend steam injection to operating costs.
deeper wells. ,

2 . Maintenance costs for DSG is higher than

4. Have applicability to offshore and arctic conventional steam generator.
environrnen ts.
3 . Difficult to control combustion at high
5 . Injected combustion gases have the potential to pressures.
enhance the oil recovery.
4 . Corrosion of burner components is a
6 . Low capital investments per BTU of heat injected. major problem.

5. Results in frequent packer failures.

7 . Eliminate the need for surface steam distribution
and quality monitoring systems. 6. High compression costs.

7 . Lack flexibility in that it can only serve

the well in which it is installed. Surface
generators on the other hand can readily
adapt to serve multiple injection wells.

8 . For wells requiring higher steam injection

rates. larger casing may be required to
install a DSG of suitable size; thus
adding significantly to capital investment
costs.

9 . Acldi tional standby air compressor is needed

to avoid generator shutdown in the event
of a compressor breakdown.

10. Response to load changes is not as quick

as a surface generator.
 Figure 6.17 is a schematic of a low pressure DSG developed by Sandia National
~ typical operating parameters for this system are shown in table 6.7. In the
~ a b 0 r a t o r y . lThe
Sandia design, the fuel and air are transported from the surface through tubes to the combustion
chamber and ignited. After ignition, the combustion is sustained by maintaining the proper &/fuel
ratio. The hot combustion products upon leaving the combustion chamber preheat the incoming
feedwater and return to the surface as exhaust gases. The preheated feedwater flows around the
combustion chamber where it picks up additional heat and converts it into steam. The steam at a
pressure higher than the reservoir pressure is injected into the formation. A high-temperature,
high-pressure packer is used to prevent the steam from entering the annulus between the casing and
the generator.
The thermal efficiency of a low-pressure DSG is extremely high. They deliver greater than
90% of the energy available in the fuel to the formation. In comparison, conventional surface
steam generators deliver only about 65% of the energy input to the formation. The major
drawbacks of a low-pressure DSG are its large size and exhaust emissions similar to those of a
surface system. Because of these limitations, industry interest in downhole steam generation is
almost exclusively centered on the high-pressure version.

WATER

FIGURE 6.17. - Low pressure downhole steam generator.14

 TABLE 6.7. - Typical Operating Parameters for a Low-Pressure DSG

Heat rate, MM BTU/br 10-20

Injection pressure, psia 1,000-2.500
Operating depth, ft 2,500-5.000
Fuel No. 2 dicsel
Maximum sandface
steam quality, % 85
Emissions Normal
Combustion pressure, psia 100
Minimum casing size, in. 1 1 -3f4
Generator length, ft 60

High-Pressure DSG
The distinguishing features of this generator are as follows:
(a) Steam is produced by direct contact with high-pressure combustion gases, which
eliminates the need for any heat exchangers.
(b) The overall size of the generator is considerably smaller than a low-pressure version
and this permits the installation of the generator in existing injection wells.
(c) The hot combustion products are injected into the formation and repressurize the
reservoir. This repressuring can enhance recovely by improving flow characteristics.
Figure 6.18 is a schematic of a high-pressure DSG developed by Sandia National
~ a b o r a t o r y lThe
~ typical operating parameters for this system are shown in table 6.8. In the
Sandia design, fuel and air are injected and mixed in the upper portion of the combustion chamber.
Since the combustion operates at the injection pressure, a large air compressor is required at the
surface to provide high-pressure air for the combustion. The fuel and air are thoroughly mixed at
high pressure in the combustion chamber prior to ignition. Once sustained combustion is
achieved, high-pressure feedwater is sprayed directly into the flame through spray nozzles. The
water is flashed into steam, and the mixture of steam and combustion products is injected into the
formation.
The overall thermal efficiency of a high-pressure DSG is about 80%. Even though the
efficiency is not as high as that for the low-pressure DSG, it is considerably higher than that for a
conventional sluface generator.
Results of the field tests conducted to date in evaluating the reliability of high-pressure DSG
under oilfield conditions have indicated a number of technical problems. Corrosion of burner
components seems to be the most severe and common problem among all DSGs. Other major
problems encountered include difficulties in controlling combustion at high pressure and frequent
packer failures resulting from the harsh DSG operating environment.
 AIR ASSISTED

4
STEAM

48 .OW ,
, '
REFRACTORY
LINER

16.00. ,L 1.25"

FIGURE 6.18. - High-pressure downhole steam generator.14

TABLE 6.8. - Typical Operating Parameters for a High-pressure DSG

Heat rate, M M BTU/hr 10-20

Injection pressure, psia 1.000-3,000
Operating depth, ft 2,500-5.OOO
Fuel No. 2 diesel
Maximum sandface
steam quality, % 80
Emissions Very low
Combustion pressure, psia 1,000-3.000
Minimum casing size, in. 7
Generator length, ft 8

Even though DSGs have been field tested successfully, these tests are of short duration-the
longest being 6 months. The DSG needs to be field tested over an extended period of time (2 to 3
years) to establish its reliability and identify operational problems.
The economic advantage of DSG over surface generation is debatable. Even though DSG
has higher thermal efficiency, this efficiency does not always translate into dollars and cents
because the cost of fuel used to drive compressors often exceeds the savings in heat. Further,
since most heavy oils of interest in the U.S. are found in shalIow reservoirs (~4,000ft), a surface
generator with insulating tubing may be more cost-effective in delivering unit heat input to the
reservoir. The advantage of DSG over suiface generators in reducing the cost of compliance with
environmental regulations is also debatable because the injected corn bustion gases more than likely
will break through to the producing wells and thereby reduce the economical advantage of DSG.
 Based on a heat-balance study of a conventional surface steam generation system and the
downhole steam generation system, Sandia National Laboratory concluded that DSG has a lower
appeal to low-injectivity shallow reservoirs and high-injectivity deeper reservoirs.l5 Figure 6.19
depicts the steam generator system selection chart recommended by Sandia. This graph, however,
excludes any consideration of investment and operating costs. The costs of energy injected into a
reservoir (1981 dollars) as a function of depth for surface and downhole steam generators are
shown in figure 6.20.
A fair comparison of the economics of the DSG versus surface steam generation is difficult
because such studies involve the comparison of an unproven technology with that of an established
technology. Published comparative economic evaluations are all preliminary and generic in nature
and reflect author's bias. To arrive at an honest conclusion, a site-specific process economic study
of the options is necessary. In table 6.9, the published equipment cost data are shown. Most of
the data were published in 1980-82. These are updated to 199 1 dollars using the U.S. Producer
Price Index. Note that the equipment costs vary with improvement in technology, effect of
inflation, and the general state of the economy.

p -- EFFICIENCY OF CONVENTIONAL
EFFICIENCY OF DOWNHOLE
6000 -
b
SELECT
4500 - DOWNHOLE
SYSTEM
I-
l
i
W
o 3000 - SELECT
CONVENTIONAL
SYSTEM
1500 -

FIGURE 6.19. - Downhole steam generator selection chart.

 9
+ CONVENTIONAL 18000 LB / HOUR
U CONVMIONAL 10000 LB / HOUR
-4- DOWNHOLE 18000 tB/HOUR
--C+ DOWNHOLE 10000 LB/ HOUR

8 -

7 -

/
-
v d
6 - I I I b I I I I I I I I I 1

0 1500 3000 4500 6000 7500

DEPTH, ft

FIGURE 6.20. - Cost of energy injected into reservoir versus reservoir depth.15

TABLE 6.9. - Comparison of Surface and Downhole Steam Generator Costs20

Surface steam generator Downhole s'leam generator

Author Year Senerator costs Water Well drilling Generator Water Well drilling
and 1991 $ per treatment and costs, treatment and
Reference MM B t u h plant costs, completion 1991 .F per plant costs, completion
1991 $ per costs, MM B t u h r 199 1 $ per costs,
MM Btu/hr 1991 $ MM Btulhr 1991 $

45100 per ft
+ $12,600
5.~90per ft
+ $10,600
-
-

High pressure DSG including compressor

Low pressure DSG - generator only.
High pressure DSG - generator only.
4 LOW pressure DSG.
High pressure DSG.
 At the present time, because of the cunent economic situations and the unproven nature of the
technology, there is lack of interest in the oil patch for DSG. It is unlikely that the DSG will be
used in the shallow California reservoirs. DSG applications may be limited to special situations
such as steamflooding of heavy oil reservoirs in Alaska where the fragile nature of the environment
and arctic climate preclude the use of surface steam generation facilities. It may also find a
practical application offshore where its compact size would be an asset.
Cogeneration
Another method of steam generation currently in use, principally in California, involves the
use of a heat-recovery steam generator (HRSG) as an integral component of a process known as
cogeneration. In the cogeneration process, the fuel (such as natural gas) is burned in a gas turbine
to generate electricity and the heat from the hot exhaust gas is recovered in a HRSG to generate
steam. Figure 6.21 shows a schematic of a steam injection cogeneration facility.
Cogeneration is defined by the U.S. Government as the simultaneous production of
electricity and thermal energy (steam) from the same fuel source. Cogeneration technology has
been used since the 1950s by the petroleum industry in such facilities as natural gas processing

TURBINE

HEAT RECOVERY STEW GENERATOR

, FLUE GAS
\

f
STEAM TO
PRODUCTION

-* OTHER USES

FIGURE 6.21. - Schematic layout of a cogeneration facility. 18

188
plants, offshore oil platforms, and crude oil pipeline applications. Steam injection operators did
not utilize cogeneration technology until the late 1970s. principally due to economic reasons. In .

the past, the low oil piice and the larger capital expenditure for cogeneration equipment combined
with the absence of a ready market for the excess generated electricity made cogeneration
economically unattractive for steam injection operators. However, the passage of the "Public
Utility Regulatory Policy Act" (PURPA) in 1978 and the rising prices of crude in the 1970s
improved the attractiveness of cogeneration for steam injection operations. One of the provisions
of PURPA requires that state utility agencies mist mandate local public utility companies to
purchase any excess power that a cogenerator has to offer. The contract with the electric utility
company is a key factor in ensuring the economic success of a large cogeneration system. In
California, the public utility commission has manged for "standard offers." Cogenerators can take
advantage of them or can negotiate a special contract with the utility, if they so choose.
In California, most cogeneration systems are owned by the operators or by companies
specially formed for this purpose. These cogeneration plants are large units with a power
generating capacity of 80 MW or more. In table 6.10. the capital cost itemization of an 80 MW
California cogeneration project is shown.18 These data are included here to indicate the capital
investment requirements for large size cogeneration plants. Small steam injection operators can
merely purchase steam from these companies. The constraints to such an arrangement are heat loss
from the steam piped long distances prior to injection and long-term purchase commitments.
Long-term purchase commitments, while they assure a steady supply of steam at a negotiated price
for the duration of a project, also requise operators to pay fos steam not used due to project
shutdown. For this reason, most small steam injection operators in Califolnia prefer to generate
the steam themselves.

TABLE 6.10. - Capital Cost Itemization of a California Cogeneration Project

(All Costs are in 1989 ~ollars)

Cost, % of
M$ Total cost

Power generation
Steam generator
General facilities
Switchyard & transmission
Emission offsets
Startup
Project engineering & managernelit
Construction interest
Offsite pipelines
Total
 Small operators who do not wish to enter a contract with large cogenerators yet wish to avail
themselves to the benefits of cogeneration can do so by installing small custom-designed skid-
mounted cogeneration units. These are designed for unattended operation in a dusty outdoor
environment and generate approximately 2.5 MW (8.53 MM BT1Jlhr) of electricity and 40 MM
BTUIhr (2,600 bbl/d) of 80% quality steam at 1,500 psig. One vendor's economic summary of a
packaged cogeneration unit (updated to 1991 dollars using the U.S. CPI) is shown in table 6.1 1-16
These cogeneration economic data are included here for illustration only, and the actual vendor
quote may differ from these 'off-the-cuff' estimates. The net cost shown in the table is the cost of
the system minus the cost of the steam generator that would have been required if the cogeneration
system had not been installed.
According to one steam injection operator who installed such a system (in the mid-80s) on
his lease, the generated power cost from cogeneration units were about 25% of purchased power
costs and the payout was about 2.4 years. l7 His annual maintenance expense averaged about 5%
of the initial turbine investment.
With the exception of the turbine and the electric generator. a cogeneration facility is designed
and operated to produce steam similarly to a standard oil field steam generator. Both require
essentially the same feedwater quality (zero hardness mi low TDS) and operate within the same
pressure ranges. Since a cogeneration steam generator is designed to recover the waste heat from
the hot exhaust gases of a turbine, only a convective heat tsansfer section is used in a cogeneration
facility. Since cogeneration units are designed to burn sweet natural gas, no SO2 is formed. The
NOx emissions are usually controlled by injecting demineralized water into the turbine combustion
chamber.
The operating problems of cogeneration steam generators we similar to those of standard oil
field steam generators. The discussion of the operation and problems of a turbine generator set is
beyond the scope of this report.
SUMMARY
Steam generators used in oilfields differ from conventional power boilers. Oilfield steam
generation equipment and techniques have evolved over the past 30 years to a highly specialized
state. This chapter reviewed the once-through wet steam generators that are used almost
exclusively in oilfields. Essential operating and maintenance techniques are discussed. The
importance of good operation practices and mechanical maintenance schedules that reduce the
overall maintenance and operating costs are emphasized. Salient features of other specialized
oilfield steam generation equipment are detailed.
 TABLE 6.1 1. - Economic Summary for a Skid-Mounted Cogeneration unit?
Capital investment1
Water treatment plant
Total capital investrnen ts

Operating costs2
Turbine fuel, 37 MM BTUhr
Supplemental fuel, 36 MM BTU/hr
Demineralized feedwater
Treatment and disposal of waste water
Operation and maintenance
Total operating costs

yi2kaww2
Electric power, 2,500 kwhr
Steam produced, 48,000 lbhr
-
$
$
$
$
32,000 per month
31,000 per month
21,000 per month
12,000 per month

$129,000 per month

Total
Monthly savings

Initial capital cost

Alternative cost
Net cost
Pay back = 2.2 yeafi
- - -- --

1. Capital investment includes the following:

(a) Gas turbine/generator set
(b) Switcb gear, controls, reiays and substation equipment and housing
(c) Waste heat recovery steam generator and associated components. These include:
Diverter valvehypass stack, duct burner, airblower, steam generator, fccdwater
preheater, feedwater pump, burner controls, and steam generator control panel.

2. Assumptions:
Steam generator capacity, Ibfhr
Power generator capacity, kw/hr
Utilization, hrfmonth
Fuel value (natural gas), $ per MM BTU
Electric power value, $ per kw-hr
Steam generator efficiency
Feedwater utilization rate, bblhr
Feedwater treatment cost, S per bbl

Steam value is computed as

steam value =
Pounds steam producedhr x 954 BTI lW4 x fuel cost $/MMBTU

Steam gencrator efficiency

REFERENCES
1. Warren, K. W. Advances in Oil Field Steam Generation. Meyer, R. F., J. C. Wynn
and J. C . Olson, eds. The Future of Heavy Cmde and Tar Sands. Second International UNITAR
Conference in Caracas, Venezuela, February 1982, McGraw-Hill, New York, pp. 685-693.
2. Struthers-Thermo-Flood Corporation: Enhanced Oil Recovery Steam Generators.
Bulletin No. TF 100-79-7-5000, 1979.
 3. Peachey, B. R. Design Consideration for Very Large Oilfield Steam Generators. Pres.
at the 35th Ann. Tech. Meeting of the Pet. Soc. of CIM, Calgary, Canada, June 10-13, 1984.
Paper No. 84-35-81.
4. American Petroleum Institute. API Recommended Practice for Installation and Operation
of Wet Steam Generators. API Publication API RP 1IT, 1st Ed., March 1983. American
Petroleum Institute, Production Dept., Dallas, TX, 1983.
5. Gjerde, E. Raw crude: A Heat Source for Steam Flooding. Pet. Engr. v. 36, No. 13,
December 1964, pp. 92-94.
6. Hampton, L. A. How various Fuels Affect the Design and Operating Costs of Steam
Generators. Pres. at the 19th Ann. Tech. Meeting of the Pet. Soc. of CIM, Calgary, Canada, May
7-10, 1968. Paper No. 6812.
7 . Prats, M. Operational Aspects of Steam Injection Processes. In: Donaldson, E. C., G.
V. Chilingarian and T. F. Yen, eds. Enhanced Oil Recovery II-Processes and Operations,
Elsevier Science Publishing Co., New York, 1989, p. 359.
8. Modular Steam System: Vapor Tech Steam Generator-A Lightweight Steam Generator
for In-field Steam Flooding-Modular Steam System. Technical Bulletin, Earth Resources
Technology Services, Phoenix, AZ.
9. Martin,W. L., M. W. Britton and R. A. Harmon. Conoco's South Texas Tar Sands
Project . In: Meyer, R. F., I. C. Wynn and J. C . Olson, eds. The Future of Heavy Crude and
Tar Sands. Second International UNITAR Conf., Caracas, Venezuela, February 1982. McGraw-
Hill, New York, pp. 987-997.
10. Jones, 0. and J. S. Davis. Solid Fuels Proven for Oil Field Steam Generation. Oil &
Gas J., v. 81, No. 8, Feb. 27, 1983, pp. 189-192.

11. Clark, S. W. Wet Oxidation Downhole Steam Generator for Recovery of Deep Heavy
Oil. Pres. at the Third International UNITAR Conf. on Heavy Crude and Tar Sands, Long Beach,
CA, July 22-3 1, 1985. Proceedings v. 3, pp. 1,116-1,119.
12. Balog, S. E., R. K. Kerr and L. A. Pradt. The Wet Air Oxidation Boiler for Enhanced
Oil Recovery. J. Can. Pet. Tech., v. 21, No. 5, September-October 1982, pp. 73-79.
13. Sperry, J. S. Development and Field Testing of the Vapor Therm Process. Pres. at the
Third ERDA Symp. on Enhanced Oil & Gas Recovery and Improved Drilling, Tulsa, OK, Aug.
30-Sept. 1, 1977. Proceedings, v. 1, pp. D-21-D-2/14,
14. Bader, B. E., R. L. Fox, D. R. Johnson, A. B. Donaldson and D. A. Krueger. Deep
Steam Project. Quarterly Report Oct. I-Dec. 3 1, 1978. Sandia Laboratories Report SAND-79-
0562, 1979.
15. Hart, C . M. Comparative Analysis of Steam Delivery Cost for Surface and Downhole
Steam Drive Technologies. Sandia National Laboratories Report No. SAND-81-0758, 1981.
16. Solt, J. C. and I. R. McNeill. Cogeneration in the Oil and Gas Industry Solar Turbines
Technical Publication No. TTS 43, Solar Turbines Inc., Div. of Caterpillar, Oak Brook, IL, 1986.
 17. Livesay, J. D. Long-Term Performance of Small Cogeneration Units in Oil Field and
Gas Plant Operation. Pres. at the Pet. Soc. of CIM and the Soc. of Pet. Engineers International
Technical Meeting, Calgary, Canada, June 10-13, 1990. Paper CIM/SPE 90- 14.
18. Harbor Cogeneration Project Fact Sheet - Union Pacific Resources, Wellmington, CA,
1989.
19. NATCO: "Therma Drive" Steam Generator. Technical Bulletin No. 1701, National
Tank Company, Tulsa, OK, 1990.
20. Nguyen, D., S. Singh and S. Wong. Technical and Economic Criteria for the Selection
of Downhole Steam Generators in Alberta. Pres. at the 38th Ann. Tech. Meeting off the Pet. Soc.
of CIM, Calgary, Canada, June 7-10, 1987. Paper No. 87-38-04.
2 1. Eson, R. L. Direct Fired Downhole Steam Generator-Field Tests. Meyer, R. F., J. C.
Wynn and J. C. Olson, eds. The Future of Heavy Crude and Tar Sands. Second International
UNITAR Conf., Caracas, Venezuela, Februa~y1982, McGraw-Hill, New York, pp. 737-743.
22. Schirmer, R. M. and R. L. Eson: A Direct-Fired Downhole Steam Generator-From
Design to Field Test. 3. Pet. Tech., v. 37, No. 10, October IY85, pp. 1903-1908.
Bibliography
Wet Steam Generators
Brusset, M. J., A. N. Edgington and R. F. Gilmour. Equipment Performance in an Alberta
High Pressure Steam Injection Project. Pres. at the 18th Ann. Tech. Meeting of the Pet. Soc. of
CIM, Bannf, Alberta, May 24. J. Can. Pet. Tech, 0ct.-Dec. 1967.
Crawford, P. B. Combustion Calculations for Steam and Hot Water Generators. Prod.
Monthly, v. 3 1, No. 1, January 1967, pp. 16-17.
Crawford, P. B. Fuel Calculations for Steam Generators. Producer's Monthly, v. 31,
No. 2, February 1967, p. 23.
Crawford, P. B. Firing Crude or Fuel Oil in Steam Generators. Producer's Monthly, v. 31,
No. 3, March 1967, p. 29.
Crawford, P. B. Combustion Furnaces for Steam Generators. Producer's Monthly, v. 3 1,
No. 4, April 1967, pp. 29-30.
Crawford, P. B. Controls for Steam Generators for Thermal Oil Recovery Programs.
Producer's Monthly, v. 31, No. 5 , May 1967, pp. 22-23.
Fanaritis, J. P., and J. D. Kimmel. Review of Once-Through Steam Generators. J. Pet.
Tech., v. 17, No. 4, April 1965, pp. 409-4 16.
Gras, E. H. Portable Steam Generating Equipment. Pres. at the 40th Ann. Fall Meeting of
the Soc. of Pet. Eng. Denver, CO, Oct. 3-6, 1965. Paper SPE 1 169.
Khatib, 2. I., E. E. Olson and M. C. Place. Effect of High Silica Content on Scale
Deposition and Pipe Wall Loss in Oilfield Steam Generators. Pres. at the 64th Ann. Tech. Meeting
of the Soc. of Pet. Eng., San Antonio, TX, Oct. 8-1 1, 1989. Paper SPE 19760.
 Owens, M. E., and B. G. Bramley. Performance of Equipment Used in High Pressure
Steam Floods. J. Pet. Tech., v. 18. No. 12, December 1966, pp. 1,525-1,531.
Sarns, G. W. and J. D. Hunter. Performance Improvement of Direct and Indirect Fired
Heaters. Pres. at the 61st Ann. Tech. Meeting of the Soc. of Pet. Eng., New Orleans, LA, Oct. 5-
8, 1986. Paper SPE 15398.
Struthers Thermo-Flood Corporation, Operating and Maintenance Practice for Struthers
Thermo-Flood Oilfield Heaters, Winfield, KS, 1980.

Bardet, C. K., L. A. Stuebinger and D. E. Wittig. Williams Holding Lease Steamflood

Demonstration Project, Cat Canyon Field, U.S. Dept. ot Energy. Repan No. DOE/ET/12058-6,
July 1983, pp. 71-75.
Sachtschall, J. R. and J. F. Dydo. Operation and Performance of a Double Alkali Scrubber.
J. Pet. Tech., v. 34, No. 11, November 1982, pp. 2,630-2,636.
Siemak, J. B. and M. P. Gelbs. Operating Experience With a Two Stage H2S Scrubber
Using Caustic Soda. Pres. at the California Regional Meeting of the Soc. of Pet. Eng.,
Bakersfield, CA, Mar. 27-29, 1985. Paper SPE 13640.
Slack, A. V. and G. A. Hollinden. Sulfur Dioxide Removal From Waste Gases. Noyes
Data Corporation, Park Ridge, NJ, 1975, pp. 176-178.
Wendt, R. E. Review of Stack Gas Scrubber Operating Experience on an Oil Fired Steam
Generator. Pres. at the California Regional Meeting of the Soc. of Pet. Eng. San Francisco, CA,
April 12-14, 1978. Paper SPE 7125.
Downhole Steam Generators
Bader, B. E., R. L. Fox and J. J. Stosur. The Potential of Downhole Steam Generation to
the Recovery of Heavy Oils. Meyer, R. F., J. C. Wynn and J. C. Olson, eds. The Future of
Heavy Crude and Tar Sands. Second International UNITAR Conf., Caracas, Venezuela,
February 1982, McGraw-Hill, New Y ork, pp. 369-377.
Davis, J. S. and J. P. Fanaritis. The Application and Economics of the Use of Insulated
Injection Tubing With Oilfield Steam Generators. Meyer, R. F., J. C. Wynn, and J. C. Olson,
eds. The Future of Heavy Crude and Tar Sands. Second International UNITAR Conf., Caracas,
Venezuela, February 1982, McGraw-Hill, New Y ork, pp. 675-684.
Stosur, I. J. G. Downhole Steam Generator-A Potential Breakthrough in Heavy Oil
Recovery. Meyer, R. F., J. C. Wynn and J. C. Olson, eds. The Future of Heavy Crude and Tar
Sands. Second International UNITAR Conf., Caracas, Venezuela, February 4982, McGraw-Hill,
New York, pp. 744-748.
Wright, D. E. and R. L. Binsley. Feasibility Evaluation of a Downhole Steam Generator.
Pres. at the SPEDOE Second Joint Symp. on Enhanced Oil Recovery, Tulsa, OK, Apr. 5-8,
1981. Paper SPE 9775.
Ware, C. H. An Evaluation of Alternatives in Downhole Steam Generation. US. Dept. of
Energy Report DOE/PO/ 1O879- 1, September 1981.
 Anon. Cogeneration Unit to Assist Heavy Oil Recovery. Oil & Gas J., v., 81, No. 44,
Nov. 7, 1983, pp. 68-69.
Davis, J. S. and W. W. Young. Cogeneration Could Provide Economic Benefits in
Steamflood EOR Operations. Oil & Gas J., v. 82, No. 18, May 5, 1984, pp. 81-86.
Dedrick, C. T. and J. S. Ahuja. Cogeneration and Enhanced Oil Recovery. Meyer, R. F.,
J. C. Wynn, and J. C. Olson, eds. The Future of Heavy Crude and Tar Sands. Second
International UNITAR Conf., Caracas, Venezuela, February 1982, McGraw-Hill, New York, pp.
5 10-515.

Western, E. R. and D. W. Nass. Cogeneration Improves Thermal EOR Efficiency. Oil &
Gas I., v. 88, No. 40, Oct. 15, 1990, pp. 41-43.
Other Tvoes of Steam Generators
Davis, J. S., W. W. Young and C. 1. Lyns. Use of Solid Fuels Possible for Field Steam
Generation. Oil & Gas J., v. 79, No. 22, June 8, 1981, pp. 129-134.
Sperry, J. S., R. S. Poston and F. S. Young. Development and Field Testing of the Vapor
Therm Process in the Carlyle Pool-Allen County, Kansas. Pres. at the Fourth Ann. DOE Symp.
on Enhanced Oil & Gas Recovery & Improved Drilling Methods, Tulsa, OK, Aug. 29-31, 1978.
Proceeding, v. 2, No. lB, pp. D-2/1-D-2/29.
Sperry, J. S., F. S. Young and R. S. Poston. Development and Field Testing of a Process
for Recovering Heavy Crude Oil in the Carlyle Pool-Allen County, Kansas Using the Vapor
Them Generator. U.S. Dept. of Energy Report No. DOEBETC-2880- 1, September 1980.
Young, F. S. and R. W. Krajicek. The Vapor Therm Process for Oil Recovery of Viscous
Crude Oil. In: Meyer, R. F., J. C. Wynn and J. C. Olson, eds. The Future of Heavy Crude and
Tar Sands. Second International UNITAR Conf., Caracas, Venezuela, February 1982, McGraw-
Hill, New York, pp. 466-468.
 APPENDIX 6-A
API RECOMMENDED FUEL OIL ANALYSIS SPECIFICATION SHEET^

Higher Heating Value (HHV)

Lower Heating Value (LHV)
Density, 60' F
or
Specific Gravity, 60' F
or
API Gravity, 60/60° F
Viscosity @ 60' F SSU
SSU
200" F SSU
Other O F SSU
Conradson Carbon Residue % Wt
Ash % Wt
Carbon (C) % Wt
Hydrogen (H) % Wt
Sulfur (S) % Wt
Nitrogen (N)
Water (H20)
Sediment
Vanadium (Va)
Iron (Fe)
Magnesium (Mg)
Sodium (Na)
Chloride as NaCl Lb/100 bbl
 APPENDIX 6-B

API RECOMMENDED FUEL GAS ANALYSIS SPECIFICATION SHI3ET4

Higher Heating Value

Lower Heating Value
Molecular Weight
or
Density, 60' F & 14.696 psia
Temperature
Supply Pressure

Components (Mol %)
Carbon Dioxide (Ca)
Hydrogen Sulfide (H2S)
Nitrogen (Nz)
oxygen (02)
Methane (Ch)
Ethane (C2&)
Propane (C3Hg)
Butanes + (C4+)
 APPENDIX 6-C

API RECOMMENDED WATER ANALYSIS SPECIFICATION SHEET^

Source:
Pressure: ps1g
Temperatme: O F (Min) O F (Max)
Components
*Calcium, (Ca)
*Magnesium, (Mg)
*oxygen, (02)
Barium, (Ba)
*Iron, (Fe)
*Sodium, (Na)
Copper, (Cu)
Potassium, (K)
Ammonium, (m)
*Chloride, (C1)
Iodide, (I)
Bicarbonate, (HCO3)
Carbonate, (CO3)
Silica, (Si02)
Sulfate, (SO4
Hydroxide, (OH) mg/l
Hydrogen Sulfide (H2S) mg/l
Organic Acids m@l
"Total Alkalinity mg/l
*Total Hardness, (CaC03) mg/l
*Total Dissolved Solids mdl
*Total Suspended Solids mdl
*pH Specific Gravity @ 60' F
Color
*Oil mgfl Resistivity @ 75' F Ohm-meter

*Minimum Data Required

 APPENDIX 6-D
API RECOMMENDED MAINTENANCE PRACTICE
FOR OILFIELD STEAM GENERATOR^

6.1 It is recommended that maintenance and inspection 6.3.4 If the Wet Steam Generator is shut down the
procedures be performed daily, monthly and annuaily. condition of the convection section and radiant
All repairs and maintenance sbould be documented. section tubes should be noted. Fin loss
The manufacturer's recommendations should always be deterioration or fouling should be noted and
a part of maintenance and inspection, and forms recorded.
should be designed for each specific application.
Consider the environment in which a generator 6.3.5 If the Wet Steam Generator is shut down, the
operates. Severe environments may require special flame stabilizer/di ffuser and fuel nozzle, used
maintenance and inspection. with heavy oil burners should be inspected and
cleaned as rcquird.
6.2 Daily Maintenance And Inspection
6.4 Safety Inspection (See Table 6 - D l )
6.2.1 A minimum daily routine of inspecting and
recording of all instrument readings is 6.4.1 It is recommended that all safety devices be
recommended and the following is a list of the tested at a minimum of once each sixty days.
minimum readings that should be recorded (See State and local codes may require more frequent
Table 6.4): testing.
a. Feedwater pump discharge pressure
b . Feedwater flow rate 6 . 4 . 2 Some regulations require a minimum of five
c. Steam outlet pressure safety shutdown devices to be responsive.
d. - Steam outlet temperature a. High steam pressure
e. Water inlet temperature b. High tube temperature
f. Radiant tube skin temperature c . Flame failure
g . Fuel nozzle pressure d. Low combustion
h . Stack temperature e. L,uwI'cc.dwaterflowrate
i . Radiant section pressure
j. Fuel rate 6.4.3 Most manufacturers and purchasing companies
k. Excess air or 0, require additional safeties, and local codes may
require others. Any additional safeties should
In addition there are other parameters that be tested and the results recorded.
require testing, calculations, or judgment and
should also be monitored and recorded. The 6.4.4 Where possible always test both the electrical
following items are recommended: and sensing portions of any safety device.
a. Water quality
b . Steam quality 6.4.5 Any safety that does not function must be
c. Flame pattern replaced or repaired.
d. Visual internal and external inspection
e. Lubricating oil levels of the feedwater 6.4.6 The following is a listing of the safety devices
pump power end. that should be tested each 60 days.
f. Lubricating oil level of the air compressor a. Flame failure
g . Filter and strainer efficiency b. High steam temperature
c . High steam pressure
6.3 Monthly Maintenance And Inspection (See Table 6.5) d. High tube temperature
e. High stack temperature
6.3.1 Feedwater pump, fluid and power ends and drive f. High burner throat temperature (oil fired
systems should be inspected. The manu- only)
facturer's recommended maintenance procedures g . Swing out burner switch
should be followed. The crankcase oil should h. HighILow atomizing pressure foil fired
be inspected and replaced as specified by the 011ly)
manufacturer. i . High fuel gas pressure
j . Low fuel pressure
6.3.2 All motors should be inspected and lubricated k . Low fuel oil temperature
as specified by the manufacturer. 1. Low fcedwater flow rate
m . Low combustion air pressure
6.3.3 Fuel, water, air strainers and filters should be n . Low instrument air pressure
cleaned and services, as required. o . Low steam pressure
 TABLE 6-D- 1 - Steam Generator Safety Inspection Check Sheet4

Unit No. State Serial Nu. Inspection Date

Make of Unit & Fuel Used Location Inspector's Signature

1. Enter OK or failed in column headed "Proper Operation"
2. Enter set point of control in column headed "Set Point"
3. Describe any safety failure under "Comments" and describe repairs made
4. Draw line through any safety listed that is not on this unit

Low combustion air pressure 1 1

Low fuel ~ressure
H i ~ hfuel gas pressure
Low steam pressure
Low instrument air
Burner throat tem ~erature
Swine out burner switch
EIigh stack temperature
Low atomizin rr Dressure
Low fuel oil 6mprature
Safety relief valves*
Visual check of external wiring, conduit, piping, tubing and fittings for obvious leaks or defects.
All gauges must be checked for proper calibration.
* Consult state and local codes for test procedures.
Electrician Date

Mechanic Date

Operator Date

Foreman Date
 with the free operation of the
6.5 Annual Maintenance And Inspection (See Appetlclix valve. It is recommended that
6-E) annually the safety valves be
removed from the unit, tested and
6.5.1 Permanent and progressive records should be reset at an approved safety valve
maintained for each Wet Steam Generator. 1t is testing facility or by the valve
recommended that the following documents and manufaccurer, State or local regu-
information be included: lations may require more frequent
All ASME Manufacturers' Data Reports. inspection or testing.
Drawings showing the location and thick- 3 . Elcctr~cal. The continuity and con-
ness of monitored or critical inspection dition of ail electrical components
locations. should be checked.
If material loss is found within the piping b. Intcrnal Inspections. Where there is
system the maximum allowable working evidence of insulation or refractory fail-
pressure and temperature should be recom- ure the material should be repaired or
puted by a qualified person and the Wet replaced.
Steam Generator derated or repaired 1. The surface of all tubes should be
accordingly. All calculations should be carefully examined for any
made a part of the annual record. All name evidence of corrosion, erosion,
plates, permits, etc., must reflect the deformation, bulging, sagging,
change. In addition, a name plate rubbing cracks or de-fective welds. The
should be included in the records. radiant coil or tubes and the
Hydrotest the steam piping from the convection section should be spot
feedwater pump discharge to the steam checked for wall thickness by a
outlet at the time of inspections. If appli- non-destructive test. If repairs are
cable record the hydrotest pressure. made to the code sec-tions of the
Schedule date of next inspections. Wet Steam Generator, a record of
Date of any significant changes in service the repair must be made. A partial
conditions. data sheet, ASME form P-3 for the
Complete pressure relieving device material or piping used, is to
information including safety relief valve accompany the repair form.
spring data and dates of latest and next 2 . Tube hangers, yokes and hanger
inspe.ction. bolts should be inspected for
The completion of a performance data thinning, cracking, stress or de-
sheet (see Ref. 4, pg. 10) is recommended. formation.
The data can be a useful inspectionlmain- 3. THE HYDROSTATIC TEST PRES-
tenance tool. S U R E SHOULD BE 1-1/2 TIMES
The Wet Steam Generator Mechanical THE MAXIMUM ALLOWABLE
Design Data Sheet (see Ref. 4. pg. 11) WORKING PRESSURE AND
should be completed and become a part of SAFETY PRECAU-TIONS MUST
the initial records. It should be checked BE EXERCISED.
and updated annually to reflect nay
changes.

6.5.2 A safety check should coincide with an annual

maintenance procedure and in addition to the
items inspected daily and monthly, the
following points should be inspected for
proper annual maintenance:
a. External Inspections. Any evidence of
steam or water leaks should be investi-
gated. Leakage from behind insulation.
coverings or supports should be
investigated and corrective action
taken.
1 , All pressure and temperature
instruments should be calibrated
and replaced as required.
2. Safety relief valves should be
carefully examined at each in-
spection and there should be no
accumulations of rust, scale or
other foreign substance in the
valve body which will interfere
 APPENDIX 6-E. - Steam Generator Annual Check ~ i s t "

fnsoe
Descri~tionof item Yes Comments
WATER FLOW SYSTEM
Water inlet flange
Suction dampener
Isolation valve
Water Met drain valve
Cooling coil valve
Feedwater pump
Oil level control
Oil reservoir
Pump motor
Belt guard
Pump by-pass
Pump relief valve
Discharge dampener
Feedwater orifice
Feedwater flow r e a d
Idet check valve
Inlet stop valve
Feedwater preheater
By-pass valves
Diverting orifice
Radiant coil vent valve
Steam discharge separator
Safety valve
Safety valve
Pressure gauges
Pressure gauge valve
Pressure gauge test valve
Vent valve
Cooling coil valve
Drain valves
Thermometer with socket
Convection section
Stopkheck valve(s)
Sample cooler
Radiant section
Blowdown valve
ANNUNCIATOR PANEL
Flame monitor
High steam temp.
High tube temp.
High stack temp.
High burner temp.
Low oil temp.
High steam press.
High atom. press.
Low atom. press.
Low gas press.
Low oil press.
Low instrument air press.
Low combustion air press.
 APPENDIX 6-E. - Steam Generator Annual Check ~ist?-Continued
InsDe mQ
i l
Yes Fault. Reol aced Comments

PNEUMATIC SYSTEM
Air compressor
Air receiver tank
HigMow press. switch
Air relief valve
Pressure gauge
Gauge valve
Instrument air filter
Air pressure regulator
Air pressure regulator
Pneumatic transmitter
Transmitter valve manifold
Water flow rate gauge
Burner control signal
Flow purge solenoid
High purge solenoid
Low fire solenoid
High signal selector
Manual loader (water)
Bias regulator (burner)
Burner operator wlpositioner
Pressureconmllcr
MAIN GAS SYSTEM
Gas inlet
Manual gas stop valve
Safety shut off valves
Vent valve
Gas pressure regulator
Gas Orifice Flanges
PILOT GAS SYSTEM
Manual pilot gas stop valve
Pilot regulator
Pilot solenoid valve
FUEL OIL PIPING
Oil inlet valve
Oil strainer
Manual bypass valve
Oil pressure relief valve
Steam/oil heater
Temp, control valve
Temp. controller
Pneumatic valve
Electric oil heater
Oil pressure regulator
Thennometer
Oil return valve
Oil meter
Oil meter valves
 APPENDIX 6-E. - Steam Generator Annual Check ~ise-xontinued
Insoc
Yes Renl aced Comments

FUEL OIL PIPING-Continued

Pressure gauge
Gauge valve
Burner oil valve
Solenoid valve
ATOMIZING AIR SYSTEM
Air stop valve
Air pressure regulator
Air solenoid valve
Air check valve
ATOMIZING STEAM
SYSTEM
Steam stop valve
Primary steam regulator
Pressure gauge
Steam separator
Steam press. relief valve
Steam trap
Secondary steam regulator
Steam wle~loidvalve
Steam check valves

BURNER
Bumer
Blower motor
Flame stabilizer1
diffusers plate
MISCELLANEOUS
Observation ports
Manometer
 APPENDIX 6-F
STEAM GENERATOR VENDORS
A. Oilfield Steam Generators
2. Babcock & Wilcox ST Co*
Babcock & Wilcox ST Co. Struthers Thermo-Hood Division
StruthersThermo-Flood Division 8900 Fourche Dam Pike Road
8900 Fourche Dam Pike Road P.O. Box 1901
P.O.Box 1901 Little Rock, AR 72203
Little Rock, AR 72203 Telephone: (501) 490-2424
Telephone: (501) 490-2424
Contact: J. D. McNeal D. used Oilfield Steam Generator Supplier
NATCO 1 . Virgles Steam Service
Division of National Tank Company Renfro Road
4550 Pierce Road Bakersfield, CA 93312
Bakersfield, CA 93308 Telephone: (805) 589-2597
Telephone: (805) 325-4146
Contact: Bert Miles
Daniel En-Fab Systems Inc.
3905 Jensen Drive
P.O.Box 21361
Houston, TX 77226- 1361
Telephone: (7 13) 225-4913
B . Qrzeneration U n i (Self-contained
~
Units)
1. Solar Turbines Inc.
Division of Caterpillar
2625 Butterfield Road, Suite 315 W
Oak Brook, I . 60521
Telephone: (708)572-0303
Contact: Cort Van Rensselger
2 . Vogt Machine Company
Dept. 24A
P.O. Box 1918
Louisville, KY 4020 1- 1918
Telephone: (502) 634- 1500

1. NATCO
Division of National Tank Company
4550 Pierce Road
]8akersfield, CA 93308
Telephone: (805)325-4146
 CHAPTER 7
STEAM DISTRIBUTION

INTRODUCTION
Steam leaving generators is directed to injection wells through a network of pipelines called
the steam distribution system. The high temperature and pressure of the steam to be injected
influences the size and installation of lines transmitting it. In the past, a steam distribution system
was considered merely a pipeline between steam generators and injection wells. However,
experience of the past decade indicated that the network can behave as an unpredictable phase
separator delivering near 100% quality steam to one well and at the same time deliver hot water to
another well on the same distribution line. Hence, the steam distribution network must be
designed not only for appropriate pressures and temperatures, but also to provide desired steam
quality at a desired flow rate to each injection well in the network. Consideration must be given to
maintaining optimum line velocities and provide for the measurement of steam quality at points
other than the generator outlet.
The objective of this chapter is to present an overview of the features and requirements of a
steam distribution network in a modem steam injection project. The basic function of the steam
distribution network in a steam injection project is to deliver steam reliably and safely to injection
wells at a desired rate and quality.
Components of a Steam Distribution Network
A steam distribution network consists of the following major components: (a) main headers;
(b) lateral steam lines; (c) wellhead steam rate contlals, and (d) wellhead assembly. The design of
a steam distribution system is based on the following factors:
1. The expected rate of delivery of steam to each injection well.
2. The expected system operating pressure (This will be principally a function of the
expected reservoir injection pressure).
3. The desired steam quality at each injection well.
4. Minimize the effects of phase-splitting.
The principles of operation of a steam distribution system are simple and straightforward.
Figure 7.1 shows a schematic of a typical steam distribution system employed in a steam injection
project The steam generator(s) deliver steam to the main header usually at a steam quality of 70 to
80%. These steam headers range in size from 12 to 24 inches, depending on the steam generation
capacity of the project and project steam requirements.
Steam is transported from a steam header to individual injector well lines by a steam lateral
system. The lines making up this system typically range between 3 and 10 inches in nominal
diameter.
 STEAM HEADER
r'

STEAM GENERATING SITE

STEAM INJECTION WELL

FIGURE 7.1. - Schematic of a typical steam distribution system layout.

The rate of delivery of steam to each individual well is controlled by the installation of some
form of rate control, in general at the wellhead itself. These control devices are currently of two
forms The first is merely a static choke driven by system pressure to critical (or sonic) flow. The
second device widely used is a manually adjustable choke or control valve operated in the
subcritical flow regime. Both forms of control are discussed in detail later in this chapter.
Finally, the steam injector downhole tubing can be expected to expand and contract as its
temperature risesand falls. Since it hasibecome common practice to install a downhole tubing
packer, the movement of the expanding tubing downhole can become somewhat restricted. The
movement of the tubing through the wellhead can become considerable. It is the purpose of the
wellhead assembly not only to deliver the steam from the distribution network to the injection well
tubing, but also to provide for the expected tubing movement at the wellhead.
The discussion within this chapter is organized into the following sections:
(a) General system pressure and tem,peraturedesign requirements;
(b) Main steam headers;
(c) Lateral steam lines;
 (d) Expansion of steam lines;
(e) Support for steam lines;
(f) Insulation and heat losses;
(g) Effects of branching on steam quality;
(h) Wellhead assembly;
(i) Wellhead steam rate control devices;
(j) Control of individual well steam quality; and
(k) Maintenance and monitoring.
A list of steam distribution network component suppliers is included in Appendix 7-A.

General System Pressure and Temperatiire Design Requirements

The distribution of steam to several wells on an oil property does not pose any unusual
engineering problem, and the design of the network is straightforward. The elevated temperature
of steam to be injected, however, influences the size and installation of the network. Hence,
careful adherence to recognized engineering and operating pmtices should be observed. The
distribution system should be designed for the expected maximum operating temperatures and
pressures within the system. Table 7.1 shows the working pressures recommended for steam
transmission lines. This table should be used to select the appropriate line size after determining
the maximum allowable frictional pressure drop. Table 7.1, taken from reference 1, is based on
ANSI (American National Standard Institute) standards 31.3 and 3 1.8. The temperature and
pressure ratings for steel flanges based on ANSI Standard 16.5 are shown in table 7.2. It is
recommended that design of the steam transmission lines be based on ANSI standards as these
allow for an ample margin of safety.
Temperature increases cause steam transmission lines to expand, as shown in table 7.3.
Hence, thermal expansion must be accounted for in the design of steam transmission lines. If
thermal expansion of the s t e m distribution lines is not adequately compensated for, the lines will
be subjected to thermal and bending stresses. Thermal stresses accelerate the corrosion of the lines
and weaken the pipe walls. Bending stresses may result in line splitting or rupture. Failure is
unlikely to occur until part of the metal wall has been removed by corrosion.
The bending stress can usually be eliminated by providing for the expansion of the lines.
Incorporation of expansion loops or swivel joints in the lines is the most practical way to relieve
bending stresses. According to table 7.3, a pipe heated from 60' to 460' F expands 3.336 in./lOO
ft. Thus, an expansion loop on a line with 250 ft between anchors would require a loop that would
handle 8.4 in. of pipeline expansion. Expansion of steam lines is discussed more fully in a later
section.
 TABLE 7.1.- Design Properties and Allowable Working Pressures (psig) for piping1
ASTM A106, grade B seamless pipe - petrolcum refinery piping code
for pressure piping ANSI B31.3-1966- Corrosion alIowanct: = 0.05

?om Allowable working pressures for tznlperatures (in OF) not to exceed
Sch. Wt of Wall I D,
NO. pipe. o D. thk. -20 to
in. 1bfit in. in. n.
I 100 200 300 400 500 600 700 800
 TABLE 7.1 -Continued

Nom Allowable work ng pressures for temperatures (in OF) not to exceed
p!pe Sch. Wt of Wall 1 D,
me, No. pqe, 0 D, hk., (d) -20to
in. lwft in. in. In. 100 200 300 400 500 600 700 800

TABLE 7.2. - Pressure-Temperature Ratings for Low Carbon Forged Steel Pipe ~langesl
ANSI Standard B 65.5 - 1968

Flange rating 1 5@1b 3Wlb

service
temperature, O F Maximum. non-shock, service pressure ratings, p i g

TABLE 7.3. - Thermal Expansion of Steel pipe2

Change Change in
temperature, Expansion, temperature, Expansion,
OF in.1100 ft "F i d 1 0 0 ft
 Main Steunz Headers
The purpose of the main steam headers is to collect steam produced by one or more steam
generators at one or more sites and deliver this steam to various steam laterals for distribution. The
steam collected by the main headers will vary in steam quality from generator to generator. In
addition, the quality of the steam delivered by a generator during its initial start-up may approach
zero.
Depending on the volume of steam it is expected to carry, the main header size may vary
from 12 to 24 in. Steam headers usually have extra strong wall thickness-more than that required
by the code-to allow for extra margin of safety. The size of the steam pipe is usually determined
using empirical steam flow equations such as the Unwin formula (Eq. 7.1 ) or Fritzsche's formula
(Eq. 7.216
The Unwin formula for steam flow is

The Fritzsche formula for steam flow is

where
d = internal diameter of the pipe, in.
L = length of pipe, in.
P = pressure in ib per sq in. gauge
W = rate of flow of steam in lb per hr
V = specific volume of steam, cu ft per lb
The Fritzsche formula is believed to give more accurate results for pipes lo-in. and larger, carrying
steam at high velocities.
The headers are usuaily sized based on the minimum acceptable pressure drop in the header.
If the available steam pressure is lower than the acceptable pressure drop, the header should have
been sized larger than normal to minimize pressure losses. Since the headers cany large volumes
of steam and are located adjacent to the generators where there is greater exposure to personnel,
they should be designed and fabricated using the most stringent standards. Construction practices
should be based on accepted standards, and pipe welds should be subjected to more frequent X-ray
inspections.
 A shut-off valve must be provided at each steam lateral connection to the header. This will
facilitate the isolation of any lateral for repair or maintenance. A bypass valve should also be
installed in parallel with the shut-off valve to allow for slow preheating of the lateral.
Because a steam generator can introduce significant amounts of cold water to the steam
header during the startup and shutdown phases, it is a common field practice to install a
"blowdown" line. This line permits the operator to divert the discharge from the generator to
atmosphere and to a sump during the startup or shutdown phases. By using this line, the operator
can minimize the stresses placed on the steam header system.

Lateral Steam Lines

Steam Flow Rates and Pressure Drop
The purpose of the steam lateral system is to deliver steam from the headers, located at the
generation sites to the steam injection wells. The necessary steam lines can vary in size from 3 to
10 in. in diameter although lateral line sizes may reach 18 in. diameter or more. The steam lateral
system resembles very much the branches of a tree. Larger lines leaving the steam headers branch
into smaller and smaller lines until the system ultimately delivers steam to the wellhead assembly.
The size of these lines is determined by the design engineer based on the Unwin steam equation or
other steam flow equations (see Eqs. 1 and 2).
Like headers, steam laterals are sized based on the pressure drop that can be tolerated by
existing pipe or based on allowable steam velocities. Steam velocities that are typical in oilfield
steam distribution networks are between 35 and 70 ftkec, with normal velocities in the range of 40
to 55 ft/sec. Velocities below 35 ft/sec will result in increased phase separation, and velocities
exceeding 70 ft/sec will result in high pressure losses and curtail the system's ability to deliver
steam to remote we~s.8
In addition to the use of the Unwin and similar equations for steam flow calculations, newer
steam distribution networks are being designed with the use of commercial pipe network analysis
computer programs. These programs permit the design engineer to try out "on paper" various
piping networks or layouts.

Steam Shut-off Valves

The designer of the steam lateral system should include a steam shut-off valve at the
beginning point of any branch. This valve should be of sufficient pressure and temperature rating
for the expected steam service. In addition, on any of the branch lines that are 6 in. or larger, a 2-
in. steam bypass valve should be placed in parallel with the shut-off valve. This bypass valve will
be useful in "preheating" the branch line prior to placing the line in service. By bleeding steam
through the 2-in. bypass, not only can the line be slowly preheated and thereby expanded without
shock, but liquids left in the line as a result of construction and testing can be delivered to the
injection wells at low and therefore safe velocities. During the steam bypass operation, injection
wells may be opened and closed in sequence beginning with the we1Is nearest the beginning of the
branch. The presence of flowing liquid in the lines may be detected by the audible differences at
the well rate control device (the steam choke or the control valve).
In laying out the steam lateral system, the designer should avoid the use of circular paths or
steam flow loops, for example, terminating one lateral branch into another. Although this might be
attractive in minimizing pressure losses, it can lead to hazardous situations when a portion of the
system must be isolated and depressurized for repair or maintenance.

Expansion of Steam Lines

Temperature variations in the steam flow line cause expansion and contraction that can be
relieved by expansion loops. An expansion loop or anchor should be installed at each point where
the line changes direction vertically (i.e., at the crest of a hill or at the bottom of a ravine). If the
steam lines are buried, the pipe should be brought to the surface for a distance great enough to
accommodate an expansion loop, then returned to undegsound. The buried line should be brought
to the surface at least every 300 ft to provide for expansion.
If a steam manifold is used to supply several wells. an expansion loop should be located at
the manifold for each line leaving the manifold.*
Three techniques are available to deal with the expansion of steam lines. They are as follows:
1. Manufactured bellows-type expansion joints. These are more expensive and their use is
usually restricted to the headers.
2. Vertical pipe loops. These are generally field fabricated and installed vertically to
conserve sudace area for wells and facilities.
3. 2-Bends. These are the least costly of the three alternatives. They are usually field
fabricated and installed. 2-bend type expansion joints also allow one to take advantage of
surface terrain and piping layout during installation.
Figure 7.2 illustrates the typical vertical and Z-bend type expansion loops used in steam injection
operations. Figure 7.3 shows several methods of providing for expansion.
Figures 7.3a and 7.3b show buried lines in which expansion takes place above ground. In
the case of figure 7.3a, the extra weight of covering forces the expansion to occur only at the loop.
When an expansion loop is used at the wellhead with the buried line. as in figure 7.3b, the line
should be heated by passing steam through the line and then covered while heating2 Figures 7 . 3 ~
and 7.3d show surface lines in which expansion is cnntrolled by placing the line on supports or on
hanging chains that allow the line to move in several disections.
 TO INJECTION WELLS

FIGURE 7.2. - Typical expansion loops used in steam injection operations to relieve
steam flow line thermal ~tresses.~

9
EXPANSION

2
EXPANSION

SUPWRTS '
EXPANSION

FIGURE 7.3. - Schematics of different expansion methods for steam injection lines?
 Dead anchors must be installed between expansion devices to force the pipe movements to
the expansion device. The location of the dead anchors is largely determined by the piping layout.
The expansion devices are usually installed approximately midway between two anchors. Table
7.4 can be used to select the loop size and anchor spacing for vertical loops. 2-bend type
expansion joints can be sized using figure 7.4.

TABLE 7.4. - Loop Size vs. Spacing

Loop Size,ft
Pipe Size, in. Spacing, ft Ileight Width

2" Sch.40 150 7 7

200 8 8
250 9 9
3" Sch. 40 150 9 8
200 10 9
250 11 11
4" Sch. 40 200 12 10
250 14 12
6" Sdr. 40 200 15 13
250 16 16
8" Sch.40 200 17 15
250 18 18
10" Sch. 40 200 19 18
250 20 20
12" Sch 40 200 20 19
250 22 20
NOTE: Use longest spacing possible.

12"
- LENGTH

- C

WIDTH

-
8"

6"
-

- 4"
10
3"
5 3"

0 I I I i I I

50 100 150 200 250 300 350 400

LENGTH BETWEEN DEAD ANCHORS, ft

FIGURE 7.4. - 2-bend expansion loop sizing chart.

 Expansion loops must be equipped with bleed valves at the upstream side* so that it is
possible to do the following:
(a) Bleed off the line when any shutdown occurs. This is very important in cold climate,
where the lines may otherwise freeze during winter.
(b) Bleed off liquid, if two-phase flow becomes a problem.
(c) Provide for w m u p of the line.

Expansion of the Steum Headers

The manufactured bellows type expansion joint is the preferred expansion device for steam
headers because of its greater reliability and safety. These devices, however, permit only a limited
amount of pipe movement. Hence, the expected amount of pipe expansion and contraction must be
accurately calculated prior to selecting the expansion joint. If the header is not properly supported,
it may laterally deflect enough under pressure to "pull" in its length and over travel the expansion
joints.
Both the laterals and the individual steam generator discharge lines which connect with the
header must be equipped with an expansion joint to facilitate the expected movement of the header.
This is generally accomplished by installing lateral line supports near the header which allow for
lateral (sideways) movement.

Wellhead Connection
Temperature changes affect the well head connections because of both vertical expansion of
the casing and tubing and horizontal movement of the steamline supplying the well. This problem
can be overcome by a variety of ways. For example, a flexible connection. such as a steam hose
can be used in low-temperature and pressure steam injection applications. However, when higher
temperatures and pressures are required, expansion joints and swivel joints must be used between
the line and the wellhead. Figure 7.5 shows a typical swivel joint used at the injection wellhead
which permits vertical movement of tubing and horizontal movement of steam line. Figure 7.6
shows an expansion manifold used to connect the Christmas tree and flow line of a steam injection
well. The dotted part of this figure indicates movement of tree and manifold due to thermal
expansion.

Support of Steam Lines

An expansion is not effective unless both lines to the loop are supported. Otherwise, the line
may creep toward one loop and not return to its original position upon cooling. The determination
of the spacing between these supports should be based on basic statics and the assumption that the
longitudinal pressure stress in a pipe is no more than one-half the allowable stress. This
FIGURE Schematic of a typical swivel joint used at the steam injection wellhead?

FIGURE 7.6. - Schematic of expansion manifold connection to steam injection well

Christmas kee.4
assumption would allow the bending stresses due to weight loading to be as much as one-half the
allowable stress. Since the effects of thermal expansion on bending stress are rarely completely
known, a span length that produces bending stress no more than one-quarter the allowable stress is
preferred. The formulas for support spacing N (ft) are:

For a continuous beam: N = llZS/4wf (7+3)

For a free span:
where N = Allowable spacing of supports, ft
z = Section modulus of pipe, inches3
2m
0.0982 (@-d4) / D
Moment of inertia, inches4
kg2
0.049 1 ( ~ ~ - d ~ )
Cross-sectional metal area, inches2
n (DW) I4
Radius of gyration, inches
v ~ ~ + d ~ / 4
Outside diameter of pipe, in.
Inside diameter of pipe, in.
Allowable stress, psi - based on ASTM Standards
Weight of line full of fluid, plus insulation and other permanent
loads, Ibf/ft
A free-span condition is rarely, if ever, encountered, and the assumption of a continuous
beam is also not representative of typical conditions. As a result. it has become practice to use a
span length between the two calculated extremes. A chart or graph is generally developed (based
on the before mentioned equations) and provided to the field construction personnel.
The construction of the pipe support varies widely from field to field and operator to
operator. Some operators make extensive use of the chain type pipe hanger. Its advantages are
that it is easily field fabricated and therefore inexpensive. In other fields a guided sleeve support is
commonly used. The advantage is a cleaner appearance as well as a more controlled pipe
movement. This may be of particular importance in areas of high piping congestion. The
disadvantages of the guided support are (1) it is more expensive and (2) the piping insulation may
be damaged as the line moves through the guide.
A more conservative approach to supporting steam headers should be taken than that
recommended for steam lateral lines. The startup or shutdown of a steam generator may introduce
cold water to the steam header. If this should occur, "water hammering" of the header can be
expected. This will result in very high instantaneous pressures within the header. These pressures
will act to place the header in a stressed condition similar to that of a loaded structural column. The
Euler equation, which predicts the failure load for structural columns, suggests that the strength of
the column can be increased by "pinning" the column at points along its length. Properly designed
guided supports can serve to "pin" the header. The equations described under the laterals section
should be used as a guide for selecting header pipe support spacing, but in no case should the
spans calculated using these equations be exceeded.

Insulation and Heat Loss

The economic successes of a steam injection process is measured in terns of oil-steam ratio
or barrels of oil recovered per barrel of steam injected. As a general rule, the oil-steam ratio can be
improved by delivering higher quality steam to the sandface. The sandface steam quality depends
on the amount of heat lost from the surface and subsurface tubings. Heat losses can be minimized
by insulating surface steam lines and employing insulated tubing downhole. Subsurface insulated
tubulars are discussed in detail in a later chapter. In this section, surface steam pipe insulation
requirements are addressed.
Even though heat losses from the surface lines in steam injection operations may be a small
fraction of total heat injected, it is generally worthwhile to insulate them to lower fuel costs, and as
a safety precaution. Heat losses from bare, buried, and insulated steam pipes are shown in
Table 7.5 as a function of temperature for various pipe sizes.2 A bare 3-in. line will lose 1,496
Btu/hr/ft length of pipe at a temperature difference of 400' F. With 1.5 in. of 85% magnesia
insulation, the heat loss is reduced to 184 Btu/hr/ft length. Figure 7.7 shows the cash loss per year
per foot of line as a function of injection line heat loss in Btulhrlft length. Steam costs were
assumed as $2.22/MM Btu (based on an oil price of $12.00 per barrel and an assumed oil heat
content of 130,000 Btdgallon). From this figure, reduction of heat loss from 1,496 to 184
Btdhrlft length results in a savings of $25.50 per year per f t length. Assuming the cost of
insulating a 3-in. pipe as $1 1.00 per ft, (see chapter 4), heat loss savings amounts to $14.50 per ft
per year or equivalence of one additional barrel of oil production per year per ft length. Hence,
significant savings in fuel consumption can be realized by insulating the surface lines.
Accordingly, surface lines, especially those from steam generators, are usually insulated in steam
injection operations.
 TABLE 7.5* - Heat losses from pipes Btufhdft length (steady state)

Bare pipe: Temperature difference, O F

Nominal
pipe size

2 488 578 1.040 1,552 2,198

3 701 935 1,496 2,25 1 3,196
4 886 1,177 1.894 2,845 4,043
6 1,279 1,701 2,740 4,127 5,878
Buried pipe: (24 in. cover-average California)

2 89 107 143 178 214

3 132 158 211 263 316
4 169 203 27 I 338 406
6 249 299 399 498 598
Insulated pipe: (1-1/2 in. 85% Magnesia)

Steam Cost = $2.22 / MM Btu

(based on an oil price of $12 a barrel,
and the heat content of oil is
assumed to be 130,000 Btu / gallon)

0 10 20 30 40 50

CASH LOSS / yr / ft of line, $

FIGURE 7.7. - Steam injection line heat loss versus cash loss.
 Depending on the expected operating pressure of the steam distribution system, the internal
operating temperature of the system can be expected to range between 350° and 600' F. At these
temperatures, the decision on the type and thickness of the pipe insulation becomes a question of
economics. Two types of pipe insulation are commonly used in stearnflood operations:
1. Fiber glass wool wrapped with a thin skin of sheet metal (usually aluminum) - the
thermal conductivity of the fiber glass wool is 0.022 Btulhr-ft-OF.
2. Calcium silicate wrapped with an impervious barrier followed by a thin skin of sheet
metal (usually aluminum) - the thermal conductivity of the calcium silicate is 0.017
Btu/hr-ft-OF.
The convection coefficient for heat transfer from the outside skin of the insulation surface is
generally taken to be in the range of 2 to 5 Btulhr-ft2-OF.
The rate of heat transfer from a unit length of pipe may be calculated by referring to
figure 7.8 and the following radial heat transfer equation.

q L = Uo (AL) AT = 2%(Ti - To)I ((l.(r/ri) /k) + Ih) (7.5)

where qlL Rate of heat transfer per unit length of the pipe, Btuflr-fl
uo Overall heat transfer rate, Btu,hr-ft2-O~
A Heat transfer surface area, ft2
AT Temperature difference between the pipe wall and the
air, OF
Ti Pipe wall temperature-assumed to be the same as the
internal steam temperature, OF
To Air temperature, OF
f Inside radius of the insulation, ft
ri Outside radius of the pipe, ft
k Thermal conductivity of the insulation, Btulhr-ft-OF
h Convective heat transfer coefficient, ~ t u / h r - f t ~-- " ~
commonly taken to be in the range of 2 to 5 ~tu/hr-ft2-OF

FIGURE 7.8. - Schematic of insulated pipe for heat loss transfer estimation.

222
 If r = rcrit = k/h in the above equation, a critical insulation thickness is reached. Adding
insulation until this critical thickness is reached will decrease heat losses. Adding insulation
beyond this critical thickness will increase the rate of heat loss. More insulation, at least in the case
of pipe, is not always the best solution to reducing heat losses.
To maintain the insulating properties of either of the two materials recommended above,
several general practices should be observed. First, the insulating material should be installed
without undue compression of the material. It is, after all, the trapped air spaces within the
insulating material which provides the desired insulating properties of the material. Second, the
insulation must be kept moisture free. This begins with the installation of ihe material under dry
conditions only. The thin metal skin applied to the outside surface of the insulation should be
installed in a manner such that rain water will not run into the insulation. One of the biggest
problems in using piping insulation in oilfield service is that the metal skin and the insulation it
protects are often damaged by well workover crews or by heavy equipment used in daily operation
of the field. In addition, field personnel often find that insulated steam lines make convenient steps
or working platforms. This should be discouraged because of the resulting damage to the
insulation, and also the safety risks. The proper siting of steps and pipeline crossings can help to
reduce this kind of damage. If the oilfield is in an area that is frequented by either grazing wildlife
or domestic stock, a means must be provided to prevent damage to the insulation, and the piping
system as well, by these animals. In some cases this involves strengthening the outer protective
skin and in others it will mean erecting barriers to prevent the animals from coming into contact
with the piping system.
Calcium silicate insulation is generally the preferred insulating material for header use
because of the higher human traffic volume around the steam generator site.
Effects of Branching on Steam Quality
Until the late seventies, it was common practice to assume that steam delivered to a steam
lateral system at 80% quality would, after traveling through the various branching points of the
steam distribution network, arrive at each wellhead at 80% quality or less after any adjustments for
heat losses in the lines. In 1978, Chevron published a research paper which demonstrated that this
was not the case. They demonstrated that in laboratory tests steam quality was not being evenly
distributed between two branches of a pipe tee but rather, depending on flow rate (and some other
parameters as well), the liquid phase would favor flowing through either branch and was rarely
split evenly between the two.
Chevron went on to demonstrate that the usual pmctice of installing the pipe tee in a "straight-
through" fashion (refer to Figure 7.9) further provoked the problem of unequal phase splitting. As
a result of further research into the problem of phase splitting at pipe tees, the installation of pipe
tees in the "dead-end" fashion of Figure 7.9 is preferred. In addition, an even split into the two
branches is preferred with a 30-70 split considered the maximum acceptable uneven split. It is also
considered good practice to install the pipe tee as level as possible.
The problem of unequal phase splitting at steam distribution system branches is unfortunately
very complex. No less than six flow regimes have been identified for the combined flow of liquid
and gases (vapors), and some authors have identified seven or more. The flow regime of a vapor-
liquid mixture can be very unstable and therefore very difficult to predict. As a result, computer
pipe network models which properly account for the phase splitting phenomenon are currently
being developed. Their further development will require modeling of existing steam distribution
networks and comparison of the modeling results with actual field measurements. To further
complicate the problem, steam distribution systems currently in operation seem to demonstrate a
tendency towards less than stable delivery of constant steam qualities. That is, at times a given
system may deliver a relatively high quality of steam to a particular well and a shon time later the
same well may be delivered a low quality. For the present, the designer will be left with only the
guidelines of good engineering practice as previously described (dead-end tees with relatively even
flow splits between branches).
Wellhead Equipment
Wellhead design for a steam injection well depends on depth, temperature, and pressure of
the steam and casing and tubing sizes. The wellhead pressure and therefore the system pressure
depend on the maximum steam injection rate that the well can sustain.

St raight-Through Tee Dead-End Tee

FIGURE 7.9. - Schematic of pipe tee installations in steam injection lines.

 Figure 7.10 illustrates a typical wellhead assembly used in a steam injection project. Figure
7.11 shows the wellhead details for a typical steam injection well.
As previously discussed, all tubular goods in an injection well will expand as temperature
increases. But the amount of expansion will not be the same for the tubing. casing, and surface
pipe. The reason for this uneven expansion is that these strings are of different lengths, and at
different temperatures. Hence, provisions for this differential expansion must be made at the
wellhead, unless a packer or an expansion joint is able to accommodate the tubing movement.
Downward expansion of tubing and casings are discussed in a later chapter. Surface expansion of
casing and tubings are usually handled by wellhead stuffing boxes. Figure 7.12 shows a typical
thermal wellhead stuffing box that allows casing to expand and contract as required when a well is
steamed. A tubing stuffing box for steam injection well is shown in figure 7.13. A tubing stuffing
box is similar in design to a casing stuffing box except that it has provisions to allow for
installation of a packer.
A variety of stuffing box designs are used in steam injection applications, depending on the
amount of expansion anticipated, depth, temperature, and pressure. Two such designs are shown
in figure 7.14. The wellhead shown in figure 7.143 provides for upward expansion of casing and
downward expansion of tubing with the rise in temperature. The wellhead shown in figure 7.14b
provides upward expansion of both casing and tubing. This wellhead design contains two separate

a -rG4TE VNVE

SCH 80 SFAMLESS LINEPIPE

r SERIES 400
TOP FLANGE FOR
SlE-TLws

FIGURE 7.10. - Schematic of typical steam injection wellhead mangernent.

 FIGURE 7.1 1. - Schematic of steam injection wellhead details.

FIGURE 7.12. - Schematic of a typical steam injection well casing stuffing box.4
 FIGURE 7.13. - Schematic of a typical steam injection well tubing stuffing box!

FIGURE 7.14. - Schematic of steam injection wellhead assembly showing casing and tubing
stuffing box arrangement.3
stuffing boxes, an upper tubing stuffing box and a lower casing stuffing box for the tubing and
casing expansion. Since this arrangement shows all the tubing weight is set on the packer, this
design is not recommended for use in steam injection wells deeper than 1,000 ft. Use of such a
design in deeper wells may cause the tube to buckle because of its own weight and result in
mechanical failure.
The wellheads used in cyclic steam wells should be equipped to handle fluid production in
addition to the free tubing and casing expansion facility. One such wellhead design is shown in
figure 7.15. This wellhead is equipped with a combination stuffing box-packoff unit that not only
allows free movement of tubing and casing through the wellhead. but also allows steam to be
injected without pulling the rods. To steam the well, the pump is lifted off its seat, and the packoff
unit i s tightened to provide a seal around the polished rod? At the end of the steaming period, the
packoff unit is loosened, the pump is seated, the stuffing box is checked for leakage, and the well
is put on production. A three-way, two-position valve is usually used in huff 'n puff operations to
permit steam injection and oil production through the same wellhead outlet. At the end of the
steaming cycle, the valve is simply turned to the production line as soon as the packoff unit is
loosened and the pump is seated.

STUFFING BOX

PACK-OFF UNIT

FIGURE 7.15. - Schematic of steamflood production wellhead airangement showing

the facilities for pump hookup.3
 As pointed out in a previous section, wellhead assembly must be equipped with a moveable
connection to allow for the free horizontal expansion of the flow line and vertical expansion of
tubing and casing. This is accomplished through the use of three swivel joints (see figure 7.10).
Grease packed swivel joints such as those offered by Buco are the most widely used swing joints
in thermal EOR fields. These joints are designed to accommodate all expansion and temperature
ranges.
Liberal use of hammer unions should be included in the wellhead assembly design to provide
for not only well service and workover, but also for future maintenance and replacement of swivel
joints and the flow rate control device.
Wellhead Steam Rate Control Devices
In all steam distribution systems, it is necessary to control the rate of delivery of steam to
each well on an individual basis. Because the wellhead injection pressure on any well can vary
significantly with time (as the result of wellbore fill for example) and because these pressures can
vary significantly from one well to the next (as the result of differences in formation permeability
as an example), it is desirable that the device selected to control these steam rates either: (1) be
capable of adjusting to varying wellhead injection pressures or (2) be uncoupled from wellhead
pressures.
Two devices are currently in use for steam injection rate control. They are as follows:
I. A static choke dlive to critical or sonic flow
2. A manually adjusted control valve operated in the subcritical flow regime
Static Chokes in Critical Flow
The use of the static choke device most often finds application in those steamflood projects
which are fortunate enough to have low wellhead injection pressures. This device rakes advantage
of the shock wave developed in the throat of a converging nozzle when a vapor (in this case steam)
is forced across the nozzle with a sufficiently high upstseam pressure (for steam the upstream
pressure must be in excess of 1.72 times the downstream pressure). The effect of the shock wave
is to decouple the rate of flow across the nozzle from the downstream pressure. This is particularly
advantageous in stearnfloods.
The following equation recommended by one choke manufacturer is generally used in the
field to determine critical steam flow

W = 59 d2 Cd d m if: P2 ~ 0 . 5 7 7PI

where W = Flow rate, bbl/d of steam (cold water equivalent)

d = Choke diameter, in.
= Coefficient of discharge, approximately 1-0.00705 Lld
 RADIUS

ENED ALLOY

ACCEPTABLE CHOKE BEAN

ROUND EDGE "FLOW THRU THE NUT"
NOTE: INSIDE DIAMETER MUST BE THE SAME
THROUGHOUT THE LENGTH OF THE BEAN
* NO INSERT ACCEPTABLE

SQUARE EDGE
\r
DESIRED

,OW
TUNGSTEN
f
CARBIDE
INSERT

DESIRED
FLOW

DESIRED L
7
FLOW

NOT ACCEPTABLE CHOKE BEAN

FIGURE 7.16. - Schematic of acceptable and nonacceptable choke inserts for steam
injection rate control choke bean.
 L = Length of choke, in., normally 6 in.
Pi = Upstream pressure, psia
PZ = Downstream pressure, psia
V1 = Upstream steam specific volume ft3nb1-11

The specific volume of steam is given by the general equation of steam properties as:
v 1 = x vg+ (I-x) Vf
where x = Steam quality, fraction
vg = Specific volume of the vapor phase @ PI, ft3nbm
vf = Specific volume of the liquid phase @ PI, ft3/lbm
Notice that as long as the upstream pressure is more than 1.72 times greater than the
downstream pressure both of the above equations apply and that neither is a function of any of the
downstream conditions (in the case of steam injection operations, the wellhead pressure).
It is particularly important when using the static choke method of rate control to make certain
that the chokes themselves are installed with the rounded radius of the choke insert facing the
incoming steam and also that the inside surface of the choke is smooth over its entire length
(usually 6 in.). Figure 7.16 illustrates several types of choke inserts available and it further
indicates those choke inserts which are considered acceptable. During the life of a steam injection
operation, it may be expected that these choke inserts will be changed several times. The inserts
should be carefully inspected with each change, and as new shipments are received, they also
should be carefully inspected to guarantee that they possess the desired round entrance and smooth
interior.
General field practice is to measure the upstream and downstream pressures across each
choke at 2-week intervals. This allows a technician to determine that the choke is or is not
operating at critical flow (subcritical flow is an indication that well work is required because the
perforations have become plugged or blocked, usually by sand fill). The pressure readings also
allow a technician to calculate the current rate of delivery of steam to the well and make a choke
insert size change to either decrease or increase the rate. This allows adjustment or trimming of the
steam system to provide the desired rate of flow to all wells in the system. In large steamflood
projects, the injection well pressure is monitored and controlled with the help of computers.8
The use of static flow chokes under critical flow is attractive for steam injection service
because of their simplicity and ease of maintenance and also because they are relatively immune to
the condition of injection wells. If injection pressures should become higher than about 250 psi, a
significant amount of power is consumed to raise generator feedwater pressure to provide the
pressure upstream of the static choke to guarantee critical flow. As a result, adjustable chokes or
control valves operating in the subcritical flow regime are often used where injection pressures are
expected to be high.
Adjustable Chokes Operated in the Subcritical Flow Regime
In steam injection projects where the steam injection pressures are expected to exceed 250
psi, the adjustable choke, or control valve, is selected as the means of controlling the rate of steam
delivery to the injector. The principle of operation is the same as that of any control valve. The
adjustable choke is placed in the path of flow, and the variable orifice within the choke is adjusted
to sufficiently restrict flow to achieve the desired rate. The rate of flow across the choke or control
valve can then be determined using the standard control valve equations for gas or steam. The
following equation can be used to size a control valve for steam flow.

Q = 1.06 Cg SIN ((347 1/ CI) s)

where Q = Rate of flow of steam, lbm/hr
dl = Steam density, lbm/ft3
PI = Valve inlet pressure, psia
Cg = Gas sizing coefficient; this value is generally published by
the valve manufacturer as a curve versus valve stem position
C1 = Liquid sizing coefficient; this value is also provided by the
manufacturer and is also a function of valve stem position
AP = Pressure drop across valve, psi
Note: The argument of the sine function in this equation should be evaluated
in degrees.
It would seem from this equation that measurement of the rate of flow across the valve in
field service is easily made by measuring the differential pressure across the valve and the static
pressure upstream of the valve. But, although this equation is very useful in initially sizing the
control valve, it is nearly impossible to make use of this equation to estimate the current rate of
delivery across the valve. This difficulty arises because the exact position of the valve stem must
be known in order to determine both Cg and Cl. As the valve stem position is changed in an effort
to adjust steam rate, the values of both Cg and C1 must both be re-evaluated.
To solve the difficulties associated with the use of the above equation, an orifice plate is
generally installed with the adjustable choke. The static and differential pressures across the static
choke are then measured, an estimate of the steam quality is made, and the orifice plate flow
equation is used to calculate the rate of steam delivery across the orifice plate. By monitoring the
differential and static pressures across the orifice as the valve stem position of the choke is
adjusted, the desired rate of steam flow may be obtained. The orifice plate flow equation is
repeated as follows:

where Q = Rate of delivery of stem across orifice plate, lbmhr

C = The orifice coefficient
Fx = Correction factor based on wet steam, specific volumes
- figy
vg = Specific volume of the satunted vapor, ft3/lbm
v, = Specific volume of the saturated steam at x quality, ft3~bm
= x vg + (1-x) Vf

Fs = Correction factor for density and the difference in measurement

units between steam and gas
= 1.Oij2l6-m
W = Censity of the saturated steam, 1bm/ft3
P = Pressure of steam upstream of the orifice plate, psia
t.l = Differentid pressure across the plate, in. of water column
A hand held calculator may be programmed to make the necessary field calculations for the
adjustment of these chokes. In addition, at least one manufacturer is currently marketing a
microprocessor based device which when attached to the proper differential pressure and static
pressure transducers, will calculate the flow rate across the orifice plate.
As in the case of the static choke in critical flow, the performance of each flow rate control
device should be checked at least once every two weeks and, in addition, a check should be made
anytime a change in the steam distribution system pressure occurs. These changes may occur for a
variety of reasons including the following:
1. Steam generator shutdown;
2. Well work on other wells within the system; and
3. Adjustment of steam rates on any of the other injection wells on the system.
The adjustable choke system of steam injection rate control is in all cases tedious and difficult
to operate consistently at the desired flow rates. This is because the rate of flow across the
adjustable choke is dependent (in noncritical flow) on not only the upstream system operating
pressure but also the downstream well injection pressure. The adjustable choke method of rate
control becomes the system of choice only when the additional operating pressure needed for a
system of critical flow chokes becomes high enough to cause either unacceptable operating
pressures or the cost of power necessary to raise feedwater pressure to the required system
pressure becomes unacceptable.
The Effect of Steam Quality on Injection Rate Control
To make use of either steam rate control system properly, the steam quality at the control
device should be accurately known. This results from the square root of the density term which is
present in both equations describing the rate of flow across either the choke or the control valve.
The accurate estimation of steam quality delivered to the wellhead and therefore across the control
device is by no means a simple task. The problem is made more difficult because no reliable
procedure or equipment has yet been developed to accurately measure the steam quality at the
wellhead. Current steam quality measurement techniques and practices are discussed in detail in
chapter 8.
In the past, field practice has been to calculate steam quality at the wellhead as the steam
quality at the steam generator site less the effects of heat loss in the distribution system. While
this makes the solution of the steam rate equations possible. it does not accurately reflect the true
quality delivered to the wellhead, and the rate of delive~yof steam across the control device cannot
be accurately calculated. Current research and field testing is disected at the following:
1. A better understanding of how the steam distribution system delivering steam to the
wellhead operates in regard to steam quality.
2. Techniques to measure the steam quality at the wellhead.
Recent laboratory tests have shown that it is possible to design and operate the steam
disaibution system to provide more reliable steam quality values to each wellhead.

Control of Individual Well Steam Quality 8

Recent advances in steam injection field practices have led to the use of a "variable" quality
steam injection. This requires that the steam distribution system deliver 80% quality steam at the
beginning of the project and then gradually reduce this quality to near zero value towards the end of
the economic life of the project
It is a common practice in large steam injection opertltions to develop different sections of the
field at different times. As a result, the individual sections are at different stages of flood and their
steam quality requirements are also different. For example, the steam quality requirement of a
section where the steam injection has just been started may be 80%, while the quality requirements
of a matured neighboring section may be 30%. Since the steam quality requirements of different
sections are different, means must exist to satisfy this requirement.
One of the simplest ways to produce adjustable steam quality is to produce steam at the
maximum quality required by an injector in the system (usually 80%) and then mix hot water (0%
quality) with steam to produce desired quality. The problem remains as to the most desirable
location for the mixing of steam and hot water.
Mixing hot water with steam results in a two-phase mixture. Phase separation will result if
this mixture is transported over long horizontal distances. Further, since steam velocities in the
distribution system usually range from 30 to 70 ft/sec, the presence of liquid slug in <team can
result in line failure at tees and ells. Hence, it is preferable to mix steam and hot water at the
wellhead to avoid the liquid slug problems.
The mixing chamber is usually located at the downstream side of the steam rate control device
(usually a critical flow choke). Steam and water are introduced into the chamber through metering
devices and intimately mixed before being injected into the well. A turbine meter installed at the
water line measures the volume of water introduced into the chamber. Steam rate is measured
using the static choke.
Though this device is satisfactory for formulating steam of desired quality, the inlet steam
quality must be known accurately if it is to be effective. Since the quality of the steam entering the
mixing chambers is usually not precisely known, this limits the usefulness of this device. To
overcome this limitation, the steam is first passed through a separator located upstream of the
mixing chamber. The steam leaving the separator is then metered through a choke into the mixing
chamber and mixed with a known quantity of water. Since the steam leaving the separator would
be of 100%quality, the quality of steam entering the well can be closely controlled.
Steam Distribution System Maintenance and Monitoring
A properly designed and implemented steam distribution system requires very little
maintenance and can be operated relatively trouble free. Problems related to steam distribution
include corrosion of buried pipes, leaky valves, and injection wellhead stuffing box packer failure.
The most troublesome maintenance problem is the replacement of insulation material which is
likely to be damaged due to normal oilfield activities.
Steam distribution system monitoring includes manual reading of downstream and upstream
choke pressure to determine the current steam injection rate. The well rate chokes will require
regular adjustment to maintain acceptable injection rate control. Wellhead steam quality should also
be regularly monitored to assure that specified quality steam is delivered to each injection well.

SUMMARY
A properly designed and installed steam distribution system is relatively trouble free to
operate and requires very little maintenance. The steam distribution system must be designed, not
only for the appropriate pressures and temperatures, but must also provide the desired steam
quality and flow rate to each injection well in the system. The major component of a steam
distribution network includes main steam headers, lateral steam lines, wellhead assembly, and
wellhead steam rate controls.
Stearnheader and lateral steam lines must be designed and constructed in accordance with
recognized standards such as ANSI Standard 3 1.4. Expansion loops must be incorporated in
steam lines to provide for the expansion and contraction of these lines due to temperature changes.
Since temperature changes also affect the wellhead connections, they must be equipped with
stuffing boxes to allow for the free movement of tubing and casing and tubing setting with steam
temperatures. The rate of delivery of steam to each individual well is controlled using a static or
adjustable choke. The performance of the controlled devices must be checked at least once a week
to assure proper functioning. In addition, a check should be made whenever a change in the steam
distribution system pressure occurs. The integrity of the steam line insulation must be periodically
evaluated and the insulation replaced as warranted.

REFERENCES
1. Natural Gas Processors Suppliers Association. Engineering Data Book, 9th Edition.
Natural Gas Processors Association, Tulsa, OK, Section 10, 1972.
2. Fitzgerald, B. M. Surface Injection and Producing Systems for Steam Operations.
Producer's Monthly, v. 31, No. 12, December 1967, pp. 18-23.
3 . Bleakley, W. B. The Hardware of Steam Injection. Producer's Monthly, v. 29, No. 8,
August 1965, pp. 2-27.
4. Eckert, L. A. Solving Mechanical Problems In Steam Stimulated Wells. World Oil, v.
161, No. 7, December 1965, pp. 89-96.
5. Bmsset, M. J., A. N. Edgington and R. F. Gilmour. Equipment Performance in An
Alberta High Pressure Steam Injection Project paper presented at the 18th Annual Technical
Meeting of the Petroleum Society of CIM, Banff, Alberta, Canada, May 1967.
6 . Crocker, S. Piping Handbook, 4th Ed. Chapter 2, Flow of Steam in Pipes, pp. 246-
253. McGraw Hill Book Company, New York, 1945.
7. Chien, S. F. Critical Flow of Wet Steam Through Chokes. J. Pet. Tech., v. 42, No. 3,
March 1990, pp. 363-370.
8. Schoen, D. M. and T. L. Frazier. Operational Review of a Large-Scale Saturated Steam
Delivery System. Paper presented at the Soc. of Pet. Eng. California Regional Meeting, Ventura,
CA, Apr. 4-6, 1990. Paper SPE 20026.
 APPENDIX 7-A
STEAM DISTRIBUTION NETWORK COMPONENTS SUPPLIERS
A. Iniection Wellhead Control Equipment C. Steam Pipe Fabricators
(X-mas tree, flow chokes, control
valves, etc.) 1. Piping Technology & Products Inc.
P.O.Box 34506
Flow Control Cooper Industries Houston, TX 77234-4506
16500 S. Main Telephone: (7 13) 73 1-0030
Missouri City, TX 77489
Telephone: (7 13) 499-85 11 Sunland Fabricators Inc.
30 103 Sunland Drive
Gardner Denver Petroleum Walker, LA 70785
Equipment Telephone: (504) 667- 1000
3325 S. Rice Avenue
Houston, TX 77056 LaBlvge Pipe & Steel Company
Telephone: (7 13) 626-2220 901 N. 10th Street
St. Louis, MO 63 101
Cameron Iron Works Inc, Telephone: (3 14) 23 1-3400
13013 Northwest Freeway
Houston, TX 77060 Progressive Fabricators
Telephone: (7 13) 939-2211 6882 N. Broadway
St. Louis, MO 63 147
FMC Corporation Telephone: (3 14) 385-5477
petroleum Equipment Group
1777 Gears Road D. Piping Insulation
Houston, TX 77067
Telephone: (7 13) 448-0211 1 . Manville Mechanical Insulation
Division
Hydril Company P.O.Box 5108
P.O.Box 60458 Denver, CO 802 17
3300 N. Beltway 8 Telephone: 1-800-654-3103
Houston, TX 77032-3411
Telephone: (7 13) 449-2000
Trico Industries Inc.
3040 E. Slauson Avenue
Huntington Park, CA 90255
Telephone: (213) 588-127 1
Daniel Flow Prpducts Inc.
9720 Katy Road
Houston, TX 77224
Telephone: (7 13) 467-6000
B. Turn Kev Steam Distribution System
Sup~lier
1. Daniel En-Fab Systems Inc.
3905 Jensen Drive
P.O. Box 2136 1
Houston, TX 77226- 1361
Telephone: (7 13) 225-49 13
 CHAPTER 8
STEAM QUALITY
INTRODUCTION
The term steam quality is commonly used to describe the vapor content of a two-phase steam-
water mixture. It is a dimensionless quantity and defined as the mass ratio of vapor to the total
mass of liquid and vap0r.l Thus, an oilfield steam generator is said to produce 80% quality steam,
if the produced steam contains 80% by weight steam and 2 0 8 by weight water.
A knowledge of steam quality is essential for the efficient operation of a steam injection
operation. Steam quality is one of the operator-controlled parameters that can impact the
economics of a steam injection project. Steam quality enters into the calculation of steam generator
efficiency and steamflood performance.
Steam generator output quality is required for several reasons. The output quality affects the
steam generator energy output. It is desirable to know the energy output of a generator, so that it
can be compared with the total energy injected at wells. If a reasonable energy balance cannot be
obtained, this is an indication that one or more of the metering devices is not functioning properly
and maintenance is required. Second, steam quality from each generator is required by plant
operators to ensure that generator firing rates are properly set and stay in adjustment. Third, it is
desirable to compare energy output from a generator with fuel consumption on a regular basis to
detect generator efficiency. Any such change is usually the result of a change in operating
conditions, which can be corrected to provide good generator efficiency.
The performance of a steam injection operation is commonly measured in terms of oil-steam
ratio, i.e., barrels of oil recovered per barrel of steam injected. The oil-steam ratio generally
improves, if the heat content of the injected steam is high. The enthalpy or total heat of steam is
strongly dependent on the steam quality, especially at lower pressures. At a given pressure a
higher quality steam carries more heat than a lower quality steam and, other things being equal, a
higher quality steam can recover more oil than s lower quality steam. Steam quality must also be
known to calculate accurately the wellhead injection sate using devices such as the critical choke.
Ideally, it would also be desirable to have a knowledge of steam quality at the bottom of the
injection string, as it enters the sandface. This would give the exact amount of energy entering the
formation and, in conjunction with the surface steam quality. would also allow an evaluation of the
effectiveness of the tubing insulation, if present.
The steam quality can be measured using a number of techniques. However, these
techniques are only approximate, since in general the steam quality varies considerably with the
operating conditions. In this chapter, some of the various methods currently available for the
measurement of steam quality have been evaluated. Only techniques of interest to steam injection
operation are reviewed. Some of the more recent techniques developed to measure steam quality at
wellheads in multiple well distribution systems are discussed. Limitations of each of the methods
reviewed are also given.

SURFACE STEAM QUALITY MEASUREMENT

Several different methods are used in oilfield operations to measure steam quality in surface
lines. These include: (a) separator method, (b) orifice metering method, (c) total dissolved solids
method, (d) electric conductivity method, (e) stack gas analysis method, (f)fixed heat rate method,
and (g) enthalpy determination method.

Separator Method
This method, based on the mechanical separation of liquid and vapor phases, is one of the
techniques widely used in steam injection projects to determine steam quality at the wellhead. The
technique is simple and yields values comparable to those of other methods.
The separator system can be used when large moisture contents are encountered in the two-
phase mixtures. The separator itself consists of an insulated cylindrical vessel (usually configured
in a vertical position) which is used to physically separate the liquid phase from the vapor phase.
Measurement of the mass rate of flow of each of the two phases as they leave the separator gives a
direct indication of quality. After separation, any suitable method of metering the two phases is
acceptable. Most systems use orifice meters on both streams. but an orifice meter in the vapor line
and a positive displacement or turbine meter on the liquid side is also satisfactory, if correction is
made for possible temperature difference between the streams.
A separator used by a large California steam injection operator is shown in figure 8.1. The
separator can be trailer-mounted and consists of the following:
1. Liquid vapor separator vessel;
2. Vessel level controller with valve;
3. Vapor line adjustable throttle (choke);
4. Vapor flow orifice and computer; and
5 . Liquid flow orifice and computer.
At each well, the trailer is installed in the injection line downstream from the rate control
device. In this manner, the steam quality delivered to the wellhead can be measured. The liquid
and vapor phases are separated and measured. They are then recombined and delivered to the
wellhead assembly for injection. The phase mass flow rates are computed automatically by flow
rate computers.
 ORIFICE
1
ADJUSTABLE
CHOKE

DEMISTER

-- I---+
SEPARATOR COMPUTER

TO
STEAM FROM I LEVEL WELLHEAD
HEADER I CONTROL

CRllCAL
I
FLOW CHOKE

FIGURE 8.1. - Schematic of equipment arrangement for steam quality measurement by the vapor-
liquid separation technique.

To obtain reliable results, the separator chamber must be thoroughly warmed to avoid any
steam condensation. If not, dilution of the liquid phase would occur and give a lower apparent
quality. In addition, insulation should be provided generously throughout the flowing chambers to
approach an adiabatic condition (no net gain or loss of heat to the surrounding area) as much as
possible. Quality can be calculated by dividing the mass rate of vapor flow by the sum of the mass
rates of vapor and liquid streams.
Tests performed by ~odgkinsonzindicated that a separator system could provide accurate
measurements of steam quality in the range of 40 to 80%. The measured values deviate from
standard chemical titration tests (discussed later) by only about 5 to 7%.
~ a h o n 3has evaluated the separator sampling techniques. He recommends samples to be
taken at distances of several pipe diameters (50- 100) downstream of any elbow, tees, valves, or
other flow constrictions. It is also essential that pressure drops through the separator be kept to a
minimum to avoid flashing of the water phase. Before taking samples, the separator must be
allowed to warm up and stabilize for a period of at least 15 minutes.

Orifice Metering Method

Orifice meters, commonly used in oilfields to measure gas and liquid flow rates, can be used
to estimate steam quality. The flow of wet steam through an orifice meter, and its relation to the
measurement of steam quality, has been investigated by sevelnl author^.^-^ This technique is
preferred by many TEOR operators, since it does not require sampling or phase separators. The
standard equation for single-phase flow through sharp-edge orifice plates or flow nozzles is

where
Wh = mass flow rate of fluid lbfhr
A h = pressure drop across the device, inches of water
V = specific volume, cu ft/lb
C = meter factor
The meter factor, C, is an empirically determined flow constant which depends on the size
and geometry of the orifice plate and the flow conditions. It is normally considered to be constant
for a range of fluid propesties and flow sates. This is a seasonable assumption provided the
Reynold's number stays above 105 for all flow conditions.
For metering flow of a wet steam through the orifice, the specific volume in Eq. 1 must be
adjusted to account for the degree of wetness. The specific volume of a two-phase steam-water
mixture (assuming the mixture to be homogeneous) is given by

where

x = steam quality, fraction of mass in vapor phase

Vg = specific volume of saturated steam, ft3/lb
Vf = specific volume of saturated liquid, ft3/lb
Although this correction is appropriate for very high qualities, it is known to introduce
significant errors for sharp-edged orifices as the tiowing stream becomes wetter. wilson4
determined that errors in mass throughput in the 1,500 to 2.000 psia range were about 5% at 80%
quality, 10%at 60% quality, and 15 to 20% at 40% quality.
~amesl*determined experimentally that Eq. 1 could be used disectly if the specific volume
term is calculated from Eq. 2 using an apparent or pseudo-quality that is related to the true quality
by
Eq. 1 then becomes

or, rewriting to solve for quality,

Quality can then be calculated directly when the mass throughput rate is known from some
independent source, such as the boiler input feedwater meter. The parameter C is determined as if
all fluid flowing was saturated vapor, the pressure drop across the orifice is measured, and Vg and
Vf are determined from steam tables at the operating pressure level of the orifice. James' work
encompassed a broad range of conditions. so Eq. 5 should be applicable for even very wet high
pressure steam, where the vapor to liquid volume ratio is not pa-ticularly high.
Though steam qualities obtained from the orifice meter method compared reasonably well
with other methods such as the total dissolved solids method, the method is only approximate and
has limitations. As increasingly wet steam fiows through the orifice. the recorded differential
pressure fluctuates. ~ i l s o n found
s that the magnitude of these fluctuations to be at least 1%, and
more often 3% of full scale deflection. Consequently, the value of the APw term in Eq. 5 is only
approximate. in addition, orifice meter measurements should be made after at least 10 minutes of
steady-state flow. Attempts to determine steam quality on an instantaneous basis, while the
variables are changing have proved to be unsuccessful.
In spite of its limitation, use of the orifice plate technique to measure steam quality is
widespread in steam injection operations. This is because the technique can measure steam quality
continuously and no samples of two-phase mixtures are required. Further, it is one of the few
methods that provides on-line indication of steam quality changes. Instruments that measure
differential pressure across the orifice and convert it to signals suitable for computer interfacing are
being marketed.12 At least one vendor markets a computer program to calculate steam quality
using an orifice plate correlation. The program requires the following information to estimate
steam quality: minimum line pressure (psig), maximum line pressure (psig), differential pressure
range (inches of water), orifice plate intesnol diameter (inches). pipe internal diameter (inches), and
minimum and maximum steam mass flow rates (Ib/day).

Total Dissolved Solids Method

The total dissolved solids method of measuring steam quality consists of comparing the
concentration of soluble solids in the feedwater to the enriched concentration in the liquid fraction
of the boiler discharge. The chloride ion, Cl'. and sometimes the sodium ion Na+ concentration
 provides a convenient tool for this check. By chemical titration, the concentration of C1' in the
liquid part of the steam-water mixture is compared with the concentration of the same ion in the
feedwater, and, assuming good quality water samples, the results obtained can be very accurate.
This method is, at present, the most widely used technique for obtaining steam quality in the field.
The sampling technique for obtaining a specimen of the water fraction from the two-phase
flowing mixture is one of the most critical steps in the procedure. This liquid fraction sample is
obtained from separators or traps in the output line of the generator and must be drawn through a
cooler to avoid flashing. If the sample is drawn off too quickly, vapor may also be withdrawn and
condensed, with a subsequent dilution of the liquid phase, therefore implying less water
evaporation in the generator and a lower output quality. On the other hand, if liquid is withdrawn
too slowly, the liquid obtained will be some composite of the effluent liquid previously left in the
separator, also giving incorrect results.
. Ion concentrations are found by adding a dilute acid to the water samples. A phenolphthalein
color indicator is used to determine when sufficient acid solution has been added. More acid
solution must be added to the outlet sample than to the feedwater sample. and the ratio of the acid
added to each sample determines the quality of the outlet sample. For example, if the effluent
sample requires an acid volume five times greater than the feedwater sample, then the final
dissolved solids concentration is five times the original, or what is the same, four-fifths of the
feedwater has been vaporized, and the steam quality is 80%.
Chemical titration techniques suffer the same limitations as all other techniques requiring
samples to be taken from the flowing two-phase pipeline; that is, the need to take a sample from a
representative cross section of the pipe and in a segment of the line located far away from any
discontinuities. Errors will be introduced into the measurement if n sample is taken very close to a
tee, elbow, or any pipe fitting.

Electric Conductivity Method

The electric conductivity of a solution of water with dissolved salts depends on the
concentration of the salts. By noting the increase in the conductivity between the feedwater and
liquid fraction of the boiler's discharge, the amount of vaporized water can be determined. This
method is similar to the chemical titration-chloride ion determination method, except that all
dissolved salts are considered instead of only one. In general, the electric conductivity method of
obtaining steam quality is a simpler and quicker method than the chloride ion measurement
technique, although it is also somewhat less dependable.
The steam quality determined by this method has several potential sources of error. First, in
using the ratio of input and effluent liquid conductivities, it is assumed that the dissolved solids are
concentrated only by the evaporation of the liquid phase as the water passes through the steam
generator. This, however, is not always the case. The effluent liquid phase contains carbonate
and hydroxyl ions produced by the thermal decomposition of bicarbonate ions in the feedwater.
The hydroxyl ions in the effluent liquid provide a conductivity out of proportion to the concentrated
total dissolved solids and when this conductivity is used directly, the cslculated quality is too high.
To avoid this situation, both input and effluent liquid samples must be neutralized to a pH of 7 with
a weak acid. Over- or underneutralization of either sample can lead to erroneously calculated steam
qualities. Secondly, because conductivity varies substantially as a function of temperature, it is
necessary to correct conductivities of feedwater and effluent samples to a common temperature
base if they have not been measured at the same temperature originally.

Stack Gas Analysis Method

A stack gas analysis may be used in conjunction with the feedwater rate and the fuel
consumption rate to check the approximate Btu content of the steam-water output of the boiler. To
use this method, the following information is required:
1. Feedwater input rate
2 . Fuel consumption rate
3. Btu content of fuel
4. Stack gas analysis for carbon dioxide and oxygen content
5. Stack gas temperature measurement
Commercial portable stack gas analysis kits are available for C02 and 0 2 determination.
From the CO2,02, and temperature values, combustion efficiency and heat losses from the stack
can be determined. The following calculation can then be made (assuming that the boiler heat
losses are negligible):
H~=HI-H~ (6)
where
HI = total heat input in fuel to burner, Btdhr
H2 = heat loss from stack determined by analysis, Btu/hr
H3 = heat content of generator water output, Btu/hr
The value of the specific heat content is:
h3 = H f l (7)
h3 = specific heat content of steam-water output, BtuAb
W = feedwater rate, from meter, lb/hr
The value of the hg, compared to the steam table values for saturated water and steam
enthalpy at the steam line pressure, will establish steam quality.
The stack gas analysis method does not require any sample from the flowing two-phase
mixture; furthermore, it does not require any information, other than the flow rate, from the
flowing mixture. However, the quality obtained from this method is only applicable to the outlet
of the steam generator. It cannot be used at either the wellhead or downhole locations.
Even when intended for measurement of steam quality at the generator outlet, this method is
not in standard use because it is error prone, more time-consuming, just as involved as the
chemical titration method, and yields less accurate values.

Fixed Heat Rate Method

This method is an attempt to fix steam quality in advance, rather than measure it. At constant
heat input rate (fuel rate to the burner), the feedwater rate is gradually reduced while observing
pressure and temperature of the discharged steam. As soon as the temperature begins to increase,
at constant pressure, the water input rate is noted. Since neither temperature nor pressure alone can
be changed as long as both liquid and vapor u e present in the system, an increase in temperature at
constant pressure must mean that all liquid is vaporized, and that the steam has entered the
superheated region. By repeating this test under several different conditions, an approximate
relation can be obtained between the feedwater input and the heat input required to produce
saturated steam. The output steam quality from the boiler will then be in inverse proportion to the
additional water throughput above the value that will produce only saturated steam.
This calibration process must be used with extreme caution. particularly if the feedwater
contains a large percent of dissolved solids. Extended periods of operation at low water rates
(forming superheated steam) will deposit scale on the water tubes. reducing thermal efficiency and
inviting corrosion. If the method must be used, feedwater rate should be increased to a safe level
as soon as it is noted that the steam generator is producing superheated steam, and the water rate
recorded.
This technique of measuring, or rather fixing, the steam quality is not in standard use by any
steam injection thermal recovery project. The method should only be considered under those
conditions where no other provisions such as throttling calorimeter, separators, or orifice
techniques have been provided, and where no possibility exists for performing dissolved solids,
electric conductivity, or stack gas analysis evaluations.

Enthalpy Determination Method

The enthalpy determination technique for measuring steam quality is another relatively crude
method which should only be employed when none of the more acceptable methods are available.
The method has been discussed by Hodgkinson, et aL2
The enthalpy of a sample from the steam-mixture is first tsansfersed into an absorbing
medium. There are two methods available to transfer the enthalpy into this medium. One is
indirectly, by the use of a heating coil, and the other is directly. by allowing the steam-water
sample to mix with the absorbing medium. Then, the temperature rise of the absorbing medium is
measured, and from this measurement the enthalpy of the steam-water sample is calculated.
Knowing the enthalpy of the steam-water mixture, its quality can be obtained by comparison with
the values for saturated liquid and vapor at the flowline pressure. The absorbing medium with
known thermal properties must be selected and its flow rate measured accurately. The rate of flow
of the steam-water mixture must also be measured and this can be done by noting the amount of
condensate if the indirect technique (with a heating coil) is used.
Although available, this technique is not in common use because calibration of the enthalpy
transfer chamber requires very precise measurement, and the criteria assuring simple design and
ease of operation have not been met.

Wellhead Steam Quality

The techniques described in the previous sections provide a means to measure surface steam
quality but require an independent means of measuring the total mass flow rate or require that the
mass flow be held constant from a point of known quality (usually zero) to the point at which the
quality is being measured. Further, beyond the first split in the surface lines, there is no easy way
to determine steam quality with any degree of confidence because beyond the first junction steam
splitting can be extremely uneven and difficult to predict. This uneven splitting of phases between
the branches results in a wide variation in wellhead steam quality. A fieldwide check of wellhead
steam quality made by one major California steam injection operator, indicated that individual
wellhead quality can vary from near zero to 100%. Table 8.1 lists the measured wellhead steam
quality? Measurement of steam quality at the wellhead is very difficult because no reliable
procedure or equipment has been developed to date. Because of this, most operators assume the
wellhead steam quality to be no more than the steam generator outlet steam quality less the effects
of heat loss in the distribution system.
As indicated in table 8.1, this method of estimating wellhead steam quality does not reflect
the true quality of steam delivered to the wellhead. Since a knowledge of steam quality is essential
for the calculation the rate of flow of steam across the wellhead control device, the well injection
rates are suspect. In recent years, however, significant effort has gone into the development of
tools that can reliably measure the actual wellhead s t e m quality. Some of the devices currently
being marketed include the following:
(a) Vibrating densitometer;
(b) gamma ray absorption technique; and
(c) neutron densitometer.
These devices are expensive, require extensive calibration, and are still under development.
Following is a brief overview of the opemting principles of these devices.
 TABLE 8.1. - Steam injection wellhead steam quality13

Flow rate, Steam quality,

Well No. bbl/day 9%

Vibrating ~ e n s i t o m e t e r
The vibrating densitometer operates on the principle that the natural or resonant frequency of
a vibrating tube containing a two-phase mixture depends on the bulk density of the two-phase
mixture. Hence, by measuring the resonant frequency, the bulk density of the two-phase mixture
can be calculated. The bulk density, along with the pure vapor and liquid density at the operating
temperature, can be utilized to calculate the steam quality.
Figure 8.2 shows a schematic of a vibrating densitometer which consists of a pair of sensor
tubes made of magnetic material and are vibrated by an electromagnet. When the frequency of
vibration of the tubes corresponds to its natural or resonant frequency. a large amplitude
 UPPER
MANIFOL- PLATINUM

TUBE

FLOW

SAMPLING TUBE

Fl[GURE 8.2. - Schematic of a vibration densitometer for steam quality determinatiod

in the tube vibration results. A strain gauge mounted on one of the tubes is used to detect the
resulting amplitude and a microprocessor correlates this amplitude response with the vibrating
frequency.
The resonant frequency of the tube is a function of the mass of the tube (i.e., the mass of the
tube itself plus the mass of the two-phase mixture inside the tube). Depending on the bulk density
of the liquid-vapor mixture inside the tube, the natural or resonant frequency of the tube will vary.
The bulk density and the natural frequency are related by the equation,

where-
P = Bulk density of liquid vapor mixture
f = Natural or resonant frequency of the vibrating tube
A,B = Constants determined by calibrating tihe meter.
A platinum resistance thermometer mounted on the tube can be used to measure the temperature of
the fluid inside the tube. From the temperature measurement and steam table, the density of pure
vapor and pure liquid can be established. Knowing the bulk density from the densitometer and the
vapor and liquid densities from the steam table, the steam quality can be calculated using the
following expression
where
x
- = Steam quality
P = Bulk density of two-phase mixture (lbm/ft3)
-
Vf
- = Specific volume of liquid (ft3hbm)
Vg = Specific volume of vapor (ft3/lbm)
Vibrating densitometer technique is still being evaluated. Its accuracy, reliability and ease of
operation are not known at this time.

Gamma Ray Absorption Technique14

This steam quality monitoring system operates on the principle of attenuation of gamma rays
by matter. The attenuation of gamma rays through a pipe filled with wet steam is related to steam
density and hence to the steam quality.
A schematic of the gamma ray steam quality monitoring system is shown in figure 8.3.
Steam is passed through a pipe section containing a two-phase mixer, where it is homogenized.
Low level gamma ray energy emitted from a gamma ray source is beamed in a precise shape
through the walls of the pipe and measured on the other side. The detector (measuring device) is
an ionization chamber filled with a pressurized gas. When ionized, a current is generated and sent
to the transmitter.

SOURCE

TRANSMITER

f
STANDARD
TWISTED PAIR

FIGURE 8.3. - Schematic of gamma ray steam quality measurement technique.14

 The gamma steam transmitter calculates steam quality from data supplied by the density
sensor and by a downstream pressure transmitter and outputs to an indicator.
To obtain reliable steam quality, the system must be calibrated over s wide range of
conditions and the calibrations must be checked periodically. The system is drift prone and hence
accuracy suffers.

Neutron Densitont eter Steam Quality Measurement system l 5 9

The principle of operating this system is identical to that of the gamma ray steam quality
monitoring system. The meter is based on the fact that a beam of thermal neutrons is strongly
scattered by hydrogenous material, such as water. The attenuation of a beam of thermal neutrons
through a pipe filled with wet steam is related to the average density of the steam-water mixture
inside the pipe, and for this reason the system is referred to as a neutron densitometer steam quality
measurement system.
The average density of the wet steam P is related to the gas phase density, Pg, the liquid
phase density, PI, and the void fraction, a, by

The void fraction, a, is the volume occupied by the gas-phase in a wet steam mixture. The
steam quality, x, which is defined as the ratio of the mass flow rate of the gas-phase steam to the
mass flow rate of the wet steam, is related to a by

where s is the slip ratio. The slip ratio is defined as the ratio of average gas-phase velocity to
average liquid-phase velocity. Hence, if the slip ratio and pressure are known, the steam quality
can be determined from Eqs. 10 and 11. However, the slip ratio, s. depends on pressure, mass
flux, steam quality, flow pattern, and orientation of flow. These relationships are not well
established and, therefore, calibration of the system over a wide range of conditions must be
undertaken. The principle of operation of a neutron densitometer is shown schematically in
figure 8.4.
The neutron densitometer steam quality measurement system is shown schematically in
figure 8.5. To measure steam quality accurately. the meter must be calibrated. The system is
usually calibrated with the steam pipe empty and with the pipe full of water. Measurement of
 FAST
NEUTRON
SOURCE STEAM-WATER
I MIXTURE

O I I I I I
THERMAL
NEUTRONS
I I I
+
TRANSM llTED

:',"EN* 0

MODERATOR SHlELD PIPE NEUTRON DFTECTOR

FIGURE 8.4. - Schematic of the principles of operation of a neutron densitometer.15

u
I+-
FLOW hl3PLE
DATA ACOUlSlTlON
PROCESSOR

FIGURE 8.5 - Arrangements for steam quality measurement using n neutron densitometer. l6
steam quality also requires knowledge of steam pr-essuse and an approximate mass flow rate. The
mass flow rate can be determined by measuring the pressure drop across a flow nozzle. The
flowing steam pressure is determined using a pressure tmnsducer. The steam quality is determined
using the information provided by the neutron densitometer and flow nozzles. A data acquisition
system interfaced with an on-line computer is utilized to calculate and display steam quality, mass
flow rate, and enthalpy delivery rate to the well. Further details on the system can be found in
references 15 and 16.
The system is still in developmental stage and has been field tested to a limited extent in
Canada. No units have been installed to date in the United States.

Do wnhole Steam Quality Measurement

To date, no reliable tools or techniques for measuring steam quality at the sandface have been
developed. Several downhole steam quality sampler designs have been proposed to collect a
representative sample of liquid-phase of steam at any depth in an injection we11;17-18 however, the
collection of a truly representative sample is very difficult and will require an extensive calibration
program to ensure accurate measurements. At the present time, sandface steam quality is estimated
from wellhead steam quality, steam flow rate, and wellbore heat losses. Special computer
programs for the calculation of downhole steam qualities from wellhead qualities are available.

SUMMARY
Accurate measurement of steam quality in an oilfield environment is both cumbersome and
difficult because steam distribution through manifolds, laterals, and tees results in uneven splitting,
and no easy way exists to determine steam quality with any degree of confidence. Some of the
techniques currently used in oilfields to measure surface steam quality include the orifice plate
method, dissolved solids technique, liquid-vapor separator method, enthalpy determination
method, and stack gas analysis technique. A11 of these techniques have limitations and do not lend
themselves to continuous, real time measurement of steam quality. Newer techniques, such as
those based on the vibration densitometer and thermal neutron densitometer are promising but are
expensive and require extensive calibration. No technique is available to measure steam quality at
the sandface. At the present time, downhole steam quality is infen-ed from wellhead steam quality
measurements. A list of vendors that can assist in steam quality measurement are shown in
Appendix 8-A.

REFERENCES
1. Strome, R. K. and D. M. McStnvick. Continuous Steam Quality Measurement in a
Steam Distribution System Quality Measurement. Presented at the Soc. of Pet. Eng., California
Regional Meeting, Ventura, California, Apr. 8- 10, 1987. SPE paper 1 6348.
 - 2. Hodgkinson, R. J. and A. D. Hugli. Determination of Steam Quality Anywhere in the
System. In: D. A. Redford and A. G . Winestock, Eds. The Oil Sands of Canada-Venezuela,
CIM Special v. No. 17. The Canadian Institute of Mining and Metallurgy, Edmonton, Alberta,
Canada, June 1977, pp. 672-675.
3. Mahon, W. A. J. Sampling of Geothermal Drillhole Discharges. United Nations
Conference on New Sources of Energy, Conf. Proceedings, v. 2, 1964, pp. 269-278.
4. Pryor, J. A. Orifice Meter Measures Steam Quality. The Oil & Gas J., v. 64, No. 22,
May 30, 1966, pp. 86-88.
5. Wilson, T. M. Steam Quality and Metering. The Journal of Canadian Pet. Tech., v. 15,
No. 2, April-June, 1976, pp. 33-38.
6. Mattar, L. Nicholson, M., K. Aziz, and E. A. Gsegory. Orifice Metering of Two-Phase
flows. Journal of Pet. Tech., v. 31, No. 8, August 1979, pp. 955-961.
7. Bennett, M. D. and K. Martin. Calibration of a Small Venturimeter for Wet Steam at
Low Reynolds Number. Proc. Instn. Mech. Eng., London, v. 184, Pt. 3C, 1970, pp. 151-153.
8. Palm, J. W., W. H. Anderson, and J. W. Kiskpatsick. Determination of Steam Quality
Using an Orifice Meter. Pres. at the Soc. of Pet. Eng. 42nd Ann. Fall Meeting, Houston, Texas,
Oct. 1-4, 1967. SPE paper 1941..
9. Collins, D. B. and M. Gacesa. Measurement of Steam Quality in Two-Phase Upflow
with Venturimeters and Orifice Plates. ASME Transactions, Journal of Basic Engineering, March
1971, pp. 11-21.
10. James, R. Metering of StevmlWater Two-Phase Flow by Sharp-Edged Orifices.
Proceedings of the Instn. Mech. Eng., London, v. 180, Pt. 1, No. 23, 1965-1966.
11. Bleakley, W. B. How to Find Steam Quality. The Oil & Gus J.. v. 63, No. 9, Mar. 1,
1965, pp. 76-77.
12. Anderson, J. L., S. E. Falke and D. N. Clum. A Microprocessor Based Steam
Generator Quality Controller. Pres. at the Soc. of Pet. Eng. 59th Ann. Tech. Conf. & Exhib.,
Houston, Texas, Sept. 16-19, 1984. SPE paper 13022.
13. Jones, J. and R. L. Williams. A Two-Phase Flow-Splitting Device That Works. Pres.
at the Soc. of Pet. Eng., International Thermal Operations Symposium, Bakersfield, California,
Feb. 7-8, 1991, SPE paper 21532.
14. Kay-Ray Inc. Steam Quality Measurement System. Tech. Bulletin KR484-789, 1986.
Kay-Ray Inc. Division of Rosemont, Mt. Prospect, Illinois 60056.
15. Woiceshyn, G . E., P. S. Yuen, H. John and J. J. Manzano-Ruis. Measurement of
Steam Quality, Mass Flow Rate and Enthalpy Delivery Rate Using Combined Neutron
Densitometer and Nozzle. Pres. at the Fifth SPUDOE Symp. on Enhanced Oil Recovery of the
Soc. of Pet. Eng., Tulsa, Oklahoma, Apr. 20-23. 1986. SPEIDOE paper 14907.
16. Wan, P. T. Measurement of Steam Quality Using a Neutron Densitometer. Pres. at the
Pet. Soc. of CIM and Soc. of Pet. Eng. Joint Intelnational Tech. Meeting, Calgary, Canada, June
10-13, 1990. Paper CIM/SPE 90-88.
 17. Fox, R. L. and A. J. Mulac. Downhole Steam Quality Tool. Sandia National
Laboratory Internal Report SD-3877, 1980.
18. Mulac, A. J. Summary of Steam Quality Measurement Program at Sandia National
Laboratories. Paper pres. at the U.S. DOYINTEVEP Joint meeting, Caracas, Venezuela, January
1981.
 APPENDIX $-A
STEAM QUALITY MEASUREMENT SYSTEM VENDORS
A. Steam Ouality Measurement System
1. Kay-Ray/Sensall Inc.
Division of Rosemont
1400 Business Center Drive
Mt. Prospect, IL 60056
Telephone: (708) 803-5100
2. Daniel En-Fab Systems Inc.
3905 Jensen Drive
P.O.Box 21361
Houston, TX 77226- 1361
Telephone: (7 13) 225-4913
B . Orifice Plate Vendors
Lambda Square Inc.
P.O.Box 1119
Bay Shore, NY 11706
Telephone: (5 16) 587- 1000
Airtrol Cornponents Inc.
17400 W. Library Lane
New Berlin, WI 53 146-2107
Telephone: (414) 786- 1711
Metals for Industry Inc.
9800 S. 2 19th E. Avenue
Broken Arrow, OK 74014
Telephone: (918) 455- 1778
Oil & Gas Specialities Company
P.O.Box 55306
Houston, TX 77255
Telephone: (7 13) 686-3444
 CHAPTER Y
THERMAL WELL COMPLETION PRACTICES

INTRODUCTION
Thermal well completions, while basically the same as those for conventional wells, differ in
mechanical aspects. The main difference between completing a steam injection well and a
conventional well is the handling of the problems associated with elevated temperatures. High
temperatures cause tubular goods in an injection well to expand. If the injection or production of
hot fluids is interrupted for some reason such as mechanical failure of a steam generator or a well
workover to correct an unexpected downhole problem, the wellbore temperature will fall causing
the tubing to contract. The heating and cooling of the tubular goods lead to severe thermal
stresses. If these stresses are allowed to exceed the design stress of the tubular goods, casing and
tubing failure may result. In addition, the effect of temperature on downhole completion
equipment must be considered in equipment selection.
Movement of sand particles into a production wellbore from semiconsolidated or
unconsolidated sands, as fluid is produced, can be a major production problem in thermal wells.
The sand production mechanism can be extremely complex and is influenced by all completion
operations ranging from first bit penetration to the start of production. The problems of sand
control in thermal recovery wells are especially troublesome because of high production rates of
reservoir fluids that result from the high volume of fluid injected in these processes. The greatest
single problem in steam injection operation is that of making lasting, high productivity well
completions resistant to erosion and corrosion at elevated temperatures.
Thus, thermal well completions must be designed to withstand elevated temperatures without
damaging to wellbore equipment. In brief, the severe service seen by thermal wells calls for
specific thermal completion designs. This chapter describes and recommends certain well
completion practices currently used in the industry.
Provided in Appendix 9-A is a list of vendors that deal in thermal well completion tools and
services. This list is not intended to be the recommended vendors; it is included here so that a
prospective operator can contact these or other vendors for additional information.

CASING DESIGN
Temperature Effects on Casings and Tubings
Steam operations impose severe stress on casing. Casing tends to elongate when heated. In
shallow wells, casing seldom fails if it has been cemented back to the surface and if the steam
temperature and pressures are low during injection. However, many casing string failures have
been reported in wells deeper than 1,500 ft, under temperatures of 400' to 650' F and pressures of
250 to 3,200 psi. Most of these failures have occurred at the c~uplings.~ Examination of failed
casings show extensive compression damage to the joints in the form of telescoping or buckling to
the point of collapse or breaking1
It is important that the temperatures effect on the yield strength, ultimate tensile strength, and
modulus of elasticity of casing materials be considered prior to preparing specifications for casing.
Quantitatively, casing will expand or contract with temperature changes in an amount determined
by the following expression,

a = coefficient of linear expansion per degree F

AL = h e a r expansion, ft
AT = change in temperature, O F
L = length of the casing, ft.
An excellent rule of thumb is that the unstressed casing will elongate 0.83 inch per 100 ft of length
per 100' F increase in temperature. Thus, a 2.000-ft tubing string subjected to a 500' F
temperature will elongate about 83 in. or almost 7 ft. The casing will also contract during a cooling
period.
If the shoe of the casing is cemented and the top is free to expand. the casing will expand out
of the ground, thus relieving casing stress. If the casing is not free and the top is securely fastened
at the bradenhead, changes in temperature will set up thermal stress in the casing. This stress will
result in the slackening of the tension generally transmitted and concentrated in the lowermost free
section of the string in the form of compression buckling* A good rule of thumb for estimating
thermal compressive forces in tubular goods is that the compression changes by about 207 psi per
O F change in temperature.3

Thermal stress, if it exceeds the elastic limit of the tubular goods, will cause both tubing and
casing to buckle helically, like a coil of spring. The magnitude of the stress depends largely on the
moment of inertia of the pipe and the radial clearance between pipe wall and any straightening
~upport.~ The support structure for casing is the open hole; for tubing, the supporting structure is
the casing. In all but very shallow wells, hole deviations and formation sloughing will cause
compressive stresses to build up at intermittent joints and may cause heated casing and tubing to
fail.
An obvious way to avoid compressive casing failure is to ensure that the compressive
stresses do not exceed the yield strength of the casing material. In new wells. this can be achieved
by employing an appropriate grade of casing; by cementing the casing under tension; and by
confrolling casing temperature through the use of thermal packers.
 140 -

120 -

too -

80 -

0 200 400 600 800 1000

TEMPERATURE. * F

FIGURE 9.1. - Tensile strength of casing versus

Gates4 and willhiteS discussed in detail the nature of casing stress failure. Both Gates and
Willhite propose that casing failure can be avoided by selecting a casing strong enough to avoid
yielding in compression at the maximum expected tern pen tu re. ~ o li day6
l noting that the tensile
strength of steel is at a maximum of 500' F (see figure 9.1) proposes that one need not be unduly
concerned about casing stress exceeding its yield point at steam temperature. However, casing
strength must be high enough to avoid tension failure upon subsequent cooling. A review of
reported casing failure indicates that casings generally fail i n tension, than in compre~sion.~
Hence, compressive casing stresses are normally tolerable. Holliday's criteria permit much higher
allowable casing temperatures and steam pressures than those of Willhite or Gates. The
recommended maximum casing temperature for various grades of casing reported by these authors
are shown in table 9.1

TABLE 9.1 - Recommended operating ternpentwe range for thermal we11 tubular goods

Casing Permissible surface steam temperature. OF

(MIGrade) Willhite Gates Hoiliday

Table 9.2 lists physical properties of four grades of seamless tubing and casing at various
temperature^.^ The ultimate tensile strength of these steels decreases slightly up to 300' F,
increases to a maximum at 500" F, then rapidly decreases with temperature as shown in figure 9.1.
The yield strengths and elastic limits are shown as function of temperature in figures 9.2 and 9.3,
respectively.
In some shallow reservoirs, steam is injected directly down the casing. These wells are
usually less than 600 ft deep, so the steam temperatures are low and casing failure is unlikely. In
deep wells, steam is rarely injected down the casing. The probability of casing failure in deep
wells is much higher due to higher steam temperatures and pressures. In deep steam injection

TABLE 9.2. - Tensile properties of various grades of seamless casing and tubing4
Tensile properties1

Tensile Modulus
Outside Wall, test Yield Tensile Elastic of
diameter, thickness temp.. strength, strength, limit, elasticity
Grade Condition in. in. OF psi psi psi 1,000 psi

J55 Hot 13-5/8 0.3 13 RT

rolled 3 00
5 00
700
9 00

Normaiized 13-3/8 0.500 ItT

3 00
5 00
700
Y 00

P 105 Normalized 10-7/8 0.375 RT

& tempered 3 00
5 00
7 00
9 00

P l 10 Quenched 10-3/4 0.547 KT

& tempered 3 00
5 00
700
900

fore two tests.

l~vera~
 0 200 400 600 800 1000
TEMPERATURE, " F

FIGURE 9.2. - Yield strength of casing versus ternperat~re.~

0 200 400 600 800 1000

TEMPERATURE, " F

FIGURE 9.3. - Elastic limit of casing versus temperature.4

wells, steam is rarely, if ever, injected down the casing for the fear of risking casing failure due to
thermal stresses. In deep wells, casing temperatures can be maintained below the injected steam
temperature by injecting the steam down the tubing and by preventing the steam from entering the
tubing-casing annulus through the use of thermal

Thermal Well Casing Design

Design of casing strings for thermal wells requires careful study. Engineers designing steam
injection well casings must consider other operator's experience in the area, service company
recommendations, the potential cost of any failure, expected cement quality, amount of cycling (for
stimulation processes), well life, erosion and corrosion.
To prevent casing failure due to thermal stresses, two criteria must be considered during
casing selection:
1. The compressive stress generated by the change in casing temperature should not exceed
the yield strength of the casing material.
2. The fiber stress at the maximum casing temperature should not exceed the yield strength
of the casing material for reasonable clearances and uncemented intervals.
These criteria can be met through the use of the following techniques:
1. Prestress the casing-prestressing the casing involves placing enough tension on the
casing before cementing in order to prevent the casing from exceeding yield strength in
compression during steam injection. As casing temperature increases, temperature-
generated compressive forces relieve the initial tension. Further heating passes the casing
through a neutral point and into compression. Prestressing requires a shoe job on the
casing to provide an anchor. The casing then needs to be pulled with hydraulic jacks
(drilling rigs usually cannot handle the amount of pull required), and then the casing is
cemented while in its stressed state.
2. Anchor the casing at the bottom and allow it to move freely-the casing can be anchored
at the bottom with a small cement job. The casing is allowed to rise through a packing
gland at the surface. This is the simplest method; however, in many cases it is
impractical ai sloughing of the formation may hinder full movement of the casing.
3. Increase the yield strength of the casing-if complete compensation is not possible, some
insulation may be needed between the tubing and casing to keep the casing temperature
within limits.
Maruyama et al., on the basis of laboratory studies, recommend heavy weight K-55 casing
with premium connection for high-temperature steam injection wells.9 Typical California thermal
well casing completions are shown in table 9.3. The shallow California thermal wells are generally
 TABLE 9.3. - Typical casing completions in California thermal wells16

Casing
Max
Depth, Pressure, Diameter TYF Coupling
Field Operator ft ~sig in. Grade type

Kern River Chevron 7 00 350 7 .O K-55 STC

Midway-Sunset Chevron 1,200 450 7 .O K-55 STC
Mt. f o s o Shell 1,800 600 8 5/8 K-55 B W
Sari Ardo Texaco 2.350 800 8 518 K-55 STC

Guadalupe Union 3,000 1.800 7.0 N-80 BU?T

completed using K-55 grade casings with buttress threads and landed in tension. Canadian
operators generally use N-80 grade casing because of the higher injection pressures and
temperatures. Casing grades should be selected based on expected operating conditions and
anticipated thermal stresses. Since most field experience shows that casing failures occur at a
coupling, use of buttress or other premium couplings is recommended. However, this will
increase the initial costs of completion. In shallow wells, where the operating pressures and
temperatures are lower, the standard short threads and couplings (STC)may be used without the
risk of failure. Many operators in the shallow Kern River (CA) fields, still uses the less expensive
short threads and couplings. Hence, the steam injection completion practice for a given field
should be a compromise between the initial completion costs and the cost of risking failure of the
well. Engineering judgement plays a large role in arriving at a safe completion design. Since
failures usually occur at the joint, the engineer should rate the joint first. apply a safety factor, and
then select the casing based on anticipated maximum casing temperature.
Casings are usually landed in tension after prestress to protect the casing from elevated
temperature. Studies indicate that a prestressed casing is less subjected to buckling than a
conventionally run suing. By placing high tensile stress initially, it is possible to absorb a higher
temperature increase and still remain below the yield point in compression.l0 For example, if the
safe operating temperature limit for a stress free N-80 casing were set at 500' F, this limit can be
increased by another 100' F, by stressing the casing. The higher operating temperature allows for
higher injection pressure, since the saturated steam pressure increases from 68 1 psig at 500' F to
1,543 psia at 600' F.
Casings are normally prestressed while cementing. The casing is run and cemented through
a shoe with a small volume of quick setting thermal cement. The shoe is anchored to about 200 ft
to the bottom to facilitate the stretching operation. lo The rig is moved off and casing jacks stress
the casing while the remainder of the cement sets up. In this way, as the casing heats up, it merely
relieves the tensile forces already in the structure, and thermal elongation is eliminated.
The amount of prestress is a function of steel grade, coupling strength, mud weight, and
collapse resistance. To prevent crushing when the load is distributed over the slip area, the
prestressed casing must be landed on a reinforced cellar designed for the load. In the past, a
two-stage cement job was used to stress the casing. Only a few operators currently use this
technique. Though the two-stage technique is less expensive (about $5,000 per job), the operator
risks casing failure when the overburden sloughs in and holds the pipe or when the tail section
does not hold.1

Tubing Strings Consideration

In steam injection wells, steam is often injected through the tubing to reduce heat losses
through the casing and to prevent well failures. Injection of steam through the tubing often results
in tubing temperatures approaching steam temperatures and this causes the tubes to elongate. The
tubing elongations, together with the relatively large clearmces between tubing OD and casing ID,
results in thermal conditions that lead to high stlass levels in the outer fibers of the tubing
strings.12 Since these stress levels often exceed those of conventional oilfield steel grades, it is
obvious that these stresses must not be allowed to develop. Use of tubing expansion joints can
relieve the thermal stresses. Tubing expansion joints are installed either at the surface or
downhole. Surface installation, especially for deeper wells, is more expensive and involves
placement of centralizing guides on the string to improve its columnar characteristics and to avoid
friction locks between tubing and casing due to elastic instability.12 In most applications,
expansion joints are placed at the packer. In many cases, the expansion joint is designed as an
integral part of a retrievable packer. The expansion joint seal is subjected to considerable stress
because of joint movement. The joint moves considerably when injection starts or when the well
cools. Many types of sealing materials are used in the oilfield. Present day expansion joint seals
are made of high temperature EPDM rubber reinforced with carbon fibers. These elastomers,
though rated to 650' F, field experience suggests that sealing is likely to fail above 550' F.

Thermal Well Completion

After the selection of casing material, drilling and completion of the well should be the next
consideration. Steamflood injection and production well dsilling and completion programs must be
carefully designed and executed properly. Any failuses i n drilling, underreaming, casing,
cementing, or the perforating program could be detrimental to we11 productivity. Steam injection
wells may be completed with or without a packer. Casing size ranges from 5-112 to 8 3 8 in. in
diameter with 7 in. common in deeper wells. California regulation requires a packer in continuous
steam injection wells to protect the casing. Expansion joints are needed to accommodate the
differential expansion and contraction of the tubing when heated or cooled. Expansion joints are
usually placed at the packer. Thermal packers are discussed more fully in a later section. This
section describes certain thermal well completion practices used in the industry. It should be
noted, however, that well completion practices for steam injection can and do vary from field to
field and operator to operator in specifics, depending on the circumstances, and no generalization is
possible. Examples of typical steam injection, production, and observation well completion
features are shown in figures 9.4, 9.5 and 9.6, respectively. The discussions in the following
section, however, are generic in nature and should be of assistance to the engineer designing a
thermal well completion program.
Drillinp Fluids
Both productivity and injectivity can be adversely affected by washouts through the
production interval and by reduction in permeability due to fresh water invasion into the formation
and resultant swelling of water sensitive clays. Drilling fluids, therefore, have to be inhibited
against clay hydration, generally with 1 to 10% brine or KC1 solutions andfor other clay stabilizing
compounds, such as hydroxy-aluminum.

FUU GPEEJINQ

GATE VALVE CHECK VALVE

GATE VALVE STEAM FROM

STEAM GENERA1'OR

7PY WELL BORE

ENT TO SURFACE

2a'.
4.T# 5-35 YUBtNQ

J. PREF. (2) 1EmHOLESIFT

CGS. SHOE SET AT T.0

FIGURE 9.4. - Schematic of a typical steam injection well completion.

 BALL VALVE
R O W LINE

ORIFICE WELL TESTOR COOLING WATER

.5#.5-35 TUBING

200" +/-

7" N-80 CASING

CEMENT TO SURFACE
WICLASS G CEMENT

SILICA FLOUR & 2%

CALCIUM CHLORIDE
TOP OF SAND
9 718" WELL 80RE

5 1/2' StOlTED LINER

SUCKER RODS 80 MESH. 6" CENTERS

GRAVEL PACKED
W/ 3/16" (APP. 4-6 MESH)
D.H. PUMP -
5' +/-W/O
CONTACT

FIGURE 9.5. - Schematic of a typical steamflood production well completion.

, 1 , Lml
Z&m=,E
MONITOR

K-55 CASING
7.
Q f m HOLE
CLASS "3'. 2 :IPOZZWN. 4% GEL.
3% c.Ck

2 37)' TUBING

CLASS'G'. 30"b SF. 3% CaClz

CUSS 0'.20% SF.3%CaCk

1 .S% R-SD (RETARDER)

2' - 821 STAINLESS STEEL

12 THERMOCOUPLE PAIRS

850' TYPICAL DEPTH

FIGURE 9.6. - Schematic of a typical steamtlood observation well completion.

 Cementing
Poor cementing techniques could cause channeling and may contribute to excessive water or
gas production in certain wells. Formation damage from cement particle invasion into the
production zone could be a severe problem in certain enhanced recovery wells. For this reason,
open-hole completions or a cement "puddling" technique. designed to minimize column height or
head while cementing casing through the production zone, is sometimes recommended. In most
areas, casing is set through and cemented with high silica flour cement. For an open-hole
completion operation, the well is drilled to gauge to the top of the producing formation and then
cemented in accordance with the best available cementing practices; i.e., the cement should possess
low-fluid loss, and the casing string should be centralized. equipped with scratchers, and rotated or
reciprocated during the cementing operation. A high-silica flour cement is recommended for all
zones experiencing high temperature.
During the cement "puddling" operation, cement with proper water loss and setting time
additives is spotted in open hole through the production interval while pumping through the drill
string equipped with scratchers. The drill string is ~lsuallyrotated and withdrawn slowly through
the production zone during the cementing operation to remove, or scmtch, mud cake from the side
of the wellbore and to prevent the formation of pockets of mud in the cement. After the cement has
been "puddled in," the drill string is removed from the well; centralized casing is run to the top of
the cement pool and then slowly through the cement to the bottom of the well. The cement is then
permitted to set prior to perforating. Thermal well cementing practices are discussed in more detail
in chapter 10.
Perforating
Jet perforating is a piercing and pulverizing process that creates a flow path through the
casing, cement sheath, and into the formation. However, cement. copper, lead and carbon from
the jet charge can penetrate and mix with crushed formation material. sometimes causing significant
perforation damage and restrictions on productivity and injectivity.
Perforations should be gravel packed with properly sized sand to prevent the "tunnel" from
being filled with formation fines when the well is placed on production. If gravel is not sized
properly, sand will enter the perforated area. become trapped in the gravel, and cause a
prohibitively high pressure drop across the pe~forations.
Completion fluids flowing across the interval at the time of casing perforation should be free
of solids because they can be driven into the perforation by the force of the charge. Perforation
debris removal methods include underbalance, backflow, perforation washing, acid stimulztion,
and swabbing. Underbalance, backfiow, and perforation washing, for the most part, are effective
remedial measures, but are not always 100% successful. Acid stimulation under certain conditions
could be responsible for reduced permeability and compressive strength of the formation,
sometimes resulting in abnormal production decline shortly after treatment. Swabbing is
undesirable in soft formations because of excessive sand removal and the uncertainty that all
perforations have been properly cleaned.
Well Completion and Workover Fluids
Colloids, brine, and bridging solids impart effective fluid loss control, excellent suspension
properties, and low friction loss to well completion and workover fluids. These colloids generally
consist of calcium lignosulfonate, hydroxyethyl cellulose and other polymers. In addition, special
fluids, such as oil base, inverted emulsion, and chalk emulsion systems have been used
successfully to protect sensitive clay bearing formations from fresh water. The chalk emulsion is
actually a water-in-oil emulsion containing acid-soluble bridging and weighting materials which
have been stabilized by finely divided acid-soluble chalk solids.
In many shallow low-pressure reservoirs in California, a stable preformed foam has replaced
mud, oil, and water as a circulating medium in well completion and remedial operations. The
foam, with a density as low as 0.3 ppg, is preformed at the surface to a consistency of aerosol
shaving cream by blending detergent, fresh or salt water, compressed air or gas, and sometimes
other special additives such as surfactants. The foam has been used in California wells to core the
completion interval; stabilize severe sanding and shale sloughing problems; retrieve open-hole
liners; complete old, low pressure wells by drilling in new liners; and recover sanded-up
equipment and cement liners in lost circulation zones. Advantages include low hydrostatic head,
elimination of formation damage, high carrying capacity for cuttings removal, low circulation
pressures, and simple installation.
O ~ e n - H o l eCompletion
Most cyclic steam wells in California are completed open-hole with a slotted liner through the
production interval. In open hole completion the casing is set on top of a producing interval. The
main advantage of open-hole completion is the increased productivity over that of perforated
completions. For example, theoretically it would require four perfect 112-in. diameter holes per ft
to penetrate the casing, cement sheath, and 8 in. of the formation to equal open hole productivity.
In addition, these openings in unconsolidated sand must be held open by gravel or by chemical
consolidation of the surrounding formation. In the following sections, some sandcontrol methods
for open-hole completion are outlined. Sand-control techniques are discussed more fully in
chapter 13.
Screens
Slotted liners, wire wrapped screens and pre-packs. have been used effectively in certain
areas to control sand production. However, it is not recommended that the well be permitted to
create its own pack around a screen placed across the producing interval. This procedure will
generally result in a disturbance of the formation, possibly causing excessive fine sand production
or plugging before the screen or pack stabilizes. All screens, therefore, should be used in
conjunction with gravel packs to retain gravel packing material which, in turn, supports the
formation sand.
The all-welded, wrapped-on-pipe screen has the highest flow capacity. Wire and pipe are
normally 304 stainless steel, but for extremely corrosive atmospheres special alloys such as
Inconel 625 and Incoloy 825 are available. Some laboratory corrosion tests have shown that
Inconel 625 has a better high-temperature corrosion and oxidation resistance than Incoloy 825.
A slot or wire width opening of two times the 10 percentile diameter of the formation sand
has been proved effective in areas containing sand with broad size distribution. In areas with
relatively uniform sand size, slots equal to the 10-15 percentile formation sand diameter have been
used satisfactorily. The self cleaning, keystone type slot or wire opening is recommended over
that of parallel sided slots in which particles 1/2 the slot width tend to wedge and plug.
Pre-Packs
Pre-packs are designed to bridge fine formation sands without the need for gravel packing.
They are fabricated with an outer cylinder of either unconsolidated or resin-consolidated sand
which is supported by a slotted mandrel. Since pre-packs necessarily must be somewhat smaller
than the wellbore into which they are positioned, the formation may subsequently shift and cause
productivity impairment. Pre-packs may plug when ( 1 ) the formation contains large quantities of
clay, (2) asphaltenes or paraffins are precipitated by viscous, low gravity crude oils, (3) emulsions
are formed, and (4) carbonate or sulfate scale is deposited. They offer the following advantages:
(I) large surface area for filtering, (2) compatible with most well fluids, (3) high permeability (50
to 100 darcies), (4) high compressive strength (5,000 psi at 150" F), ( 5 ) can be run on a wire line
or tubing, and (6) withstand temperatures to 500' F.
To reduce the chances of formation movement asound the pre-pack and the risk of plugging
with formation fines or clay, this device should be used in conjunction with underreaming and
conventional or consolidated sandpacks.
Ooen-Hole Gravel Packing
Open-hole gravel packs should provide higher productivity than inside gravel packs because
restrictive casing perforations are eliminated, and the underreamed wellbore improves radial flow
into the well. Open-hole gravel packing are prefemd over other completion techniques in stratas
of clay and shale since the gravel should prevent migration of the shale or clay to the screen and
sealing it off.
Gravel packing consists of underreaming the wellbore 6 to 12 in. larger than the casing
diameter; running and hanging the wire wrapped linen; packing with gravel using a viscous, high-
gravel concentrated (15 tbfgal) slurry at low circulation rates to prevent intermixing of the sandpack
with formation sand; washing to remove grave! bridges; and then repacking, if necessary. During
the foregoing operations, a nondamaging completion fluid should be used as suggested earlier.
Also, preflushes of clay stabilizing material should be used prior to both underreaming and gravel
packing as will be discussed later. In addition, the hole should be enlarged slowly to prevent
corlcscrewing; a caliper log should always be sun in the underreamed hole to determine if sloughing
has occurred; and debris should be removed from the well prior to running the liner.
The ratio of gravel size to formation sand size should be estimated from Karpoffs rule which
states that gravel size should range from 5 to 10 times the 50 pescentile or median formation sand
diameter. Sand movement should be properly restrained under these conditions since the gravel
pore openings, theoretically, are properly sized relative to the sand particle diameter.
Effectiveness of gravel packs can sometimes be determined by radioactive tracer methods.
Gravel packs in open hole injection wells sometimes tend to slump soon after the start of injection,
and logging may indicate that repacking is required.
Consolidated Pack
The consolidated pack is a slurry consisting of a cai-rier fluid, resin (or other type of bonding
agent), coupling agent, sand, and catalyst, which is blended at the surface and pumped behind a
liner or in open hole where the resin or bonding agent is permitted to cure. This process is
designed to achieve gravel packing and sand consolidation in a single injection step. If a liner is
used, any consolidated material remaining in the wellbore is simply drilled out. In most open hole
completions, no liner is used and the consolidated pack is redrilled through the entire producing
zone with a regular bit. All the same rules and precautions associated with conventional open-hole
gravel packing and drilling also apply to this p3mculiu technique.
The main advantage of the consolidated pack treatment is that consolidation of the sand is
assured in all areas where the sand laden slurry can be pressure packed. The pack possesses
excellent strength (5,000 psi) and permeability (60 darcies) and is stable in most well environments
up to 500' F. The process works well with clay bearing formations, and excess resin can be used
to consolidate a portion of the formation behind the pack to stabilize both sand and clay when a
special clay stabilized compound, such as Hallibunon's Claylok or Claysta, is injected ahead of the
resin.
sed-Hole Com~letion
Cased-hole completions in steam injection operations generally are recommended only for
injection wells although they may be used for producers under cenain circumstances. If it is found
that open-hole completion cannot be satisfactorily performed, or is not desired for some reason,
then setting the casing with the best cementing technology should be implemented along with the
best available well completion, perforating, gravel packing. and/or chemical sand consolidation
methods.
 In unconsolidated formations, the sand immediately be hind the perforation must be
stabilized, as previously discussed, either with a sandpack or with chemical or artificial
consolidation. Another technique is to gravel pack a wise wrapped liner inside and across the
perforated interval of the long string of casing.
Clav Stabilization
Serious reductions in permeability of the formation can occur when clay minerals restrict
flow by either expanding to fill the pore volume or dispersing and lodging in restrictions. The
expanding force acting on clays is caused by the affinity of exchangeable interlayer cations and
surfaces for fresh water. The inherent negative charge on almost all clay minerals is neutralized by
adsorption of cations, producing a positive surface charge with a negative inner charge. These clay
particles with an electric double layer repel each other and, thus, disperse.
Chemicals are now available which stabilize many water-sensitive formations. One such
compound, a positively charged hydroxy-aluminum ion which is prepared in the field by reacting
aluminum chloride and sodium hydroxide in a high shear device, is absorbed and polymerized on
the negatively charged clay mineral surface to form a stabilizing network that prevents further
migration. This chemical, Claylok, a trademark of Chevron Research Company, has been
successfully used to improve permeability following acid treatments, stabilize formation fines,
desensitize clay bearing formations prior to steam injection, and reduce formation damage during
perforating and gravel packing. Most field brines and fresh water will not remove the treatment,
but mixtures having pH values below 4 or above 9 will damage its effectiveness.
Halliburton has a process that uses an organic, oil-soluble chemical, trade name SFD-3, to
shrink water-swollen clays and then surround them with a hard t'uran-type resin which increases
permeability and stabilizes clay in some dirty formations. Another Halliburton product, Claysta, is
organic in nature and stabilizes clay in a manner similar to Clnylok. but has the added advantage
that it is stable to subsequent acid or caustic treatments.
It appears that these clay stabilizing compounds have possible application in open hole as
well as in cased hold completions. Injection of these chemicals prior to underreaming and gravel
packing may eliminate or significantly reduce formation damage caused by clay swelling.
Incorporating these inhibitive chemicals into the gravel pack slurry, drilling fluid, and/or other
completion fluids may also prove to be advantageous. All possibilities should be evaluated in the
laboratory before implementation.
 Well Workover Practices
Treatments for some typical situations are described as follows:
A. Case 1
Assumptions
1. Well has not been previously steamed.
2. Sand production problem.
3. Fonnation sensitive to fresh water.
General Procedure
1. Bail out and clean up well.
2. Run injectivity test with filtered (1 micron) 2% potassium chloride (KCl) solution.
Adequate injectivity should be approximately 2 bbllrnin at no more than 300 psi
surface pressure.
3. Run cement bond log (CBL), temperature At andfor spinner survey with 2% KC1
solution.
4. If formation is not taking fluid uniformly, acidize with 100 gavft* 15%hydrochloric
acid (HCI), followed by 200 gaVft mud acid,** followed by 100 gaYft 3% HC1, and
then followed by 600 gaVft 1% filtered KC1 solution (spacer between acid and
hydroxy aluminum).
5 . Inject 5 bbllft hydroxy aluminum.***
6. Run spinner survey or profile to dete~mineif all perforations are taking solution.
7. Oveflush with 5 bbVft filtered 1% KC1 solution.
8. Install injection well wellhead or pumping well wellhead and pumping unit.
9. Shut-in well and age 24 to 48 hours.
10. Start steam injection in injection well or place production well on production.

* Per ft of perforated interval.

** Mud acid consists of 12% HCl +3% hydrofloric acid (HF) +0.38 inhibitor
+0.3% surfactant +0.3% iron sequesteran t +O. 3% anti-sludging agent (Dowel1
products)
*** Injected hydroxy aluminium should be 0.3 Molar and, therefore, must be diluted
20-fold with 1% KC1 water. Alwavs add 1% KC1 to concentrate.
 caS!2
Assumption
1. Well has not been previously steamed.
2. Sand production problems.
3. Fonnation sensitive to fresh water.
4. Well needs to be gravel packed or re-graveI packed.
General Procedure
1. Bail out, clean up well, and acidize, if necessary (Steps 1-4 in Case 1).
2. If well is perforated, shoot additional perforations (8 shots per ft) under 2% KC1
solution.
3. Install gravel pack in hydroxy aluminum while keeping well full with hydroxy
aluminum. Pack fluid should incorporate hydroxy aluminum, or 2% KC1 solution
when possible.
4. If open hole, remove old liner, install new liner, and gravel pack in hydroxy
aluminum.
5. Run steps 5-9 in Case 1.
ciw2
Assum~tions
1. Well has been previously steamed.
2. Sand production problems
3. Clay and sand migration are problems.
4. Fonnation sensitive to fresh water.
General Procedurg
1. Bail out and clean up well.
2. Cool well with filtered (1 micron) 2% KC1 solution until temperature of formation
around wellbore is less than 200' F.* Twenty-five barrels of cooling water per
perforation is usually a sufficient quantity for cooling.

Temperatures greater than 200' F will cause aluminum chloride to precipitate in formation.

Screening
Certain preliminary tests should be run in the laboratory to determine which completion
technique is most likely to be successful. The following is an outline of proposed tests which
should be run for the purpose of designing the best or optimum well completion:
1. Permeability, porosity, and water semitivi ty.
2. Clay content and types of clays present, if any.
 Grain size distribution - to be used for the proper selection of slotted liner size and/or
conventional or consolidated grain size.
Effect of steam condensate - permeabilities before and after injection.
Fluid penetration studies - determine depth of fluid penetration in core and resultant
damage from conventional mud, extremely low water loss mud, invert emulsion, chalk
emulsion and fluids containing bridging material of calcium carbonate, and oil soluble
resins.
Degree of clay or fine sand migration in core samples during fluid or steam injection.
Effectiveness of clay stabilizing compounds, such as Claylok, Claysta, and SFD-3-furan
resin combination, in native cores.
Compatibility of clay stabilizing compounds in presence of and as a part of well
cornpletion fluids.
Chemical consolidation and compressive strength of consolidated native cores and
compare with clean sand chemical consolidation.

ested Steam Injection and Production Well Drillinp and Completion

Procedures
In the following section, the drilling and completion procedure followed by a California
steam injection operator is outlined.14 These procedures detail the steps involved in the drilling
and completion of steam injection and production wells. These procedures are meant only to be a
guide for the engineer in designing such well completions.
1. Steam Injection Well
Drill the well with "best" low-water loss drilling mud using current drilling practices
for that area.
Run 2-4 joints (depending on thickness of reservoir) of casing and set the casing with
a high-silica flour cement, using centralizers and scratchers, while rotating or
reciprocating the casing to remove mud cake and pockets of mud from annulus during
the cementing operation. A synthetic lubricant should always be used on threads
while making up casing.
Plug back well with 20-40 mesh sand and cement plug or standard bridge plug to
depth 1-2 ft below intended perforation.
Install BOP. Pressure test casing to 3.000 psi with fresh water.
Run neutron, gamma ray, CCL, and other desired well surveys.
Run open-ended 2-7/8 in. O.D.EUE tubing,* equipped with casing scraper, to plug-
back and reverse-circulate well with 10 bbl diesel fuel followed by 2% caustic and
1% detergent solution until returns are clean. Displace cleaning solution with fresh
 water followed by 5% Nitrox** solution. Circulate 1-2 well volumes. Displace 5%
Nitrox solution with filtered 0.2% Nitrox solution.
Pull tubing and perforate casing with one hole using suitable jet shot (3/4-in. diam.
hole and 9-11 in. penetration) at a depth determined from electric log. To prevent
flowback of sand in unconsolidated regions, perforating should be done with
pressure differential from wellbore into formation. After perforating, keep hole full
of 0.2% Nitrox solution.
Run injectivity and pressure fall-off tests with 0.2% Nitrox solution. Injectivity
should be at least 1 BPM at pressure less than fracture pressure. Pressure falloff
should be at least 500 psi/min.
If injectivity test is unsatisfacto~y,either reperforate at same depth or clean up existing
perforation with mud acid. Before reperforating or using mud acid, however, tag
bottom to make certain there is no sand fill. Repeat injectivity and pressure fall-off
tests.
Repeat steps g to i until adequate injectivity and fall-off we attained.
Run 2-7/8411, O.D. EUE tubing with pup joint@), crossover, packer, and telescoping
union. Space out and set packer to 5 ft above perforation. Packer should be set in
special alloy casing no closer than 25 ft from perforation.
Remove BOP and install wellhead.
Purge all surface lines and equipment with 5% and 0.2% Nitrox solution. Install and
pressure test to 3,000 psi all injection lines and Christmas tree.
commence injecting steam.
Steam injection will continue over the life of the project at various increased rates,
depending on the size of the stearnflood.

* Again, always use synthetic grease while making up tubing.

** Nitrox consists of 2 parts sodium nitrite and 1 part sodium hydroxide.

2. Production Well
a. For liner type completions, drill to the top of the producing formation with standard
drilling mud using current drilling practices for that area. For "set through"
completions, skip steps a, c, and e.
b. Set the casing with standard low-water loss cement, using centralizers and scratchers,
while rotating or reciprocating the casing to remove mud cake and pockets of mud
from annulus during the cementing operation.
 Drill through the production sand with the "best" completion fluid as determined from
laboratory screening tests. Clay stabilizing agents should be incorporated into the
completion fluid, if needed.
If required, inject clay stabilizer through entire production interval.
Underream formation 6-12 in. using "best" completion fluid to circulate out cuttings.
Run caliper log and other desired logs with "best" completion fluid.
Run properly designed prefaced liner or wire wrapped perforated pipe and perform
tailored gravel pack or consolidation pack with clay stabilized completion fluid, or
Perform properly tailored open hole consolidation pack with clay stabilized
completion fluid. Permit bonding agent to cure sufficiently, and drill through with
standard bit, using best completion fluid. A slotted liner used only to properly guide
the bit could be incorporated into this process.
Lower tubing to bottom and reverse circulate, and clean with 4% KC1 solution.
Set retrievable bridge plug, install steam quality expansion type casing head, install
BOP, and recover bridge plug. In place of expansion type casing head, a telescoping
union or expansion joint could be run above packer if packer is used. If no packer is
used, no expansion joints are required; however, downhole cooling may be required
during production of hot well fluids.
Run 2-7/8-in. O.D. tubing, packer (if required), 2 joints special alloy tubing,
expansion joint (if required), and seating nipple.
If packer is used, space out to set packer inside special alloy casing at least 20 ft
above pay zone, gravel pack, or consolidated pack. If no packer is used, position
bottom of tubing at top of pay. Tubing should be lined with straight phenolic
coating. All materials below packer and including packer should be fabricated from
special alloy material. If no packer is used, the bottom 8 joints of tubing should be
special alloy.
rn. If packer is used, displace annulus fluid with salt water containing 80-100 ppm cobalt
catalyzed sodium sulfide oxygen scavenger and Tretolite KW 12 or Visco 938 film
coating chemical at 0.5% by volume.
n . Set packer, remove BOP and install wellhead.
o. Run rods and pump with coupon rack on bottom,
p. Test well. When it is evident that well will flow, recover rods, pump, and coupon
rack.
q . Set coupon rack in seating nipple and swab well if necessary.
r. After well has cleaned up and stabilizes, conduct static BHP and BHT surveys.
 DO WNHOLE E Q U I P M E N T
After successful drilling and completion of the wells, the next important step is to install a set
of downhole equipment to minimize thermal stresses on casing and improve steamflood
(stimulation) efficiency. Downhole equipment includes thermal packers and expansion joint and
steam deflectors.
Thermal Packers
The injection tubing string should be equipped with a theimal packer. The thermal packer
provides a seal between the injection tubing and the inside of the casing, closing the annulus to
steam injection. In the case of an open hole completion, packers seal against the formation. Use
of packer with an expansion joint will: (1) reduce thermal stress, (2) reduce primary cement
failures, (3) reduce wellbore heat loss to the casing and formation, and (4) prevent the casing from
bursting if injection pressures become too high. A thermal packer will normally reduce the average
temperature of the casing and cement sheath by approximately 120' F and reduce thermal stress by
approximately 20,000 psi. To obtain the full benefits of the packer, the annulus must be vented
early in the heating period to remove any steam formed by evaporating water in the annulus. Not
all steam injection wells are completed with thermal packers. Many cyclic steam injection wells
and a few steamflood injectors in California are completed without packer to reduce well servicing
and workover costs. These are discussed in a later section.
Packer selection for thermal recovery wells is primarily a problem of selecting retrievable or
permanent equipment. This decision is influenced by such considerations as pilot or large scale
flood, soak, or drive etc. Whenever long periods of uninterrupted injection are planned,
permanent completion is preferred. Retrievable packers are the preferred choice if long
intemptions of the injection well are anticipated, so that the packer is available for use in another
well.
Retrievable thermal packers come in either single or double grip models. Single grip models
are used for steam injection below the packer and are usually tension set. This way pressure from
below tends to further set the packer. Double grip packers are used for pressure control above and
below the packer. Many thermal well retrievable packers come with an integral expansion joint.
Thermal packers come in a variety of sizes to fit casing from 4- 112 to 13-3/8 in. OD, and most are
desigaed with an operating limit of 2,100 psia and 640' F.
Packers should be located as high as possible i n the weil to permit downward tubing
expansion, but close enough to the formation to confine the steam coming from the tubing.
Typical retrievable and permanent packer locations for steam injection wells are shown in figure
9.7.l3 Packer installation for a multiple zone steam injection well is shown in figure 9.8.13
 EXTENSION
/ JOINT

RETRIEVABLE

-
PACKER

\ SEAL
ASSEMBLY

- DRILLABLE
PACKER

FIGURE 9.7. - Schematic showing retrievable and permanent packer position in steam injection
well. 13

PARALLEL ANCHOR WITH HlGH

TEMPERATURE SECONDARY
STINGER SEALS

PARALLEL FLOW TUBE WITH

HlGH TEMPERATURE SEALS

- THERMAL TRIMMED
PERMANENT PACKER

UPPER ZONE PERFORATIONS

HIGH TEMPERATURE
LANDING SEAL NIPPLE

THERMAL TRIMMED
PERMANENT PACKER
LOWER ZONE PERFORATIONS

FIGURE 9.8. - Schematic detailing packer installation for multizone completion.13

 The performance of a packer tubing system plays a major role in the success of any steam
injection project. Continued high injection rates without excessive heat losses are necessary for
efficient utilization of injected heat and sustained oil production. In this respect, packer plays a
crucial role in the economic success of the project. This is because: (a) The cost of replacing failed
wells, packers and tubing is high in terns of capital and lost production; (b) The price of a packer-
tubing system is large and it must provide sufficient increased earnings or savings to justify their
installation; and (c) The selected packer should be able to lower the wellbore heat losses (and they
usually do). The cost of heat loss can be high in terms of operating costs, if steam costs (fuel,
water, labor) are high, or oil production, if steam generating capacity is restricted.
Packers do fail-packer failures in high pressure injection wells (pressure >700 psi,
temperature >500° F) are generally caused by expansion joint assembly failure (seal failures).
Details of a packer system used by a California thermal EOR operator to alleviate the casing
stress problems associated with high pressure steam injection (1,400 psi and 588' F) in shallow
wells (less than 3,000 ft) are shown in figure 9.9.14 The major components of the system are a

FIGURE 9.9. - High-pressure steam injection well packer details. l4

locking type compression set packer, insulated tubing, and a sui-face expansion joint. Use of
custom packers such as this and those offered by major packer vendors (Guiberson-Dresser and
Otis) have practically eliminated the well failures.
The most common operational problem associated with the packers include leakage or
sticking of packers and thermal expansion joints. These problems can be minimized by carefully
running and setting the packers. Sufficient slip area must be provided; Otherwise, danger of
ruining the casing exists when high pressures are applied
Packer Installation
The reliability of a thermal packer can be enhanced and costly workovers avoided, if certain
precautions are followed prior to the packer installation. eates4 advocates the following:
1. Scrape the casing to remove any cement or scale to provide a clean, smooth surface on
which to set the packer.
2. Displace fluid in the hole below the packer setting depth by bailing or by dumping water
down the annulus. To obtain the full benefits of the packer, the annulus must be vented
during the early heating so as to remove any steam which occurs by evaporation of water
in the annulus.
3 . Provisions must be made for the expansion and contraction of the tubing.

Seal Systems
One of the keys to successful steam injection operation is the ability to seal against high
pressure, high temperature steam. Downhote sealing points include (1) casing to open hole;
(2) tubing to casing annulus; (3) packer to casing, and (4) tubing to packer.
Casing to open hole and tubing to casing annulus seals involve thread connections. By
design, threaded joints on oil country tubular goods will not be pressure tight because of the root-
crest clearance, unless coated with a suitable thread compound. Thread seal reliability depends
heavily on the mechanical properties of the filless used in these compounds. In steam injection
applications, special high temperature sealing compounds with nonmetallic fillers must be used to
prevent leakage. Present day thermal well thread sealing compounds, though expensive (about
$8.00 per pound), are highly reliable and contain fillers that retain their physical properties even
after long periods of exposure to the steam injection environment. These sealants are rated to
1,200' F and employ a blend of copper, molybdenum disulfide, and tenon as the filler material.
Packer to casing and tubing to packer sealing depends on the reliability of elastomers used in
the thermal packers. Present day packer sealing elements are fabricated out of EPDM elastomers
with carbon fiber reinforcements. Though packer vendors rate these seals to about 600' F and
3,000 psi, field experience indicates these seals usually fail at temperatures above 525' F. Hence,
before selecting a particular packer, its temperature and pressure limitations must be investigated.
 Packerless Completion
Thermal packers are expensive and cost several thousand dollars; and, as pointed out
previously, their use must be justified in terms of increased earnings or savings. In the United
States, most steam injection wells are shallow and heat losses in such wells are small (less than 5%
at high injection rate). Further, the use of packers in wells increases the well servicing and
workover costs. Also, the relatively shallow depths do not provide sufficient hold down weights
for conventional weight set packers. Thermal expansion (and contraction) of the tubing preclude
the use of packers set in tension. For these reasons most shallow cyclic wells in California are
completed without a packer. California regulations, however, require a packer in continuous steam
injection wells to protect the casing.
SUMMARY
Steamflood injection and production well completion practices, while basically the same as
those used for conventional waterflood injection and production wells, differ in mechanical aspects
related to the heat factor. Thermal well completions are more expensive but are necessary to avoid
failures due to the stress caused by steam injection temperatures. A carefully engineered well
completion program for steam injection may make the difference be tween economic success and
failure of a seemingly attractive project. Downhole mechanical problems and excessive heat loss
can be minimized if the well completion is given as much technical consideration as the surface
equipment
Thermal production well completion practices are similar to those of injection wells from a
tubing and casing consideration. The primary factor in selecting casing size is the size of
production equipment to be placed inside the casing. In the United States, most production wells
an completed open-hole with a slotted liner through the production interval. Careful consideration
should be given in selecting thermal packers, and temperature and pressure limitations of the
packer should be investigated.
REFERENCES
1. Nelson, C. G . Program is Designed to Analyze Casing Buckling in Thermal Recovery.
Oil & Gas J., v. 73, No. 49, Dec. 8, 1975, pp. 79-82.
2. Holmquist, D. E. Prestressed Casing Tolerates High BHT's. World Oil, v. 173, No. 6,
November 1971, pp. 80-82.
3. Humphrey, H. C. Casing Failures Caused by Thermal Expansion. World Oil, v. 151,
No. 6, November 1960, pp. 105-108.
4. Gates, C. F. and B. G . Holmes. Thermal Well Completions and Operation.
Proceedings of Seventh World Petroleum Congress, Mexico City, 1967, pp. 419-429.
 5. Willhite, G . P. and W. K. Dietrich. Design Criteria For Completion of Steam Injection
Wells. J. Pet. Tech. v. 19, No. 1, January 1967, pp. 15-21.
6. Holliday, G. H. Calculation of Allowable Maximum Casing Temperature to Prevent
Tension Failures in Thermal Wells. Pres. at the ASME Petroleum Mechanical Engineering
Conference, Tulsa, Oklahoma, Sept. 21-25, 1969. Paper 69-PET- 10.
7. Prats, M. Thermal Recovery. Soc. of Pet. Eng.. Monograph No. 7, Soc. of Pet Eng.,
Dallas, 1982, p. 142.
8. Bleakley, W. B. The Hardware of Steam Injections. Prodricers Monthly, v. 29, No. 8,
August 1965, pp. 2-27.
9. Maruyarna, K., E. Tsuru, M. Ogasawxa, Y. Inoue and E. J. Peters. An Experimental
Study of Casing Performance Under Thermal Recovery Conditions. Pres. at the Soc. of Pet.
Eng., California Regional Meeting, Bakersfield, California, Apr. 5-7, 1989. SPE paper 18776.
10. Dietrich, W. K. and G. P. Willhite. What Ccrnoco Learned From Steam
Stimulating Deep Wells. World Oil,v. 162, No. 7, June 1966, pp. 107- 1 14.
11. Dietrich, W. K. and G. P. Willhite. Solving Cat Canyon Casing Problems. Pet.
Eng., v. 39, No. 9, August 1967, pp. 55-61.
12. Leutwyler, K. and H. L. Bipelow. Temperature Effects on Subsurface Equipment
in Steam Injection Systems. J. Pet. Tech., v. 17, No. 1, January 1965, pp. 93- 101.
13. Thermal Recovery. Guiberson-Dresser Technical Bulletin 5337, Guiberson-
Dresser, Houston, Texas.
14. J. Mondragon. Union Pacific Resources. Welinington, California. Personnel
Communication, April 1991.
15. Leutwyler, K. How Temperature Affects Thermal Well Completions. Pet. Eng.,
v. 36, No. 12, November 1964, pp. 84-89.
16. Chu, C. State-of-the-Art Review of Steamflood Field Projects. Pres. at the Soc.
of Pet. Eng. California Regional Meeting, Ventura, CA, Mar. 23-25, 1983. SPE paper 11733.
 APPENDIX 9-A
THERMAL WELL COMPLETION TOOLS AND ACCESSORIES SUPPLIERS
A. Casings and Tubings D. Well Completion and Workover Services
Kilsby-Roberts Baker Hughes h c .
P.O. Box 9500 3900 Essex Lane, Suite 1200
Brea, CA 92622 Houston, TX 77073
Telephone: (7 14) 579-8823 Telephone: (7 13) 439-8600
Trico Industries Inc. Baker Service Tools
15707 S. Main Street P.O. Box 40129
Gardena, CA 90247 Houston, TX 77240
Telephone: (2 13) 5 16-5000 Telephone: (7 13) 466-8600
Hydril Company BJ-Titan Services Company
P.O. Box 60458 5500 North west Central Drive
Houston, TX 77205-0458 Houston, TX 772 10
Telephone: (7 13) 449-2000 Telephone: (7 13) 462-4239
B. Subsurface Flow Control Equipment 4. Hall i burton Services
(Landing Nipples, Lock Mandrels, etc.) 1015 Bois d' Arc, Drawer 1431
Duncan, OK 73536
1. Hydril Company Telephone: (405) 25 1-3760
P.O. Box 60458
Houston, TX 77205-0458 Schlumberger Well Services
Telephone: (7 13) 449-2000 5000 Gulf Freeway
P.O.Box 2175
2. Otis Engineering Corporation Houston, TX 77252-2 175
2601 Beltline Road Telephone: (7 13) 928-4000
P.O. Box 8 19052
Dallas, TX 7738 1-9052
Telephone: (214) 418-3000
C . Thermal Packers and Expansion Joints
1. Guiberson Division
Dresser Tndustries Inc.
P.O. Box 6504
Houston, TX 77265
Telephone: (7 13) 750-2301
2. Otis Engineering Corporation
2601 Beltline Road
P.O. Box 819052
Dallas, TX 773 8 1-9052
Telephone: (214) 4 18-3000
3. Baker Hughes Inc.
3900 Essex Lane, Suite 1200
Houston, TX 77073
Telephone: (7 13) 439-8600
 CHAPTER 10
THERMAL WELL CEMENTING PRACTICES

INTRODUCTION
Cement is almost exclusively used to fill the annular space between casing and open hole in a
well completion operation. The primary functions of any cementing job are (1) to restrict fluid
movement between formations and (2) to support the casing. Good cement jobs are essential for
the successful operation of a well. In thermal wells it is even more critical. Steam injection wells
present special challenges when one designs a cement job for such wells. In most cases, the
cement sluny is subjected to relatively low temperatures during the cement job and early curing.
However, after the cement sets, it must withstand the thermal shock associated with the initiation
of steam injection. Another complicating factor is the problematic weak and unconsolidated
formation often encountered with thermal wells. This chapter presents an overview of current
steam injection well cementing practices. Vendors such as those listed in Appendix 10-A should
be consulted for additional information.

Steam Injection Well Cementing Requirements

Although cements used in thermal wells are subject to thermal shock at the initiation of steam
injection, they must retain adequate compressive strength and low permeability during the life of
the well. Thermal stress on the cement and casing requires uniform high quality bonding
throughout the well. It is also advantageous to have low thermal conductivity cement such that the
injected heat goes predominandy to the oil bearing sand rather to the overburden.
Good cementing practices, such as the use of spacers. centralizers, and mud conditioners are
also very important. However, such practices are wasted unless the cement is properly designed
for long-term stability and adequate performance characteristics. Two kinds of cement, with
additives, are routinely used in the completion of steam injection wells: Portland cement (API
Class A, G or H cement) and high alumina cement. In general, Portland cement is useful in
applications up to about 650' F; however, beyond 600' F, use of high alumina cement is
recommended?

THERMAL CEMENT CHEMISTRY~*~-6

Portland Cement
Conventional oilfield Portland cement cannot be used in thermal well completion applications
because it begins to lose its compressive strength at about 230' F. Silica flours are usually added
to the cement to halt strength retrogression. The silica flour plays an important role in improving
the cement's strength.
 Ordinary Portland cement is essentially a calcium silicate mater-ial. the primary components
being dicalcium silicate and tricalcium silicate. When water is added to the cement, it hydrates to
form a calcium siIicate hydrate gel. It is this gel that is sesponsible for the strength and integrity of
the set cement at ordinay temperatures. In addition, a substantial amount of calcium hydroxide is
also liberated.
The calcium silicate hydrate gel provides good binding at lower temperatures, but at about
230' F, this gel undergoes a phase transition and convens to a phase called "alpha dicalcium silicate
hydrate' (a-gel). The a-gel is, unfortunately, a much denser material that is prone to shrinkage.
The shrinkage is accompanied by a loss of compressive stnngth and an increase in permeability.
Though the amount of strength reduction is severe (from about 4,000 psi to 2,800 psi in one
week), it is still sufficient to support the casing in a well (the minimum API acceptable compressive
strength is about 500 psi). However, the real problem is the drastic changes in permeability. The
changes in permeability may create greater problems. Cements exhibiting 0.0 1 m D permeability
after one day at 320' F can exhibit 1 m D permeability after one month. Normally, this permeability
increase is of little importance in the high permea bi 1i ty r~eservoii-s
associated with the stearnflood
operations. However, this permeability increase will cause steam to migrate to zones behind the
casing and weaken the casing-cement bond. This weakened bond is easily broken by the thermal
expansion of the casing. Thesmnl well cement studies indicate, that for the prevention of interzonal
communication, the water permeability must not exceed 0.1 m D at steam injection temperaturesS4
In figures 10.1 and 10.2, the compressive strength and permeability pe~formanceof neat Portland
cements at 400' F are shown, respective^^.^
Portland cement slurries are usually made suitable for steam injection applications by
stabilizing them with the addition of silica flour. When silica flour is added to the cement, a
portion of the additive reacts with the calcium hydroxide to f o ~ malpha dicalcium silicate hydrate
(a-gel). The remaining silica reacts with the a-gel to form what is known as the tobermorite
phase? The tobermorite phase is a better cementing binder than a-gel and retains the high
compressive strength and low-permeability characteristics of the Portland cement. In figures 10.3
and 10.4, the compressive strength and permeability performance of silica flour augmented
Portland cements are shown, respectively.7
For steam injection well cementing applications. normally 30 to 60% (by weight of dry
cement), silica flour is added to the Portland cement. The average being about 40%. The
minimum temperature at which silica flour should be used is 230' F. Recent research indicates that
regular silica flour is the best additive for temperatures ranging from 230' to 600' F . ~Above
650' F, these mineral phases begin to dehydrate to form calcium oxide. In steam injection
operations, the dehydrated cement will begin to rehydrate i n the presence of steam and begin to
disintegrate due to volume increase.
 5000
-ii
u:

8
t
4000

a
3000
C3
ia5
5 2000
r 1 Class G - 44% Wder
2 Class G - 3861~Waler
,000 -
3 Class H 32% Water
'

0
0.000
0 3 6 9 12 15 18 21 24
CURING TIME, months

FIGURE.10.1. - Compressive strength of neat Portland cement at 400' F?

-
1 Class G 44% Water
-
2 Class G 38% Water
-
3 Class H 32%Water

CURING TIME. months

FIGURE 10.2. - Permeability behavior of neat Portland cement at 400' F.7

 Stabilized with 35 % silica

0 3 6 9 12 15 18 21 24
CURING TIME. months

FIGURE. 10.3. - Compressive strength of Portland cement stabilized

with 35% silica flour at various tempesatures.7

-
1 Silica Sand 400" F
2 Silica Flour - 400'' F
3 Silica Flour - 600"F
Stabilized with 35 % silica

CURING TIME, months

FIGURE. 10.4. - Permeability behavior of Postland cement stabilized

with 35% silica flour at various temperature^.^
 Alumina silicate cements such as the "Pozzolan" cements, which contain fly ash, can
chemically bind the free calcium hydroxide in Portland cements5 but are often unreliable at the high
temperatures associated with a steam weH, and their use is not recommended.3 Thus, for all
practical purposes, the Portland cements are satisfactory for steam injection well completion up to
600' F, if sufficient silica flour is added to the cement. Since very few steam injection operators
inject steam above 600°F, silica flour augmented Portland cement is satisfactory for most steam
injection applications. Silica flour is also inexpensive and is compatible with all commonly used
retarders, friction reducers, low water loss additives, and lost circulation materials.

High Alumina Cement

In applications where a refractory binder is required, high alumina cement can be used.
These are speciality cements whose primary cementitious constituent is monocalcium aluminate.
When water is added to the high alumina cement, it forms three metastable calcium aluminate
hydrates (mono-, di- and tetra-calcium aluminate hydrate), which eventually converts to vicalcium
aluminate hydrate. Unlike the Portland cement, the high alumina cement does not produce calcium
hydroxide as one product of the reaction. Above 440° F, the tricalcium aluminate hydrate begins to
dehydrate and above 525' F, it begins to decompose with formation of calcium oxide and calcium
aluminate.
Because of their excellent resistance to thermal shock. these cements are widely used to
cement in situ combustion wells where the temperature often exceeds 1 .OOOO F. Their stability at
such temperatures is mainly due to the absence of calcium hydroxide. The strength and durability
of high alumina cements are primarily controlled by the water-to-cement ratio. The durability
decreases with the increase in water-cement ratio. Hence, the addition of water should be kept at a
minimum necessary to obtain a pumpable slurry. A variety of materials are used as extenders in
high alumina cement slurries to obtain desirable chasactei-istics. These include high alumina
crushed firebricks, fly ashes, diatomaceous earth, and perlite.
High alumina cements are recommended for cementing those wells where the steam injection
temperature is expected to exceed 600° F. These cements, however, are expensive and cost much
more than Portland cement plus silica flour. Further, its behavior under steam injection conditions
is hard to predict. Laboratory tests are recommended before its use in a steam well.

STEAMFLOOD CEMENTING PRACTICES

Steam Well Problems

Steam injection wells are frequently less than 4,000 ft in depth; and, as such, these wells
generally have normal formation temperatures (less than 125' F). These temperatures do not affect
primary cementing. After the cement has set, however, a steam injection well must withstand
temperatures up to 650' F, but not until steam injection begins.
The formations associated with steam injection wells are usually unconsolidated, weak and
have low fracture gradients. Hence, lost circulation of cement and fluid loss problems are often
present. To avoid fracturing the weak formations with cement and the associated cement loss, low
density cement slurries are necessary. Another problem associated with the thermal well is the
thermal expansion of the casings and wellhead growth. This calls for a cement with good
expandable properties. To minimize heat loss to the over- and underburdens, the cement should
have good insulating properties.
These unique characteristics of thermal wells and the associated performance requirements of
cementing materials are often at cross purposes. For example, as mentioned previously, thermal
well cement must retain the strength and low-pelmeability characteristics of ordinary cement at
elevated temperatures. This requirement can be met through the use of high density cement
slurries. Unfortunately, since the formations associated with steam wells are weak, high density
slurries are generally not suitable because of the loss circulation problem. Further, thermal well
completion calls for cements with good insulating properties (i.e., low thermal conductivity
characteristics), but high density cements are poor insulators. Therefore, considerable research has
been performed to formulate cements with the above desired properties.
Until a few years ago, low density Portland cement slurries were prepared by adding light
weight filler materials (such as perlite, gilsonite, powdered coal and diatomaceous earth) or water
absorbing thickeners such as bentonite and sodium silicate. The performance of selected low
density slurries are shown in figures 10.5 through 10.8.7 These figures indicate that high
compressive strength and low water permeability are not linked. Further. field experience indicates
that conventional, filler cements with densities less than 12.5 pounds per gallon (ppg) perform
poorly in steam injection wells due to permeability increa~e.~
Recently, two new methods of preparing low density slurries have been developed. These
methods not only reduce the slurry density to a very low level, they were also able to retain the
compressive strength and low-permeability character-isticsof the cement at elevated temperatures.
The method includes (1) addition of hollow glass or. ceramic micro spheres9 and (2) foamed
cement.lO Of these two techniques, foam cements are preferred for thermal applications due to
their superior performance.7
With the addition of proper surfactants and stabilizers, it is now possible to prepare low
density slumes with high compressive strength and extremely low-permeabilities. Foamed cement
made from a base slurry stabilized for high temperatures exhibits excellent performance
 1 Fly Ash - 15.6 pm
-
2 PerlitdBentonite 13.0 ppg
-
3 PerliteIBentonite 11.9 ppg
-
4 Diatomaceous Earih 13.6 ppg

0
0 3 6 9 12 15 18 21 24
CURING TIME. months

FIGURE. 10.5. - Compressive strength of conventionally extended

Portland cement at 400' F?

1 Fly Ash 15.6 ppg

- 2 PerliteIBenlonite - 13.0 ppg
0
E
10 -
3 PerlitelBenlonite 1 1.9 ppg
4 Diatomaceous Earth - 13.6 ppg

W
a 0.1 -

3 6 9
CURING TIME. months

FIGURE. 10.6. - Permeability performance of conventionally extended

Portland cement at 400' ~ . 7
 1 Fly Ash - 15.6 ppg
2 PerlitelBentonite - 13.0 ppg
3 PerliteIBentonite - 11.9 ppg
4 Diatomaceous Earth - 13.6 ppg

3 6 9
CURING TIME. months

FIGURE. 10.7. - Compressive strength of conventionally extended

Portland cement at 600' F?

1 4B

3
dl

2
4,
1 Fly Ash - 15.6 ppg
-
2 PerlitdBentonite 13.0 ppg
3 PerlitdBentonite - 1 1.9 ppg
4 Diatomaceous Earth - 13.6 ppg

I I I

0 3 6 9 12
CURING TIME. mnlhs

FIGURE. 10.8. - Permeability performance of conventionally extended

Portland cement at 600' F . ~
characteristics at steam injection temperatures. Although foamed cement with densities as low as 9
ppg show excellent performance characteristics in terms of compressive strength, their water
permeabilities are somewhat higher than microsphere ~ e m e n t . ~
A typical cement formulation recommended for most steam injection wells could consist of
50% Class G cement, 35% -200 mesh silica flour and 15% microspheres.

Cementing Practices
Given a good composition of thermally stable, bondable cement, it is essential that the cement
be applied properly to assure adequate zonal isolation and uniform bond quality. Good cementing
practices is even more critical in thermal wells to ensure that the integrity of the bond is maintained
under temperature induced stress conditions. Cement should be returned to the surface on every
string of casing to assure complete fill-up of cement in the casing hole annulus and to anchor the
casing f m l y to the ground.
Prior to the cementing operation, the drilling mud must be removed to assure good stable
bonding. Mud removal can be enhanced through the use of spacers and was he^.^ Most operators
use chemical preflushes ahead of the cement job to help remove the mud in the casing and
formation wall. The chemical preflush, which is normally water-based, should contain a good
mud thinner and a surfactant to leave the pipe and formation surface in a water-wet condition.l 1
Care should be exercised in selecting the mud thinners, since some of them (such as quebracho,
lignosulfonates) added to water may retard cement setting. l Dilute mix of Portland cement put in
turbulant flow is an excellent preflush and aid in erosion of gelled mud and filter cake. Because of
great variation in mud system, the chemical wash should be selected for the particular mud system
in use.
Effective centralization is a critical factor in obtaining a good primary cement job. Enough
centralizers must be used to produce a uniform sheath of cement. In straight hole, one centralizer
per joint is recommended. Centralizers should be placed in gauge sections of the hole as
determined by caliper or other logs. In crooked hole, centralizer placement depends on hole
deviation.
Floating and guiding equipment should be used to assure good cement job. Float collars
should be located one or two joints above the float shoe to prevent mud contaminated cement from
being placed outside the bottom casing joining. l Use of scratchers should be given serious
consideration, since they aid in the removal of mud cake and break the mud gel. They also help to
mix up the mud with cement, thus reducing channeling. Hole washout must be taken into
consideration in estimating the cement volume required to achieve the desired fill-up. The actual
cement volume to be used should be at least 15%more than the estimated value.
 The success of the cement job depends on the quality of cement mixing. Weight of cement
sluny should be monitored to ensure that the con-ect amount of water is used to prepare the slurry.
Wiper plugs should be used to wipe mud off casing ahead of cement as well as to separate mud
and cement. Consideration should be given as to whether or not to reciprocate and/or rotate the
casing while cementing to assure successful mud displacement and enhance the formation of good
uniform cement sheath. Cement should be circulated near turbulence condition to aid in the
removal of mud and to reduce the possibility of mud channels remaining in the productive zone.
Use of friction reducers with the slurries promote turbulence flow and should be considered.
Good operator and service company supervision during cementing operations is critical to
minimize cement job failures. The slurry should be placed at the highest practical rate without
exceeding the fracturing pressure of the formation. Use of sonic or ultrasonic logs are
recommended to monitor the presence of cement and the quality of casing-cement bond. Proper
interpretation of the log is critical and the service of experienced engineers should be enlisted to
interpret the logs.

SUMMA WY
This chapter presents a brief overview of thermal well cementing practices. Neat Portland
cements (API Class A, G or H) are not appropriate for completing steam injection wells. These
cements lose their compressive strength and show permeability increases at temperatures above
230° F. However, Portland cements with appropriate additives can be used to cement steam
injection wells, provided well temperatures do not exceed 600' F. Above this temperature, high
alumina cements are recommended. Fine mesh silica flour 30% to 60% by weight of dry cement
should be mixed with Portland cement and used in thermal applications.
Since the formation associated with the steam injection wells are usually unconsolidated and
weak, high density cements should not be used. Ceramic microspheres can be used to prepare
ultra low density cements with acceptable performance for steam injection wells.
Good cementing practices are critical in steam injection well completion. Cement returns to
the surface is a must. The hole should be well circulated prior to cementing. Pipe should be
suitably equipped with floating and guiding equipment. Adequate number of centralizers must be
used to assure good cement sheath. During cementing operations, mud removal can be greatly
enhanced through the proper application of spacers and washers. Use of bottom plugs, chemical
washes, excess cement, and good supervision will assure good cementing job.
REFERENCES
1. Allen, T. 0. and A. P. Roberts. Production Operations, v. 1 ; Well Completions,
Workover and Stimulation, chapter 4. Oil and Gas Consultants International. Inc., Tulsa,
Oklahoma, 1878.
 2. Cementing For Ultra-High Temperature Wells. Hdliburton Services. Technical Bulletin
NO. C- 1297.
3. Nelson, E. B. Improved Cement Slurry Designed For Thermal EOR Wells. Oil & Gas
J., v. 84, No. 48, Dec. 1, 1986, pp. 39-44.
4. Eilers, L. H. and R. L. Root. Long-Term Effects of High Temperature on Strength
Retrogression of Cements. Pres. at the 46th Annual California Regional Meeting of the Soc. of
Pet. Eng., Long Beach, California, Apr. 8-9, 1976. SPE paper 587 1.
5. Taylor, H. F. W. The Chemistry of Cements. Academic Press, London, v. 2, 1964.
6 . Smith, D. K. Silica Flour-Mechanism For Improving Cementing Composition For
High Temperature Well Conditions. Pet. Eng. International, v. 52, No. 15, December 1980, pp.
43-48.

7. Nelson, E. B. and L. H. Eilers. Cementing Steamflood and Fireflood Wells-Slurry

Design. Pres. at the 34th Annual Technical Meeting of the Pet. Soc. of the Canadian Institute of
Mining, Banff, Alberta, Canada, May 10-13, 1983. Paper No. 83-34-23.
8. Chmilowski, W., A. Frankiw and R. J. Ford. Evaluation and Improving Thermal
Cementing Practices. Pres. at the 35th Annual Tech. Meeting of the Pet. Soc. of the Canadian
Institute of Mining, Calgary, Alberta, Canada, June 10- 13. 1984, Paper No. 84-35-115.
9. Griffin, T. J. and W. Chimilowski. Cement Spacers and Washes Can Improve
Stimulation and Production Characteristics of Oil and Gas. Pres. at the 29th Annual Tech. Meeting
of the Pet. Soc. of the Canadian Institute of Mining, Calgary, Alberta, Canada, June 13-16, 1978.
Paper No. 78-29- 12.
10. Olanson, M. T. Application of Foam Cements in Alberta. Pres. at the 35th Annual
Tech. Meeting of the Pet. Soc. of the Canadian Institute of Mining, Calgary, Alberta, Canada,
June 10-13, 1984. Paper No. 84-35-72.
11. Cain, J. E. and S. H. Shryock. Cementing Steam Injection Wells in California. J. Pet.
Tech., v. 18, No. 4, April 1966, pp. 431-436.
 APPENDIX 10-A
THERMAL WELL CEMENTING SERVICE VENDORS
A. Thermal Well Cementing: Services

1. Dowell-Schlumbergei-Inc.
12012 Wickcheseer, Suite 300
Houston, TX 77079
Telephone: (7 13) 870-8959
2. Halliburton Services
1015 Bois d' Arc, Drawer 1431
Duncan, OK 73536
Telephone: (405) 25 1-3760
3 . BJ-Titan Services Company
5500 Northwest Central Drive,
Suite 100
P.O. Box 4442
Houston, TX 77210
Telephone: (7 13) 462-4239
 CHAPTER 11
THERMAL WELL LIFTING EQUIPMENT

INTRODUCTION
The production of oil from thermal wells by artificial lifts is more difficult and expensive than
producing from conventional wells for several reasons. Lifting conditions can vary widely during
steam stimulation cycles. Temperatures may range fsom 75' to 600° F, viscosities from 10,000 cP
to 1 cP, water-oil ratios from 0.1 to 20, liquid production rates from 10 to 1,000 bbllday, gas-oil
ratios from 50 to 1,000 SCF/STB and sand cuts fsom 0 to 18%. These conditions impose severe
strain on the lifting systems. Produced vapor, though mostly steam, may also contain acid gases.
The presence of high temperature, high water cut and acid gases can result in downhole corrosion.
Although different types of artificial lift equipment has been utilized to lift oil from steamed well,
the most prevalent form of lift for fluids in thermal operations is the conventional rod pump.
Corrosion and abrasion (due to sand production) in combination with the mechanical stresses of a
reciprocating pump jack takes a heavy toll on the downhole pump. Problems associated with the
lifting of heavy oil in thermal well by pump jacks has resulted in the emergence of newer breeds of
pump jacks offering the control and flexibility required for optimizing production in these wells.
This chapter presents an overview of the pumping problems associated with the lifting of
heavy oil from thermal wells. The problems are discussed primarily as they affect rod pumps.
THERMAL WELL PUMPING PROBLEMS
Thermal wells are generally associated with low gravity, high viscosity crudes, produced
from unconsolidated formation. Some of the pumping psoblems associated with such wells
include rod floating, sand production, steam flashing, varying produced gravity, varying inflow
rates, and system operational problems.
Rod Fall and Rod Drag
In heavy oil wells, the rate of movement of the sucker rod on the downstroke is greatly
influenced by oil viscosity. In steam operations, prior to steam breakthrough, the downhole
temperatures are low enough that the oil tends to stay viscous. The viscous oil can cause
considerable viscous drag in the production equipment. This viscous drag or frictional force on the
rod can be easily overcome during the upstroke of the pump jack. However, during the
downstroke only gravitational forces aid the rod movement and the frictional forces can
considerably slow down the rod movement.
The rate at which the rods move on the downstroke is called the rod fall or rod float rate. It is
typically in the range of 10 to 60 ft per minute (0.5 to 3 strokes per minute).l Thus, the rod float
rate constrains the beam pumping unit operation. Attempting to sun the pump jack at a speed faster
than the rate at which the rod can sink creates s condition known as rod tloat. Rod float will result
in the polished rod clamp and canier bar to sepuute on pump downsuoke.
Since pump jacks are normally a single speed device, the canier bas travels at the same speed
on the upstroke as on the downstsoke. The resulting collision between the downward moving
clamp and rod string and upward moving cassier bar can cause ~najosdamage to both surface and
downhole equipment.
To accommodate extra rod stresses resulting fsom viscous forces. oversized rod strings are
usually used. Since the oversized rod reduces the annular clearance between the rod coupling and
the tubing inside diameter, it aggravates the rod tloat psoblerns. Most operatoss attempt to soften
the rod float effect by providing maximum annula- clearance with the use of iasger diameter tubes.
To date, many operators avoid rod float conditions by lowesing the pump speed downstroke
through the use of motor sheave^.^ Since the fluid production rate is limited not by pump size, but
rather by pumping speed, rod float restricts well psoductivity. Production restrictions can result in
high fluid levels in the well. which increases the bnckpsessuse on the well. Increased backpressure
reduces inflow rates and will result in the loss of average production.
Many operators use a longer stroke surfiice unit and downlmle pump io increase production.
However, this is a costly and only pastially effective solution. A larger subsul-face pump diameter
could be installed to increase production, but pump diameters are limited by sand settling
problems, pump compression ratios and psotection fl-om high temperatures because of steam.
Thus, productivity of a well is severely impairbed by rod float. On some wells, increased
backpressures cause sand to settle.
Further, the high viscosity of heavy oil causes conventional subsur-face pumps to operate less
efficiently because of slow closure of traveling and standing v a ~ v e s .The
~ viscous friction of fluid
flowing through the traveling valve on the downstroke fi~nherreduces the rod fall rate. To avoid
rod float, the upstroke w v e l rate must match the downstroke lute. This imposed slow upstroke
results in sluggish closure of the traveling valve. Thus, a percentage of production is lost on every
stroke? In many wells, restricted flow because of rod float will keep a well from being pumped
off.
Sanding
Much of the world's heavy oil is found in unconsolidated formation with high sand content.
Sand production from unconsolidated heavy oil reservoirs is one of the major problems affecting
heavy oil production from theimal wells. Production of sand particles with the fluid causes severe
operating problems because of abrasive effects of sand on downhole equipment and accumulation
of sand across the perforations. Experience with thermal recovery projects in unconsolidated
reservoirs indicates that despite the use of sand exclusion measures. some sand production is
unavoidable. Furthermore, fluctunting well bore conditions due to we11 stimulation and varying
production rates may also cause an increase in sand production. The presence of sand in the
production fluids damage the sucker rod pump. Damages to the pump include erosion of the ball
and seat, and seizure of the p l ~ n g e r . ~
Unlike conventional operations where s well is routinely pumped off and the pump jack shut
down to reduce the effects of fluid pound, pumps in thermal wells are kept running to avoid
complications imposed by a well sand flow. When fluid stops moving, the sand held in
suspension in the fluid settles out on the pump. This condition often necessitates costly workover
and frequent servicing of the pumping equipment. In extreme cases, sand problems dictate a
complete recompletion of the well. In wells where sanding is severe, operators have reported
pulling sucker rod pumps only after three weeks of service because of wear and plunger seizure4
Steam Breakthrough
When thermal wells are pumped too fast, hot fluid and in some cases steam itself is brought
back to the surface. This can result in damage to the sulfxe equipment and cause production rates
to drop. Steam interference can significantly influence pump performance and adversely affect
pump efficiencies. Field investigations in Canada revealed that many cyclic wells where steam is
produced along with oil, steam significantly affected the pump performance. The barrel fillage
ranged from 60% to 8 0 8 and the corresponding pump efficiencies wen 30% to 688.5
Production Conditions Variations
In steam operations, the composition. gravity and viscosity of the produced oil can and does
change daily. This is because of the steam distillation and solvent drive mechanism associated with
such processes. Further, oil and stimulation fluids (steam, hot water, and noncondensible gas) do
not flow into the wellbore at a constant ratio. This is because of the gravity override and fingering
of the stimulation fluids as well as uneven heating of the reservoir sand.
Varying inflow rates and the fluid properties causes rod fall rate to change. As discussed
previously, fluctuation in the rod fall rate seriously impairs the pump performance. The traditional
approach to this problem is to monitor the operation of the beam unit closely and implement
appropriate corrective action as needed. If the operator foresees a change in rod float rate or a
pump off condition becomes imminent, he alters the pump speed rate to correct the problem. This
is usually done by changing the pump drive belt sheaves. This approach is not only labor intensive
and inefficient but also very expensive. Further, the daily changes in fluid gravity causes the beam
pump to remain out of balance most of the time.
 System Operational Problems
Beam pumping units are usually designed and manufactured according to the API RP IIL
specifications.6 Since this specification does not consider problems peculiar to thermally
stimulated wells, any pump designed according to this specification is inappropriate for heavy oil
lifting. Most of the production system failures such as parted rods, overstressed or busted gear
boxes and low pump efficiencies (high fluid level) can be traced to the faulty design. For example,
for a 12' API oil, the AH specification underestimates the gear box loadings by as much as 300%.
This is because the specifcation does not account for the head effects caused by the extremely high
viscosities of heavy oil?
In the conventional beam unit, the upstroke and downstroke speeds are matched by adjusting
the counterweights on the walking beam. In the heavy oil wells, extra counterweights are needed
to overcome the viscous forces during the upstroke. Since the downstroke speeds are limited by
the rod fall rate, the gear box does not receive any torque from the rods. Thus, the gear box must
lift the entire counterbalance unassisted. On the other hand, if attempts are made to balance the unit
to match for the downstroke, the unit may become overly underbalanced for the upstroke. In this
situation, the gear box must not only lift the rod and fluid loads, but must also overcome the
viscous force without additional counterweights. In either situation, the gear box is overstressed.

SOLUTIONS TO HEAVY OIL THERMAL WELL PUMPING PROBLEMS

Though the conventional beam pumping unit is versatile, reliable, inexpensive, and widely
used in the oilfield, they may be inefficient in meeting the production demands of stearnflood
production wells. Their operating range is limited and does not provide the flexibility needed to
optimize the production from these wells. The rigid mechanical coupling of the system units (i.e.,
crank, pitman and the beam) do not permit stroke lengths to vary dynamically. Stroke length
adjustment is essential to accommodate the varying inflow rates and to reduce gear box stress.
Traditional approaches used in the United States thermal operations to improve the pump
performance include: (1) setting the pump speed to achieve an estimated average production;
(2) alter pump speeds mechanically by changing sheave size; (3) use of variable speed motors to
change pump speed; and (4) use of pump off controllers. Each of these approaches have
limitations. By setting the pump speed to achieve an average production, the man-hours needed to
change pumping speeds is eliminated. However, with this approach, pump efficiency is reduced
because of the increased time needed to produce the water back after steam breakthrough. Further,
as pointed out earlier, if the well inflow is higher than the average production rate, this can result in
high fluid levels in the well and this has the effect of causing sand settling. If the average
production rate is greater than well inflow rate, higher pump speed will result in severe fluid pound
and unnecessary maintenance. The limitation of changing motor sheaves to alter pump speed were
already discussed. The use of a variable speed motor to change pump speed, though attractive
from the operational prospective, has its limitations. Use of variable speed motors require
someone to watch production rates or fluid pound indications to determine when to change the
pump speed. Over and under counterbalancing can be severe when variable speed motors are
used? The required gear box torque will be increased considerably if the unit is slowed on the
downstroke, because the counterbalance inertia cannot be used to assist the motor.
The inadequacies of the conventional beam pumps to meet the service demands of heavy oil
production have led to the development of alternate pumping techniques. These include
modification of conventional pump jacks to improve its flexibility and novel pumps such as the
diluent pumps, cavity pumps and chamber lift pumps. None of these pumps are widely accepted
and they are used principally in the heavy oilfields of Canada and Venezuela, where the oil is more
viscous than those found in the United States.
Novel Pump Jacks
The downhole pump, the sucker rod, the produced fluid, and surface unit all contribute to the
efficiency and economics of heavy oil production. Of these. the surface unit plays a major role and
any improvement in its performance can result in significant improvement in the pump efficiency.
An ideal surface unit should embody all of the following characteristics:3
minimal capital outlay
long, slow pump strokes
low surface profile
infrequent and uncomplicated maintenance
self optimized production rate
high mechanical efficiency
robust constr.uction
minimal wear to downhole equipment
variable upstroke and downstroke speeds
use of field proven technology.
Several arrangements that are coupled with existing conventional pump jacks to achieve one
or more of the aforementioned characteristics have been marketed in the past decade. Since these
systems were developed to meet certain production application requirements, they have sacrificed
some of the desirable characteristics of a conventional beam unit. The use of these novel pump
jack units in the field are growing, especially in Canada. There are differences between the various
systems in their approach and capabilities. A brief overview of few selected units are presented
here to appraise the operator of the options available to him. Many of these units are prototypes
and are field tested in Canada. The authors are not aware of any of these units being used in the
United States.

HEP ~ u m p 7
This is a hydraulic, variable speed, surface pumping unit that utilizes a hydraulic system to
transmit energy from the prime mover to the sucker sod string. The pump was developed to
eliminate the gear box in the conventional beam unit in favor of a high torque, low speed motor.
The system uses &draulics to transmit the power from the prime mover to the sucker rod
strings, Electronics to control the rod motion, and a pneumatic system to provide counterbalance
effects. Hence, the name HEP.
The system utilized a double-acting piston and cylinder hydraulic motor, mounted on the
wellhead to actuate the rod string. The piston rod is connected to the polished rod by means of
flexible wireline, carrier bar and rod clamp. A vadable displacement pump, which is capable of a
wide range of discharge rates, is used to hydraulically transmit input power from the prime mover
to the hydraulic piston. The displacement pump dischalge rate and direction of motion are
controlled electronically. In this way, the motion of the polished rod is controlled automatically.
Stroke speed and the velocity profile are varied by changing the control panel settings. This feature
allows upstroke and downstroke rod speeds to vuy independent of each other. Counterbalance for
the pumping system is provided by a nitrogen filled hydraulic system. The unit offers 3 different
stroke lengths and the desired stroke length can be selected by a switch inside the electronic control
panel.
The HEP has exhibited its superiority over conventional beam pumps in the field tests.
However, the system has two major drawbacks that prevent its widespread application. First, the
reliability of hydraulic cylinders (the system that transmits power from the prime mover to the rod
strings) in relation to long-term continuous operation is suspect. Secondly, difficulties have been
encountered in effectively counterbalancing the system. There are two concerns with the nitrogen
filled hydraulic counterbalance system: leakage and actual counterbalance effect.* As a gas, the
nitrogen pressure is dependent on ambient temperature and wide variations in temperatures affect
the counterbalance capability. Also, since the pressure varies inversely as volume, large volumes
are needed to minimize pressure fluctuations.
PC 3000 system3
The PC 3000 system operates like an air-balanced beam pump unit and utilizes a low speed,
high torque hydraulic motor and a nitrogen system to provide the needed counterbalance. A
hydraulic system is utilized to lift the beam. rod string, and tluid load on the upstroke. A
hydraulically driven winch is used to pull the beam in the downstroke. This system also allows the
operator to vary the upstroke and downstroke speed independently to accommodate any pumping
condition. The unit is still in the developmental stage and waiting field trial.

Variable Speed Beant ~ i l r n ~ ~

This system is a conventional beam pump unit equipped with a variable speed controller to
vary the upstroke and downstroke speed independently. The unit also gives the operator control
over the acceleration and deceleration of their units at each end of the stroke. This feature pennits
the operator to fine tune the stroking profile. Since the stroke length are restricted by the walking
beam geometry, this unit has no provision to adjust the stoke length. Counterbalance is achieved
as in the conventional pump.
This unit is a prototype system and has been field tested to a limited extent. Field trials are
promising, but several problems are yet to be solved satisfactorily. Rapid variations in well
pumping conditions cause the unit to operate erratically and necessitate the operator to make
frequent adjustments to maintain proper operation.

Diluent pump'
Diluent pumps are used to lift highly viscous sand laden crude oils. The system depends on
the use of a diIuent to lower the viscosity of in situ crude and make it purnpable. Downhole
blending also improves rod fall and pump performance. Figure 11.1 shows the schematic of a
diluent pump used in the Cat Canyon field of California to produce the 6' API oil. This pump is
activated by sucker rods and requires dual tubing strings. The sucker rods and pump plunger
operate in one string called the power string and the other string acts as a conduit for produced
fluids. The diluents are injected through the hallow sucker rods or side strings to improve rod fall
and pump performance. The dual tubing strings airangement permits the isolation of sucker rods
and pump plunger from the viscous sand laden crudes. These pumps are more expensive to install
and operate. Their use is usually restricted to tar sand cyclic wells.
Other types of pumps used in producing heavy oil include chamber lift (gas lift) pump1O and
cavity pump11 These are prototype pumps developed and used in Venezuela to produce heavy
crudes. The chamber lift pump is a modified version of the conventional inremittent flow gas lift
pump with an accumulating chamber and is employed to lift heavy oil from wells with very low
bottomhole pressure and in cyclic wells.
The cavity pump is basically a subsurfuce rotary positive displacement pump actuated by
sucker rods, which in turn are driven by a motor installed at the wellhead. The advantage of such a
pump lies in its ability to move the fluid continuously, contrary to beam pump which produces
only on upstroke. Some of the operational conditions used that have to be considered with this
pump include:l l
 TYPE Y CONVENTIONAL
TYPE X
DILUENT PUMP
DILUENT INJECTION DILUENT INJECTION
DILUENT INJECTION

HOLLOW 1 PRODUCTION
SUCKER ROD

PULL TUBE
DISCONNECT

PULL
TUBE
SEAL
ASSEMBLY
HOLLOW
PULL TUBE
- PUMP SEAT
SPRING
LOADED
CHECK -
VALVE

PLUNGER -
PUMP /
BARREL

OPTIONAL
SPRAY NOZZLE

EXPLANATION
I:'=:=.:=='l
BLENDED CRUDE

FIGURE 11.1. - Schematic of a diluent pump used in the Cat Canyon field of
California to produce the 6' API oil?
1. Fluid level has to always be a minimum of 300 ft above the pump to avoid starter damage
due to friction heat.
2. In wells with high sand production. a prepack filter must be used below the pump to
avoid starter damage.
3. Wells with high GOR will require gas anchors and pumps with sufficiently large
capacities to handle gas and liquid.
 U.S. Thermal Well Pump Systents
Despite its disadvantages, rod pumps are used almost exclusively in US. thermal oil
production. This is because the alternative lifting methods such as the gas lift are more problem
prone and economically unattractive to operate. Both insert pumps and tubing pumps are used in
the U.S. steamflood operation. Insert pumps are preferred over tubing pumps due to the
undesirability of performing a tubing job to replace a worn pump barrel in a potentially hot well.
Most operators use the heavy-wall, full-barrel, top hold down pumps with stainless steel friction
ring assemblies. Many operators employ slow speed, longer stroke pumps to handle large
volumes of fluid produced after steam breakthrough. Operators' experience indicate that it is not
possible to obtain accurate liquid levels in wells producing large volumes of steam. Field
experience in such wells, indicate basing pumps off condition on fluid pounding alone is not sound
and can often lead to steam lock in the pump.14
Use of Pump-Off Controls in Thermal Well
When the productive capacity of a well is less than the pump lifting capacity, the pump
barrels are only partially filled during the upstroke. This is known as a 'pump-off condition1l and
can lead to severe fluid pound problerns.12 The fluid pound associated with pump-off is
responsible for damage to the rod string, pump, and in some cases, surface equipment. The
pump-off problem can be eliminated if the pumping system capacity can be matched exactly to the
productivity rate of the reservoir. This is very difficult to achieve in practice and impossible in
thermal wells.
As stated previously, the inflow rate in thermal wells are constant but varies over a wide
range. For example, in cyclic wells the inflow rate may vary from about 20 bbYday gross before
stimulation to in excess of 300 bbVday after stimulation. This creates a unique pumping problem.
Since the fluid production rate depends on the pump speed, it is impossible to accommodate both
extremes at a constant speed. If the pumping speed is set to satisfy higher production rates, then as
the cycle progresses the inflow rate decreases leading to a pump-off problem and unnecessary
maintenance. If the pumping speed is set to satisfy the lower production rate, it is obvious that
there will be production loss during the early stages of the production cycle. Similar situations can
arise in steamfloods where the inflow rates are low before steam breakthrough and high after
breakthrough.
As a compromise, it is a common practice in steam injection opesations to set the pump speed
to achieve an average production rate for the tlood or cycle. However, this severely reduces the
pumping efficiency because of the increased time needed to produce the water back and to achieve
a pumped-off condition.
Through the application of pump-off controllers, it is now possible to operate pumping units
at faster pumping rates without sacrificing equipment, production or man-hours. Pum p-off
controllers are increasingly being used in California thermal operations to improve pumping
e f f i ~ i e n c ~ . l 3One
- ~ ~large California cyclic steam operator set the initial pumping unit speed to
satisfy the peak production rate for the well. As the production riltes declined and a pumped-off
condition was approached he was able to detect the condition with the help of a pump-off controller
and shut down the unit for a preset time to allow entry of fluid to the well. This solved the
problems of pumping unit and downhole damages associated with fluid This approach
also has the advantages of power savings and reduced maintenance cost while providing an
efficient way to produce steam stimulated wells. The savings realized by this particular operator
included? 31% reduction in power consumption; 238 seduction in well work expenditure and a
substantial increase in per well oil production. In spite of its de~nonstsatedadvantages, pump-off
controllers are not yet used widely because of its high initial cost (about $4,50O/well installed) and
availability of cheaper alternatives such as variable speed motors.
SUMMARY
The production of oil from thermal wells by artificial lifts is more difficult and expensive than
producing conventional wells. Pumping problems encountered in the production of heavy oil from
thermally stimulated wells include: high sand psoduc ti on. vruy ing produced gravity, varying
inflow rates, varying viscosity, vapor interference and system problems. Because of its versatility,
reliability and low cost, rod pumps are the pump of choice in thermal operations. However, severe
problems are encountered in the use of rod pumps as the lifting device in thermally stimulated
heavy oil wells. These include rod floating and overloading due to high fluid viscosity, pump
sticking and erosion with high sand production, heavy crude plugging, and gas locking under
steamflood conditions. The inadequacies of the conventional beam pumps to meet the service
demands of heavy oil production led to the development of alte~natepumping techniques. These
include modification of conventional pump jacks to alleviate some of the aforementioned problems,
and novel pumps such as the diluent pumps, cavity pumps and chamber lift pumps.
These new breeds of pumps are still in the prototype stage and used principally in the heavy
oil fields of Canada and Venezuela. In the United States, despite its drawbacks, rod pumps are
used almost exclusively in the thermal operation. Insert type rod pumps are used in the United
States thermal operation. Use of pump-off controllers and variable speed drives are used to extend
the operating range of a given rod pump.
A list of thermal well lifting equipment vendors is included in Appendix 11-A. It is
recommended that the operators follow the pump vendor's recommendation in selecting the
appropriate lifting equipment for the production well.
 REFERENCES
1. The University of Texas-Lessons In Well Servicing and Workover-Artificial Lift
Methods, Lesson 5-A home study course. Petroleum Extension Service, The University of
Texas, Austin, Texas, 1971.
+ 2. Beyea, D. F. and M. J. McKinnon. Optimizing Pump Speed Throughout Production
Cycles. Pres. at the Fourth Annual Canadian Heavy Oil and Tar Sands Technical Symposium,
Calgary, Alberta, Canada, Feb. 18, 1987.
3. Cockshutt, D. and W. Thomas. New Developments in Beam Pumping Technology: PC
3000. Pres. at the Canadian Heavy oil Association Thermal Well Completion Seminar, Edmonton,
Alberta, Canada. Aug. 11, 1988. Proceedings of Thermal Well Completions Seminar, D. J.
Theriault, Editor.
4. Sudol, T., R. Ridley and D. Nguyen. New Sucker Rod Pump Design for Sand
Producing Wells. Pres. at the 5th UNITAR International Conference on Heavy Crudes and Tar
Sands, Aug. 4-9, 1991, Caracas, Venezuela-R. F. Meyer, Editor. Heavy Crude and Tar
Sands-Hydrocarbons for the 21st Century. v. 2, published by Petroleos de Venezuela, S.A.,
Caracas Venezuela, October 1991.
5. Wong, A. and K. E. Frankiw. Analysis of Thermal Well Pumping Performance at the
Norcen-Bodo Steam Pilot. Pres. at the Canadian Heavy Oil Association Thermal Well Completion
Seminar, Edmonton, Alberta, Canada, Aug. 11, 1988.
6. American Petroleum Institute--Recommended Practices for Design Calculation for
Sucker Rod Pumping System, API-RP IIL, 4th Edition. American Petroleum Institute, Division
of Production, Dallas, Texas, June 1988.
7. Tomlinson, C. E. T. and R. J. Scot. The Application of a Hydraulic, Variable Speed
Pumping Unit for Heavy Oil Production. Pres. at the 1st Annual Canadian Heavy Oil and Oil
Sands Technical Symposium, Calgary, Alberta, Canada, Feb. 16. 1984.
8. Hogervorst, G. J. and T. B. Kimmel. Pump Jacks: A Changing Technology. Pres. at
the 35th Annual Technical Meeting of the Petroleum Society of CIM, Calgary, Alberta, Canada,
June 10-13, 1984. Paper No. 84-35-04.
9. Vonde, T. R. Specialized Pumping Techniques Applied to a Very Low Gravity, Sand
Laden Crude--Cat Canyon Field, California-In The Future of Heavy Crude Oils and Tar Sands.
First UNITAR International Heavy Oil Conference Proceedings edited by R. F. Meyer and C. T.
Steele. McGraw-Hill Book Co., New York, 1981. Chapter 64. pp. 574-585. Also pres. at the
50th Annual California Regional Meeting of SPE. Los Angeles. California, Apr. 9- 1 1, 1980. SPE
paper 8900.
10. Caceres, C. A. and 0. L. Cordero. Chamber Lift: Updating Technology and Putting It
To Work. Pres. at the 5th UNTTAR International Conference on Heavy Crudes and Tar Sands,
Aug. 4-9, 1991, Caracas, Venezuela. Conference Proceedings, v. 2, R. F. Meyer, ed. Published
by Petroleos de Venezuela, S.A., Caracas, Venezuela. October 1991.
11. Uzcategui, E. Application of Progressive Cavity Pump in Maraven's Heavy Oil Fields.
Pres. at the 5th UNITAR International Conference on Heavy Crudes and Tar Sands, Aug. 4-9,
1991, Caracas, Venezuela. Conference Proceedings, v. 2, R. F. Meyer, ed. Published by
Petroleos de Venezuela, S.A., Caracas, Venezuela, October 199 1 .
 12. Westerrnann, G. W. Successful Application of Pump-Off Controllers. Pres. at the 52nd
Annual Fall Tech. Conf. & Exhib. of the Soc. of Pet. Eng., Denver, Colorado, Oct. 9-12, 1977.
SPE paper 6853.
13. Acton, J. F. Pump-Off Controller Application for Midway-Sunset Cyclic Steam
Operations. Pres. at the 1981 California Regional Meeting, Bakersfield, California, Mar.25-26,
1981. SPE paper 9915.
14. Yoch, R. J., R. L. Williams and J. A. Jones. Pump-Off Control Application in Thermal
Recovery Operations. Pres. at the California Regional Meeting, Ventura, California, Apr. 8-10,
1987. SPE paper 16366.
 APPENDIX 11-A
THERMAL WELL LIFTING EQUIPMENT SUPPLIERS
A, Rod Pump Vendors
Trico Industries Inc.
15707 S. Main Street
Gardena, CA 90247
Telephone: (2 13) 5 16-5000
Lufkin Industries Inc.
P.O. Box 849
Lufkin, TX 75902-0849
Telephone: (409) 634-221 1
Sunward Industries
6800 Hampden Avenue
Denver, CO 80224
Telephone: (303) 758-4141
Subsurface Pumping System Inc.
147 11 Bentley Circle South
Tustin, CA 92680
Telephone: (7 14) 665-6867
Peterson Industries Inc.
2800 S. Peterson Road
Claremore, OK 740 17
Telephone: (918) 342- 1977
1-800-388-7867
B . Rod P u m Controls
~ and AnaIvsi~
System: Pump Off Controllers
Delta-X Corporation
1000 S. Loop West, Suite 150
Houston, TX 77054
Telephone: (7 13)748- 1184
1-800-231-9813
Dura Controls Ltd.
5535-97 Street
Edmonton, Alberta,
Canada T6E-3H8
Telephone: (403) 437-596 1
 CHAPTER 12
USE OF INSULATED TUBULARS IN THERMAL PROJECTS

INTRODUCTION
Heat losses in the steam injection well can be very detrimental to a steamflood project.
Unless efforts are made to minimize losses, the economics of the project can be severely impacted
by increased energy costs and, in the case of deep reservoirs, the steam quality can be reduced to
an unsatisfactory level. High heat losses can also raise casing temperatures to a level that risks
failure under the stress of thermal expansion.
Insulated tubing is frequently used to minimize heat loss in the injection well, and maximize
the downhole steam quality. This will also lower the longitudinal expansion and thermal stress in
the casing.
The object of this chapter is to discuss briefly the wellbore heat losses and how they can be
minimized using insulated tubing. The topics discussed include ( 1 ) wellbore heat losses;
(2) advantages of using insulated tubing; (3) insulated tubing design requirements; (4) insulated
tubing construction and selection criteria; (5) insulated tubing installation procedure; (6) insulated
tubing performance; and (7) insulated tubing cost effectiveness.

Wellbore Heat Losses

Generally, in thermal recovery of petroleum. low quality steam is used for injection so that
low quality feedwater, free of hardness, may be used to generate steam. Because the saturated
steam carries less heat than superheated steam, it is important that the steam reach the formation
with as little heat loss as possible. As deeper formations are considered, the heat losses in the
wellbore become even more important.
crawfordl has shown that for 2.5 in. tubing in a 7-3/8-in. casing. the heat losses in Btu'dd
may be approximated from a chart. His example was developed for a well depth of 1,000 ft in
which 250 bbYd of 400' F steam was injected. The total heat loss could range from 1 million
Btu'dd up to more than 16,000,000 Btuls/d. This depends on the overall heat transfer coefficient
between the tubing and the formation. This coefficient ranges from 5 for the lower figure to 240
for the higher loss. For uninsulated tubing, a reasonable value for the coefficient is between 80
and 160, giving a total heat loss between 10,000,000 and 15,000,000 Btufs/d,or approximately
15,000 pounds of steam condensed per day. This is equivrtlent to 45 barrels of water. For deeper
wells, the loss becomes even greater; at 2.000 ft, 100 barrels of condensation, and at 5,000 to
6,000 ft, 200 barrels.
The important variables in calculating the heat loss are the diameters of the tubing and the
casing, the temperature and pressure of the injected steam. and the depth of the well. Equations
have been developed by ~ a m e and ~ * saner3 but they are complicated, and tedious calculations are
necessary to apply them. However, charts have been prepared by Huygen and ~ u i t t ?and they are
much easier to apply. One of these charts is shown in figure 12.1. This chart is for 2-112-in.
tubing in 5-112-in. casing, and gives heat losses both for injection into the casing and injection
through the tubing. For 400' F steam injected through tubing, the heat losses for the first day
would be 600 Btu/hr-ft. For the 1,000 ft well, the daily loss would be 14.4 million Btu. After a
year, this would decrease to 9.6 million. Using a chart for 7-in. casing, these numbers do not
change appreciably. They check reasonably well with the previous calculation. It is of some
interest that injection through the casing would increase these values for heat loss to 36 million Bhl
and 14.9 million Btu.
These losses have caused a number of studies to be made for methods of improving the
efficiency of steam delivery. One showed that a packer at the bottom of the well would prevent
steam from coming back up the annulus between the tubing and the casing. An attempt to use an
insulating fluid in the annulus gave problems largely due to decomposition of the fluid? Painting
the outside of the tubing with aluminum paint gave some success but is difficult to apply. ~illhiteg
has shown how these procedures affect the heat transfer coefficient in figure 12.2.

Benefits of Using Insulated Tubing

The most successful method of reducing wellbore heat losses is to use insulated tubing. A
comparison of the heat losses by Davis et a1.6 is shown in figure 12.3. Uninsulated 2-718-in.
tubing in a 7-in. casing was compared to insulated tubing similar in size over the range of 1,000 to
3,000 ft well depth. The benefit of the insulation is increased as the depth of the well increases.
Besides the obvious savings in the amount of steam used, there is an indirect savings in the ability
to use a smaller generator capacity with consequent savings in capital investment.
Not only is insulation very effective in reducing heat losses, it also results in a lower casing
temperature. This lower temperature reduces the stresses that are placed on the casing and cement
by expansion. The prevention of casing failure due to heat stress is an important factor. Steam
injection down wells with poor cement bonding, inadequate or unsupported casing leads to casing
failure. The cause of the failure is excessive variation of casing temperature.

Insulated Tubing Design Requirements

Different criteria are necessary for cyclic injection and steamfloods. In the former, the well is
used for both injection of steam and for production of oil. In early stimulations, the steam was
injected down the annulus between the tubing and the casing. Later the steam was injected down
the tubing with the rods and pump intact.
The tubulars used to conduct the steam downhole into the oii-bearing formation present
different requirements from surface line applications and, therefore, require different design
 I TUBING SURFACE ANNULUS I

FIGURE 12.2. - Variation of overall heat transfer coefficient (U) with

tubing temperature for different tubing surfaces and
annulus pressure.9

2-718" 0.D TUBING IN 7"CASlNG (UNINSULATED)

0 0.5 1 1.5 2 2.5 3

WELL DEPTH ( THOUSAND OF FEET )
ESTIMATED HEAT LOSS AS FUNCTION OF DEPTH

FIGURE 12.3. - Estimated heat loss as function of depth."

approaches than insulated surface lines. The in-well tubulars must be of restricted diameters to
conform to well-casing size. Sufficient casing clearance and size tolerance must be provided to
accommodate couplings and the effects of well deviation fi-om vertical. The insulated tubular must
be able to sustain the various loads associated with vertical running and pulling as well as the need
to support its own weight when suspended from the wellhead.
The environment of the well is such that corrosion resistance to well fluids and sour gas is
also a problem not faced by the surface-line insulation. To satisfy these special needs, the design
trend for insulated tubulars has been to use an inner API tube to convey the steam and an outer API
tube to carry the loads and protect the insulation in the sealed annulus between the tubes. In these
dual tube applications, with an inner tube diameter of 2 in. or greater and an outer tube of 4.5 to
6 in. diameter, the limit of net insulation thickness is approximately 1 in. This requires highly
effective insulation material and a relatively large differential expansion across a small gap due to
thermal differences from the inner to the outer steel tubes.

Insulated Tubing Types and Selection Criteria

Two basic designs of insulated tubulars can be classified as: (1) prestressed concentric
insulated tubing, and (2) double wall tubulars with expansion bellows.6 They are shown in
figure 12.4.
Welding the inner tube to the outer tube provides mechanical and sealing integrity of the
insulating media. Weld placement and follow-up heat treating affect the thread profile.
Prestressing the inner tube compensates for thermal stress differences between it and the
outer tube. During steam injection the high temperature inner tube tends to expand more than the
lower temperature outer tube. Resultant compressive loads on the inner tube without adequate
inner tube prestressing could cause the tubing to fail. Required prestress depends on the relative
tubing sizes as well as the expected temperature variations. Insulated tubing, used for both
injection and production, requires design flexibility allowing for the outer string being both hotter
and cooler than the inner string.
The threads must provide a satisfactory mechanical connection to prevent leakage. Use of a
strong connection with a sealing element accomplishes this purpose.
An example of the double-wall tubular is the Kawasaki Thermal Systems (formerly General
Electric Co.) Them CaseM insulated tubular. The most often requested size is the combination of
a 2-3/8-in. tube as the steam conductor and 4-112-in. API tubing as the outer covering of the
insulation. The patented insulated tubular, figure 12.5. uses a multilayer fiber and foil insulation in
a reduced pressure inert gas environment to achieve thermal isolation. The inner and outer tubing
are hermetically sealed at each end of the 40-ft joints through a rnetdlic bellow welded to each tube.
 b 3 E D

COLLAR TUBING CASING

STANDARD BUTTRESS DIFFUSER SLEEVE

THREAD COUPLING
\ /

INNER TUBING
\

FIGURE 12.4.- Schematic of basic insulated tubular designs.6

RVNERnrsUUrR CP(mC4L)
7 - 7 W . 0.21r WALL
AM GRADE N-BOI L.80

-CENTRALIZER (TfPICAL)

OUTER CASING ( 7 Y P W )
e4-IR'. 0.25' WALL
API GRADE U-56

--COUPLNG INSCUTOR SLEEVE

FIGURE 12.5. - Typical insulated tubing construction.l0

The individual assemblies are joined by conventional threaded couplings secured at the time of
deployment into the well. The newest and most effective of the Thel-rnoca~e'~~ series is the 750
model which has the insulation annulus at a high vacuum supported by gathering agents to
maintain the vacuum. An exploded view of this insulated tubular is depicted in figure 12.6.

Insulated Tubing Instullution Procedures

Completion designs are dependent on casing strength and location of other zones relative to
the zone being steam stimulated. Three variations of the insulated tubing string completion design
and reasons for their use can be cited.7
1. Expansion joint immediately above the packer and water in the tubingkasing annulus.
This design produced heat losses on noninsulated expansion joints capable of degrading cement
above the steam zone.
2. Expansion joint at the surface with the annulus blown dry, packer immediately above
perforations. The use of this design in old wells with H-40 casing resulted in negligible boil off
and no casing damage. Concern over compressional loads causing packer failure or cork screwing
of the tubing limited the design to shallow wells.
3. No packer or expansion joint, tubing bottom at perforations. This was the least
expensive insulated tubing completion and was used where cement integrity immediately above the
steam stimulated zone was unimportant. Adequate strength casing was necessary to prevent casing
failure. This design resulted in highest overall heat losses.
Use of shorter (Range 2) length tubing permits easier handling on slant and small service
rigs. The tubing will not bow as much as on longer tubing resulting in less likelihood of thread
galling due to misalignment, especially with slant rigs. Rig operating times are less with the
Range 2 tubing strings.
The use of thermal packers with thermoplastic elements and external expansion joints have
been useful in avoiding operational problems including steam leakage at high pressures. Some
packers have inadequate springs in the packer setting mechanism and the springs take on a
permanent set and do not function properly on packer release, but this is corrected by using higher-
temperature rated springs. Operational problems with packers are more common on deviated
wells.
The critical time when handling insulated tubing was with the tubing and the casing hot.
Some precautions that can be taken to minimize the risk cf failure include:
Flow wells back. This allows well cooling and takes advantage of high production rates.
Pump hot kill fluid down the tubing after the well dies. The tubing can be picked up and
hung free, the well remains dead.
Unset and leave packers to allow contraction before attempting to pull them out of the hole.
 INNER
TUBE

COUPLING
INSULATOR

THERMOCASE
JOINT

FIGURE 12.6. - Exploded view of a field installed insulated tubular.lO

 Insulated Tubing Performance
As an example of the benefits of insulated downhole steam injection tubing, overall heat
losses were evaluated for uninsulated 2-718-in. tubing and insulated tubing in a 7-in. casing.
Actual wellbore losses are strongly influenced by the quality of well installation, specific reservoir
characteristics, and several other factors. In this evaluation oven11 heat losses were conservatively
analyzed by a method proposed by ~ a r n e on ~ zan equivalent basis for insulated and uninsulated
tubing. As illustrated in figure 12.3, heat losses in the injection well are a primary function of
wellbore configuration and well depth and are independent of steam tlow over a range of practical
applications. Thus, the impact of wellbore heat losses. particularly for uninsulated tubing,
becomes more significant at greater well depths and lower per-well steam-injection rates. The use
of insulated tubing can reduce the wellbore heat loss by over 70% compared to uninsulated tubing.
Insulated Tubing Cost Effectiveness
An example of the cost effectiveness of insulated tubing is given in table 12.1. The insulated
tubing chosen is Kawasaki Thermal Systems Thermocasem tubing. Although this tubing is
expensive ($40/ft), it is widely used and durable. In the table it is compared with bare injection
tubing. The case chosen is for a well 3,000 ft deep and the use of steam at 596' F and 1,500 psia.
As shown in the table, the heat loss for the base tubing is 45.9% while that for the insulated
tubing is only 14.6%. The payout is shown for $14 oil to be 11.8 months. Thus, the insulated
tubing should pay out in a relatively short time for well depths greater than 3,000 ft and at steam
rates of less than 15,000,000 Btdhr.
SUMMARY
Heat losses in the wellbore are quite appreciable and become greater as the depth of the well
increases. Consequently, much consideration has been given to methods for minimizing these
losses. Isolation of the tubing from the casing by a packer gives some improvements as does
painting the tubing with aluminum paint. However. the most effective method is to insulate the
tubing. This has been shown to be cost effective with a payout of less than 2 years. Vendors such
as the one listed in Appendix 12-A can help in the design and selection of insulated tubulars for
steam injection wells.
 TABLE 12.1. - Cost Effectiveness of Insulated Pipe

L = 3,000 ft Bare 3 in. Kawasaki

P = 1,500 psia Injection ThermocaseTM
T = 596" F Tubing 5 in. x 3-1/2 in.

1. Heat in (Btdhr)
(Ib h r )
2. Above ground heat loss
(Bt u b )
3. Below ground
A. Heat loss (Btuhr)
B. Condensation loss
(Btuhr) 2,78 1.500
(I bhr) (5,OO)
4. Heat out ( B t u h ) 6,764.500
5. Casing temperature, O F 490
6. Heat loss, % 45 -9
7. Steam quality at sandface, % 53
Payout
AfklAa
1. 80% s t e m f S . 1 ton s t e w o d u c e d oill;

-
- ton Prod. Oil.
Yr

2. 5Wo steam aualit~(6 ton steadton produced oil):

Oil = 9,193 - 7,814 = 1,379 to" Oil

Yr

4. A Oil S a v b

1 , 3 7 9 f M x 2 . 0 0 0 ~ ~ bbl x~=$I22,580/yi
Yr ton 350 1b x 0.9 bbl

$40/ft x 3.000 ft x '

yr
$122,580
x12= 11.8 rnos.
Yr
 REFERENCES
1. Crawford, Paul B. Heat Loss When Injecting Steam Down Tubing in Thermal Recovery
Programs. Producers Monthly, v. 30, No. 11, November 1966, pp. 16-17.
2. Rarney, H. J., Jr. Wellbore Heat Transmission. J. Pet. Tech., v. 14, No. 4, April
1962, p. 427.
3. Satter, Abdus. Heat Losses During Flow of Steam Down a Wellbore. J. Pet. Tech.,
V. 17, NO. 7, July 1965, pp. 845-851.
4. Huygen, Hans H. A. and J. L. Huitt. Wellbore Heat Losses and Casing Temperatures
During Steam Injection. Producers Monthly, v. 30, No. 8, August 1966, pp. 2-8.
5. Willhite, G. P., J. H.Wilson and W. L. Martin. Use of an Insulating Fluid for Casing
Protection During Steam Injection. J. Pet. Tech., v. 19. No. I 1 , November 1967,
pp. 1,453-1,456.
6. Davis, J. S. and J. P. Fanaritis. The Application and Economics of the Use of Insulated
Injection Tubing With Oil Field Steam Generators. Chapter 70 in The Future of Heavy Oil and Tar
Sands, edited by R. F. Meyer, J. C. Wynn, J. C. Olson. Second International UNITAR Conf.,
Caracas, Venezuela, February 1982, McGraw-Hill, New York, pp. 675-684.
7 . Kutzak, A. R. and D. W. Gunn. The Use of Insulated Tubulars in Thermal Projects.
Pres. at the Soc. Pet. Eng. California Regional Meeting, Bakersfield, CA, Apr. 5-7, 1989. SPE
paper 18810.
8. Wrobel, J. R. and J. Raydan. Applications Summary on the Use of General Electric Co.
ThermocaseTMInsulated Steam Tubulars for Thermal Recovery of Low API Gravity Crude.
Chapter 67 in The Future of Heavy Oil and Tar Sands, edited by R. F. Meyer, J. C. Wynn and J.
C. Olson. Second International UNITAR Conf., Caracas, Venezuela, February 1982, McGraw-
Hill, New York, pp. 653-659.
9. Willhite, G. P.. Over-all Heat Transfer Coefficients in Steam and Hot Water Injection
Wells. J. Pet Tech., v. 19, No. 5, May 1967, pp. 607-6 15.
10. Kawasaki Thermal System: Therm CaseTMInsulated Tubular Technical Bulletin.
Kawasaki Thermal Systems Inc., Tacoma, W A, 1989.
 APPENDIX 12-A
DOWNHOLE INSULATED TUBING SUPPLIERS

1. Kawasaki Thermal Systems Inc.

5401 Business Park South,
Suite 223
Bakersfield, CA 93309
Telephone: (805) 328-9404
 CHAPTER 13
SAND CONTROL PROBLEMS

INTRODUCTION
Some oil-bearing formations are so weakly held together that sand grains are produced with
the oil. This presents several difficulties. If the sand is lifted to the surface, separation and
disposal are required. It poses abrasion problems both to the tubing and to the pumps. It may clog
flow patterns and reduce the production of oil. Clogging may occur in the formation itself or in the
slots, perforations, or screens of the producing equipment.
While sanding may be a problem with primary production wells, the problem becomes much
greater when steam is injected into the formation. Some of these extra difficulties may be
mentioned. Steam dissolves the gravel packing at the bottom of the well as well as the formation
sand. It pushes the gravel away from the screen and into the formation sand. The dissolved silica
precipitates as the steam cools. The condensed steam swells clays and precipitates scales.
Because of the non-uniformity of the occurrence of the unconsolidated sands, it is difficult to
give a general treatment of the problems. Each well must be evaluated on its own to give the most
advantageous solution to the problem. However, there is a great deal of experience which can be
brought to bear on the design.
This chapter will discuss some of the parameters used in deciding how to design the well
completion. The subjects to be discussed are: (1) Occurrence and identification of problem
causing sands, (2) Prevention of problems in producing wells, (3) Use of open-hole or gravel-
pack completion, (4) Screens, (5) Gravel packing (6) Design of gravel packs for steam injection
processes, and (7) Chemical methods of sand control.

Occurrence and Identification of Problem-Causing Sands

Sand control must be considered if the well produces or is expected to produce sand grains
with the oil. This is the result of producing from an unconsolidated sand formation.
Unconsolidated sands range from the so-called "quicksand," in which the binding forces of the
formation are very minor through the partially consolidated sand which releases some sand during
oil production. Cores are difficult to obtain frorn"quicksand." Cores from the partially
consolidated sand cores appear to be solid but crumble when handled.
Unconsolidated sands most frequently occur in the shallow tertiary formations which are the
primary target of steam stimulation operations. Sanding is a problem in California, in Alberta,
Canada, in Venezuela, and other locations, but does not occur with sufficient regularity to be
predicted from location alone. However, the occurrence of sand in nearby wells should alert the
operator to be prepared for sand.
 Many times a steam stimulation project follows a period of production without stimulation,
and the history of the primary production should indicate whether sanding is likely to be a
problem. However, in wildcat or frontier situations, it may be worthwhile to conduct a test on the
well before deciding on the completion method.
Testing usually involves producing the well at gradually increasing rates until either sand is
produced, or the anticipated rate of production is reached. The test may be made either on the well
or on a particular interval of the formation. If sand is produced, then sand control methods should
be considered.
There are several ways in which logs can be used to predict the tendency of a well to produce
sand. One such method is the combined modules technique, developed by Stein and ~ i l t i eand l is
based on data from acoustic and density logs. The combined modules is compared with results
from a well test; and, assuming that all wells in the field are completed similarly, their values for
the combined modules would show their tendency to produce sand. The lower the value, the less
likely is the well to produce sand. A later report indicated a method for applying the combined
modules to wells of different completion geometries. This uses a comparison of well parameters
(production rate, formation volume factor, permeability,viscosity of reservoir fluid, number of
perforations) to make the comparison with the test well. Another method is the mechanical
properties log developed by Schlumberger which is based on resistivity, density, acoustic, and
neutron logs.
Some wells produce sand free until water cuts increase significantly or until production
problems occur. Consequently, it is necessary to be alert for signs of sanding after production
starts. Some of the production problems that may be observed are: sucker rod pump failure by
sand cutting or seizing; sand fill up in settling tanks or oil-water separators; and erosion of surface
chokes and elbow and tee fittings by flowing sand. A common problem that starts sand flow in a
producing well results when of slots in a slotted liner erode to the extent they no longer prevent
sand entry.

Prevention of Problems in Producing Wells

Although it may seem obvious, it is much easier to take preventive measures rather than wait
for problems to arise that require remedial treatment. The most important preventive measure one
can take is to assure that the well is completed properly.
In an effort to minimize completion costs, many steam injection operators have adopted poor
completion techniques. Wells should be completed in accordance with the best accepted practice
for a given area. Although the use of underreamed open holes and conventional gravel packing
systems are adequate in many California fields, they may not be satisfactory in other fields. Gravel
packs in open hole wells sometimes tends to slump soon after the start of steam injection. In other
cases, adaptation of open hole gravel packing techniques has resulted in the deposition of dirt and
fluid loss additives on the formation and plugging of screens with solids. Some of this plugging is
removed by the first steam that is injected, but this produces thief zones. This is due to both the
solubility of silica in steam and the physical force of steam injection.
~ u r v e ~ s ~ofysteam
5 stimulation projects have revealed a number of problems relating to
sanding. These are shown in Table 13.1. To make an intelligent choice for a production program
it is necessary to obtain as much information about the character of the formation as possible. For
example, in some wells the production of sand leads to cavities which may cause the casing to
deform; in other wells the sand body may be fluid enough to reconform and fill the space.

Use of Open-Hole or Gravel Pack Completion

Canadian reservoirs have encouraged more experimentation in sand control because of the
pervasive occurrence of unconsolidated sand. The early wells were completed with open hole
completion and underreaming. This was based on the assumption that open hole completion
would result in higher production and that the sand could be handled above ground. Special
pumping methods, downhole equipment, and surface facilities were developed to handle
uncontrolled sand production economically. Indeed, in areas where sanding is a minor problem,
this approach is still used. Today, open hole completion is more prevalent in California heavy oil
fields than in Canada.
Sand flow from unconsolidated formations can be controlled through chemical or mechanical
means to prevent or conect a variety of potentially serious and costly problems, such as production
loss caused by sand bridging in casing, tubing, andlor flowlines; failure of casing or liners from
removal of surrounding formation by compaction and erosion; abrasion of downhole and surface
equipment; and disposal of produced formation materials.
Some of the first efforts to prevent the sand from being produced involved screens-a
technique long used in water wells. Amoco Canada(3) experimented with four configurations in
the Lindbergh field:
1. Wire-wrapped screen gravel-packed inside casing,
2. Wire-wrapped screen gravel-packed inside open hole,
3. Wire-wrapped screen inside open hole without gravel pack (i.e., "barefoot" screen)
4. Wire-wrapped screen inside perforated casing without gravel pack.
All systems were found to be effective in controlling sand, but all showed lower production
rates than offset producers. The "barefoottfopen-hole completion had the highest production but is
not suited to formations with interbedded water and gas or with poor hole stability. It was decided
that the wire-wrapped screen inside perforated casing was most suitable for the Lindbergh field.
 TABLE 13.1. - Sanding Problems Encountered in U.S. Steam Stimulation Projects
Location ProbIem Solution Reference

Kern River Field Sanding; Wire wrapped screen

California Pump Life 3-4 mos. inside open hole
Liner scratched each
time it was pulled
Midway Sunset Field Severe sanding with Use of 6 9 8 inch (2
California jet perforations 50-mesh foamed-in-tight-
hole slotted liners
Mount Poso Field Failure of lead seal Replaced adapter (2
California adapter at the liner top
Inadequate gravel packing Sodium aluminate
consolidation treatment
T a m Field Sanding Gravel-packing inside (2)
Oklahoma open hole (no screens)
California Fields Sanding Gravel-Packing (5

Dome Petroleum, on the other hand, investigated4 sand control methods including open hole,
gravel pack, and cased completions with screens. Dome decided that cased hole would work the
best in Lloydminster fields. Conclusions on the use of screens are shown in table 13.2. Dome
concluded that each project had different constraints on the producing wells, which were not
compatible with screen usage (e.g., high gas rates or tough emulsions), but that wire-wrapped
screens inside casing resulted in an effective completion and improved a specific well's cash flow.
They recommended research be performed to find a better method of pumping fluid containing
high sand cuts.
Screens
The simplest, most consistently reliable approach to sand control is the application of
mechanical sand retention devices. Screens, slotted liners, and gravel are used. In this aspect of
sand control technology, the most important single design consideration is the proper sizing of
linear openings or gravel pore space relative to producing formation particles.
Formation grain size is required to properly size mechanical devices for bridging or absolute
stoppage, without undue limitation of flow capacity. This information is obtained through sieve
analyses of representative samples of formation material. Formation samples may be obtained
from sidewall samples or cores prior to completion. Cores provide the best source because
sidewall, bailed, or flowed samples are subject to contamination.
When slotted liners or wire-wrapped screens are used for sand control without a gravel pack,
slot width must be properly sized relative to the fornation sand to be excluded. Coberly showed6
that where sands have a broad size distribution, as in California, a slot width of twice the
 TABLE 13.2. - Use of Screens on Canadian Oil ~ a n d s . ~

Field Experience

F'rairie Lake Screens were not effective on cold production but were successful
with hat production. Sand production and periods of high servicing
oocurred occasionally and good produdion runs were obtained both with and
without a screen in the well. Screens were not worth the extra cost.
Lindbergh Screens had no detrimental effect on stimulated production.
Use of a sneen improved the recovery by 10%. 'Ibis may be enough
to make the well economic, if the sand problems are not severe. In wells
with severe sanding problems, this marginal improvement in production
is nat suff~aentto improve the economics.
Morgan 'Ihe use of screens was unsuccessful but a shut-in revived the wells.
Note: Bath the Lindbergh and the Magan fields were combination
h e m d drives utilizing combustion with added water.

10 percentile diameter of the formation would facilitate bridging and retain most of the sand. The
10 percentile diameter is the theoretical sieve size that will pass 90% of the total formation sample.
Where sands are more uniform and rounded, the recommendation may be to make the slot width
equal to the 10 percentile diameter so that more of the sand will be retained. Slots may be tapered,
with the small dimension on the outside of the liner or screen, so that it will be self cleaning.
Slotted liners7 may be obtained with slots ranging from 0.012-0.50 inches. While they have
a relative low initial cost, there are disadvantages to their use. The smallest slot widths may be too
large for some producing formations. Compared to wire-wrapped screens they have a relatively
small inlet area and, because they are made from low carbon steel, are somewhat subject to
corrosion or erosion.
Available wire-wrapped screen types include: wrapped-on-pipe, grooved type, ribbed type,
and all-welded (Fig. 13.1). The wire is normally stainless steel wrapped on J or K grade pipe.
Slot openings as narrow as 0.003 inch can be obtained. Wire-wrapped screens are less subject to
comsionlerosion than slotted pipe, and they have greater flow capacity. The wrapped-on-pipe
screen has the least flow capacity, and the all-welded screen has the highest flow capacity.

Gravel Packing
The use.of a gravel pack is the most common procedure in the control of sand. The term
"gravel" is a misnomer, as a fine sand is the usual medium. The size of the gravel is selected
similarly to the selection of slot size for screens. The sieve analyses of the formation sand are used
to determine the size of the gravel which will satisfactorily retain the formation sand when the well
is producing oil.
 GROOVED TYPE
ALL WELDED

IMPRESSED SPACING LUGS SOLDER STRIP

OR WELD B
RIBBED N P E

FIGURE 13.1. - Types of ~creens.~

The median size of the formation sand grains is obtained from the sieve size, which will pass
50% by weight of the sand. The diameter of the sand grain corresponding to that sieve size is
obtained* from table 13.3. According to work by Saucier99gravel six times that size will be
most satisfactory (Fig. 13.2) with larger gravel allowing too much formation sand to pass and
smaller gravel reducing the production rate. For example if the formation sand median is 140
mesh, the sand grain size is 0.0049 in. and six times that would be 0.0294 inch. The latter
corresponds to 25 mesh, and referring to Table 13.4~10the commercial size sand would be 20-40
U.S. mesh.
There are three variations on gravel packing. The f i t invdves packing the open hole, and
this provides the highest production rate if the formation sand is retained sufficiently. The second
 TABLE 13.3. - Sand Sieve Sizes

STANDARD STEVEOPENINGS~ STANDARDSIEVEOPENINGS~

MESH SIEVE OPENING MESH SIEVE OPENING

US? Tyler Inches Millimeters US? Tyler Inches Millimeters

Series Series Series Series
0.315 8.00 25 0.0280 0.71
0.312 7.925 24 0.0276 0.701
0.265 6.73 30 28 0.0232 0.589
0.263 6.68 35 0.0197 0.50
0.223 6.73 32 0.0195 0.495
0.221 5.613 40 0.0165 0.42
0.187 4.76 35 0.0164 0.417
0.1 85 4.699 45 42 0.0138 0.351
0.157 4.00 50 0.01 17 0.297
0.156 3.%2 48 0.01 16 0.295
0.132 3.36 60 0.0098 0.250
0.131 3.327 60 0.0097 0.246
0.111 2.83 70 0.0083 0.210
0.110 2794 65 0.0082 0.208
0.0937 238 80 0.0070 0.177
0.093 2.363 80 0.0069 0.175
0.0787 200 100 0.0059 0.149
0.078 1.981 100 0.0058 0.147
0.0661 . 1.68 120 115 0.0049 0.124
0.065 1.651 140 150 0.0041 0.1104
0.0555 1.41 170 170 0.0035 0.088
0.055 1.397 200 200 0.0029 0.074
0.0469 1.19 230 250 0.0024 0.062
0.046 1.168 270 270 0.0021 0.053
0.0394 1.00 325 325 0.0017 0.044
0.0390 0.99 1 400 400 0.0015 0.037
0.0331 0.84
0.0328 0.833

Chemical Engineers' Handbook 3rd. Edition, McGraw XiR.

* Hydraulic Fracturing Proppant Scseeas
used in US.

-
A

-
-
-
- LOW GRAVEL
PRODUCTION ,

DIAMETER RATIO, PACK MEDIANI FORM. M E W

-
FIGURE 13.2. Grave1 size selection (After ~aucier).~
 TABLE 13.4. - Most Commonly Utilized Gravel Sizes for Sand Control

Gravel size, Gravel size, Screen Gauge,

U.S. Mesh in. in.

involves packing the annulus between the liner and the casing. The third squeezes the gravel
through the casing and the formation.
The procedure for gravel packing as outlined by Sumanll for the third variation consists of
six steps:
1. Run a wash tool with cup packers to clean the perforations and circulate out a cavity
behind the cement. Backsurging may be used in low pressure wells that could be damaged by
washing.
2. Prepack perforations by pumping properly sized gravel into the cavity outside the cement
using a viscous fluid and high gravel concentration up to 15 pounds sand per gallon fluid (1,800
kilograms per cubic meter).
3. Apply squeeze pressure and drive fluid out of gravel to compact the perforation pack.
Reverse out excess gravel.
4. Run screen and circulate gravel into place using viscous or non-viscous fluid.
5. Pull work string with screen wash pipe.
6. Run production tubing, latch into top of screen and set a production packer to keep screen
pack in place.
Although laboratory testsll.12 indicate that the severe conditions in the well might be
expected to destroy the gravel pack, most installations seem to hold up fairly well. Vigilance is
necessary to be sure that the pack is doing its work, and replacement may be called for if the sand
production increases.
Design of Gravel Packs for Thennal Wells
To demonstrate the special requirements of a thermal gravel pack, the most basic hookup14
will be discussed. The completion (Fig. 13.3) consists of a bull plug, high temperature screen,
blank pipe, expansion joint, gravel pack extensions with sliding sleeve or a perforated extension,
and a retrievable high temperature seal bore packer. The equipment deviations from a standard
gravel pack are the high temperature screen, expansion joint, and high temperature packer.
 SC-1 THERMAL PACKER

GRAVEL PACK EXTENSION

WITH SLIDING SLEEVE

THERMAL EXPANSIONJOINT

SHEAR OUT SAFETY XllNT

HCTEMP SCREEN

MEDIAN -
S1NTEREDBAUXITE
SANO

FIGURE 13.3. - Schematic of a thermal well gravel pack completion.15

The most important element in a successful thermal gravel pack installation is the ability to
retain sand both from the gravel pack or the formation without restricting production. The
retention of sand is just as important as the inability to produce or inject because of plugging.
High Temperature Screens. Wire-wrapped screens and slotted liners are most
commonly used to hold the gravel-pack material in place. A typical wire-wrapped screen for high
temperature sand control application is shown in figure 13.4. Slot plugging has been shown to be
a primary disadvantage of slotted liners and not a consequence of a wire-wrapped screen. This is
FIGURE 13.4. - High temperature screen.15
largely due to the slot opening being paralleled to the direction of expansion. As the slotted liner
expands due to the temperature change, the gravel pack grains are "rolled" or forced into the slot
opening, since the moving liner is in direct contact with the grains.
Slotted liners are generally designed to provide only 2.5% to 3%of their surface area open to
flow. This is required to maintain the tensile strength. With such a small amount of area open to
inflow, even a minor amount of plugging will restrict production. Slotted liners, with slots cut
perpendicular to the axis pose significantly reduced tensile strength and are unsuitable for most
applications.
Wire-wrapped screens offer a greater amount of open surface area, some 10 to 20 times that
of an equal size slotted Liner. Successful screen designs must address one of the two
consequences of thermal stimulation, i.e., resistance to thermally generated forces or allowance for
expansion. Screen designs should permit a large ID screen which will not restrict production or
injectivity, but the OD should be sized to provide a minimal radial clearance of 0.75 to 1.0 in. with
the casing ID. This will facilitate gravel pack removal.
Expansion Joints. Expansion joints are run in the thermal gravel pack system to protect
the screen assembly, gravel-pack extensions, and gravel-pack packer from forces caused by the
screen base elongation and contraction. It is designed to prevent buckling of the blank pipe and
screen assemblies by relieving the thermally generated forces. The system must be designed to
allow for the expansion of the entire assembly. The expansion joint should be rotationally locked
to facilitate removal of the gravel-pack assembly if necessary.l4
To eliminate space-out difficulty, and to ensure that the assembly is positioned on bottom, the
expansion joint should be shear-pinned in the fully expanded position while running the assembly
into the well. The packer is set and the gravel pack is performed with the expansion joint in
position. When the forces caused by thermal expansion exceed the shear pin ratings, the
expansion joint is activated and collapses to relieve the expansion forces.
The shear value of the pins should be adequate to prevent premature shear while landing the
screen on the bottom, but must also be weak enough to shear before any damage occurs due to
screen expansion. Normally a 14,000 lb force shear rating is acceptable.
The high-temperature seal is the same as the high-temperature screen seal. Neither of these
seals are exposed to large pressure differentials and primarily serve as barriers to movement of
solids. Since the function is not that of a dynamic seal, premature wear and failure is not a
concern.
High Temperature Packer: The primary objective of the gravel-pack packer is to create a
seal that will perform satisfactorily for the life of the completion. The high-temperature packer is a
retrievable, seal-bore packer which can be used both as a gravel-pack packer and an
injectiodproduction packer. The primary design consideration given to this piece of equipment is
the selection of a packing element system.
Through the use of insulated tubing, heat losses can be minimized and a higher temperature
steam can be injected into the formation. With the ability to reach a 550' F (290' C) downhole
temperature and 2,000 psi (13,780 kPa) sandface pressures, conventional oilfield packing systems
are not adequate. Packing elements that do not fail at high temperature must be used in the packing
system to maintain sealing integrity. Carbon fibers, graphite; and, until recently, asbestos are used
as packing elements in high temperature applications.
The bulk-material-packing-element systems typically utilize multiple packing elements and
low-alloy-steel backup rings with wire mesh extrusion rings. These rings help support the bulk
materials which are not resilient and therefore lack compression-set resistance. Compression-set
resistance, a feature of elastomeric packing elements, is the elastic characteristic that maintains
sealing integrity.
Some packers intended for thermal applications employ a metal-to-metal packing element
consisting of soft alloys such as brass, lead, or aluminum. Such packing systems are very good
gravel migration preventers but are generally capable of withstanding only a 1,500 psi (10,300
kPa) pressure differential. Critical internal packer connections are typically sealed through the use
of threaded metal-to-metal seals. With careful design and manufacture, these seals are effective in
providing proper pressure containment at elevated temperatures.

Chemical Methods of Sand Control

Treatments to consolidate formation sand are available1* but are largely for low-temperature
use. They consist of resins which are pumped into the formation and are allowed to set up either
on a time schedule or by injecting a curing agent. Such resins are epoxy types, phenol
formaldehyde, or furan resins. Generally, they are not used in steam stimulation wells because
they are unstable at higher temperatures. The use of sodium aluminate to consolidate sanding wells
has been reported.7

SUMMARY
Sand control is an important consideration in steam stimulation of heavy oil because much of
the heavy oil occurs in formations with unconsolidated sands. However, because its occurrence is
not easily predictable, each well must be designed based on its specific characteristics.
In some instances, the preferable procedure is to produce the sand with the oil and perforin
the separation above ground. However, it is often more desirable to leave the sand in the
formation.
 Although both mechanical and chemical methods are available for sand control, the
mechanical techniques are usually the choice for thermal wells. These include slotted liners,
screens, gravel packs, and various combinations of these. Special equipment for thermal wells
include temperature screens, expansion joints, and high temperature packers. Vendors such as
those listed in Appendix 13-A are well equipped to design a sand control program for thermal
production wells and should be consulted.

REFERENCES
1. Stein, N. and D.W. Hiltie. Estimating the Maximum Production Rate Possible from
Friable Sandstones Without Using Sand Control. J. Pet. Tech., v. 24, No. 9, September 1972,
pp. 1157-1160.
2. Chu, C. State-of-the Art Review of Steamflood Field Projects. J. Pet. Tech., v. 37,
No. 10, October 1985, pp. 1887-1902.
3. ha,J.F., and D.W.Middleton. Development of Sand Control Techniques for Steam
Stimulated Wells in the Lindbergh Field. Energy ProcessingKanada (May-June 1986) 14-17.
4. Marjemson, D.M., and J.A. Sayre. Dome Petroleum's Experience with Sand Control in
Lloydminster Heavy Oil Fields. Pres. at the 38th Annual Technical Meeting of the Pet. Soc. of
CIM, Calgary, Alberta, Canada, June 7-10, 1987. Paper No. 87-38-05.
5. Farouk, Ali, S.M., and R.F. Meldau. Current Steamflood Technology. J. Pet. Tech.
v. 31, No. 10, October 1979, pp. 1332-1342.
6. Coberly, C.J. Selection of Screen Openings for Unconsolidated Sands. API Drilling
and Production Practices, 1937, pp. 189-201.
7. Suman, G. 0.Jr. World Oil's Sand Control Handbook. Gulf Publishing Co.,
Houston, TX, 1975.
8. Ayres, H. J., and J. Rarnos. Guidelines to Sand Control-Part 2. Petroleum Engineer,
v. 44, No. 9, September 1972, pp. 82-98.
9. Saucier, R.J. Considerations in Gravel Pack Design. J. Pet. Tech., v. 26, No. 2,
February 1974, pp. 205-212.
10. Halliburton Services. Sand Control Brochure, 1974.
11. Surnan, G. 0.Jr, and R E. Snyder. Sand Control Design Criteria and Gravel Packing
Concepts. Pres. at the Soc. Pet. Eng. International Tech. Symposium, Beijing China, Mar. 18-
26, 1982. Paper SPE 10031.
12. Underdown, D.R. and Kamalendu Das. Stability of Gravel Packing Materials for
Thermal Wells. Presented at the Soc. of Pet. Eng. International Symposium on Oilfield and
Geothermal Chemistry at Denver Co., June 1-3,1983. Paper SPE 11793.
 13. Sacuta, A., D.M. Nguyen, and G. A. Kissel. Stability of Nickel-coated Sands as a
Gravel Pack Material for Thermal Wells. Presented at the Soc. Pet. Eng. California Regional
Meeting, Oakland, CA, Apr. 2-4, 1986. Paper SPE 15058.
14. Weirich, J.B. and T.E. Zaleski. Thermal EOR requires special design for gravel packs.
Oil Gas J., v. 84, No. 46, November 17, 1986, pp. 45-50.
15. Weirich, I. B. and E. T. Zaleski. Gravel Pack Equipment Requires Special Design for
Thermal Recovery. Presented at the Canadian Heavy Oil Association Thermal Well Completion
Seminar, Edmonton, Alberta, Canada, Aug. 11, 1988. Paper No. 3
 APPENDIX 13-A
SAND CONTROL AND GRAVEL PACK SYSTEM VENDORS

1. Baker Sand Control System

1010 Rankin Road
P.O.Box 61486
Houston, TX 77208-1486
Telephone: (713) 443-7590
2. Solum Oil Tool Corporation
2750 Rose Avenue
Signal Hill, CA 90806- 1928
Telephone: (213) 427-5504
3. Halliburton Services
Drawer 1431
Duncan, OK 73536
Telephone: (405) 25 1-3760
4. Guiberson Division
Dresser Industries
P.O. Box 6504
Houston, TX 77265
Telephone: (7 13) 750-230 1
5. Houston Well Screen Company
11939 Aldine Wesdleld
Houston, TX 77039
Telephone: (7 13) 449-726 1
6. Otis Engineering Corporation
P.O. Box 819052
Dallas, TX 75381-9052
Telephone: (214) 418-3000
 CHAPTER 14
STEAM INJECTION PROFILE CONTROL
INTRODUCTION
When steam is injected into a nonuniform formation, the steam enters the formation with a
flow inversely proportional to the resistance encountered. Thus, the greater amount of steam will
enter the more permeable (less resistant) sections of the formation while lesser amounts of steam
enter the less permeable (more resistant) sections. If the formation consists of several sand layers
separated by shale stringers, the steam will seek the most permeable layer and as that zone is
depleted the resistance becomes less until a thief zone may develop where the steam is diverted
from the oil and has little effect on its recovery.
In early completions where an open hole gravel pack was used with the tubing ending at the
top of the formation, the amount of steam entering each layer of the sand was determined by the
permeability of the layer. In addition, water would separate from the steam and migrate to the
bottom because of higher density, and the bottom layer would only be exposed to water instead of
steam. The fust improvement was to extend the tubing to the bottom sand layer so that the mixed
watdsteam would contact the lowest layer but also would be forced up the annulus to contact the
other layers.
It is, of course, desirable to know how effectively the steam is contacting the oil, and
considerable effort has gone into measurement of the amounts of steam going into the various pacts
of the formation. Originally, the spinners that were used to measure water injection were applied
to steam measurement. A temperature survey was also used. However, more sophisticated
methods using radioactive tracers have become common.
Various methods have been used to improve the injection profile. These depend in part on
the completion method that was chosen for the well. It is also desirable to know the profile at
some distance from the injection, and monitoring wells. These methods also reveal the effects of
steam ovemde in which the steam has risen to the top of the formation because of gravity, leaving
the bottom part of the formation untouched.
This chapter will discuss (1) distribution of steam liquid and vapor in the wellbore,
(2) measurement of steam injection profile including spinners, steam surveys, and radioactivity
methods, (3) methods of improving steam injection profiles, and (4) monitoring wells.
Vendors such as those listed in Appendix 14-A should be consulted to develop a steam
injection profile control program.
Distribution of Steant/Water in Tubing
Steam of less than 100% quality has the possibility of separating into two phases. The
extremes range form mist flow to annular f1ow.l These two conditions are shown in figure 14.1.
 ENTRAINED
LIQUID
DROPLETS

LIQUID ----(

VAPOR -

MIST FLOW ANNULAR FLOW

FIGURE 14. 1. - Mist and annular flow regimes for two-phase flow. l

For the mist flow, the velocity of the two phases are essentially equal, while for the annular flow
the velocities may be quite different. By the use of radioactive tracers, a determination of the
regime existing in the process may be determined.
The effect of the phase separation is important to the determination of the injection profile
because the water brings much less heat to the formation than the steam. Thus, if a lower zone is
receiving only water, it will be stimulated much less than the upper zones which receive steam.
For this reason, completion practices have changed from the early open hole completion with the
tubing terminating ahead of the formation to be stimulated to a completion where the tubing goes to
the bottom of the well and introduces the steam there to rise up the annulus.
Measurement of Steam Injection Profile
Measurement of the steam injection profile is important so that adjustments may be made in
the production methods to assure a complete sweep across the total oil-bearing formation. Various
tools have been used, but the radioactive tracers seem to be gaining the preferred status. Earlier
methods included spinners and temperature surveys.
 Spinners
The spinner is a direct approach to measuring the velocity of the steam at different positions
in the well.= The tool is basically a free rotating impeller positioned in the pipe by a centralizer.
The steam passing the tool causes the impeller to rotate at a rate proportional to the velocity of the
steam. The rate of rotation is translated into an electrical signal which is transmitted to the surface
through the logging cable.
The configuration of the spinner is shown in figure 14.2. In many respects it is similar to the
spinners used to measure the injection of water into a waterflood injection well, but because of the
higher temperature of the steam environment some changes are necessary. Conventional electrical
insulation and packing materials are not satisfactory and teflon has been used. The high velocity of
the steam results in high rotation rates that require strengthening the impeller and its support

SPINNER

FIGURE 14.2. - Diagram of spinner tool.2

340
 The survey procedure is likewise similar to that for the water injection. However, because of
the higher velocity of the steam, it may be necessary to bypass the steam while the spinner is
lowered through the tubing. A general procedure for a spinner survey is given in table 14.1.

TABLE 14.1. - Procedure for Determining Steam Injection Profile Using a spinner2

Record impeller RPM at tbe following stations: 30 to 50 ft below the bottom of the tubing, 5 to 10 ft above the liner
top, 5 to I0 ft below the liner top, and just above the perforations. This procedure will detect losses between the
stations except at the liner top.
Make a down survey at 40 to 60 fpm and stop at the depth where the impeller stops rotating.
Make an up survey at 40 to 60 fpm.
Make a down survey at 60 to 80 fpm to pickup. This run will locate the liquid level, if any. If the surveys check, the
tool is withdrawn.
The recordings at the surface are a plot of spinner RPM versus depth. The plot is equated to percent steam entering the
formation by assuming the highest value of RPM is equal to 100% of the steam and the zero RPM represents 0% of the
steam.

Examples of two runs are shown in figure 14.3. Figure 14.3a shows a well where the steam
is being distributed over the face of the formation. Figure 14.3b shows a well that illustrates the
need for profile improvement. Although the perforation interval is about 500 ft, practically all of
the steam is entering a 15 ft section. This also shows the liquid level as some 150 ft above the
bottom of the perforations.

Temperature Surveys
A temperature survey2 during steam injection shows only the lowest point of steam injection
which is indicated by a rapid cooling to the normal well temperature. This start of rapid cooling is
also the top of the liquid level and should check with the value determined by the spinner survey.
The temperature survey is primarily a supplement to the spinner survey in determining the injection
profile.
The temperature measuring tool used in steam wells is the normal instrument adapted for
work in the higher temperature. It has a thermistor with a much wider range of temperatures. An
improved instrument using a platinum resistance thermometer was recently described?
Used as a supplement to the spinner survey, the temperature survey is shown in figure 14.3.
In figure 14.3a7the temperature is shown to slowly cool off but with no liquid level to cause the
rapid cooling. In figure 14.3b, at the point of injection, the temperature drops but then becomes
constant down to the liquid level where it starts to cool down to the formation temperature.
 DEPTH
7M
INJECTION 1020 bbWday 70% Quality 98 PSI

TEMP O F
290 300 310

DEPTH
INJECTION 1410 bbWday 77% Quality f 25 PSI
700

TEMPERATURE

I D I
f
I
I
LIQUID LEVEL

270 280 290 300 310 320

TEMP O F

FIGURE 14.3. - Steam spinner s~rve~s.2 The upper chart is an

acceptable one, while the lower chart shows need
for profile improvement
 When the temperature survey is used by itself to determine the profile, it is usually used
during the soak period. It is assumed that the hottest sections received the most steam. Thus
qualitatively, a profie can be obtained by equating injection to sections of elevated temperatures.

Radioactive Tracer Surveys

The information that can be obtained from the spinner and temperature surveys is limited.
The inertia of the spinner makes its results questionable at low inputs of steam, and the qualitative
nature of the temperature survey leaves much to be desired. Beyond that, these surveys are not
applicable when the tubing is run to the bottom of the well and many completions are made in that
manner. Consequently, it is important to have a method which will not have these problems. The
use of radioactive tracer surveys was developed to fill this need.
The first systems depended on the use of radioactive iodine, I- 131. This material has a short
half-life (8.1 days) and is not particularly hazardous if properly handled. It decays to stable xenon-
131 through the emission of five beta particles (electrons) and six gamma-ray photons. It was
injected in the form of sodium iodide or methyl or ethyl iodideP The procedure was to run a
gamma log as a base line; inject the radioactive tracer so that it would plate out where the steam
entered the formation; and then run another gamma log to see where it had plated out The amount
of gamma radiation detected indicated the amount of steam passing that point.
Because of its solubility in water, sodium iodide tends to collect in the water phase of the
steam and thus indicates higher injectivity for those parts of the formation contacted by water.
Methyl or ethyl iodide was used to maintain the iodide in the steam phase, but ~guyen5has shown
that these iodides decompose in the hot steam and are absorbed by the water.
An alternative which measures the steam rather than the water is the use of radioactive inert
gases such as krypton-85 (Kr-85) and xenon-133 (Xn-133). Properties of these gases as well as
those of iodine- 131 are compared in table 14.2. The procedure using these gases differs somewhat
from that used with sodium iodide. A slug of tracer is injected into the steam flow stream and
tracer velocity is measured at specific depths in the well. This is done with a dual gamma detector
where the time to pass from one sensor to the next is measured. Knowing the wellbore geometry,
the amount of steam passing the point can be calculated. A combination of the method&-7 using
iodide to determine water and inert gas for steam gives the most complete information.
Radioactive steam tracer surveys are routinely run in steam injection wells to check for tubing
holes, packer leaks, open perforations, and steam migration behind casing. These surveys are
required by the California Division of Oil and Gas. Current California regulations require that
krypton-85 instead of sodium iodide- 131 be used in steam tracer surveys.*
 TABLE 14.2. - Properties of Tracers

Water solubility at steam

temperature and pressure 0 0 100%

Charge 0 0 -1
Half-life 10.7 yrs. 5.2 days 8.0 days

Energy leveI 517 kev 81 kev 364 kev

% Gamma Emissions 0.5 99.0 100

The procedure for the survey using iodide431 is given in table 14.3. The most common
survey is run with the sodium iodide dissolved in water. If the injected steam is in one phase or in
the mist regime, this is satisfactory. The sodium iodide may also be dissolved in methyl alcohol.
This has been shown* to tag both the gas phase and the liquid phase. To use this system, it must
be recognized that the velocity of the gas phase is faster than that of the water phase. This results
in two spikes on the record, and they must be interpreted to show how much steam and water are
entering a formation. Methyl or ethyl iodide has been used in an attempt to place the iodide in the
steam phase, but it has been shown5 that each decomposes in the hot steam and forms hydrogen
iodide which is soluble in water.

TABLE 14.3. - Procedure for Running Radioactive Tracer Survey With Sodium 1odide2

1. Run a background gamma log from the surface to pickup depth. As in the case of the temperature tool, it is usually not
necessary to bypass the steam while running into the well.

2. Bring the gamma logging tool to a station above the liner top and record the radiation intensity continuously.

3. Inject the tracer slug. As the slug passes the gamma tool the increased intensity will be recorded.

4. As soon as the slug is past the logging tool, run a gamma log down to pickup depth.

5. Immediately make a log up to the surface to detect any possible casing leaks.

6. The steam injection profile is constructed using the gamma logs. The increase in intensity over background for any
interval is attributable to the tracer being carried to that area by the injected steam. The area under the enhanced gamma
curve less the area under the background log is equated to the total amount of steam being injected. By dividing the
interval into the zones of particular interest and measuring each area, the percentage of the steam going into any zone
can be calculated. A cumulative curve can then be drawn by adding up the percentage and plotting percent of steam left
against depth.
 The procedure for using the inert gases is shown in table 14.4. Although this is a more
expensive test, it adequately measures the steam going into the various zones. The vapor phase of
the steam is the most important phase from a heat content and volume standpoint. Both krypton
and xenon are thermally stable gases and have no charge so that they do not associate with the
formation. The plating out technique is therefore not applicable. The use of this method on three
types of completions is shown in figure 14.4 where the tubing ends (a) above the perforations,
(b) below the perforations, and (c) within the perforations. For both (a) and (b), measurements are
taken at four positions while for (c) only three positions are necessary.
The velocity can also be used to measure the quality of the steam at the injection area.4 The
wellhead steam flow rate, the downhole pressure, and the vapor velocity are used to develop this
equation:
Steam Quality (in percentage) =
247 x Density of vapor x Distance between detectors x cross-sectional area
- - - - - --

Steam flow rate (BPD water equivalent) x Transit time in sec.

In the above equation:

Density is in lbmlcu ft;
Distance between Gamma ray detectors is in ft; and
Cross-sectional area is in sq ft.

TABLE 14.4. - Procedure for Running Radioactive Tracer Survey Using Inert Gas Tracers

1. The dual gamma ray detector is lowered into the well and held stationary at a specified depth.

2. A slug of radioactive inert gas tracer is injected into the surface steam line.

3. The gamma ray counts from the surface and downhole detectors are displayed on the chart recorder and stored in the
computer.

4. The tool is then moved to another depth of interest and another slug of tracer is injected.

5. The vapor phase injection profile is calculated directly from the tracer transit times across the dual gamma tool. In
some cases, vapor velocity may be too high for accurate determination of transit time across the tool. In these cases
transit times from surface to tool measured at two different depths are substituted. These transit times are converted to
an equivalent transit time based on the distance between detectors on the logging tool.

6. The vapor phase injection profile is determined by material balance between total flow and flow at different depths. At
a given depth, the fraction of the total flow by the tool is given by:

Fraction of total flow =

1 0 % flow in sec.
Transit time at a given depth in sec.
 STOP 1

-1
I STOP 2

14.4. - Survey points for different tubing tail configuration^.^

(a) above perforations, (b) below perforations, (c) within
perforations.

An example of the combination method4 is a steam injector completed with four 0.25 in. jet
holes per ft over three perforated intervals (Fig. 14.4). The tubing ends within the bottom set of
perforations. The steam packer is set 5 ft above the top perforations. Both a vapor phase survey
using krypton and a conventional liquid phase survey using sodium iodide were mn. Surface to
tool transit times were determined from stops 1 and 3 to determine the 100% flow transit time in
the annulus. It was 0.83 seconds. Stops 2 and 3 showed annular transit times of 1.7 and 1.1
seconds, respectively. Using the equation in table 14.4, the percentage of total vapor flow going
by stops 2 and 3 is 49% and 75%. Thus, the flow is 49% out of the top perforations, 26% out of
the middle set, and 25% out of the bottom set. These results and the results from the sodium
iodide survey are shown in figure 14.5. The liquid phase survey shows almost all of the liquid
exiting the bottom set of perforations. Calculating the steam quality by the above equation shows
that between stops 1 and 3, it was 37%. This can then be used to calculate the heat distribution for
the well, and this is shown in figure 14.5 to be 3336, 20%, and 47% for the top middle, and
bottom perforations respectively,
 Methods of Altering Profiles
Early use of open hole gravel pack c~rn~letions,~ revealed that the vertical steam distribution
was poor. Initial attempts to achieve selective injection included the injection of plugging agents
such as ground calcite, using the resistance of the gravel pack outside the liner combined with close
fitting stingers inside the liner, and filing the liner with gravel to cover a thief zone. However, no
satisfactory solution was found to divert steam in a fully dotted, gravel packed liner.
With blank sections (nonslotted) in the liner string, both mechanical and plugging methods
were described? In the mechanical method, a steel friction ring was mounted on a mandrel that
was forced by pipe weight into a slightly smaller polished nipple installed in the liner. These
provided cutoffs between productive zones so that after steaming the lower formation, it was cut
off and the steam pressure opened the sleeve to steam the upper formation. The plugging method
also required special hardware: a port collar and an opening/squeeze tool. The port collar was
placed in the middle of blank liner sections. The openinglsqueeze tool opens and closes the collar
and forced the plugging material into the pore space of the gravel pack to effectively block any
steam flow behind the section of blank liner separating the zones of interest. Although cement was
tried, better plugging agents were sought and a mixture of bentonite, silica flour, barites and water
was extensively used. A mixture of polymer gel, bentonite, and cement was also used.

STOP 1

STOP 2

STOP 3

FIGURE 14.5. - Survey results.5 (a) well configuration, (b) vapor phase profile
by krypton, (c) liquid phase profile by sodium iodide, (d) heat profile.
 The unconsolidated nature of the California sands have caused several schemes of profile
improvement to be developed. Notable among them are the limited access method based on
perforation designs and the concentric tube and the parallel tube methods.
Concentric Tube Method
Concentric-pipe injection was one of the fust methods used to control steam injection into
two oil sands using a single wellbore.9-10 A schematic of the process is shown in figure 14.6.
Steam is injected simultaneously into the inner and outer pipes which are used to separate the flow
for injection into the two target sands.
Normally 144-in. tubing is run inside 2-718-in. pipe in wells completed with 5-1/2-in.
casing or 2-3/8-in. pipe is run inside 4-in. pipe for wells completed with 7-in.casing. A downhole
expansion device is used on the outer pipe and the wellhead is modified to handle expansion of the
inner pipe. A single-string thermal packer is set above the upper oil zone to prevent the steam from
flowing up the casing annulus. A second single-string thermal packer is set between the two target
oil zones to keep the injected steam separated into the individual zones. The tail of the outer pipe is
located opposite the upper oil zone and the tail of the lower pipe is located opposite the lower oil
zone. A variation of this method uses the casing as the outer pipe.
A number of problems have caused this method to be less popular than some other methods.
The pressure drop through the annulus between the two pipes is greater than that in the inner pipe
causing heat flow from the inner to the outer pipe and increasing steam quality in the outer pipe and
decreasing steam quality in the inner pipe. In practice this exchange of heat results in severe scale
buildup.

Parallel Tubing Injection

The parallel tubing method10 places two tubing strings side-by-side in the wellbore. The
completion scheme is shown in figure 14.7. The wellhead is modified to handle two pipes. A
large casing (typically 7-in. or 9-5/8-in.) is required to accommodate the two strings. A dual-string
thermal packer is used above the upper oil zone and a single-string thermal packer is placed
between the two target oil zones. Insulated tubing is used between the packers to reduce heat loss
where one of the strings is in direct contact with low-pressure steam in the tubing-casing annulus.
The system is run in three stages:
1. Set the permanent thermal packer
2. Set the dual packer assembly with the long string.
3. Stab in the short string with a J-latch.
A travel joint on the long string and the J-slot seal assembly on the short string allows
independent expansion of both strings.This system shows no differential in quality of delivered
steam, and divides the steam as desired.lO
 EXPANSIONJOINT
OUTER TUBING

UPPER
THERMAL PACKER

INNER TUBING
CROSS-OVER JOINT

LOWER
THERMAL
PACKER

FIGURE 14.6. - Schematic of concentric tubing completi

J-LATCH

GUIDE AND SEAL BORE ASSEMBLY

SHORT STRING SEAL ASSEMBLY

- EXPANSIONJOINT

DUAL THERMAL PACKER

PERMANENT THERMAL PAC:KER

FIGURE 14.7. - Schematic of parallel tubing completion.11

 Limited Entry Injection
A standard completion procedure for steam injection wells is the open hole, gravel-packed,
slotted liner configuration shown as the first design in figure 14.8. The slotted liner is designed
with slots as large as possible to pennit steam delivery and still maintain the gravel pack integrity.
The slots are uniform over the length of the producing zone and steam is delivered somewhat
equally over the formation. This results in an injection profile which may not fit the requirements,
especially if there are zones separated by shale stringers.
It was discovered that selected perforation of the casing would distribute the steam in a more
desirable manner. First mentioned by Gates and ~ r e w e r l and
l later described by ~rnall,lzthese
completion practices are shown as the second and third examples of figure 14.8. The perforations
are sized to attain critical flow conditions. They are distributed vertically in order to obtain the
desired injection profile.
Under critical flow conditions, changes in the pressure downstream cannot be transmitted
upstream because the steam velocity in the perforation equals the velocity of sound in steam.
Critical flow conditions prevent the reservoir pressure from influencing the flow mechanics in the
perforation. Therefore, at constant upstream pressure, the maximum steam flow rate cannot be
exceeded regardless of even an extremely low reservoir pressure. However, the steam injection
rate can be increased by simply increasi g the bottom hole i jection pressure.

FIGURE 14.8. - Three steam injection well completion de~i~ns.13

 For critical flow to be maintained (at a steam quality of 60%), the ratio of reservoir pressure
(or discharge pressure) to downhole injection pressure must be less than 0.578 (Table 14.5). For
a bottomhole injection pressure of 450 psia, the reservoir pressure must be less than 260 psia. As
formations considered for steam injection are generally low pressure reservoirs, this does not pose
a severe restriction.
To help achieve uniform injection profiles, it is important that the diameter and shape of each
perforation be as uniform as possible. Therefore, perforating guns and charge designs are
carefully selected to provide the most accurate hole size possible.
To assure proper sizing of the perforations, some designs for limited entry injection place the
perforations in the tubing instead of the casing. As these can be prepared on the surface, they can
be more accurately sized?-l2 In addition, limited entry outlets may be designed and constructed
in various ways as long as critical flow may be achieved and maintained. For example, critical
flow nozzles, chokes, or steam deflectors can be used.

TABLE 14.5. - Calculation of the Critical Pressure ~ a t i o l ~

When the discharge (downstream) pressure of a perforation is reduced below

a certain critical pressure the mass flow of steam does not increase for any further
decrease in the discharge pressure. The critical pressure ratio (x,), expressed as a
ratio of the critical discharge pressure (PC)to the bottomhole injection pressure (P),
can be calculated as follows.
Critical discharge ratio:

where PC = critical discharge pressure

P = bottom hole injection pressure
Cp = specific heat at constant pressure
C, = specific heat at constant volume
f, = steam quality
W, s = watedsteam.
Values for k and xc for steam are given below:
 Critical flow nozzles consist essentially of a short cylinder with a flared approach section. In
general, the length of the straight section tube is about 112 times the throat diameter but can be
longer. In addition, a tapered divergent section can be added at the exit of the throat to provide
some degree of pressure recovery of the exiting steam.
Steam chokes are quite similar to nozzles but have no convergent entry or divergent exit
sections. Chokes are commonly used in surface lines to Limit steam flow. However, they may be
used d o w n h ~ l e . ~ ~
An example of a steam deflector is shown in figure 14.9. A portion of the steam flow exits
the tubing string through single or multiple slots located concentrically around the tubing. The total
area of the milled slots is equal to the cross-sectional area needed to achieve and maintain critical
flow.

MILLED SLOTS
/

MANDREL

MILLED SLOTS

FIGURE 14.9. - Steam deflector design! *

 An example of limited entry injection using critical flow chokes is shown in figure 14.10. A
thermal packer is placed between the two target oil zones to keep the injected steam separated once
it has passed through the limited entry outlets. The pipe above the top packer may be bare or
insulated. However, the section of the pipe exposed to low pressure steam in the casing between
the two packers should be insulated to prevent excessive heat loss from the steam inside the tubing.
Use of Monitoring Wells
Monitoring wells are most frequently used in connection with steam injection projects,l5
usually to obtain a temperature survey. Not only does this give the time of arrival of the
steamflood front, but it also provides some measure of the profile of the front. This may offer an
opportunity to make corrections in the plan for the steamflood. Some of the precautions to be used
in the evaluation of temperature data have been stated.16
In addition, the temperature survey indicates the amount of steam override which is
occumng. Because steam is lighter than the oil, it tends to rise and may become segregated at the
top of the formation. Thus, the oil at the bottom of the formation may remain untouched. Some
effort has gone into the study of using steam foams to prevent steam override.17

EXPANSION JOINT

NIVERSAL THERMAL PACKER

UPPER STEAM CHOKE

RETRIEVABLETHERMAL PACKER

LOWER STEAM CHOKE

FIGURE 14.10. - Schematic of limited entry completion.1l

 SUMMARY
Steam injection profiles are a measure of the effectiveness with which the steam contacts the
oil-bearing formation. They can be measured by spinner surveys, by temperature surveys, and by
radioactive tracer techniques. When the profile is found to be undesirable, it can be changed by
diverting the steam. This can be done by plugging a thief zone or by directing the steam to a
particular zone. In the parallel tube method, tubes lead the steam to particular sections of the
formation. Limited entry techniques may also be used in which perforations are placed opposite to
sections according to the amount of steam required by that section. Monitoring wells are used to
check the temperature profile out in the formation.

REFERENCES
1. Elson, T. D. and K. C. Hong. Distribution of Steam Liquid and Vapor in an Injection
Wellbore. R. F. Meyer, J. C. Wynn, J. C. Olson, eds. The Future of Heavy Oil and Tar Sands,
Second International UNITAR Conf., Caracas Venezuela, February 1982, McGraw-Hill, New
York, pp. 662-665.
2. Bookout, Donald E., J. J. Glenn, Jr., and Herman E. Schaller. Injection Profiles During
Steam Injection. Producers Monthly, v. 31, No. 8, August 1967, pp. 2-8.
3. Dillier, J. M. and R. H. Clark. Downhole Temperature Measurements. U.S. Patent
4,8 11,598, Mar. 14, 1989.
4. Lichtenberger, G. P. A Primer on Radioactive Tracer Injection Profiling. Pres. at the
28th Annual Southwestern Petroleum Short Course, Lubbock, TX.Apr. 23-24, 198 1, pp. 251-
265.
5. Nguyen, T. V. and C. E. Stevens. The Use of Inert Gas Radioactive Tracers for Steam
Injection Profiling. Pres. at the SPE California Regional Meeting, Long Beach, CA, Mar. 23-25,
1988. Paper SPE 20035.
6. Nguyen, T. V., B. Davenport, C. E. Stevens, J. C. Reis, and R. S. Millhone. steam
Injection Profiling. U.S. Patent 4,8 l7,7 13, Apr. 7, 1989.
7. Nguyen, T. V. and B. Davenport. Steam injection Profiling. U.S. Patent 4,793,414,
Dec. 27, 1988.
8. Crowe, T. L. A Radioactive Steam Comparison Between Krypton-85, Xenon- 133, NaI-
131 (Methyl Alcohol Base) and NaI-131 (Water Base). Pres. at the Soc. Pet. Eng. 60th California
Regional Meeting, Ventura, CA, Apr. 4-6,1990. Paper SPE 20035
9. Burkill, Guy C. C. How Steam is Selectively Injected in Open Hole Gravel Packs.
World Oil,v. 194, No. 1, January 1982, pp. 127-136.
10. Anderson, G. W. and S. 0. Hutchison. Concentric Steaming String Downhole
Apparatus. U.S. Patent 4,399,865, Aug. 23, 1983.
 11. Hong, K. C. and S. Griston. New Methods for Controlled Injection of Steam Into
Multiple Sands. Pres. at the 6lst Ann. Tech. Conf. and Exhib. of the Soc. Pet. Eng., New
Orleans, LA, Oct. 5-8, 1986. Paper SPE 15472.
12. Gates, C. F. and S. W. Brewer. Steam Injection Into the D and E Zones, Tulare
Formation, South Belridge Field, Kern County, CA. J. Pet. Tech., v. 14, No. 21, March 1975,
pp. 343-348.
13. Small, G. P. Steam-Injection Profile Control Using Limited-Entry Perforations. Pres. at
the 1985 California Regional Meeting of the Soc. Pet. Eng., Bakersfield, CA, Mar. 27-29, 1985.
Paper SPE 13607.
14. Hong, K. C., S. Griston and J. W. Ault. Limited Entry Method for Multiple Zone,
Compressible Fluid Injection. U.S. Patent 4,640,355, Feb. 3, 1987.
15. Webb, C. H. Downhole Fixed Choke For Steam Injection. U.S. Patent 4,770,244,
Sept. 13, 1988.
16. Widmyer, R. H. Use of Monitor Observation Wells in the Monitoring and Evaluation of
Oil Recovery Projects. Pres. at SPWDOE Fifth Symp. on Enhanced Oil Recovery, Tulsa, OK,
Apr. 20-23,1986. Paper SPEfDOE 14956.
17. Griston, S. Fluid Effects in Temperature Observation Wells. Pres. at the 64th Annual
Tech. Conf. and Exhib. of the Soc. of Pet. Eng., San Antonio, TX, Oct. 8-11, 1989. Paper SPE
19740,
18. Patzek, T,W. and M. T. Koinis. Kern River Steam Foam Pilots. Pres. at the SPE/DOE
Enhanced Oil Recovery Symp., Tulsa, OK, Apr. 17-20,1988. Paper SPEDOE 17380.
 APPENDIX 14-A
STEAM IN.1ECTION PROFILE CONTROL SERVICE VENDORS
A. Spinner Tool and Survey
1. International Tool Company
7339 Kingsly
P.O. Box 803
Houston, TX 77001
Telephone: (713) 641-0373
B . Radioactive Tracer and Temperature
Survevs
Halliburton Logging Services
550 Ming Avenue, Suite 190
Bakersfield, CA 93309-8401
Telephone: (805) 833- 1952
Atlas Wirehe Services
10205 Westheimer
Houston, TX 77042
Telephone: (7 13) 972-4000
Exploration Logging Inc.
7000 Hollister Road
Houston, TX 77040-5337
Telephone: (7 13) 744-3600
Schlurnberger Well Services
SO00 Gulf Freeway
Box 2175
Houston, TX 77252-2 175
Telephone: (7 13) 928-4000
 CHAPTER 15
EMULSION PROBLEMS IN STEAM INJECTION PROJECTS

INTRODUCTION
A large portion of the oil produced by steam injection process is accompanied by water in the
form of an emulsion. The emulsion problem is much more severe in thermal operations than in
waterflood. The stability of the emulsion varies widely with the crude oil properties and producing
formation. These emulsions are difficult to break and the separation of the two phases consumes
considerable time, money, and efforts and requires specialized equipment and techniques. To
minimize the transportation and process costs, the crude oil purchasers limit the water content of
the oil they purchase to less than 3%. The cost of processing the produced fluids to meet the
purchaser's specification is second only to the fuel cost, and any savings in the treatment cost
significantly impacts the economics of the operation and improves the profits. The treatment costs
can be lowered by studying the treatment problem and selection and use of appropriate treating
methods, equipment, and procedures. This requires a basic understanding of the emulsions and
treating methods. The purpose of this chapter is to appraise the reader about how the crude oil
emulsions are formed and to discuss briefly the methods used in treating and breaking the
emulsion. The equipment used to dehydrate the crude oil is discussed in detail in chapter 16.

Definition of an Emulsion
An emulsion is a stable mixture of two immiscible liquids with one liquid intimately
dispersed in the second liquid in the form of fine droplets. The dispersed fluid is called the internal
or discontinuous phase while the continuous fluid is called the external phase. For an emulsion to
remain stable, the presence of a third component called the emulsifier is necessary. The emulsifier
inhibits the coalescence of the droplets. A common example of an emulsion is mayonnaise which
is a suspension of olive oil in vinegar with egg as the emulsifying agent.
An oilfield emulsion is an intimate mixture of oil and water. When water is dispersed in oil,
it is called a water-in-oil (wlo) or a "nomal" or "regular" emulsion. It is the most common form of
oilfield emulsion. When oil is dispersed in water, it is called an oil-in-water (o/w) or at'reverse"
emulsion. Reverse emulsions are more common in steam injection operations due to large
production of water. A w/o emulsion is usually very thick and viscous. A drop of this emulsion
does not disperse when added to water. This is the kind of emulsion that is treated in wash tanks
and heater treaters. The olw emulsion is usually less viscous than the oil itself and is usually
brownish in color. A drop of this kind of emulsion will readily disperse when added to water.
The following discussion is concerned with w/o emulsions because most oilfield emulsions are of
this type.
 Emulsion Formation and Stability
Two conditions must be satisfied before oil and water can form a stable emulsion.
a. There must be sufficient agitation to disperse water in oil or oil in water as minute
droplets. The agitation necessary to mechanically break a liquid into fine droplets can
result from the passing of fluids through pumps, chokes, tubing, manifold, valves or
other surface or subsurface equipment The greater the amount of agitation, the smaller is
the size of discontinuous phase droplets. Emulsions that have smaller droplets of
discontinuous phase are usually more stable and more difficult to treat than those that
have larger droplets.
b. Presence of an emulsifying agent is also necessary to form an emulsion. Emulsifying
agents are surface-active compounds that attach themselves to the dispersed water
droplets in the oil and form a protective film around it. This film prevents the droplets
from joining the adjacent particles of water. The emulsifying agents commonly found in
crude oil include asphaltenes, resins, oil soluble organic acids, and napthanic
compounds. Oil wet solids such as sands, clays, silt, scale, and corrosion products that
collect at the oil-water interface also act as emulsifiers.
The formation of emulsions result in the creation of an electric charge on the dispersed particles.
With isolated exceptions, the emulsified oil droplets carry a negative charge. Generally, low
gravity high viscosity crude oils form a more stable emulsion than oils of high API gravity.
Asphaltic based oils also emulsify more readily than paraffin based oils. The factors which affect
the stability of emulsions are as follows:
(a) The differences in densities of the crude oil and water;
(b) oil viscosity;
(c) the cut or volume percentage of dispersed water in the crude oil;
(d) age of the emulsions;
(e) solids.
I. Viscosity The rate of movement of a water droplet through the oil phase is directly
proportional to the viscosity of the crude. The water droplets move more slowly
through a high viscous crude and require more time to separate and settle down than in
a less viscous crude.
11. Density Difference: A greater density differential between water and oil will cause the
water droplets to settle faster. If an oil is heavy, that is, has high specific gravity, it
will tend to keep water drops in suspension longer. Similarly, fresh water droplets
which weigh less will not tend to settle as rapidly as heavier salt water droplets.
111. In addition to droplet size of the dispersed liquid, the ratio of these
droplets to the total fluid volume will also affect the emulsion stability. An emulsion
 with 50% oil and 50% water will separate more readily than an emulsion wherein the
percentage of the dispersed phase is considerably less than the external phase. This
phenomena has to do with the distance between water particles which directly
influences the force of attraction between droplets. The greater the distance between
particles, the weaker the force of attraction, and the less the probability of coalescence.
IV. #be of Emufsio~: A fresh emulsion is usually less difficult to treat than an aged
emulsion which has had a chance to set and settle out most of its free water. What
remains, after the free water has settled out, is an emulsion with fewer droplets of
dispersed water; therefore, there is less chance of colliding and coalescing, and
consequently the emulsion is more stable than when it is first produced.
V. Solids: Solids such as sand, silt, clays which are often produced with oil and water
tend to concentrate at the oil-water interface and contribute to emulsion stability.

Methods Used to Break Emulsions

In order to break a crude oil emulsion, it is necessary to rupture the interfacial film which
surrounds the droplets and coalesce the dispersed droplets. This can be accomplished by the
following ways:
(1) Thermal
(2) Chemical
(3) Mechanical .
(4) l3ectrical
Thermal: In the thermal method, the heat is applied to break the emulsion. The use of heat to
break emulsion has the following benefits:
Heat reduces the viscosity of the oil, and causes thermal currents to set in within the
treating vessel. As a result of these thermal movements, small droplets of fluids will
collide, rupture the film, and coalesce. Also, the reduced viscosity allows the water
droplets to settle more rapidly through the less viscous oil.
Heat increases the density difference between the oil and water, thus accelerating the
settling of the water droplets.
Heat also melts and solubilizes solids such as parafEms which may be acting to stabilize
the emulsion, thereby removing them from the interface.
Heat may also cause the fluid droplets to expand to a point that they will rupture their
captive films, especially in the presence of chemical deemulsifiers.
Dehydration in most steam injection operations is accomplished by the use of chemical
emulsion breakers. This method is popular because the chemicals are easily applied to the
emulsion at reasonable cost, and usually minimizes the amount of heat and settling time required.
 The chemical deemulsifiers are surface active agents that migrate to the oil-water interface,
lower the tension between oil and water and thus rupture or weaken the captive film sufficiently to
disperse the emulsifier back into the oil. For the chemical to be effective it must have (a) a strong
attraction to the oiUwater interface; (b) an attraction for water droplets with similar charge and bring
them together; (c) the ability to neutralize the emulsifier and promote the rupture of the interfacial
film; and (d) the ability to make solid particles such as clays to water wet and cause them to leave
the interface and be diffused into the water droplets.
It must be remembered that a given chemical emulsion breaker may be excellent and efficient
for one emulsion and entirely unsatisfactory for another. It is important for effective and
economical treatment that the operator enlist the service of the chemical supplier such as those listed
in Appendix 15-A to analyze his specific problems and recommend a suitable chemical
deemulsifier.
Mechanical: If the intensity of the collision between the dispersed droplets is sufficiently high, the
interfacial film can be ruptured faster than the droplets can be reformed, and the emulsions breaks.
This is the principle behind mechanical methods of treatment of emulsion. Mechanical agitation,
ultrasonic vibrations, and centrifuging are some of the ways emulsions are resolved. Agitation
techniques are not widely employed in the oilfeld because agitating most oilfeld emulsions has the
tendency to make the emulsion worse.
Electrical: The small water droplets dispersed in the crude oil can be coalesced by subjecting the
water in oil emulsion to a high voltage electric field. Under the influence of the electric field, water
droplets become mutually attractive due to induced electric charges on the drops. The effect of
these charges and the resultant forcible collision of drops overcome the stabilizing films, and a
rapid separation of oil and water follows.

Emulsion Breaking
A. Oil-in-Water Emulsions
These will be discussed first because they are more prevalent in steam injection operations.
A stable oil-in-water emulsion is a colloidal system of electrically charged oil droplets surrounded
by an ionic atmosphere. Steamflooding encourages the formation of these emulsions because of
the high water to oil ratio, shearing in the formation, and the presence of emulsifying agents such
as silt and clays in the formation. There is nothing that can be done to prevent the formation of oil-
in-water emulsions.
Some emulsification is also caused in surface equipment by pumping wells off, gases coming
out of solution, and centrifugal pumps in the gathering system. In the steam injection operation,
the pumps are often pounded in order to keep the wells pumped off and to produce the maximum
amount of oil. The emulsions, however, are made worse as a result. The principal gas that comes
out of solution in a steam injection operation is carbon dioxide. Since the release of carbon dioxide
causes water to become acidic, it encourages the formation of oil-in-water emulsions. Therefore,
the only thing that can be done to reduce the formation of oil in water emulsions in the wells and
production gathering system is to design the system such that the fluids are in laminar flow and
avoid centrifugal pumps wherever possible.
Oil-in-water emulsions can be broken by chemical and/or physical methods. Chemicals are
commonly used to treat these emulsions and to enhance mechanical treatment. In breaking
emulsions, the stabilizing factors must be neutralized to allow the emulsified droplets to coalesce.
The accumulated electrical charges on the emulsified droplet are neutralized by introducing charges
opposite to that of the droplet. Chemical emulsion breakers provide this opposite charge. The
dielectric constants of water and oil cause emulsified oil droplets to carry negative charges.
Therefore, to destabilize an oil-in-water emulsion, a cationic (positive charge) emulsion breaker
should be used.
The treatment of oil in water emulsions is normally divided into two steps:
1. Coagulation. This is destruction of the emulsifying properties of the surface-active agent
or neutralization of the charged oil droplet.
2. Flocculation. This is agglomeration of the neutralized droplets into large separable
globules.
Both inorganic and organic oil in water emulsion breakers are available from chemical service
companies. Organic emulsion breakers are the preferred emulsion breakers in Kern River Field
because part of the produced water is usually discharged into an agricultural canal, and there are
limitations on the amount of inorganic materials in that water. "Inorganic" emulsion breakers
contain inorganic salts such as zinc or chromium or iron which increase the specific gravity of the
water and encourage separation of water and oil.
The selection of a chemical for breaking oil-in-water emulsions must be done with care to
make sure that this chemical is compatible with the oil treating chemical and does not have any
undesirable side effects. One good rule-of-thumb is to use products from the same chemical
company for both treatments. The chemical companies are very aware of incompatibility problems
and can supply products that work together effectively.
The preliminary testing for oil-in-water emulsion breakers is the bottle test in which the
service npresentative places samples of the emulsion in glass bottles, adds various doses of his
chemical, shakes the bottles and observes the effect of the chemical on water clarity. The
following pitfalls are present in this kind of bottle testing:
1. The sample should be fresh and tested immediately at the site. Do not believe any results
on a sample that has been shipped. Several days of agitation on a truck or train serve to
break most emulsions.
 2. The chemical should be used neat (100% straight out of the bottle) even though only very
small amounts are being used, and measurement is difficult. Dilution of oil-in-water
emulsion breaker chemicals affects their pH and decreases their effectiveness.
3. The amount of agitation used in the testing should simulate the amount of agitation
actually found in the system. Emulsion breakers which work only after prolonged hard
shaking will not usually work in a system that only has s short run of pipe that is in
laminar flow.
One final precaution: The effectiveness of the chemical program is generally composed of 30
to 40% the effectiveness of the chemical and 60 to 70% the effectiveness of the chemical company
service representative. Chemical companies all have effective chemicals, however, there will be
large variations in the abilities of the representative who provides the service.
B. Water-in-Oil Emulsions
Water-in-oil emulsions are viscous, concentrated emulsions which are formed when oil
comes into contact with water and solids. It has been observed in many steam injection operations
that breaking the obvious oil-in-water emulsion that is produced as a byproduct of steamflooding
reveals a "hidden" water-in-oil emulsion which then must be treated in order to be able to sell the
oil. Water-in-oil emulsions are stabilized by formation fines and asphaltenes.
Water-in-oil emulsions are also broken by a combination of time, temperature, and chemical.
The chemical treatment of this kind of emulsion is directed toward destabilizing the dispersed water
droplets and solids or destroying the emulsifying agents. The mechanical facilities which are
usually wash tanks or heater treaters are critical here. The facilities and the chemical must work
together for cost-effective separation. There is frequently a close balance between heat and
chemical. The field engineer needs to study carefully the cost of heat vs. the cost of the chemical in
his own system.
It should be emphasized that no two oilfield emulsions are alike. The chemicals and
procedures used to treat the emulsion produced from one field may not work on an emulsion from
a different field. Within the same field, emulsions can vary from well to well and from year to year
during the life of the field.
The selection of a chemical to break water-in-oil emulsions must be done with the same care
as with oil-in-water emulsions. Bottle testing is again used as a guide to selecting the chemical.
Here the oil phase emulsion is poured into bottles, allowed to come to the temperature of the
system, chemical added and the water drop recorded over a period of a few hours. At the end of
the test a sample of oil from near the oil-water interface should be tested to determine how much
water is remaining, that is, whether the sample is "dry" and the oil can be shipped.
The following precautions apply to this kind of testing:
1 . Fresh samples should be used within a few hours of sampling to get reliable results.
 2. Neat chemical, not dilutions, should be used.
3. Oil-in-water emulsion breaker as well as water-in-oil emulsion breaker should be present
in the final stages of testing to check for potential chemical incompatibility.
4. The temperature and time used in the testing should closely simulate those actually
present in the treating situation.
The chemical service companies also provide water-in-oil emulsion breakers.

SUMMARY
There are two kinds of oilfield emulsions: oil-in-water emulsions, in which water is the
continuous phase and water-in-oil emulsions, in which oil is the continuous phase. Both kinds of
emulsions are broken by a combination of time, temperature, agitation, and chemical.
The selection of emulsion breaking chemicals should be accompanied by bottle testing which
carefully simulates system conditions. The emulsion breaker chemical is only as good as the
chemical service company representative who administers the chemical program. If the oilfield is
remote, and no service will be provided, the company should make provision for training of its
own personnel in chemistry and emulsion breaking.

GENERAL REFERENCES
1. Bansbach, P. L. and D. V. Bessler. Cold Treating of Oilfield Emulsions. Pres. at the
22nd Annual southwestern Petroleum Short Course, Lubbock, TX, April 1975,.pp. 241-249.
2. Smith, H. V. and K. E. Arnold. Crude Oil Emulsions in Petroleum Engineering
Handbook, edited by H. B. Bradley. Chapter 19, Soc. of Pet Eng., Richardson, TX,1987, pp.
19-1 to 9-15.
3. R. A. Brewer. Chemelectric-The Electrical Coalescing Treater. Pres. at the 13th
Annual Southwestern Petroleum Short Course, Lubbock, TX,April 1966, pp. 145-153.
4. Bertness, T. A. Thermal Recovery: Principles and Practices of Oil Treatment. Pres. at
the Soc. of Pet. Eng. 40th Annual Fall meeting, Denver, CO, Oct. 3-6, 1965. SPE paper 1266.
 APPENDIX 15-A
EMULSION TREATMENT CHEMICAL SUPPLIERS

1 . Nalco Chemical Company, VISCO Division

485 1 Stine Road
Bakersfield, CA 933 13
Telephone: (805) 834-6590
2. Tretolite Chemicals
Petrolite Oil Field Group
333 Palmer Drive
Bakersfield, CA 93309
Telephone: (805) 397-5 105
3. Baker Performance Chemicals Inc.
3920 Essex Lane
Houston, TX 77027
Telephone: (7 13) 599-7400
4. Eisenrnan Chemical
3900 Essex Lane
Houston, TX 77027
Telephone: (713) 439-8764
5 . Champion Chemical Inc.
Oil Field Chemicals Division
105 Wilco Building
Midland, TX 79701
Telephone: (915) 563-0863
 CHAPTER 16
SURFACE PRODUCTION FACILITIES

INTRODUCTION
Aside from water treatment and steam generation systems, a steam injection project contains
several types of hardware for the collection, treatment, and disposal of the produced fluids.
Collectively, this hardware is called the surface production facility (see Fig. 16.1) and includes a
production gathering system and the oil dehydration and storage system. A casing gas vapor
recovery system is used to recover and process the produced vapor from the well casing and is also
found in many large steam injection projects. The pipings, vessels, and other items associated
with the vapor movery system are not part of the production facilities.
In steam injection operations, more than a third of the mnfuel operation costs result from the
operation of the production facilities. History of steam injection operations reveal many projects
have failed as a direct result of an improperly designed and operated surface facility. The proper
design and operation of the surface equipment is of critical importance to the success of any steam
injection operation. The objectives of this chapter are to present an overview of the design and
operation features of various production equipment and their operational problems. A list of
production equipment vendors is presented in Appendix 16-A. The service of these or others
should be enlisted in the selection of equipment
PRODUCTION GATHERING SYSTEM
The production gathering system is nothing more than a multitude of pipelines and associated
pumps used to transport the produced fluids to the treatment plant. The automatic well test system
(AWT) is an integral part of the gathering system. The system may contain one or more lines that
branch off to each well or it may consist of a separate line to each well as distribution dictates. The
complexity of the production gathering system network depends on the size of the project.
A schematic of a typical production gathering system network is shown in figure 16.2. It
consists of (1) a production manifold that receives the fluids from th., production well and
transports them to the oil dehydrations facility directly or through a main gathering manifold; (2) a
series of lines from individual wells, which route the production either to the production manifold
or to a common test line or to a purge line through an automatic three-way diverter valve; (3) a
common test line that gathers the flow from individual wells and transports it to a test tank forthe
purpose of gauging and testing the oil and water production; and (4) a purge line that also serves as
an observation line. In a cyclic operation, the production manifold also serves as the steam
injection manifold for a certain period of time when the wells are being steamed. Similarly, the line
to each well from the manifold is a dual purpose line used for steaming the well for a certain period
FIGURE 16.1. - Schematic of a steamflood surface production facility.
 PRODUCTION T!A'

PRODUCTION
/ v/

FIGURE 16.2. - Schematic of a typical steamflood production gathering network.

of time. Usually a single productiodinjection manifold serves about 20 wells. The size of the
lines used in the gathering system depends on the volume of fluids produced and may range from
about 4 in. for individual lines to about 24 in. for the main manifold. Depending on the size of the
project, the total length of the gathering network ranges from several thousand feet to several
miles.
The entire production gathering system is energized by the pumping units. The pump must
have sufficient capacity to lift the projected amount of fluid and transport it to the treatment plant.
The line pressures must be kept down to avoid backpressures on the pumping units. Hence, the
lines must be sized properly to keep the pressure down. In designing the production gathering
system, flexibility and the need for the maintenance and repair of lines must be kept in mind. In
large projects, two or three parallel gathering lines are used in different parts of the field to permit
shutdown of the parts of the system for repair and maintenance.
Since steaming processes often times produce gases such as CO2 and noncondensible
hydrocarbons along with steam, it is important that air eliminators be installed throughout the
production gathering system to remove the gases. If these gases are not removed, they will build
up on the top of the pipe and restrict the flow of the production fluids. When this happens, the
solids are concentrated in the liquid stream. This, together with the increased velocity, will
dramatically increase erosion of the lines.
In many large California steam injection projects, often times the production comes from the
leased properties. Under the terms of the lease agreement, it may require separating oil and water
at the lease line and metering of the oil. If such is the case, then separate facilities must be
constructed at the lease line to separate oil and water. The lease facilities usually consist of a
primary and secondary wash tank and one or more shipping tanks. The oil is skimmed from the
primary to secondary and then to the shipping tank. When the shipping tank is full, it is manually
gauged, prior to shipping to the oil dehydration plant. A positive displacement pump is utilized to
pump the oil back into the production gathering system. The water is waterlegged into the drain
tank. Any oil collected at the top of the drain tank is skimmed and pumped back into the
production gathering system using positive displacement pumps. Depending on the size of the
project, several drain tanks (each with a capacity of 500 to 1,000 bbl) are utilized to hold the water
from the lease tanks. The water is also discharged into the production gathering lines using
centrifugal pumps.
Since the produced fluids are in emulsified form, an emulsion breaker (a chemical that aids
the breakup of the emulsion) is injected into the gathering line to resolve the emulsion. High
temperature, longer residence time, and agitation all aid in the breakup of the emulsions. Since all
of the parameters favorable to the breakup of the emulsion are present in the gathering system,
usually only a small amount of chemical is added to the system to initiate the breakup of emulsion.
The emulsion breakers feed points are usually located downstream of the AWTs. Only a minimum
amount of chemical needed to initiate the breakup of the oil-in-water emulsion must be added and
full advantage of the residence time in the line should be taken. Careful attention must be paid to
the amount of treatment chemicals used because overtreating would inhibit the resolution of water-
in-oil emulsion formed in the oil dehydration plant.
Use of single reverse emulsion breaker throughout the gathering system is recommended to
permit the ease of administration and to avoid potential incompatibility problems which could exist
if two or more chemicals were used. Emulsions and emulsion breaking are discussed more fully in
chapter 15.
Automatic Well Test (A WT) Units
The AWT unit is utilized to measure the oil and water production rates from individual wells
and is an essential component of the oilfield production gathering system. Accurate measurement
of crude oil production from individual wells is needed for a variety of reasons.
Individual fluid production from wells is necessary for optimizing production operations and
for reservoir management. It is also needed for calculating royalty and working interest payments
and for guiding daily production operation. In large operations, each individual well is expected to
contribute its share to total oil production and the AWT unit provides a means of determining the
well productivity and indicates when to shut down uneconomic wells. Production data are also
needed to meet any contnctual requirements and government regulations.
 In steam injection operations, data obtained from AWT units are utilized as the number one
diagnostic tool to determine the changes in reservoir characteristics and to establish well workover
needs. These data are also utilized in many instances to gauge the success (both technically and
economically) of the steam injection procesd Hence, it is important that data gathered from AWT
units be accurate and reliable. To illustrate how vital these data are, consider a typical waterflooded
reservoir in the United States.
Many U.S. waterflooded reservoirs are currently producing at high watercuts, and most of
them contain wells that are capable of producing in excess of 500 barrels of fluid per day (bfpd).
For such wells, a small error in the watercut will result in a large percentage error in the oil
production rate. For example, a well producing 600 bfpd at a 95% watercut is producing 30
barrels oil per day (bopd). If the watercut is measured at 94% or 1% less than actual value, the
calculated oil rate would be 36 bopd. The 6 bopd difference represents a 20% error in oil
production rate. Not only is the oil production rate of this well incorrect, other wells in the system
will have to make up the difference if an allocation method is used. Since this is usually the case,
this may result in the continued production of uneconomic wells. Unfortunately, it is sometimes
very difficult or uneconomical to obtain accurate production data because of the time consuming
nature of the tests and difficulties in the calibration and operation of metering devices and sampling
equipment. The problem is even more acute in steam injection operations. The hawking of a
variety of well test hardware designs, as well as a wealth of recent AWT related papers, is a
testimony to the difficulties in obtaining accurate and reliable production data.
The AWT System
There are several popular production well testing methods used in the oil patch. All
techniques employ a test vessel to separate oil, water and gas, and meters to measure the flow rate
of individual phases. A typical automatic well testing system used in an oilfield is shown in figure
16.3. This system consists of a group of testlproduction manifolds, a test vessel and metering
elements. The well to be tested is diverted to the test vessel, by activating a three-way control
valve on the test/production manifold. Many installations use a three-phase separator (a direct-fred
heater treater) to separate and measure the oil, water, and gas individually. Other installations use a
two-phase vessel and measure the watercut with a continuous sampler such as a capacitance probe
on the emulsion stream. The two-phase vessels are less expensive to purchase and to operate than
the three-phase heater treater type arrangement and require no emulsion breakers. Due to severe
emulsion problems, three-phase separators are universally used in steam injection operations.
The volume of the produced fluid is usually measured with the aid of positive displacement
or turbine meters. These meters have moving parts which are subject to erosion and corrosion and
 TEST LlNE COMMON LlNE
f TO GATHERING

OBSERVATION LlNE

FROM WELLS

FIGURE 16.3. - Schematic of steamflood automatic well testing system.

eventual failure. Further, since these moving parts do not fail in an obvious manner, they require
constant and costly calibration and testing. Without such tests and calibration, the problem of
faulty meter readings will go undetected and introduce error in measurements. For these reasons,
mass flow meters are increasingly being used in larger steam injection operations to improve the
accuracy of well test data? Further, since the mass flow meters do not have any moving parts,
they are practically maintenance free, and the meter calibration is relatively simple. Also, mass
flow meters are not affected by the variation in fluid volume caused by thermal expansion and
contraction. Mass flow meters, however, are more expensive than common oilfield flow meters
and require more training for operators.

TREATMENT OF PRODUCED FLUIDS

The oil produced by steam injection is accompanied by water and much of this is produced in
the form of emulsion. The shearing action of steam through the formation causes a rather severe
oil-in-water emulsion. Further, the thermal wells are usually pumped-off to maximize the oil
recovery and also increases the severity of emulsion. Since much of the steam injection operation
is conducted in unconsolidated formations, sand is produced along with the fluids. The water and
sand must be removed from the oil before it can be sold to refineries. In addition, the produced
water must be treated to remove oil and solids before it can be recycled. Water is separated from
oil in a dehydration plant. Most of the sand also drops out of the fluid in the treatment plant.
Further, solids separation can be achieved by centrifuge or flotation techniques. A variety of
treatment systems are marketed to treat and dehydrate the emulsified oil. In selecting a treating
system, a number of factors should be considered in determining the most desirable method of
treating the crude oil to meet sales requirements. Some of these factors are (1) tightness of the
emulsion, (2) specific gravity of the oil and produced water, (3) corrosiveness of the crude,
produced water and casing head gas, (4) scaling tendencies of the produced water, (5) quantity of
fluid to be treated and percent of water in the fluid, and (6) equipment operating pressures.
In steam injection operations, chemicals and heat are used to destabilize the emulsion. The
addition of heat has a dual effect, i.e., the specific gravity and viscosity of the oil both decrease as
the temperature is increased. This combination of decreased specific gravity and viscosity of the
oil amplify the differences in densities between oil and water. This difference in densities aids in
the separation of water from oil.
A variety of equipment is used in steam injection operations to dehydrate the oil and to
remove sand. These include: freewater knockout vessels, wash tanks, heater treaters, and storage
tanks. The sediments from the tank bottoms are cleaned using desanders. In addition, accessory
equipment that is not basically necessary to the operation of the dehydration plant is also included
as part of the dehydration plant. These include the lease automatic custody transfer (LACT) units
and cooling towers to cool the produced waters for treatment in the depurators.
Not all of these units are found in all operations. The amount and type of equipment needed
depend on the volume of the fluids to be handled, severity of emulsion and sanding problems,
waste water specification, etc. Several different types of equipment or systems may satisfactorily
resolve an emulsion, but particular types of equipment or systems may be superior to others
because of basic considerationsin design, operation, initial cost, maintenance, and operating costs,
and performance.5 Effort should be made to select the minimum number of pieces of equipment
for each treating system to lower initial and operating costs.
Basic descriptions of various pieces of equipment used in a steamflood dehydration plant are
as follows.

Freewater Knockout (FWKO) Vessels

In steam injection operations, where large volumes of water are produced along with oil, it is
both desirable and economical to separate as much water from oil as possible before attempting to
treat the emulsion. The freewater knockout vessels or oil-water separators are used for this
purpose. The FWKO vessels are the ftrst of a series of equipment utilized to dehydrate the oil.
The hot produced fluids from the gathering systems enter the FWKO vessels where the produced
oil and emulsion are allowed to separate from water. FWKO units are normally large cylindrical
vessels which operate under pressure for the free gravity separation of oil and water. The oil-water
interface in the vessel is controlled by an interface level control which operates a water discharge
valve.
 Depending on the volume of the produced fluids, one or more FWKO vessels are used in the
process. The vessel must be large enough to permit the separation of water from oil in reasonable
time. Both vemcal and horizontal configurations are utilized. Schematics of horizontal and vertical
FWKOs are shown in figures 16.4 and 16.5, respectively. In tables 16.1 and 16.2, the size and
capacities of the horizontal and vertical vessels are given.4
The residence time in the FWKO ranges from 3 to 6 hours. The free water is removed from
the vessel through a water dump valve (usually controlled by a capacitance type interface
controller). This prevents the dumping of oil out of the water dump valve by keeping the
emulsion-freewater interface level at a predetermined set point. Normally, there is no oil discharge
valve and the oil, emulsion, and gas is flowed through a connection in the top of the vessel on to
the treating system.
Variations of freewater knockouts are often used to accomplish specific treating purposes.
Flow splitters are one variation of the freewater knockout designed for specific applications. The
flow splitter vessels have two or more separate compartments to collect the oil before it is
discharged from the freewater knockout. The oil is discharged in multiple streams, depending on
the number of separate oil compartments in the vessel. The free water is discharged from the
vessel as it would be in a standard horizontal freewater knockout using an interface level control
and water discharge valve. The oil flows over adjustable weirs into separate compartments and
each is equipped with an oil level control and separate oil discharge valve. Any gas separated is
discharged out the top of the vessel through a separate gas line. The purpose of these vessels is to
ratio the oil out of the freewater knockout to different pieces of treating equipment. This type of
vessel would have application where the oil volume, produced and passed through the freewater
knockout, was so large that it could not be handled by a single piece of treating equipment.
Therefore, the flow splitter is used to ratio the oil flow to several treaters. Or, the operator may
already have several items of treating equipment on hand and wants to use them in a large central
treating installation where the flow has been increased due to a steamflood.
Many steamflood operators use a cone-bottom FWKO. This design is used if sand
production is anticipated to be a major problem. Normally, 45' and 60' cones are used as the
bottom head of the vessel. Water jets are usually used to dislodge and flush the sand from the
vessel.
Emulsion breakers and antifoaming agents are usually added upstream of the FWKO to
partially break the emulsions. The gross emulsions leaving the FWKO usually consist of 40%
water and 6 0 8 oil and, depending on the operation, the water content of emulsion may range from
10% to 50%. The water leaving the FWKO vessel usually contains about 100 to 400 ppm of oil
and this oil is usually recovered in a depurator.
 WTW WTER
VALVE mLEr

FIGURE 16.4. - Typical horizontal freewater k n o c k o ~ t . ~

SAFETYVALVE OIL & GAS OUTLET

7 /- PRESSURE GAUGE

INTERFACE FLOAT

GAUGE GLASS

16" MANWAY

MECHANICAL

DRAIN

FIGURE 16.5. - Typical vertical freewater knockout.4

 TABLE 16.1. - Specifications for Horizontal Freewater Knockouts"

Volume of
Specifications fluid in vessels

Standard
Size Inlet & Drain water Vol. Vol. Total
Dia. x W .P. Outlet Conn., valve, Water, Oil, Vol.,
length, ft psi Coon., in. in. in. bbl bbl bbl

3
4
4
4
4
6
6
6
6
8 In - 6 Out
8
8

TABLE 16.2. - Specificationsfor Vertical Freewater ~nockouts4

Volume of
Specifications fluid in vessels
Standard
Size Inlet & Drain water Vol. Vol. Total
Dia. x W.P. Outlet Conn., valve, Approx. Water, Oil, Vol.,
length, ft psi Conn., in. in. in. wt. lb. bbl bbl bbl

The FWKO is relatively maintenance free. The main problem which occurs is the buildup of
solids on the bottom of the tanks. The tanks must be cleaned periodically, depending on the
severity of solid buildup.
Settling Tanks
Some steam injection operators use settling tanks instead of heater treaters to dehydrate oil.
Various names are given to these settling tanks and some of the most common are gun barrels,
wash tanks and dehydration tanks. Designs for these tanks differ in detail from vendor to vendor
and field to field. The essential components of a settling tank include: a gas separation chamber or
gas boot, a downcorner, water wash section, spreader or deflector plates, and oil collectors. The
internal design of the wash tanks vary from operator to operator and depends on the overall
process selected for the facility, emulsion properties, flow rates, and desired effluent qualities.
Many settling or wash tanks employ heat to aid in the treatment process. Heat can be added to the
liquid by an indirect heater, a direct heater, or any type of heat exchanger.
A direct fired heater, also called a "jug heater," is one in which the fluid to be heated comes in
direct contact with the immersion type heating element or heating tube. The units are normally
constructed so that the heating element can be removed for cleaning, repair, or replacement. Direct
heaters are usually used to heat low pressure noncomsive liquids.
An indirect fired heater is one in which the fluid passes through tubes immersed in a bath of
water or other heat transfer medium. The heat transfer medium, in turn, is heated by an immersion
type heating element similar to the one used in a direct fued heater. Indirect fxed heaters are more
expensive than direct fued heaters and cost more to maintain. Indirect fired heaters are generally
used to heat corrosive or high pressure fluids.
Schematics of a wash tank, used by one large California steam injection operator to dehydrate
the oil, is shown in figure 16.6. These are 10,000 barrel welded mild steel tanks and have
internals consisting of two stacks of heating coils and a spreader bar. The tanks are maintained at
190' F by circulating steam through the heating coils.

GAS LOOP GAS BOOT FROM

SURGE
TANK

SKIMMER TROUGH
C 1
OIL OUTLET
1-1 \-]+-THERMAL
PLATES
0 01- (TYPICAL)
t
u
- WATER OUTLET
' \ TO DEPURATOR
PERFORATED
DEFLECTOR PLATES

FIGURE 16.6. - Schematic of an oilfield wash tank.

 The function of the gas boot is to separate gas from the incoming fluid stream. The emulsion
enters the gas boot, where a momentum change causes gas to separate. The gas boot is usually a
simple piece of pipe as shown in figure 16.6. In some units, they are more elaborate and contain
nozzles or baffles to help separate gas. The oil and water then passes through the gas boot to enter
the bottom of the tank through a spreader device. An oil-water interface is maintained in the tank
by means of an outside water leg on the tank or through the use of an electronic probe. Electronic
probes are most often used in heavy oils to sense the interface and automatically trigger a water
dump valve.
A downcomer directs the emulsion below the oil-water interface to the water wash section.
In large tanks, such as the one shown in figure 16.6, a spreader is used to distribute the flow over
the entire cross-section of the tank. The function of the spreader or the deflector plate, which
contains small holes or slots, is to disperse the emulsion into very small droplets which are
subjected to washing action as the droplets float to the top of the tank. This permits the water
released from the emulsion to drop out. If the droplet size is too big, there will not be sufficient
"washing" action and the oil will take longer to dehydrate.
The whole key to efficient wash tank operation is maintaining a stable oil-water interface
which is well above the accumulated sediment. The plant operator should check the location and
appearance of oil pad every hour and adjust the pad as needed to maintain a good interface.
However, all changes should be made slowly.
Maintenance of wash tanks consists of keeping the heating coils in good condition and
cleaning the accumulated tank bottoms every 3 months. Since heat aids in the breakup of the
emulsion, it is important that heating coil surfaces be film free to promote better heat transfer. Oil
cuts in the wash tanks must be monitored every 2 hours or so with the objective being to have a
water and sediment free oil (less than 3% basic sediment and water [BS&W]) under normal
operating conditions. In large operations, the oil from the first wash tank is skimmed to a second
wash tank and then to the shipping tank. This is to accommodate any upsets and to ensure that the
dehydrated oil meets the pipeline specification.
Heater Treater
Most steam injection operators use heater treaters to break emulsions. A heater treater is a
pressure vessel that operates on the same principle as the wash tank. A heater treater can heat the
emulsion to temperatures above the boiling point of water, without boiling the water.
The heater treater (also called an emulsion treater) combines all of the various pieces of
equipment used to treat an emulsion in one vessel. The heater treater is designed to include in one
unit any or all of the following elements: oil and gas separator, freewater knockout, heater, water
washing section, filter section, stabilizing section, heat exchanger and electrostatic field.
 Although the heater treaters can be operated at atmospheric pressure, they are often operated
under low working pressure (typically from 10 to 50 psig), depending on the construction of the
vessel and the type of controls used. Heater treaters are available in both vertical and horizontal
configurations. The emulsion, along with the treating chemicals, enters the vessel near the top and
flows downward.
-
Vertical Treaters
One of the most commonly used crude oil emulsion treating system is the vertical heater
treater. A variety of designs are available. Three such designs are shown in figures 16.7, 16.8
and 16.9.
In the design shown in figures 16.7 and 16.8, the emulsion enters near the top of the treater
into a gas separation section. In figure 16.9, the emulsion enters near the bottom and flows
upward into a gas separation. This section must have adequate space to separate gas from the
liquid. The gas separation section usually has an inlet diverter and a mist extractor.
The emulsion flows through a downcomer to the bottom portion of the treater, which serves
as a FWKO and water wash section. This section should be sized for sufficient retention time to
allow the free water to settle out. This will minimize the amount of fuel needed to heat the liquid
rising through the heating section.
The oil and emulsion flows upward through the water which serves as a washing medium.
The water is heated by a fire tube projecting into this compartment After leaving the heated water
wash, the emulsion rises into a settling space where water is broken out of the emulsion, settles
out, and falls back into the water wash. The clean oil rises and passes through the oil outlet. The
water in the bottom of the unit passes out a water outlet to the disposal system. The oil-water
interface level is controlled by an interface controller or an adjustable external water leg. The
operating pressure is kept well above the saturated steam pressure at the operating temperature to
prevent the water from boiling.
Horizontal Heater Treater
The external and internals of a typical horizontal heater treaters are shown in figures 16.10
and 16.11. The horizontal treaters operate much like vertical treaters. The incoming emulsion,
with chemical added, enters the front section of the treater where gas is flashed. The liquid flows
downward to near the oil-water interface where the emulsion is water washed and the free water is
separated. The oil and emulsion rises past the fire tubes and flows into a second section of the
vessel where water is broken out of the emulsion and falls back into the bottom. The clean oil is
removed through the outlet. The oil-water interface in the inlet section of the vessel is controlled
by an interface controller, which operates a dump valve for the free water.
 GAS OUTLET,

RELIEF VALVE
SAFEW HEAD
(SELECTED ASME CODE
MIST EXTRACTOR SIZES ONLY)
GAS EQUALIZER

GAS SEPARATING EQUALIZING LINE

ABLE ADJUST
EMULSION CONDUCTOR
\ ATER SIPHON

FLAT BAFFLE &

FILTER SUPPORT
CONICAL BAFFLE &
FILTER SUPPORT
FLAT BAFFLE &
FILTER FILTER SUPPORT
SECTIONS
CONICAL BAFFLE &
DOWNCOMER FILTER SUPPORT

FREEWATER
KNOCKOUT BY-PASS t ,
NORMAL INTERFACE
L E C -

WATER VALVE

WATER
OUTLET

OUTLET b

FIGURE 16.7.- Schematic of a vertical heater treatm4

 ----
OIL LEVEL

FIREBOX
-- HOOD

NORMAL IMmFACE
----- LEVEL

\ DRAIN
CONNECTION

FIGURE 16.8. - Schematic of a second type of vertical heater treater.4

 SAFETY HEAD
(SELECTED ASME CODE
RELIEF SIZES ONLY)

SIPHON

GAS SEPARATING
SECTION

OIL
LEVEL
I -

- OIL
OUTLET

\ DRAIN
CONNECTION
RIGHT SIDE V l W

FIGURE 16.9. - Schematic of a third type of vertical heater treater.4

 FUEL
HSTR.

TO SALES

FIGURE 16.10. - Schematic of one type of horizontal heater treatere4

GAS
OUTLET REUEF

FIGURE 16.11. - Schematic of a second type of horizontal heater treater?

 Generally, horizontal treaters have a larger settling or coalescing section than vertical treaters
and, therefore, are often used to treat heavier oils. The larger sizes of the horizontal treaters allow
for larger fm boxes and therefore the capability to handle larger volumes of fluids. Also, the oil-
water interface area in a horizontal treater is larger, and this permits more rapid settling of oil and
water particles within the vessel. One possible disadvantage of horizontal treaters is that they
require more floor space than vertical designs.
The dimensions of a typical horizontal heater treater used in a stearnflood operation are 12 ft
in diameter by 30 ft in length and can process 540 barrels of fluid. These units are usually
operated at 60 psig and 260' F.
Electrostatic Treaters
Electrostatic treaters (see figure l6.12), often called chemelectric or electrochemical treaters,
are similar to horizontal heater treaters except that high voltage, alternating current electric grids are
added. ELecvicity is often an effective means of breaking emulsions. As the heated emulsion rises
through the electric field, the water droplets are given a charge. When charged, the droplets move
about rapidly, colliding with each other with enough force to coalesce into larger and larger drops
until they settle out. The clean oil continues to rise to the top of the vessel where it is collected and
removed.
The electrical system consists of a transformer and electrodes which are suspended, one
above the other, in one section of the unit. The electrodes are usually arranged so their cross-
sectional area is perpendicular to flow of the fluids.
With electrostatic treating units, it is possible to use lower heating temperatures than are used
with the other units. It is also sometimes possible to treat the emulsion at the temperature at which
it is produced with no additional heat. Not only do lower temperatures require less fuel to fire the
heater, they also lessen problems with scale and corrosion formation and, most importantly, reduce
the chance of gravity and volume losses that occur at higher temperatures. One disadvantage of an
electrostatic treater is that the grid is prone to plugging by solids. This would lead to a particularly
difficult situation with oil from unconsolidated formations such as those found in California.
Practically all oil requiring treatment contains a certain amount of entrained sludge and solids,
and a bottom drain is provided on most heater treaters to permit removal of these materials. The
presence of a large quantities of solids can be a problem in any heater treater, but particularly for
those electrostatic units where plugging is frequently observed.

Emulsion Breaker Treatment

A good emulsion breaker treatment is vital to the success of most heater treater operations,
because the emulsions are generally severe enough that heat alone will not resolve the emulsion in a
 GRID TRANSFORMER
EMULSION GAS
INLET OUTLET

FIGURE 16.12. - Schematic of an electrostatic treater.

reasonable amount of time. Careful bottle testing (see chapter 151, will identify chemicals which
will provide fast water drop and dry oil at the interface. It must be remembered, however, that the
results of bottle testing cannot always be taken too literally. In the cases of unconsolidated
formations, such as Kern River, CA, control of solids and a good interface are vital to the success
of the separation process, be it wash tanks or heater treaters. A small amount of emulsion
remaining at the interface after the f i t day of operation will build up on the subsequent days and
eventually upset the treater entirely.
As with all oil and water separation processes, careful monitoring is the key to success. Oil
cuts (BS&W) and oil counts should be monitored every 2 to 4 hours. In addition, pressures,
temperatures, chemical usage, and fuel consumption should be monitored daily for cost-effective
operation.

Lease Automatic Custody Transfer (LACT) Unit

A lease automatic custody transfer ( L A W system is an arrangement of equipment designed
for the unattended transfer of liquid hydrocarbons from producing leases to the transporting
carrier. Proper means must be provided for quality determination (%BS&W), net-volume
determination and fail-safe operation. The basic systems are divided into two categories:
(1) measuring tank systems and (2) positive displacement (PD) metering systems. A schematic for
a positive displacement metering system is used in steamflood is shown in figure 16.13.
 PRODUCTION FROM LEASES
RATDN FACILITIES

TRANSFER PUMP
8S & W MONITOR AND CONTROL VALVE

A
A MP
SAMPLER AND CONTAINER
AIR AND GAS EL

PROVER TANK OR MASTER

CHECK AND BACK

FIGURE 16.13. - Schematic of a LACT system.

A PD meter is a device installed in a piping system in which flowing liquid is constantly and
mechanically isolated into segments of known volume. These segments of liquid are counted as
they are displaced, and their accumulated total continuously and instantaneously indicated by the
meter register in units of liquid quantity. These fixed quantity liquid segments are united as they
emerge from the measuring element
Tank Bottoms Cleaning
In the U.S. and other parts of the world, the reservoirs associated with steam injection
operations are unconsolidated. Sand is, therefore, produced along with the formation fluids and
drops out in the tanks in the dehydration facility. In many large steam injection operations in
California, the sand collects at the rate of almost 1 ft/wk at the bottom of FWKO (to include wash
tanks or heater treaters), and must be removed periodically to maintain effective treating action. In
large operations, the tank bottoms are usually cleaned once every 3 months. The tank bottoms
usually contain considerable amounts of oil and can be recovered by cleaning the sediments. The
profits realized from the sale of this oil usually pays for the cleaning and disposal costs of the tank-
bottom materials.
The oily bottom sediment is first hosed into a concrete pit. A slurry pump, located at the
bottom of the pit, is utilized to transfer the sediment to a process tank The contents of the process
tanks are thoroughly mixed and transferred to a sediment tank through a set of hydrocyclones. The
solids, which drop out in the hydrocyclone, are further treated. The liquid portion is returned to
the process tank. The liquid portion is recycled several times through the hydrocyclone until the
fluid returning to the process tank is nothing but water and oil. The most common type of
hydrocyclone used to separate the fluid from sand is the cyclone desander.
 Cyclone Desanders
Cyclone desanders (hydrocyclones) are commonly used in steam injection operations to
separate sand particles from the liquid. Cyclone desanders are conical-shaped devices that make
use of centrifugal force to separate the solid from the liquid.
The fluid enters through a tangential opening in the large end of the cone-shaped housing.
This results in a whirling motion or "cyclone" action of the fluid. The fluid and solid particles
move downward in a spiral pattern forcing the heavy particles to move toward the outer perimeter
of the cone. Gravity forces these particles to slide downward and force out the apex. The
remainder of the fluids move toward the vacuum created at the center of the cone, and are drawn
off at the top as overflow. The overflow contains particles less than 30 microns in size and sends
them to a sediment tank.
The sediment accumulated in the sediment tank is pumped to a decanting centrifuge using a
cavity pump. A light solvent is usually injected into the pump suction to aid in the recovery of oil.
The decanting centrifuge is a rotating cone-shaped drum, which turns at high speed and thus
effectively separates the solids. An augur within the rotating drum scrapes the particles off the side
of the drum and forces them out of the discharge port. The fluid in the center of the drum is
discharged through the liquid discharge port. The cleaned solids are hauled to a disposal site.
Operation, Maintenance and Monitoring Considerations
Neither the equipment nor the operation of a steam injection oil dehydration plant are
particularly complicated. However, careful monitoring of fluid and equipment is critical for proper
plant operation. In large steam injection operations, where the dehydration plant spreads over a
large area, the operation is manpower intensive. Some of the operating and maintenance problems
associated with dehydration plant include: malfunction of burners in the heater treater; deposition of
soot on the walls of the fire tube; deposition of scales and solids on the heating tubes and nearby
surfaces; sand buildup; erosion of pumps and valves, due to the abrasive actions of sand;
malfunction of water dump valve; malfunction of instruments and controls; and corrosion. Smith5
has discussed, in considerable detail, these and other operational problems associated with
emulsion treating equipment. He also discussed the economics of crude oil emulsion treatment.
Interested readers are directed to reference 5 for more details.
A utornation of Dehydration Plant
Because of the large physical size of a dehydration plant, and the equipment used, operations
tend to become highly labor intensive in large steam injection operations. For example, the oil
dehydration plant in one large California steamflood operation covers 11 acres and consists of
7 freewater knockouts; 17 heater treaters; 21 storage tanks; and 5 LACT units; and numerous
pumps, valves, and other miscellaneous equipment.6 The operation and maintenance of such a
plant is highly labor intensive. If an upset occurs, it may take from 20 minutes to one hour to
locate the trouble spot. Operations such as these would highly benefit from automation. The
current trend in large steam injection operations is to automate production operations to reduce
operational costs. The oilfield automation goes by various names such as "Supervisory Control
and Data Acquisition (SCADA)" and "Sample Control and Alarm Networks (SCAN)." These are
discussed more thoroughly in references 6 and 7. Depending on the complexity of operation, the
installation costs will range from 1 to 3 million dollars. Maintenance costs include those associated
with the daily upkeep of the system, monthly computer software maintenance, monthly hardware
maintenance, and skilled labor. In Table 16.3, the cost and benefits of oilfield-production
automation is depicted.* Automation is expensive, and an economic analysis must be performed to
justify the investment and maintenance costs of the system.

SUMMARY
As a result of severity of emulsion problems and sand production in steam injection
operations, the cost of processing the produced fluids to meet the pipeline specification is
significant and second only to the fuel cost. By judicious selection of equipment, and adopting
prudent operation practices, treatment costs can be lowered. A variety of equipment, along with
chemical deemulsifiers, are utilized to treat the thermally produced oil. These include gun barrels,
heated wash tanks, heater treaters, electric dehydrators, and hydrocyclones. Not all the equipment
is used in all the steam injection operation. The nature and severity of produced emulsions dictate
the type of equipment most appropriate for a particular job. The type, configuration, size and
usage varies from field to field.
This chapter has briefly described the facilities and equipment commonly used in steam
injection operations to process the produced fluid. The overall treatment costs can be lowered by
selecting the equipment and facilities based on ease of operation, initial cost, maintenance cost, and
performance. Efforts should be made to select the minimum number of pieces of equipment and
simplest design to optimize initial and operating costs. The system should be designed to
accommodate the maximum anticipated throughput The amount of excess capacity to be built into
the treating system should be based on an assessment of the cost of the extra capacity balanced
against the risk of not being able to treat the peak throughput. Only the equipment needed to
accomplish the task should be purchased and installed at the start of the project. Additional
features or equipment can be added later in the life of the project, if necessary.
 TABLE 16.3. - Computerized Automation of Oilfield Productions--€osts and ~enefits8

(A &crcased operating expenses and increased iocaac)

(B base case maintenance capital decreax)
1
. . . . 1 Cornpuler nod peripherals
a Decreased downtime from decreased subsurface failures a Backpremre valve leaking I-
2m b l e cost -of
b
c
Detect low pump efficiency mue quickly
Detect gas locking probkmr more quickly
b
c
Three-way valve leaking
Pump failure
Telemetry equipment -
flangibk cost cnly intangibles arc considered
in manpower cost)
d Detect casing check valve leak m a t quickly d Power failure Injection well end devices -A
e Detect trash in pump more quickly e Header valve kaking - 1
f Detect standing or traveling valve pobkm in pump f N.O.C. failure (net oil cornpuler) Reduction well end &vices a Logistic board
mom quickly g High vessel pressure b Calibration
g h t e c t collapsed casing m a t quickly b Accurate test Cabk installation c Fuses
b Detect casing leak more quickly i Immediate ahmu ZLoadccllandFpbL
i Higher quality and quantity test and test hislory from . . Junction boxer md m i ~ l l a n e o u s a Repairs cx replacement
which to identify and plan work 2 e b Cabk repairs
j Immediate probkms alarm a Tank levels Test quipment and spares 3 PoJilionwt. b e
k Ability to isolate wells down and place back cn b Injection volumes a Repairs a replacement
reduction after a power failun c Roductim volumes Softwnre l o e m b Alignment
I & tect crowd flowlines at fist installation d Check line and vessel pressure 4Fieldcabkcuu
(better data) Soflware implementation a Replaw cabk
m Detect higb a low rates on injection wells more 3-
quickly a Monitor calhodic protection Labor B-
n Detect large kaks in inection lines more quickly b Control injection volumes I hiech%nical failures (Automation mly)
o Detect wellbore scale buildup more quickly c Monitor flowline pressure 2 Electrical failures
p Detect tubing kaks and par& more quickly a Equipnent repairs or rcplaamcnt
. . 3 Net oil computer
s1udIet a E q u i p n t repairs or replaccmcnt
a Establish directional permeabilty tzends 4 RTU Wb,
b Detect possible channels from a Equipnrnt rcpairs or replacement
a POC (Pumpoff conlrolkr) injection to produang wells 5 AWTpanel
b Loading alarm c Establish possible relation between pump sticking a Equipmen4 rtprirs or replrccment
c Ability to track pumps from weU to well more quickly r b k m to slress failure 6 Rus
d Ability to detect sklk buildup in t b ~pump and tbg. d ffecls of infill drilling upon offset production a Replacemnt
m a e quickly e Motor evaluations 7 Field cable cub
e Ability to delect tubing travel more quickly f Cornprism of steamflood pattern a Cable ~placernent
f Ability to detect sticking pump m m quickly c Iniecaon w e u ~
g Ability to detect pump Lagging bottom more quickly 1 Rate
b Ability lo detect all overloads prior to failure more a Turtim mcter rates and pickup
quickly b Frequency to DC converter
c Cable
aod d Calibration
a Detect tearing failure prior to failure 2 PI?surr
b Detect bridle failure prior to failure a Trmsmit[er
c Detect downhok overloads to prevent gearbox Overloads b Cahlc
d Detect bells slipping or off c Cahbrrtion
3 Reld cable cuts
4 RTU boards
5 Fuss
D m
1 Cleaning fluids
2 Spm elecuoriics p l s
E Monthly computer sofiware maintenance
F Monthly computer hardware rnainten.u~ce
 REFERENCES
1. Flahive, R. M. and P. J. Hickey. Production Well Testing Utilizing a Mass Flow Meter.
Paper pres. at the 62nd Annual Fall Meeting of the Soc. of Pet. Eng., Dallas, TX,Sept. 27-30,
1987. SPE paper 16882.
2. Hohn, P. P. and F. R. Morton. Capacitance Water-Cut Probe Utilization in the Kern
River Field. Paper pres. at the Soc. of Pet. Eng., California Regional Meeting, Bakersfield, CA,
Apr. 5-7, 1989. SPE paper 18780.
3. Christianson, B. A. and E. L. Berger. San Ardo Field Production Testing System
upgrade. Paper pres. at the Soc. Pet Eng. International Thermal Operations Symp., Bakersfield,
CA, Feb. 7-8, 1991. SPE paper 21533.
4. Sivalls, C. R. Crude Oil Treating Systems Design Manual, Technical Bulletin No. 166,
Rev. 2. Sivalls Inc., Odessa, TX, September 1986.
5 , Smith, W. V. and K. E. Arnold, Crude Oil Emulsions, Chapter 19 in Petroleum
Engineering Handbook. Edited by H. B. Bradley, Soc. of Pet. Eng., ~ichkdson,TX, 1987, pp.
19-1 to 19-34.
6 . Strome, R. K. and K. P. Beal. Heavy Oil Dehydration Facility Retrofitted With
Computer. Paper pres. at the Soc. of Pet. Eng. International Thermal Operations Symp.,
Bakersfield, CA, Feb. 7-8, 1991. SPE paper 21535.
7. Shore, R A. The Kern River SCAN Automation System-Sample Control and Alarm
Network. Paper pres. at the Soc. of Pet. Eng., California Regional Meeting, Bakersfield, CA,
Nov. 8- 10, 1972. SPE paper 4173.
8. Jentsch, W. A. and R. D. Marrs. Computerized Automation of Oilfield Production
Operations: An Extensive Five Year Study Into the Costs and Benefits. Paper pres. at the Soc. of
Pet. Eng., 61st Annual Fall Meeting, New Orleans, LA, Oct. 5-8, 1986. SPE paper 15392.
 APPENDIX 16-A
STEAM INJECTION PRODUCTION FACILITIES VENDORS
A. Surface Production Equipment Vendors
NATCO, A Division of
National Tank Company
Brookhollow Central ID,Suite 750
2950 N. Loop West
Houston, TX 77092
Telephone: (7 13) 683-9292
Sivalls Inc.
2200 E. 2nd Street
P.O.Box 2792
Odessa, TX 79760
Telephone: (9 15) 337-2624
Modular Production Equipment Inc.
P.O.Box 690965
Houston, TX 77269-0965
Telephone: (7 13) 320-8796
Daniel En-Fab Systems Inc.
3905 Jensen Drive
P.O.Box 21361
Houston, TX 77226-1361
Telephone: (7 13) 224-7937
B . Automatic Well Test (AWT) Svstem
1 . Petroleum Automation Systems Inc.
325 S. Hale Avenue
Fullerton, CA 92631
Telephone: (7 14) 773-4040
 CHAPTER 17
STEAM INJECTION PROJECT PERFORMANCE MONITORING TOOLS

INTRODUCTION
The cost-effective operation of a steam injection project will require diligent monitoring. The
performance of an individual well and surface equipment, especially the steam generator, must be
constantly monitored and appropriate action taken when problems arise in order to reduce operation
and maintenance costs.
Fuel, labor, and supplies make up more than 50% of the steam injection project's operating
expenses. Hence, constant monitoring and control of these costs are crucial to the economics of
the operation. In a typical steam injection project, approximately 30% of the produced oil is
consumed to generate steam. Any improvement in the steam generator thermal efficiency would
reduce total fuel use and increase the operating revenues. For example, the fuel requirements of an
oil-fired 50 MM Btulhr steam generator can be reduced by roughly 5,300 bbYyr by a 5% increase
in thermal efficiency. This would result in an increase of over $63,00O/yr in operating revenues at
an oil price of $12.00/bbl. Thermal efficiency of the steam generator can be improved by
monitoring and controlling the excess oxygen used in the combustion process and the flue gas exit
temperature. In addition, fuel requirements can be reduced by optimizing the steam injection rate to
an individual well pattern. When carefully monitoring the steam injection profde and the casing
gas production, the operator can optimize the injection rate.
Apart from the water treatment and steam generation costs, a steam injection project will incur
numerous other expenses such as those associated with the operation and maintenance of surface
production facilities, servicing of the wells, disposal of produced waters, and steamflood
monitoring. These expenses are by no means minor and must be carefully monitored and
controlled to improve the project's operating margins. The operational costs can be lowered by
fine tuning the performance of all field facilities.
Monitoring tools and procedures provide the data necessary for optimizing project
performance. These include the acquisition of physical data such as pressure, temperature, flow
rate, and fluid volumes as well as economic data such as fuel usage rate and itemized costs of
operating the surface facilities. The performance data must be made available to the field personnel
on a predetermined time schedule so that corrective actions can be taken to improve equipment
performance. The economic data must also be made available to the engineering staff and
management so that informed decisions can be made.
Several steam injection operation monitoring tools have evolved over the years and can be
broadly grouped into two categories: (1) physical data monitoring tools and (2) economic data
monitoring tools. Examples of physical data monitoring tools include an automatic well testing
system, steam generator fuel usage report, water treatment plant throughput, and electrical power
consumption. Examples of economic data monitoring tools include surface facility operational cost
reports and capital equipment replacement cost reports Following is a brief discussion of various
steam injection operation monitoring tools.

Physical Data Monitoring Tools

Automated Well Testing
The automatic well test units (AWT) are an important steamflood performance monitoring
tool. Data obtained from these units are utilized as the number one diagnostic tool to determine the
changes in reservoir characteristics and to establish well workover needs. 'These data are also
utilized in many instances to gauge the technical and economic success of a steam injection project.
Though simple in concept, the operation and maintenance of an AWT unit is expensive and
requires the service of an impressive number of technicians and field personnel.

Steam Generator Fuel Usage Report

Steam injection operations are energy intensive, and fuel costs account for more than 50% of
operation and maintenance expenses. In many areas, lease crude is burned to generate steam. This
reduces the volume of fuel available for sale. Hence, close control of fuel usage is critical to the
economics of an operation. For these reasons, a daily report of fuel use should be a part of every
steam injection operation. This report should contain not only the amount of fuel (in equivalent
barrels of fuel oil) burned the previous day, but also the volume of fuel consumed at each generator
site and the fuel objective for that day. This report must be distributed to the operating personnel
on time so that appropriate actions can be taken to correct or improve their operations.

Steam Distribution-Steam Injection Rates

Since steam usage and hence fuel consumption can be lowered by optimizing the steam
injection rate to an individual pattern, an accurate log showing the volume of steam injected into
each well should be maintained. This log should include weekly steam intake by each injection
well and should list any injectivity problems. The rate of steam injection into each well should be
calculated periodically from pressure readings taken on a similar time schedule. This steam usage
report should then be distributed to the appropriate operating and engineering personnel so that any
identified problems can be corrected.

Water Treatment System

The successful operation of a steam injection project depends primarily upon a trouble-free
water treating system. Field experience indicates that most steamer downtime is caused by water
treating problems. Hence, the water treatment facility must be closely monitored and any

393
operational problems reported on a daily basis. A daily report of plant throughput volumes should
be prepared with appropriate comments regarding the operation of the plant during the preceding
24-hr period. Also, as in the case of fuel usage report, it should be prepared and distributed to the
operating personnel on time.

Electric Power Consumption Report

Next to the cost of the fuel used for steam generation, the single la-gest operating expense in
steam injection operation is the purchase or onsite generation of electric power. The electric
requirements of individual equipment must be carefully monitored and actions taken to optimize
electrical power consumption. Metering equipment must be installed at various points of use and
periodic reports on electric power consumption be prepared. This report must then be distributed
to the appropriate personnel so the operator can recognize the affects of his activities on electrical
costs.

Comments on Phvsical Data Monitoring Tools

Steam injection operations are field specific and each field will require a different set of
operating reports. The examples cited in the previous paragraphs are intended to provide a guide
as to the type of report that has been found most useful in steam injection operations. Other
examples of reports of value to the operating personnel may include: (1)flue gas analysis and flue
gas temperature monitoring reports, (2) oil dehydration facility upset report, etc. However, before
embarking upon the preparation of a new report, the purpose of the report and its value to the
operating personnel should be given careful consideration.

Economic Data Monitoring Tools

Once the physical parameters affecting the performance of a steam injection operation have
been identified and optimized, action must be taken to reduce operation and maintenance expenses.
The economic optimization begins with a break down of field activities into their primary functions
and the cost of performing each activity. The operating expenses associated with each task is
usually presented as fuel and non-fuel expenses. The non-fuel expenses include: (1) employee
wages and benefits, (2) cost of contractor supplied services, (3) materials and supplies expense,
(4) utilities, and (5) overhead expenses. Fuel expenses include both, cost of purchase and storage.
The operating expenses must be presented to the operating personnel as unit costs. For
example, the water treatment plant operation expense should be reported as $/bbl of softened water
and the production gathering expense as $/bbl of gross fluid produced. Presenting operating
expenses to field personnel in such a fashion enables them to make informed decisions. Examples
of this might include the decision to use an additional amount of chemical emulsion breaker and
thereby reduce the heater-treater fuel requirements. This not only allows the operating personnel to
forecast the effect of such a change, but also enables them to pinpoint the success or failure of this
change in operations. The operating expense report also allows the performance of 'what-if
calculations and forecasts the effect of physical and operating parameter changes on operating
expenses under various scenarios.

Monitoring Capital Expenses

The equipment associated with the steam injection operation is mechanical in nature and as
such, will wear out with use and require replacement. Also, advances in technology render certain
equipment obsolete and therefore it must be replaced. Capital money must be used to replace the
worn out or obsolete equipment. Periodical reports on the physical condition and the cost of
maintenance for each piece of equipment must be prepaed and presented to personnel responsible
for capital expenditures. Such a tool not only allows management personnel to make informed
decisions, but also monitors the success of their activities.
Since the expenditure of capital funds for either maintenance or expansion, usually involves
the coordination of the installation or construction of several pieces of equipment, it frequently
becomes difficult to determine which activities are proceeding on schedule, which are behind, and
which are ahead of schedule. Since current expenditures are often a good indicator of activity,
monitoring of capital expenditures on a monthly basis can be an effective tool for project planners
and designers. By reviewing this report, the activities showing higher than projected expenses can
be given a closer look and corrective action taken.

Monitoring Tools Improvement

A well designed monitoring tool allows the operational personnel to better understand the
effects of their decisions and actions on their own operation, as well as the interactions of their
operations with other activities. However, no tool is perfect, and there is always room for
improvement. Monitoring tools can be improved and made more useful by incorporating the user
recommended changes. Since the recommendations for improvement in monitoring tools must
come from those individuals directly involved in day-to-day field operations, management should
ensure that effective communicationsexist at all levels of operation.

GENERAL REFERENCE
Dever, R. E. and F. A. Womack: Production Data Reporting and How It Aids Surveillance in
Thermal Recovery Fields. Pres. at the 1983 California Regional Meeting of the Soc. Pet.
Eng., Ventura, California, Mar. 23-25, 1983. Paper SPE 11683.
 CHAPTER 18
ENVIRONMENTAL ISSUES

INTRODUCTION
In recent years, steam injection operators have been faced with increasingly stringent
environmental regulations which are oriented towards preventing or ameliorating significant
degradation of air and water quality and land use. These environmental laws and regulations
significantly impact the design and operation of steam injection processes. Federal, state, and local
agencies are all involved in the enactment and implementation of various environmental laws and
regulations. Although the laws and government agencies that administer the environmental
programs differ from state to state, the overall pattern of administering these laws is uniform
throughout the country.
Prospective steam injection operators are required to obtain necessary environmental permits
before an operation can begin. These permits require operators to monitor the environmental
conditions of their operations, keep certain records, and report periodically to the enforcing
agency. Violation of environmental regulations will result in severe penalties or criminal
convictions. Hence, it is essential that the operators be aware of the essence of these regulations,
so that inadvertent noncompliance with applicable environmental rules and regulations can be
avoided.
The purpose of this chapter is to outline the steps involved in obtaining an environmental
permit and to briefly summarize the environmental laws of relevance to steam injection operations.
Only federal laws are summarized. Since the environmental regulatory and compliance
requirements of the states vary from state to state, they are not discussed. Recently, the U.S.
Department of Energy published an EOR environmental regulation handbook1 detailing state
environmental laws. It is recommended that the prospective operator consult this or other
publications2-5for the requirements of the state where they plan to conduct an operation.

OBTAINING AN ENVIRONMENTAL PERMIT

Before a steam injection operation can begin, an operator must obtain necessary
environmental permits from the federal, state and local agencies to conduct the oeeration. This
section, adapted from reference 1, describes the general procedures for obtaining environmental
permits and offers some general pointers about post-construction compliance and enforcement

1.1 Obtaining an Environmental Permit

Step 1. Define Operation
 The specific type of operation planned will determine which permits will be needed, and how
much time should be allowed from project conception to actual operation. For example, a chemical
recovery process may involve handling, use, and disposal of chemicals that are very strictly
regulated. A thermal recovery project, on the other hand, will have little or no solid waste to
dispose of, but will generate significant amounts of air pollution. The more precisely one can
define the project at the start (e.g., which chemicals will be used; what size compressor will be
needed) the better one can focus on the relevant laws and permits.
Step 2. Identify the Facility Sik
Because environmental laws are designed to protect the quality of the environment and
because environmental conditions vary from place to place, the permits needed and the conditions
for obtaining them will depend on the site chosen. If several alternative sites, or a general area has
been defined, environmental conditions and permit requirements should be used as criteria for
selecting a specific site. An operation that is unacceptable at one site may be acceptable at another
site only a short distance away. Air quality, for example, can be extremely variable.
Step 3. Survey Environmental Conditions at the andidate Sitels)
A quick survey of environmental conditions should identify critical problem areas before any
substantial investments are made. The types of information to look for at this time include general
descriptions of air and water quality, hydrological factors affecting injection for reservoir pressure
maintenance andlor waste disposal, special topographic features (e.g., wetlands, floodplains),
special land areas in the vicinity (e.g., natural preserves, federally-owned lands), and similar
characteristics that might entail extraordinary environmental standards or permit procedures.
Step 4. Tdentifv the Required Permits
Steps 1-3 may not actually occur in sequence. Rather, they are three of the elements in the
environmental evaluation of site and operational feasibility. Once a site or small number of sites
have been chosen and the operating mode determined, the required permits can be identified. This
chapter will be useful as a starting point for this step, but it will be important to verify current
requirements with the regulatory agencies before proceeding further. The following considerations
should be kept in mind when identifying the required permits.
Review potential requirements for every aspect of the operation that "pollutes" or
modifies the natural environment: air pollution (including on-site storage of oil or
volatile chemicals), wastewater streams, anything injected into a well for either
production or waste disposal, surface and subsurface construction, and surface
transport (trucks and roads, pipelines). Some details (e.g., roads) may not be covered
by state or federal law but will probably be subject to municipal or county permits.
Review both federal and state requirements. An operator may even need permits from
both the federal and state governments for the same discharge. If the facility site is on
 federal lands, the permit requirements established for that area by the agency in charge
should be identified, in addition to the general environmental laws described in this
handbook.
Step 5. Establish Direct Contact with the Pernittin? A~encies
Early contact with the agencies responsible for granting permits has several benefits:
1. The latest requirements and any pending regulatory changes are immediately available.
2. Clarification of confusing requirements and direct verification as to whether or not a
permit is needed.
3. Immediate help is available for determining requirements of specific application forms.
4. "Good faith" can be established in complying with agency rules.
5 . Personal contacts can help smooth out any administrative problems.
6 . Avoids surprises of requirements not clearly spelled out in a specific law.
7. A facility can be described in favorable terms before opposing entities contact the
agency.
8. Plans can be changed early on if modifications are necessary to avoid unattainable
requirements or if newly promulgated regulations have to be met
Step. 6. Identi the Environmental. Engineering. or Other Needed Studies
Very close attention should be given to the information required to obtain each permit. A
common frustration experienced by many permit applicants is to be told by an agency, at the last
minute, that they need to undertake an environmental study to answer a particular question.
Careful reading of permit applications and discussions with agency staff should enable
environmental requirements to be identified early in the process so the project will not be delayed.
Step 7.
For some facilities, the environmental studies will take one or two years to complete. A case
in point for steam injection facilities is ambient air quality monitoring. The U.S. EPA requires a
full year of monitoring data for a pre-construction permit application, which means that planning
for monitoring must begin about two years before the expected date for starting construction.
Step 8. Complete the Permit Applications
Once all required information has been collected, the application forms can be completed.
Usually, there is no advantage in filing applications far in advance of the deadline; in fact, some
permits become invalid if they are not "used" within a certain time. On the other hand, if the
expected review time is, for example, 6 months, submitting the application 9 to 12 months before
construction will provide a cushion for bureaucratic delay and negotiation of disputed terms or
appeals from adverse agency decisions.
Step 9. Stav in Touch With the Agency
By staying in touch periodically with the person assigned to review your application, the
operator keeps attention on the application and shows the agency genuine interest in compliance
and desire to avoid time delays. Periodic contact is also the best way to uncover any disputed
issues, while there is still time to resolve them by supplying more information or by negotiation. It
is important to maintain records of telephone calls, meetings, and correspondenceit may be
advantageous if then is opposition to the proposed facility, either inside or outside the agency.
Step 10. Take Advantw of Procedu-~hts
The typical agency procedure for reviewing and deciding on a pennit application is as
follows:
1. Application submitted.
2, Application reviewed for completeness; applicant notified if application is complete or if
more information is required.
3. Agency makes a tentative (or proposed) decision to grant or deny permit, or to grant it
under certain conditions.
4. Agency gives public notice of its tentative decision (including notice to the applicant).
Some types of pennits require specific notice to adjacent property owners.
5 . On request, agency holds a public hearing to hear the comments and criticisms of the
applicant and any project supporters or opponents.
6. Agency reviews written comments and remarks made at hearing and reaches a final
decision.
7 . Agency notified applicant and other interested parties of fmal decision.
8 . Within a certain time after the final decision, any interested party (including the
applicant) can appeal the agency decision through an established administrative appeal
process.
9. Appeals board (commission, examiner, etc.) conducts hearing (usually like a trial) and
upholds or overturns any agency decision.
10, Finally, parties may take their case to state or federal court to seek "judicial review" of
the final decision after appeal.
The permit applicant has the same rights as any other person to request hearings, appeal
agency decisions, or seek judicial review by the courts. If one believes the agency misunderstands
the project, misinterprets the law, or is providing unfair treatment, then procedural rights should be
used as a counter measure. In many systems the right to appeal, or the right to judicial review,
depends on utilizing early opportunities to to resolve a specific point.
1.2 Compliance and Enforcement
Theoretically, compliance with environmental regulations is a simple matter. The permit
received will specify the operating standards to be achieved and any other conditions, limitations,
or requirements. As long as one abides by the permit, compliance is achieved. In the real world,
however, a number of common problems and questions arise that can be answered generally for all
states and the federal agencies.

1.2.1 Compliance
osets. Equipment Failure. Etc.
Most environmental laws impose "strict liability" on the facility, which means that the
government is legally justified in penalizing every violation, regardless of size or fault.
Permits may or may not expressly provide for minor violations due to occasional situations.
If a permit does not make any provision, the general administrative practice is to excuse occasional
violations due to circumstances beyond the operator's reasonable control. However, if negligence
contributed to the violation or if a facility has a record of problems, enforcement will probably be
stricter.

Chawes in the Facility or Its Omration

Generally, a permit to construct, discharge, or operate is specific to the location, facility
design, and method of operation identified in the pexmit application. Any signifcant changes from
the operation so described will probably require a modification of the permit or a completely new
permit, unless the level of discharge is being reduced. The permit or the specific procedural rules
of the agency may also specify when notice is to be given to the agency of any changes in the
facility or its operation. Relocation of the facility also usually requires a new permit.

Chan~esin Laws and Reeulatio~

Permits will generally insulate operators from changes in the "rules of the game." There are
several important exceptions to this general statement, however. Foremost is the fact that most
permits are issued for fixed periods (5 years is common). At the end of that period, the operator
must apply for a permit renewal, and the agencies may use that opportunity to introduce any new
legal requirements. Most permit programs also allow the permit to be revoked or modified at any
time for various specified reasons. For example, a wastewater discharge containing toxic
compounds is subject at any time to new controls on the toxics. Frequent violation of the permit is
normally grounds for revoking it.
1.2.2 Enforcement
Monitoring. Recordkeepin?. and Reporting
More often than not, a permit will require monitoring of environmental conditions, the
keeping of certain records, and periodic reporting to the agency. The U.S. EPA and most state
agencies take these requirements seriously, because they rely on self-monitoring and self-reporting
to identify trouble spots. The few criminal convictions that EPA has obtained for violation of
environmental laws have involved failures to report activities, falsification of monitoring data, and
similar infractions. Close adherence to these requirements will stand an operator in good stead if
involved in more substantial problems with the agency.

A special reporting requirement in the Clean Water Act applies to spills of oil or hazardous
substances. Most states have a similar law. Under federal law, any spill of oil (or any spill above
specified amounts of over 300 listed substances) that reaches or may reach surface water must be
reported immediately after it is discovered to the EPA or to the Coast Guard. The source of the
spill will be liable for a moderate penalty ($500 - $5,000) in addition to all costs of clean-up or
containment.

Inspections
Virtually every environmental law authorizes state or federal officials to inspect a facility and
owner's operation records during business hours. (They are also authorized to enter a facility at
any time to take emergency measures to protect the environment or the public health.) Although
the Supreme Court has ruled that OSHA inspections cannot be conducted against the owner's will
without a warrant, the decision may not apply to environmental laws. In any case, such warrants
will be routinely issued because of the broad authority granted to these agencies.

Enforcement Against Violations: Penalties

The environmental laws usually allow an agency to choose between suing a violator
immediately in court and issuing some type of administrative order to the violator to correct a
violation. In practice, agencies almost always use the administrative order approach, if only
because litigation is timeconsuming and expensive. In fact, many agencies prefer to use informal
negotiations rather than formal orders to obtain compliance. This is especially true at the state
level; as a rule, EPA prefers the formal approach.
For minor violations, the agencies usually seek simply to have the problem corrected. More
significant violations, or repeated violations, will probably also result in a civil penalty. A civil
penalty, which the agency can collect just by proving the violation, is designed to compensate for
the environmental damage that occurred. It carries no implication that the source acted criminally;
criminal penalties are separately authorized and can be imposed only after a court conviction.
The statutes often authorize enormous civil penalties, such as $25,000 per day. However,
penalties of that size are reserved for the largest corporations and the worst violations. More
routinely, penalties for small facilities will vary from about $500 to almost $10,000 for the entire
violation, depending on how long it lasted, how serious the environmental harm was, and how
much money the violator saved by allowing the violation to occur. The compliance record of the
violator, his efforts to correct the violation, and his general attitude toward the agency will also
influence the amount of the penalty. If one feels strongly that the amount of the penalty that the
agency is asking for is too high, the whole case can be brought to court where the judge sets the
penalty.
Final authority for all enforcement matters lies with the courts. If in disagreement with an
agency about whether a violation occurred, about the corrective measures to prevent further
violations, or about the penalties or other sanctions they seek, the matter may be brought to court to
be decided by a judge or a jury, as the case may be. The agency usually has the choice of going
directly to the court without providing advanced notification to the violator.
In order to answer correctly the questions in the permit application, a prospective thermal
EOR operator should be aware of the essence of the environmental rules and regulations of
relevance to his project The following sections briefly summarize the major federal environmental
laws and regulations of relevance to thermal operations.
Major Laws
The environmental laws that have the greatest impact on steam injection processes pertain to
air quality, water quality, hazardous wastes and environmental quality. Following is a list of major
federal laws that have relevance to steam injection processes.
Air Quality -Clean Air Act and Amendments
Water Quality -Clean Water Act and Safe Drinking Water Act
Hazardous Wastes -Resource Conservation and Recovery Act (RCRA)
Environmental Quality -National Environmental Policy Act (NEPA)

Federal Regulatory Framework

The federal environmental policy is formulated by codifying a variety of public laws and acts.
Any new program enacted by congress is called an act. Acts are amended through the enactment of
public laws. A public law may include amendments to several acts.
The environmental statutes, whether an act or a public law, are periodically published as
United States Codes (USC). The USC is organized into different titles. For example, statutes
pertaining to clean air act can be found in Title 42, Sections 740 1 and the following (42 USC 7401
et seq.). Regulations promulgated by federal agencies are initially published in the Federal
Register (FR). The final versions of the regulations are then incorporated into the Code of Federal
Regulations (CFR). The CFR is updated quarterly and published in its entirety annually. Since
regulations take effect as soon as the final version appears in the FR,a person cannot be sure of
full regulatory compliance by reviewing the current edition of the CFR. Regulations pertaining to
the environmental area can be found in the Title 40 of CFR,

Enforcement Agencies
The environmental regulations are enforced by a number of agencies. At the federal level, the
U.S. Environmental Protection Agency (EPA) is entrusted with enforcing laws dealing with air
quality, water quality, hazardous wastes, and hazardous materials. At the state level, many
different agencies are involved with implementing and enforcing laws pertaining to different
environmental areas. The State EOR environmental regulatory agencies are shown in Table 18.1.
The agency jurisdiction may sometimes overlap. As an illustration, a summary of different
agencies and their principal area of authority in California are outlined.
Air Resources Board (ARB)
The ARB is a state agency whose primary responsibility is to coordinate the state-wide air
quality programs. It is also responsible for implementing programs designed to attain the state and
national ambient air quality standards. In addition, this agency supervises the overall scheme to
control toxic air pollutants and conducts research on various air quality matters.
Air Pollution Control and Air Quality Manalrement Districts (APCD/AQMD)
These are county or multi-county agencies responsible for implementing the state air quality
laws pertaining to stationary sources of air pollution. There are 34 single county APCDs, five
multi-county APCDs, and three AQMDs.
State Water Resources Control Board (SWRCB)
Like ARB, SWRCB is a state agency whose primary function is to coordinate the state's
water quality program. The SWRCB has the authority to regulate the discharge of wastes to land
and injection of toxic waste to wells.
Rerional Water Qualitv Control Boards (RWOCB)
RWQCB is a regional agency responsible for administering the state's water quality program
within the region. It also has the authority to develop water quality control plans, issue of waste
discharge permits, and regulate waste disposal sites. The state is divided into nine RWQCBs.
De~artmentof Health Services (DHS)
DHS is a state agency entrusted with implementing the state's hazardous waste laws and
regulations including hazardous waste facility permitting.
 TABLE 18.1 - State EOR Environmental Regulatory ~genciesl

Underground
Oil & Gas Boardl Water Quality Injection Hazardous
State CommissionlDivision Air Quality (NPDES & Class I Wells) (Class I1 Wells) Waste

Alabama State Oil & Gas Board Air Division Water Division State Oil & Gas Board Land Division
420 Hackberry Lane Dept. of Envira. Mgt. Dept. of Environ. Mgt. 420 Hackberry Lane Dept. of Envirn. Mgt.
P.O. Drawer 0 1751 Congressman 1751 Congressman P.O. Drawer 0 1751 Congressman
Tuscaloosa, AL 35486 WL Dickenson Dr. WL Dickenson Dr. Tuscaloosa, AL 35486 WL Dickenson Dr.
2051349-2852 Montgomery, AL 36130 Montgomery, AL 36130 2051349-2852 Montgomery, AL 36130
2051271-7700 2051271-7700 205/271/7700

California Division of Oil & Gas Air Resources Board Water Resources Control Board Division of Oil & Gas Toxic Substances
Dept. of Conservation 1102 Q Street 901 P Street Dept. of Conservation Control Division
1416 Ninth St., Rm 1310 P.O. Box 2815 Sacramento, CA 95814 1416 Ninth St., Rrn 1310 Dept. of Health Services
Sacramento, CA 95814 Sacramento, CA 95812 9161445-3993 Sacramento, CA 95814 400 P Street
9161445-9686 9161322-2990 916/445-9686 Sacramento, CA 95814
9161324-7193
P.
0
Colorado Oil & Gas Conservation Div. Air Pollution Water Quality Control Div. Oil & Gas Conservation Div. Waste Management
Dept. of Natural Resources Control Division Colorado Dept. of Health Dept. of Natural Resources Colorado Dept. of Health
1580 Logan St., Suite 380 Colorado Dept. of Health 4210 East 1 1 th Avenue 1580 Logan St., Suite 380 4210 E. 1 ltb Ave.
Denver, CO 80203 4210 E. 11th Ave. Denver, CO 80220 Denver, CO 80203 Denver, CO 80203
303/894-2100 Denver, CO 80220 303133 1-4530 3031894-2100 303133 1-4830
3031331-8500

Illinois Oil & Gas Division Div. of Air Pollution Water Pollution Control Board Oil & Gas Division Oil & Gas Division
Dept. of Mines & Minerals 2200 Churchill Road 2200 Churchill Road Dept. of Mines & Minerals Dept. of Mines & Mincrals
300 W.Jefferson, #300 Springfield, IL 62706 Springfield, IL 62706 300 W. Jefferson, #300 300 W. Jefferson, #300
Springfield, it 62706 2171782-7326 2171782-1696 Springfield. IL 62706 Springfield, IL 62706
2171782-7756 2171782-7756 21 71782-7756

Kansas Conservation Division Bureau of Air & Waste Mgt. Conservation Division Conservation Division Bureau of Air & Waste Mgt.
Kansas Corp. Commission Dept. of Health & Envirnment Kansas Corp. Commission Kansas Corp. Commission Dept. of Health & Envir.
200 Colorado Bldg. Forbes Field, Bldg. 740 200 Colorado Sldg. 200 Colorado Bldg. Forbes Field, Bldg. 740
202 W. 1st Street Topeka, KS 66620-0002 202 W.1st Street 202 W. 1st Street Topeka, KS 66620-7202
Wichita, KS 67202-1286 9131296-1570 Wichita, KS 67202-1286 Wichita. KS 67202-1286 9131296-1600
316/263-3238 3161263-323s 3141263-3238
 TABLE 18.1 - State EOR Environmental Regulatory ~genciesl--Continued

Underground
Oil & Gas Boardl Water Quality Injection Hazardous
State CommissionlDivision Air Quality (NPDES & Class I Wells) (Class I1 Wells) Waste

Louisiana Office of Conservation Air Quality Division Office of Water Resources Office of Conservation Hazardous Waste Division
Dept. of Natural Resources Dept. of Envir. Quality Dept. of Envir. Quality Dept. of Natural Resources Environmental Quality
P.O. Box 94275 P.O. Box 82135 P.O. Box 82215 P.O. Box 94275 P.O. Box 82178
Baton Rouge, LA 70804-9725 Bluebonnet Blvd. Bluebonnet Blvd. Baton Rouge, LA 70804-9725 Baton Rouge, LA
5041342-55 15 Baton Rouge, LA 70884-2135 Baton Rouge, LA 70884-2215 504/342-5515 70884-2178
5041765-0219 5041765-0634 5041765-0634

Michigan Geological Survey Division Permit Section Surface Water Quality Div. Geological Survey Div. Waste Mgmt. Div.
Dept. of Natural Resources Air Quality Division Dept. of Natural Resources Dept. of Natural Resources Dept. of Natural Resources
P.O. Box 30028 Dept. of Natural Resources P.O. Box 30028 P.O. Box 30028 P.O. Box 30241
Lansing, MI 48909 P.O. Box 30028 Lansing, MI 48909 Lansing, MI 48909 Lansing, MI 48909
5 171334-6974 Lansing, MI 48909 5171373-8088 5 17/334-6974 5 17/373-2730
5 171373-7023

P
a Mississippi State Oil & Gas Board
500 Greymont Ave., Suite E
Office of Pollution Control
Dept. of Envir. Quality
Office of Pollution Control State Oil & Gas Board State Oil & Gas Board
Dept. of Envir. Quality P.O. Box 1332 P.O. Box 1332
P.O. Box 1332 P.O. Box 10385 P.O. Box 10385 500 Greymont Ave., Suite E 500 Greymont Ave.
Jackson, MS 39201 Jackson, MS 39289-0385 Jackson, MS 39289-0385 Jackson, MS 39201 Suite E
6011354-7142 6011961-5171 6011961-5171 601/354-7142 Jackson, MS 39201
601/354-7142

Montana Oil & Gas Conservation Div. Air Quality Bureau Water Quality Bureau Water Quality Bureau Hazardous Waste Bureau
Natural Resources Bt Dept. of Health & Dept. of Health & Envir. Dept. of Health & Eavir. Dept. of Health &
Conservation Dept. Envir. Services Services Services Envir. Services
2535 St. Jobas Ave. Cogswell Building Cogswell Building Cogswell Building Cogswell Building
Billings, MT 59102 1400 Broadway 1400 Broadway 1400 Broadway 1400 Broadway
4061656-0040 Helena, MT 59620 Helena, MT 59620 Helena, MT 59620 Helena, MT 59620
4061444-3454 4061444-2406 406/444-2406 4061444-2821
 TABLE 18.1 - State EOR Environmental Regulato~y~genciesl--Continued

Underground
Oil & Gas Board/ Water Quality Injection Hazardous
State CommissionIDivision Air Quality (NPDES & Class I Wells) (Class I1 Wells) Waste

Utah Div. of Oil, Gas & Mining Utah Bureau of Air Environmental Health Divisio Div. of Oil, Gas & Mining Div. of Oil, Gas & Mining
Utah Dept. of Natural Resources Quality Control Utah Dept. of Health Utah Dept. of Natural Utah Dept. of Natural
Suite 350, 3 Triad Center UT dept. of Health 1950 W. North Temple Resources Resources
355 W. North Temple P.O. Box 1660 P.O.Box 16690 Suite 350, 3 Triad Center Suite 350, 3 Triad Center
Salt Lake City, UT Salt Lake City, UT Salt Lake City, UT 841 16-0690 355 W. North Temple 355 W. North Temple
84180-1203 84116-0690 8011538-6 146 Salt Lake City, UT Salt Lake City, UT
8011538-5626 8011538-6108 84180-1203 84180-1203
8011538-5340 8011538-5340

Wyoming Oil & Gas Conservation %vision of Air Quality Oil & Gas Conservation Oil & Gas Conservation Hazardous Waste Mgt.
Commission Dept. of Envir. Quality Commission Commission Dept. of Envir. Quality
P.O. Box 2640 122 W. 25th Street P.O.Box 2640 P.O. Box 2640 122 W. 25th Street
777 W. 1st Street Cheyenne, WY 82002 777 W. 1st Street 777 W. 1st Street Cheyenne, WY 82002
P Casper, WY 82602 3071777-739 1 Casper, WY 82602 Casper, WY 82602 3071777-7752
0
4 3071234-7147 307/234-7 147 3071234-7 147
 Normally, the lowest level of government agency is given the authority to implement the
various laws and regulations. For example, the APCD is responsible for enforcing air quality laws
and regulations including issuance of permits for new air pollution source within the district.
However, some districts are permitted to regulate only portions of laws. In such cases, the agency
which retains portions of authority may also be involved, and agency overlaps can occur.
The major federal environmental regulations that impact steam injection operations are briefly
described in the following pages. Other applicable federal regulations of relevance to steam
injection operations are summarized elsewherd-2 The abbreviations used in this chapter are listed
in Table 18.2.
Air quality Regulations Trnpactin~Steam Injection Operations
The federal government plays a leading role in developing a regulatory framework within
which all thermal enhanced oil recovery operators must operate. Federal environmental regulations
and standards supersede all less stringent state and local regulations. State and local
governments, however, do have the authority to promulgate and enforce environmental standards
more stringent than their federal counterparts. For example, State of California's air quality
requirements are more stringent than those stipulated under federal statute. Kern County, CA, has
adopted even more stringent measures to attain and maintain state and national ambient air quality
standards. This section briefly describes, in general terms, the federal air quality regulations to
which the steam injection operators must comply.
The U.S. Environmental Protection Agency (EPA) is the primary agency entrusted with the
responsibility of implementing the Federal Clean Air Act (CAA). The purpose of CAA is to protect
and enhance the air quality and to attain the National Ambient Air Quality Standards (NAAQS).
Under the CAA, each state has the primary responsibility to prepare and submit to the EPA, a State
Implementation Plan (SIP) which details the method by which NAAQS are attained and
maintained. EPA regulations pertaining to air quality can be found at 40 CFR Subchapter C - Air
Programs.
The provisions of CAA that impact steam injection operators are as follows:
National Ambient Air Quality Standards,
National Ambient Air Quality Standards (NAAQS) are the primary guidelines used to
measure the air quality of a region. NAAQS sets the ceilings for which each pollutant may not
exceed. EPA set the NAAQS according to established criteria. These criteria are reviewed at least
once in every 5 years by an independent scientific committee. The air quality standards are set on
the basis of scientific data and analysis only. EPA is not required to consider economic or
technical feasibility in setting air quality standards.
 TABLE 18.2. - Abbreviations Used in Text

APCD Air Pollution Control Dist. (California)

ARB Air Resortrces Board (Calidomia)
AQCR Air Quality Control Region
AQMD Air Quality Management Dist. (California)
BAn Best Available Control Technology
CAA Ciean Air Act (federal)
CCR California Code of Regulations
CFR Code of Federal Regulations
CWA Clean Water Act (federal)
WS Dept. of Health Services (California)
DOG Div. of Oil & Gas [California)
EPA Environmental Protection Agency (federal)
LAER Lowest Achievable Emission Rate
NU@ Natl. Ambient Air Quality Standards
mE
S Natl. Pollutant Discharge Elimination
System
NSPS New-Source Performance Standards
FL' Public Law
F'SD Prevention of Significant Deterioration
RCRA Resource Conservation and Recovery Act
RWQCB Regional Water Quality Control Board
(California)
SDwA Safe Drinking Water Act
SIP State Implementation Plan
SWRCB State Water Resources Control Board
(California)
USC U.S.Code
UIC Underground Injection Control

There are two types of air quality standards: primary and secondary. The object of the
primary standards is to protect the public health, while allowing for ample margin of safety. The
aim of the secondary standard is to specify a level of air quality considered necessary to protect the
public welfare from known or anticipated adverse effects, including the effects on economic values
and personal comfort.
CAA has designated six pollutants as harmful, and standards have been established. These
pollutants include: sulfur dioxide (SO2), nitrogen oxides (NO,), particulates, carbon monoxide
(CO), ozone, and lead. At one time, EPA had adopted NAAQS for hydrocarbons, but these
standards were later rescinded. These standards are implemented through SIPS (CAA, Section
110). Most steam injection operations employ lease crude fired steam generators. These crude oil
fired steam generators emit S@, NOx, and particulates. In addition, oilfield wellheads can emit
hydrocarbons, depending on the degree of control employed.
EPA has designated 247 Air Quality Control Regions (AQCR). Although NAAQS should
not be exceeded in any of the regions, they are not directly enforceable. EPA has set emission
limitations for each pollutant to attain NAAQS. If the actual air pollutant concentration in an air
district exceeds NAAQS, more stringent pollution control devices on the emission source are
imposed to lower the concentration to an appropriate level. EPA has rated the AQCR as either
'clean' or 'nonattainment' for each criteria of pollutant. Nonattainment areas are those areas in
which state and federal ambient air quality standards have not been met for the specified criteria
pollutant. Procedures to bring the nonattainment areas to attainment are implemented by SIPS.
The current national primary and secondary ambient air quality standards are shown in 'Fable 18.3.

TABLE 18.3. - Current National Primary and Secondary Ambient Air Quality Standards
Federal primary Federal secondary
Air contaminant Averaging time standard standard

Nitmgen dioxide1 Annual average

Sulfur dioxide Annual average

24 Hour

3 Hour
1 Hour

Suspended Annual geometric

particulates Mean

Hydrocarbons 3 Hour 160 pg/m3

(corrected for 6-9 AM 2 ( ~ . 2 4ppm)
methane)

1 Hour

8 hour

Carbon monoxide 8 Hour

1 Hour

90 Day
30 Day

Source:
Note: ppm = parts per million
pg/m3= micmgrams per cubic meter
mg/m3 = milligram per cubic meter
l ~ i t m dioxide
p is the only one of the nitrogen oxides considered in the ambient standards.
2 ~ a x i m u m3-hour concentration between 6 and 9 A. M.
 State Im~lementationPlans (SIP) (42 USC 7410. Sec. 110'1
To implement the CAA, states are required to adopt and submit to EPA, a State
Implementation Plan (SIP) detailing with the basic strategies for implementation, maintenance, and
enforcement of NAAQS within the state. SIP forms the blueprint for achieving air quality goals
within a state. The SIP provides the emission limitations, schedules, and time tables for
compliance by stationary sources of air pollution such as oilfield steam generators. EPA must
approve the SIP for each state. SIP should contain measures necessary for achieving the primary
and secondary standards. In setting these measures, the state does not need to consider their
technical or economical feasibility.
SIP must assure attainment of NAAQS by prescribed dates. SIP must meet federal
requirements, but each state may choose its own mix of emissions for stationary and mobile
sources to meet NAAQS. CAA prohibits the adaptation of any SIP without a public hearing, and
the sources affected by SIP are expected to participate. Requirements of SIP are contained in 42
USC,Sections 7407(a) and 7410(a)(l).

Emission Limitations
CAA has developed minimum technological standards for various sources of air pollution.
These sources are divided into two groups: stationary and mobile sources. Since stationary
sources are the originator of pollutant in steam injection operations, only stationary source
standards are outlined here.
In establishing the framework for controlling emissions from stationary sources, CAA makes
a distinction between new and existing sources. Since it is typically less expensive for new
sources to incorporate state-of-the-art control technologies, the regulatory burdens fall more
heavily on the new sources. Existing sources are regulated through SIP. Each state must develop
a standard of performance for existing sources using EPA guidelines. If a state fails to establish
standards or if the state standards are not acceptable to EPA, EPA may promulgate its own
standards.
To control the pollutants from new stationary sources, CAA directs EPA to establish 'New
Source Performance Standards' (NSPS). NSPS reflect the degree of pollution control achievable
through the best available and adequately demonstrated pollution control technique. In selecting
the best available control technology for each pollutant, the EPA must take into account the cost of
achieving such emission reduction and energy requirements.
EPA has delegated the authority to implement and enforce NSPS to various state and local
agencies; although it always retains independent enforcement authority.
 Prevention of Significant Deterioration (PSD) (42 USC 7470 et. seq.)
In 1977, Congress amended the CAA to prevent significant future degradation of the
Nation's clean-air areas. A clean-air area is one where the air quality is better than the ambient
primary or secondary standard. Thus,the purpose of PSD is to "keep clean air clean." To achieve
the stated purpose, states were required to identify, in their SIP, emission limitations and other
measures necessary to prevent significant deterioration of air quality with respect to criteria
pollutants (42 USC, 7473).
To implement this program, CAA divided clean-air areas into three groups. This
classification determines the increment by which S@ and, suspended particulates may be increased
in a given area. In Class I areas, which includes national parks and national wilderness areas, only
a minor air quality degradation is permitted. Class I1 areas, which include regions designated by
states as within national primary and secondary ambient air quality standards, moderate
degradation is permitted. In Class III areas, which include all other regions, substantial air quality
degradation is permitted. In no case does PSD permit air quality to deteriorate below secondary air
quality standards. The permitted air quality increments for PSD are shown in table 18.4.
"Increments" are the maximum amount of deterioration that can occur in a clean-air area over
the baseline. "Baseline" is the existing air quality for the area at the time the f ~ sPSD
t is applied.
Increments in Class I areas are smaller than those for Class II, and Class I1 increments are smaller
than those for Class III areas. For the purpose of PSD,a major emitting source is one which falls
in one of 26 designated categories, and whose potential emission rate is greater than 100 tondyr.
Fossil fuel fired steam generators, which are greater than 250 MM BTUfhr heat input are in the
PSD designated categories. In addition to the 26 PSD designated categories, there is an additional
"catchall" category designated as a major pollutant source-if it emits more than 250 tonsfyr of
designated pollutant. PSD defines the potential emission rate as the rate to be expected without air
pollution control equipment.
Steam injection operations are a significant potential source of sulfur dioxide, nitrogen
oxides, and particulates (assuming clustering of boilers). Most pollutants are emitted from crude
oil fired steam generators. Most oil field steam generators used in steam injection operation are
smaller than 250 MM BTU/hr size and hence fall within the catchall category. These generators
will be subject to PSD review if their potential emission rate exceeds 250 tondyr. The typical
emissions from oil fired steam generators of different sizes burning 1.09% sulfur fuel, are given in
Table 18.5. It can be seen that a steam injection operator with two generators would be subject to
PSD for SO3
 TABLE 18.4. - Permitted Air-Quality Increments for Prevention of Significant Deterioration
Averaging

Pollutant Time Class I Class I? Class III

Totd suspended particulate 1 Year 5 19 37

24 hours 10 37 75
Lead 3 months None None None
so, 1 Ye= 2 20 40
24 hours 5 91 182
3 hours 25 512 700
NO, 1 Year None None None
CO 8 hours None None None
1 hour None None None
Ozone 1 hour None None None

TABLE 18.5 - Typical Emissions From an Oil-Fired Steam Generator

Typical Typical
Approximate daily fuel yearly operating Emissions Emissions
rated output consumption schedule (lblbblfudl) (towearl
(lo6 Btuhr) (bbVday) (days) so21 Nq2 Particulate HC soZ1NO2 Particulate HC

~ of fuel containing 1.09 wt % sulfur.

l ~ s s u r n i nuse

Nonattainment Areas (NAA) (42 USC 7501 et. seq.)

Nonattainment areas are those areas in which the state and federal ambient air quality
standards have not been met for the specified criteria pollutant. For these areas, the SIPS must
include plans to cleanup existing sources of emissions in order to achieve attainment. New
construction in a NAA is prohibited unless SIP has been amended and approved by EPA. Sources
wishing to locate in nonattainment areas must meet the following conditions:
a. Must show that the project will result in net air quality benefits.
b. Must comply with the "lowest achievable emission rate" (LAER). LAER is a type of
emission rate which reflects the control technology available and the emission limits required by
law.
c. Demonstrate that all other sources owned by the applicant within the state are in
compliance wit! all applicable emission limitations and standards.
 d. Obtain emission offsets to achieve a net reduction in emissions. An offset refers to the
amount by which other sources must reduce their emissions to allow for the amount to be produced
by the new source; thus, making room for development.
To permit future new source construction in NAA, EPA allows existing source to bank
offsets. A banked offset can be sold or traded to other sources.

Best Available Control Technology (BACT)

for Steam Injection Operation Pollutants
Steam injection operations subjected to PSD regulations must employ the best available
control technology to achieve maximum degree of reduction with respect to a particular source of
pollutants. BACT is a pollution control technique defined for categories of equipment and takes
into account energy and environmental and economic impacts along with other costs.
From a practical point of view, BACT can be a costly issue when permitting a new project.
Since BACT is defined for categories of equipment, a district imposed BACT for a particular
equipment may not have been previously tried. Even if proven in practice, BACT technology is
often costly. In California BACT requirements vary with districts.
The BACI' for the major steam injection operation related pollutants are as follows:
(a) BACTfor.SQ.l.
The EPA approved BACT for the control of SO2 from oil fired steam generator is fuel oil
containing less than 0.05% by weight sulfur, or the equivalent rate achieved by scrubbing.
(b) BACT for NOx
For N 4 , the EPA is requiring a case-by-case analysis. It maintains that BACT, at a
minimum, shall be a modification of burner that will result in the least amount of oxygen to be
consumed for combustion. California steam injection operators frequently utilize low NO, burners
to control NOx emissions.
(c) I3 ACT for Particulate Matter
BACT for particulate matter has not been defined. EPA maintains that SO2 scrubbers should
satisfy the BACT requirements for particulates. This is because the SO2 scrubbers, although
primarily designed for SO;! removal, also remove a small percentage of particulate matter.
Particulate matter emissions from oilfield steam generators are small, and it would take an
average of nine or more 50 MM BTU/hr units to produce more than 250 tondyr.

Lowest Achievable Emission Rate (LALTIC)

Steam injection operators wishing to locate in nonattainment areas must comply with 'lowest
achievable emission rate" (LAER). LAER for a particular pollutant is the most stringent emission
limit for the pollutant contained in the SIP'S of the U.S. In no instance can the LAER be permitted
to be less stringent than the amount allowed under an applicable new source performance standard.
Unlike BACT, the LAER does not permit cost effectiveness to be taken into consideration. Thus,
LAER is more stringent than BACT.
The LAER for an oil fired steam generator is considered to be 0.05 wt % sulfur in fuel or the
equivalent rate achieved by scrubbing. This is based on technology achievable in practice for these
types of sources. LAER, however, h a changing thing and must reflect the advances in
technology and SIP'S requirement. As SIP requirements change and become more stringent,
LAER must reflect such changes. Similarly, as scrubber technology advances, LAER must also
reflect such changes.

The Clean Air Act (CAA) Amendments of 1990

The CAA amendments of 1990, signed into law on November 15, 1990, is the fust major
revision of the CAA since 1977. The act addresses several problems encountered in the 35-year
history of the CAA. The 1990 amendments had made several significant changes to the NAAQS
and revised the nonattainment programs. The revision contains new requirements that an area must
meet before it can qualify as an attainment on unclassifiable area with respect to ozone, carbon
monoxide, and particulate matters. The area classification provisions of the 1990 amendment. is
expected to result in redesignation of many currently attainment areas as nonattainment areas. The
impact of 1990 CAA amendments on steam injection project sittings and operations will not
become clear until well into the 90s, but is expected to be minimal. The salient features of the 1990
CAA amendments are summarized in reference 3.

Water Quality Regulations Impacting Steam Injection Operations

This section summarizes the major water quality laws impacting steam injection operations.
These include Clean Water Act (CWA), Safe Drinking Water Act (SDWA) and Underground
Injection Control (UIC) Program, Toxic Substances Control Act (TSCA), Spill Prevention
Regulations and regulations governing the handling, storage, and disposal practices of oilfield
waste waters.
Federal Clean Water Act (CWA)
The objective of CWA is to restore and maintain the chemical, physical, and biological
integrity of the Nation's water. EPA has nationwide authority to implement CWA, including the
promulgation of regulations.
To achieve its stated objectives, CWA has set effluent standards to limit discharges from
point and nonpoint sources and established ambient standards to maintain the quality of surface
waters. The Clean Water Act can be found at 33 USC starting at section 1251. The EPA
regulations are found at 40 CFR Subchapter D -Water Programs.
 Steam injection operation effluent guidelines are enforced through the National Pollution
Discharge Elimination System (NPDES). To receive a discharge permit, a steam injection operator
must comply with all applicable effluent limitations for the particular discharge under steam
injection operations. NPDES are effective for terms not exceeding 5 years. NPDES permit are
issued by EPA or by a state having a certified CWA program.

Safe Drinking Water Act (SDWA)

The SDWA has two primary objectives:
(a) Protection of public water supply system, and
(b) Protection of underground drinking water sources.
To accomplish these objectives, EPA has established:
(a) National Primary Drinking Water Regulations to protect public health (40 CFR,
Part 141), and
(b) State Underground Injection Control (UIC) program regulations (40 CFR, Parts
144-149).
The National Primary Drinking Water Regulations establish maximum contaminant levels for
possible physical, chemical, microbiological, and radiological pollutants in public water systems.
IC Wells
The Underground Injection Control Regulations of SDWA require states to establish UIC
waste disposal programs to prevent underground injection activities which endanger drinking water
resources. Depending on the toxicity of the injected fluids, underground injection wells are
classified as Class I, Class 11, Class m,Class IV,or Class V wells. The definition of these wells
is as follows:
Class I Wells used by generators of hazardous waste or owners or operators of
hazardous waste management facilities to inject hazardous waste beneath the
lowermost formation containing, within 114 mile of the wellbore, an underground
source of drinking water.
Class n Wells which inject fluids:
(1) Which are brought to the surface in connection with natural gas storage
operations, or conventional oil or natural gas production and may be commingled
with waste waters from gas plants which are an integral part of production
operations unless those waters are classified as hazardous waste;
(2) For enhanced recovery of oil or natural gas;
(3) For storage of hydrocarbons which are liquid at standard temperature and
pressure.
 Class III Wells which inject for extraction of minerals.
Class N Wells used by generators of hazardous waste or of radioactive waste for injection
into a formation which, within 114 mile of the well, contains an underground
source of drinking water.
Class V Injection wells not included in Classes I, 11, 111or IV.
Enhanced oil recovery operators are particularly interested in Class II injection wells. On rare
occasions, an EOR operator may use a Class I injection well.

Miscellaneous Regulations Governing Oil and Gas Wastewaters

These regulations enforced by the U.S. Department of Interior (DOI) govern the handling,
storage, and disposal practices of waste waters from thermal EOR fields located on federal and
Indian lease lands. These regulations required that by October I, 1977, the waste waters produced
in oil and gas recovery operations be disposed only by:
(a) Subsurface injection
(b) Impoundment in lined pits, or
(c) Other acceptable methods.
Stringent limitations are placed upon the disposal of produced water in unlined pits. Monitoring
requirements are established for disposal to both lined and unlined pits. Monitoring activities for
water impounded in lined pits are to include daily measurements of chloride, sulfate, and other
constituents which are potentially toxic to animal, plant, and aquatic life.

Spill Prevention Regulations

EPA has established regulations to prevent the discharge of oil and oil products into or upon
the navigable water of the U.S. These regulations require the development of spill prevention
control. As far as the steam injection operations are concerned, the practices of on-site mixing or
storage of oil related substances will be affected by these regulations. In order to ensure
compliance with these regulations, surface water monitoring during rainstorms as well as during
and immediately following any discharge of retained waters into surface water bodies, is required.

Classification of Injection Wells in California

In California, wells injecting only filter backwash or filter backwash commingled with
produced water are classified as Class I1 wells. Wells injecting water softener regeneration brine
or air scrubber wastes into an oil producing formation are also classified as Class II wells. On the
other hand, wells injecting water softener regeneration brine or scrubber liquor into a non-oil
producing formation are classified as Class I or Class V wells. This classification depends on the
toxicity of the injected fluid.
 Waste Management Regulations Impacting Steam Injection Operations
This section summarizes the federal and state waste management regulations impacting steam
injection operations. The principal federal law that provides framework for managing waste is the
"Resource Conservation and Recovery Act'' (RCRA).

Resource Conservation and Recovery Act (RCRA)

(42 USC, Sections 6901-6099K).
Among the objectives of RCRA are the provisions for the safe disposal of discarded materials
and the regulations for the management of hazardous wastes. The U.S. EPA is the primary agency
which administers the provisions of RCRA. The act required EPA to prepare guidelines for the
effective management of solid waste. The term "solid waste" is defined broadly to include
garbage, refuse, and other discarded materials and includes liquids and gaseous materials together
with solids.
The disposal practices for such wastes are to be such as to protect public health and welfare
and prevent deterioration as required by other federal laws. This includes protection of the surface
and groundwater quality from leaches and runoff, protection of ambient air quality, disease and
vector control, safety, and esthetics. Many states implement their own solid waste programs.
Most oilfield wastes were exempted from classification as hazardous waste by the EPA in 1988.
Table 18.6 lists EPA classification of oilfield wastes under RCRA.
No ise Quality Regulations Impacting Steam Injection Operations
The U.S. Noise Control Act (42 USC, Section 4901, et. seq.) authorizes EPA to set ambient
noise quality criteria. EPA requires the noise levels, because of the operation of one or more
pieces of equipmeut, not to exceed a given value. This value depends upon demographic
characteristics of the land surrounding the EOR site.
The noise associated with TEOR activities arise from two areas: site preparation activities
and field test activities. The site preparation activities include activities associated with the drilling
of observation wells, workover of existing wells, and movement of heavy-duty vehicles used in
the operation of several major pieces of equipment. The typical pieces of equipment include
crawler tractors, air compressors, diesel generators, pumps, and heavy trucks. The noise
associated with field test activities arise primarily from the operation of steam generators.
Since most thermal EOR fields are in rural areas, compliance with noise requirements is not
considered to be a major environmental issue.
 TABLE 18.6. - EPA List of Exempt and Nonexempt Oilfeld Wastes from RCRA
Hazardous Management ~equirements~

Exempt Wastes Nonexempt wastes

PPoducedwatea Urwsed fracauing fluids or acids

Driiling fluids Gas plant cooling tower clearring wastes
Drilling cu€tings Painting wastes
Rigwash Oil and gas service company wastes, such as empty
Dridling fhMs and cuttings from offshore operations druans, dnun rinsate, vacuum auck rinsate,
ofo on^ sandblast media, painting wastes, spent solvents,
Well completion, treatment, and stimulation fluids spilled chemicals, and waste acids
Basic sediment and water and other tank bottoms Erom Vacuum truck and drum rinsafe from bucks and
storage facilities that bold product and exempt waste drums transporting or containing nonexempt
Accumulated materials such as hydrocarbons, solids, waste
sand, and emulsion from production impoundments Refinery Wastes
Pit sludges and contaminated bottoms from storage or Liquid and solid wastes generated by crude oil and
disposal of exempt wastes tank bottom reclaimers
Workover wastes Used equipment lubrication oils
Gas plant dehydration wastes,including glycol-based Waste compressor oil, filters, and blowdown
compounds, glycoi filters, filter media, backwash Used hydraulic fluids
and molecular sieves Waste solvents
Gas plant sweetening wastes for sulfur removal, Waste in transportation pipeline-related pits
including amine, mine filters, mine fdter media, Caustic or acid cleaners
backwash, precipitated amine sludge, iron sponge, milex cleaning wastes
and hydrogen sulfide scrubber liquid and sludge Boiler refractory bricks
Packing fluids Incinerator ash
Mucedsand Laboratory wastes
Pipe scale, hydrocarbon solids, hydrates, and other Sanitary wastes
deposits removed from piping and equipment prior Pesticide wastes
to transportation Radioactive tracer wastes
Hydrocarbon-bearing soil Drums, insulation, and miscellaneous solids
Pigging wastes from gathering lines
Wastes from subsurface gas storage and retrieval,
except for the listed nonexempt wastes
Constituents removed from produced water before
it is injected or otherwise disposed of
Liquid hydrocar'bonsremoved from the production
stream but not from oil refining
Gases removed from the production stream, such
as hydrogen sulfi& and carbon dioxide, and
volatilized hydrocarbons
Materials injected from a producing well during the
process known as Mowdown
Waste m&oil from primary field operations and
production
Light organics volatilized from exempt wastes in reserve
pits or impoundments or production equipment
 Sources of Pollution in Steam Injection Field Activities
In this section, the source and type of pollutant likely to be generated in a typical thermal
EOR production field are identified. The potential emission/effluents are described for the
environmental parameters of air quality, water quality, and waste management.

Air Quality
In a typical steam injection project, air emissions occur during site preparation and field
operations. Air emissions evidenced during site preparation facilities consist primarily of carbon
monoxide, hydrocarbons, nitrogen dioxide, sulfur dioxide, and suspended particulates. In
addition, uncontrolled fugitive dust emissions occur in areas of land disturbances caused by
drilling, bulldozing, etc. The magnitude of the fugitive emissions depends upon the time of year,
the methods of construction employed, the actual size of the arca disturbed, and the type of control
measure utilized. Estimates of uncontrolled emissions from all equipment employed in the field
during the site preparation phase are shown in Table 18.7.
Air pollutant emissions generated during a typical steam injection field activity include those
emanating from steam generators and wellheads. The only significant emissions to the atmosphere
in normal operation are those resulting from the burning of fossil fuels for steam generation. Most
steam generators used in oilfields are in the 50 MM BTUIhr heat input size range. Steam
generators produce SO2, NO,, and particulates. Additionally, small amounts of unburned
hydrocarbons and traces of carbon monoxide are also emitted. Onsite storage tanks and wells to be
steamed also emit hydrocarbons. Among these, sulfur dioxide is of critical concern because of the
stringent federal, state, and local regulations limiting its legal emission level. Table 18.5 lists the
typical emission rates for all pollutants expected for different sizes of generators. For this
computation, it is assumed that the steam generator will use a fuel containing 1.09% sulfur by
weight.
Wuter Quality
Steam injection operations produce large quantities of waste effluents. These waste effluents
include those generated by site preparation activities, such as drilling and well workovers, effluent
from production wells, flue gas scrubber waste, and water softener regeneration brine. Storm
water runoff from construction areas has the potential to affect the quality of local surface waters.
Runoff from construction sites may include clay and silt particles, inorganic and organic matter
from decayed vegetation and soil, oil from paved areas, and oil and grease from construction
equipment
 TABLE 18.7. - Estimated Air Emissions From a Typical Steam Injection Project During Site Preparation Activities
Emission factorslgmlhp-hr Emission factors Ibhr
(Diesel engines) (Heavy duty equipment)

Estimated emissions, tons

I Estimated emissions, tons

Activity Equipment Operating time Total time,

hours CO HC NOx SO2 TSP CO HC NO, SO2 TSP

Working over 350 hp diesel 100 brslwell 85,400

existing injection engine to .
and production operate rig
wells

Drilling 250 hp diesel 3 hrslwell 1,500

observation wells engine to
operate auger
drill

Site preparation Dozers (3) 500 brs.1dozer 1,500

Loaders (4) 500 hrsfloader 2,000

Tractors (4) 400 hrsltractor 1,600

Transportation Heavy duty 1500 hrsltruck 15,000

of material trucks (10)
and equipment

General Miscellaneous 400 hours 4,000

 Local groundwater quality has the potential to be affected by steam injection waste water
effluent disposal activities. Some of these include:
Potential of seepage of injected or reinjected materials through the formation into
underground aquifers;
Potentid of leaching from unlined waste disposal pits;
Potential of accidental surface spills during storage and transport of waste effluents; and
Potential of secondary fractures, which may connect the formation with aquifers.
Total protection of groundwater from waste is impossible because the control of all flow
paths from waste to groundwater aquifers, except casing leaks, is beyond reliable engineering
control.
Waste Management
A typical steam injection process generates wastes both during site preparation phase and
field testing phase. The wastes produced from site preparation activities include:
Clay, silt, and dust particles;
Organic and inorganic matter from decayed vegetation;
Drilling wastes such as mud, brines, etc; and
Oil and grease from construction machinery.
The f i s t two types of wastes are disposed of by landfill and are of no environmental concern.
Drilling wastes and oilfield brines, because of their potential damage to local water and eco system,
require careful handling and must be disposed of in state-approved sites.
The wastes generated from field operations activities include:
Sludge produced from sciubbers;
Spent liquids such as scrubber fluids;
Oily wastes;
Hazardous (toxic) wastes
The handling and disposal of these wastes call for special measures and are outlined as follows:
The scrubber liquids must be treated onsite prior to their disposal into local surface
waters;
Scrubber sludges are difficult and costly to dispose of and are a potential source of
contamination of local surface and subsurface water at the disposal site;
The oily wastes are collected separately and are disposed of according to local regulatory
requirements; and
The hazardous wastes are handled in accordance with the state regulatory requirements.
 SUMMARY
The environmental requirements for candidate domestic steam injection oil recovery projects
were identified and evaluated from federal, state, and local regulatory view points. From these, the
following conclusions have been derived.
Environmental regulations pertaining to ambient air quality and groundwater quality
greatly impact the growth of the steam injection processes;
Cumnt regulations are sufficient for controlling noise pollution; and
Environmental issues such as solid- and liquid-waste handling procedures require site-
specific details that must be evaluated against the applicable governmental regulatory
requirements.

REFERENCES
1. Madden, M. P., R. P. Blatchford and R. B. Spears. Environmental Regulations
Handbook for Enhanced Oil Recovery. U.S.Dept. of Energy Report No. NIPER-546, December
1991.
2. Sarathi, P. Environmental Aspects of Heavy Oil Recovery by Thermal EOR Processes.
Pres. at the Soc. of Pet. Eng. Western Regional Meeting, Long Beach, CA, Mar. 20-22, 1991.
SPE paper 21768.
3. Sarathi, P. Environmental Aspects of Heavy Oil Recovery by Thermal EOR Processes.
J. Pet. Tech., v. 43, No. 6, June 1991, pp. 662-721.
4. IOCC. EPMOCC Study of State Regulations of Oil and Gas Exploration and
Production Wastes, Interstate Oil Compact Commission, Oklahoma City, OK, December 1990.
5. American Petroleum Institute. API Environmental Guidance Document-Onshore Solid
Waste Management in Exploration and Production Operations. American Petroleum Institute,
Production Division, Dallas, TX, January 1989.
 APPENDIX 18-A
HERMAL EOR ENVIRONMENTAL CONSULTANTS

1. wz I x .
4800 W o n Drive, Suite 114
Bakersfield, CA 93309
Telephone: (805) 326- 1 1 12