CANADIAN HEAVY

OIL ASSOCIATION

SPE/PS-CIM/CHOA 97856
PS2005-390

Unlocking the Value in West Sak Heavy Oil

G.W. Targac, R.S. Redman, E.R. Davis, S.B. Rennie, and S.O. McKeever, ConocoPhillips, and
B.C. Chambers, BP Exploration

Copyright 2005, SPE/PS-CIM/CHOA International Thermal Operations and Heavy Oil Symposium
Finally, the enhanced recovery process has evolved from
This paper was prepared for presentation at the 2005 SPE International Thermal Operations waterflood to a viscosity reducing water-alternating-gas
and Heavy Oil Symposium held in Calgary, Alberta, Canada, 1–3 November 2005.
(VRWAG) process, improving expected recovery by 2-3
This paper was selected for presentation by an SPE/PS-CIM/CHOA Program Committee
following review of information contained in a proposal submitted by the author(s). Contents of
percent of OOIP.
the paper, as presented, have not been reviewed by the Society of Petroleum Engineers,
Petroleum Society–Canadian Institute of Mining, Metallurgy & Petroleum, or the Canadian
Heavy Oil Association and are subject to correction by the author(s). The material, as Application of new technology and optimized development
presented, does not necessarily reflect any position of the SPE/PS-CIM/CHOA, its officers, or
members. Papers presented at SPE and PS-CIM/CHOA meetings are subject to publication
decisions have reduced development cost by approximately
review by Editorial Committees of the SPE and PS-CIM/CHOA. Electronic reproduction, 25% in terms of $/BOE and unlocked value in a major
distribution, or storage of any part of this paper for commercial purposes without the written
consent of the SPE or PS-CIM/CHOA is prohibited. Permission to reproduce in print is resource.
restricted to a proposal of not more than 300 words; illustrations may not be copied. The
proposal must contain conspicuous acknowledgment of where and by whom the paper was
presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax West Sak Overview
01-972-952-9435.
The West Sak and Ugnu heavy oil deposits are located within
the Kuparuk River Unit (KRU) on the North Slope of Alaska.
Abstract These deposits are part of a larger heavy oil belt that includes
West Sak is a heavy oil accumulation within the Kuparuk the Orion and Polaris Fields within the Prudhoe Bay Unit, and
River Unit on the North Slope of Alaska. It is a Cretaceous, the Schrader Bluff and Ugnu heavy oil sands within the Milne
shallow marine sandstone. It contains 7-9 billion barrels of oil Point Unit (see Figure 1). The estimated total oil in place
in place with an oil gravity that ranges from 10-22 degrees within this heavy oil belt is 20 to 25 billion barrels, with about
API. Initial oil production began in 1997 at approximately two-thirds of the oil being located within the ConocoPhillips
3,000 BOPD and has increased to over 16,000 BOPD in operated KRU.1
March 2005. Development plans are in place to achieve a rate
of over 40,000 BOPD by 2007. The West Sak formation is a lower shoreface to inner shelf,
Cretaceous-aged formation that has an average gross thickness
This paper describes the evolving development plan for the of about 500’ and an average net thickness of about 90’. The
West Sak field, with emphasis on the technical advances that top of the West Sak reservoir ranges from 2400’ SSTVD on
have resulted in large-scale commercial development. Early the western edge of Kuparuk to about 3800’ SSTVD on the
West Sak development consisted of stimulated vertical wells eastern edge. The West Sak Core Area, which is the warmest,
on a 40-acre waterflood pattern with typical production rates best oil quality portion of the West Sak reservoir, is located on
of 150-250 BOPD. Utilizing the evolution in horizontal and the eastern edge of the Kuparuk Field (see Figure 2). It
multi-lateral drilling technology, the development plan has contains about 2.5 billion barrels of oil with oil gravities
progressed to extended reach multi-lateral injectors and ranging from 16 to 22 degrees at a reservoir temperature of
producers with horizontal and undulating slotted liner about 75 degrees F. In this area, live-oil viscosities range
completions is excess of 8000 feet per lateral. Peak rates of from 20 to 100 cp. The northern portion of the Core Area is
over 5000 BOPD and sustained rates of over 1500 BOPD have currently under waterflood development at Drill Sites (DS)
been achieved. With the higher reservoir throughput rates, the 1B, 1C and 1D. The 2004 production rate from the 1B/1C/1D
distance between wells has increased, reducing well count and area was about 8700 BOPD. A new development at DS-1J is
improving the development cost per barrel. planned for the southern portion of the West Sak Core Area in
2005.
Significant changes have also been made to the completion
design and production strategy. These include changing from The West Sak and Ugnu reservoirs in the KRU contain about
sand exclusion to sand management, adding intervention 16 billion barrels of heavy oil in place. However, much of this
capabilities with multi-lateral completion equipment, oil is low quality (< 15 degrees API) and is located at shallow
optimizing the drill-in-fluid, and adding a backup gas lift depths, where the reservoir is close to the base of the
system to the standard electrical submersible pump (ESP)
permafrost (≈ 1,600 feet subsea), and therefore is relatively
completions.
cold, which increases the viscosity of the oil. Low API
2 SPE/PS-CIM/CHOA 97856

gravity coupled with low temperatures results in much of the three of the West Sak sand packages (“D”, “B” and “A”
West Sak oil having in-situ viscosities greater than 300 Sands), are well developed and oil-filled. In addition, the
centipoise (cp). Because of the difficulties associated with quality of the oil is amongst the best present in the entire area.
producing high viscosity oil in an arctic environment, West A gravel pad, road, pipelines, power lines, and on-pad
Sak development activity to date has been confined to the facilities were constructed, and a total of 15 vertical wells
West Sak core area. were drilled in a five-acre inverted nine spot pattern (see
Figure 3). Because this project represented the first attempt to
commercialize the West Sak reservoir and given that the
Milne
challenges associated with producing heavy oil on the North
Slope were recognized, a concerted effort was made to acquire
considerable rock and fluid property data as well as data on
uk

reservoir performance from the pilot wells. Some of the data

O
ri

Pol

acquired during the pilot project included: conventional cores

par

on

West
ari

Prudhoe
s

in four wells, pressurized fluid samples in one well, and a

Sak
Ku

large number of electrical and nuclear logs. The pilot project

(16 billion
barrels OOIP) operated for about two years and produced about 900,000
barrels of oil. The pilot project proved that the West Sak
= Heavy Oil = Light Oil could be waterflooded with vertical wells on tight well
spacing. The pilot project data has been particularly useful for
planning the DS-1J project, since the pilot wells are located
Figure 1: West Sak location
near the center of the DS-1J development area, and, therefore,
tightly constrain many of the geologic and reservoir related
parameters.

DS 1J
Gravel Pad

Well Penetrations
at Top West Sak

Top D Sand Structure Map

1,000 feet West Sak Pilot Area
Figure 2: Location of the West Sak Field and DS 1E
Figure 3: Drill Site 1J Pilot Project Wells
West Sak Pilot project
The West Sak heavy oil deposits within the KRU were West Sak Vertical Development: 1997-1998
discovered in 1971. During the 1970’s, numerous exploration More than a decade after the completion of the pilot program,
and appraisal wells were drilled to delineate the extent of the a second attempt to develop the West Sak reservoir with
West Sak reservoir and the underlying Kuparuk light oil vertical wells was made at DS-1D in 1997. DS-1D was
reservoir. By the late 1970’s, the Trans-Alaska Pipeline selected as the location for the next West Sak development
System (TAPS) had been completed, and the decision was drilling program, because it is a drill site with existing
made to develop the Kuparuk field, which contained almost infrastructure, minimizing the overall cost of the development.
six billion barrels of OOIP and is the second largest field in The primary differences in design between the DS-1D wells
North America. Oil production from Kuparuk field and the DS-1J pilot program wells was that the DS-1D wells
commenced in 1981 and eventually reached a peak of 320,000 were drilled on a wider spacing (40 acres for 1D development
BOPD. Hundreds of Kuparuk development wells were drilled versus 5 acre for the pilot project), reducing the overall well
during the 1980’s and 1990’s, providing additional well count per unit of area, and the producers were able to utilize
control that has proved to be invaluable for characterizing the more modern fracture stimulated completions and sand control
shallower West Sak reservoir. methods.
By the early 1980’s, with oil prices at record high levels, a While the DS-1D program delivered marginal economic
decision was made to fund a West Sak pilot project to results, information gained from the 18 vertical producers and
determine the feasibility of adding West Sak development 11 vertical water injectors provided important information
drilling to the ongoing Kuparuk development program. The regarding waterflood response, zonal conformance, and ESP
DS-1J area was chosen for the location of the pilot project run times. The information gained about waterflood response
since exploration and appraisal wells had indicated that this was particularly valuable; with rates ranging from 100 to 400
was the “sweet spot” of the West Sak within the KRU. All
SPE/PS-CIM/CHOA 97856 3

BOPD. The ability to utilize geochemical fingerprinting to 1C-178 = Alaska Record for most lateral section at 11,812 feet
allocate production to the individual West Sak sands in a well 79-5/8
- 5 / 8 ”Casing
C a s in g

was also proven at DS-1D. This is a valuable surveillance tool D lateral = 6,2656 0feet; B lateral = 5,547 feet
00’ - 6600’
D Sand
given the commingled West Sak production. W est S ak D S and’

B Sand
W est S ak B S and’
S lo tte d L in e r
West Sak Horizontal Development: 1999-2000
By 1999, it had become obvious that development plans based 5,000
Highest Production Rate ever achieved from a West Sak well

Production (bopd)
upon vertical production wells were not economically viable.

Allocated Daily
4,000
3,000
To improve project economics, operators on the North Slope
2,000
began experimenting with horizontal production wells, which
1,000
had become an attractive alternative to vertical wells in multi-
0
layered reservoirs like the West Sak due to advances made by 13-Jun 13-Jul 12-Aug 11-Sep 11-Oct
industry in multi-lateral drilling technology. With multi-
lateral technology, two or more of the West Sak pay sands can Figure 5: 1C-178 Wellbore Schematic (top) and Production
be accessed from a single well. By year-end 2000, a total of History (bottom)
12 multi-lateral or single horizontal wells had been drilled in
North Slope heavy oil reservoirs, including nine wells drilled In addition to the year on year lateral length drilling advances,
at Milne Point and three wells at West Sak. By year-end 2001, a number of other continuous improvements and step-change
the total number of multi-lateral wells had increased to 25, advancements have reduced the cost of drilling and
with continued rapid growth occurring every year since then completing West Sak wells. Some of the more notable
(see Figure 4). With this increasing inventory of horizontal advances in drilling cost reduction include: 1) improved multi-
and multi-lateral wells, considerable knowledge has been lateral junctions, 2) use of rotary steerable directional tools, 3)
gained on horizontal well performance and minimizing creation and population of a torque and drag database, and 4)
drilling costs. recognition that upgraded solids handling systems, pumps, and
top drives can dramatically improve drilling efficiencies. The
50,000 75
impact of these and other advancements on reducing drilling
Orion/Polaris Horizontal and ML Wells time and costs was clearly demonstrated by the results of the
Number of Horizontal Producers

40,000 West Sak Horizontal and ML Wells 60 2003 West Sak drilling program, which achieved significant
Milne Point Horizontal and ML Wells “learning curve” improvements compared to past West Sak
Oil Rate (bopd)

30,000 Number of Horizontal Producers 45 programs. The 2003 drilling program approached the level of
performance achieved by BP at Milne Point, where over three
20,000 30
times as many multi-lateral and horizontal wells were drilled
10,000 15
as of year-end 2002 (Milne Point 29; West Sak 9) and where
the reservoir sands are deeper, and therefore, easier to drill
0 0 (see Figure 6).
Jan-98

Jan-99

Jan-00

Jan-01

Jan-02

Jan-03

Jan-04

Jan-05

Figure 4: North Slope Heavy Oil Multi-lateral Number of Producers North Slope Heavy Oil Horizontal & Multi-Lateral Wells
and Production Rates 35
West Sak Pre-2003
30
West Sak Optimization: 2000 to 2004
25
The 2000 to 2003 West Sak multi-lateral horizontal drilling
Drilling Days

campaigns at DS-1B, 1C and 1D have been critical for proving 20

the technologies central to the present DS-1E and DS-1J 15

development plans. Over this time period, drilling capabilities
10
have evolved to the point that it is now possible to drill very
West Sak 2003
long lateral sections, which greatly improves both recovery 5

per well drilled and the development cost per barrel of oil 0
recovered. Several lateral sections of over 6,000 feet were 5,000 10,000 15,000 20,000
drilled in 2003, and 1C-178 set a new Alaskan record for the Total Footage Drilled

most lateral section drilled in a single well (11,812 feet). This Milne "S" Pad Orion/Polaris West Sak Pre-2003 West Sak 2003

well recorded the highest ever West Sak initial through- Figure 6: Comparison of 2003 West Sak Drilling Performance to
wellbore production rate at 5,118. The well stayed above the Other Programs
previous record rate of 1,900 BOPD for most of the first 45
days of its life (see Figure 5). The most significant change to completion design at West Sak
was the decision to switch from using downhole sand
exclusion screens in all West Sak production wells to using
0.125” to 0.25” slotted liners (non-sand exclusion). This
4 SPE/PS-CIM/CHOA 97856

change was made early in 2003 based on the knowledge that Multi-Lateral Injector
BP was utilizing a similar design at Milne Point. To support 79-5/8
- 5 / 8 ”Casing
C a s in g

this decision a multidiscipline investigation of West Sak solids D Sand

6000’ - 6600’

production was conducted jointly in June 2003 with W est S ak D S and’

ConocoPhillips Alaska Inc., (CPAI) and ConocoPhillips’ B Sand

W est S ak B S and’

Upstream Technology (UT) organization.2 This study S lo tte d L in e r

determined that sand management, or handling solids

Horizontal Undulating Injector (HUI)
production at the surface, is by far the most cost effective
solids control strategy. Because of the fine-grained nature of 79-5/8
- 5 / 8 ”Casing
C a s in g

West Sak solids, even state-of-the-art downhole solids 5300’

D Sand
exclusion technology allows a large percentage of solids to W est S ak D S and’

70’
flow into production wells. As a result of this project, slotted W est S ak B S and’ S lo tte d L in e r

liner completions will be utilized on all West Sak wells going B Sand
forward, which will result in an expected cost savings for the
DS-1E and DS-1J programs of approximately $60 MM. Figure 7: Comparison of Horizontal Undulating & Multi-lateral
Injector Well Designs
In addition to the large gains made in producer well
performance since 2000, significant advances in West Sak From 2000 to 2003, a total of thirteen West Sak multi-lateral
injector design have also been realized. The switch from or horizontal producers were drilled from DS-1B, 1C, and 1D.
vertical injectors to horizontal injectors, beginning in 2002, Four horizontal injectors were also drilled and completed. Of
was the most important change. This was driven both by these 17 wells, eight were drilled in 2003. In general, the
necessity, since the cost of drilling and injection tie-ins for results of the 2003 drilling program met or exceeded
three vertical injectors per horizontal producer was cutting into expectations, as is shown in Figure 6. All of the well designs,
the profitability of West Sak developments, and also by the artificial lift strategies, and other elements of the current DS-
realization that horizontal injection wells were being utilized 1J development plan were proven in the field either by the
successfully in other fields around the world, including the 2003 program or prior multi-lateral and horizontal wells.
ConocoPhillips operated Alpine field on the North Slope. Figure 8 shows wells that have been drilled at DS-1B, 1C, and
In 2002, a single horizontal injector, the 1D-103 well, was 1D area, which is referred to as the “developed portion of the
drilled. This well utilized a horizontal undulating design to West Sak core area” in other parts of this document.
provide injection to both the “D” and “B” Sands with a single
lateral (see Figure 7). The horizontal undulating design was
chosen because it offered the maximum cost savings given
that a single lateral was cheaper to install than separate laterals
in the “D” and “B” Sand. In 2003, three additional horizontal
injectors were drilled, with one being a “D” Sand only
horizontal well, and two being similar to the 1D-103
horizontal undulating injection well. Injection logs run in
several of these wells have indicated good conformance, with
water injection along the lateral corresponding to permeability.
In addition, dedicated horizontal laterals have higher injection
rates than horizontal undulating laterals. Based on project
value, dedicated injector laterals were selected for DS-1E and
DS-1J projects.
Along with the injectivity tests in 2003, 1C-135, a horizontal
slotted liner producer in the “D” Sand, was placed on water
injection and then returned to production. This field test was
designed to measure sand production and completion integrity
after water breakthrough. Results from the test confirmed
previous modeling predictions that sand production rates
should be the same before and after water breakthrough.

Figure 8: DS 1D, 1C and 1B West Sak Development Map

SPE/PS-CIM/CHOA 97856 5

Development Strategy and had stabilized injection rates of 1000 to 1500 BWPD.
The West Sak development plan continues to evolve to Three injection logs run during the first year indicated water
improve development economics. This section summarizes injection was evenly distributed among the D and B pay zones
some of the major changes from the original vertical well five- in the lateral. During 2003, a single D lateral was drilled that
spot pattern development to the currect multi-lateral direct line indicated that injection rate was a function of net pay
drive development plan. contacted by the lateral. For example, a 6000’ horizontal
undulating injector contacts only 4000’ of net pay, while a
Pattern Configuration and Alignment. The original West dedicated 6000’ dual-lateral injector contacts 12000’ of net
Sak DS-1J pilot project was an inverted nine spot on 5 acre pay, three times as much. Therefore, the development plan
spacing. During the two years that the DS-1J pilot project was changed from undulating injectors to dedicated lateral
in operation, water breakthrough occurred most rapidly in the injectors. With the advent of new multi-lateral technology and
north-south direction. Based on this performance, the pattern systems allowing access in order to intervene and isolate
configuration selected for DS-1C/1D was a staggered line laterals, the change improved the ability to control zonal splits
drive with rows of vertical injectors and producers aligned in a between “D” and “B” Sand injection and also to increase
north-south direction, which is also consistent with maximum injection capacity.
principle stress direction from borehole breakout data. The
water breakthrough behaviour of this pattern configuration has A Sand Development. The initial multi-lateral development
been favourable over the past eight years of waterflooding. wells targeted only the “D” and “B” Sands in the Upper West
After most of the 1D drill site had been developed, the pattern Sak. This left the deeper stacked “A” sands (“A4”, “A3”,
configuration was modified to replace vertical producers with “A2” and “A1”) in the lower West Sak undeveloped. In an
horizontal dual-lateral “D” and “B” sand producers aligned in attempt to develop the majority of the “A” Sand interval, a
a north-south direction. The next major changed was to horizontal undulating “A” Sand well was drilled in 2003. This
replace vertical injectors with horizontal injectors. The pattern well was 5000’ long and cut the “A” Sand section 5 times with
configuration was now in a direct line drive with both an amplitude of 140’. The undulations cut across three of the
horizontal injectors and producers aligned in a north-south sands with two shale/silts in between. No attempt was made
direction. in the lateral completion string to isolate shales/silts or place
blanks adjacent to known unstable sections. This well would
Multi-lateral Producers. The stabilized rate versus time for not sustain production due to excessive solids production. A
West Sak producers is shown in Figure 9. As shown, vertical number of difficult cleanout operations were successfully
producers with fracture treatments can deliver stabilized rates implemented and production was temporarily re-established.4
of about 250 bopd. By converting from vertical wells to short However, solids production always returned, quickly choking
dual-lateral horizontal wells, average well rates increased to production until production ceased. After several events and
500 to 750 bopd. Increasing lateral length to about 6000’ over a million dollars spent trying to maintain production, the
increased rates to 1000 to 1500 bopd. Then, adding an “A” well was shut-in and awaits a sidetrack.
Sand lateral to make the wells tri-laterals increased production
to 1500 to 2000 bopd. The trend in producers has been to From this experience, a new strategy for completing the “A”
move from simple, low rate wells to more complex, high rate Sand had to be developed in order to provide production
wells. assurance. With the largest portion of the “A” Sand reserves
in the “A2”, a tri-lateral well strategy was devised with only
the “A2” portion of the “A” Sand accessed. This “A2” Sand
lateral was still undulated between two pay sands with
silt/shale in between. However, the undulation amplitude was
now only about 30’ and much easier to drill. More
importantly though, new “A” Sand lateral design isolated non-
pay sections with blank pipe and new swelling rubber packer
(SRP) technology to reduce solids production. SRPs are an
emerging technology, where wellbore fluids react with
specially formulated rubber to effectively “set” the packer.
This enabling technology allows for slots, blanks and SRP’s to
be run as a one trip completion string without the need for
washpipe. Then in the presence of oil based fluid (either mud,
diesel, or crude) the SRP “grows” or swells from its run-in ID
to the OD of the drilled hole to “set” isolating the troublesome
Figure 9: West Sak Stabilized Oil Production Rates versus time
shale/silt section behind blank pipe. 5,6
Multi-lateral Injectors. West Sak vertical injector rates
Production and injection data from several tri-lateral wells
average about 400 bwpd, injecting into the “D”, “B” and “A”
completed during 2004 at 1E pad indicates that the modified
Sands. In 2002, a horizontal undulating well was drilled. This
“A” Sand lateral design is successfully maintaining production
well was 5000’ long and cut across the “D” and “B” Sands
and allowing injection.
five times. This well replaced three vertical injection wells
6 SPE/PS-CIM/CHOA 97856

Well Spacing Optimization. In the DS-1C/1D development, The West Sak Small Scale Enhanced Oil Recovery (WS-
there was approximately 900’ between injector and producer SSEOR) pilot project was started at DS-1C. This pilot uses the
rows. At DS 1E spacing increased to 1100’ in conjunction Miscible Water Alternating Gas (MWAG) displacement
with injector well design changes. Oil quality data collected process. Injection of Kuparuk MI began in this pilot in Dec
in 2004 allowed DS-1J planned spacing to be increased to 2003 and it is continuing to operate.
1250’, which reduced the well count from 37 to 31 wells
saving over $40 MM (see Figure 10).

80

70

60

Oil Viscosity, cp
50
VRI

40 WSP 8i lab data (VRI Gas)

30

20

10

0
0 1 2 3 4 5
Num ber of Gas Contacts

Figure 11: Oil Viscosity versus gas contacts for West Sak Pilot
Figure 10: West Sak 1J Well Spacing Change from 1100’ to 1250’ Well 8I “D” Sand
Well Spacing
Both the WS-SSEOR pilot project and DS-1E are planned to
use the MWAG recovery process because they share gas
Well Lengths. Initial well lengths on 2000-2001 horizontal injection facilities with major Kuparuk MI developments at
wells ranged from 2000’ to 3500’. From 2002-2005, well DS-1C and DS-1E. The DS-1J project will use viscosity
lengths continued to increase. The longest lateral drilled to reducing injectant (VRI) instead of MI, as in the WS-SSEOR
date is about 8400’ in 1E-102. Stabilized production rates Project. Engineering studies indicate that the composition of
increase linearly with well lengths and the incremental cost to VRI is optimal for the West Sak Reservoir.
drill longer laterals is low. Thus, the current DS-1J
development has planned wells ranging from 6000 to 8000’.
Drilling Optimization
Recovery Process. The West Sak Pilot Project, which is a Upon the economic success of the three first multi-lateral
vertical nine spot development on five acre spacing, produced horizontal West Sak wells in 2000, it became readily apparent
about 9.3% OOIP at a 45% watercut during the 2 years it was that economics would be even more successful by optimizing
in operation. Based on this performance, the projected well construction. Drilling and well completion costs were by
ultimate pilot waterflood recovery was estimated to be 21% far the largest portion of the capital cost, and any reduction in
OOIP at a 95% watercut. The vertical well portion of the DS- drilling costs and or increases in well productivity would
1D development, which is on 40 acre spacing, has produced clearly decrease the cost per barrel produced. Yet such an
about 5% OOIP at 39% watercut. Several dual-lateral improvement was not without challenges. The shallow
producers with vertical injection support at DS-1D have vertical depth of the reservoir rock (+/- 3600 feet), the
produced 8% OOIP at 50% watercut. Based on pilot project complexity and unproven nature of the multi-lateral junction
and development data, the West Sak is expected to recover 15 systems, and the unknowns about long term reservoir
to 20% OOIP from waterflooding. performance presented ongoing challenges for well
construction optimization.
Although initial oil rates are high, medium viscosity oils (15 to
100 cp) have low waterflood recoveries, and should be good The first three CPAI multi-lateral wells were drilled in 2000,
targets for thermal or miscible gas EOR processes. However, in the heart of the core area from DS-1D. These wells were
conventional thermal methods are difficult in Alaska because dual-laterals in the West Sak “B” and “D” Sands, with lateral
of high well costs, large well spacing, and thick permafrost. lengths ranging from 2,400 feet to 3,900 feet, and unwrapped
The VRWAG injection process at West Sak will use produced horizontal departures (the horizontal length of the well
gas from the Kuparuk reservoir blended with indigenious trajectory) from the surface of 4,900 to 7,700 feet. The multi-
Natural Gas Liquids (NGLs) from Kuparuk and imported lateral junctions in these wells were TAML (Technical
NGLs from Prudhoe Bay. With multiple gas contacts of Advancement of Multilaterals) level 4, with the lateral cased
enriched hydrocarbon gas, the West Sak oil viscosity can be and the junction cemented. The laterals were completed with
reduced by 90% (see Figure 11). This viscosity reduction sand exclusion screens, and the lift mechanism used was
significantly improves oil fractional flow and ultimate electric submersible pumps.
recovery from the reservoir.
SPE/PS-CIM/CHOA 97856 7

The progression in lateral lengths for these three wells and the of 7-5/8” casing are now drilled with a 6-3/4” bit rather than a
resultant increase in oil flow rates made clear the value of smaller 6” bit used on earlier laterals, wireline tools are no
longer laterals. However, the challenges of drilling longer longer used to orient the lateral liner hangers prior to setting,
laterals at shallow vertical depths were already apparent. Even and a completion system has been designed and installed in
with the first three wells, heavier “push” pipe had to be run on conjunction with the multi-lateral system that provides the
top of the screen running strings to overcome the drag forces capability of hydraulic isolation between laterals and lateral
from the horizontal sections. These wells, with horizontal intervention with coiled tubing and wireline tractors.
departure to vertical depth ratios of only 2 to 1, were already
approaching the limits of what the drilling industry had done Another ongoing optimization of West Sak well construction
(see Figure 12, “Industry ERD Envelope: TVD versus has been the hole and casing size of the wells. The first
Equivalent Departure”) horizontal wells were constructed with 7-5/8” casing landed in
the West Sak Sands (7-5/8” casing was the minimum size that
Equivalent Departure (m) could be used due to the large diameter of the ESP pumps) and
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
0
6-3/4” and 6” laterals drilled. In 2003 the first horizontal
undulating injector was drilled, to provide the injection into
West Sak 1000
4000 the “B” and “D” Sands that otherwise would have required
2000 three conventional injection wells. Early in the planning
TVD BRT (ft)

TVD BRT (m) stages for this well it became clear that a rotary steerable
8000
3000
Amethyst Andrew
Bruce
Colombia
Chirag
Foinaven
system would be needed to drill the 60 foot amplitude
12000 4000
Goodwyn
Miller
Harding
Milne Point
undulations and to reach total depth. The 4-3/4” rotary
16000
Niakuk
Pompano
Pedernales
Magnus
5000
steerable systems needed to drill a 6-3/4” hole were not readily
Marnock Schiehallion
Starnmeer
Valhall
Ula/Gyda
Wytch Farm
6000 available or consistently reliable; consequently this well was
20000
0 4000 8000 12000 16000 20000 24000
Yacheng
Alpine
28000
West Sak 1C/1J
Phillips North Sea
32000 36000
planned and drilled with 9-5/8” casing landed in the West Sak
Equivalent Departure (ft) Sands, and an 8-1/2” lateral. Subsequent undulating wells
were drilled with a similar “big bore” hole size and casing
design, and certain advantages of this design were recognized.
Figure 12, “Industry ERD Envelope: TVD v.Equivalent Departure”
These advantages included, in addition to a more reliable
rotary steerable drilling system, lower equivalent circulating
Planned wells for the 2001 to 2003 drilling campaign had densities and a 5” drill string less prone to buckling than the 4”
lateral lengths of 4,000 to 6,200 feet, oriented only north or string used on the 7-5/8” equipped “small bore” wells. But
south to minimize the impacts of natural fractures on the early over time, 4-3/4” rotary steerable tools have become more
water breakthrough, with unwrapped horizontal displacements available and more reliable. In early 2005, a 4-3/4” rotary
ranging to nearly 12,600 feet (Horizontal to vertical ratio of steerable tool was used to drill a 7,500 foot West Sak lateral.
3.33). A systematic process was put in place to ensure that This has resulted in more and more of future West Sak wells
torque, drag and hydraulic implications were properly being planned as less costly “small bore” wells, when buckling
considered in the well design. A formal procedure of and hydraulic limitations are not an issue.
recording and utilizing drilling data was begun in 2002. At
regular intervals during operations (i.e. once per stand while Rotary steerable drilling assemblies are seen as a key enabling
drilling), parameters such as up weight, down weight, torque, technology for West Sak drilling, allowing drag friction to be
flow rate, pump pressure, and equivalent circulating density overcome with rotation. This technology has the potential to
were recorded by hand. An electronic system also recorded to reach geologic targets that may not be otherwise be
digital rig parameters at one second intervals. Drilling attained. Thus rotary steerable tools have been used on wells,
engineers at the rig were tasked with ensuring the quality of where it was not absolutely necessary, to gain information on
this data and performing torque and drag modelling. An system performance to optimize future wells. As more and
experienced engineer, with a great deal of experience in torque more rotary steerable information is gained, the benefits of
and drag modelling, was added to the multi-disciplined, town- continuous rotation, less pressure drop, and a less tortuous
based planning team. These changes allowed wells and wellbore may be found to offset the risks associated with a
laterals to get progressively longer and less expensive. less reliable system.
After the success of the first three multi-laterals, it was A continuous drilling campaign was seen as another key
recognized that there was a potential for significant savings in element in reducing drilling costs. In 2002, only two West
the construction of the multi-lateral junctions. In early 2001, a Sak wells were drilled, and both suffered from inefficient
review of available multi-lateral systems was completed, in performance. The development team realized that
which the installed costs, construction risks, and implications improvements in drilling metrics would occur if several wells
for long term well operability and intervention were could be scheduled consecutively, and these wells could be
considered. The result of this review was a change from the drilled with the same rig and crews. Consequently an eight
Level 4 junctions to Level 3 junctions. This change resulted in well drilling program was carried out in 2003, and a thirteen
six fewer trips per dual-lateral well. This Level 3 system well program, begun in early 2004 is nearly complete as of
continues to be used for the tri-laterals being drilled today, and this writing. As a result of these continuous programs, well
has been continually improved. For example, the laterals out construction metrics have improved dramatically. As
8 SPE/PS-CIM/CHOA 97856

previously noted in Figure 6, the metrics of the 2003 campaign than previous water based mud wells. However more
were on par with similar heavy oil wells drilled by BP at the importantly, and as predicted, improved injection performance
Milne Point Field on the North Slope. appears to be allowing for significantly higher water
injectivity. Preliminary results indicate a significant
With a steady program, it was realized that further benefits improvement in injector performance over previous water
were possible by getting a rig optimized for West Sak based mud recipes.
development. The 2003 wells were consciously planned for a
specific rig that had surface locations planned from a new well Results show that the overall process of integrating the drill-
row on an existing pad (Kuparuk DS-1C) with well spacing to in-fluid, completion design, inflow performance modeling,
accommodate this rig. Wellhead and other surface facilities and operations procedures should be considered a best practice
were designed for this specific rig. The advantages of this top- and an example of how an integrated study ultimately provides
drive-equipped rig over other available rigs included: the a field development with the best project value. Using the
ability of this rig to rapidly move from pad to pad, as well as current field development economic model, this process added
from well to well; and state-of-the-art linear shakers and waste reserves, improved project value and helped maximize project
fluids processing equipment (solids and liquid segregation economics
system, tankage, and a down hole injection pump). The rig
has since been upgraded with a high volume centrifuge and Drilling Optimization Summary. The result of these drilling
has been retained on a long term contract. optimizations, as well as changes in completion strategy and
drill-in fluids has allowed progressively longer laterals to be
Drilling Fluid Optimization. A drill-in-fluid/formation successfully completed. In 2001 a multi-lateral well with a
damage minimization study was undertaken by 4,600 foot lateral was successfully completed; in 2002 a well
ConocoPhillips Alaska and its upstream technology with a 5,200 foot undulating lateral was completed; in 2003 a
organization to determine the optimum reservoir drilling fluid. 6000 foot lateral was completed, and in 2004 an 8,400 foot
The goal of the study was to maximize well productivity and lateral was successfully completed. In this same time frame
well injectivity, while evaluating total mud cost in order to horizontal displacement has increased from about 5000’ to
optimize project value.3 12500’. Overall these improvements have provided access to
more reserves with fewer wells, cutting development costs and
The in-depth study was comprised of drilling fluid rheological dramatically improving the value of West Sak projects. For
design, laboratory filtercake testing, core based filtrate testing, example, development area reachable from DS-1J had doubled
injectivity and productivity analysis associated with several due to this work.
reservoir drill-in fluid (RDF) recipes in order to the optimum
fluid blend. Production Assurance
West Sak production will place an additional load on Central
Lab tests were completed on: Processing Facility 1 (CPF-1) due to increased total liquid
• Crude Compatibility rates, higher produced fluid viscosities, heavier crude,
• Lubricity (steel to steel & rock to steel) increased solids loading and production of finer grained solids.
• Shale Stability Because of these impacts, a team was chartered in 2003 to
• General Rheology evaluate both CPF-1 operating integrity and facility limits
• Mud Filtrate invasion tests with core to determine issues. The results of this project indicate that given
Return Perm appropriate amounts of heat and chemicals introduced at DS-
• Filtercake Removal tests w/ceramic disk tests to 1E and DS-1J impacts on CPF-1 performance will be
determine return permeability and removal manageable.
effectiveness
Heat. In addition to typical oilfield installations of cross-
Test results and well productivity calculations illustrated that country flowlines and power, wellsite flowlines and testing
an oil based mud (OBM) was the optimum RDF. Lab tests equipment, the new West Sak developments (DS-1E, 1J and
and inflow performance modeling showed injectivity and beyond) will include significant investments in process heat at
productivity improvements associated with reducing water the drill sites. Additional heat requirements are a function of
based filtrate invasion and permeability reduction due to water the nature of the West Sak crude oil (its viscosity, density and
and ineffective filtercake removal. interaction with water), the processing system at CPF-1, and
the low producing temperatures of the wells. The West Sak
At the time of writing, ten wells have been drilled and developments flow into Kuparuk’s CPF-1, which currently
completed at DS-1E incorporating the fluid changes. Total handles about 60,000 BOPD and 250,000 BWPD, with
mud costs/ft have actually been reduced by approximately approximately 75% sourced from the Kuparuk reservoir. This
19% over previous water based mud systems resulting in volume results in low residence time in the plant’s separation
additional capital savings previously not accounted for. vessels, so efficient separation is critical to maintain
acceptable sales crude and injection water quality. West Sak
Additionally, both peak flow rates and sustained flow rates oil has a specific gravity of 0.95, resulting in a low density
have been inline with well performance calculations and better difference relative to the produced water (SG = 1.01). In
addition the oil, produced at viscosities around 75 cp, tends to
SPE/PS-CIM/CHOA 97856 9

form emulsions with produced water that can increase overall Emulsion Breaker. The emulsion breaker product is
viscosity by a factor of three or more at water cuts up to required to coalesce water droplets in the produced emulsion
around 60 percent. These emulsions also tend to tie up and allow them to separate from the oil phase. An important
produced formation fines which, if not separated from the flow item regarding the West Sak emulsion, in addition to the low
streams, impair injection water quality and cause serious temperature and high viscosity, is that the oil/water/gas is
degradation in the life of injection water pumps. lifted to the surface using submersible pumps. Thus, fluids are
sheared as they pass through the pumps, which creates rather
In 2003, these processing issues were studied and it was small droplets of water in the oil. Wells are also equipped
determined that significant amounts of chemicals (discussed with gas lift valves, so that when a downhole pump is out of
below) and heat would be required to permit large-scale West service, the fluid will be lifted using artificial gas lift. Gas
Sak production without impairing overall performance of the lifted wells are likely to have a significant amount of foam
CPF-1 processing system. In addition, the study concluded incorporated with the oil-water emulsion.
that the best location for the heat is at the drill sites. By
heating the produced fluids from wellhead temperatures of Since the existing Kuparuk emulsion breaker has been
about 55 degrees F to around 140 degrees F at the drill sites, demonstrated to resolve the West Sak oil/water emulsions
the residence time in the pipelines to CPF-1 allow the water- under current operating conditions, the primary interest was
oil emulsions to break down prior to arriving at CPF-1’s improving the performance of the current product under
primary separator. particular conditions that the new West Sak well development
will cause. Heat, residence time, and dilution with Kuparuk
A significant amount of effort has also been applied to crude oil has been shown to improve the oil/water separation.
determine the optimal amount of heat and type of heaters to Depending on the particular point in the production system,
install at DS-1E and DS-1J. Heater design for these projects is Kuparuk oil may or may not be available to dilute the West
complicated by the low heat transfer coefficient into the West Sak fluid stream, so the ability to treat 100% West Sak
Sak produced fluids, H2S content of the fuel gas, and scaling emulsion was mandatory.
tendencies of the produced water. Options including
conventional bath-type heaters, direct-fired heaters, hot oil Products that can break the emulsion at lower temperature
heat transfer heaters, and various ideas involving use of the have the advantage that less heat will be needed in the
higher-temperature produced water were considered. In the processing, thereby decreasing the size of the heaters required,
end, a 20 MMBTU conventional bath-type heater was selected the amount of fuel consumed, and reducing emissions from the
for the smaller DS-1E project, with provisions for expansion burned fuel. Emulsion breaker will be injected as far upstream
to 40 MMBTU if necessary. At DS-1E, the processing in the process as is possible, most likely at the wellhead.
problems are mitigated by the co-production of approximately Products injected through the wellhead injection system must
25,000 BPD of Kuparuk oil and water. DS-1J, lacking this be free of solids and be able to flow through the distribution
advantage, and expecting roughly three times the flow rates of tubing, so viscosity and temperature dependence are important
DS-1E, has selected a 50 MMBTU hot oil heat transfer heater factors to consider in selecting an emulsion breaker.
design (2 ea. 25 MMBTU units) that can be upgraded to 75
MMBTU. It is expected that future West Sak developments Antifoam. Heavier crude oils such as West Sak tend to
will also install process heat at the drill sites. These slowly release their dissolved gas, and when they do, form
investments, along with the use of chemicals, are expected to tight, full-bodied foam similar to shaving cream. This foam
provide good production assurance for the West Sak can carry throughout the CPF-1 process facility and cause high
developments. oil losses to the produced water system. Antifoam injection
upstream of the well-test facility is also required to get good
Chemicals. Because the West Sak production will be co- well test data from West Sak wells. Current antifoam usage is
mingled with the existing Kuparuk produced fluids, all higher than desired and a combination of on-pad heat and an
products must be compatible with the Kuparuk chemical suite. improved antifoam chemical for the West Sak fluid is
Thus, compatibility must be shown to exist for proposed required.
products. Where this conflicts with the overall goal of the
lowest-cost/best performance, a cost-benefit analysis was Scale Inhibitor. The West Sak formation water has low
performed to determine the proper combination of products. tendency to precipitate and deposit scales under reservoir and
normal producing conditions. However, scale control will be
The basic purposes of the chemicals for West Sak production necessary for at least three reasons: 1) the downhole ESP
are to: 1) break produced oil/water emulsions, particularly at pumps have a history of scale deposition causing pump
cooler temperatures, 2) prevent formation of inorganic scales, failures, 2) the West Sak reservoir is being waterflooded with
particularly on the surface of heater tubes whose temperatures Kuparuk produced water (PWI) that has a high scale
may reach 200 F, 3) reduce foam produced as the gas breaks precipitation tendency, partially because it is also mixed with
out of the oil-water emulsion, 4) accelerate separation of fine seawater at CPF-1. While sufficient scale inhibitor is present
suspended solids to the water phase, particularly in pads that in the injected water, all of that inhibitor is stripped away
may build up in separators from time to time and 5) prevent during its passage through the reservoir. As produced water
corrosion. injection breaks through to the West Sak producing wells,
scale formation will initiate from the reservoir all the way
10 SPE/PS-CIM/CHOA 97856

through the production system. Anticipated scales from formulation includes some emulsion breaker, which may or
computer modeling include BaSO4 and CaCO3, though if may not be compatible with the emulsion breaker selected
corrosion occurs and iron is dissolved, then FeCO3 will also from this work. Thus, alignment of the emulsion breaker
form, 3) In order to process the West Sak fluids, heating will packages in the CPF-1 area may be required if compatibility
be required. This is the most severe service from a scale issues arise. At the present time, the water cuts from the
inhibition standpoint. A direct-fired heater could be used to currently producing West Sak wells are low, so it is difficult to
elevate the temperature of the West Sak oil/water emulsion so know whether the corrosivity will increase significantly as the
that the viscosity is reduced and to allow breaking of the water becomes the external phase at higher water cuts. This
emulsion, but the tube-wall temperatures of >400 °F would effect was important in increasing corrosivity of nearby
cause scale deposition and fouling even with the most Prudhoe Bay and Kuparuk Fields.
effective inhibitors tested. Thus, a hot oil heat transfer heater
was selected to reduce the tube temperatures so that scale Other corrosion challenges may occur later in the waterflood
inhibitors could be effective. life, since reservoir souring of the West Sak reservoir will
likely occur. The natural H2S scavengers present in the
reservoir in the form of iron-containing minerals will act to
Solids and Pad Busting Control. The West Sak reservoir reduce the H2S concentrations seen at the producer wells and
is an unconsolidated sandstone with relatively poor rock delay the onset of souring. Lift gas used on some of the West
strength. As the viscous oil and water flow through the rock, Sak is the same as the rest of Kuparuk and contains both CO2
particularly near the wellbore, solids are suspended and and H2S. The lower temperature of the produced oil and water
become entrained in the fluids. This is especially true of fine downhole will increase the solubility of these corrosive gases,
formation solids such as the clay minerals kaolinite, illite, so this may have some differential increase in the corrosivity
chlorite, and mixed layer smectite clays. Previous work has of the West Sak fluids. The formation water in the West Sak
shown that these minerals are fairly oil-wet in their natural reservoir is much fresher than Kuparuk, so until West Sak
state in the reservoir, particularly the expandable clays. produced water breakthrough dominates the produced water
Investigation showed that asphaltene molecules have composition, the buffering capacity of that water will be lower
intercalated (inserted themselves) into the clay layers of at than the rest of KRU. This will have the effect of lowering the
least some of the clay species and thus, are stable and quite pH and increasing the corrosivity.
oil-wet. These particles are easily transported by the produced
fluid and are difficult to separate. They can cause processing Artificial Lift. Artificial lift is employed on West Sak wells to
upsets at the CPF-1 separation train when solids-laden pads provide on the order of 1000 psi of drawdown below the
established at the oil-water interfaces in the vessels preventing reservoir pressure of approximately 1600 psi. Historically,
the passage of water down through the interface and oil most West Sak wells have used ESPs as the artificial lift
upwards. method. ESPs were initially conventional tubing-deployed
centrifugal ESPs and electric submersible progressive cavity
A treating product that prevents or breaks up established pumps (ESPCPs). Recognizing the high rig-based
solids-laden pads in the separation vessels and allows solids to intervention costs in Alaska, and the fact that pump sections
sink to the vessel bottoms is desired. Solids can then be tend to fail before motor sections, ConocoPhillips (ARCO at
removed with existing sand jet skids, which have sufficient the time) and Centrilift worked to develop pump sections that
capacity to handle increased West Sak solids production. The could be deployed on wireline and mated to the tubing-
application point of this product would likely be inside of deployed motor section. Initial wireline deployed pumps were
CPF-1. of the ESPCP design, but subsequently wireline-deployed
centrifugal ESP pumps have been developed and installed.
Corrosion Inhibitor. Like the rest of the Kuparuk field,
West Sak facilities use carbon steel and thus, are susceptible to In addition to ESPs, hydraulic jet pumps have been installed to
corrosion. The West Sak facilities will require corrosion provide artificial lift to West Sak wells; these were chosen for
inhibition similar to Kuparuk. One additional component at the 2003 development program after observing BP’s success
West Sak will be the high suspended solids present in the with jet pumps in their Milne Point Schrader Bluff
fluids. Previous work established that a significant proportion development. Finally, gas lift has been used to produce West
of the corrosion inhibitor adsorbs on the high surface-area Sak wells on occasion, typically in a temporary fashion when
solids and corrosion inhibition. Since particular products may ESPs fail and a workover rig is not available. Gas lift has an
adsorb less than others, this parameter should be added to the advantage in that it is the primary lift method used in the
protocol for testing Kuparuk corrosion inhibitors. Also, the KRU, but provides 50% less drawdown compared to ESPs or
impact of West Sak oil and brine on the corrosion inhibitor jet pumps.
performance needs to be established. Inhibitor partitioning
between the West Sak oil and water phases may differ from This existing mix of artificial lift techniques prompted a 2003
Kuparuk fluids. artificial lift strategy study for the DS-1E and DS-1J
developments. ESPs offered the advantage of optimum
The current West Sak producing areas, DS-1B, DS-1C and drawdown, but with 3-5 year expected run lives and limited
DS-1D, are being inhibited with about 100 ppm of the same workover rig availability, well uptime was only expected to be
corrosion inhibitor used throughout Kuparuk. This about 75% for an all-ESP development. Jet pumps could
SPE/PS-CIM/CHOA 97856 11

achieve higher well operability and lower operating costs, but the West Sak DS-1E and DS-1J wells have low hydrating risk
the scale of the DS-1J development would require a large, and downhole heat trace is not required.
expensive jet pump facility to be constructed at the drill site.
Reservoir management would also be impacted with jet pumps Sand Management. With the change in completion strategy
due to the difficulty in determining formation water from sand exclusion to sand management, sand/solids
production at the expected power fluid ratio of three to one. production delivered to CPF-1 was a concern. As a part of the
Gas lift, with significant infrastructure already available, West Sak Sand Strategy study, sand production rate
provided the lowest cost solution but sacrificed oil rate and predictions were made in order to use as a facility design basis
reserves due to higher flowing bottomhole pressures (less and determine value.2 At DS-1E, sand production rates under
drawdown). the new strategy initially were higher than expected. However
after about 100 days of production, the stabilized sand
The artificial lift study concluded that a hybrid strategy production rates have come into line with estimates from the
provided the best solution. By combining ESPs as the primary ConocoPhillips sand rate model. Figures 13, 14, and 15 below
lift mechanism with a backup gas lift system, high well illustrate solids production data from the DS-1E development.
operability will be achieved without sacrificing oil rate and Figure 14 illustrates the measured field solids percentage and
with minimal additional capital investment. In addition, it is Figure 15 shows how individual wells perform and roll up into
envisioned that late in field life when oil rates are low and ESP the solids production rate for DS-1E. Figure 13 shows, with
workovers become uneconomic, gas lift will become the the seventh bar, how the actual 1E pad percent solids rates
primary artificial lift method. This strategy has been compare to the original study predictions. The star
employed in the DS-1E development with favorable results to annotations on the original prediction bars, bar eight and nine,
date. show where current averages relate to predictions. As shown,
the predictions match field data very nicely.
Heat Trace. Early in the West Sak development, external
tubing heat trace was installed in all producing wells. While
Sand Rate Estimates for West Sak 1E & 1J Pad Development
West Sak crude does not have waxing tendencies or A/B/C/D Horizontal Undulating Producers Completed with Slotted Liners

asphaltene deposition problems, hydrate formation is a 10

Highest 10-Percentile Value
P50=50-Percentile Value
concern due to the low formation temperature of 75 degrees F Lowest 10-Percentile Value

and surface permafrost. Hydrating temperature for West Sak Current Rolling Drill Site
S a n d R a te , V o lu m e % o f P ro d u c e d F lu id

Average % Solids Rate = 0.55

gas at wellhead pressures is 47 degrees F, whereas unheated 1 Steady State Solids Rate
flowing temperatures from vertical wells on gas lift can be as approx. 0.1 %

low as 35 degrees F. As the development plan has moved to

horizontal multi-lateral wells and incrementally increased
lateral lengths, the higher flow rates have eliminated the need 0.1

for downhole heat tracing.

A 2001 field-based study concluded that West Sak wells 0.01

producing above 625 BPD would not require heat trace. Modeling Studies Laboratory
Studies
Field Studies CPAI Sept 03
Well Site
CPF-1 Inlet
Solids Sample
BP S-Pad June 1D-102 Reverse
03 Review (11 Gaslift Test
1E-Pad
Development
Sand Control Sand Control
Study Prediction Study Prediction
Centrifuge Test (3 wells) Wells Single Well Rate Drillsite Rate
However, due to the limited scope of this study, a modeling wells)

study was conducted in 2003 in support of the DS-1E and DS- Figure 13: 1E Pad Results Comparison to Sand Study Statistical
1J developments using ConocoPhillips’ Well Performance Prediction
Model program. In this study, it was found that the critical
variable of flowing wellhead temperature was affected by:
West Sak 1E Pad Solids Production Data
• Well flow rate
•
10
Water cut Daily Sand Vol%

• Lift method (ESP or gas lift) Avg Daily Sand Vol%

• Casing design
•
Daily Sand Rate, %Solids

1
Formation depth
• Well departure

Recognizing the variability of formation depth (3000’ to 0.1

3700’) and well departure (~2000’ to 7000’ +) in the DS-1E

and DS-1J developments, each of the planned producers was
individually modeled at a variety of flow rates and water cuts 0.01
9/1/2004 10/1/2004 10/31/2004 12/1/2004 12/31/2004 1/31/2005 3/2/2005 4/1/2005
with both ESP and gas lift. As expected, the shallowest,
highest departure wells will have the lowest flowing Figure 14: West Sak 1E Pad Sand Production Rate (% solids)
temperatures. Flow rates higher than 1000 BPD are required
to remain outside of the hydrate envelope. Based on this work,
12 SPE/PS-CIM/CHOA 97856

technology with blank liners to isolate select portions of

West Sak 1E Pad Solids Production Data
laterals (e.g., around faults, shales and unconsolidated sand)
100
optimizing oil based mud flowbacks, treating emulsions, and
Total Daily Sand Vol%
Avg Daily Sand Vol%
oil quality prediction versus height above oil-water-contact.
1E-168 Daily Sand Rate, vol%
10 1E-166 Daily Sand Rate, vol%
1E-126 Daily Sand Rate, vol%
1E-114 Daily Sand Rate, vol%
1E-112 Daily Sand Rate, vol%
In addition to local knowledge sharing, worldwide company
Avg Daily Solids Rate, vol%

1
experts were brought in, along with expertise in other heavy
oil producing assets such as Venezuela and Canada, to share
0.1
ideas and technology.

West Sak 1E Project

0.01
The DS-1E project is a westerly expansion of the West Sak
DS-1B/1C/1D development area within the KRU (Figure 17).
0.001
1-Sep-04 1-Oct-04 1-Nov-04 1-Dec-04 1-Jan-05 1-Feb-05 3-Mar-05 3-Apr-05
Over 50 West Sak wells have been drilled from DS-1B, 1C
and 1D since 1997, and average daily production in 2004 was
Figure 15: West Sak 1E Pad Sand Production Rates (% solids) by
Well approximately 8,700 BOPD.
1E / 1J Monthly Sand Production Estimate Vs. Actuals
100 70,000

90
60,000
Sand Production, yd^3/day

80
Liquid Rate, bbl/day

70 50,000

60
40,000

50

30,000
40

30 20,000

20
10,000
10

- -
01/01/04 12/31/04 12/31/05 12/31/06 01/01/08 12/31/08

Date

P10 P50 P90 P10 Actuals P50 Actuals P90 Actuals Production

Figure 16: West Sak 1E/1J Sand Production Forecast

This field data along with solids production modeling has now
been used to forecast expected solids to CPF-1. As shown in
Figure 16, a range of sand production estimates has been
provided for a prediction. Actuals have been overlaid to show
how close they match the model. The combination of
sand/solids rate modeling and gathering of detailed field data
has become an effective tool for managing sand production, Figure 17: West Sak 1E Development Plan
understanding the impact to field operations, maintaining
production assurance and ensuring that the value associated The DS-1E development plan consists of four tri-lateral
with changing to sand management is successfully achieved. horizontal production wells (“D”, “B” and “A2” sands), two
dual-lateral horizontal production wells (“D” and “B” Sands),
Knowledge Sharing four tri-lateral horizontal injection wells, one dual-lateral
In early 2003 a cross asset/cross company Viscous Regional injection well and two conventional deviated injection wells.
Team was formed to work similar problems, share best The horizontal wells have lateral lengths ranging from 3,040
practices, and accelerate the pace of Alaska heavy oil feet to 8400 feet. Over 153,000 feet of production lateral
development. Initially four sub-teams were formed to work section will be drilled during the DS-1E program, which is
rate prediction, depletion planning, sand control and artificial approximately 50,000 feet more lateral section than has been
lift. Additional teams have been added when necessary to drilled to date in existing West Sak DS-1B/1C/1D wells.
work EOR, stratigraphy and oil quality. The teams made
considerable progress on several key technical issues, DS-1E is an existing Kuparuk drill site that was built in the
standardized several philosophies and work programs, and 1980’s. The gravel pad and road are already in place, as are a
helped justify approving the West Sak DS-1E and DS-1J 14-inch production line, 8-inch water injection line, 6-inch lift
projects. gas pipeline and 6-inch miscible injection line that are utilized
by 35 Kuparuk wells. The DS-1E development also required a
Best practice sharing included the implementation of slotted new powerline and remote electrical and instrumentation
liners, optimizing sand management, the initiation of SRP module to support the six ESP producers.
SPE/PS-CIM/CHOA 97856 13

two wells will be lifted using jet pumps utilizing the DS-1J
The DS-1E development is expected to recover 38 MMSTB of water injection header.
oil and have a peak oil rate of about 9,000 BOPD.

West Sak 1J Project

The DS-1J project is a proposed southerly expansion of the
West Sak development area within the KRU (Figure 18). To
date, West Sak development drilling has been confined to the
“West Sak Core Area”, where West Sak oil quality is highest.
The DS-1J project will develop the area immediately south of
the existing West Sak drill sites.

Figure 19: Typical Tri-Lateral Producer

The DS-1J gravel pad and road are already in place, as are a
six-inch lift gas pipeline and most of the pipeline vertical
support members (VSM) that will be required. New
infrastructure and facilities that will be installed as part of the
DS-1J project include: overhead power lines, on pad
production facilities, and pipelines to and from CPF-1, where
the DS-1J crude will be processed, and from which injection
water, lift gas and injection gas will be sent to DS 1J.

The DS-1J project will be the second large all-horizontal water

alternating gas development project operated by
ConocoPhillips on the North Slope, with the first being the
Alpine Field, which is located about twenty miles due west of
the KRU. Water alternating gas EOR is also utilized in the
ConocoPhillips operated Kuparuk, Tarn and Meltwater fields,
which have been developed using mostly vertical fracture
stimulated wells.

Many of the injection wells that are to be drilled as part of the

Figure 18: Location of the West Sak Field and DS 1J
DS-1J project will be pre-produced to clean up drilling related
formation damage before putting the wells on injection. Once
The development plan for DS-1J calls for drilling thirty one injection commences, alternating slugs of water and gas will
wells: eleven tri-lateral horizontal production wells (“D”, “B” be placed in the reservoir, with the initial slug being water,
and “A2” Sands), four dual-lateral horizontal production wells which will be followed by gas approximately 12 to 24 months
(“D” and “B” Sands), two single lateral horizontal production later. Injection gas will be manufactured at CPF-1 especially
wells (“D” Sand), eleven tri-lateral horizontal injection wells for West Sak, since engineering studies and economic analysis
and three dual-lateral horizontal injectors (see Figure 19 for a indicate that it is more economic to utilize a leaner gas
schematic showing tri-lateral well design). Lateral lengths in injectant than is used in the Kuparuk and WS-SSEOR miscible
these wells will range from 4,800 feet to 8,000 feet. More than water alternating gas (MWAG) flood.
440,700 feet of lateral section will be drilled during the
execution of this project, which is nearly twice as much lateral The West Sak DS-1J development is expected to recover 137
section as has been drilled to date in existing West Sak wells. MMSTB and have a peak oil rate of about 25 MSTB/Day.

A producer-bounded, line-drive VRWAG flood will be

implemented to recover the West Sak heavy oil in the DS-1J West Sak Future: Beyond 1J
area. Because of the structural simplicity of the development In additional to the West Sak Core Area, there are two other
area, it will be possible to drill near-perfect patterns (see major areas of potential development within the Kuparuk
Figure 18) with wells aligned in the maximum stress direction. River Unit. (Figure 20) First is the Northeast West Sak Area,
The artificial lift method for all but two of the production which has similar oil quality to the Core Area but more faults.
wells will be ESP with permanent gas lift backup. The other Second is the Western West Sak Area, which has similar
faulting to the Core Area but poorer oil quality.
14 SPE/PS-CIM/CHOA 97856

8. West Sak artificial lift strategy has moved from

vertical wells with ESPs to a hybrid system of ESPs
with gas lift backup to improve well operability.
9. Since ESP pumps tend to fail more often than ESP
motors, West Sak has moved from tubing conveyed
pumps to wireline retrievable pumps to reduce the
frequency of rig workovers.
10. The West Sak recovery process has shifted from
waterflood to VRWAG. This increases oil recovery
by swelling the reservoir oil and reducing its
viscosity.
11. West Sak production assurance strategies have
changed from diluting small volumes of West Sak oil
with hotter less viscous Kuparuk production to
applying heat and chemicals at the drill site to prepare
the West Sak crude for processing.

Acknowledgements
The authors would like to thank BP Exploration Alaska and
the other co-owners of the Kuparuk River Unit for their
permission to publish this work. The conclusions presented in
this paper are those of the Operators and may not reflect those
of other Working Interest Owners.

Figure 20: Future Potential West Sak Development Areas References

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