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Accurate, robust, and real-time quantification of oil-based mud (OBM) filtrate contamination using data from downhole fluid analysis (DFA) sensors remains a challenging problem, especially under difficult sampling conditions and for advanced sampling tools with complex inflow geometries and active guarding of filtrate flows. Such tools and conditions lead to contamination cleanup behaviors that do not necessarily follow the simple power-law models that are commonly used in contamination monitoring algorithms. Moreover, the need for improved efficiency calls for more automation in sampling operations, especially in high-activity regions with many wells and sampling stations. Achieving such automation within existing contamination monitoring workflows has been proven to be challenging. In this paper, we deploy a new method for contamination monitoring, based on the inversion of DFA data using a full 3D numerical flow model of the contamination cleanup process. This flow model predicts the evolution of filtrate contamination as a function of time and pumped volume and can thus be used to forward-model the DFA sensor responses. Sensor data, such as optical density, mass density, and gas-oil ratio, are then inverted in real time to provide contamination predictions. Real-time computation is enabled through fast, high-fidelity proxy models for the cleanup process. The proxy models are trained on and validated against a library of 300,000 precomputed full-scale numerical simulations covering a wide range of hardware configurations and sampling environments. We applied the new method on 14 field sampling stations of oil sampling in OBM conditions, with four different types of sampling inlets: single probe, radial probe, dual packer, and focused radial probe. The data sets also included challenging stations with cleanup conducted over multiple 4-hour sessions with possible reinvasion of mud between sessions. We found that contamination predictions with the new method are in good agreement with results from laboratory analysis. Compared to the previous algorithms, the new contamination monitoring algorithm is applicable for all types of sampling hardware, a wider set of operating conditions, and over the full history of a sampling station (i.e., from formation fluid breakthrough to a clean sample). This latter attribute enables robust early-time predictions of the pumping time remaining to reach a clean sample. Finally, the new method is independent from manual user intervention and thus lends itself well to workflow automation.
Accurate, robust, and real-time quantification of oil-based mud (OBM) filtrate contamination using data from downhole fluid analysis (DFA) sensors remains a challenging problem, especially under difficult sampling conditions and for advanced sampling tools with complex inflow geometries and active guarding of filtrate flows. Such tools and conditions lead to contamination cleanup behaviors that do not necessarily follow the simple power-law models that are commonly used in contamination monitoring algorithms. Moreover, the need for improved efficiency calls for more automation in sampling operations, especially in high-activity regions with many wells and sampling stations. Achieving such automation within existing contamination monitoring workflows has been proven to be challenging. In this paper, we deploy a new method for contamination monitoring, based on the inversion of DFA data using a full 3D numerical flow model of the contamination cleanup process. This flow model predicts the evolution of filtrate contamination as a function of time and pumped volume and can thus be used to forward-model the DFA sensor responses. Sensor data, such as optical density, mass density, and gas-oil ratio, are then inverted in real time to provide contamination predictions. Real-time computation is enabled through fast, high-fidelity proxy models for the cleanup process. The proxy models are trained on and validated against a library of 300,000 precomputed full-scale numerical simulations covering a wide range of hardware configurations and sampling environments. We applied the new method on 14 field sampling stations of oil sampling in OBM conditions, with four different types of sampling inlets: single probe, radial probe, dual packer, and focused radial probe. The data sets also included challenging stations with cleanup conducted over multiple 4-hour sessions with possible reinvasion of mud between sessions. We found that contamination predictions with the new method are in good agreement with results from laboratory analysis. Compared to the previous algorithms, the new contamination monitoring algorithm is applicable for all types of sampling hardware, a wider set of operating conditions, and over the full history of a sampling station (i.e., from formation fluid breakthrough to a clean sample). This latter attribute enables robust early-time predictions of the pumping time remaining to reach a clean sample. Finally, the new method is independent from manual user intervention and thus lends itself well to workflow automation.
A computational fluid dynamics (CFD) and hydraulic system cosimulation method was implemented to understand formation tester dual-inlet dual-packer cleanup in oil-based mud. The simulation includes miscible multispecies fluids in the formation, the dual-packer interval (sump), and the formation tester flowlines, with the objective of reconciling a long-observed dual-packer discrepancy between simulated and observed formation fluid cleanup and generating operational best practices. A commercial CFD simulator is used to perform coupled simulations for flow in formation rock and in the dual-packer sump. Unlike reservoir simulators, which apply a simplified sandface condition using a well model, the CFD simulator includes the dynamics of fluid flow in the wellbore. Next, a simplified hydraulic tool flowline model is coded using JAVA, and a JAVA scripting functionality within the CFD simulator connects the CFD solver with the hydraulic model. This method includes mud, mud filtrate (filtrate), and reservoir hydrocarbons and honors the full pressure and flow rate history from the reservoir to the tool. Results show that when fluid sampling cleanup is initiated, flow into the dual-packer sump always starts from the top of the interval. This is caused by the pressure gradient difference between the sump (mud) and formation fluid (filtrate and native hydrocarbon). Simulations with a light hydrocarbon formation fluid result in native fluids fingering through the higher-viscosity filtrate. As the sump pressure continues to decrease, fluids start to enter the interval farther down, creating some density-driven flow circulation in the sump, particularly when the pumps are stopped for an early pressure buildup. The sump region below the lower inlet cleans up much more slowly because the heavier mud is not easily displaced with filtrate or hydrocarbon. Cosimulation that includes the flowline adds significant insights. While sump pressure is driven by flow from formation and by the dual-packer interval fluid densities, measured pressure at the tool pressure gauge also depends on the friction loss between the tool inlet and gauge (which is a function of flow rate, valve positions, and flowing fluid viscosity), flowline fluid head, and potential inlet filter restrictions. The method represents the dynamic responses of the system which is used to explain counterintuitive gauge pressure observations and cleanup behavior. Current commercial reservoir simulators routinely model flow through porous media, but they do not include detailed flow behavior in the wellbore section that is isolated by the dual packer. Similarly, hydraulic flow simulators exist, but are not often coupled to the reservoir. The novelty of this cosimulation is the ability to simulate the interactions between the formation rock, the dual-packer interval, and the flowlines, which are used to explain counterintuitive pressure phenomena and dual-packer cleanup.
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