The New Flow Control Devices Autonomously Controlling the Performance of Matrix Acid Stimulation Operations in Carbonate Reservoirs

Matrix acidizing is a common but complex stimulation treatment that could significantly improve production/injection rate, particularly in carbonate reservoirs. However, the desired improvement in all zones of the well by such operation may not be achieved due to existing and/or developing reservoir heterogeneity. This paper describes how a new flow control device (FCD) previously used to control water injection in long horizontal wells can also be used to improve the conformance of acid stimulation in carbonate reservoirs. Acid stimulation of a carbonate reservoir is a positive feedback process. Acid preferentially takes the least resistant path, an area with higher permeability or low skin. Once acid reacts with the formation, the injectivity in that zone increases, resulting in further preferential injection in the stimulated zone. Over-treating a high permeability zone results in poor distribution of acid to low permeability zones. Mechanical, chemical or foam diversions have been used to improve stimulation conformance along the wellbore, however, they may fail in carbonate reservoirs with natural fractures where fracture injectivity dominates the stimulation process. A new FCD has been developed to autonomously control flow and provide mechanical diversion during matrix stimulation. Once a predefined upper limit flowrate is reached at a zone, the valve autonomously closes. This eliminates the impact of thief zone on acid injection conformance and maintains a prescribed acid distribution. Like other FCDs, this device is installed in several compartments in the wells. The device has two operating conditions, one, as a passive outflow control valve, and two, as a barrier when the flow rate through the valve exceeds a designed limit, analogous to an electrical circuit breaker. Once a zone has been sufficiently stimulated by the acid and the injection rate in that zone exceeds the device trip point, the device in that zone closes and restricts further stimulation. Acid can then flow to and stimulate other zones This process can be repeated later in well life to re-stimulate zones. This performance enables the operators to minimise the impacts of high permeability zones on the acid conformance and to autonomously react to a dynamic change in reservoirs properties, specifically the growth of wormholes. The device can be installed as part of lower completions in both injection and production wells. It can be retrofitted in existing completions or be used in a retrievable completion. This technology allows repeat stimulation of carbonate reservoirs, providing mechanical diversion without the need for coiled tubing or other complex intervention. This paper will briefly present an overview of the device performance, flow loop testing and some results from numerical modelling. The paper also discusses the completion design workflow in carbonates reservoirs.