SPE-171094-MS

A Successful Gravel-Packing Technique in Vertical and Deviated Wells

with Enlarged Open Hole in Cased Completions: A Case Study, Rubiales
and Quifa Fields
A. Florez and M. Osorio, Pacific Rubiales Energy

Copyright 2014, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Heavy and Extra Heavy Oil Conference - Latin America held in Medellin, Colombia, 24 –26 September 2014.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Rubiales and Quifa fields are the major oilfield in Colombia; two heavy oil reservoirs (API in the range
11.3° to 14.4°) with unconsolidated sandstone formation with high permeability, however, there is low
productivity in vertical and deviated wells, caused by formation damage from drilling fluids, and cased
gravel packing completion.
These two formation damages have been mitigated by applying a successful gravel packing technique
in both vertical and deviated wells. On June 30, 2014, the oil production rate was 186 thousand BOPD,
of which 14.5 thousand BOPD (7%) came from 162 vertical and deviated wells with the successful gravel
packing technique.
The successful gravel packing technique consists on first running a standard cemented 7 inches casing
and then cutting the casing in the production zone and enlarge the open hole section from 8.5 inches to
13 or 16 inches diameter to remove cement bond overpassing the washout. Finally, the enlarged open hole
section is gravel packed with mesh 20-40.
The completion technology purpose is to increase the well productivity, isolating high water saturation
intervals on both top and bottom of the oil zone, reducing the skin damage.
Before 2007, 30 wells were completed with conventional cased hole gravel packing. Most of these
wells were damaged having to be frequently stimulated with organic treatment; 14 of these wells have
been re-completed using gravel packing technique. The results show an increase in the productivity index
from 2 to 5 times, compared to conventional completion and showing a maximum increase in total fluid
rate from 600 BFPD to 3000 BFPD.
Finally, some examples are presented comparing gravel packing using this technique and the cased hole
completion method. Operation procedures, advantages, limitations, and production results are presented
in individual well performance comparisons. The successful application of this technology has contributed
to increase oil production in Rubiales and Quifa fields development and it has also been extended to others
analogues fields.
2 SPE-171094-MS

Introduction
The Rubiales and Quifa fields are located 465 km East from Bogota, Colombia, South America
(APPENDIX A). Both fields are part of the same reservoir and the boundaries are mainly contractual.
Rubiales was discovered in 1980 and began full production development in 2006, while Quifa was
discovered and developed in 2008.
Both fields cover an area of 102,131 hectares of a heavy oil reservoir API in the range 11.3 to 14.4
°API, high viscosity between 310 cP and 730 cP @ 147°F with unconsolidated sandstones, within an
active and strong aquifer.
At the beginning, Rubiales field was developed with vertical wells which were completed with cased
hole gravel packing (further on referred as: conventional completion). This technique has been used to
control the sand production. To December 2007, 30 wells that had been completed using this method, and
presented low productivity and skin damage, mainly due to asphaltenes precipitation and emulsion
formation. Several intervention jobs were designed using organic solvent compounds to repair the skin
damage. The result of these organic treatments, although successful, but mostly temporary and had to be
repeated approximately every 6 months.
In order to increase productivity and reduce skin damage the conventional completion was changed,
instead of casing perforating, the casing was cut and the production interval was enlarged and then packed
with gravel 20-40 mesh. In 2008, a gravel packing vertical well was selected as a pilot test in order to
value the results and apply the new completion (Gravel Packing Technique with enlarged open hole in
cased completions) to new and existing wells.
Once the pilot test results indicated large benefits, in 2008 was launched a campaign to work over the
cased hole gravel packing existing wells with this new completion, as well as the new wells. Below there
is an exposition of the obtained results, advantages, damage mitigation, used technique, and learning curve
of this process.
Geology characteristics1
The stratigraphic sequence in the Rubiales Field consists of rocks ranging from Paleozoic to Tertiary
(Guayabo, León and Carbonera), separated by regional unconformities (APPENDIX B). The deposition
system of braided rivers is composed of mainly sands with lateral deposition bodies that are commonly
interbedded with fine overbank sediments. The structure of the Rubiales Field consists of a monocline
with a dip below 4° in the direction N50°W.
The Areniscas Basales Unit is the producing reservoir in the Rubiales Field (APPENDIX C). This unit
consists of quartz-arenites and sub-arc sandstones that are light gray, fine-grained to coarse and friable,
with porosities ranging from 25% to 32% and permeabilities between 5 and 13 Darcy. The formation
thickness varies from 130 to 200 feet. The bottom contact is discordant with the Paleozoic and gradually
moves toward the ceiling with the Carbonera Intermediate Unit.
Reservoir and fluids characteristics1
The Rubiales Field occupies an area of 56,000 hectares, with 20 to 80 feet of oil sand thickness. The
Areniscas Basales Unit depth is between 2,400 feet and 3,000 feet TVD. The production mechanism is
a strong artesian aquifer with an oil-water contact tilted in the north-west direction. The reservoir pressure
is typically normal, with 1170 psi at 2700 feet TVD.
The reservoir oil is heavy one (11.3 to 14.4 API), has a low GOR (5 to 8 SCF/STB) and has a high
viscosity 310-730 cP at 147°F).
Problem description2
During the initial development of Rubiales, vertical wells were cased hole gravel packing completed, in
order to control the sand production. This type of completion was used in 30 wells which were perforated
SPE-171094-MS 3

with big hole charges at 21 shots per foot. This

conventional completion presented several disad-
vantages exposed below:
● Emulsion blocks formed in the formation
skin, around the well, due to the high turbu-
lent flow in the productive interval.
● Low productivity index since the perforated
area does not overpass 3% of the productiv-
ity interval. The cased hole gravel packing is
performed only in the perforated orifices
causing a significant drop of the productivity Figure 1—Colloidal Instability Index
index (about 60%).
● High washouts presence requires double
perforation, big hole, and high perforating in order to surpass the cement around the casing.
Several wells have required re-completion so that the perforating contacts the formation will
increase (APPENDIX D).
● Formation damage due to asphaltenes precipitation caused by a high drop in pressure and
temperature around the wells. In order to repair this damage, an organic treatment has been
proposed, however the effect has been proved to last no more than 6 months, after which the
process must be repeated.

Formation damage3
In Rubiales, aside from the damage caused by the emulsion blocks, and fine material migration, it is also
possible to have damage due to asphaltenes precipitation, generated by high draw down pressure required
to produce vertical wells. Several surface oil samples were subject to SARA analysis, indicating the
presence of asphlatenes between 21 to 44%. The colloidal instability index for 20 wells, taking into
account the saturated (paraffin), aromatic, resins, and asphaltenes components, the index results were
larger than 0.9 in 16 wells, which indicates a non-stable condition in the system, when there is a change
in the pressure with the asphaltenes precipitation (see Figure 1).
This condition is generated when there is an increase in the paraffins, allowing that portion of the
asphaltenes to form colloids, separating from the oil as an aggregated while the remaining portion stays
suspended, stabilized by peptizing agents such as resins that are absorbed and avoid aggregation.
Due to the described effect, it is necessary to mitigate this non-stable condition through the use of
organic treatments, removing the formation damage and allowing connectivity.

Organic treatments
Due to the disadvantages of the cased hole gravel packing completion, which affects the productivity
index caused by the damage generated by using this conventional completion, and in addition to this, the
asphaltenes precipitation, a temporary remediation method is used by injecting an organic compound
treatment. This treatment is a mix of 54.5% Diesel, 40% Xylene, 5% mutual solvent, and 0.5% of
surfactant.
By December 2013 in the Rubiales field 162 vertical and deviated wells have the new completion while
only 55 have been completed using conventional completion (14 of wich have been re-completed to the
new completion). Out of these last 55 wells, 20 wells have treated with organic remediation between 2 to
5 times during their production history quintupling the initial production index in a temporary basis, and
then declining after approximately 6 months (See Table 1, Productivity index in Wells with organic
treatment).
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Table 1—Productivity Index in Wells with organic treatments

CASED HOLE GRAVEL ORGANIC PI BEFORE PI AFTER
PACKING WELLS TREATMENTS (#) (BFPD/psi) (BFPD/psi) RATIO

RB-006 2 - - -
RB-010 2 1.5 9 6
RB-012 1 2 2 1
RB-026 1 - - -
RB-028 1 - - -
RB-031 5 0.3 0.8 3
RB-033 1 1 2 2
RB-034 4 0.5 3.5 7
RB-036 3 - - -
RB-038 5 1 6 6
RB-041 5 2 8 4
RB-047 1 0.3 2 7
RB-051 1 0.7 2 3
RB-079 3 0.8 4 5
RB-113 1 0.2 2 10
RB-147 1 - - -
RB-217 2 0.2 2 10
RB-221 1 0.1 0.5 5
RB-619 1 - - -
RB-625 1 0 5 -

Figure 2—PI, Wells with conventional gravel packing

Productivity Index (Pi)

A thorough analysis of the productivity index (BFPD/psi) data was conducted in order to measure the
input flow efficiency in cased hole gravel packing completion and its effect in the formation damage.
Figure 2 depicts the productivity index behavior through the 52 conventional completion wells in the field,
registering indexes of 3 BFPD/psi in 60% of the samples.
Gravel Packing Technique with Enlarged Open Hole in Cased Hole
Completions4
Based on the previous experience with the cased hole gravel packing completion, it is necessary to start
a proper evaluation for the window and enlargement to 13 inches on vertical and deviated wells technique
and its implementation (see Figure 3).
The technique consists in:
SPE-171094-MS 5

1. Run a 7 inch casing down to 30 feet above

the bottom hole.
2. Perform cementation job.
3. Run an evaluation login for cement quality.
4. Assemble and lower the well completion
string with the Section Mill.
5. Correlate and position the Section Mill
blades down to the window depth stop.
6. Cut the 7 inch casing in order to open the
window.
7. Assemble and lower the enlargement tool
down to the window depth stop, set the tool
and perform the enlargement to 13 or 16
inches according to the need.
8. Assemble and run the gravel pack string, Figure 3—Gravel packing vertical well with enlarged open hole in cased
positioning the screen in front of the produc- completions

tive interval and perform the gravel packing.

9. Run the artificial lift equipment.
10. Begin the well production process.
Considering the procedure and the reservoir con-
ditions for this case study, the following advantages
were found:
● Remove any formation damage caused by
the perforation fluids, mainly the calcium
carbonate.
● Remove the washout cement that has been
filled up during the cementing process. In
conventional completion there is partial pen-
etration in this zone. Figure 4 —Production History Well RB-41
● Reduction in the asphaltenes precipitation
due to the larger flow area the pressure drops
decrease during the production. The flow
area corresponds to the 100% of the exposed
sandstone.
● Reduction in the number of organic treat-
ments necessary for each well, each of these
treatments represents a cost of USD $150M,
including equipment and fluid treatment.
● Compared with the standard completion the
new completion allows to selectively acti-
vate one or two productive interval using
effectively the lithological seals that allow
holding back the water flow with a good
mechanical isolator with cemented casing. Figure 5—Productivity Index History
6 SPE-171094-MS

Figure 6 —Comparison PI/FT in Converted wells

Results Analysis
In order to verify the efficiency of the new completion for the existing conditions of the reservoir, and
complying with the requirements of the new completion, a pilot test was developed selecting a cased hole
gravel packing completion well to be enlarged (RB-041). Before the well is re-completed, it was
stimulated with 5 organic treatments in order to reestablish its productivity; however the damage will
reappear within six months of intervention.
Figure 4 depicts the increase in the productivity index from 1.5 BFPD/psi to 20 BFPD/psi in well
RB-41, once it was worked over with the new completion. In addition to the increase in productivity, the
profitability had an additional improvement since the formation damage was no longer an issue, avoiding
the need for any organic treatment.
After the obtained results in 2008 at RB-41 an implementation campaign for the new completion
technique took place initially in the cased hole gravel packing wells with an average productivity index
less than 3.0 BFPD/psi (see Figure 2).
Figure 5 shows the behavior of the productivity index throughout the production history of the
re-completed wells, beholding an increase in the productivity index of almost 5 times the initial values.
In addition to this, for comparing purposes, the PI was normalized by the number of feet in production
before and after the intervention (IP/FT) in order to have a better contrast of the well input for every foot
finding that the IP increase is in average 5 times better (see Figure 6).
Taking into account the positive results obtained in the converted wells to the new completion, the
technique exposed in this case study is extended to the new wells in both fields subject of study. As of
December 2013, 162 wells have been completed with the new methodology determining that 70% of the
wells have an average productivity index of 12 BFPD/psi (see Figure 7). Besides the increment in the
productivity index a substantial decrease of 5 to 1 has been observed in the intervention frequency on the
wells for organic treatment, hence lowering the production costs.
Lessons learned
During the implementation of the new completion, the following lessons have been registered within its
own learning curve necessary for a successful application:
● This type of completion is limited to thicknesses larger than 4 feet since it has restrictions due to
the blades opening used to cut the casing.
● Some effect has been observed in the cement integrity: Due to the extra torque applied to the
casing and the cement in the enlargement operation. It is acceptable to have an effect 2 feet above
SPE-171094-MS 7

Figure 7—Productivity index in new completion wells.

or below the production interval, however, this could be minimized by applying the proper
perforation parameters in each and every case individually. (See APPENDIX E).
● In highly deviated wells, there has been a length restriction of the window since any window larger
than 30 ft. presents difficulty to set the screen production string.
Conclusions
The wells completed using the exposed solution shows a better productivity index, hence, a larger fluid
production conditions. The productivity index increases 5 times (from 5 to 25 BFPD/psi) using the new
completion.
The completion using an extended open hole window becomes the best option for Rubiales and Quifa
Fields, as long as the water-oil contact is not reached in the same productive interval and it is a suitable
enlargement candidate.
Organic treatments decrease from 5 to 1, lowering the production costs.
By using the new completion exposed it was found a clear solution to the disadvantages of the
conventional cased hole gravel packing completion such as remove washout, reduce formation damage,
large formation connectivity, increase productivity index and reduce organic treatments.
Out of the 279 vertical and deviated wells at December 2013, 162 of them had new completion and 55
had conventional completion, out of which 14 have been converted using the new completion. The
remaining 62 wells present either a mix completion methodology or their production history is not
representative to the purpose of this analysis.

Acknowledgement
We would like to thank Pacific Rubiales Energy S.A. to allow us the publication of this document, as well
as the engineering and geology staff for their technical support provided along the development of this
work.

Nomenclature
BOPD ⫽ Barrels of oil per day.
BFPD ⫽ Barrels of fluid per day.
Km ⫽ Kilometers.
cP ⫽ Centipoises.
°F ⫽ Degree Fahrenheit.
8 SPE-171094-MS

TVD ⫽ True vertical depth.

SCF ⫽ Standard cubic feet.
STB ⫽ Stock-tank barrel.
PSI ⫽ Pounds per square inch.
PI ⫽ Productivity index.
PI/FT ⫽ Normalized Productivity index.
MUSD ⫽ Thousands of dollars.

References
1. Florez, A., Araujo, Y., Parra, W., Uzcátegui, M. and Lavado, R. 2012. Improved Heavy Oil
Recovery by drilling Horizontal Wells in Rubiales Field, Colombia. Paper SPE 153581 presented
at the SPE Latin American and Caribbean Petroleum Engineering Conference held in Mexico
City, Mexico, 16-18 April.
2. Economides, M. J., Hill, D. A, y Ehlig-Economides, C. A.: Petroleum Production Systems,
Prentice Hall, Englewood Cliffs, NJ (1994).
3. Asomaning, S., Test Methods for Determining Asphaltenes Stability in Crude Oils, Petroleum
Science and Technology, Vol. 21, Nos. 3 & 4, pp 581–590, 2003.
4. Barry, M. D., Hecker, M. T., Haeberle, D., Blacklock, J. D., & Yeh, C. S. (2007, January 1).
Openhole Gravel Packing With Zonal Isolation. Society of Petroleum Engineers. doi: 10.2118/
110460-MS.
SPE-171094-MS 9

APPENDIX A

Rubiales and Quifa fields location in Colombia

APPENDIX B

Regional geology.
10 SPE-171094-MS

APPENDIX C

Stratigraphic pattern in the Rubiales Field.

APPENDIX D

Schematic Washouts.
SPE-171094-MS 11

APPENDIX E

Damage in the cement of ⴙ/ⴚ 2 ft. of the window depth top in the USIT log.