PAPER 2006-633

Twenty Years of Steam Injection in Heavy Oil

Fields in Brazil
K.G.O. PDUA, J.C. SOUZA JR., D.F.S. CURSINO
Petrobras
This paper has been selected for presentation and publication in the Proceedings at the 1st Heavy Oil Conference.
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The authors agree to assign the right to publish the above-titled paper to WHOC, who have conveyed non-exclusive right to the
Petroleum Society to publish, if it is selected.

The steep augment of steam generation facilities

required important improvements on the quality of the steam
generation process. They were required to guarantee the
necessary quality of the steam and the final results in terms of
heavy oil recovery. Starting on 1997, several measures have
been implemented, among them the ISO 9000 certification and
the process automation and control.

Abstract
This paper reviews the twenty years of steam injection in heavy
oil fields of Alto do Rodrigues area. The review includes the
beginning, consolidation and expansion of this enhanced
recovery method. Main topics involve project management of
cycled injection and steam drive along with steady
improvements on the quality control of the whole steam
generation process. At the end, this work shows the positive
impacts on the recovery factor and environmental issues

The first pilot of steam drive project was also

implemented in 1997 in Estreito Field. The preliminary results
indicated technical and economic feasibility. Other pilot
projects not only in Estreito Field but also Alto do Rodrigues
Field were stated and expanded.
Following the consolidation and success of the cyclic
steam injection projects all around the heavy oil fields, two
large scale steam drive projects were planned for the future
years.

1. Introduction
The steam injection, as a method of enhanced recovery, was
first implemented in 1984 in Alto do Rodrigues area. The area,
located in the Potiguar Basin, State of Rio Grande do Norte,
northeast of Brazil, mainly encompasses heavy oil fields.

Reservoir studies suggest that in the future the steam

drive projects will replace the cyclic steam injection projects,
particularly in the main developed areas. The last ones might
remain active in the border areas of Estreito and Alto do
Rodrigues fields.

The first steam injection projects in this area were

implemented in Estreito and Alto do Rodrigues Fields. They
comprised pilot projects of cyclic steam injection in small areas
of the fields. The objective was to evaluate the technical and
economic feasibility of steam injection as a method to enhance
the heavy oil recovery. The preliminary results suggested that
the thermal method was technically and economically feasible.

This work presents a brief history of application,

discusses the reservoir management, some important production
parameters, such as Oil Steam Ratio OSR, and the quality
improvements on the steam generation process necessary to
achieve the required steam characteristics and to assure good
results on the oil recovery.

The positive outcome led to, from 1992 on, a large

number of steam injection projects and a significant increase of
steam generation facilities to meet the rising demand for steam.

one in Alto do Rodrigues Field and other small areas. The good
results of the projects led to the expansion to a large scale
project involving the two important heavy oil fields of the area.

2. History
2.1. Brazil

In the beginning of 1999, the steam generation

process was certified according to ISO 9002 standard. The
certification followed several improvements on the steam
generation process with the definition of tasks and creation of
standards. The aim was to achieve ultimate excellence on the
operational performance and oil recovery.

The first steam injection project in Brazil took place in

Carmopolis Field, State of Sergipe, northeast of Brazil, in 1978,
with a steam generator of 15 MM Btu/hr energy capacity. In
1982, a second project was implemented in Fazenda Belm
Field, State of Rio Grande do Norte, northeast of Brazil.

The whole steam generation facility involves several

kilometers of steam injection lines, 3 mobile steam generators
and 18 fixed ones located in 9 sites. Figure 2 depicts the
evolution of total capacity of steam generation in terms of
MMBtu/hr.

In the Alto do Rodrigues area, the first steam injection

project was applied in 1984 in Estreito and Alto do Rodrigues
Field.
Nowadays, a great number of steam injection projects
are undertaken in the states of Esprito Santo, Bahia, Sergipe
and Rio Grande do Norte. Figure 1 shows the location of the
main heavy oil fields in Brazil where the thermal method of
enhanced oil recovery is currently applied.

MMBtu/
h

800
700
600
500
400
300
200
100
0

Faz.
Bel
m
(1982)
Estr
eito
(198
4)

1984 19851986 1987 1988 19891990 1991 1992 1993 19941995 1996 1997 1998 1999 2000 2001 20022003 2004

Casta
nhal
(1981
)

Yea

Sirizin
ho
(1995)
Carm
polis
(1978)

Figure 2 - The Evolution of Total Capacity of Steam Generation

3. Project Management
3.1. Reservoir Characteristics

Faz.
Alvorada
(1999)

The total original oil in place of the two fields, Alto do

Rodrigues e Estreito, reaches 163 MM sm3/d. The primary
objectives of the steam injection projects in both fields are the
heavy oil zones of Au Formation. The reservoirs are shallow
fluvial sandstones (160-350m) with good permeability and
porosity characteristics and aquifer support. The fluid possesses
a significant oil viscosity (800-10000cp) and a small API
gravity (14 17). As a consequence the well productivity is
small and the water breakthrough pretty fast because of the
disfavorable mobility ratio.
The primary recovery in both fields is small (less
than 9%. The well spacing has been progressively reduced
from 400 to 100 meters. Most wells are vertical or slightly
directional. More than 20 horizontal wells have been drilled,
particularly in areas with environmental difficulties such as
above Au river.
As a consequence of the low oil recovery, a
supplementary recovery method was required in order to
anticipate the oil production and enhance the economic
parameters of both fields. Based on several pilot projects the
thermal method of cyclic steam injection was initially adopted
in both fields with excellent results.

Rio Preto
Oeste
Faz. (2000)
Alegre
(2001)
Faz. So
Jorge
(2001)

Figure 1 Location of Main Heavy Oil Fields in Brazil

2.2 Alto do Rodrigues Area

The application of steam injection as a method of enhanced
heavy oil recovery was initiated in the Alto do Rodrigues area
in July 1984. The first project took place in Estreito Field and
the second one in Alto do Rodrigues Field in the very same
year.
Both projects comprised a cyclic steam injection with a
mobile steam generator of 15 MMbtu/hr of energy capacity.
The first one was applied in the well ET-089 and the second one
in the well ARG-049.
The results of the thermal method were excellent
since the beginning. In both fields, the pilot projects present
economic and technical feasibility and were soon expanded to a
large scale from 1992 on.

3.2 Cyclic Injection

The modus operandi of a cyclic steam injection
comprises a period of steam injection, soaking and production.
The economic parameter defines the number of cycles.
The reduction of oil viscosity with the increase of
temperature around the well justifies the increase of well
productivity, the anticipation of oil production and some

Following the consolidation of the cyclic steam

injection method, the first successful pilot project with steam
drive was initiated in 1997 in Estreito Field, in a small area with
71 meters wells spacing. Other pilot projects followed the first
2

improvement on the ultimate oil recovery. The cyclic steam

injection, as an enhanced oil recovery method, has been applied
with success all around the world in heavy oil fields with an
ultimate recovery as much as 25% in the project area.
In Estreito and Alto do Rodrigues Fields, more than
7000 cycles of steam injection in more than 1000 wells (mainly
vertical) were carried out. Two horizontal wells were joined to
form the first U-shape well in the world with cyclic steam
injection. Unfortunately, the special U-shape well and the other
horizontal wells present poor economic results.
The volume of steam injected in the wells, based on
numerical studies, ranged from 90 to 130 ton/m of the reservoir
thickness. Steam quality is around 75 to 80% (wet saturated
steam).
Additional to the thermal effect, a new type of cyclic
steam injection is under current application and evaluation. The
new project involves the use of naphtha added to steam in order
to help the reduction of oil viscosity. Laboratory studies suggest
that the new technique may increase the oil recovery. Some
pilot projects are being applied in the field. The results are still
under evaluation.

steam flood in both fields. The concomitant operation in the

entire area, through the injection in several patterns at the same
time, will lead to a better drainage and capture of bypassed oil.
The global project in both fields is associated to the
construction of a new thermoelectric plant that will provide a
superheated steam leading to better heat efficiency. Figure 3
presents the conceptual system of distribution of the steam
generated by the thermoelectric plant. The total steam rate is
around 611 ton/h. The expansion of the steam drive of steam
should involve 530 well-column injectors and 630 well-column
producers in both fields. An additional production of 45 MMbbl
is foreseen.
A1-ARG

A10-ET

12

18

16 14

20
12

14

10

3.3 Steam drive

The modus operandi of this thermal method is the continuous

injection of steam in a pre-defined pattern of injection and
production wells. In most cases the implementation of this
method follows the application of the cyclic steam injection
method after the oil around the well has been depleted.
The cyclic injection method normally has shorter
payout time and higher rate of return than those of the steam
drive because of the rapid response of production and the low
investment associated. Additionally, the oil steam ratio of the
cyclic injection is higher than that of the steam drive. However,
steam drive allows the recovery of a great amount of oil through
re-pressurization and drainage of part of the oil that could not be
reached with the cyclic injection.
During the eighties, two pilot projects were performed
in Fazenda Belm and Alto do Rodrigues. The outcome of both
cases was not positive. The Initial disappointment led to a reevaluation of the whole process including reservoir studies and
numerical simulation. The studies suggested the increase of the
volume of steam injected from previous 60 ton/day to 120
ton/day in future projects.
New pilot projects were implemented from 1997 on in
Estreito and Alto do Rodrigues Field. Steam drive was applied
in five spot patterns with different well spacing ranging from 71
to 141 meters. The idea was to investigate the effect of well
spacing on the final results due to the inherent reservoir
heterogeneities. The preliminary results indicated technical and
economic feasibility and led to the expansion of steam drive to
larger areas of both fields.
After a long time of application, the cyclic steam
injection method in Alto do Rodrigues demonstrates a clear
exhaustion of positive results. More and more these projects
are getting closer to be marginal reaching the economic limit of
OSR around 0.1 m3/m3. Following the good results of the
steam drive pilot and the exhaustion of the cyclic steam
injection, new but small steam flooding projects come on
stream, taking advantage of the available steam left by the
previous project.
A numerical simulation was performed in both fields
involving inherent reservoir characteristics, new operational
improvements and the history match of all previous pilot
projects. The studies suggested a large scale application of

Rio
Au

10

A2-ARG
A5-ARG

16

A11-ET

24

Termoau

Figure 3 - Conceptual System of Distribution of the Steam

Generated by Thermoelectric Plant
The future large scale steam flood project in the area is
now being planned and is estimated to come on stream in 20072008.
In the meantime, continuous studies are being
undertaken to optimize the injection scheme and timing, the
volume of steam per well and the overall well pattern.
Additionally, continuous tests of new equipments that can stand
high temperatures and the overall steam generation process are
also being performed in order to guarantee full safety and great
performance.

4. Improvements on Steam Generation

and Injection
4.1 ISO 9000 Certification
The certification process comprised the implementation of a
system of quality, based on the norms ISO 9000 series that
embraced the planning stages, conception of the system,
elaboration of patterns, manuals and specifications, training,
implementation of routines and recurrent evaluations. The
main factors that contributed to the success of the project
were the commitment of the high administration,
availability of resources and well defined goals for the
whole team.
4.1.1 Contract of Steam Supply
A contract of steam supply is set up between the reservoir
management as customer and the operation management as
vendors. The contract is discussed and negotiated annually.
Monthly commitments of steam quality, rate and pressure,
among others, are specified in the contract based on the
3

reservoir management requirement and operation management

capacity. The whole schedule of steam distribution is based on
a detailed program comprising steam quotas, wells and
priorities set up by the reservoir management. The operation
management receives the program, plans the schedule, measures
and controls the overall distribution of steam.

of data (SCADA). Figure 4 illustrates the architecture of the

system.

ESCGV

ESCGV2

INTRANET

4.1.2 Benefits obtained with the Certification

ESCCISC

The process of certification conducted to a significant increase

of the operational performance due to the following aspects
i. standardization of all the tasks;
ii. guarantee of facts and variables registrations;
iii. incorporation of improvements;
iv. previsibility of the actions;
v. on-job training;
vi. focus on the customer.

ESCGV1

Rede DH+

UTC11

Rede DH+

UTC13
GV-13

GV-14

GV-29a

GV-29b

EV-1

4.2 Automation and Control:

4.2.1 Prior Situation

EVASSU

Initially, the steam generators used complete pneumatic controls

for the water rate / capacity of the burner ratio, outlet steam
pressure / water rate ratio and pressure of the fuel gas. The
loops of instrumentation were pneumatic. There was no remote
monitoring and no automatic control of important parameters
such as the steam quality and oxygen level resultant of the
combustion.

TABA

GV-02

GV-30

Figure 4 - The Architecture of the SCADA

The information of the steam generators is
concentrated in a Central Terminal Unit. This unit, composed
by a CLP, communication module and radio-modem, is
responsible for the communication, in a way to make the
acquisition of data periodically, to monitor communication
failures and to send eventual commands.

The programmable logical controller was based on

aeromechanic relay, destined to solve interlocks functions,
timing and detention of process alarms. This conception
resulted in many failures, in low combustion quality and in a
shorter guarantee of the steam quality.

All the steam generators can be analyzed in full detail

through its individual screen, as indicated below in the
illustration, figure 5, where its process variables are visualized
and the command can be given of " STOPPING " the generator.

4.2.2 Implementation of a System of Control, Supervision and

Data Acquisition (SCADA)
The implementation of a control system, supervision and data
acquisition (SCADA), contemplated the installation of remote
terminal units (UTR) in each steam generator, with the
substitution of the pneumatic control loop for electronics,
facilitating the remote monitoring of the whole process.
The control and safety systems of the steam
generators aimed to control the variables involved in the
process of transformation of water in steam keeping them in the
range specified by the operator and safety's limits and contract.
It would also mitigate personal and material damages with the
remote monitoring, registration of abnormalities and the
historical registration of the variables.
The steam generators possess the control of feeding
water rate, steam quality, O2 level in the exhaustion gases, fuel
gas rate and pressure.
The loops are controlled by devices of the
proportional-integral-derivative type (PID), digital implanted in
a Programmable Logical Controller (CLP). The control is made
by two devices, a CLP and a controller of the burner, starting
from the signs of sensors of flame, pressure, temperature, rate
oxygen level, position and status.

Figure 5 - Individual Screen of Steam Generator

Figure 6 presents the summary screen that allows the
visualization of the main variables of process of all the steam
generators simultaneously, and alarm conditions and shutdown.

The programmable logical controllers of each steam

generator send its data periodically based on radio or cable
transmission to the control system, supervision and acquisition
4

5. Conclusion
Alto do Rodrigues Field and Estreito Field possess about 163
MMm3 of oil "in-place ". A great part of it, around 109 million
of m3 is submitted to the enhanced recovery method of steam
injection. The two fields have a cumulative production of 17
MMm3 of heavy oil. Half of it, about 9.3 million m3, may be
attributed to the thermal method of steam injection (cyclic and
continuous).
The participation of the produced oil from steam
injection projects in the area and whole state of Rio Grande do
Norte and Cear is still increasing. However, the current
recovery factor from cyclic steam injection projects suggests
that this method is heading to the exhaustion. Current recovery
of the cyclic steam injection is near 20%, with an oil steam ratio
OSR of 0.5 m3/ton, while the foreseen ultimate recovery in the
areas they are applied is around 24%.
Figure 6 - The Summary Screen

Figure 8 presents the percentile participation of

production of the main heavy oil fields in the area.

2.3 Automation Results

The implementation of the System of Control, Supervision and
Acquisition of Data in the process of generation of steam led to
an increment in the performance of the machines and a larger
operational reliability.

HEAVY OIL PERCENTAGE OF TOTAL PRODUCTION

35

% HEAVY OIL RATE (HISTORY)

30
HEAVY OIL PERCENTAGE
OF TOTAL PRODUCTION (%)

% HEAVY OIL RATE (FORECAST)

25

Figure 7 depicts the improved performance due to the

instrumentation of the generators of steam, after implementing
the project in the year of 2002.

20

15

Stop hours/Month

10

500
5

400
300

0
1980

200

1985

1990

1995

2000

2005

2010

2015

2020

2025

2030

100
0
2000

2001

2002

2003

2004

HEAVY OIL PERCENTAGE OF TOTAL

CUMULATIVE PRODUCTION

Year
25

HEAVY OIL PERCENTAGE OF

TOTAL CUMULATIVE PRODUCTION (%)

Figure 7 - The Improved Performance due to the

Instrumentation
Since the steam quality is a basic premise for a good
efficiency in the mechanism of oil recovery, the implementation
of the control system provides better assurance that the
specified parameters required by the reservoir management will
be achieved.
Other benefits with automation can be observed as

e.
f.
g.
h.

HEAVY OIL PERCENTAGE OF TOTAL

CUMULATIVE PRODUCTION (FORECAST)

15

10

follows.
a.
b.
c.
d.

20

HEAVY OIL PERCENTAGE OF TOTAL

CUMULATIVE PRODUCTION (HISTORY)

1980

1985

1990

1995

2000

2005

2010

2015

2020

2025

2030

Figures 8a, 8b - The Participation of production

Remote monitoring of the occurrences;

Automatic registering of occurrences;
Easier information;
Greater reliability and safety in the control of the
process;
Easier maintenance and operation;
Optimization of the labor;
Reduction in the number of failures;
Improvement in the quality of the combustion.

6. Perspectives
The following perspectives can be foreseen to the area of Alto
do Rodrigues:
a.
b.

Implementation of a large scale project of steam flooding

using superheated steam associated with a thermoelectric
plant;
New reservoir studies seeking improvements in the
efficiency of the method such as steam quotas, schedule,
well pattern and profile

c.
d.
e.
f.
g.

Steam injection with an addictive (naphtha) that would

help the oil viscosity reduction;
New equipments that operate safely at high temperatures;
Control of the produced water of the reservoir, with
development of blocking products of the production of
water that resist high temperatures;
Studies and Implementation of projects of injection of
water for discharging and re-injection, because of the high
volumes of water that are produced;
Expansion of steam injection projects to new heavy oil
fields and horizons.

7. References
1.Silva, W. A. C. M. and Souza Jr, J. C., Steam Generation
Process Control and Automation, Paper IBP172_04 presented
in Rio Oil & Gas Expo and Conference 2004, Rio de Janeiro,
oct. 04-07
2.Medeiros, M. A. C. and Carvalho Neto, J, The
Implementation of Quality System, Paper IBP21798
presented in Rio Oil & Gas Expo and Conference 1998, Rio
de Janeiro, oct. 05-08.