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Prediction of Heavy-Oil Viscosities

With a Simple Correlation Approach


A. Bahadori, Southern Cross University, and M. Mahmoudi and A. Nouri, University of Alberta

Summary Ghetto et al. 1995; Petrosky and Farshad 1995; Wakabayashi 1997;
Heavy-oil development is becoming increasingly important be- Bennison 1998; Miadonye and Puttagunta 1998), and are mainly a
cause of the continuous decline in conventional-oil production. For function of density (or API) and temperature. These correlations
heavy-oil reservoirs, the oil viscosity usually varies dramatically are used when viscosity measurements are not available. Consid-
during production processes such as in thermal processes. When erable errors may be introduced when these correlations are used
producing heavy oil, the high viscosity is a major impediment to for assessing heavy-oil viscosity. To increase accuracy, composi-
recovery. Oil viscosity is often correlated directly to the reserves tional terms, such as the percent of saturates, aromatics, resins, and
estimate in heavy-oil formations and can determine the success asphaltenes, should be used in the correlation (Al-Maamari et al.
or failure of a given enhanced-oil-recovery scheme. As a result, 2006). Therefore, we use a new correlating parameter called cor-
viscosity is an important parameter for performing numerical rected API (CAPI), as proposed by Al-Maamari et al. (2006), which
simulation and determining the economics of a project. can be used for heavy-oil characterization.
In this work, a simple-to-use correlation has been developed to The results in this paper are the product of analysis of heavy-oil
correlate the viscosity of heavy oil to temperature and to a simple data collected from the open literature for various heavy-oil fields
correlating parameter that can be used for heavy-oil characteriza- around the world. Distinctive parameters that have been considered
tion. The reported results are the product of the analysis of heavy- are crude-oil gravity (API) and compound class distributions [i.e.,
oil data collected from the open literature for various heavy-oil saturated hydrocarbons (Sa), aromatic hydrocarbons (Ar), resins
fields around the world. The tool developed in this study can be (Re), and asphaltenes (As)] (Al-Maamari et al. 2006):
of immense practical value for petroleum engineers, providing a
method for quick assessment of the viscosity of heavy oils. In par- Sa . .................................................(1)
CAPI = API
ticular, petroleum and production engineers would find the pro- Ar + Re + As
posed correlation to be user-friendly, with transparent calculations
involving no complex expressions. The units in Eq. 1 for Sa, Ar, Re, and As are mass fraction. In
The new proposed correlation shows consistently accurate view of the aforementioned issues and the importance of viscosity
results. This consistency could not be matched by any of the widely in heavy-oil production and processing, it is necessary to develop
accepted existing correlations within the investigated range. For all an accurate and simple correlation for predicting the viscosity of
conditions, the new correlation provided better results than existing heavy crude oil as a function of temperature and for correlating
correlations in the literature. parameters that can be easily assessed. This paper discusses the
formulation of such a predictive tool in a systematic manner. The
Introduction proposed method is an exponential function that leads to well-be-
The continuing decline in conventional crude-oil reserves com- haved (i.e., smooth and nonoscillatory) equations, enabling more-
bined with the continuing high worldwide demand for oil has led accurate and nonoscillatory predictions.
to the increased role of unconventional resources, especially heavy In the majority of cases, existing correlations indicated a good
crude oil, in the world (Pedersen and Fredenslund 1984; Butler prediction of crude-oil viscosity for the oils from which they were
1991; Al-Maamari et al. 2006). There are many challenges to the derived. However, when used with other crude oils from other
successful exploitation of these resources (Willman et al. 1961). regions, these correlations are, in most cases, not accurate and
One of the major issues is the high viscosity of the heavy crude certain modifications are needed to obtain acceptable viscosity
oils, which makes production and processing difficult (Monnery predictions.
et al. 1995; Mehrotra et al. 1996). Heavy crude oil and tar-sand This correlation is only for dead-oil viscosity; therefore, the vis-
oil are petroleum or petroleum-like liquids or semisolids occurring cosity/API correlation is the focus of this paper. A new correlating
naturally in porous media. These oils are characterized by viscosity parameter, CAPI, is used for heavy-oil characterization. It is not a
and density (Puttagunta et al. 1993). function of pressure. The reported results are the product of anal-
The viscosity of heavy oils is a critical property in predicting ysis of data from many heavy oils collected from the open literature
oil recovery (Mehrotra 1990) and selecting a production approach. for various heavy-oil fields around the world.
Several viscosity correlations are available in the literature (Meh-
rotra 1991a, b; Miadonye et al. 1992; Puttagunta et al. 1992; Miad- Methodology for the Development of a Novel Correlation
onye et al. 1993; Puttagunta et al. 1993; Singh et al. 1993a, b; De The primary purpose of the present study is to accurately correlate
the viscosity of heavy crude oil as a function of temperature, and
as a function of a simple correlating parameter that can be used for
Copyright 2015 Society of Petroleum Engineers
heavy-oil characterization.
This paper (SPE 157360) was accepted for presentation at the SPE Heavy Oil Conference The Vandermonde matrix is a matrix with the terms of a geo-
Canada, Calgary, 1214 June 2012, and revised for publication. Original manuscript
received for review 25 June 2014. Revised manuscript received for review 23 September
metric progression in each row (i.e., an m n matrix) (Bair et al.
2014. Paper peer approved 5 November 2014. 2006):

66 Oil and Gas Facilities February 2015 February 2015 Oil and Gas Facilities 1
Table 1Tuned coefficients used in Eqs. 11 through 14.

1 1 12 ... 1n 1 If we substitute Eq. 3 into Eq. 8, we obtain a system of linear equa-
tions in the coefficients ak. The system in matrix/vector form reads
1 2  2
2 ... 2n 1 (Fulton and Harris 1991; Horn and Johnson 1991; Bair et al. 2006)
V = 1 3  2
3 ... 3n 1 .......................................(2)
     x0n x0n 1 x0n 2 x0 1 an y0

1 m  2
mn1 xn
xn 1
x1n 2 x1 1 an 1 y1
m 1 1
= . .............(9)
      
or
x n
x n 1
x n2
xn 1 a0 yn
n n n

Vi , j = ij 1 ..................................................................................(3)

for all indices i and j. The determinant of a square Vandermonde We have to solve this system for ak to construct the interpolant
matrix (where m = n) can be expressed as (Bair et al. 2006) P(x). The matrix on the left is commonly referred to as a Vander-
monde matrix (Fulton and Harris 1991; Horn and Johnson 1991;
det (V ) = (
1i < j n
j )
i . .........................................................(4)
Bair et al. 2006).

Development of the Correlation. The data required to develop


The Vandermonde matrix evaluates a polynomial at a set of this correlation include the viscosity of heavy oil as a function of
points. Formally, it transforms coefficients of a polynomial a0 + temperature and the corrected API (CAPI) (Henshaw et al. 1998;
a1x + a2x2 +... + an1xn1 to the values that the polynomial takes at Al-Maamari et al. 2006). The following methodology (Bahadori
the points i. The nonvanishing of the Vandermonde determinant and Vuthaluru 2009; Bahadori 2010, 2011) has been applied to
for distinct points i shows that for distinct points, the map from co- develop this correlation by use of Matlab technical computing
efficients to values at those points is a one-to-one correspondence, language (Matlab 2008):
and thus that the polynomial interpolation problem is solvable with 1. Correlate the viscosities of heavy oil as a function of the
a unique solution. This result is called the unisolvence theorem CAPI for a given temperature.
(Fulton and Harris 1991). They are thus useful in polynomial in- 2. Repeat Step 1 for other temperatures.
terpolation because solving the system of linear equations Vu = y 3. Correlate the corresponding polynomial coefficients, which
for u, with V being an m n Vandermonde matrix, is equivalent to were obtained for different temperatures, vs. temperature: a =
finding the coefficients uj of the polynomial(s) (Bair et al. 2006; f(T), b = f(T), c = f(T), d = f(T) (see Eqs. 11 through 14].
Fulton and Harris 1991; Horn and Johnson 1991). Eq. 10 represents the proposed governing equation in which
four coefficients are used to correlate the viscosity of heavy oil as a
n 1
function of temperature and as a function of the CAPI:
P ( x ) = u j x j . .......................................................................(5)
j=0 b c d
ln ( ) = a + + + , .............................(10)
For degree n1, which has the property CAPI ( CAPI )2 ( CAPI )3

P (i ) = yi , for i = 1, ..., m, .......................................................(6) where

the Vandermonde matrix can easily be inverted in terms of La- a = A1 + B1 T + C1T 2 + D1T 3, ..................................................(11)
grange basis polynomialseach column is the coefficient of the
Lagrange basis polynomial, with terms in increasing order going
b = A2 + B2T + C2T 2 + D2T 3 , .................................................(12)
down. The resulting solution to the interpolation problem is called
the Lagrange polynomial.
Suppose that the interpolation polynomial is in the form (Bair c = A3 + B3T + C3T 2 + D3T 3 , .................................................(13)
et al. 2006; Fulton and Harris 1991; Horn and Johnson 1991):

P ( x ) = an x n + an 1 x n 1 + ... + a2 x 2 + a1 x + a0 . ............................(7) and

d = A4 + B4T + C4T 2 + D4T 3 , ................................................(14)


The statement that P interpolates the data points means that

P ( xi ) = yi , for all i {0,1,..., n}. ..............................................(8) with the relevant coefficients reported in Table 1.

2 Oil and Gas Facilities February 2015 February 2015 Oil and Gas Facilities 67
Table 2Viscosity data used in developing the new correlation (Al-Maamari et al. 2006; Henshaw
et al. 1998).

 =  SG , ...........................................................................(15) in significant errors when it comes to predicting the viscosity of


heavy crude oils because the correlations do not involve the com-
where is the dynamic viscosity in cp, is the kinematic viscosity position of heavy oil. The inclusion of the heavy-oil composition in
measured in cSt, and SG is specific gravity. These optimum tuned the proposed correlation ensures a more-accurate viscosity assess-
coefficients help to cover temperatures up to 180C and CAPI as ment because it recognizes the difference in the viscosity of oils
low as 6. The optimum tuned coefficients given in Table 1 can be that have the same gravity in API but have different compositions.
further refined according to the proposed approach if more data be- Further viscosity and compositional data are required to make a
come available in the future. more-objective performance comparison. Table 4 summarizes the
In this work, our efforts were directed toward formulating error assessments for various correlations at different temperatures.
a correlation that can be expected to assist engineers for rapid It can be seen from the table that most correlations result in higher
calculation of the heavy-oil viscosity as a function of temperature errors at lower temperatures.
and the CAPI. The proposed tool is simple and novel. The selected It is expected that our efforts in formulating the tool will pave
exponential function to develop the tool leads to well-behaved (i.e., the way for arriving at an accurate prediction of the viscosity of
smooth and nonoscillatory) equations, enabling reliable and accu- heavy crude oil. The tool developed in this study can be of great
rate predictions. practical value for experts and engineers, providing a method for
obtaining a quick assessment of the viscosity of heavy crude oil.
Results In particular, petroleum engineers would find the approach to be
Table 2 summarizes the data used to develop this correlation. Fig. 1 user-friendly, with transparent calculations involving no complex
shows the proposed correlation curves in comparison with the liter- expressions.
ature data (Henshaw et al. 1998; Al-Maamari et al. 2006) that were
used to calibrate the correlation. Note that the data that were used Conclusions
in developing and calibrating the correlation had gravities less than In this work, simple-to-use equations are presented for the estima-
15 API [corrected API (CAPI) less than 6] and temperatures in the tion of heavy-oil viscosity as a function of temperature, and of a
range of 40 to 177C. Figs. 2 and 3 show the results from the pro- simple correlating parameter that can be used for heavy-oil char-
posed method and its smooth performance in the prediction of the acterization (corrected API). The performance of the proposed
viscosity of heavy oil as a function of temperature and CAPI. correlation was examined against the performance of several cor-
The performance of the proposed correlation, as well as other relations in the literature. It was found that the proposed correlation
correlations in the literature, was examined against the literature resulted in the most-accurate predictions for the data used in that
data. Table 3 compares the performance of various exsiting corre- exercise. Note that the correlation was developed with viscosity
lations with that of the proposed correlation in predicting the vis- data in the range of 8.7 to 14.5 API and in the temperature range
cosity of crude oil. It should be noted that the same set of data of 40 to 177C. Therefore, care must be exercised when the cor-
that was used for the correlation calibration was used for the per- relation is used in the assessment of viscosity (in API) and tem-
formance assessment, which does not allow an unbiased perfor- perature ranges outside of those of the data used in calibrating the
mance comparison. It shows that the existing correlations can result correlation.

68 Oil and Gas Facilities February 2015 February 2015 Oil and Gas Facilities 3
5
10
T = 40C
Data
T = 50C

Kinematic Viscosity (mm2/s)


4 Data
10 T = 60C
Data
T = 70C
Data
3 T = 100C
10
Data
T = 135C
Data
T = 177C
2 Data
10

1
10

0
10
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5
Correlating Parameter (CAPI)

Fig. 1The calibration of the predictive tool for the estimation of viscosity of heavy oil (Al-Maamari et al. 2006; Henshaw et al. 1998).
Kinematic Viscosity (mm2/s)

4
10
T = 40C

3
10

2
10

T = 110C

1.5 2 2.5 3 3.5 4 4.5 5 5.5


Correlating Parameter (CAPI)

Fig. 2The smooth results of the predictive tool in estimating the viscosity of heavy oils for temperatures less than 110C.

90

80
Kinematic Viscosity (mm2/s)

70

60

T = 110C
50

40

30

20

10

0 T = 180C
1.5 2 2.5 3 3.5 4 4.5 5 5.5
Correlating Parameter (CAPI)

Fig. 3The smooth results of the predictive tool in estimating the viscosity of heavy oils for temperatures greater than 110C.

4 Oil and Gas Facilities February 2015 February 2015 Oil and Gas Facilities 69
Table 3Comparison of the prediction error for different correlations.

Unlike complex mathematical approaches for estimating the d= correlating parameter in the viscosity correlation
viscosity of heavy oils, the proposed correlation is straightforward D= fourth tuned coefficient
and would be greatly helpful for engineers, especially those dealing i= index
with petroleum engineering and heavy-oil production. Addition- j= index
ally, the level of mathematical formulations associated with the m= matrix row index for m n matrix
estimation viscosity of heavy oil can be easily handled by an en- n= matrix column index for m n matrix
gineer or practitioner without any in-depth mathematical abilities. P= polynomial
The proposed method has a clear numerical background, wherein Re = resins
the relevant coefficients can be retuned quickly if more data be- Sa = saturated hydrocarbons
come available in the future. SG = specific gravity
T= temperature, K
Nomenclature u= coefficient of polynomial
a= correlating parameter in the viscosity correlation V= Vandermonde matrix
A= first tuned coefficient x= correlating parameter in viscosity correlation
API = oil gravity, (API = 145/o, 135) X= data point
Ar = aromatic hydrocarbons y= correlating parameter in viscosity correlation
As = asphaltenes Y= data point
b= correlating parameter in the viscosity correlation z= correlating parameter in viscosity correlation
B= second tuned coefficient = matrix element
c= correlating parameter in the viscosity correlation o,R = oil specific gravity at reservoir conditions
C= third tuned coefficient = kinematic viscosity, mm2/s
CAPI = correlating parameter = oil dynamic viscosity, cp

70 Oil and Gas Facilities February 2015 February 2015 Oil and Gas Facilities 5
Table 4Maximum prediction error for different correlations at several temperatures.

od = dead-oil viscosity, cp Bennison, T. 1998. Prediction of Heavy Oil Viscosity. Presented at the IBC
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troleum Science and Engineering 5 (3): 261272. http://dx.doi.
org/10.1016/0920-4105(91)90042-L. Alireza Bahadori is a lecturer in the School of Environment, Science, and
Mehrotra, A.K., Monnery, W.D., and Svrcek, W.Y. 1996. A Review of Prac- Engineering at Southern Cross University, Lismore, New South Wales,
tical Calculation Methods for Viscosity of Liquid Hydrocarbons and Australia. During the past 20 years, he has held various process- and pe-
Their Mixtures. Fluid Phase Equilibria 117 (12): 344355. http:// troleum-engineering positions and was involved in many large-scale proj-
dx.doi.org/10.1016/0378-3812(95)02971-0. ects at the National Iranian Oil Company, Petroleum Development Oman,
Miadonye, A. and Puttagunta, V.R. 1998. Modeling the Viscosity-Tem- and Clough AMEC. Bahadori is the author of more than 200 articles, in-
perature Relationship of Nigerian Niger-Delta Crude Petroleum. Pe- cluding a number of SPE papers. His 10 books have been published by
troleum Science and Technology 16 (5 & 6): 627638. http://dx.doi. multiple major publishers, including Elseviers Natural Gas Processing,
org/10.1080/10916469808949803. Wileys Corrosion and Materials Selection for Petroleum Industries, and
Miadonye, A., Puttagunta, V.R., and Singh, B. 1993. Prediction of the Viscosity Springers Pollution Control in Oil and Gas Industries. Bahadori holds a
of Crude Oil Fractions from a Single Measurement. Chem. Eng. Commun. PhD degree from Curtin University, Perth, Western Australia.
122: 195199. http://dx.doi.org/10.1080/00986449308936156.
Miadonye, A., Singh, B., and Puttagunta, R.V. 1992. One-Parameter Cor- Mahdi Mahmoudi is a PhD degree candidate at the University of Alberta.
relation in the Estimation of Crude Oil Viscosity. SPE-26206-MS. Previously, he worked as a completion engineer for National Iranian
https://www.onepetro.org/download/general/SPE-26206-MS?id= South Oil Company. Mahmoudis research interests include petroleum
general%2FSPE-26206-MS. geomechanics, wellbore hydraulics, and heavy-oil-production technolo-
Monnery, W.D., Svrcek, W.Y., and Mehrotra, A.K. 1995. Viscosity: A Crit- gies. He holds an MSc degree in petroleum engineering from the Uni-
ical Review of Practical Predictive and Correlative Methods. Can. J. versity of Louisiana at Lafayette.
Chem. Eng. 73 (1): 340. http://dx.doi.org/10.1002/cjce.5450730103.
Pedersen, K.S. and Fredenslund, A. 1984. Viscosity of Crude Oils. Alireza Nouriis an associate professor of petroleum engineeringat the
Chemical Engineering Science 39 (6): 10111016. http://dx.doi. University of Alberta and a consultant to the petroleum industry in areas
org/10.1016/0009-2509(84)87009-8. related to petroleum geomechanics, including physical and numerical
Petrosky, G.E. and Farshad, F.F. 1995. Viscosity Correlations for Gulf of modeling of sand production, numerical simulation of hydraulic frac-
Mexico Crude Oils. Presented at the SPE Production Operations, turing, and caprock-integrity assessment. He has 5 years of industrial
Symposium, Oklahoma City, Oklahoma, 24 April. SPE-29468-MS. experience and has been the author of nearly 70 technical papers, 30
http://dx.doi.org/10.2118/29468-MS. of which were published in SPE-affiliated journals or conference pro-
Puttagunta, V.R., Miadonye, A., and Singh, B. 1992. Viscosity Temperature ceedings. Nouri holds a PhD degree in sand-production control from
Correlation for Prediction of Kinematic Viscosity of Conventional Dalhousie University. He is a member of SPE and is a registered profes-
Crude. Trans. Inst. Chem. Eng. 70: 627631. sional engineer in Alberta.

72 Oil and Gas Facilities February 2015 February 2015 Oil and Gas Facilities 7

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