25 YEARS

LESSONS LEARNED AND BEST LESSONSLEARNEDANDBEST PRACTICESINCOLOMBIANFIELDS PRACTICES IN COLOMBIAN FIELDS

DanielOrtega Daniel Ortega LinaSalinas LeonardoGranados Leonardo Granados

SPEPCPConference,Edmonton Canada,September2010 SPEPCPConference,Edmonton

OUTLINE

1.Objectives 2.Colombian Background of Oil Market 3.Colombian 3 Colombian PCP systems Application 4.Colombian PCP systems Distribution 5.Lessons Learned ( ) and Best Practices (LL) (BP) with PCP systems installed in Colombia. 6.Remaining Ch ll 6R i i Challenges. 7.Conclusion.

OBJECTIVES

Show what has been the Lessons Learned y and Best Practices for PCP Systems in Colombia. Use this presentation as an analysis (root cause analysis troubleshooting) for similar well conditions

COLOMBIA BACKGROUND

2010GOAL 2012GOAL 2015GOAL

= = =

0.8 1 1.3

mb/d mb/d mb/d mb/d b mb/d mb/d

COLOMBIA BACKGROUND
700 600 500
586 518 521 646

KBPD

400 300 200 100 0 Y2006 Y2007 MEDIUMOIL Y2008 HEAVYOIL Y2009 TOTAL
151 181186 137 191 193 137 247 202 138 281 227

SOURCE:BEM ACIPET

LIGHTOIL

MAINFOCUSISTODEVELOPHEAVYANDEXTRAHEAVYOIL MAIN FOCUS IS TO DEVELOP HEAVY AND EXTRA HEAVY OIL FIELDSTOREACHTHEGOALS

PCP APPLICATION & GROWTH

The case studies analyzed correspond to installed systems with operators and the experiences obtained in various Sedimentary Zones: Valle Medio, Cuenca Superior, Zones: Medio, Llanos Orientales, Catatumbo and CaguanPutumayo; 5 of the 23 sedimentary zones, CaguanPutumayo; where can be found the main oil reserves (3.1 BILLION is the total Colombian oil reserves)

PCP APPLICATION & GROWTH

900 800 700 600 500 400 300 200 100 0 Y2004 Y2005 Y2006 Y2007 Y2008 Y2009 Y2010Q1

PCPSYSTEMINSTALLED

Most of the companies have adapted water flooding methodology in mature fields (medium oil) in addition to the policy of focusing on heavy oil reservoirs, represents increasing potential application for PCP systems. systems.

PCP DISTRIBUTION

26% 39% 34%

MATUREFIELDS(WF) MATURE FIELDS (WF)

MEDIUM LIGHTOIL MEDIUM LIGHT OIL

HEAVYANDEXTRAHEAVYOIL HEAVY AND EXTRA HEAVY OIL

MATURE FIELDS FOR PCP SYSTEM REPRESENTS: REPRESENTS:

FIELDS WITH WATER INJECTION AND THE COMPANIES CAN NOT CONTROL ADEQUATELY THIS PROCCESS. PROCCESS. OIL BASINS WITH UNCONSOLIDATED SANDS. SANDS. PROBLEMS WITH THE MAIN POWER. POWER. SOME WELLS WITH OUT SURVEY. SURVEY. PRODUCTION BETWEEN 500 2000 BFPD. BFPD. % BSW 85 95%. 95%

LL AND BP PCP MONITORING

POWER CURRENT TRANSDUCER: The measurement of power consumption per line-phase in real time. VOLTAGE TRANSDUCER: The measurement of the voltage between phase - phase and phase earth earth. POWER CALCULATION: With this values we can calculate the power

746

TORQUE MOTOR RPM: Is obtained from values of frequency and nameplate motor. MOTOR TORQUE: is obtained from the relation between torque and power power. ROD TORQUE: It is obtained from the ratio of pulleys or gears and motor speed.

R .B .P . =

Mayor Minor

_ Pulley _ Pulley

RPMmotor RPMrod

T motor =
T
ROD

HP motor 5252 RPM motor

HP
ROD

HP ROD = HPmotor Effic .

= T
motor

5252
ROD

RPM

R . B . P . Effic

LL AND BP MONITORING

EFFECT
Welldown.

ROOTCAUSE
Tubingleakage

TROUBLESHOOTING
Install coiled rod or conventional rod with centralizers. Install tubing rotator.

LL AND BP MONITORING

EFFECT
Rod Resonance (Different speed in surface than in the bottom). )

ROOTCAUSE
Stator Rotor ft. Multiphase fluid. p Slant well. Rod OD.

TROUBLESHOOTING
RPM increase the speed to equalize ( (avoid resonance) speed surface and ) p bottom. Install rotor tight. Install rod with greater OD.

LL AND BP MONITORING

EFFECT
Increasing Torque.

ROOTCAUSE
SolidContents

TROUBLESHOOTING
Flush by JOINT Coil Tubing (3/4 OD) Service. Increase the torque capacity of the PCP system.

LL AND BP MONITORING

EFFECT
Well downandlostproduction ( (Backspin). p )

ROOTCAUSE
Lowreliabilityinthemainpower.

TROUBLESHOOTING
Install equipment with control . Check Valve or bull plug. backspin

LL AND BP MONITORING

EFFECT
Well down.

ROOTCAUSE
TubingstringDisconnection.

TROUBLESHOOTING
Install the adequate anchor system. Adequate make up in tubing installation.

LL AND BP MONITORING

EFFECT
Well down

ROOTCAUSE
.RodstringFailure (broken).

TROUBLESHOOTING
Verify what is the maximum torque of the rod. Verify VFD programming. Analyze corrosion issue.

LL AND BP EXTRA HEAVY OIL

CONDITION
BHT PUMPSETTING DYNAMIC LEVEL PRODUCTION API BSW THP CHP %EFVOL MIDDLE PERFS OPERATIONTORQUE CURRENT POWERCONSUMPTION POWER CONSUMPTION MEASURED SPEED RUN LIFE LIFE % PSI PSI % FT LBXFT AMP HP RPM /HZ DAYS 10 97 9.500 9 500 1.375 99 45 180 INSTALLED INSTALLED 24DIC/09AND STILLRUNNING

UNITS
F FT FT FT

PCP
250 7.000 6.000 330 8 7 10 500 1.100 500 1 100

ESP
7.000 6.000 280

10 43 9.500 9 500 N/A 156 175 50 48(MAX) 48 (MAX)

LL AND BP LIGHT OIL

CONDITION
BHT PUMPSETTING PUMP SETTING DYNAMIC LEVEL PRODUCTION API THP CHP %EFVOL OPERATION TORQUE MIDDLE PERFS AROMATICS SPEED
SOURCE: PARDEY RICARDO

UNITS
F FT FT FT 48 PSI PSI % LBXFT FT % RPM DAYS

PCP
120 835 598 1090

110 98 85 600(CONSTANT) 1.250 17 170 342

RUN LIFE

ELASTOMER USED IN THiS WELL IS NBR WITH 25% ACN, SOLUBILITY PARAMETER IS CLOSE TO 9.4 (CAL/CM3)1/2 . THE FLUID IN THIS WELL HAS AROMATICS MOLECULES WITH PARAMETER SOLUBILITY NOT CLOSE TO THE ELASTOMER (TIPICALLY, POLIMER DISSOLVE IN LIQUIDS WITH PARAMETER DIFFERENCE BETWEEN 0.47 OR 0.71 0 71 (CAL/CM3)1/2 , AT THIS PRESSURE AND TEMPERATURE TEMPERATURE. SOLUBILITY PROPERTIES DEPENDS OF TEMPERATURE AND PRESSURE

LL AND BP WITH SOLIDS

CONDITION
PUMPSETTING DYNAMIC LEVEL PRODUCTION API PUMPDISPLACEMENT PUMPLENGTH SUCKERROD OD GRADE SURFACE SYSTEM MOTORSPEED BELT &PULLEYSRATIO THP CHP %EFVOL MAX TORQUECAPACITY OPERATION TORQUE MESH %SANDCUT SPEED MTBF PSI PSI % LBXFT LBXFT SIZE % RPM DAYS BFPD/RPM FT IN HP RPM 0.8 14 7/8 D78 30 1.200 3,6:1 500 10 85 482 85 20 4 150 28

UNITS
FT FT BFPD

SYSTEM A
3.250 3.000 80 27

SYSTEM B
3.250 3.000 80

0.8 14 1 97NON API 50 1.200 5 500 10 75 1.117 120 20 4 175 INSTALLED 10NOV2009 ANDSTILLRUNNING

LL AND BP WITH SOLIDS

OPERATION TORQUE WAS IN 175 LB X FT. SAND PLUG (NON CONSOLIDATED SAND). WE AVOID PUMP STUCK WITH 805 LB X FT IN TORQUE (4.5 TIMES OPERATION TORQUE). ADDITIONAL TORQUE REQUIRED WAS 630 LB X FT.

LL AND BP WITH SOLIDS

OPERATION START UP AFTER PUMP STUCK

WHAT HAPPENS IF WE HAVE THE SAME FLUID WITH SAND PLUG PROBLEMS, IN A DEEPER PUMP INTAKE AND HIGHER PRODUCTION?
OPERATION TORQUE WAS IN 1.030 LB X FT WE HAD SURFACE EQUIPMENT WITH TORQUE CAPACITY UNTIL 1.650 LB X FT AND CAN NOT AVOID PUMP STUCK. IF WE DO CORRELATIONS WITH PREVIOUS SLIDE, WE WILL BE REQUIRING BETWEEN 3.5 (ROTOR LOOSE) UNTIL 4.5 (ROTOR TIGHT) TIMES OF OPERATION TORQUE, TO AVOID PUMP STUCK.

LL AND BP HANDLE CORROSION

SUCKER ROD (SR) Coupling C li (CPLG) Spacing COILED ROD (CR)

ConcentrationOf CorrosiveAgents Hole H l Angle

ConcentrationOf CorrosiveAgents ConcentrationOf CorrosiveAgents

CONDITION
TUBING WEAR CORROSION FAILUREINTHEROD
1 = EXCELLENT / 2 = GOOD / 3 = FAIR / 4 = POOR

Hole Angle

SRWITHCPLG
4 2

CRFORCORROSIVE FLUID(W/OINHIBITOR)
1 3

CRFORMEDIUM CORROSIVE FLUID(W/OINHIBITOR)

1 4

WITH BATCH INHIBITOR CORROSION, WE CAN IMPROVE THE CR RUN LIFE. BATCH FREQUENCY DEPENDS OF THE % CO2 - % BSW - % H2S RPM - MATERIAL

LL AND BP TO AVOID ED
CONDITION
PUMPSETTING DYNAMIC LEVEL PRODUCTION TBG CSG API PUMPDISPLACEMENT ELASTOMER PUMPLENGTH THP CHP EFVOL C02 OPERATION TORQUE MAIN POWER FREQUENCYFAILURE FREQUENCY FAILURE MTBF
SYSTEM A = W/O BULL PLUG
BULL UG PLUG

UNITS
FT FT FT IN IN

SYSTEM A
6.000 5.500 110 27/8 7 23 28

SYSTEM B
6.000 5.600 115 27/8 7 23

BFPD/RPM

0.8 NBR STD

0.8 NBR STD 25 500 10 55 60 220 20 305

FT PSI PSI % % LBXFT TIMES PERWEEK DAYS

/

25 500 10 55 60 210 20 19

SYSTEM B = WITH BULL PLUG

THE GREATEST DROP IN PRESSURE GENERALLY OCCURS WHEN HAPPEN A SHUT DOWN ( (FLUIID LEVEL BETWEEN TUBING AND CASING EQUALIZES THROUGH THE PUMP), THIS EFFECT CAN CAUSE ED. BULL PLUG FUNCTION IS TO ED. RESTRICT THE MOVEMENT OF FLUID THROUGH THE PUMP (TRIES TO KEEP THE INTERNAL PRESSURE IN THE PUMP) AND AVOID ED . PLEASE DO NOT USE THIS TOOL IN WELLS WITH SOLIDS AND YOU MUST BE VERY CAREFUL FOR SPACE OUT. OUT.

REMAINING CHALLENGES
IT 1st CURRENTLY
USE SONOLOG TO MEASURE THE FLUID LEVEL, ADD OTHER PARAMETERS (TORQUE + PRODUCTION + THP) TO ONLY ANALIZE SNAPSHOT MOMENT AND NOT SIMULTANEOUS. THE MAXIMUM TORQUE TO APPLY THE RODS IF YOU HAVE THE ADEQUATE TONGS IS BETWEEN 2.000 2.500 LB X FT (MAX COULD BE 2.800). THE TEST IN LAB IS DONE WITH WELL CONDITIONS CONDITIONS, PRESSURE VESEL COMPATIBILITY, OIL SAMPLES AND INFORMATION PROVIDED BY THE CUSTOMERS. ACCORDING TO THE EXPERIENCE IN THE FIELD , WE TEST WHAT IS THE TORQUE SYSTEM REQUIRED TO AVOID WELL FAILURE (PUMP STUCK).

CHALLENGES
DESIGN A PCP SYSTEM CARD LIKE SURFACE / DOWNHOLE DYNACARD TROUGH PCP SYSTEM TORQUE (REMIND THAT TORQUE MEASURE DEPENDS ON THE FLUID LEVEL + THP) TO INTERPRETE WELL CONDITIONS BEHAVIOR JOINT PCP SYSTEM PERFORMANCE SIMULTANEOUS LY. DESIGN AND FIND RELIABILTY PCP (ESP PCP ???) SYSTEMS TO HANDLE TORQUE BETWEEN 2.500 3.500 LB XFT OR MORE TO INCREASE SHARE IN WELLS WITH EXTRA HEAVY OIL AND HIGH TORQUE REQUIREMENT. ADEQUATE AND DYNAMIC TESTS TO DETERMINE SOLUBILTY PARAMETERS WITH PREVIOUS TIME, BEFORE THE INSTALLATION OF PCP SYSTEM TO CHOOSE THE RIGHT ELASTOMER TO DIFFERENT WELL CONDITIONS (LIKE FLUID LEVEL AND TEMPERATURE). ESTIMATE THE MAXIMUM OPERATION TORQUE REQUIRED FOR EACH WELL CONDITIONS AND PCP SYSTEM (PUMP LENGTH AND FIT BETWEEN ROTOR AND STATOR), TO AVOID A PUMP STUCK. BEFORE EACH INSTALLATION AND WITH THIS JUSTIFY, THE FLUSH BY WITH COILED TUBING ( IN) SERVICE. ESTIMATE WHAT IS THE OPTIMUM BATCH INHIBITOR CORROSION (BEST RECOMENDATION IS TO DO CYCLIC INJECTION WITH LOW INHIBITOR RATE) FOR EACH WELL CONDITIONS DEPENDING GAS PERCENTAGE AND COMPOSITION BSW AND PCP SYSTEM CONFIGURATION (RPM ANNULAR SPACE OD ROD), PREVIOUS EACH INSTALLATION.

2nd

3rd

4th

5th

ACCORDING TO THE EXPERIENCE IN THE FIELD, WE TRY TO FIND WHAT IS THE OPTIMUM BATCH INHIBITOR CORROSION (CUSTOMERS DOES NOT WANT INCREASE LIFTING COST).

CONCLUSION
WECONTINUETOEXPANDTHEUSEOFPCPSYSTEMSTHROUGHAPPLICATIONKNOWLEDGE,AND FORTHISREASONBELIEVEWEDONOTYETKNOWTHEFULLLIMITATIONSOFTHESYSTEM

CURRENT TECHNOLOGIES AND PRACTICES DOES NOT PERMIT US TO DEVELOP ADDITIONAL PCP SYSTEM APPLICATIONS AND INCREASE THEIR CURRENT RELIABILITY. IN ORDER TO IMPROVE PCP APPLICATION WE NEED RELIABILITY. TO ENHANCE PUMP CAPABILITY THROUGH DESIGN, MANUFACTURING AND AUTOMATION FOR BETTER PUMPING CONTROL AT WHICH POINT THE PCP SYSTEM WILL BENEFIT FROM INCREASED SHARE OF THE ALS MARKET. MARKET.

QUESTIONS