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25 YEARS25 YEARS

LESSONS LEARNED AND BESTLESSONS LEARNED AND BESTLESSONS LEARNED AND BEST LESSONS LEARNED AND BEST PRACTICES IN COLOMBIAN FIELDSPRACTICES IN COLOMBIAN FIELDSPRACTICES IN COLOMBIAN FIELDSPRACTICES IN COLOMBIAN FIELDS

Daniel OrtegaDaniel OrtegaDaniel OrtegaDaniel OrtegaLina SalinasLina Salinas

Leonardo GranadosLeonardo GranadosLeonardo GranadosLeonardo Granados

SPE PCP Conference, Edmonton SPE PCP Conference, Edmonton ‐‐ Canada, September 2010Canada, September 2010

OUTLINEOUTLINE

1.Objectives2.Colombian Background of Oil Market3 Colombian PCP systems Application3.Colombian PCP systems Application4.Colombian PCP systems Distribution

( )5.Lessons Learned (LL) and Best Practices(BP) with PCP systems installed in(BP) with PCP systems installed inColombia.

6 R i i Ch ll6.Remaining Challenges.7.Conclusion.

OBJECTIVESOBJECTIVES

• Show what has been the Lessons Learnedand Best Practices for PCP Systems inyColombia.

• Use this presentation as an analysis (rootcause analysis – troubleshooting) forsimilar well conditions

COLOMBIA BACKGROUNDCOLOMBIA BACKGROUND

2010 GOAL 2010 GOAL = = 0.8 0.8 mbmb/d/dbb/d/d2012 GOAL 2012 GOAL = = 1 1 mbmb/d/d

2015 GOAL 2015 GOAL = = 1.31.3 mbmb/d/d

COLOMBIA BACKGROUNDCOLOMBIA BACKGROUND

700

586

646

500

600518 521

300

400

191 202227

186 193247

281KBPD

100

200 151 137 137 138181 191 202186 193

0

Y 2006 Y 2007 Y 2008 Y 2009

LIGHT OIL MEDIUM OIL HEAVY OIL TOTALSOURCE: BEM ‐ ACIPET

MAIN FOCUS IS TO DEVELOP HEAVY AND EXTRA HEAVY OILMAIN FOCUS IS TO DEVELOP HEAVY AND EXTRA HEAVY OILMAIN FOCUS IS TO DEVELOP HEAVY AND EXTRA HEAVY OIL MAIN FOCUS IS TO DEVELOP HEAVY AND EXTRA HEAVY OIL FIELDS TO REACH THE GOALS FIELDS TO REACH THE GOALS

PCP APPLICATION & GROWTHPCP APPLICATION & GROWTH

TheThe casecase studiesstudies analyzedanalyzed correspondcorrespond toto installedinstalled systemssystems withwith operatorsoperators andand thetheexperiencesexperiences obtainedobtained inin variousvarious SedimentarySedimentary ZonesZones:: ValleValle MedioMedio,, CuencaCuenca Superior,Superior,LlanosLlanos Orientales,Orientales, CatatumboCatatumbo andand CaguanCaguan‐‐PutumayoPutumayo;; 55 ofof thethe 2323 sedimentarysedimentary zones,zones,wherewhere cancan bebe foundfound thethe mainmain oiloil reservesreserves ((33..11 BILLIONBILLION isis thethe totaltotal ColombianColombian oiloilreserves)reserves)

PCP APPLICATION & GROWTHPCP APPLICATION & GROWTH

800

900

600

700

300

400

500

100

200

300

0

Y 2004 Y 2005 Y 2006 Y 2007 Y 2008 Y 2009 Y 2010 Q1

MostMost ofof thethe companiescompanies havehave adaptedadapted waterwater floodingflooding methodologymethodology inin maturemature

PCP SYSTEM INSTALLEDPCP SYSTEM INSTALLED

fieldsfields (medium(medium oil)oil) inin additionaddition toto thethe policypolicy ofof focusingfocusing onon heavyheavy oiloil reservoirs,reservoirs,representsrepresents increasingincreasing potentialpotential applicationapplication forfor PCPPCP systemssystems..

PCP DISTRIBUTIONPCP DISTRIBUTION

26%26%39%

34%

MATURE FIELDS (WF) MEDIUM LIGHT OIL HEAVY AND EXTRA HEAVY OIL

MATUREMATURE FIELDSFIELDS FORFOR PCPPCP SYSTEMSYSTEM REPRESENTSREPRESENTS::

•• FIELDSFIELDS WITHWITH WATERWATER INJECTIONINJECTION ANDAND THETHE COMPANIESCOMPANIES CANCAN NOTNOT CONTROLCONTROL ADEQUATELYADEQUATELY THISTHIS PROCCESSPROCCESS..

MATURE FIELDS (WF) MEDIUM ‐ LIGHT OIL HEAVY AND EXTRA HEAVY OIL

FIELDSFIELDS WITHWITH WATERWATER INJECTIONINJECTION ANDAND THETHE COMPANIESCOMPANIES CANCAN NOTNOT CONTROLCONTROL ADEQUATELYADEQUATELY THISTHIS PROCCESSPROCCESS..•• OILOIL BASINSBASINS WITHWITH UNCONSOLIDATEDUNCONSOLIDATED SANDSSANDS..•• PROBLEMSPROBLEMS WITHWITH THETHE MAINMAIN POWERPOWER..•• SOMESOMEWELLSWELLS WITHWITH OUTOUT SURVEYSURVEY..•• PRODUCTIONPRODUCTION BETWEENBETWEEN 500500 –– 20002000 BFPDBFPD..•• %% BSWBSW 8585 9595%%•• %% BSWBSW 8585 –– 9595%%..

LL AND BP PCP MONITORINGLL AND BP PCP MONITORINGPOWERPOWERPOWERPOWER

• CURRENT TRANSDUCER: The measurement of power consumption perline-phase in real time.

• VOLTAGE TRANSDUCER: The measurement of the voltage between phase- phase and phase – earthphase and phase earth.

• POWER CALCULATION: With this values we can calculate the power

746

TORQUETORQUE

• MOTOR RPM: Is obtained from values of frequency and nameplate motor.

• MOTOR TORQUE: is obtained from the relation between torque and power• MOTOR TORQUE: is obtained from the relation between torque and power.

• ROD TORQUE: It is obtained from the ratio of pulleys or gears and motorspeed.

motorHPT 5252×

RPMrodRPMmotor

PulleyMinorPulleyMayorPBR ==

__...

EfficHPHP ×motor

motormotor RPM

T =

....5252 EfficPBRTRPM

HPT motorROD

RODROD ××=

×=

.EfficHPHP motorROD ×=

LL AND BP MONITORINGLL AND BP MONITORING

EFFECTEFFECT ROOT CAUSEROOT CAUSE TROUBLE SHOOTINGTROUBLE SHOOTING

• Well down. •Tubing leakage • Install coiled rod or conventional rodwith centralizers.• Install tubing rotator.



•Rod Resonance (Different speed insurface than in the bottom).

• Stator – Rotor ft.• Multiphase fluid.

•RPM increase the speed to equalize(avoid resonance) speed surface and) p

• Slant well.• Rod OD.

( ) pbottom.• Install rotor tight.• Install rod with greater OD.



•Increasing Torque. •Solid Contents • Flush by JOINT Coil Tubing (3/4 OD)Service.• Increase the torque capacity of thePCP system.



Well down and lost production (Backspin).

• Low reliability in the main power. • Install equipment with backspincontrol .( p )• Check Valve or bull plug.



Well down. •Tubing string Disconnection. • Install the adequate anchor system.• Adequate make up in tubingAdequate make up in tubinginstallation.



Well down •. Rod string Failure (broken). • Verify what is the maximum torque ofthe rod.• Verify VFD programming.• Analyze corrosion issue.

LL AND BP EXTRA HEAVY OILLL AND BP EXTRA HEAVY OIL

CONDITION UNITS PCP ESPBHT ° F 250BHT F 250

PUMP SETTING FT 7.000 7.000

DYNAMIC LEVEL FT 6.000 6.000

PRODUCTION FT 330 280PRODUCTION FT 330 280

API 8

BSW % 7 ‐ 10

THP PSI 500 1 100THP PSI 500 ‐ 1.100

CHP PSI 10 10

% EF VOL % 97 43

MIDDLE PERFS FT 9 500 9 500MIDDLE PERFS FT 9.500 9.500

OPERATION TORQUE LB X FT 1.375 N/A

CURRENT AMP 99 156

POWER CONSUMPTION HP 45 175POWER CONSUMPTION MEASURED

HP 45 175

SPEED RPM / HZ 180 50

RUN LIFE DAYS INSTALLED 48 (MAX)RUN LIFE DAYS INSTALLED 24 DIC /09 AND STILL RUNNING

48 (MAX)

LL AND BP LIGHT OILLL AND BP LIGHT OIL

CONDITION UNITS PCP

BHT ° F 120

PUMP SETTING FT 835PUMP SETTING FT 835

DYNAMIC LEVEL FT 598

PRODUCTION FT 1090

API 48API 48

THP PSI 110

CHP PSI 98

% EF VOL % 85

OPERATION TORQUE

LB X FT 600 (CONSTANT)

MIDDLE PERFS FT 1.250

AROMATICS % 17

SPEED RPM 170

RUN LIFE DAYS 342SOURCE: PARDEY RICARDO

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 THEELASTOMER (TIPICALLY, POLIMER DISSOLVE IN LIQUIDS WITH PARAMETER DIFFERENCE BETWEEN 0.47 OR0 71 (CAL/CM3)1/2 AT THIS PRESSURE AND TEMPERATURE0.71 (CAL/CM3)1/2 , AT THIS PRESSURE AND TEMPERATURE.

SOLUBILITY PROPERTIES DEPENDS OF TEMPERATURE AND PRESSURE

LL AND BP WITH SOLIDSLL AND BP WITH SOLIDS

CONDITION UNITS SYSTEM A SYSTEM B



PRODUCTION BFPD 80 80

API 27

PUMP DISPLACEMENT BFPD/RPM 0.8 0.8

PUMP LENGTH FT 14 14

SUCKER ROD OD ‐ GRADE IN 7/8 – D78 1 – 97 NON API

SURFACE SYSTEM HP 30 50

MOTOR SPEED RPM 1.200 1.200

BELT & PULLEYS RATIO 3,6 : 1 5

THP PSI 500 500

CHP PSI 10 10

% EF VOL % 85 75

MAX TORQUE CAPACITY LB X FT 482 1.117

OPERATION TORQUE LB X FT 85 120

MESH SIZE 20 20

% SAND CUT % 4 4

SPEED RPM 150 175SPEED RPM 150 175

MTBF DAYS 28 INSTALLED 10 NOV 2009 AND STILL RUNNING


• 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.


OPERATIONOPERATION START UP AFTER PUMP STUCKSTART 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 CORROSIONLL AND BP HANDLE CORROSION

C li

SUCKER ROD (SR) COILED ROD (CR)

Coupling (CPLG)

SpacingH l

Concentration Of Corrosive Agents

Hole Angle

Concentration Of

Concentration Of Corrosive Agents

Hole Angle

Corrosive Agents

CONDITION SR WITH CPLG CR FOR CORROSIVEFLUID (W/O INHIBITOR)

CR FOR MEDIUM CORROSIVEFLUID (W/O INHIBITOR)

TUBING WEAR 4 1 1

CORROSION FAILURE IN THE ROD 2 3 4

1 = EXCELLENT / 2 = GOOD / 3 = FAIR / 4 = POOR

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

LL AND BP TO AVOID EDLL AND BP TO AVOID EDCONDITION UNITS SYSTEM A SYSTEM BCONDITION UNITS SYSTEM A SYSTEM B



PRODUCTION FT 110 115PRODUCTION FT 110 115

TBG IN 2 7/8 2 7/8

CSG IN 7 ‐ 23 7 ‐ 23

API 28API 28

PUMP DISPLACEMENT BFPD/RPM 0.8 0.8

ELASTOMER NBR STD NBR STD

PUMP LENGTH FT 25 25

THP PSI 500 500

CHP PSI 10 10

EF VOL % 55 55

C02 % 60 60

OPERATION TORQUE LB X FT 210 220

MAIN POWER FREQUENCY FAILURE

TIMES PER WEEK 20 20

BULL BULL PLUGPLUG

FREQUENCY FAILURE

MTBF DAYS 19 305

SYSTEM A = W/O BULL PLUG / SYSTEM B = WITH BULL PLUGSYSTEM A = W/O BULL PLUG / SYSTEM B = WITH BULL PLUG

((UGUG

THETHE GREATESTGREATEST DROPDROP ININ PRESSUREPRESSURE GENERALLYGENERALLY OCCURSOCCURS WHENWHEN HAPPENHAPPEN AA SHUTSHUT DOWNDOWN (FLUIID(FLUIID LEVELLEVEL BETWEENBETWEENTUBINGTUBING ANDAND CASINGCASING EQUALIZESEQUALIZES THROUGHTHROUGH THETHE PUMP),PUMP), THISTHIS EFFECTEFFECT CANCAN CAUSECAUSE EDED.. BULLBULL PLUGPLUG FUNCTIONFUNCTION ISIS TOTORESTRICTRESTRICT THETHE MOVEMENTMOVEMENT OFOF FLUIDFLUID THROUGHTHROUGH THETHE PUMPPUMP (TRIES(TRIES TOTO KEEPKEEP THETHE INTERNALINTERNAL PRESSUREPRESSURE ININ THETHE PUMP)PUMP)ANDAND AVOIDAVOID EDED .. PLEASEPLEASE DODO NOTNOT USEUSE THISTHIS TOOLTOOL ININ WELLSWELLS WITHWITH SOLIDSSOLIDS ANDAND YOUYOU MUSTMUST BEBE VERYVERY CAREFULCAREFUL FORFORSPACESPACE OUTOUT..

REMAINING CHALLENGESREMAINING CHALLENGES

ITIT CURRENTLYCURRENTLY CHALLENGESCHALLENGES

1st1st USE SONOLOG TO MEASURE THE FLUID LEVEL, ADDOTHER PARAMETERS (TORQUE + PRODUCTION +

DESIGN A PCP SYSTEM CARD LIKE SURFACE / DOWNHOLEDYNACARD TROUGH PCP SYSTEM TORQUE (REMIND THATOTHER PARAMETERS (TORQUE + PRODUCTION +

THP) TO ONLY ANALIZE SNAPSHOT MOMENT ANDNOT SIMULTANEOUS.

DYNACARD TROUGH PCP SYSTEM TORQUE (REMIND THATTORQUE MEASURE DEPENDS ON THE FLUID LEVEL + THP) TOINTERPRETE WELL CONDITIONS BEHAVIOR JOINT PCP SYSTEMPERFORMANCE SIMULTANEOUS LY.

2nd2nd THE MAXIMUM TORQUE TO APPLY THE RODS IF DESIGN AND FIND RELIABILTY PCP (ESP PCP ???) SYSTEMS2nd2nd THE MAXIMUM TORQUE TO APPLY THE RODS IFYOU HAVE THE ADEQUATE TONGS IS BETWEEN2.000 – 2.500 LB X FT (MAX COULD BE 2.800).

DESIGN AND FIND RELIABILTY PCP (ESP – PCP ???) SYSTEMSTO HANDLE TORQUE BETWEEN 2.500 – 3.500 LB XFT ORMORE TO INCREASE SHARE IN WELLS WITH EXTRA HEAVY OILAND HIGH TORQUE REQUIREMENT.

3rd3rd THE TEST IN LAB IS DONE WITH WELL CONDITIONS ADEQUATE AND DYNAMIC TESTS TO DETERMINE SOLUBILTY3rd3rd THE TEST IN LAB IS DONE WITH WELL CONDITIONS,PRESSURE VESEL COMPATIBILITY, OIL SAMPLESAND INFORMATION PROVIDED BY THECUSTOMERS.

ADEQUATE AND DYNAMIC TESTS TO DETERMINE SOLUBILTYPARAMETERS WITH PREVIOUS TIME, BEFORE THEINSTALLATION OF PCP SYSTEM TO CHOOSE THE RIGHTELASTOMER TO DIFFERENT WELL CONDITIONS (LIKE FLUIDLEVEL AND TEMPERATURE).

4th4th ACCORDING TO THE EXPERIENCE IN THE FIELD ,WE TEST WHAT IS THE TORQUE SYSTEM REQUIREDTO AVOID WELL FAILURE (PUMP STUCK).

ESTIMATE THE MAXIMUM OPERATION TORQUE REQUIREDFOR EACH WELL CONDITIONS AND PCP SYSTEM (PUMPLENGTH AND FIT BETWEEN ROTOR AND STATOR), TO AVOID APUMP STUCK. BEFORE EACH INSTALLATION AND WITH THISJUSTIFY, THE FLUSH BY WITH COILED TUBING ( ¾ IN) SERVICE.

5th5th ACCORDING TO THE EXPERIENCE IN THE FIELD, WETRY TO FIND WHAT IS THE OPTIMUM BATCHINHIBITOR CORROSION (CUSTOMERS DOES NOT

ESTIMATE WHAT IS THE OPTIMUM BATCH INHIBITORCORROSION (BEST RECOMENDATION IS TO DO CYCLICINJECTION WITH LOW INHIBITOR RATE) FOR EACH WELL

WANT INCREASE LIFTING COST). CONDITIONS DEPENDING GAS PERCENTAGE ANDCOMPOSITION ‐ BSW AND PCP SYSTEM CONFIGURATION(RPM – ANNULAR SPACE – OD ROD), PREVIOUS EACHINSTALLATION.

CONCLUSION CONCLUSION

WE CONTINUE TO EXPAND THE USE OF PCP SYSTEMS THROUGH APPLICATION KNOWLEDGE, AND WE CONTINUE TO EXPAND THE USE OF PCP SYSTEMS THROUGH APPLICATION KNOWLEDGE, AND FOR THIS REASON BELIEVE WE DO NOT YET KNOW THE FULL LIMITATIONS OF THE SYSTEMFOR THIS REASON BELIEVE WE DO NOT YET KNOW THE FULL LIMITATIONS OF THE SYSTEM

CURRENTCURRENT TECHNOLOGIESTECHNOLOGIES ANDAND PRACTICESPRACTICES DOESDOES NOTNOT PERMITPERMIT USUS TOTO DEVELOPDEVELOP ADDITIONALADDITIONAL PCPPCP SYSTEMSYSTEMAPPLICATIONSAPPLICATIONS ANDAND INCREASEINCREASE THEIRTHEIR CURRENTCURRENT RELIABILITYRELIABILITY.. ININ ORDERORDER TOTO IMPROVEIMPROVE PCPPCP APPLICATIONAPPLICATION WEWE NEEDNEEDTOTO ENHANCEENHANCE PUMPPUMP CAPABILITYCAPABILITY THROUGHTHROUGH DESIGN,DESIGN, MANUFACTURINGMANUFACTURING ANDAND AUTOMATIONAUTOMATION FORFOR BETTERBETTERPUMPINGPUMPING CONTROLCONTROL ATAT WHICHWHICH POINTPOINT THETHE PCPPCP SYSTEMSYSTEM WILLWILL BENEFITBENEFIT FROMFROM INCREASEDINCREASED SHARESHARE OFOF THETHE ALSALSMARKETMARKET..

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