1PETROZUATAsMulti-Phase Meter

Application

by

Luigi Bortolin

2 Introduction of Petrozuatas project MPFM application & scope

Initial decision and follow-up

Hardware being used

Early operating experience

Specific problems observed to date

Overall assessment

TAMU MPFM Seminar

PRESENTATION OUTLINE

3BANK11.PPT

CARIBBEAN SEA

Puerto La Cruz

CiudadGuayana

CARACAS

JOSE

ZUATA

Pariaguan

CiudadBolivar

MaracaiboLake

CERRO

HAMACANEGROMACHETE

Upgrader

Marine Facilities

Production Ops & Drilling

A Fully Vertically Integrated Venezuelan Oil Company

KL-32

Future Pads Pads with MPPs

*

*

Construction in Progress

BC-22

GH-31

JK-25HI-25 LM-25

IJ-27

GH-29

DE-24

DE-22

DE-26

IJ-31

LM-25

LM-21

BC-24

GH-33

JK-23

DE-20

Gas Well 79X

IJ-29

LEGEND

San Diego de

CabruticaCabrutica Bridge

Atascosa Bridge

WaterDisposalWell.

20 Diluent &36 Blend Pipelines

BC-26

LM-21

Gas WellII-17G

BC-17

FG-25

**

*

**

**

*

HI-22

FG-19 HI-19 FG-19

GH-25MPP

FG-19 BC-14 DF-14

DF-17

JK-14

JK-20

JK-17

LM-14

FG-19 FG-22

KL-28

N-14

NO-18

NO-21

NO-24

NO-27

IJ-33

D-16

BC-20

LM-21LM-17

LM-21LM-19

LM-21LM-23

LM-21LM-21

WaterDisposal

Well.

Complete

Drilling Ready

*

Main Station & Zuata Pump Station

Engineering in Progress

36Diluted Crude

20Diluent

Pipelines

Marine Operations

4

Shareholders

JV between Conoco Orinoco (50.1%) and PDVSA (49.9%)

Over $ 2 billion of assets employed

130,000 BPD Upgrader based on Conocos Delayed Coking

technology

2 pipelines 200 km long, 36 & 20 dia, 530,000 BPD (17API-

180 F) blend and 150,000 BPD (47API) diluent

130,000 BPD Extra-Heavy Oil Production (8-10 API)

production facilities on 90 sq mile area

35 year life

1.5 to 1.6 billion BO reserves (35 years life)

TAMU MPFM Seminar

PETROZUATA DIMENSIONS

5Orinoco BeltProduction Facilities

Upgrader

Cardn Refinery47 MBPD @ 23 API

Lake CharlesRefinery

57 MBPD18 API

Diluted Crude: 36 line, 160 - 170 MBPD, 15-17 API

COKE - PHASE II3000 TCPD 65 MBPSD @ 15 API

Diluted CrudePhase I

Synthetic CrudePhase II

104 MBPD @ 23 API

PETROZUATA, C.A.

Production - Pipeline transportation- Refining

Diluent: 20 line, 40 - 45MBPD, 47 APIPipelines

120 MBPD, 8 - 9 API

Extra Heavy Crude Oil

6ORINOCO BELT - La Faja

CARIBBEAN SEA

Puerto La Cruz

CiudadGuayana

CARACAS

JOSE

ZUATA HAMACAMACHETE

CERRONEGRO

Venezuela

Pariaguan

ZUATA HAMACAMACHETE CERRONEGRO

ORINOCO BELT

GENPRES P

Oil In Place - 1.2 Trillion Barrels

7 MAR CARIBE

CARACAS CUMANA

MACHETE(CPV)

ZUATA

CDAD. BOLIVAR

EL TIGRE

HAMACACERRO NEGRO

BARCELONAJOSE

PIPELINES

PETROZUATASINCOR

MORICHAL

MATURIN

GUIRIA

PTO. ORDAZ

VEHOP VENEZUELA EXTRA HEAVY OIL PROJECT

P

E

T

R

O

Z

U

A

T

A

Ameriven

Operadora CerroNegro (OCN)

Orinoco Belt (Faja) Strategic Association Activity

20 & 3620 & 36

8Main Station

FIRE WATER TANK25.000 Bbls

POWER HOUSE

POWERGENERATION

PRIMARYOIL TREATING

CRUDE HEATERS

FLARE

DILUENT STORAGE80.000 Bbls

OFF-SPEC OIL TANK80.000 Bbls

ZUATA PUMP STATION

STORM WATERCONTAINMENT

DEHYDRATED OIL STORAGE220.000 Bbls

PRODUCED WATER STORAGE5000 Bbls

DEHYDRATED OIL STORAGE220.000 Bbls

ZUATADUCTOPIPELINES20 & 36

WAREHOUSE

OFFICES

SECONDARYOIL TREATING

SEPARATORS

CONTROL BUILDING

34.5 kV SUB-STATION

ROAD TO WELLS HI, IJ, JK, LM

SECURITY BUILDING

DILUENT PUMPS

FIRE WATER PUMP PIPELINE BOOSTER PUMPS

PRODUCED WATER TREATING EQUIPMENT

DILUENT STORAGE80.000 Bbls

FLARE

SINCORPIPELINES16 & 26

SINCOR DILUENT BOOSTER PUMPS

SINCOR DEHYDRATEDOIL STORAGE

2 X 220.000 Bbls

SHARED DEHYDRATEDOIL STORAGE220.000 BblsSHARED BLEND

BOOSTER PUMPS

CONDENSATE TANK3.000 Bbls

D/PPT_Pres/1999/Apr99/MS_Diagram

METERSTATIONS

9Main Station - Separation, Power Generation, Storage, Oil Export

10Zuata Pump Station - Receives Diluent and Sends Blend North

11

Oil processing 132,000 bpdPower generation 58 MWRotating Equipment 50,000 hp. Roads 98 km.Power lines 97 km.Gathering 239 km.

Field capacities and statistics

12

Cold horizontal well development in unconsolidated sands

Extensive use of multi-laterals and more complex horizontal

well designs

Extensive use of multi-phase technology

- Seven 2000 hp multi-phase pumps (MPPs)

- Twenty three multi-phase meters in service (MPFMs)

(out of 44 purchased)

TAMU MPFM Seminar

Field development - Whats new or different

13

Hairy Fishbone DesignHairy Fishbone Design

STACKED DUAL LATERAL WELL PROFILESTACKED DUAL LATERAL WELL PROFILE

14JK25 Well Cluster - 8 wells, both ESP & PCP artificial lift systems

15Multiphase Pumps boost flow-lines pressure, thus eliminate remote flow-line stations

16PCP lift system - motor at the surface turns rods which drive a downhole pump

17ESP lift system - power is feed downhole to a motor which drives a pump

18

Currently - 23 clusters and 101 wells

By End 2001 - 42 clusters and 272 wells

Long Term - >50 clusters and 700 wells

TAMU MPFM Seminar

Multiphase metering dimensions

19

Well Rate Ranges

Normal Extreme

Blend (X-Heavy + Diluent)

BPD/Well 500 - 2000 2000

Water Conc - % 0.5 - 2 5 - 20

Gas -SCF/Bbl 100 - 200 300 - 1000

X-Heavy Properties - 8 to 10 API

Diluent Properties - 30 API Mesa & 47 API Naphtha

TAMU MPFM Seminar

Multiphase metering dimensions

20

Knowledge of MPFM development and testing in Europe

and USA

Shared experience testing heavy oil wells with

conventional test facilities in California and Venezuela

Large areal extent of the field development and high well

count

Strong desire for increased well test accuracy and

frequency

TAMU MPFM Seminar

MPFM decision drivers

21From Oil & Gas Journal, Oct. 26, 1998, Nunes et al.

TAMU MPFM Seminar

22

Common Flow Patterns - Challenge in Multiphase Flow MeasurementCommon Flow Patterns - Challenge in Multiphase Flow Measurement

Bubbly Flow

Stratified Flow

Wavy Flow

Semi-Slug Flow

Slug Flow

PistonFlow

AnnularBi-Directional

Flow

Gas Oil Water

TAMU MPFM Seminar

23

1- Shrinkage in the Tank as Function of the Percent Diluent

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25 30

Time [hours]

1

-

S

h

r

i

n

k

a

g

e

[

%

]

22% dil. Well 46% dil well 1

TAMU MPFM Seminar

24

Comparison Between the MPFM and The Tank flow rate

0

500

1000

1500

2000

2500

3000

1

3

3

6

5

9

7

1

2

9

1

6

1

1

9

3

2

2

5

2

5

7

2

8

9

3

2

1

3

5

3

3

8

5

4

1

7

4

4

9

4

8

1

5

1

3

5

4

5

5

7

7

6

0

9

6

4

1

6

7

3

7

0

5

7

3

7

7

6

9

8

0

1

8

3

3

8

6

5

8

9

7

9

2

9

9

6

1

9

9

3

1

0

2

5

1

0

5

7

1

0

8

9

Time [minutes]

F

l

o

w

R

a

t

e

[

b

p

d

]

TankMPFM

well 4

well 1well 1 well 5

well 1

dil 22%

dil 11%dil 6% dil 13%

dil 27%

TAMU MPFM Seminar

25

Comparison Between the MPFM and The Tank flow rate

0

500

1000

1500

2000

2500

3000

1

4

1

8

1

1

2

1

1

6

1

2

0

1

2

4

1

2

8

1

3

2

1

3

6

1

4

0

1

4

4

1

4

8

1

5

2

1

5

6

1

6

0

1

6

4

1

6

8

1

7

2

1

7

6

1

8

0

1

8

4

1

8

8

1

9

2

1

9

6

1

1

0

0

1

1

0

4

1

1

0

8

1

1

1

2

1

1

1

6

1

1

2

0

1

Time [minutes]

F

l

o

w

R

a

t

e

[

b

p

d

]

TANKMPFM

well 2 well 4

well 2

well 2

well 6

dil 11.5%

dil 13.4%dil 6.5%

dil 26.6%

dil 22.7%

TAMU MPFM Seminar

26

Trends of Well 2 and 6

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0 2 4 6 8 10 12 14 1 6 1 8 20 22 2 4

Time (hours)

F

l

o

w

R

a

t

e

[

b

p

d

]

0

50

100

150

200

250

D

i

l

u

e

n

t

[

%

]

B lend Flow Rate diluent flow Diluent Frac tio n

TAMU MPFM Seminar

27

1) Viscosity effects (requirement for diluent injection)

2) Temperature

3) Calibration frequency and procedure

4) High Gas Void Fractions

5) Effects of incomplete mixing

6) Applicable physical properties for the flow computer

7) Field data capture and transmittal, particularly with

downhole diluent injection

TAMU MPFM Seminar

Primary initial concerns

28

Decision taken early - mid 1995, based on cost benefit analysis

versus conventional well testing and high probability of successful

implementation if we selected on vendor and did extensive testing

Followed-up with extensive testing

Offshore GOM

North Maurice Meter/Test Facility

In Cerro Negro at Bitor

In Zuata at Maravens San Diego Norte Pilot Plant (SDNPP)

Intevep at Tia Juana

TAMU MPFM Seminar

MPFM decision timing & follow-up

29

France - Elf at Pecorade

Italy - AGIP at Ticate

Norway - Norsk Hydro at Porsgrunn

- Statoil on Gullfaks B

USA - Texaco near Humble

- Conocos North Maurice Test Facility, Lafayette

Venezuela - Intevep

TAMU MPFM Seminar

MPFM test facilities

30

Bitor/JVCO (Statoil,Jantesa, Distral-Termica,

Conoco, Bitor) CerroNegro, Venezuela (April,

1996)

TAMU MPFM Seminar

Evaluation and Testing by Evaluation and Testing by MaravenMaraven, S.A. (June, 1995), S.A. (June, 1995)San Diego Del San Diego Del NorteNorte

31

TAMU MPFM Seminar

32

At initial stage, no one MPFM covered the entire

operational spectrum

Testing is critical in selecting the right meter for each

application

Significant effort is required to develop and maintain the

computer software for each meter type and application

TAMU MPFM Seminar

Early testing confirmed

33

Vendors quoted accuracy on a different basis i.e. % of

reading vs. % of full scale, or a combination of the two,

different turndown ratios per quoted accuracy and

different operational range limitations (e.g. viscosity

limitation, operation in changing density conditions

etc.).

Petrozuata concluded that the choice meter should

maintain accuracy over the entire field conditions.

TAMU MPFM Seminar

Early testing confirmed

34

Options Considered -

AGAR, FLUENTA, MFI

Vendor Selected -

AGAR Corporation of Houston

TAMU MPFM Seminar

Vendor selection

35

Primary Reasons for selecting Agar

Results in multiple tests showed superior performance at the field conditions. Severaldesign and conceptual differences were connived as important:

1) Operates in high accuracy over a very wide viscosity range.(slide 18)

2) Does not require operators input of constantly varying wellsproperties. (See SPE 36539)

3) Can be self-verified at any time (every measuring device is checked against factory calibration)

4) Operates over all flow regimes. (slide 19)

TAMU MPFM Seminar

Vendor selection

36

Manifold - Wells feed into an 8 port multi-port valve that is automated and programmable. Well test frequency and duration can be

changed from the Main Station

Test Data - Test data feeds to a PLC that also receives flowrate info

from the diluent injection skid. PLC reconciles total diluent

injected at a cluster along with total blend production from

same cluster to allocate blend to each well and calculate net X-

heavy production as well test data is updated. All well test data

is feed to the Main Station Control Room and historician via

microwave

TAMU MPFM Seminar

Total system configuration

37

TAMU MPFM Seminar

Prefabbed Prefabbed Cluster Piping Skid w/8-Well Multi-Port Valve for Well TestingCluster Piping Skid w/8-Well Multi-Port Valve for Well Testing

38

TAMU MPFM Seminar

Multi-Port Valve for Well Testing with Automatic Actuator for Remote ProgrammingMulti-Port Valve for Well Testing with Automatic Actuator for Remote Programming

39BC17 Well Cluster - Cluster Piping & Diluent Injection Skids

40Multiphase Meters Provide Valuable Well Test Info for Reservoir Management

TAMU MPFM Seminar

41

GVF Determination - Nuclear (gamma ray densitometer)

and non-nuclear type. A density based system requires

input of fluid density. Performance implication when

density changes.

Total Volume measurement - positive displacement, cross

correlation.

Method for high GVF - Inline or partial separation

Watercut Technique - Dielectric, Gamma ray,

Capacitance/inductance, or microwave

TAMU MPFM Seminar

MPFM types /classification

42

Orientation - Inline , Upflow

Hardware Configuration

- Oval gear for total volume

- 2 momentum (venturi) meters for

differential gas/liquid velocity

- microwave device for water/oil ratio

Model Number: MPFM-301, 3 size

TAMU MPFM Seminar

AGAR MPFM characteristics

43

TAMU MPFM Seminar

44

Measure Q(vol.)

Measure DP(mom1)

CalculateQ(g), Q(l)

CalculateQ(w), Q(o)

MeasureWatercut (c)

DisplayQ(o), Q(g), Q(w)

Measure DP(mom2)

TAMU MPFM Seminar

45

TAMU MPFM Seminar

Early operating experience - Key learnings

Meter performed to Vendor specifications out of the box, yetinitial field adjustment was required to extend the dynamic range of themeter

Several field conditions contributed to a maintenance rate that washigher than expected. Once issues where investigated by Petrozuata andAgar, remedies were found, and maintenance rate decreased. This wasachieved by automating several features such as tubing lines purging.Preventive maintenance is key to keep the meters operating properly.

Out of range operation lead to low accuracy.

Expectation of high well test accuracy can be achieved if attention ispaid to details.

46

TAMU MPM Seminar

Early Operating Experience

Dynamic Range - Flow turndown in the field was high150-3500 BPD, The meter had an accuracy specification thatin low flow rates was wider than the field conditionsrequired. Rather than using a smaller instrument at theserates, Petrozuata requested AGAR to extend the dynamicrange of the meter. After several field tests, this was achievedand the overall meter tolerance was cut by half.

Early signs of erosional wear have been observed, mostlikely due to sand, and hardfacing is being added to neworders. The PD meter is constructed out of of Silicon Carbidebearing and Tungsten Carbide coated stainless steel parts.First unit was purchased in 1994 and is still operable.

47

MPFM Liquid Flow Vs. Tank Flow

0

500

1000

1500

2000

2500

3000

0 500 1000 1500 2000 2500 3000

Tank flow [bpd]

M

P

F

M

f

l

o

w

[

b

p

d

]

+/- MPFM Tolerance +/-10% All Test Points New MPFM Tolerance

TAMU MPFM Seminar

48

TAMU MPFM Seminar

Daily Allocation Factor

Typical daily allocation factor correction in early production stage - 20-25%

Typical daily allocation factor correction in late production stage, after the extension of the meters dynamic range,and improved maintenance - 1-3%

Fiscalized Monthly Allocation Factor

Typical monthly allocation factor correction in early production stage - 14%

Typical monthly allocation factor correction in late production stage, after the extension of the meters dynamic range, and improved maintenance - 1-2%

49

TAMU MPFM Seminar

Overall assessment Under worst conditions, MPFM has still beaten theconventional well testing separators, for data reliability andfrequency, and for ease of operation. Also from a costeffectiveness perspective

The only way to go as the number of wells and productionarea increases dramatically.

Incorporation into an automated well test and field datascapture system, was not a problem.

Systems approach is required for better wells'performance understanding.