Comparative Analysis of Production Method with PCP Systems at Rubiales Oil Field (Colombia)

SPE - 114191

C. A. Rubio – P. A. Agudelo: Weatherford Colombia LimitedJ. E. Peñaloza: Meta Petroleum Limited

Houston TX, April 2008 – SPE PCP Conference

Table of Contents

1. Objectives.2. General Context – Rubiales Oilfield.3. Typical Completions (PCP & ESP). 4. Historical Behavior of Oil Production.5. Operation Parameters and BS&W

Behavior (PCP & ESP).6. Comparison: RB-31(PCP) vs. RB-45 and

RB-47 (ESP). 7. Power Requirements ESP vs. PCP. 8. Conclusions.

Objectives

Compare artificial lift systems at Rubialesoilfield (PCP vs. ESP) into wells behavior.

Show the advantages and disadvantages that can offer each kind of artificial lift method.

Establish the best alternative to produce Rubiales oilfield ensuring the minimum bottom draw down and warranting stable production conditions. (BS&W).

General Context – Rubiales Oilfield

• Llanos Orientales Colombian Basin (Paleozoic – Upper Tertiary). South – East Region of the country.

• Average BS&W: 81%

• Oil Gravity (°API): 12,3 @ 60 °F

• Average Production Depth: 2500’ (762 m)

• 33 Production Wells, 9 with PCP Systems and 24 with ESP Systems.

Typical Completion PCP Production String

Drivehead with Electric Motor

Polished Rod

Sucker Rod String

Tubing String

Tubular PCP Stator and Rotor(5 Bbls/RPM/Day – 2200 psi)

Non Turn Anchor

Gravel Pack

Typical Completion ESP Production String

TUBING BONNET

MASTER VALVE.

PUMPING TEE

SWAB VALVE.

WING VALVE.

TREE CAP

VSD: SPEEDSTAR, 2000 TM, 390 KVA, NEMA 3R

6 PULSE, 460 V, CKT BREAKER R3A420KCB.

TRANSFORMER: 400 KVA, ABB, VBT=480 Volt.

VAT = 1102 - 3817 Volt. 3 a 90 Hz, 20 Taps

24 6 4-1/2" 11,6 #/FT P-110 BTC BLANK PIPE #REF! #REF! 79,30 5,00

25 1 X-OVER 5" BTC BOX x 4 1/2" LTC PIN #REF! #REF! 0,58 5,52

26 27 4 1/2" LTC MESH RITE 11,6 #/FT #REF! #REF! 887,33 5,20

27 1 X-OVER 4 1/2" LTC BOX x 4 1/2" BTC PIN #REF! #REF! 0,54 5,00

28 1 STINGER SEAL #REF! #REF! 0,97 5,00

29 1 JOINT 4 1/2" BTC 11,6 #/FT, P-110 #REF! #REF! 9,68 4,50

30 1 WASH DOWN SHOE #REF! #REF! 2,10 5,00

COMPLETION FLUID : FILTERED BRINE (KCl) DENSITY (PPG) : 8,5 PPGINTERVALS THICK (ft) SPF

3418' MD - 4392' MD > 46' TVD N.A

CSG # JTS DESCRIPTION SHOE (ft) COLLAR(ft) TOC (ft)9 5/8" 5 K-55, 36#, BTC, R-III 236 N.A SURFACE

7" 68 N-80, 23 lb/ft, R-II, BTC. 3400 3195

REMARKS : HORIZONTAL HOLE

3 * 3" LP.

3 1/8" x 3000 psi WP THREADED 3" LP

3 1/2" x 3 1/8" ACME- 3000 psi WP

3 1/8" x 3000 psi WP THREADED 3" LP

FEPCO

FEPCO

FEPCO

FEPCO

FORMATION GUN TYPEN.A

REV. BY: I. AREVALO

FEPCO

SBL-REDA

SBL-REDA

BASALES SANDS

FEPCO

7-1/16" x 3 1/8" - 3000 psi

3 1/8" x 3000 psi WP THREADED 3" LP

236' 9 5/8" CSG SHOE

RTE:16'

3400' 7" CSG SHOE

3390' QUANTUM PACKER

TD @ 4655'

4 1/2" LTC MESH RITE 11,6 #/FT FROM 3490 FT TO 4377 FT

Hanger

Tubing String

Drain Valve (Bleeder Valve)

Check Valve

Discharge Head

Pump (70 stages average, 1200 – 10.000 BFPD)

Intake

Motor

Multisensor Type “O”

Horizontal Well

Historical Behavior of Oil Production

RUBIALES HISTORICAL BEHAVIOR OF OIL PRODUCTION

0

5000

10000

15000

20000

25000

30000

35000

Ago

-200

4

Feb-

2005

Sep

-200

5

Mar

-200

6

Oct

-200

6

Abr

-200

7

Nov

-200

7

Jun-

2008

Time

Oil

Prod

uctio

n (B

OPD

) Production drop duemeteorologic contingence

Pareto Diagram – Oil Production

PARETO DIAGRAM - OIL PRODUCTION

0200400600800

1000120014001600180020002200240026002800300032003400360038004000

RB

-63

H

RB

-61

H

RB

-58

H

RB

-65

H

RB

-75

H

RB

-55

H

RB

-42H

RB

-62

H

RB

-54

H

RB

-67

H

RB

-64

H

RB

- 45

H

RB

-68

H

RB

- 48

H

RB

-60

H

RB

-57

H

RB

-59

H

RB

- 25

RB

-66

H

RB

-43D

RB

- 33

RB

- 04

RB

-79

RB

-51

H

RB

- 38

RB

- 41

RB

- 10

RB

- 31

RB

- 47

RB

- 39

RB

- 30

RB

- 37

RB

-44D

WELLS

BO

PD

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

PRODUCTION FORECAST RUBIALES OIL FIELD

29,292 BOPD

80% OIL PRODUCTION 23,197 BOPD

20% OIL PRODUCTION 6,095

PCP Systems Wells

Operation Parameters of PCP Systems Wells

RB-10 RB-30 RB-31 RB-33 RB-37 RB-38 RB-39 RB-41 RB-80Velocity (RPM) 190 130 60 255 92 220 205 200 70Torque (%) 67 35 95 76 93 69 33 67 18Middle Point of Perforations (feet) 2634 2630 2938 2657 2660 2657 2693 2621 2600Pump Intake Depth (feet) 2421 2403 2574 2393 2487 2440 2430 2426 2457Total Liquid Column (feet) 900 1787 234 804 218 1072 1816 1207 2188Depth of Level (feet) 1521 616 2340 1589 2269 1368 614 1219 269BFPD (Barrels of Fluid per Day) 1029 633 299 1244 422 1175 809 1047 257BS&W (%) 83 87 30 65 72 80 80 75 90BOPD (Barrels of Oil per Day) 175 82 209 435 118 235 162 262 26Volumetric Efficiency (%) 97 88 90 88 83 97 71 90 63PIP (psi) 384 762 100 343 93 457 775 515 933PWF (psi) 475 859 255 456 167 550 887 598 994

Rubiales 31 Well:

Since 2003

30% BS&W (average)

200 – 500 BFPD

BS&W Behavior – PCP Wells

BS&W BEHAVIOR - PCP WELLS RUBIALES OIL FIELD

0,00

20,00

40,00

60,00

80,00

100,00

120,00

28-Jun-03 14-Ene-04 01-Ago-04 17-Feb-05 05-Sep-05 24-Mar-06 10-Oct-06 28-Abr-07 14-Nov-07 01-Jun-08

Date

BSW

(%)

RB-30 RB-33 RB-37 RB-38 RB-41

Lineal tendency with asoft slope. Stableconditions along the time

RB-04 RB-025 RB-042H RB-043D RB-044D RB-045H RB-047 RB-048H RB-051 RB-054H RB-055H RB-057HFrecuency (Hz) 36 56 46 44 36 52 38 56 59 51 50 41

Total Liquid Column (feet) 1940 1291 2023 1083 381 2090 393 1455 309 1464 1641 961

Depth of Level (feet) 751 1244 927 2024 2870 1174 2038 1857 2101 1127 1462 2064BFPD (Barrels of Fluid per Day) 2614 4537 8600 4774 234 8844 282 7958 479 8160 9990 4952

BS&W (%) 88 85 84 84 71 88 42 89 32 85 84 86BOPD (Barrels of Oil per Day) 314 681 1376 764 68 1061 164 875 326 1224 1598 693

PIP (psi) 840 559 863 469 165 905 170 630 134 917 700 410

RB-058H RB-059H RB-060H RB-061H RB-062H RB-063H RB-064H RB-065H RB-066H RB-067H RB-068H RB-075HFrecuency (Hz) 55 43 37 44 44 42 38 45 39 39 38 39

Total Liquid Column (feet) 1166 1411 2218 1625 1686 1735 1873 1161 1222 1280 1734 1947

Depth of Level (feet) 1842 1731 639 1070 1110 1128 1088 1709 1634 1345 1056 853BFPD (Barrels of Fluid per Day) 7374 4508 5058 5171 7760 6416 7555 3450 2549 1966 2334 1685

BS&W (%) 65 83 84 46 82 39 84 43 81 27 55 14BOPD (Barrels of Oil per Day) 2581 766 809 2792 1397 3914 1209 1967 484 1435 1050 1449

PIP (psi) 505 602 946 693 719 740 799 495 521 546 740 830

Operation Parameters of ESP Systems Wells

Rubiales 45 Well: Since 2006

85% BS&W (average)

1000 BOPD

BS&W Behavior – ESP Wells

BS&W BEHAVIOR - ESP WELLS RUBIALES OIL FIELD

0,00

10,00

20,00

30,00

40,00

50,00

60,00

70,00

80,00

90,00

100,00

18-Ene-07 09-Mar-07 28-Abr-07 17-Jun-07 06-Ago-07 25-Sep-07 14-Nov-07 03-Ene-08 22-Feb-08

Date

BSW

(%)

RB-54H RB-60H RB-62H RB-64H

Strong slope inBS&W tendency

Comparison: BS&W Behavior –RB-31 and RB-45 Wells

BSW Behavior - RB-31 and RB-45 Wells

0,00

20,00

40,00

60,00

80,00

100,00

120,00

7-ag

o-03

16-s

ep-0

3

26-o

ct-0

3

5-di

c-03

14-e

ne-0

4

23-fe

b-04

3-ab

r-04

13-m

ay-0

4

22-ju

n-04

1-ag

o-04

10-s

ep-0

4

20-o

ct-0

4

29-n

ov-0

4

8-en

e-05

17-fe

b-05

29-m

ar-0

5

8-m

ay-0

5

17-ju

n-05

27-ju

l-05

5-se

p-05

15-o

ct-0

5

24-n

ov-0

5

3-en

e-06

12-fe

b-06

24-m

ar-0

6

3-m

ay-0

6

12-ju

n-06

22-ju

l-06

31-a

go-0

6

10-o

ct-0

6

19-n

ov-0

6

29-d

ic-0

6

7-fe

b-07

19-m

ar-0

7

28-a

br-0

7

7-ju

n-07

17-ju

l-07

26-a

go-0

7

5-oc

t-07

14-n

ov-0

7

24-d

ic-0

7

2-fe

b-08

13-m

ar-0

8

22-a

br-0

8

1-ju

n-08

Time

BS&

W

RB-31 RB - 45

Shut off due meteorological contingence (june 2007)

16 months keeping the "same"value of BS&W

Fastly increase of BS&Wtendency (3 months approx.)

Skin on wellbore dueorganic treatment

Rubiales - 47 Well

FREQUENCY VS BS&W - RB-47 WELL

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

65,00

70,00

75,00

80,00

19/01

/2006

19/02

/2006

19/03

/2006

19/04

/2006

19/05

/2006

19/06

/2006

19/07

/2006

19/08

/2006

19/09

/2006

19/10

/2006

19/11/2

006

19/12

/2006

19/01/2

007

19/02

/2007

19/03

/2007

19/04

/2007

19/05

/2007

19/06

/2007

19/07

/2007

19/08

/2007

19/09

/2007

19/10/2

007

19/11

/2007

19/12/2

007

DATE

BS

&W

(%) -

FR

EQ

(Hz)

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

BFP

D-B

OP

D-

PIP

BSW RPM O HZ BFPD

BOPD PIP

BS&W Tendency during 2006

Diesel Requirements to ESP Systems

ENGINE MODELNOMINAL

KVA PRIME MODE

NOMINAL KW PRIME

MODE

A-B B-C A-C A B CRB-025 55,0 NT855-G6 313 250 472 471 471 148 149 148 121,1 102,93 41,17 34,70 219,99 4491,6 82,43 789,17

RB-042H 45,0 NT855-G6 313 250 482 482 482 276 276 276 230,4 195,85 78,34 57,44 364,22 8359,9 83,33 1393,60RB-043D 41,0 NT855-G6 313 250 474 474 475 117 118 118 96,7 82,17 32,87 29,61 187,77 3913 85,76 557,21RB-044D 35,0 NT855-G6 313 250 474 475 475 60 60 62 49,9 42,39 16,96 19,88 126,04 241,5 74,62 61,29RB-045H 51,0 NT855-G6 313 250 474 475 475 187 190 191 155,7 132,31 52,92 41,89 265,60 8667 86,21 1195,18RB-047 36,0 NT855-G6 313 250 473 473 472 41 43 42 34,4 29,23 11,69 16,65 105,60 290,2 41,15 170,78

RB-048H 56,0 NT855-G6 313 250 472 472 472 247 246 246 201,4 171,17 68,47 51,40 325,92 7993,9 83,05 1354,97RB-055 49,0 NT855-G6 313 250 477 477 477 296 296 296 244,5 207,86 83,15 60,38 382,87 9749,3 83,04 1653,48RB-056 45,0 NT855-G6 313 250 462 462 463 138 142 144 113,2 96,20 38,48 33,05 209,55 7328,8 88,57 837,68RB-057 43,0 NT855-G6 313 250 478 478 478 250 250 250 207,0 175,93 70,37 52,57 333,30 5246,1 82,39 923,84

RB-060H 35,0 NT855-G6 313 250 479 479 479 110 110 110 91,3 77,57 31,03 28,49 180,64 4725 85,03 707,33RB-061H 38,0 NT855-G6 313 250 463 463 463 126 126 126 101,0 85,89 34,35 30,52 193,54 3395 30,26 2367,67RB-064H 38,0 NT855-G6 313 250 495 495 495 196 196 196 168,0 142,83 57,13 44,47 281,93 7601 88,27 891,60

CONS. DIESEL

(GAL/DAY)BFPD

DIESEL REQUIRED TO ESP SYSTEMS - RUBIALES OILFIELD

DIESEL CONS. BSW BOPDUSED %

LOADCONS. KVA

CONS. KWATT

SWELL Hz

PHASE VOLTAGE (VOLTS)

PHASE CURRENT (AMPERES)

170,841,2290105,616,711,734,436RB-47H

BOPDBS&WBFPDDiesel Cons.

(gal/day)

Diesel Cons.

UsedLoad (%)

KVA Cons.

HzWell

Diesel Requirements to PCP Systems

20631298,574,911,862,940,760RB-31

BOPDBS&WBFPDDiesel Cons.

(gal/day)

Diesel Cons.

UsedLoad (%)

KVA Cons.

RPMWell

POZO RPM´s ENGINE MODEL

NOMINAL KVA PRIME

MODE

NOMINAL KW PRIME MODE

INPUT VOLTAGE (VOLTS)

CURRENT (AMPERES)

CONS. KVA

CONS. KW

USED %LOAD

DIESEL CONS. (L/HR)

DIESEL CONS.

(GAL/DAY)BFPD BSW BOPD

RB-010 190 4BT3,9-G4 69 55 440 48 36,58 31,09 56,53 10,96 69,50 1028,1 81,11 194,21RB-030 130 4BT3,9-G4 69 55 479 29 24,06 20,45 37,18 8,41 53,31 646,4 88,29 75,69RB-031 60 4BT3,9-G4 69 55 461 51 40,72 34,61 62,93 11,81 74,86 298,5 31 205,97RB-033 255 4BT3,9-G4 69 55 450 41 31,96 27,16 49,39 10,02 63,52 1247,9 66,77 414,68RB-037 110 4BT3,9-G4 69 55 470 48 39,07 33,21 60,39 11,47 72,73 488,6 74,46 124,79RB-038 220 4BT3,9-G4 69 55 452 39 30,53 25,95 47,19 9,73 61,68 1121,5 72,46 308,86RB-039 205 4BT3,9-G4 69 55 452 27 21,14 17,97 32,67 7,81 49,53 788,8 80,85 151,06RB-041 220 4BT3,9-G4 69 55 452 38 29,75 25,29 45,98 9,57 60,67 1068,2 71,17 307,96RB-079 110 4BT3,9-G4 69 55 456 41 32,38 27,52 50,04 10,11 64,07 525,5 47,37 276,57

DIESEL REQUIREMENTS TO PCP SYSTEMS

Conclusions• PCP’s at Rubiales oilfield have permitted to keep the

production conditions in the wells that have this kind of artificial lift system in comparison with ESP’s.

• With PCP systems can ensure better production development of the wells and bigger productivity life of them.

• PCP completions are appropriate to be installed in horizontal or deviated wells with the Rubiales typical configuration, according with completions of the present.

At Rubiales oilfield there are some cases where it’s possible to re-evaluate the artificial lift selected. PCP and ESP systems.

• To select a kind of artificial lift system it’s very important to analyze power requirements to ensure save costs along the time.