Potential Papers - Gas Well De-Watering Workshop

SPE PCP Advanced Technology Workshop Page 1 April 19 – 20, 2004

Presentations - Spring 2004 SPE ATW PCP Workshop

No. Author/Presenter Title, Abstract, Notes

Session I --- New Advances in PC Chairs: David Blackall & Ken Saveth Pump Materials & Technology 1 Brian Wagg Real Time Measurement of Elastomer Swell C-FER Technologies Advanced test methods can be used to enhance the process of identifying suitable elastomers for PCP applications. One such method consists of real-time measurement of elastomer swell, in a simulated downhole environment, to help separate the effects of compression/decompression, temperature change and chemical interaction between the elastomer and the produced fluids. In this presentation, example results obtained with this method are discussed, including tests where elastomers were exposed to diluent, carbon dioxide, and high temperature.

2 Luc Chatelain New Advances in PCP Elastomer Technology SPE PCP Advanced Technology Workshop Page 2 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes PCM Pompes This presentation will show the latest advances in elastomer technology applied to PCP. We will show first what each PCP elastomer is composed of, and the limits of use currently observed. The use of the PCP expanded widely in the last few years and constraints on PCP elastomer are more and more severe, leading to the need of deep research on new elastomer technology able to withstand better these difficult downhole conditions. The pur- pose of this presentation is to introduce the studies made on the pumping of fluid containing high light aromatics portion, which is one of the current limitation of use of the PCP nowadays. We will present how the lab studies were conducted to develop a new elastomer, and its latest industrialization status. This innovative elastomer will widen even more the use of the PCP in many problematic light oil wells and ensure PCPs an extended lifetime.

3 Christian Bratu New PCP (NPCP) for Two - Phase Mixture (Liquid - Gas) and Viscous Liquids Consultant SPE PCP Advanced Technology Workshop Page 3 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes The New PCP (NPCP) concept is dedicated to boost two-phase mixtures with various void fractions (liquid - gas and solid particles), viscous liquid, and of course, traditional liquid.

Then the characteristic of NPCP working mode is entirely different from the traditional PCP, including < R&M Tri -Phase System >:

 Control of pressure distribution and internal leakage (slippage) flow rate, along the pump, for various gas void fraction (GVF), i.e. from 100% gas (GVF = 1.) to 100% liquid (GVF = 0.)

 Control of the temperature evolution along the pump, i.e. stabilization of the temperature in order to protect the mechanical parts (e.g. stator elastomer)

 Control of the cavitation risk, i.e. the pressure distribution along the pump is always positive, when the inlet pressure is low and for various viscous liquids and / or gas void fractions

 Large flow rate pump design, i.e. due to the pressure & leakage control the rotor- stator contact is handled and therefore the rotational speed (and flow rate) can be increased

In general, the controlled running process of the N PCP, which is entirely different of existing PCP, offers the pos- sibility to adapt the pump design to the specific production parameters.

Moreover, the N PCP is a reliable system and the thermo-mechanical behavior is under control: no unstable vi- brations, no cavitation risk, protection of the stator elastomer and mechanical parts.

The NPCP improved reliability in sever production conditions is an important economic factor.

The NPCP architecture is based on the traditional PCP and the design and manufacturing process of new components are of traditional engineering competence.

The industrial applications of NPCP are covering a large area that is not accessible to the existing PCP:

 Two-phase flow production (liquid- gas, and solid particles), with various gas fractions (from 100% gas to 100% liquid), in stationary and transient production conditions.

 Low inlet pressure, for liquid and two-phase flows, without cavitation risk SPE PCP Advanced Technology Workshop Page 4 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes  Viscous liquid (mixed with gas, or not), without cavitation risk

 Large flow rate, i.e. increase the rotational speed in order to enhance the pump capacity.

The results obtained on actual NPCP confirm the main performances in two-phase and liquid flows. Moreover, the design analytical method is confirmed too; thus, one can get the optimal design taking into account the production parameters.

Therefore, the table hereafter compares the PCP and the New PCP:

 The pumps functional behavior in two-phase and viscous liquid flow

 The production applications

 The controlled New PCP system allows a large area of industrial applications, which is not accessible to traditional PCP.

Session II --- Well Monitoring and Chairs: Cleon Dunham & Giulia Restaino Optimization 1 Julian Cudmore Advanced PCP Monitoring SPE PCP Advanced Technology Workshop Page 5 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes Phoenix Downhole pressure, temperature and vibration monitoring systems are being successfully utilized on ESP systems to provide extended operation and advanced diagnosis techniques. The same principles can be applied to ESPCP/ PCP artificial lift with similar results and some significant advantages due to the different lifting mecha- nism.

Key points to be discussed:

 The importance of measuring discharge pressure to ascertain correct Pump rotation immediately on start up.

 Discharge pressure to track diluent injection effects in heavy oil wells.

 Use of Delta pressure (Discharge pressure – Intake pressure) to reduce horsepower requirements.

 Use of Intake pressure with Variable Speed Drives to automate a constant draw down.

 Use of vibration trends to avoid resonant drive frequency

 Use of vibration and discharge temperature to track slip and pump wear

 Use of Delta P (Discharge pressure – Intake pressure) to track pump performance over time.

2 Klaus Mueller & John Fraser The Mukhaizna Heavy Oil Field - A World Class ESPCP Operation Petroleum Development Oman The Mukhaizna field is a giant heavy oil field in southern Oman that, although discovered in 1975, could not be developed cost effectively until 2000 due to technical challenges associated with lifting high viscous crude from a relatively deep reservoir at acceptable rates. Key enabling technologies were horizontal wells and electrical sub- SPE PCP Advanced Technology Workshop Page 6 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes mersible progressing cavity pumps (ES-PCPs). Initial field appraisal and testing was carried out using vertical wells and surface driven PCPs. Production rates from these vertical wells were poor and long term tests were plagued by frequent rod breaks especially during well start-up. Whilst horizontal drilling technology was well es- tablished in Oman by the late eighties, it was not until the late nineties that ES-PCP technology could be considered as a potential lift system to produce heavy oil at high rates. Nevertheless, relying on ES-PCPs for the development of the field was a major out-step when the field development plan was prepared in 1998, as little was known about the long term reliability of these systems. However, with the correct design specifications, installation, operating, and work-over procedures, ES-PCPs have proven to be the right choice. Critical success factors were the use of down-hole pump and reservoir data recording and continuous remote monitoring systems, variable speed drive technology and specific pump installation and work-over procedures. To date, after three-and-a- half years of operations, outstanding pump run times have been achieved. It appears that pump speed and water cut are key factors influencing the pump mean time between failures.

The continuous quest to increase production and reduce cost has lead to a number of technical developments and improvements in conjunction with ES-PCP technology. One of these was the development of a slimmer ES- -PCP gear box, which was initially intended for a slim well design, but has become the preferred choice for many small to medium size pumps due to it’s superior performance and lower cost. Another special development was a semi-selective completion using a surface operated hydraulic sleeve below an ES-PCP to enable testing of indi- vidual legs in dual lateral wells. For production optimization purposes, pumps have also been run successfully in pump-off control mode governed by pump intake pressure.

Today Mukhaizna is the biggest single field ES-PCP operation worldwide. Although future developments of the field may include reverting to surface driven PCPs in low rate wells in the more marginal areas of the field, further exciting technology challenges lie ahead in conjunction with ES-PCP lifting of heavy crude at elevated temperatures at the initial stages of the thermal development planned to take place in the central part of the field.

This paper describes the initial ES-PCP lift system design, the teething problems encountered and lessons learnt, the technical development to further improve the pump design and reduce well cost, pump performance, as well as potential future developments to address changing production conditions with respect to both cold and thermal developments in the field.

Notes SPE PCP Advanced Technology Workshop Page 7 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes SPE PCP Advanced Technology Workshop Page 8 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes 3 Scott Weatherill PCP Automation for Heavy Oil Applications e-Production Solutions This presentation discusses the components and validation for installing a real-time optimization system on a heavy-oil PCP well. The presentation includes details of a real-time PCP optimization solution case study in Venezuela as well as discussion on the benefits of the system.

Ideas discussed include: how managing both surface and down-hole information can greatly reduce mechani cal failures while maximizing production.

To properly facilitate the system it is necessary to install hardware devices that supply the critical real time data, but also use this information to automatically adjust the system to enhance well performance.

Host systems capable of capturing well data and displaying it in a useful and easy-to-use method for both op erations and engineering groups should be put in place during the initial completion of the well.

A complete and properly engineered system will reduce costs, increase production, validate design, and supply the operator with a method to manage the well more proactively.

No. Author/Presenter Title, Abstract, Notes Panel Discussion Covering Ses- Notes sions I and II

Session III --- Open Session Chairs: Lonnie Dunn & Shauna Noonan 1 Tim Soltys Maximize Gas Production & Minimize Work-over Costs (One Innovative De-Wa- Weatherford Artificial Lift Systems tering Solution for the Life of the Well)

This presentation discusses the life cycle of a typical coal bed gas well. We will discuss how daily operation of these wells and the artificial lift system is impacted as the water rates decline and then show how the complete de-watering stage of the well can be accomplished through an innovative approach with one artificial lift method. Through this approach we will show how a well can be produced from an initial rate, but not limited to, 500 bbl/days down to 3 bbls/day without ever pulling the tubing. This concept will illustrate how work-over costs can be reduced and common operating practices such as stop clocking or cycling the well can be eliminated. A case history discussion will show how one operator in the Raton Basin is increasing total gas production 3 to 4 fold and realizing reduced operating costs based on this approach.

No. Author/Presenter Title, Abstract, Notes SPE PCP Advanced Technology Workshop Page 11 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes 2 Jorge Robles ISO 15136.2 - Surface Drive Standard: Update CFER Technologies In April 2002 a committee was formed to draft the ISO standard for progressing cavity pump surface drive equipment. The committee submitted a draft document for review by the ISO Work Group in August 2003. Details of the contents of the draft document and expected benefits will be discussed. Additionally, the process that re- mains until it is published as an ISO Standard will be outlined.

No. Author/Presenter Title, Abstract, Notes 3 Jason Kollatschny Finding Success with the PCP Through a Stepped Design & Application Process in the R&M Energy Systems Boscan Field

Progressing Cavity Pumps (PCPs) have proven to be a great improvement over rod pumping systems for about ten percent of the more than 500 active wells in the heavy oil super giant Boscán field. A multidisciplinary team has identified technical, mechanical, operational and procedural techniques that have greatly increased the run time and efficiency of pumping for the wells. Significant lessons learned include the requirement for pumping system designs tailored for each specific well location, excellent contractor technical support at all stages of design, installation and maintenance, and daily monitoring of the installed wells.

The installed PCPs at Boscan have not only reduced field power consumption, but also manpower operating costs, capital costs and cycle time. They have significantly improved field safety and reliability as well. Careful at- tention to detail has given the operator encouragement that the program can be expanded to at least fifty percent of the field producing wells.

Session IV --- Emerging Applica- Chairs: Ryan Chachula & Ken Saveth tions (Thermal, Offshore, Light Oil, etc.) 1 Mike Guidrey Elastomeric Formulation Considerations to Reduce the Effect of Swell in PC Pump Ap- R&M Energy Systems plications

Elastomeric swell is one of the most common material issues related to Progressing Cavity Pumps. This research study investigates the effect of well fluids on PCP elastomers. Correlation between plasticizer type and physical properties are examined on specimens aged with well fluids from various global locations. The practical aspects of elastomer swell in field application are discussed.

No. Author/Presenter Title, Abstract, Notes 2 Ryan Chachula / Ken Saveth ESPCP Deployment in an Offshore Exploratory Well Test String (Presentation Pending) Encana / Centrilift Exploratory drilling in the Campos Basin offshore Brazil to determine field commerciality can be very challenging, particu larly from a well testing perspective. Uncertainties (not totally known or unexpected) include: heavy and high viscosity oils, inflow performance and skin factor, reservoir fluid properties and flow assurance issues, and varying degrees of sand production. As a result, new production lift technologies and downhole test configurations from the conventional approach are required to effectively test and subsequently develop these offshore heavy oil reservoirs.

Due to the high probability of encountering heavy viscous oil, a non-conventional emerging artificial lift application was deemed necessary as a back up to an unsuccessful flow test. This presentation outlines the methodology, key success factors and various ESPCP optional string designs considered by both EnCana and Centrilift to achieve success for both vertical and extended horizontal well flow tests.

Panel Discussion Covering Ses- Notes sions III and IV

Break-Out Sessions 1 Cleon Dunham PCP Automation/Optimization Giulia Restaino Notes

2 Ken Saveth Advanced Developments in PCP Components SPE PCP Advanced Technology Workshop Page 16 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes Lonnie Dunn Notes

3 Ryan Chachula Challenging Applications for PCP's David Blackall Notes SPE PCP Advanced Technology Workshop Page 17 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes Keynote Address Richard Spears Artificial Lift Market is Growing Spears & Associates A Lesson From Starbucks

With the rig count soon to decline in the US and the international rig count slowly rising, the service and equipment sector will get very little help from new well drilling in 2004. Nevertheless, the artificial lift market is growing more strongly than most other sectors as fields mature and as production be- comes more valuable. Richard will speak about these oilfield market trends and will also explain how producers of maturing fields can learn a powerful lesson from that most unlikely of companies: Star- bucks.

No. Author/Presenter Title, Abstract, Notes Session V --- Heavy Oil Applica- Chairs: Lonnie Dunn & Ken Saveth tions 1 Thomas Crowe Kern River PCP System ChevronTexaco The Kern River Field is a thermal operation located in Bakersfield, California. PC pumps installed in Kern River were used primarily in large gross wells and wells having sand problems. Eight of the original 23 wells are presently running since they were first introduced in early 2001. Some of the problems experienced during this time have been:  Pump failures caused by inaccurate sonic fluid levels and well pump off  Pump failures due to inaccurate downhole temperatures.  Rod failures due to over torque or poor makeup.  Safe Control of backspin during pulling operations  Environmental problems associated with leaking stuffing boxes.  Poor monitoring and slow response

Field testing has been done over the past 8 months to identify and correct these problems. A brief discussion of this testing with solutions will be presented.

No. Author/Presenter Title, Abstract, Notes 2 Lonie Dunn Experimental Investigation of High Volume Viscous Fluid PC Pumping Weatherford Artificial Lift Systems Progressing cavity (PC) pumps made their first inroads as a method of artificial lift for the oilfield in low volume (<200 BPD) sand laden heavy oil applications. While now the dominant method of lift for these traditional heavy oil wells, they are also seeing increased use in new high volume heavy oil applications. These applications, which can have rates that exceed 3000 BPD, introduce new issues and challenges. To better understand field performance an experimental study was carried out using special equipment to test a number of full-size PC pump geometries with several viscous fluids. Results from this testing will be presented with a focus on highlight- ing the unique characteristics of high volume viscous fluid pumping and their implications in terms of equipment selection and operation to maximize overall pump efficiency and life.

No. Author/Presenter Title, Abstract, Notes 3 Rosaura Heath PCPs in PDVSA Western Venezuela. General Overview PDVSA INTEVEP Because of the advantages that Progressing Cavity Pumping system brings to the production of medium and heavy oil, a significant increment (15 %) of this artificial lift system has been seen in recent years. PDVSA has not escaped to this reality. A General Overview about Progressing Cavity Pumps in PDVSA -Occidente is ex- plained. The system configuration and oil wells characteristics of main reservoirs in this area are shown: What do we have now? How many wells? We pretend to share our experiences increasing the middle time between fails (MTBF) and best practices in designing and operating PCP systems, as well as the results of changing wells production methods from Gas lift to PCP and from Sucker Rod pumping to PCP. Finally we present the prediction of PCP scope in future.

Session VI --- Case Histories / Chairs: David Blackall & Le Cong Le Best Practices 1 Juan Carlos Barrios Optimization of PCP Systems in SINCOR Field Veronica Fernández Sincor SINCOR is a Venezuelan operating oil company created in 1997. The company is comprised by Total Venezuela S.A., PDVSA Sincor S.A., and Statoil Sincor A.S. Upstream operations started in 1998 to exploit the Zuata field located in the Orinoco Belt in Southeastern Venezuela. Reservoir is characterized by an 8° API heavy crude oil in unconsolidated sand. A total of 335 wells have been completed up to the present. Well completion operations started in June 2000. Most common well servicing is pump replacement. Wells have been completed with PCPs for cold production and equipped with lines for injection of diluent. This presentation summarizes the optimization of PCP systems in Sincor field aimed to minimize operating time and costs. Optimization is based on a systematic process for pump failure analysis in order to identify the major failure modes, field implementation of corrective actions focused on pump speed control, and use of new technologies for PCP systems.

2 Bruce Weir Insertable PCP System - Offshore West Africa SPE PCP Advanced Technology Workshop Page 22 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes Shaunna Noonan ChevronTexaco This presentation describes an ongoing PCP pilot located offshore Africa. The first phase of installations oc- curred in 1998 on wells that had been previously produced via gas lift. These were conventional top drive systems with some modifications made for the offshore environment. Several operational and design issues lead to a second phase of installations in 2002 that deployed the insertable PCP variant.

3 Pat Harris Out of Africa: ExxonMobil's Implementation of PCPs in Chad SPE PCP Advanced Technology Workshop Page 23 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes ExxonMobil With the continual development of international oil and gas plays, reservoirs are often located in remote places that pose unique challenges in terms of the design and operation of artificial lift systems.

This presentation will focus on the selection, testing and development of progressing cavity pumps (PCP's) for the ExxonMobil Chad Project located in the southern part of Chad, Africa. The Chad Project has been on-stream since July 2003 and has a significant number of PCP currently in operation.

Panel Discussion Covering Ses- Notes sions V and VI

Session VII --- PC Pump Drive Chairs: Ken Saveth & Ryan Chachula SPE PCP Advanced Technology Workshop Page 24 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes Methods (Alternative Deployment) 1 Mike Findley Comparative Efficiency of ESPCP David Olson Centrilift An important factor of the total cost of an artificial lift system is its efficiency over the life of the well. Efficiency is defined as energy used per barrel of fluid produced. This paper identifies the efficiency of ESPCP systems in comparison to various artificial lift methods. The paper then integrates the efficiency and the mode of deployment into a total system cost calculation.

Performance data of artificial lift approaches under differing well conditions are gathered through survey of published data and field data collection. The data are analyzed by computer and proprietary performance software.

The analysis shows the expected efficiency of the artificial lift methods under certain well conditions.

These results, when used in a total system life calculation, provide one basis for selection of artificial lift means and de ployment for wells.

2 Alejandro Ameglio Hollow rods: Field Performance of PCPRod®, A New Technology For PCP Systems Tenaris SPE PCP Advanced Technology Workshop Page 25 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes After four years of their introduction, the hollow rods PCPRod® have been thoroughly tested at the oilfields in the most diverse conditions of use.

Their use embraces wells of high flows of extraction, wells with high viscosity oils, wells with problems of sand, and some applications of deviated wells.

The objective of this presentation is to describe these four years, analyzing the different performance of these rods in different environments of use.

This work is, in turn, continuity of the technical paper SPE 69558, in which the technology was described, com- menting the first installation in field.

The work describes the analysis of operating conditions of wells, interventions records and general performance of the hollow rods PCPRod®

3 Ken Carstensen New Design API Modified Sucker Rod Connection Permian Rod Operations SPE PCP Advanced Technology Workshop Page 26 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes The steel API sucker rod connection design used in beam and progressing cavity pumping systems has been an industry standard since the 1920's. During these many years of continuous use, improvements have been made both large and small, yet this three-part connection system is responsible for the majority of rod string failures. Af- ter 3 1/2 years of development we now bring to the industry a new API modified four-part design with a method and system for precise makeup that expand load-bearing capabilities and extend the working life of sucker con- nections.

This presentation describes development and testing work performed, information acquired, systems and methods created, and how the new API modified connection solves problems, eliminates or greatly extends time between failures keeping work over and associated costs to a minimum.

Session VIII --- Pushing the Enve- Chairs: Le Cong Le & Cleon Dunham SPE PCP Advanced Technology Workshop Page 27 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes lope - Severe Applications 1 Paulo Gasse The Use of Undersized PC Pumps in Brazilian Fields Petrobras In spite of the great development of PCP at the nineties, this artificial lift system is still viewed by many users as a solution for shallow wells with viscous fluids at low flow rates... Probably, it's because of the reduced MTBF obtained at other applications. This presentation intents to share our experience in the utilization of undersize PC pumps, as a solution to increase MTBF in deeper wells (until 6000 ft), at Brazilian fields, reaching the same operational standards as (or even greater than) Reciprocating Rod Lift.

2 Jack English Drive Rod Applications And Experiences In The Orinoco Extra Heavy Oil Belt Ameriven This presentation covers drive rod applications, experiences and developments in an Extra Heavy Oil field in Venezuela. These rods, including the 1-1/2” drive rod, power some of the largest PCP’s operating in the world to- SPE PCP Advanced Technology Workshop Page 28 April 19 – 20, 2004

No. Author/Presenter Title, Abstract, Notes day.

The pump and rod combinations are pushing the operating envelope beyond previously perceived limits with respect to volume and torque. The presentation will highlight the performance, problems and solutions, and lessons learned through daily operations.

Panel Discussion Covering Ses- Notes sions VII and VIII SPE PCP Advanced Technology Workshop Page 29 April 19 – 20, 2004

SPE ATW for Progressing Cavity Notes Pumping – Final Wrap-Up