.- -.

... ... .. m
Socistyof Petroleum Engineers
,.. Akq. Arwti., 27.29 WI 1994.

SPE 26987 Producing Extra Heavy Oil from the Orinoco Be!t by Electrical Submersible Pumping System - A Pilot Test
R. Gonzalez and M. Reina, Corpoven S.A. q SPE Mambar
C.W;W This ww 1994 SUCie!y 0+ P.UO!,UA Englnew,, l.c. 111 Lat. A. E4mniCarlbbOa Peokm E.ww!F& COnfarsC4 hdd in B..,

wia @&laTed !0, Pr<$e3m3~l-,Ke

ABSTRACT EIeaw and extra-heavy oils have. !cmn traditionally

produced using sucker rod pumpq. However, this production method is inefficient\ highly energy corrsumin~ mrd the umtirl life of the equipment is abort. Therefore, other methods of artificial Iii have to be evaluated, irr order to exploit the hemg oil resm-vea more efficiently and economically. In this papiir, the results of a pilot teat &irrgan eleztrieal submergible pump to produce extra-hea~ oil (9.2 AH) in the Orinoco Belt, Eastern Vene-zda, are presented. The ma@num preductioo rate obtained was 1,170 BOPD (186 M%), tibkh iS 700 BOPD (i ii M3D] hider than the maximum rate obtained with sucker rod pumping in .&e .gune weil. NO diueni was used in ~ this particular test. The pumping efficiency obtained (37.7V.) indicate~ that with a higher capaci~ pump, production rates of up to 2,000 330PD (318 M3/D), without the use of diuent, can be achieved.

INTRODUCTION
The Orinoco Belt comprises aevemd massive sceumrdations of heavy and extra-heavy oils pamlleiirrg the rrorthem bank of the Orinoco River in the southern flank of the Eastern Venezuela Basin. The API gravity of the oil ranges &o~. 6 to 160~1 at surfice conditions and the oil vxscosity ranges ffom 140 to 21,000 eerrtipoises at 140 F (6OC). The average sand porosity is about 30~o and the permesbfi~ ranges &om 1 to 12 darcies. Reservoir depth ranges fkom 600 f~ (183 M) irr the SoUth to 4,000 feet (1,219 M) along the northern border of the area. Although, the earliest exploratory well was drilled irr 1935, exploitation of the area did not begin until IW19, when petrbleos de Venezuela (PDVW and ita affiliates commenced an aggressive. exploration equrign. Since its begirrnin~ the production method utilized in the area haa been sucker rod pumping with d~uent. WM this method, production ratas of up to 1,300 BOPD (207 M3/D) with 3..5 in (8.89 cm] pumps and 2,000 BOPD (318 M3LD) with 4.5 irr 785

PRODUCING RXTRA HEAVY OIL FROM THS ORINOCO BELT BY ELECTRICAL SLIBMSRGIBLE PUMPING SYSTEM - A PILOT TEST

26987

(11.43 cm) PUMPScan be obtained. Nevertheless, the lifting capacity of these pumps is considered low, due to the high productivity index of the wells. Therefore, other production methods need to be evaluated to exploit the huge hea~ oil reserves of the OMoco Belt, more efficiently and economically. Corpoven S.A,, an afHiate of PDVS~ has accumulated extensive technical experience using Electrical Submergible Pumps (ESP) in Barinas and Apure States, Southwestern Venezuela, where it produces 27 MBOPD (4,292 M~/D) of mdlum gravity oils (22-26 API) ffom 40 wells. The need for a more efficient production method for the exploitation of its heavy oil areas motivated Cnqroven to evaluate the ESP h the Orinoco Bek, Well MFB-1 59, which is completed in the U1,3 sand (MPB-53 Reservoir), was then selected for the test. The test was conducted in a period of one and a half months. The test was made in three phases. In each phase, the following parameters were monitored: bottom hole and well head flowing pressures and inlet and outlet pressure of the diluent injected to the pump and to the flowing line. Aditionstly, formation fluid samples were collected and sent to the laboratory for analyses. The well was tested for 24 hours for each pump frequency. Irr this paper the results of this test are presented, as well as a brief description of the reservoirs rock and fluid properties and the operating characteristics of the pump utikzed during the test.

sand thickness of the reservoir is 75 feet (22.86 M), with a maxirnurn net oil sand thickness development of 174 feet (53 M). The estimated volume of oil originally @ place is 1,950 MMSTB (3 10X106M3). The petrophysical parameters of the reservoir are aumrnarized in Table 1. The average values for each parameter are as follows Porosity = 30%, Shale Content = 5%, Water Saturation= 17%, Horizontal Permeability = 10.6 darcies, Vertical Perrneabfity = 5.3. darcies. There is no free gas, origimdly, present in the reservoir. Reservoir oil and gas samples were recombined irr -the l+oratory to reservoir conditions of pressure and temperature, 1,160 psi (7992 kpa) and 137 F (58 C), to obtain a solution gas-oil ratio of 106 SCF/STB. A subsequent PVT enaIysis yielded an API Oravity of 9.2 API and nn oil fomration volume factor of 1.073 RB/STB. Using itatic bottom hole pressure surveys end pressure decline curves, it was determined that, at the time of the evrduatiom the bottom hole pressure and temperature in well MPB-159 were 1,065 psi (7,334 Irk) and 137 W (58 C), respectively. The productivity index (PI), at the stated conditions, was estimated to be 3.86 BOPD/psi. PI and RPI curves are shown in Figure 2. me average production rate is bigher than 400 BOPD (64 M31D) per well and the total eutmmdative production for the resewoir, in eight and a half years of prodoctio~ is as follows: 44.1 MMSTB (7.0 MMSCM)of Oii, 5.4 MMSTB (0.86 MMSCM) of water, and 38.5 MMMSCF (1,09. MMSCM) of gas. It should be mentioned that, aproxirnately, 900/0 of the curnnmlative production has been obtained through the use of Cyclic Stesrn Irjection.

.. ... ..

ROCK AND FLUID PROPERTIES

The reservoir selected for the test was the MFB-53 (fMP H-15) rwemoir, located irr the Bare Field of the Orinoco Belt (See F@re 1). This is the largest. resemoir that has been discovered in the Orinoco Belt, to date. The dmcnsions of the reservoir are 23,786 feet (7,250 M) Iorrg irr the North-South direetion and 34,448 feet (10,500 M) wide in the East-West diieetion, The average net oil

786

I
3 .R GONZALEZ M FMNA AND
26987

CIIAIZACTERITICS WELL MFE-159 OF ~,..

Well Ml%-] 59 was drilled and completed ori@raUy in the U1,3 ~_d, wit~ open hole gravel pack irr 1983. It was placed on production in 1985. Figure 3 shows the location of the well in the reservoir. During its produ~ion Me, it had been equipped with a sucker rod pumping unit to M its productio~ which had reached 1,200 BOPD (191 M3/D), early on, In Deceniber 1991, 7,286 tons of ateant were injected into the well, at-ler which it was placed on production with 1,200 BOPD (191 M3/D). By August 1993, its cunmndative production was 1.12 MMSTB (178 MSCM). Three months prior to the evahration of the electrical submergible pump (September 1993], the average ~roduction rate hti been 400 BOPD (64 M3/D), F@rre -4. shows the actual wfdls completion diagr~ which consists of 7 in .(17.8 cm) casing, 3.5 in (8.S9 cm) production tubii~ the electrical submergible pump whose wction port is at 2,65rS feet (808 M), the protection (housing), two 160 Hp motors, and the bgtim hole pressure-temperature recorder. The weU had been gravel packed for sand control. The type of cable used is REDALEAD cl) ffom REDA #lOJ. Additionally, a 1.25.irr(3. 18 cm) coiled tubing was installed, taped to the production string, in order to inject diluent ilom the surface to the ayction end of the pump. Thu8, reducing tie formation crude viscosity for a more efficient pump performance.

-Eksctric motors with additional horsepower to --. . that reqmred by the desigm two 160 Hp units. -Pumping efficien~ irr the order of. 51?/~ according to the performance profile for the selected pump. -Capable of handIing highly viscous heavy cntdes. A design program was mn considering oil production with and without dduent. The results of . the design program are sirown in Table 3. The electrical submer@ble pump selected was of the type GN-200 -540 Series - ARZtlJ, which has 107 stages and is highly resistant to abrasion. The pumping capaci~ at maximum efficiency (66%) is 3,000 BOPD (477 M3/D) and at 50% efficiency it is 1,500 BOPD (238 M3/D), at a frequency of 60 Ik. The pump perfomce profile is presented irrFigure 5. Accor&mg to the design requiremerrta, the needs of the electric motor was 286 Hp, but due to safety reasons two 160 Hp motors were sekcted instead. Aa to the transformer capacity, the design progmrrr indicated a 169 KVA, however a 390 KVA transformer was installed, which ha8 a 480 volts input voltage and a 1,153 volts output voltage, with 82.5 amps at 60 Hz in each motor. The bottom hole pressure and temperature recorders were designed to work under maximum preswres and temperatures of 5000 psi (34,450 kpa) and 500 F (260 C), respectively.

JWMNXITON PERFORMANCE
The evaluation test was conducted in three phases. which are discussed as foUows.

PUMP INSTAL-UTIONDESIGN
The installation design was performed taking into consideration the basic data shown in Table 2 and considering the foUowing factors: -Pumps highly resistant to -d temperatures. f])REDATrademark 787 abrasion and high

Frequency Variation from Wlgh to Low and Diluent Rates from High to Low
Dmng this phaa~ which was considered as the start-up and system adjustment stage, high dduent rates were used to guarantee trouble &ee operation in the handling of conventional crude by the pump. (1)~A Tmde_k

4 PRODUCING

EXTRA HEAVY

OIL FROM THE ORINOCO BELT BY ELECTRICAL PUMPING SYSTEM - A PILOT TEST

SUBMERGIBLE

26987

The l@lr initial fiequencics (up. to 70 I@ were aPPfi~ as & s.sf@Y m~sure io the loading and maximum displacement of the pump during start-up, although these were reached increasing the ficquency step by step ilom 30 to 70 Hz. In this tlrst phase, diluent was injected at a rate of 1,590 BID (253 M3/D) through the annular space between the casing and the production string, due to the fact that it was not possible to irje@ dduent through the coiled tubing, probably due to an obstruction or a fkttcrrrrbrg of the 0.5 in (1.27 cm) tail pipe while lowering it when completing the wel. Under these conditions, and at a frequency of 70 Hz, the production rate reached 570 BPD (91 M3/D) of formation crude, wtile the pump handled a total of 2,160 BPD (343 _M3@) of diluted 19 API erode. The observed amperage waa 43 amperes and the bottom hole conditions were 700 psi (4,823 kPa)and211 F (99 C). The results of a ae~ond and third teats at 65 and 45 H.q respectively, are shown in Tables 4 and 5. It was observed that during the evaluation at 45 Hz and with 700 BPD (111 M3/D),-the pump drained the entire diluent cohrnm above ii, after which a t%lure occurred, causing the equipment to stop and the well to start flowing naturally at a rate of 1,000 BOPD (159 M3fD) initially, to decrease later to 240 BOPD (38 M3/D). The well produced naturally for three days and had a bottom hole temperature of 185 F (85 C).

Inflow Performance Relationship (IPR) curve is also presented on the mph. It can be seen that at the same bottom hole pressure attained by the pump, the well irrtlow is between 1,500 (238) and 1,700 BOPD (270 M3/D), while the pump was able to M an average of 1,100 BOPD (175 M3/D). This means that with the pump installed the well is capable of producing horn 65 to 70% of the oil volume provided by the formation. Figure 6 shows the production rate versus tlequency curve, At 65 Hz a sudden drop in the production is observed. This was due to a drop in amperage from 31 to 21 amps, halfway during the test. The drop in amperage was due to some. additional vohrrne of gas entering the pump, which was not present during the rest of the teat.. The two points shown at the right end of the graph, above and below the results for 70 ~ were obtained during tbe third phase of the .ewduation with diluent injection into the well. During t~ a&md phase, diluent was injected in the flowline, at the wellhead, to improve the separation and treatment process at the flow station. Table 5 shows the diierent rates of dhrent irjection. ~. Figure 7 shows the behavior of the bottom hole temperature irrder flowing conditions and the surf@ temperature of the fluid mixture. The diff~ence in temperature is also plotted against It cair be obaeryed ~at the crude production. ternpe&e irrcrca&s as the production rate increases. The difierencc in temperature tends to decreasewith increasing production, reaching 75 F (24 C) at 1,095 BOPD (174 M3/D). This last point on the graph corresponds to the evaluation carried out with diluent in.@ last phase. F@.rre 8 showa the behavior of the bottom hole temperature during flowing conditions, where a difference of 34 T (19 C) is observed between the well flowing naturally at 185 T (85 C) aiid when it flowed at maximum rate, at 60 J+@with a temperature of 219 F (104 C). This last temperature was obtained because both 160 Hp irotors were dissipating more heat at that condition,

Frequency Variation from Low to High Without Diluent

In this phase, with bottom hole conditions st.~~q .,. at 630 psi (4,34 1 k%,), 01 F (94 C), and 15 2 amperes, the low, ,~equency (35 Hz) teti WE ..,. performed, without dduent. A production rate of. 684 BPD (109 M3/D) of 9.2 API @avhy crude was attained. The results of this test are summarized in Tables 4 and 5. Figure 2 shows a graph of bottom hole pressure versus productio~ for the 35 Hz teat, The well

788

R GONZALEZ

AND M. REINA

26987

CmmtnrIt Freqrrmrcy with DiIuentin the Well This last phase, or complimentary phase, was per%ormedto observe the wells production behavior with diluent injection at the bottom, but ordy after the well had atabtied with the ekctrical Submergible equipment at low diluent rates. During the fiat test in this phase, diluent was injected at a rate of 223 BPD (35 M3/D), while the total fluid Ii&d reached a rate of 1,189 BPD (189 M3iD) of 11.7 API diluted crude. Another teat carried out yielded 1,170 BPD (186 M3/D) with a dfluent injection rate of 506 -B/D (80 M3iD). Thus, obtaining a total Iiiig of 1,677 BPD (267 M~/D) of diluted 13..9API crude. The results of these tets are graphically presented in Figures 6, 7, and 8. Table 6 shows a listing of the electrical parameters, both measured sod calculated. They include the horsepower required by the pump, the horsepower output by the motors, the calcdated amperage, the voltage and capacity utilized by the transformer. It cart be obsewed that the maximumhorsepower used by the electrical submergible pump was 225 Hp and the ma.xirmrmcapacity used by the transformer was 178 KVA out of the 300 KVA available.

The electrical submergible equipment design considered a 504 pumping d%ciency in the performance curve for the pump selected, over a maximum of 660/. efficiency and a capacity of 3,000 BPD (477 M3/D) at 60 &, The production rates obtained were compared to the prodrrc@on test results at 60 m which was taken as the base case. These results abow that the rates obtain@ match the pump capacity at 40%0efficiency in the performance curve. The curves described before (theoretical production and pumping capacity at 40% e5ciency) match with rninimaI deviations up to 60 !++~tb $re observed production cume, deviating later a? !55HZ for the reasons explained before. Figure 10 shows the behavior of the pumping capacities versus tlequerrcies. The described results show that fl.rture design of electrical submergible equipment to be used under conditions similar to those present in well MFB-I 59 should consider designing installations with 40% pumping efficiency, taken from the models calibration curves end type of pump which complies with the expected capacity requirements. F@re 5 presents the behavior eficiency curves calculated utilizing information from the weU head, meimored production, pump horsepower, and the rest ef6cienciea which were obtained from the production measured-pumping capacity ratio, at different fiequerrcies. This ratio was used to correct the ticiency due to the use of viscous crude against the capacity taken from the calibration curves for the handling of water. The reaulta show a real average efficiency of 35/0, while the maximum obtained was 37.70/0at 60 Hz. Considering the results of the real pumping eficiency applied to other pump models with higher capacities, it is estimated that production rates of up to 2,000 BOPD (318 M3113)can be attained. Table 7 lists the different types of pumps and tbeii capacities at 37,7% &ciency, correapondmg to the asme pump manufacturer. It is then conchrded that a model GN-2000 pump, which ia capable of producing 1,950 BOPD (310 M3/D) at 37.7%.

~~

RESULTS
Well MB-159 had produced with a sucker rod pumping unit since its orighrd completion in 1983, The last production teat with the %cker rod, pump was 400 BOPD (64 M3/D), while during the evaluation of the electrical submergible pump it produced an average of 1,100 BC)PD (175 M3~), which represents 700 additional berrela of oil per day. The sample calculations made show that the volume of gaa entering the pump was no more than 5Athe totai volume produced at bottom hole cm-dtions, which justifies not installing downhole gas separators. The wells producing gas-oil ratios during the evaluation teat averaged 250 SCFL?HB.

_.

789

6 PRODUCING

EXTRA

BEAVY

OIL FROM THE ORINOCO PUMPING

BELT BY ELECTRICAL TEST

SUBMERGIBLE

26981

SYSTEM - A PILOT

efficiency at 60Hz, is the best possible choice for the conditions of the well under evaluation. Figure 11 shows the different viscosity versus temperature behavior curves for the different crudes produced (formation and dfluted) during the evaluation tests. The8e graphs simulate bottom hole as well as surface temperature of the fluids at dflerent viscosities, ranging tlom 1,100 SSU (23S cps) at average bo~om hole temperature, to 1,800 SSU Qj730 cps) at average surface temperature for fornmtion crudes having a gravity of 9,6 API and a vkcosity of 300 SSU (65 cps) at average bottom hole temperature and a viscosity of 900 SSU (195 cps) at average Sufiace temptiature for a ,dditex+l crude of 13.9 API.

- The measured production was equivalent to 40% of the installed pump capacity. - .The obse~ed pumpbrg etliciencies were between 35 and 37.7%. - A GN-5200 (REDA) pump is required to produce the maximum production rates expected flom well MFB-159.

REFERENCES 1.
American

Irrsiitute Petroleum Recommended Practice for Sizing and Selection of Electric Submersible Pump Installations. API Recommended Practice IIU(RF llU). The System. Catalog

i20NCLUsIONs AND RECOMENDATTONS 2. - The maximumproductionobtainedwitout diluent

at 60 Hz was 1,130 BOPD (180 M3/D) and 1,170 BOPD (186 M3/D) at 70 Hz with dfluent injection. - The production from well MPB-159 increased 700 BOPD (111 M3/D), going tlom 400 BOPD (64 M3/D) with a sucker rod pump to 1,100 BOPD (175 M3/D)witb an electrkd submergible pump, - The maximum Iiimg capacity observed was 2,160 BOPD (343 M3/D) of a diluted mixture of 19 AN Gravity, - The electrical submergible equipment evahrated in these teats was capable of producing behveen 65 to 70% of the wells potential.. -The heat dissipated by the two 160 Hp motors increa8ed the flowing bottom hole temperature by 34 F (19 C). -The maximum capacity reqtired for the 300 KVA transformer irratakd was 178 KV~ or 59.3V. of the installedcapacity. 790 3. CentriMt-Hughes 1992.

Powerg M. L.: Yfbe Depth Constraint of Electric Submersible Pumps. Paper presented at the 1993 SPE Electrical Submergible Workshop. REDA Submergible Pumps for Petroleum Industry. Catalog 1992. the

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PERFORAllONS TOTAL DE Pm PFUMMYVOL?AGE STARC SO~OM FLOWWG

SOITOM

38ar.37m 3233 460/450 VOLTS, Wss PS3 Ss7 Psl mm

HOLE PRESSURS HOLE PRESSURE

PROOUGlliSN RATE {BUILD UP lesT) PROWCINOSX

3.86 S/nmsl 137F. 9.3. API 1.C4 5% fw Pclm 6s4 PSI .s7 *5Q Psl

S4ST?OM HOLS TSNPERANRE CRUOE OIL GRAVilY WATER SPECS=fS GRAVTW WATER CONTENT GAs.ol I?Ano

BUSELE POINT PRESSURE GAS s~auc GRAV31Y

W13_L HEAD PRESSURS

791

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TABLE #3

SPE2698?
PARAUETER DILUENT WITH DILUENT

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3200

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POWER

(HP)

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2347
40

2247

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TABLE #4 M*URED vAmABLEs

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37 lK m .

SURFACE PRES8URECOIITEMPIOFI
7s 70 70 126 1$4 i2c

H1oH Low m SOTTOM HOLEDILUENT.

E 1$4

211 Zfs Its

l.. FREQUENCY LOW TO lb DILUENT W THE FLmmlNE.

X-CONSTAMT

FREQuENcY FLOUUNC

DILUENT THE BOTTOM w

HOLE AND IN WE

m 70

34 al

870

690

Mt 2M

792

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TABLE M PilOWJCmON 7iATE V3 FREQUENCY

spE26987
PUMP LmmG ml)

FRE-auw
EVAUJAllON

CONOITiONS

WI

PRcaKnclN RATE @ml

CiLUEMT 801T0M . MOLE

IWO) FISWIJNE

.$%x

lAREwmL#J#lHHmJ~ HOLE 2,-7WQUEWY WUJENT LCW lQ HIGH FLOWJKZ

m m

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7W

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TABLE 9S ELW7RKAL VARV@LES

FREOUE!+SV EvuuAnON

PUMP

Pm

(w
Hwl 10 I.Ow SOTIOM 78 m 4S

warm

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224 w 8$ 3?3 an m

w.
49.8 42.* W.*

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TABIA # 7

ELECTRICAL SUBMERGIBLE PUMPS CAPACITIES

S40 SERIES-i7EDA

FREQuENCY: 60 HZ
EFFICIENCY 40%

CRUDE OIL GRAV17Y: 9.6 API

.MQwL
GN- 3200 GN- 4000 GN- 52OO GN- 5+300 GN- 70M GN-1OOOO

~
1170 1500 ?950 2100 2650 3700

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SpE26987 A

TRAP B-15 PILOT PROYECT

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FIGURE # 1, GEOGRAPHICAL

LOCATION

TRAP B-1 5. BARE BLOCK

PI

=...

----

0 0 500 1,200 1.500

\ 2.OCO 2.500

3,01M 3.5W

4.000

4.500

.-

PRODUCTION FIGURE # 2. Pl, RPI ANO PRODUCTION

RATE (t3/D)

PROFILE ~~~ 795

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FIGURE #3:

LOCATION OF WELL MFB-159

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FIGuRE # 4, COMPLETION

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DIAGRAM. WELL MFB-159

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8PE26987
-C+.?bdsnkan--Reds Ri8u P51+u=IICH i stag= - et3200 540 Z6Pies -3500 C3irV8 m

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FIGURE

# 5. PUMP

PERFORMANCE

CURVE

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30 35 40 45 50 FREOUENCY FIGURE # 6. PRODUCTION RATEvs FREOUENCY 797 55 (HZ) 60 65 70

75

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200

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0 100 200 30.0. ..40.0 500 600 700 800 900 1,000 i.100 1.200 ?,300

..
. PRODUCTION. R.ATE (B/D)

FIGURE # 7, TEMPERATURE

VS PRODUCTION

RATE

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1501 0

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10 20 30 40 (HZ) 50 60 70 FREQUENCY

FIGURE # 8. BOTTOM HOLE TEMPERATURE. VS FREQUENCY 798

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.:. ..SPE26987

66% EFF.

+ 50% EFF. .* 40% EFF.

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354045505560 6570 -75

EST. PROD.

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FREQUENCY

(HZ)

FIGURE # 9, PUMPING CAPACITY VS FREQUENCY

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CALCULATED * REAL .
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FREQUENCY FIGURE # 10, PUMPING-EFFICIENCY

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==-,.-,.-. --

10.00

9.3-API 9,6SAPI .7API

*11

+ 13.9-API * 15.2dAPl

+ 19API * 22.5-API

Ic

I
. .+ .. 110 120 130 140 150 160 170 . -.. .....-... *%... 180 190 200

1 100

210

220

.:.

TEMPERATURE FIGURE # 11. VISCO51TV VSFREQUENCY

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.
.

800