Asociacin Colombiana de Ingenieros de Petrleos

Boosting Drilling Performance in Colombia's La-Cira Infantas Field

P. Bonilla, Occidental de Colombia
A. Castillo, Occidental de Colombia

Categora:
Artculo Tcnico X
Tesis Pregrado
Tesis Posgrado
Derechos de Autor 2009, ACIPET

Este artculo tcnico fue preparado para presentacin en el XIII Congreso Colombiano del Petrleo organizado por ACIPET en Bogot D.C. Colombia, 1o - 4 de Diciembre de 2009..

Este artculo fue seleccionado para presentacin por el comit tcnico de ACIPET, basado en informacin contenida en un resumen enviado por el autor(es).

Abstract
Oilfield assets are subject to a daily and perpetual decline, and investments have to be made in order to offset natural depletion, and as
oil fields mature, from the technical standpoint recovering the remaining reserves is increasingly difficult. The amount invested to
overcome the depletion rate and increase the production is challenged by efficiency losses and rising expenses such as those generated
by conservative drilling parameters, train wrecks, hidden flat times and experience of the various service crews personnel available
in todays industry.

Until the World entered in the current recession there was a steady growing demand for oil that had enhanced the attractiveness of
continuing the development of mature oil fields worldwide. The increases in oil prices were driven not only by actual demand but also
by the perception that demand growth for oil and gas would continue, but this behavior was halted in the summer of 2008, and
although prices have recovered to the level they had in late 2007, prices have failed to stabilize or to advance further due to a lack of
consensus on whether the global crisis is in its final stages. The oil price increase was also accompanied by cost increases for the
Operators for over the last five years, which include increased taxes, commodity inflation and higher service and equipment prices;
making possible that only conventional oil and current deepwater projects are profitable at today's prices.

However, managing drilling costs efficiently and the perspective of future growing demand for oil, and the utilization of the
infrastructure allows the continuity of the development of the La Cira-Infantas mature oil fields in Colombia. This paper will focus on
the wellbore construction and engineering aspect of the development of this mature field, more specifically the adoption of state-of-
the-art rig technology and drilling practices aimed at drilling faster, and safer.

The deployment of automated drilling rigs is proving to be beneficial and expectations to further improve the drilling performance
are high, the learning curve has been steep and the engineering and practices can be applied anywhere in the world.

Introduction
The La Cira-Infantas field is being redeveloped by Ecopetrol and Occidental. Since the commencement of the redevelopment in late
2005, oil production has been increasing, from September 2005 to June 2009 the production has increased from 5,000 BOPD to
25,000 BOPD and production is expected to reach 40,000 BOPD with further development. This has involved expanding the drilling
activity.

The La Cira-Infantas field is the first oilfield discovered in Colombia and has been in production for over ninety years, since 1918.
Located in the Middle Magdalena River Valley (Figure 1), near the city Barrancabermeja, the La Cira Infantas are two distinct fields
with separate closure although both are on the same structure, and produce oil from the same formation, Mugrosa1. It has produced
over 730 million barrels of oil from an estimated O.O.I.P. of 3.9 billion barrels of oil and was near a field-wide plug and abandon
decision four years ago but partners Ecopetrol and Occidental decided to implement a waterflood redevelopment project in 2005. The
drilling and workover activity has steadily ramped up from 2006 to the date. New wells are generally preferred as the old wells lack
the benefit of openhole logs and generally have mechanical problems. Workovers are pursued when considered prudent2.
2 PABLO BONILLA / ALEJANDRA CASTILLO ACIPET

Figure 1. La Cira-Infantas Location. Middle Magdalena Valley.

Development Status
Currently, La Cira-Infantas field has over 1800 wells approximately, being drilled and worked over (Figure 2), and this includes
deviated producers, vertical producers, deviated injectors and vertical injectors. This field produces to C zone (Mugrosa formation),
which consist of approximately 600 feet of section, about 30 - 40% net to gross ratio.

The development drilling strategy is to drill vertical and deviated wells (injectors and producers) in Mugrosa formation. The main
target is C1 formation, but in the future, the A and B zone will be completed.

The productive area of the field covers 16,000 acres, with wells scattered in an area 12 miles long by 4.5 miles wide, thus requiring
several rig moves to complete the years schedule.

Well Design. The wells are mainly drilled in two sections, the surface hole and the production hole (Figure 3). The surface hole is
very often a vertical hole drilled with a packed assembly up to around 350 ft, directional work is rarely performed in this section, only
when the target zone is shallow and the displacement relative to the surface are large enough to disturb the production/injection pattern
due to the high inclinations and further displacement at TD, in order to reduce the well inclination and thus keep the pattern
disturbance at the minimum possible.

Most of the directional work is performed in the production hole, using both positive displacement motor and MWD/MWD. The
directional profile is also worked in such manner that a smooth operation is obtained at all times. The motor is selected to match the
bit and the overall design of the BHA, such as quantity of stabilizers needed, their placement along the BHA and their size, which
allow for reduction in percentage of slide depending on the well profile. The wells TD, normally, vary in a range of 2,000 ft to 5,000
ft.

In vertical wells directional tools generally are used both to monitor verticality and improve well positioning by making
corrections as required, also, since this is a mature field several old wells are nearby so collision avoidance also requires tight
directional control. In addition to that motors are also used to improve drilling performance.
ACIPET BOOSTING DRILLING PERFORMANCE IN COLOMBIA'S LA-CIRA INFANTAS FIELD 3

Figure 2. La Cira-Infantas Location. Updated schedule. New wells and WO operations.

WELL DESIGN
9 5/8, 36#, K-
55, BTC, R3

@ 340 pies

AB-C

B3-C

C1

C3
7" 26 lb., N-80, BTC.

C5
@ TD

Figure 3. General Well Designs.

4 PABLO BONILLA / ALEJANDRA CASTILLO ACIPET

Casing program. Typical casing program includes, but is not limited to, the following strings: 16, 83 ppf, B-X42, to 25 fts
MD.(Conductor pipe). 9 5/8", 36 lb, K-55, BTC, R3 to 350 ft MD. 7", 26 ppf, N-80,BTC to bottom (2,000/5,000 ft).

Mud program. Surface section. This interval is drilled using water base mud. The normal mud weight range is 8.9 9.8 ppg.
Production Section. This interval is drilled using, normally, a polymer mud (water base). The normal mud weight range is 8.9 9.3
ppg. But some cases require increase the mud weight up to 13.5 ppg.

Cementing program. Surface casing is cemented to surface with 15.8 ppg tail cement. Production casing is cemented with 12.8 ppg
tail cement to either 300 ft above the top of the AB-C sand or the A or B sand, depending on the potential for production of either sand
to guarantee proper zonal isolation for future development; the 12.5 ppg lead slurry is used from this depth to surface.

Automated Rig Technology

Under the current scope of work, the addition of state-of-the-art drilling rigs has allowed the reduction of the drilling cycle by
improving flat-spot operations such as rig move times, BOP nipple up and test, casing running and cementing, as well as the use of
optimized drilling parameters through using an electronic driller, running casing with the drilling crew, using a super-single rig set up
with specialized drillpipe/casing handling equipment, eliminating wiper trips, replaced by top drives and backreaming and specific
built-for-purpose equipment3 as opposed to the small conventional drilling rigs that were used until recently. In areas where there are
hundreds of shallow directional wells to be drilled from pads, the fastest-drilled well is usually the lowest-cost well which increases
the attractiveness of investing in state-of-the-art technology with rewards due to the economies of scale.

Current drilling is being implemented by two Helmerich and Payne FlexRigs, equipped with technology that is shortening the
drilling cycle. A key feature of the rig design is that it uses variable frequency AC drives (VFD) and Programmable Logic Control
(PLC) technology. This, together with integrated electronic instrumentation, gives the driller better control of the drawworks, top
drive, mud pumps and virtually every other significant piece of equipment, which ultimately leads to improved safety and reliability.
In addition, they are more easily transported in the field.

This advanced technology coupled with tested drilling practices offer more efficient performance (Figure 4). The operating metrics
are much better than those of the older rig fleet equipped with kelly.

FT/RIG DAY
900
Conventional Rig 1
Conventional Rig 2
800 Conventional Rig 3
Conventional Rig 4
Flex Rig 1
700 Flex Rig 2
Average Conv Rig
Average Flex Rig
600

500

400

300

200

100

0
Jan-08 Feb-08 Mar-08 Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09

Figure 4. Footage per Day Per Rig since January 2008

ACIPET BOOSTING DRILLING PERFORMANCE IN COLOMBIA'S LA-CIRA INFANTAS FIELD 5

There are two components in efficiency gains. The main reason for reduced drill days is greater hydraulic horsepower available at
the bit. An increase in power available allows distroying more rock per unit of time and and improved hole cleaning during the drilling
process. Flowrate, Standpipe Pressure and Hydraulic Horsepower at the Bit are in the order of 1.4 to 2 times larger with the automated
rigs than with the conventional rigs.

The second component involves reducing cycle time through faster rig moves (Figure 5). The rigs are designed to move efficiently
from well to well and from pad to pad. Component modularity is coupled with trailer-mounted equipment: one-piece substructure,
BOP attached to the substructure and integrated top drives, features that make rig-moving not only faster, but safer.

MOBLIZATION DAYS
4.0

Conventional Rig 1
Conventional Rig 2
3.5
Conventional Rig 3
Conventional Rig 4
Flex Rig 1
3.0
Flex Rig 2
Average Conv Rigs
2.5 Average Flex Rigs

2.0

1.5

1.0

0.5

0.0
Jan-08 Feb-08 Mar-08 Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09

Figure 5. Mobilization Days Per Rig since January 2008

All in all, the rig innovation delivers value on multiple fronts personal and financial. Two areas of personal impact are safety
improvements and personal operator comfort.

From a safety perspective, the Flex Rigs have delivered significantly better Injury Illness Rates (IIR) than conventional rigs
similarly employed. Flex Rigs have an outstanding record of 0% IIR since their introduction in the project to June 2009 (Figure 6).

The other personal impact area relates to operator comfort. These latest generation rigs use an integrated control system that allows
for hoisting and lowering of the drill string with a single joy stick. The variable frequency AC drive in combination with an electronic
driller and block control system greatly reduces the physical exertion and stress placed on the operators. These features together with a
climate controlled closed cabin completely rewrites the drilling operators daily experience. The new rigs also include mechanized
tubular handling which greatly reduces the repetitive manual labor required for making-up and breaking-out tubulars.

Financially, the main comparison driving the economics is rather straightforward and a function of a step-change improvement in
cycle time per well (Figure 7). Another impact is that cash flow will start earlier on each well as oil flows start earlier on each well
since the rig allows for simultaneous drilling and production.
6 PABLO BONILLA / ALEJANDRA CASTILLO ACIPET

IIR ACCUMULATED 2008-2009

6.0

5.08

5.0
4.34

4.0 3.56

3.0

1.72
2.0

1.0

0.00 0.00

0.0
Conventional Rig 1 Conventional Rig 2 Conventional Rig 3 Conventional Rig 4 Flex Rig 1 Flex Rig 2

Figure 6. Injury Illness Rates (IIR) since January 2008

RIG DAY COST/FT

300
Conventional Rig 1
Conventional Rig 2
Conventional Rig 3
250 Conventional Rig 4
Flex Rig 1
Flex Rig 2
Conventional
Flex Rigs
200

150

100

50

0
Jan-08 Feb-08 Mar-08 Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09

Figure 7. Cost per Foot per Rig since January 2008

ACIPET BOOSTING DRILLING PERFORMANCE IN COLOMBIA'S LA-CIRA INFANTAS FIELD 7

Results
Over 100 wells have been drilled to date using two new Flex Rigs, the drilling rate has been successfully increased , flat times are
reduced (Figures 8 and 9) and lessons learned have been applied not only chronologically but shared between both rigs thus improving
performance from well to well and rig to rig. Lessons learned were also applied to the smaller conventional rigs initially operating in
the La Cira-Infantas fields and healthy competition amongst these rigs evidently improved the overall performance.

Before September 2008 four conventional rigs were being used and in average they drilled 14 wells per month, in December 2008
the two flex rigs were already drilling 11 wells per month and the other four were drilling 16 wells per month. Due to the early success
of the program, and the need to optimize the capital expenditure in tune with the current market situation only the two flex rigs remain
in operation, drilling an average of 14 wells per month and reducing the well cost-per-foot in more than 20% (Figure 10).

FEET PER RIG DAYS FEET PER DRILLING DAYS

800 800
703
700 700

557
600 600
483 475
500 500 441
391
353
400 334 400

300 300

200 200

100 100

0 0
2006 2007 2008 YTD June 2009 2006 2007 2008 YTD June 2009

Figure 8. Overall Feet/Day from Rig Release to Rig Release Figure 9. Overall Feet/Day from Spud to Rig Release for the
for the project since 2006. project since 2006.

COST PER FOOT

200 179 180

172
180
151
160

140

120

100

80

60

40

20

0
2006 2007 2008 YTD June 2009

Figure 10. Cost per Foot for the project since 2006.

Conclusions
The use of technology can help to overcome the decline rate, or even restart of closed, mature fields which are scattered all around the
world. Apart from drilling demands, new technology has emerged to make rigs a safer and more comfortable place for rig crews. The
deployment of automated drilling rigs has allowed to consistently apply lessons learned from within the Organization.

Acknowledgements
The authors would like to thank Ecopetrol and Occidental management for their support of this project and this paper. Additionally
the aouthors would like to thank the contributions being made by our colleagues at every level in the project.
8 PABLO BONILLA / ALEJANDRA CASTILLO ACIPET

References
1. Dickey, P.A., La Cira-Infantas Field - Colombia, Middle Magdalena Basin, Structural Traps VII, AAPG, Treatise of Petroleum Geology,
Atlas for Oil and Gas Field, 1992.
2. Prieto, M.A., Mantilla, J., Owens, B.K., Lobo, A., Fernandez, F., Redevelopment Progress for Colombias La Cira-Infantas Field, SPE
120794, presented at the 2009 Latin American and Caribbean Petroleum Engineering Conference, Cartagena, Colombia, May 31 June 3,
2009.
3. Lindsay, J.W, Marchand, S., Tauzin, J. , Innovative Technology for Todays Land Rigs - FlexRig, AADE 01-NC-HO-29, presented at the
AADE 2001 National Drilling Conference, Drilling Technology- The Next 100 years, Texas, March 27 - 29, 2001.