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This paper was prepared for presentation at the SPE Heavy and Extra Heavy Oil Conference - Latin America held in Medellin, Colombia, 24 26 September 2014.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
One of the major impacts on progressing cavity (PC) pumps is the amount of free gas that enters the pump
intake. PC pumps can handle increased amounts of free gas but under certain conditions this can have
detrimental consequences on pump life, decreasing pump performance and pump production capacity.
The higher the gas rates through the pump the higher the internal temperature. This temperature increase
accelerates elastomer degeneration and fluid penetration into the elastomer to the bonding agent. Having
a high volume of gas entering the pump decreases the amount of fluid slippage which does not allow for
an even pressure distribution throughout the entire length of the pump. This uneven pressure distribution
increases the workload to the discharge of the pump causes a premature failure. In order to overcome these
issues charge pumps technology was tested.
The study was completed in the Orinoco Belt, Petropiar field. This is an unconsolidated sandstone
formation with high fluid flow rate wells, 430 bbls/d at an average of 11 API. Reservoirs change through
their productive life varied the operational conditions in the Orinoco Faja wells. Historically intake
pressures were higher than 500 psi, GORs average 25 scf/stb resulting in free gas levels lower than 50%.
Recently, data shows intake pressure lower than 250 psi, GORS higher than 1000 scf/stb resulting on free
gas levels over 90%.
This is the first charge pump installed in Petropiar field. The strategy for this project was to start
identifying well candidates where charge pumps can improve the PC pumps performance through gas
separation and reduction of gas volume fraction (GVF) at pump intake. It also considered a well facilitys
conditions in order to get more variables and the most accurate information for this trial evaluation. The
overwhelming results after installing the charge pump allowed the expansion of this technology to
different wells with similar conditions regardless of well fluid production rate, sand, or water cuts. This
is all part of a combined effort for finding reliable and cost effective solutions for challenging applications.
Introduction
Venezuelan Petropiar Joint venture operates as part of the Ayacucho division in the Orinoco Belt, the
worlds largest known hydrocarbon deposit. The company produced 175,000 b/d of extra-heavy crude
during 2012 with production slated to reach a peak of 181,000 b/d.
2 SPE-171102-MS
performance was analyzed from the results shown in Fig. 9. Tests were performed at 150RPM, 1.5:1
charge ratio, 80 seating angle, and 2,570 Cp fluid average viscosity.
There is a big impact (almost twice) on gas separation efficiency comparing hole size from 1/8- to
3/8-in. diameter, even if the total open area is the same for less than 30% of free gas. There is also a
considerable improvement in separation by increasing hole size from 6/16- to 7/16-in., and by increasing
the total open area. The impact of hole size or area will not make much difference on gas separation
efficiency for free gas fractions lower than 30%. For critical gas volume fraction (over 50%) the hole size
provides tremendous change performance difference (25% improvement) on gas separation efficiency.
Oil Viscosity
The bubble point of heavy oil is lower than for light and medium oil, so the gas takes longer to be liberated
from the heavy and viscous fluid. During Lab tests when free gas was injected separation efficiency was
not impacted by oil viscosity. Fig. 10 shows an experimental test performed at 300RPM, 1.5:1 charge
ratio, and 80 seating angle.
As we can see in Fig.10, the pup joint configuration has more impact on separation efficiency than does
oil viscosity.
Pump Speed
In Fig. 11 the trend suggests that an increase in the pump speed reduces the separation efficiency. Pump
speed is directly proportional to the fluid speed inside the pup joint. As the liquid flow velocity increases,
it would carry more gas pockets towards the production pump. This occurs when liquid flow velocity
exceeds the minimum required for natural separation, which consequently increase separation time.
As in the pup joint open area analysis, as the gas volume fraction increases, the impact of the speed
on the separation efficiency increases.
progressive failures from pump discharge to intake. Based on all failure analyses reviewed in the past
years, explosive decompression (ED) is now a minor phenomenon. Although ED is present it was not a
major contributing factor in the failures and did not contribute to the type of damage observed particularly
in terms of the heat and chunking. During the past two years we still have the progressive top to bottom
deboning but now it is occurring much more quickly.
The increase of accumulated production after the first year with the charge pump system resulted in an
additional 20 Mbls compared to the previous year; it is equivalent to over $900k net profits for the Faja
oil market.
The contribution of the tubing non-centralization (avoiding no-turn tool) and higher deviation angle on
the outstanding results have not been measured.
Low gas separation efficiency forced users to procure larger pumps to operate at higher speeds,
inducing localized extreme stress and heat generation inside the pump, reducing dramatically its run life.
Charge pump systems can meet production targets using shorter pumps and lower speeds.
For next trial stage, a higher charge ratio can be tested in order to compare gas separation efficiency
under similar well conditions.
It is important to check charge pump rotor/primary stator combination in order to validate a proper
match.
Low volumetric efficiency on GVF applications is not caused by slippage, so increased rotor/stator fit
will not improve pump volumetric efficiency. Indeed lower fit will contribute to free gas flow through the
pump; however, it can be compensated for by adding stages to the pump.
Because of availability, in this trial 7/16 in. hole diameters instead of 5/8 in. were used. Evaluation of
the use of bigger holes and area effect on gas separation can be tested.
References
1. Weatherford, Technical Bulletin Charge Pump System Design and Operation, TB-P123, V 1.8,
Edmonton, AB, Canada, 2013.
2. Weatherford, Technical Bulletin Charge Pump Rotor Installation, TB-P117, V 1.3, Edmonton,
AB, Canada, 2013.
3. Robles J., Perez M., Bettenson, J., Noble, E., 2010, Design and application of charge PCP
systems in high GVF heavy oil horizontal Wells, 2010 SPE PCP Conference, Edmonton, AB,
Canada.
4. Noble, E., Dunn, L., 2004 Investigation of Pressure Distribution in PC Pumps, 2006 PCP
Advance Technology Workshop, Houston, TX, USA.