SPE 108054
Artificial-Lift Systems Overview and Evolution in a Mature Basin: Case Study of Golfo
San Jorge
Marcelo Hirschfeldt, Paulino Martinez, Fernando Distel. Universidad Nacional de la Patagonia San Juan Bosco. Argentina
Copyright 2007, Society of Petroleum Engineers
This paper was prepared for presentation at the 2007 SPE Latin American and Caribbean
Petroleum Engineering Conference held in Buenos Aires, Argentina, 15–18 April 2007.
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Abstract
The Golfo San Jorge basin, located in the central
Patagonia, is the oldest productive basin of Argentina, where
the first economic discovery took place in 1907, in Comodoro
Rivadavia.
With 11,680 active oil wells, is the first oil producer basin
of Argentina producing 258,549 bpd of oil and 2.56 MM bpd
of water.
The main characteristics of the basin are:
- Faults and sand stone lens
- HWOR
- Increasing fluid flow rate per well
- Complex fluids: corrosive, heavy oil, gas, sand and
scale
- Multiphase fluids
- Multilayer reservoir: from 1.800 to 9000 feet
In this context, the selection, operation and optimization of
the different Artificial Lift Systems (ALS) plays an important
role for following the development of the basin.
This paper describes the best practices, experiences and
trends, using ALS as Progressing Cavity Pump(PCP), Electric
Submersible Pump(ESP) and Sucker Rod Pumping(SRP); and
a basic description about Gas Lift, Plunger Lift and Hydraulic
jet Pumping experiences.
Information as pump depth, flow rates, operational
conditions, surface and sub-surface installations description,
technical limits, failures statistic and new technologies from
more than 9,000 active wells from different oilfields were
collected and analyzed.
As result of this overview, an ALS reference guide was
completed with parameters and benchmarking indicators; and
some important conclusions appear.
Complementary information will be presented in the
Appendix (Fig-A1, A2, Table-A1, etc)
Introduction
The East-West trending Golfo San Jorge basin is the oldest
and most prolific oil basin of Argentina It covers 28,000 M
Acre, with 1,127 MMbo (Dec-05) of OOIP and is located in
the central Patagonia. (Fig-A1)
The first commercial oil discovery took place in 1907 and
since then close to 2,900 MMBOE were extracted. Located in
the central part of Patagonia Terrane, it is an intracratonic
extensional basin. During late Jurassic-early Cretaceous times,
the extension related to the Gondwana break-up generated
many isolated small half-graben basins, with a NW-SE
structural trend. Later, a new extensional-transtensional stress
field originated a WNW-ESE trending, and reduced
extensional deformation continued until the Oligocene.
The basin is essentially asymmetric; in the eastern section
the dominant extensional faults are on the northern flank with
the southern flanks being a less faulted, flexural type margin.
In contrast, the western section is asymmetric but its major
faults are on the southern flank, being the northern flank a
flexural margin. The central section of the San Jorge basin is
dominated by NW and NNW trending extensional faults that
were reactivated by compression in Tertiary times.
The basin produces 258,549 bpd of oil (44 % of the oil
production of Argentina), and 2.56 MM bdp of water (91%) at
November 2006. Close to 2.6 MMbpd of water are injected in
2,400 wells in water flooding projects, therefore 41% of the oil
is produced from this method. (Fig-A2)
Close to 97 % of the wells were completed with 5½”
casing, and depending on the companies, new wells are
completed with 7” casing. Vertical wells are the most common
and directional wells are drilled in some projects (water
flooding, parallel to faults)
Artificial Lift System (ALS) in Golfo San Jorge
From the begining of the activity in Golfo San Jorge Basin,
100 years ago, several ALS have been used in order to
produce the oil from each well.
The basin offers different conditions depending the mature
state of the oilfields: high water percentage, high and low flow
rate, free gas and in solution, heay and light oil, flowing wells
and high GOR reservoirs .
2 SPE 108054

At the present time, ALS as SRP, PCP and ESP are the
most popular systems used for producing 98 % of the total
fluid of the basin. And in smaller quantity, wells produced by
hydraulic jet pump, pluger and gas lift.
The growing reservoir depth and flow rate of fluid per
well, present a permanent challenger for the different ALS and
specialist.
In this context, the selection, operation and optimization of
the different systems plays one of the most important roles for
following the basin development.
One of the common factors in all oil wells, is the casing
diameter, where 5½” diameter forces to use 2⅞” tubing and 1”
sucker rod.
For this reason during the last years, one of the main
targets of the companies and engineers has been to increase
the technical limit and life of each system.
wells
Fig.3 – Cross plot pump depth vs flow rate (SRP) from 7,663
Distribution and evolution The cross plot (Fig.3) shows a range of depth from 1,000 ft
The number of active oil wells is 11,887 with the follow to 10,000 ft for low flow rates. This range of applications falls
distribution: as the flow rate requirement increases, representing the
mechanical limit of the system (sucker rods and pumping
Table 1. Artificial lift distribution units).

System wells % Best Practices and new development.

SRP 9,141 76.9 The most important developments and best practices have
PCP 1,469 12.4 been applied for increasing the mechanical limit of the system,
ESP 1,234 10.4 the cicle of life and to improve the fluid handling, due to the
Others 43 0.3 increment of the flow rate and to optimize the production..

Others: Hydraulic Jet pump, Plunger and Gas Lift (nov.06) Pumping units. Common pumping units are: the
conventional, Mark II and air balance. Around 45 % of the
The Fig.A3 shows the evolution of the most important units are Mark II, being the biggest units 912,000 and
artificial lift systems from 1999. 1,280,000 lbxft of torque and only one experience with a MII-
1824-427-216, the biggest pumping units of Argentina.
During the last eight years, the number of wells per system
it has grown in function of the advance of the technology and Long Stroke Pumping Units. As the depths increase, as
of the new requirements of the basin. well as the SPM (stroke per minutes) and stroke length, and
PCP is the system that increased the number 237 % from the effective down hole stroke and volumetric efficiency falls.
1999. One of the reasons for this important growth is the new Slower speeds and longer strokes result in more complete
development in materials as elastomers, sucker rods, pumps pump fillage and lower dynamic loading. (see the pumping
design and surface instalations. And in the other hand, the unit model Fig-A4). This is the main characteristic of this unit.
field engineers and companies began to study the system and Dynamometer cards run on these applications are similar
to try new challenges. to a theoretically perfect card. An example of a dynamometer
The second is the ESP with 224 %, where the growing card is showed in Fig-A5.
reservoirs depth and flow rate in water flooding projects
forced to the system to reach demanding production forecast The next examples represent two real experiences in Golfo
One of the performance indicators we use to measure the San Jorge Basin from seventeen (17) wells runing:
failure index of the system is the Pulling Jobs per Well per
Year. Table 2. Long stroke pumping units instalations
Well # 1 Well # 2
Failure index (FI)=(Pull. Jobs per month /num. of wells) x 12
Setting depth pump - ft 7,850 11,230
Sucker rod pumping (SRP) Pump diameter - in TH-2¼” TH-1 ¾”
SRP is the oldest artificial lift in the basin and the most Pumping Unit R-900-360-289
popular with 9,141 units running, In spite of this, the growth Sucker rod string 1”-7/8"-1 5/8” Grade D
of the wells from 1999 was 18%, the minimum of the all Stroke - in 288
systems, but this continues being a flexible alternative with a SPM 3.9 3.5
wide operation range. Fluid Flow rate-bpd 870 125
The Fig.3 shows a cross-plot depth vs. flow rate with
information from 7,663 active wells.
SPE 108054
Hydraulic Pumping Units. A few experiences with
hydraulic pumping units promise a great development of these
due to flexibility for managing the speed and stroke length.
Fig-A6.
Sucker rod string. Grade D ¾”, ⅞” and 1” are the most
common, and some experiences with high strength rods. It´s
usual to use sinker bars for improving the performance of the
rod loading.
Oversize pin sucker rod. This modification was created for
increasing the limit of the grade D sucker rod string in
demanding condition of depth and flow rate and reinforcing
the pin of the rod.
The sizes developed are: 3/4 “ SR(sucker rod) with ⅞” pin
and ⅞” SR with 1” pin, increasing the capability of the system
to 15-20% (more flow rate or deepest setting pump).
Pumps. Rod pumps from 1½” to 2” in 2⅞” tubing and tubing
pumps from 2¼” to 3¼” (in 5½” casing) are used. (See for
details Fig-A7)
Hold downs (pumps anchors). Can be mechanical or cup
type. In deep wells bottom and top anchors are used for
improving the locking.
Ring plunger. They are intended for use when metal
plungers are unable to produce the well due to sticking or
galling when aggressive sands or large percentages of
particulates are being pumped. One of the example is the use
of fourteen (40) soft rings in shallow wells (less than 3,000 ft),
high flow rate, high water % and sand. Other practice is the
use the convination between soft and hard rings.
Self lubricated plunger. This plunger has two seal rings at
the extremes of the plunger and it is filled with a silicon fluid
between these rings and creating 100% of staunchness
between plunger and barrel, ideal for producing fluids with
sand.
Ring valve or “sand valve” on the valve rod of a rod pump
prevent the sand settling between the barrel and the plunger
during downtime, ensure very efficient pumping operations in
gassy wells.
Two Stage Hollow Valve Rod Pump. It is a rugged pump
which overcomes most gas locking conditions and has the
ability to produce a moderate quantity of sand or other
particulates. The secret to the success of the Two Stage
Hollow Valve Rod Pump is its modified upper compression
chamber
Guided valve. Is composes of a hemisphere, penetrated by
a stem which projects vertically above and below. This
component is called the valve plunger. The stem guide above
and below the valve plunger is manufactured with a single
cross member containing an aperture for the stem.
The guided valve plunger eliminates the inherent problem
of violent uncontrolled contact of the ball's multi-surface
3
sealing are with the valve chamber, thus eliminating
irreversible damage to it and the chamber.
Control and monitoring. More than 600 Intelligent Well
Controllers (IWC) has been installed in pumping units in
Cerro Dragón Oilfield (Pan American Energy). These devices
are connected to RTU that collects and transmit real time
information as: dynamometric cards, motor, power bands,
gearbox and production pipe line. The information is recorded
and processed for managing the system.
Failures analysis.
Analyzing information from 6,000 wells the average FI is
0.4 -0.7. Some factors are responsible for the amplitude and
variability of this index:
- The range of depth reservoirs and its characteristics
present different fluids and problems(sand, scale,
heavy oil, corrosion, temperature)
- Different criteria for inspecting and selecting
materials
- The mature sate of the basin (flow rate, water %)
The most common failures are:
- Sucker rod breaks (pin fatigue is the most common)
- Sticking or galling of a metal plunger in the barrel
- Tubing wear
Progressing Cavity Pump (PCP)
The application of Progressing Cavity Pumps for artificial
lifting in Golfo San Jorge Basin is still new compared to other
technologies, but is the second largest systems with 1,469
wells and a growth from 436 PCP´s since 1999.
The technology is advancing rapidly and that, combined
with new techniques which are learned empirically,
continually expands the range of applications.
The smallest investment, compared with other systems, is
one of the reasons of this important growth.
Although in their beginnings, the PCP was used to produce
wells with viscous fluids and high contents of solids, the use in
high flow rate conditions has been growing every day.
Fig.4 shows a cross-plot depth vs. flow rate with
information from 1,175 active wells.
12,000
10,000
8,000 A
pump depth - ft
6,000
4,000
B
2,000
0
0 1,000 2,000 3,000 4,000
flow rate - bpd
Fig.4 – Cross plot pump depth vs flow rate (PCP) from 1,175 wells
4 SPE 108054
The zone A in the Fig.4 shows a low flow rate area where
the maximum is 300 bpd and a depth range is since 1,800 ft to
6,000 ft. This area also represents the beginnings of the system
in the basin, when the pumps were selected only for low flow
rate wells.
In the zone B, the depth average is 3,000 ft and a great
flow rate amplitude. This describe the important applications
of the system in sallow reservoir produced by secondary
recovery (water flooding) where in most of the cases the use
of the same model of pump let to produce from 250 to 1,200
bpd.
Best Practices and new developments
The best practices and technologies have been directed to
increase the run life and the limit of the system. We can
mention some practices:
- To select the best rotor and stator combination
- High flow rate pumps for 5½” casing
- Increase the torque limit of the rod string
- Rod string and Tubing wear prevention
- Down hole and surface, control and monitoring.
Drive heads. Direct and right angle are the two type of
models used in the basin. (Fig-A7)
Electric prime mover is the common installation and IC
motors with right angle drives in remote areas.
Hydraulic Backspin Control Device. The original drive
heads were designed for small PCP’s in heavy oil service, but
as PCP’S increased in capacity, the potentially hazardous
incidents have been increased. Friction Brake with hydraulic
pump is used in drive head where the hydraulic horsepower is
a critical factor. When the rods backspin, the hydraulic motor
at the wellhead will force the hydraulic fluid to flow
backwards through the system brake and activates the calipers
for griping the disk. (Fig-A8)
Pumps. Tubular single lobe pumps are used made of NBR
(acrylonitrile-butadiene rubber) and HNBR (Hydrogenated
acrylonitrile butadiene rubber) elastomers. The temperature
limit for NBR elastomer is 195 ºF and for HNBR 260 ºF
(information from the manufactures)
An small quantity of insert pump for 2 ⅞” tubing are
running but it´s not a common use.
High flow rate pumps for 5½” casing has been the last
trends, where the only variable for increasing the volumetric
constant of the pump was to increase the rotor pitch length.
Example of high-flow rate single lobe pump
Rotor pitch length: 7.8” (200 mm)
Flow rate: 490 bpd @ 100 RPM
Max lift (100%): 6,500 ft
Estimated pump length 45 ft
Past experiences with 2:3 multilobe pumps were not
satisfactory. Models as 415-4800 (415 bpd@100 RPM- 4,800
ft of lift) were operated over 350 RPM and several problems
appeared, as hysteresis, high vibrations, tubing and sucker rod
failures.
Suker rods. The standard sucker rods used are 1” and ⅞”
grade D, and some experiences with high strength rods.
Hollow rods. A special product was developed to work
under rotating loads in PCP and to resist infinite life to fatigue.
This results in a "box-box" pipe and a sleeve/pipe nipple
connection that allows an external flush joint, i.e. without
shoulder in the joint area to minimize turbulence and local
loads losses due to flow velocity. A flush connection notably
reduces friction between tubing and rod generating savings
due to failures decreases as well as reductions in tubing and
rod consumption. The Max torque for 48 mm OD Non upset
is 1,000 lbxft and 1,500 lbxft for External Upset. (See for
details Fig-A9)
Control and monitoring.
Variable Frequency Drive (VFD). Every day, the number
of VFD are increasing and it has become an important tool for
driving the PCP´s, controlling speed, torque and linking down
hole sensors information with the drive. This is translated in a
better protection of the equipment, bigger run life and
production optimization.
Down hole temperature and pressure sensor. Down hole
sensors provide reliable pressure and temperature readings.
The sensors are used with controllers and the VFDs to
provide more accurate control on the well based on the
changing down hole conditions. In addition, these sensors are
used to evaluate reservoir conditions. Until today, only 25
down hole sensor were installed and the first reason for this
poor number is the high prices of this products (around 45 %
of the total price in a complete equipment for 4,500 ft)
Monitoring- SCADA and data logger. The use of SCADA
systems and/or data logger collectors has been a successes full
experience for taking decisions and failure/performance
analysis.
(See for details Fig-A10)
Failures analysis.
Analyzing information from 800 wells, the range of failure
index per year (pulling job/well/year) was 1.0-1.4
This index is bigger than the SRP failure index, and one of
the reasons is the PCP´s are used frequently where other ALS
couldn’t operate. It’s the case of high flow rate condition
(more than 1,000 bpd), more than 90 % of water and sand
production.
The most common failures are:
- Elastomers fatigue (Histéresys). Common situation at
RPM mayors at 400 RPM, where the right selection
of rotor and stator fit is fundamental.
- Premature failure of sucker rods unions for
overloading or in the bodies for flexion-torsion
combined stresses.
- Tubing and sucker rods friction wear.
(See for details Fig-A11)
SPE 108054
Others good practices have been implemented for reducing
the failure index and improving the systems life:
Test bench in the oilfield: companies as CAPSA, in
Diadema oilfield, designed and made a test bench for testing
the pumps recovered during pulling operations and the new
pumps, too.
Rod string and Tubing wear prevention. The use of tubing
rotator is a new practice, but an interesting trend for improving
the life of the systems.
ESP (ELECTRIC SUBMERCIBLE PUMPS)
More than 37 % of the total fluid of the basin is produced
by ESP with a total of 1,234 pumps running.
The system plays an important role due to the mature state
of the basin and the continuous growth of the flow rate and
depth of the reservoirs.
The Fig.5 shows a cross-plot depth vs. flow rate with
information from 922 active wells.
12,000
10,000
8,000
pump depth - ft
6,000
4,000
2,000
0 configurations for increased motor protection. They are
0 1,000 2,000 3,000
flow rate - bpd
Fig.5 – Cross plot pump depth vs flow rate (ESP) from 922 wells
The total average flow rate is 1,200 bpd and the pump
depth is 6,350 ft.
The ESP system covers an application since 3,000 feet
depth to 9,000 ft. The top limit in most of the cases is the
temperature and as it begins to increase the flow rate, the horse
power transmission is the other limit.
Best Practices and new developments
With the combination of centrifugal pumps, electrical
motors, seal chambers, special Makes and separators, surface
controls, cables, and new materials technologies, there seems
today be something new in the area of ESP’S.
Motors. The use of shrouded 375 series motor in 5½” casing
is one of the most interesting experience due to the important
role of this possibility in multilayer reservoirs opened. (See
Operating Electrical Submersible Pumps Below the
Perforation).
High temperature motors. As the depth and flow rate
increases, the down hole temperature too. The applications of
5
new insulating materials as PolyEtherEtherKertone (PEEK)
are used for increasing the temperature resintence. (500 ºF)
Pumps. Radial flow stages and mixed flow stages are used.
Been the sand one of the most important problems, abrasion
resistant pumps are used frequently.
ARS - (AR Stabilizer), C (Compression) and ARC- (AR
Compression) are used depending of the severity of the sand
and well conditions.The severity of sand abrasion depends on
a number of factors: Quantity of sand, Acid solubility, Particle
size distribution, Quantity of quartz and geometry (angularity)
Seals. Two individual types of seals have been used during the
last years: labyrinth and bag chambers.
Multiple arrangement of sealing chambers, labyrinth and
bags are used for increasing the life of the motors and system,
but new technologies and practices has been applied for
increasing the life of the motors, to reduce the number of the
protectors and reduce the cost.
Modular Protector. This proven technology of both the
labyrinth protector and the positive seal protector are featured
in the Modular Protector.
Some submersible applications have required that two or
more protectors be bolted in tandem to achieve adequate
protection. The Modular Protector could eliminate the cost of
tandems by combining multiple protector sections in one unit.
Common components are used to assemble multiple labyrinth
and/or positive seal sections in a variety of configurations to
match individual well conditions or customer requirements.
(Fig-A12a)
AR-HT-HL seals. Seal sections can be used in tandem
4,000
available in both bag type and labyrinth-style designs to meet
specific applications.
- AR (abrasion-resistant) seals are designed to provide
radial stabilization and minimize vibration
transmitted to the motor. Up to four chambers in one
housing are available.
- HT (high-temperature) seals incorporate specialized
elastomers and thrust bearings for increased bottom
hole Temperatures.
- HL (high-load) seals employ increased load-carrying
capabilities for compression or larger pumps and/or
extremely deep applications.
(Fig-A12b)
Down hole sensors. A long way for traveling exists in this
area. A few experiences have demonstrated the necessity of
improving the technology for increasing the limit of
temperature of the sensors, the most common failure in these
installations. The technologies exist in the market, but some
companies needs to incorporate it in the local area.
High-reliability plug-and-play ESP systems with
integrated down hole Measurement technology. The system
arrive onsite prefilled with oil from a controlled environment,
eliminating these difficult tasks at the wellsite. Remaining
6 SPE 108054
tasks have been simplified. Fewer component connections
than previous-generation ESPs and an improved pothead
connection result in simpler, shorter installation times and
improved quality control of equipment makeup. The
technology also has improved capabilities:
- Plug in pothead
- Improved heat dissipation and thermocouple to
monitor motor winding temperature in real time
operation
- Enhanced materials in bearing on protector head
- Higher strength shaft materials on protectors
(For graphic details see Fig-A13)
Operating Electrical Submersible Pumps Below the
Perforations. The ESP uses the flow of well fluid to cool the
motor. This has been traditionally done by landing the ESP
above the perforations, or by using a shroud to redirect the
fluid around the motor, a typical situation in Golfo San Jorge
multilayer reservoirs, where the distance between top and
bottom perforation it could be 3,000 ft.
Recirculation electric submersible pump (ESP) systems.
As the Fig-A14a shows, the recirculation pump directs fluid
though the recirculation tube to the bottom for cooling.
Shrouded ESP. With more than 370 wells installed in the
basin, this practice is one of the main responsible for the
increasing flow rate in some oilfields.
Around 99 % of the shrouded ESPs are in 5½” casing with
375 series motor. In spite of this possibility, the shroud often
creates some problems, including: misdirected fluid flow
witch creates motor heating and excessive heat causes scale
buildup between motor and shroud. The Table 3 represents
some information about 375 series motor running in Golfo San
Jorge.
Table 3. ESP´s with shrouded 375 Series motors
Min Averag Max
Num of wells more than 370
Max HP installed 40 90 130
Average intake depth [ft] 4,167 7,300 8,500
Flow rate [bpd] 200 533 1,447
For graphic details see Fig-A14b
Failures analysis.
Analyzing information from 800 wells, the range of failure
index per year (pulling job/well/year) is 0.3 -0.5
Abrasion is a common problem in high flow rate
conditions and high water % in unconsolidated reservoirs or
fracturated after compleations. We can mention:
- Excessive radial wear is critical in the top and bottom of
the pump due to vibration which can be transferred to the seal
or other coupled pumps.
- Excessive Stage down thrust wear which can cut through
the impeller shrouds.
- Erosive wear in flow passes which will degrade hydraulic
performance.
These problems generally contaminates the seals and a
later motors failure appears for lack of insulation.
GAS LIFT
When the production flow is of the type multiphase, the
gas lift is one of the most appropriate systems for producing a
well, since it simulates a natural flowing. Although the tubing
flow or continues gas lift is the most common in the word,
exists other techniques as annular gas lift.
Annular Gas Lift. When an important separation exists
between top and bottom perforations, typical configuration in
Golfo San Jorge, the use of conventional gas lift (tubing flow)
would force to set the packer above the first perforation and
the production won't be good.
For this reason the use of Annular Gas Lift (injecting gas
through the tubing) is the one of the best alternative and
practice in Golfo San Jorge reservoirs. Fig-A15
Although gas lift is one of the most reliable artificial lift
systems, the availability of gas compressor plants is a decisive
factor for the application of the system.
PLUNGER LIFT
This system is used commonly for dewatering gas and
condensed wells that produce below its critical flow.
This condition is reached when the speed of the gas in the
tubing is not the sufficiently high thing to drag the liquid
particles that consequently finish accumulating in the bottom
of the well (load up process).
One of the reasons of the low numbers of wells produced
by pluger lift, is others systems as sucker rod pumping with
small pumping units are used as dewatering systems for gas
wells.
A typical installation consists of a stop and spring set at the
bottom of the tubing string and a lubricator and catcher on the
surface acting as a shock absorber at the upper end of the
plunger's travel. The plunger runs the full length of the tubing
between the stop and lubricator. The system is completed with
the addition of a controller (time and/or pressure) and motor
valve with the ability to open or close the flowline.
Plungers. Depending on the applications, differents plungers
are used . Fig-A16
Mini Flex Plunger. It has Eight interlocking stainless steel
pads and a "Flex" design. The surface of the pads is bigger
than others plungers and it offers more contact area with the
inside part of the tubing string. It`s the most efficient
conventional plunger. Used in wells with gas productionless
than 5,000 m3/d.
Fiber-Seal Plunger. No moving parts make this an ideal
plunger where sand is present. The efficiency of Fiber-Seal
makes its use possible where others will not work. Other
application is where tubing restrictions (irregular internal
diameter) exist.
Two-piece plunger / plungers with by-pass. The concept of
this plunger is to increase the falling speed, and increase the
number of cycles.
SPE 108054
HYDRAULIC JET PUMP
Hydraulic Jet pumps have not seen as much use as some
others methods in recent years, but some interesting
experiences has been developed recently.
The applications for this method began as a solution for
producing wells with high percent of sand where sand control
have not been possible to use, and in wells with heavy oil.
Another situation is the use in directional wells where others
systems have not been possible to use.
Experiences in Diadema Oilfield (CAPSA) and Cañadon
Perdido / Restinga Ali oilfields (Repsol-YPF) are the most
important in the basin during the last years.
Production of high percentage of sand. To make an
effective sand control in 5½” is very difficult and impossible
in most of the cases, when the distance between top and
bottom perforation is big. For this reason, to produce the sand
could be the only alternative for choosing. The follow example
describes the average situation in shallow wells:
Example of Jet Pumps installations
Pump /packer depth: 3,000 ft
Casing: 5½”
Tubing: 2⅞”
Power fluid: produced water
Power fluid flow rate: 1,100-1,400 bpd
Injection pressure: 1,500-2,000 psi
Production flow rate: 800-1,200 bpd
% of sand: since to 1,000 ppm ( ASTM D-4807)
Max. oil viscosity: 28,000 CP@80ºF
Where the water supply was a problem, autonomous unit
horizontal PC Pumps were used, allowing the use in remote
areas. Fig-A17
Hydraulic jet Pump in a horizontal extended well. The well
is located in Restinga Alí oilfield, operated by Repsol-YPF.
The productive reservoirs are located at 1,500 ft
(Glauconítico) and a horizontal displacement from the vertical
of 3,000 ft. The other particular characteristic is the power
fluid is pumped from a vertical well produced by an ESP.
Summary and conclusion
The Table A1 (pag 13) and the figures A18,A19 (pag 12)
are presented as a summary.
- Five and half (5 ½") casing provide an important
restriction to the technical capacity of the different ALS. It
limits the tubing string OD (2⅞"), maximum sucker rod OD (1
") and the pump diameter (ESP, PCP and SRP). New
technologies are developed every day for increasing the flow
rate and the hydraulic horsepower transmission, but 7" casing
should be evaluated for completing new wells in water
flooding projects.
- The distance between top and bottom perforation could be
3,000 ft in deeper wells with more than 20-30 reservoirs
opened, presented a big challenger for all ALS for the right
production of the reservoirs.
7
- Sucker Rod Pumping continues being a flexible
alternative with a wide operation range. Long stroke pumping
units at lower speeds could be an alternative for deep wells or
high flow rate conditions. Over size pin sucker and high
strength rod are others complementary alternatives for
increasing the limit of the system. An important experience
exist using pump-off controllers and monitoring, but only 7 %
of the wells operated by SRP have this system.
- Progressing Cavity Pumps began as an alternative for low
flow rate, heavy oil and sand production, and is a common
alternative to use this system as the last resources for
producing problematic wells. For this reason the index failure
is bigger compared with others.
PCP is a new system but a competitive alternative for
producing high flow rate wells (1,800 bpd @ 3,000 ft) due to
the flexibility and smaller initial investment and recent.
Hollow rods have been one of the last innovations in high
torque applications, and the first experience in the world was
born in Comodoro Rivadavia 8 years ago.
Down hole pressure and temperature sensor are expensive
for the most PCPs users, therefore the growth of this important
tool will be very slow.
-Electric Submersible motors 375 series operated below
perforations is a success full experience in a basin where the
growing flow rate and depth reservoirs in water flooding
projects, increase every day.
Down hole sensor is not a common experience and some
companies should incorporate proven world wide technology.
High-reliability plug-and-play ESP system is a new but
promissory practice.
- Gas Lift system is used in areas where the gas production
is one of the cores of the business and the facilities for
compressing gas exist, being this one of the limitations of the
growth.
Plunger Lift is used commonly for dewatering gas and
condensed wells that produce below its critical flow, and some
times the second stage in these wells is to install a sucker rod
pump with small pumping unit. In spite of this very
interesting experiences have been developed in HGOR
oilfields.
- Hydraulic Jet Pump covered a necessity when the
companies needed to produce wells with severity problems
with sand production (unconsolidated reservoirs); directional
wells and in a horizontal extended well.
Where the water supply was a problem, autonomous unit
horizontal PC Pumps were used, allowing the use in remote
areas. Other experience is the use of ESP producer well as
power unit for producing a horizontal extended well.
After 100 years of continuous production, Golfo San Jorge
Basin is not only the oldest basin of Argentina, also the first
oil producer and with more development during the last years.
This has been possible thanks to dedication and
professionalism of all people related directly and indirectly
with the Industry.
8 SPE 108054
Acknowledgements
The authors would like to thank all colleagues of the Golfo
San Jorge Basin for the value of the information and personal
experiences.
References
1. Moyano H., Dalle Fiore R., Mazzola R., Ponce C.,
Ferrigno E: “Application of Intelligent Well
Management System to Optimize Field Performance
in Golfo San Jorge Basin, Argentina”, paper SPE
95046-MS, presented at 2005 SPE Latin American
and Caribbean Petroleum Engineering Conference,
20-23 June, Rio de Janeiro, Brazil
2. Bizzoto P, Dalle Fiore R, De Marzio L, Pan
American Energy. Ingeniería de Gas UGGSJ:
“Producción simultánea de gas y petróleo en
reservorios multicapas del Yacimiento Cerro Dragón”
, Tecnoil Magazine. 2006
3. Olmos D. E., Ernst H. A., Villasante J. A., Johnson
D. H., Ameglio A. F: “Hollow rods: development of
a new technology for PCP”, paper 69558-MS,
presented at the 2001 SPE Latin American and
Caribbean Petroleum Engineering Conference, 25-28
March, Buenos Aires, Argentina.
4. Dottore.E, De la Vega.N, Bolland "Como mejorar el
Desplazamiento Efectivo de las Bombas de
Accionamiento Mecánico que trabajan en pozos con
Gas libre “ presented at Jornadas de Producción
IAPG. Comodoro Rivadavia.2005
5. Figari E., Strelkov E., Laffitte G., Cid de la Paz M.,
Courtade S., Celaya J., Vottero A., Lafourcade P.,
Martinez R., y Villar H: “Los sistemas petroleros de
la cuenca del Golfo San Jorge. Síntesis estructural,
estratigráfica y geoquímica”, IV Congreso de
Exploración y Desarrollo de Hidrocarburos, ACTAS
I: 197-238. 1999.
6. R.S. Aracena, O.A. Munoz, J.W. KnightBaker
Hughes Centrilift: “Experiences with the
Recirculation System Electrical Submersible Pump in
Argentina ” SPE ATW on ESP and PCP Systems,
San Carlos de Bariloche, Argentina. April 17-20,
2005
7. Hirschfeldt M, Segurado J, Pan American Energy;
Antoniolli M, Weatherford : “PCPump Automation
in Cerro Dragón Area, Golfo San Jorge Basin”
presented at SPE ESP and PCP Systems Applied
Technology Workshop. Bariloche, Argentina. April
2005
8. Leiguarda D, Palasin M, Pan American Energy;
Santos D, ESP Wood Group: “ESP experience in
Cerro Dragón Area, Golfo San Jorge Basin”
presented at SPE ESP and PCP Systems Applied
Technology Workshop. Bariloche, Argentina. April
2005
9. Fernadez Castro H, Nercesian F, Grande R, Pan
American Energy; Saiz JJ, Weatherford.: ”Uso de
unidades de bombeo de carrera larga” presented at
Congreso de Producción IAPG Mendoza 2006
10. García F, Vleugels A, Sanchez J I, Hirschfeldt M,
Pan American Energy: “Criterios de selección de
bombas mecánicas no convencionales” presented at
Congreso de Producción IAPG Mendoza 2006
11. Bertomeu F, Giraldo M, Olivera L, Repsol-YPF;
Nvarro F, Schlumberger: “Production optimization
through the use of new technologies with electric
submersible pumps “ presented at SPE ATW
Management of High WOR/High Gross Production
Oilfields. November 2006 Comodoro Rivadavia.
Patagonia, Argentina.
12. Hirschfeldt M, OilProduction.net “Artificial Lift
Experience in Golfo San Jorge Basin” presented at
Artificial Lift Conferences IQPC. February 2006.
Jakarta, Indonesia.
13. Di Giuseppe, Do Nascimiento, Repsol-YPF “
Experiencia con Jet Pump Hidráulico” presented at
Jornadas de SEA. IAPG 2002. Comodoro Rivadavia
14. Gabor Takacs, Ph.D: “Suker rod pumping manual”
PennWell Books.
15. Clegg Joe Dunn, Shell Oil Co: “High-Rate Artificial
Lift”, paper SPE 17638 PA, presented at the 1988,
Journal of Petroleum Technology,
16. Lea James.F., Amoco Production Research; Winkler
H.W., Texas Tech U.: “New and Expected
Developments in Artificial Lift”, paper SPE 27990,
presented at the 1994 University of Tulsa Centennial
Petroleum Engineering Symposium, 29-31 August,
Tulsa, Oklahoma
17. Lea James F. and Herald W. Winkler: “What's new in
artificial lift”, part 1 and 2. World Oil Magazine Vol.
225 No. 4).
18. Brown Kermit E., SPE, U. of Tulsa. “Overview of
Artificial Lift Systems”, paper SPE 9979, presented
at the 1982, Journal of Petroleum Technology,
October.
19. Wilson B.L., Mack John, Foster Danny: “Operating
Electrical Submersible Pumps Below the
Perforations”, paper SPE 37451-PA, presented at the
1998 Production & Facilities Journal, Vol 13,
Number 2, May, pages 141-145.
20. Matthews.C & Skoczylas.P, C-FER: “Surface Drive
System Standardization Technologies”. SPE PC
Pump ATW Calgary 2003
SPE 108054 9

APPENDIX

Fig.A1 – Golfo San Jorge Basin Location

3,500 500

3,000 450

2,500 400
Total Fluid - M bpd

WATER
Oil - M bpd

2,000 350

1,500 300

1,000 250
OIL
500 200

0 150
Jul-99

Jul-00

Jul-01

Jul-02

Jul-03

Jul-04

Jul-05

Jul-06
Ene-99

Ene-00

Ene-01

Ene-02

Ene-03

Ene-04

Ene-05

Ene-06

Fig.A2 – Golfo San Jorge Oil and Total fluid production evolution
Fig-A4 – Long Strok Pumping Units

12,000 12,000

11,000 ESP 11,000

10,000 10,000
Number of wells

PCP
9,000 9,000

8,000 SRP 8,000

7,000 7,000

6,000 6,000
Jul-99

Jul-00

Jul-01

Jul-02

Jul-03

Jul-04

Jul-05

Jul-06
Ene-99

Ene-00

Ene-01

Ene-02

Ene-03

Ene-04

Ene-05

Ene-06

Fig-A5 – Surface and down hole dynamometric card (left) MII unit,
Fig.A3– Artificial Lift Evolution
(right) Long stoke unit
10 SPE 108054

Fig-A6 – Hydraulic Pumping Unit Fig-A9 – Hollow rod

Fig-A7– Direct Drive Head

Fig-A10 – Downhole sensor and surface RTU

Fig-A8 – Hydraulic brake Fig-A11 – (a) Histeresys failure process – (b) tubing wear
 SPE 108054 11

a b
a b

Fig-A12 – Protectors (a) Modular – (b) AR-HT-HL Fig-A13 – High-reliability plug-and-play ESP Fig-A14 – (a) recirculationg pump (b) shrourded
motor

a b

Fig-A16 – (a) Mini Flex Plunger (b) Fiber-Seal Plunger (c)

Two-piece plunger /with by pass

Fig-A17– Jet Pump power unit with horizontal PC

Fig-A15– Anullar gas lift installation. Pump
12 SPE 108054

12,000

SRP

10,000 PCP

ESP

8,000
pump depth - ft

6,000

4,000

2,000

0
0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000
flow rate - bpd

Fig-A18– Cross plot flow rate vs. pump depth – 9,760 active wells represented

Well distribution by flow rate range

80%
6,581 wells SRP BME
70%
ESP
807 wells PCP
60% PCP

50%
% of the wells

888 wells ESP

40%

30%

20%

10%

0%
0-250

250-500

500-750

750-1000

1000-1250

1250-1500

1500-1750

1750-2000

2000-2250

2250-2500

Range of flow rate - bpd

Fig-A19– Well distribution by flow rate
SPE 108054 13

Table-A1– Artificial Lift Summary – SRP, PCP and ESP

Sucker Rod Pumping Progressing Cavity Pumping Electric Submersible Pumping

Number of wells 9,141 1,469 1,234

Average Flow rate -
bpd 200 400 1,200

Range of fluid flow 72% of wells < 250 bpd 55 % < 250 bpd - 69% < 500 bpd 72 % between 500-1500 bpd
rate
Average Pump Depth
- feet 5,384 3,658 6,350

Conventional, Mark II and air balance. Direct and Right angle Drive head
Surface Instalations Longe stroke pumping units Electric prime mover
Hydraulic pumping units Hydraulic break for high horse power

Rod pump and tubings pump
Ø since 11/2" to 31/4"
Pumps / Seals
Mechanical or cup type Hold downs, Ring
plunger, Self lubricated plunger, Ring
valve, Two Stage Hollow Valve Rod
Pump, Guided valve
Tubular and insertable single lobes pumps ARS - (AR Stabilizer), C (Compression)
and ARC- (AR Compression)
NBR (acrylonitrile-butadiene rubber) and
HNBR (Hydrogenated acrylonitrile Radial flow stages and mixed flow stages
butadiene rubber) elastomers.
Seals(protectors) :labyrinth and bag
chambers - modular AR/HT/HL
not satisfactory past experiences with 2:3
multilobe pumps (high vibration at rpm >
300

Grade D and High Strength / use of sinker bars

Sucker Rod
Over size pin: 7/8" SR with 1" pin / 3/4"
hollow rod 48 mm
SR with 7/8"
Failure Index:
Pulling Job / well/ 0.4 - 0.7 1.0 - 1.4 0.3 - 0.5
year

Sucker rod breaks (pin )

Sucker rod breaks (pin, coupling and body) Abrasion and scale
Excessive radial wear
Failures descrption Elastomers fatigue (Hysteresis) Excessive Stage down thrust wear

Sticking or galling of a metal plunger in the Tubing and sucker rods friction wear. Erosive wear in flow passes
barrel High temperature: poor refrigeration
Down hole temperature and pressure sensor
Control and SCADA
monitoring
Pump-off controler
VFD
Data Loggers
Casing 51/2" - Tubing 2 7/8"
The temperature limit for NBR elastomer is Motor temperature
System Limit Maximum SR diameter : 1" / Maximum 195 ºF and 260ºF for HNBR
SPM: 9 and Stroke: 192" in MII units Power transmition limit: Maximus number
Max torque SR 1" Grade D = 850 lb x ft of motor S-375 (6)= 128 HP
Long Stroke Pumping Units High flow rate single lobe pumps Pumps Below the Perforations
Well # 1 Well # 2
Rotor pitch length: 7.8” (200 mm) 375 Series Motors
Setting depth pump - ft 7,850 11,230 Flow rate: 490 bpd @ 100 RPM
Pump diameter - in TH-2¼” TH-1 ¾” Min Averag Max
High Light Pumping Unit R-900-360-289
Max lift (100%): 6,500 ft Num of wells more than 370
Sucker rod string 1”-7/8"-1 5/8” Grade D Max HP installed 40 90 130
Stroke - in 288 Average intake depth [ft] 4,167 7,300 8,500
SPM 3.9 3.5 Flow rate [bpd] 200 533 1,447
Fluid Flow rate-bpd 870 125
Hollow rod 48 mm