See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/239816872

Production Optimization by Combined Artificial Lift Systems and Its Application

in Two Colombian Fields

Article · April 1999

DOI: 10.2118/53966-MS

CITATIONS READS

2 1,043

2 authors, including:

Hubert Borja
PWES
4 PUBLICATIONS 2 CITATIONS

SEE PROFILE

All content following this page was uploaded by Hubert Borja on 14 January 2019.

The user has requested enhancement of the downloaded file.

SPE 53966
Production Optimization by Combined Artificial Lift Systems and Its Application in Two
Colombian Fields
Hubert Borja, SPE, and Ricardo Castano, HOCOL S. A. (a NIMIR Petroleum Company)
Copyright 1999, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the 1999 SPE Latin American and Caribbean
Petroleum Engineering Conference held in Caracas, Venezuela, 21–23 April 1999.
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 of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes without the written consent of the Society of Petroleum Engineers is
prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300
words; illustrations may not be copied. The abstract must contain conspicuous
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
Abstract
The application of combined artificial lift systems yields
improved production in terms of costs and rates at better
conditions than could be expected from using only one of the
individual systems. This new approach overcomes restricting
conditions such as tubular size, operating depth, water cut and
corrosive gases, while preparing the wells for future condition
changes as a result of waterflood/pressure maintenance
programs in progress. These combined systems were initially
designed for two Colombian oil fields.
The concept considers a primary system such as rod pumping
or ESP combined with gas lift as secondary system. The
design envelope provides a wide operating range, allowing
individual operation of the primary, the secondary and the
combined system, reaching the optimal technical and
economical performance while the combined system is
operating. The operating envelope is framed in terms of
production rate and power consumption.
The paper presents the concept of “equivalent depth”
(compared to “operating depth”), the design methodology,
downhole equipment and field operating conditions and
benefits.
The long-term benefits are a reduction in production
downtime, decrease in the artificial lift investment by the use
of downsized equipment and a reduction in the operational
cost due to lower power requirements. Actual field data is
presented to corroborate these benefits.
Introduction
The Balcon and Tello fields were discovered in 1988 and 1972
respectively. At present, Balcon field is under a waterflooding
program, and reservoir modeling predicts a big increase in
total fluid production out of the existing and future oil
producers.
Wells in the Balcon field have been installed with gas lift as
an initial artificial lift system. According to the production
forecast, the existing lifting system will not supply enough
energy to achieve the forecasted fluid rate per well, and this
limitation is worsened because of other mechanical limitations
(Production casing and liner size, depth, FBHP and FBHT
etc.).
Economic analysis was performed to evaluate the replacement
cost of the existing lifting system, with the results of a
marginal project. Options to reduce the capital expenditure
and to optimize the exiting assets utilization were analyzed
resulting in the project to combine the gas lift (GL) with an
Electro Submersible Pump system (ESP), that has been called
ESP-GL or "Electrogas". This will allow wells to produce
enough fluid to accomplish production rates predicted by the
reservoir model.
The Tello wells are mainly lifted by rod pumping (RP). The
field has been producing on primary recovery and reservoir
pressure has been continuously depleted. Most of the wells
have good productivity but the majority of them produce at
very low pump intake pressure. This promotes rod strings
failure and severe pumping condition; therefore direct lifting
cost and production are affected, thus increasing unit costs.
A similar approach used for Balcon field was applied to Tello
field and the combined artificial lift systems of rod pumping
(RP) as primary lifting with gas lift (GL) as secondary lifting
system was evaluated.
Several benefits and advantages are derived from the
application of the combined artificial lift systems in Balcon
field: MMUS$ 1.5 in 36 months comparing the combined
system to a conventional Electrosubmersible system. For Tello
2 HUBERT BORJA, RICARDO CASTANO
a yearly saving of MUS$ 50 and an average production
increase of 50 bopd are expected.
To design and evaluate the combined artificial lift system it
was not necessary to develop system models or sophisticated
correlations. Conventional design tools for the artificial lift
(RP, ESP and GL) can be applied. In reality, the proposed
system is the combined application of the well-developed
artificial lift technology available in the oil industry.
Experiences on the combined artificial lift systems application
are not common in the industry 1, and no reference were found
on the combined RP-GL system in the revised technical
literature.
It is necessary to point out that the designs and evaluation of
the systems proposed here were developed specifically for
Balcon and Tello fields, however this approach is applicable
in many other situations.
Fields description
The Balcon and Tello fields are located in The Upper
Magdalena Valley nearby the city of Neiva in Colombia and
are operated by HOCOL S. A.
Balcon field produces from the Caballos formation of early
Cretaceous age, at the average depth of 9700’ and belongs to
the Palermo Association Contract. Reservoir drive mechanism
is by solution gas with a weak aquifer. In early 1996 a
waterflood process commenced. Fig. 1 shows typical well
sketch of an oil producer.
Tubing
3.5” 7” Casing
9000’
Perforations 5”
9700’
10000’
Fig. 1 - Balcon well sketch
Tello field is producing from the Monserrate formation that
corresponds to the Upper Cretaceous age at a depth of 8100’.
The field is located in the Tello-1161 Concession contract
area. Reservoir drive mechanism is solution gas combined
SPE 53966
with a moderate aquifer. Pressure maintenance by water
injection commenced in 1997. Typical well sketch is shown in
Fig. 2.
Casing
9-5/8”
500’
Tubing
3.5”
7”
Pump
Perforations 8000’
8100’
8500’
Fig. 2 - Tello well sketch
Development of the Concept
Artificial lift systems are designed and installed to boost fluid
production from wells that are producing at a depth were the
reservoir energy is insufficient. Power requirement and
surface/subsurface size of the equipment depends on the well
depth, desired production rate, water cut, etc.
For any artificial lift system power demand can be calculated
simply by applying hydraulic horsepower calculations that
take into consideration differential pressure through the
system, total fluid rate and efficiency according to the type of
lifting system. In summary artificial lift system should provide
the fluid with enough energy to reach the gathering facilities.
The above, in simple terms, means that with less differential
pressure, the system will be required to supply less energy. In
this respect benefits are very clear regarding equipment size,
power supply, operating costs, etc. On the other hand, gas lift
is used to reduce the pressure profile in the tubing in order to
allow fluids from the reservoir to reach the production
facilities. Reducing the weight of the fluid column is the
principle that is used to combine a primary artificial lift
system. This basically means that, by injecting gas in the fluid
column, pressure discharge requirements for rod pumps or
ESP is reduced.
Fig. 3 schematically shows the pressure profile inside the
tubing with the rod pumping or ESP system working alone
and the pressure profile of a combined artificial lift system,
where the fluid column has been lightened due to the injected
gas. Less differential pressure through the pump ( ∆P ) means
less energy to be supplied by the system to the fluids to reach the
production facilities. The benefits taken from this are smaller
SPE 53966 PRODUCTION OPTIMIZATION BY COMBINED ARTIFICIAL LIFT SYSTEM AND ITS APPLICATION IN TWO COLOMBIAN FIELDS
surface/subsurface equipment, less power consumption and
less capital expenditure.
THP Pressure
Regular
D
e
p D
t
h
Combined
∆P
Pwf
Fig. 3 - Pressure profiles for regular and
combined systems.
All the principles of gas lift design, related to pressure
injection, depth of injection, available gas volume and gas
liquid ratio (GLR) are applied to the proposed combined
artificial lift system. Furthermore, as it happens in the
conventional gas lift system, there are optimal points for gas
injection, related to the phenomenon of vertical/horizontal
multiphase flow in pipes.
To evaluate the net effect of the combined artificial lift
systems, the concept of “equivalent depth” for the pump can
be used. That means a new functional depth instead of the
operational (actual) depth that should be used to evaluate the
performance of the system. This value is the result of
comparing the pressure profile of a regular artificial lift system
and the combined system using gas lift.
Fig. 4 shows the actual discharge point A of a regular ESP or
rod pumping and the discharge point B of a lightened fluid
column due to gas injection. The B pressure value extended to
point C on the gradient curve of a regular system represents an
equivalent point in pressure but at a different depth for the
subsurface pump. This in simple terms means that this is the
new level of pressure required to design the pump for lifting
the corresponding fluid rate. The actual depth of the pump has
not changed. Point D means the equivalent subsurface pump
setting of the combined systems with respect to the
conventional system. The pressure difference between A and
B represents less power for an artificial lift system in terms of
dynamic head.
3
Pressure
THP
Regular
Combined
C
Equivalent depth
Operating depth
B A
Fig. 4- Pump “equivalent depth” by lightening of the
column with gas injection
The equivalent depth concept is particularly important to
design and evaluate the benefits of the combined artificial lift
systems in some particular cases. Amongst other benefits the
system can be adjusted to the continuos changing conditions
of a reservoir, under a waterflooding/pressure maintenance
program, that will impose a continuos change in the pressure
profile inside the tubing.
In the process of designing combined artificial lift systems for
specific well conditions, the conventional artificial lift system
is designed first, as it will perform in the point A in the Fig. 4.
Then with the same well inflow performance, the artificial lift
system is designed for a shallower depth.
The shallower depth is inferred from the less pressure
requirements obtained by injecting gas at specific points in the
tubing. In this respect, and following this approach, all the
primary artificial lift requirements can be calculated for each
equivalent depth between the points A and D as shown in the
referred Fig. 4. The equivalent depth is obtained by following
the regular steps for gas lift design, taking into account the
injection pressure, the amount of gas and the depth of the
injection point.
Fig. 5 shows, for a specific case, how increasing the gas
injection while keeping constant the other parameters reduces
the equivalent depth.
Fig. 6 shows, for the same case above, how the equipment
requirement (power consumption, size) is reduced if this is
designed for shallower equivalent depths. Equipment showing
large reductions are: pumping unit, electric motor size, grade
of sucker rod in the rod pumping system; and pump, motor,
cable and VSD in ESP system.
4 HUBERT BORJA, RICARDO CASTANO SPE 53966

between 2000 and 5000 ft. The Fig. 9 illustrates the effect of
D the gas injection depth on the resulting equivalent depth, this
is an indication of the final benefits such as equipment
downsizing and power consumption savings3.
Qg (Kscfd)

Power
A Cable
Gas Conduit

Equivalent Depth
Casing
Fig. 5 - Relationship between equivalent depth and
gas injection
Gas l ift Mandrel
and val ve

Power
Equipment and Power

Equipment

ESP

D A Fig. 7 - Electrogas installation

Equivalent Depth scheme using gas conduit

Fig. 6 - Effect of changing equivalent depth

Both in Figs. 5 and 6, it is clear how the obtained equipment

and performance from the system matches with that derived
from the theory. Point A is the operating depth and point D is
the final equivalent depth. Power
Cable
Reduction in equipment requirements and power consumption
that can be obtained by applying combined artificial lift Casing
systems yields positive business results in terms of cost
reduction, investment and existing assets optimization.
Gas lift Mandrel
and valve

Evaluation and application of the combined system

for the two fields.
The combined systems have been evaluated for Balcon and
Tello fields. One of the main restrictions was the necessity of
continuing separating the gas downhole, to avoid gas lock
problems, with a simultaneous gas injection from the surface
for gas lifting. Two alternatives were evaluated to solve that
Pr oduction Packer
situation. The first alternative was to inject the gas into the
tubing using a parallel gas conduit connected to the gas lift ESP wi th Gas handler
mandrels as shown in the Fig. 7. The second alternative
considers using a gas handler device2 to be able to pump the
gassy liquid with the ESP; this installation is shown in the Fig. Fig. 8 - Electrogas installation
8. In the first alternative the gas conduit diameter is restricted using the gas handler system
by the casing size and, due to the pressure losses within the
gas conduit the gas injection point is considerably shallower
than when using the gas handler device, the difference is
SPE 53966 PRODUCTION OPTIMIZATION BY COMBINED ARTIFICIAL LIFT SYSTEM AND ITS APPLICATION IN TWO COLOMBIAN FIELDS 5

2000
P inj = 2000 ft pressure of a regular ESP system. All the other results and
P inj = 4000 ft
P inj = 6000 ft
benefits are proportional to this pressure reduction. These
Qg (Kscfd)

1500 discharge pressures have been calculated with flow

correlations selected from field historical data and
1000 corroborated with recent downhole gauge measurements in
installed wells.
500
It is remarkable that in two wells there is a functional depth
D A
reduction (operating minus equivalent depth) of more than
0 5000 ft, this is more than 50% of the actual depth. The total
2000 4000 6000 8000 10000
power consumption saving is about 400 kW, representing a
Equivalent depth (ft)
net yearly saving of some KUS$ 110. Figs. 11 and 12 show
Fig. 9 - Effect of the gas injection point on the resulting the relationship for production rate with equivalent depth
equivalent depth. reduction and power saving.

Currently there are four Balcon wells producing with the 700 0

Depth reduced, ft
Electrogas combined system. The alternative of using the gas 600 0
handler device was selected based upon a technical and 500 0
economic evaluation. The installation of the combined system 400 0
in Balcon started on middle 1998 resulting in a production
300 0
increase of some 3300 bopd.
200 0
100 0
For one of these wells, the Fig. 10 shows the reduction in
number of required pump stages and power consumption by 0
0 100 0 200 0 300 0 400 0
reducing the equivalent depth. In general terms, injecting
bfpd
higher gas rates or having deeper injection points reduce the
equivalent depth. As in a gas lift system there are technical Fig. 11 - Reduction in functional depth with
the combined system.
and economic optimum points to operate the system.

140
350
Power (kW) 120
KW saved

300 100
80
250 Stages
60
40
200
20
150 0
0 1000 2000 3000 4000
D A
100 bfpd
6000 7000 8000 9000 Fig. 12 - Power saving by using the ESP-GL
Equivalent depth (ft) combined system.
Fig. 10 - Reduction in pump stages and power
consumption by reducing the equivalent depth.
The required pump and motor size is reduced between 33%
and 67%. Downsizing of these and other ESP components
The implementation of the “Electrogas” system in Balcon such as VSD and cable, means a decrease in equipment
field is being conducted with an integral contract with investment of some KUS$ 700. The average total dynamic
incentive provisions. head (TDH) of the combined system is 57% lower than in a
conventional ESP system.
Table 1 is a summary of the actual operating conditions and
benefits from the ESP-GL system in the Balcon field. The key The effect of reducing the equivalent depth for these wells can
issue for the changes and benefits, as a result of injecting gas be compared with an increase of the tubing internal diameter
to lighten the fluid column, is the reduction in the pump by about 1.5 in.
discharge pressure. There are reductions up to 1885 psi, with a
general average of 44% as compared with the discharge Another observed advantages are:
6 HUBERT BORJA, RICARDO CASTANO SPE 53966

• The ability to reduce production losses when the ESP is
off by continuing gas injection. It has been experienced
that at least 30% of the normal production can be
obtained with the gas lift alone.
• The operating envelope is wider than with single systems
allowing adjustments to cater for changing well
conditions.
• Problems such as tubular size restriction and operating
depth were solved with the installation of the combined
system
• Decreased internal tubing corrosion by reducing the
partial pressure of corrosive gases by decreasing the
pump discharge pressure
For the Tello field the implementation of rod pumping – gas
lift combination (RP-GL) is being evaluated. The Figs. 13 and
14 show the resulting conditions by combining these two
systems. Additional to the peak torque reduction there is a
decrease in power requirements and stress on the rod string.
For the installation of the RP-GL combination it is possible to
use similar schemes like those in Figs. 7 and 8.
1000
800
Qg (Kscfd)
The points A and D appear in Figs. 8 to 14 for comparison
purposes, having the same meaning that in Fig. 4.
General Advantages
On top of the above-summarized advantages for the two
fields, additional benefits can be expected from combined
artificial lift implementation, the following are the most
important:

To add in one system, the flexibility of the ESP or rod
pumping (primary) system plus the gas lift (secondary)
system. This is because frequency or stroke speed can be
combined with amount of injected gas to get the most
from both systems.

To improve the optimum operation envelope of both
systems and to avoid any overloading to the primary
artificial lift system. For example Fig. 15 shows the
operating envelope (well and pump performances) of a
combined system: While in a regular system the safe
operating envelope is a line, in the combined systems it is
an area.

600 Max. Hz

400
Matching area of wel l
200 and ESP systems
A
TDH

D
0
4000 5000 6000 7000 8000
Min. Hz
Equivalent depth (ft)
Well inflow
Fig. 13 - Change in subsurface rod pump equivalent
depth by injecting gas.
Q
Fig. 15 - Flexibility and matching of ESP-GL
900 and well’s IPR.
Peak torque (Klb-pul)

800

To avoid downhole equipment change because of changes
in well productivity.
700

To improve running life of the downhole equipment.

To increase the span of the downhole equipment
600 selection.

To apply chemical for downhole treatment using the gas
D A injection stream.
500
4000 5000 6000 7000 8000
To reduce operating and further development costs in
Equivalent depth (ft)
fields with: deep wells, slim holes, high water cut, high
producing rate, remote location and continuous
Fig. 14 - Peak torque reduction with the RP-GL productivity variation due to waterflooding or enhanced
combined system. recovery programs.

To extend the life cycles of the existing artificial lift
infrastructure in mature fields.
SPE 53966 PRODUCTION OPTIMIZATION BY COMBINED ARTIFICIAL LIFT SYSTEM AND ITS APPLICATION IN TWO COLOMBIAN FIELDS 7

To reduce production deferment, in case of failure or
To reduce excessive load during primary system start up,
malfunction of a system, by producing wells at reduced mainly in wells which require the unloading of heavy
rate until the problem is rectified control fluids.

Conclusions
1. Field application shows that combined artificial lift
systems generate significant cost savings.
2. In the economic and technical evaluations of a combined
system, equipment life cycles should be considered.
3. Better flexibility can be obtained from a combined system
4. In the process design of a combined system, both
optimum-operating envelopes should be determined for
the systems.
5. Due to their interdependency, combined systems require
specific procedures for start up and operation.
6. In the combined system, primary system has a high
dependency on gas lift performance requiring good
equipment protections in case, for example, of no gas
injection.
Acknowledge
The authors would like to thank HOCOL S.A. and
ECOPETROL for the support received to publish this paper.
We also would like to thank our colleagues for their help.
References
1. Devine, D.L., Eads, P.T., Lea, J.F. and Winkler H.W.:
“Combination gas lift/ESP system increase flexibility” World
Oil (October 1990) 77-82
2. Kallas, P. and Way, K.: "an electrical Submergible Pumping
System for High GOR Wells" paper SPE presented at the
Annual Electric Submergible Pump Workshop, 1995.
3. Borja H., and Castano R.: “Aplicacion de Metodos Combinados
de Levantamiento Artificial Para Optimizar Produccion”
presented at the VII Colombian Congress of Petroleum (October
1997).

Description Well-1 Well-2 Well-3 Well-4

Gas injection point, ft 8022 8256 8885 9011
Production Rate, bfpd 3450 2450 1790 1185
conditions Water cut, % 0 70 0 1.1
Pump ESP simple, psi 3173 3930 3902 3130
discharge ESP-GL, psi 2350 2297 2030 1245
pressure
Reduction, psi 823 1633 1872 1885
Operating, ft 9110 9250 10530 9190
Pump depth Equivalent, ft 6500 5300 4800 3900
Reduction, ft 2610 3950 5730 5290
Required Pump stages, % 38 47 60 65
equipment size Motor name plate 33 46 50 67
saving
TDH reduction, % 39 47 68 73
Power consumption saving, % 41 53 67 68

Table 1. Summary of the actual operating conditions from the “Electrogas” combined system in the Balcon field.

View publication stats