PETROZUATAs

Multi-Phase Meter
Application
by
Luigi Bortolin
1

TAMU MPFM Seminar

PRESENTATION OUTLINE

Introduction of Petrozuatas project

MPFM application & scope
Initial decision and follow-up

Hardware being used

Early operating experience

Specific problems observed to date

Overall assessment
2

A Fully Vertically Integrated Venezuelan Oil Company

CARIBBEAN SEA

Pipelines
CARACAS

20
Diluent

Puerto La Cruz

Lake
JOSE

Maracaibo

Marine Facilities

36
Diluted
Crude

Pariaguan

Marine Operations

CERRO
NEGRO

MACHETE

ZUATA

HAMACA

Ciudad
Guayana

Ciudad
Bolivar

20 Diluent &
36 Blend Pipelines

JK-14

DF-14

LM-14

Gas Well 79X

D-16

BC-17

Water
Disposal
Well

BC-20

Gas Well
II-17G

JK-17

DF-17

DE-20

HI-19

FG-19
FG-19

LM-21
LM-17

NO-18
LM-21
LM-19

JK-20

NO-21
LM-21
LM-21

BC-22

FG-19
FG-22

DE-22

HI-22
JK-23
LM-21
LM-23

San Diego
de
Cabrutica

N-14

FG-19
BC-14

Water
Disposal
Well

BC-24

DE-24
FG-25

BC-26

GH-25
MPP

HI-25

JK-25

DE-26
IJ-27

LM-21
LM-21

LEGEND

Cabrutica
Bridge

NO-24

LM-25
NO-27

KL-28

Main Station & Zuata Pump Station

Upgrader

GH-29

Complete

IJ-29

KL-32

Drilling Ready

GH-31

Construction in Progress
Engineering in Progress
Future Pads

GH-33

Atascosa
Bridge

IJ-31

IJ-33

Pads with MPPs

Production Ops & Drilling

3
BANK11.PPT

TAMU MPFM Seminar

PETROZUATA DIMENSIONS
Shareholders

JV between Conoco Orinoco (50.1%) and PDVSA (49.9%)

Over $ 2 billion of assets employed

130,000 BPD Upgrader based on Conocos Delayed Coking
technology

2 pipelines 200 km long, 36 & 20 dia, 530,000 BPD (17API180 F) blend and 150,000 BPD (47API) diluent

130,000 BPD Extra-Heavy Oil Production (8-10 API)

production facilities on 90 sq mile area

35 year life
4

1.5 to 1.6 billion BO reserves (35 years life)

PETROZUATA, C.A.
Production - Pipeline transportation- Refining
Orinoco Belt
Production Facilities
Upgrader
Diluted Crude: 36 line, 160 - 170 MBPD, 15-17 API
Pipelines
Diluent: 20 line, 40 - 45MBPD, 47 API
120 MBPD, 8 - 9 API
Extra Heavy Crude Oil
COKE - PHASE II
3000 TCPD

65 MBPSD @ 15 API
Diluted Crude
Phase I

Synthetic Crude
Phase II
104 MBPD @ 23 API

Cardn Refinery
47 MBPD @ 23 API
Lake Charles
Refinery
57 MBPD
18 API

ORINOCO BELT - La Faja

Oil In Place - 1.2 Trillion Barrels

CARIBBEAN SEA

CARACAS
JOSE

Puerto La Cruz

Pariaguan

CERRO
NEGRO

MACHETE
ZUATA

HAMACA

Ciudad
Guayana

Venezuela

ORINOCO BELT
MACHETE

ZUATA

HAMACA

CERRO
NEGRO

6
GENPRES P

PETROZUATA

VEHOP
VENEZUELA EXTRA HEAVY OIL PROJECT
MAR CARIBE
GUIRIA
CUMANA

CARACAS

BARCELONA

JOSE

20 & 36
PIPELINES

MATURIN

MORICHAL

EL TIGRE
ZUATA

CERRO NEGRO
MACHETE
(CPV)

HAMACA

PTO. ORDAZ
CDAD. BOLIVAR

Operadora Cerro
Negro (OCN)

Ameriven
PETROZUATA
SINCOR

Orinoco Belt (Faja) Strategic Association Activity

Main Station
ROAD TO WELLS HI, IJ, JK, LM
SECONDARY
OIL TREATING

SECURITY BUILDING

WAREHOUSE
POWER
GENERATION

PRIMARY
OIL TREATING

CRUDE HEATERS

SEPARATORS

CONTROL BUILDING
POWER HOUSE
34.5 kV SUB-STATION

DILUENT PUMPS
DILUENT STORAGE
80.000 Bbls
OFFICES
OFF-SPEC OIL TANK
80.000 Bbls

STORM WATER
CONTAINMENT

FLARE

FIRE WATER TANK

25.000 Bbls
FIRE WATER PUMP

SINCOR
PIPELINES
16 & 26

ZUATA
PUMP STATION

DILUENT STORAGE
80.000 Bbls

PIPELINE
BOOSTER PUMPS
METER
STATIONS

ZUATADUCTO
PIPELINES
20 & 36

DEHYDRATED OIL STORAGE

220.000 Bbls

PRODUCED WATER STORAGE

5000 Bbls
PRODUCED WATER TREATING EQUIPMENT

SINCOR DEHYDRATED
OIL STORAGE
2 X 220.000 Bbls
CONDENSATE TANK
3.000 Bbls

SINCOR DILUENT
BOOSTER PUMPS

SHARED BLEND
BOOSTER PUMPS

SHARED DEHYDRATED
OIL STORAGE
220.000 Bbls

FLARE

DEHYDRATED OIL STORAGE

220.000 Bbls

8
D/PPT_Pres/1999/Apr99/MS_Diagram

Main Station - Separation, Power Generation, Storage, Oil Export

Zuata Pump Station - Receives Diluent and Sends Blend North

10

Field capacities and statistics

Oil processing
132,000 bpd
Power generation
58 MW
Rotating Equipment 50,000 hp.
Roads
98 km.
Power lines
97 km.
Gathering
239 km.

11

TAMU MPFM Seminar

Field development - Whats new or different

Cold horizontal well development in unconsolidated sands

Extensive use of multi-laterals and more complex horizontal

well designs

Extensive use of multi-phase technology

-

Seven 2000 hp multi-phase pumps (MPPs)

Twenty three multi-phase meters in service (MPFMs)

(out of 44 purchased)
12

STACKED DUAL LATERAL WELL PROFILE

Hairy Fishbone Design

13

JK25 Well Cluster - 8 wells, both ESP & PCP artificial lift systems

14

15

Multiphase Pumps boost flow-lines pressure, thus eliminate remote flow-line stations

PCP lift system - motor at the surface turns rods which drive a downhole16pump

17
ESP lift system - power is feed downhole to a motor which drives a pump

TAMU MPFM Seminar

Multiphase metering dimensions

Currently - 23 clusters and 101 wells
By End 2001 - 42 clusters and 272 wells
Long Term - >50 clusters and 700 wells

18

TAMU MPFM Seminar

Multiphase metering dimensions

Well Rate Ranges
Normal

Extreme

500 - 2000

<100, > 2000

Water Conc - %

0.5 - 2

5 - 20

Gas -SCF/Bbl

100 - 200

300 - 1000

Blend (X-Heavy + Diluent)

BPD/Well

X-Heavy Properties - 8 to 10 API

Diluent Properties - 30 API Mesa & 47 API Naphtha
19

TAMU MPFM Seminar

MPFM decision drivers

Knowledge of MPFM development and testing in Europe

and USA

Shared experience testing heavy oil wells with

conventional test facilities in California and Venezuela

Large areal extent of the field development and high well

count

Strong desire for increased well test accuracy and

frequency

20

TAMU MPFM Seminar

From Oil & Gas Journal, Oct. 26, 1998, Nunes et al.

21

TAMU MPFM Seminar

Common Flow Patterns - Challenge in Multiphase Flow Measurement
Bubbly Flow
Piston
Flow

Stratified Flow
Wavy Flow
Semi-Slug Flow

Annular
Bi-Directional
Flow

Slug Flow

Gas

Oil

Water
22

TAMU MPFM Seminar

1- Shrinkage in the Tank as Function of the Percent Diluent
100
90
80

1- Shrinkage [%]

70
60
50
40
30
20

22% dil. Well 4

6% dil well 1

10
0
0

10

15

Time [hours]

20

25

30

23

TAMU MPFM Seminar

Comparison Between the MPFM and The Tank flow rate
3000

well 1

2500

well 1

dil 11%

dil 6%

2000

well 1
dil 27%

well 4

1500

dil 22%
1000

500

Tank
MPFM

Time [minutes]

1089

1057

1025

993

961

929

897

865

833

801

769

737

705

673

641

609

577

545

513

481

449

417

385

353

321

289

257

225

193

161

129

97

65

33

0
1

Flow Rate [bpd]

well 5
dil 13%

24

TAMU MPFM Seminar

Comparison Between the MPFM and The Tank flow rate
3000

well 2
dil 11.5%

2000

well 2

well 4

dil 6.5%

dil 13.4%

well 6

1500

dil 22.7%
well 2

1000

dil 26.6%
500

TANK
MPFM

Time [minutes]

1201

1161

1121

1081

1041

1001

961

921

881

841

801

761

721

681

641

601

561

521

481

441

401

361

321

281

241

201

161

121

81

41

0
1

Flow Rate [bpd]

2500

25

TAMU MPFM Seminar

Trends of W ell 2 and 6

250

500 0
450 0

200

350 0

150

300 0
250 0

100

200 0
150 0

50

100 0
50 0

0
0

10

12

14

16

18

20

22

24

T ime (hou rs)

B lend Flow R ate

diluent flow

Diluent Frac tio n

26

Diluen t [%]

Flow Rate [ bpd]

400 0

TAMU MPFM Seminar

Primary initial concerns

1)

Viscosity effects (requirement for diluent injection)

2)

Temperature

3)

Calibration frequency and procedure

4)

High Gas Void Fractions

5)

Effects of incomplete mixing

6)

Applicable physical properties for the flow computer

7)

Field data capture and transmittal, particularly with

downhole diluent injection
27

TAMU MPFM Seminar

MPFM decision timing & follow-up

Decision taken early - mid 1995, based on cost benefit analysis
versus conventional well testing and high probability of successful
implementation if we selected on vendor and did extensive testing
Followed-up with extensive testing

Offshore GOM

North Maurice Meter/Test Facility

In Cerro Negro at Bitor

In Zuata at Maravens San Diego Norte Pilot Plant (SDNPP)

Intevep at Tia Juana

28

TAMU MPFM Seminar

MPFM test facilities

France

- Elf at Pecorade

Italy

- AGIP at Ticate

Norway

- Norsk Hydro at Porsgrunn

- Statoil on Gullfaks B

USA

- Texaco near Humble

- Conocos North Maurice Test Facility, Lafayette

Venezuela - Intevep

29

TAMU MPFM Seminar

Bitor/JVCO (Statoil,
Jantesa, Distral-Termica,
Conoco, Bitor) Cerro
Negro, Venezuela (April,
1996)

Evaluation and Testing by

Maraven, S.A. (June, 1995)
San Diego Del Norte

30

TAMU MPFM Seminar

31

TAMU MPFM Seminar

Early testing confirmed

At initial stage, no one MPFM covered the entire

operational spectrum

Testing is critical in selecting the right meter for each

application

Significant effort is required to develop and maintain the

computer software for each meter type and application

32

TAMU MPFM Seminar

Early testing confirmed

Vendors quoted accuracy on a different basis i.e. % of

reading vs. % of full scale, or a combination of the two,
different turndown ratios per quoted accuracy and
different operational range limitations (e.g. viscosity
limitation, operation in changing density conditions
etc.).

Petrozuata concluded that the choice meter should

maintain accuracy over the entire field conditions.
33

TAMU MPFM Seminar

Vendor selection
Options Considered AGAR, FLUENTA, MFI
Vendor Selected AGAR Corporation of Houston
34

TAMU MPFM Seminar

Vendor selection
Primary Reasons for selecting Agar
Results in multiple tests showed superior performance at the field conditions. Several
design and conceptual differences were connived as important:

1) Operates in high accuracy over a very wide viscosity range.

(slide 18)
2) Does not require operators input of constantly varying wells
properties. (See SPE 36539)
3) Can be self-verified at any time (every measuring device is
checked against factory calibration)
4) Operates over all flow regimes. (slide 19)

35

TAMU MPFM Seminar

Total system configuration

Manifold - Wells feed into an 8 port multi-port valve that is automated and
programmable. Well test frequency and duration can be
changed from the Main Station
Test Data - Test data feeds to a PLC that also receives flowrate info
from the diluent injection skid. PLC reconciles total diluent
injected at a cluster along with total blend production from
same cluster to allocate blend to each well and calculate net Xheavy production as well test data is updated. All well test data
is feed to the Main Station Control Room and historician via
microwave

36

TAMU MPFM Seminar

Prefabbed Cluster Piping Skid w/8-Well Multi-Port Valve for Well Testing37

TAMU MPFM Seminar

38
Multi-Port Valve for Well Testing with Automatic Actuator for Remote Programming

BC17 Well Cluster - Cluster Piping & Diluent Injection Skids

39

TAMU MPFM Seminar

40

Multiphase Meters Provide Valuable Well Test Info for Reservoir Management

TAMU MPFM Seminar

MPFM types /classification

GVF Determination - Nuclear (gamma ray densitometer)
and non-nuclear type. A density based system requires
input of fluid density. Performance implication when
density changes.
Total Volume measurement - positive displacement, cross
correlation.
Method for high GVF - Inline or partial separation
Watercut Technique - Dielectric, Gamma ray,
Capacitance/inductance, or microwave

41

TAMU MPFM Seminar

AGAR MPFM characteristics

Orientation - Inline , Upflow
Hardware Configuration
- Oval gear for total volume
- 2 momentum (venturi) meters for
differential gas/liquid velocity
- microwave device for water/oil ratio
Model Number:

MPFM-301, 3 size
42

TAMU MPFM Seminar

43

TAMU MPFM Seminar

Measure
Q(vol.)

Measure DP
(mom1)

Measure DP
(mom2)

Measure
Watercut (c)

Calculate
Q(g), Q(l)
Calculate
Q(w), Q(o)

Display
Q(o), Q(g), Q(w)
44

TAMU MPFM Seminar

Early operating experience - Key learnings

Meter performed to Vendor specifications out of the box, yet
initial field adjustment was required to extend the dynamic range of the
meter
Several field conditions contributed to a maintenance rate that was
higher than expected. Once issues where investigated by Petrozuata and
Agar, remedies were found, and maintenance rate decreased. This was
achieved by automating several features such as tubing lines purging.
Preventive maintenance is key to keep the meters operating properly.

Out of range operation lead to low accuracy.

Expectation of high well test accuracy can be achieved if attention is

paid to details.
45

TAMU MPM Seminar

Early Operating Experience

Dynamic Range - Flow turndown in the field was high
150-3500 BPD, The meter had an accuracy specification that
in low flow rates was wider than the field conditions
required. Rather than using a smaller instrument at these
rates, Petrozuata requested AGAR to extend the dynamic
range of the meter. After several field tests, this was achieved
and the overall meter tolerance was cut by half.

Early signs of erosional wear have been observed, most

likely due to sand, and hardfacing is being added to new
orders. The PD meter is constructed out of of Silicon Carbide
bearing and Tungsten Carbide coated stainless steel parts.
46
First unit was purchased in 1994 and is still operable.

TAMU MPFM Seminar

MPFM Liquid Flow Vs. Tank Flow
3000

2500

MPFM flow [bpd]

2000

1500

1000

500

0
0

500

1000

1500

2000

2500

3000

Tank flow [bpd]

+/- MPFM Tolerance

+/-10%

All Test Points

New MPFM Tolerance

47

TAMU MPFM Seminar

Daily Allocation Factor
Typical daily allocation factor correction in early
production stage

- 20-25%

Typical daily allocation factor correction in late production

stage, after the extension of the meters dynamic range,
and improved maintenance
- 1-3%

Fiscalized Monthly Allocation Factor

Typical monthly allocation factor correction in early
production stage

- 14%

Typical monthly allocation factor correction in late

production stage, after the extension of the meters dynamic
range, and improved maintenance
- 1-2%

48

TAMU MPFM Seminar

Overall assessment
Under worst conditions, MPFM has still beaten the
conventional well testing separators, for data reliability and
frequency, and for ease of operation. Also from a cost
effectiveness perspective
The only way to go as the number of wells and production
area increases dramatically.
Incorporation into an automated well test and field datas
capture system, was not a problem.
Systems approach is required for better wells'
performance understanding.

49