SPE-209734-MS

New Mechanism of Sand Management Above ESPs: Cases Study in

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Colombia

Anderson Delgado, Jorge Espinosa, and Maria Hernandez, Gran Tierra Energy; Gustavo Gonzalez and Luis
Guanacas, Odessa Separator Inc; William Aya and Juan Perdomo, Sonoma

Copyright 2022, Society of Petroleum Engineers DOI 10.2118/209734-MS

This paper was prepared for presentation at the SPE Artificial Lift Conference and Exhibition - Americas held in Galveston, TX, USA, 23-25 August 2022.

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 have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper 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
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Abstract
One of the most expensive artificial lift systems in the oil industry is the Electric Submersible Pump (ESP)
system, hence the unavoidable need of extending the run life of wells that have installed this system.
Following the need of extending the run life, a sand regulator has been designed to protect the pump during
shutdowns, and it has been incorporated into traditional sand control configurations to offer extensive
protection above and below the pump.
This paper will explain the mechanism of the sand regulator as well as the benefit of installing this system
alone above the pump or complemented with a sand control system below the pump. The candidate wells
to this integrated solution were selected from MMV (Middle Magdalena Valley) and Putumayo Basins,
in Colombia. The wells had sand problems history and it was necessary to review pump designs, pulling
reports and sensor parameters. Well conditions such as production, tubing size, and particle size distribution
were analyzed to build the best design for every single well. In the design the geometry of the well was
assessed to accommodate the cable and CT (Capillary tube) line downhole.
The ADN Field in Colombia is characterized by heavy oil production (API between 13-18°), with fluid
production between 1,000-2,000 BFPD, with a viscosity of 270 - 3090 cP @ 122°F, water cuts oscillating
depending on the waterflooding effect (Between 1% to 95%) and high fine sand production (200 – 24,000
ppm). The CH Field wells produce between 1,000 – 6,000 BFPD, with API between 17-20°, high water
cuts (> 77%) and a high sand production between 100 – 3,000 ppm. The wells selected had other type of
sand control and management systems and were highly affected by frequent shutdowns. The Sand Regulator
design was installed in 20 wells and was compared with the performance achieved using traditional sand
control solutions. After the installation, production has remained stable in all the wells applied, allowing to
reduce the PIP of the well of up to 400 psi. Less current consumption has been observed after each shutdown
in all the wells, extending the run life of some wells up to double the average. Sensor parameters were
analyzed after each pump restart to determine how difficult it was to restart operation after shutdowns.
Compared to the tools installed above the ESP, this sand regulator allows flushing operation through it
with flow ranges from 0.5 to 5 bpm. In addition, the unconventional design of this tool has opened the door
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to a new concept of ESP protection that works in wells with light or heavy oil and can be refurbished or
inspected completely without cutting the tool.

Introduction
Sand control has become one of the most important aspects of evaluation, whether a project is viable or not
may be defined for the different sand control options in the market, especially in wells with high flow rate

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where the ESP system is currently one of the most used ALS. The sand management gets difficult when
the sand is produced with heavy oil and medium to low water cuts. High viscosities fluids coupled with
high sand production create a mix with low mobility that requires large open area and limits options for
efficient solids control. Figure 1 illustrates the nature of the oil produced and the mix formed with sand in
some wells installed with the new sand management system.

Figure 1—Heavy oil and oil + sand mixture – Records from Gran Tierra Energy (GTE)

A high sand production will cause many damages in the ESP system, when this enters in the pump the
sand being either a formation nature or from a frac job it starts wearing the pump stages and the mechanical
seal may present damage due to the vibration product of the presence of sand. The damage could create
a path that will allow the fluid to flow through the seal and into the dielectric oil causing a failure in the
system. The erosive nature of the sand will affect the impeller vanes affecting the hydraulic capacity of the
pump this would increase the clearance on the stages triggering more recirculation and end up in a lower
pump efficiency, which will increase the lifting cost. Another issue commonly faced due to the volume of
sand is sand packed off in the pump stages limiting the production of fluid. Figure 2 shows some records
gathered from the fields analyzed in this paper.

Figure 2—Pump stages packed off with sand – GTE

SPE-209734-MS 3

It is important to highlight that if there is a shutdown and there is sand inside the production tubing
when the ESP restarts, it may cause a broken shaft, or the pump wouldn't be able to start due to high motor
current required. This last problem has become one of the main issues in the two heavy oilfields in Colombia
analyzed in this paper. Figure 3 summarizes the root causes of the failures reported by GTE, being sand
the main cause with 76%, followed by high gas inflow with 17% and corrosive fluid with 7% of the total
failures. From the pumps' failed components, the shaft has been the most affected one with wide margin

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compared to the rest of components damaged (figure 3).

Figure 3—Failure causes and failed components - GTE

Different technologies for the control and management of solids have been installed in these fields to
extend the run life of the downhole equipment, however the clogging of the upper pump and some of these
systems continues to be a recurring problem in the ESP equipment. Figure 4 shows the pump and another
sand management system installed above the pump discharge completely plugged with sand.

Figure 4—Pump stages and sand management tool plugged – GTE

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This research presents a solution to manage the sand production above the ESPs. The solution is compared
with previous methods used for the same purpose and comparing parameters such as sand production, fluid
production, pump frequency and run life.

Technology Description
The Sand Lift is a sand management system installed directly on the discharge of the pump. When the pump

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is producing fluids, this system does not represent a restriction to the fluid thanks to its large open area in
the internal components, table 1 summarizes the total open area depending on the dimensions of the tool. In
simulations carried out in computational flow models using up to 8,000 BFPD, pressure drops of less than
10 psi were estimated from the discharge of the pump to the neck section of the tool. Now, when the pump
shuts off, the internal system of the Sand Lift works as a flow regulator to the pump. The internal inverted
mesh mechanism reduces the volume of solids flowing towards the discharge of the pump, thus avoiding
the saturation of the upper pump stages. An important feature unlike other technologies is that the Sand Lift
does not have check valve systems, so it does not completely seal the tubing and allows flushing operations
through the production tubing to the pump. This feature is especially beneficial in cases where solid control
systems are not used below the pump, and it is desired to clean the sand stored in the pump stages. Acid
treatments can also be injected without affecting the internal components of the Sand Lift.

Table 1—Technology specifics

During restart of pump operation, the Sand Lift uses pump discharge pressure as fuel to displace fluid
and solids in its chamber. The internal design of the lower ports act as jet ports to sweep and break up any
type of solid around. Computer simulation results have shown that the fluid velocity in the bottom jet ports
can reach up to 132 in/s. It is important to clarify that this scenario is possible when the pump can reach
enough discharge pressure, however, when there are solids in the lower pumps and an adequate discharge
pressure cannot be generated, the system will not be able to generate the jetting effect, hence the importance
of using combined sand control systems above and below the pump. After the reset, the fluid will move
through the inner string and out through the inverted mesh into the tool body and then into the tubing. The
inner string has a dart that travels up and down depending on the operation. The main purpose of the dart
during the pump restart is to clean out the flow area inside the inner string and avoid sand packaging in the
mesh. After the pump restarts, the dart will travel upwards opening the flow area below it and seating at the
top section of the inner string in the dart garage. The complete tool operation is illustrated in Figure 5. The
general design of this tool was thought to analyze its internal components after removing it from the well
to provide production engineers with more information about types of solids, volume of solids and severity
of downhole problems. Because of this all components of the Sand Lift are inspectable and replaceable
without having to cut the tool. This design facilitates the inspection and reconditioning of the tool, which
avoids cost overruns for the purchase of new equipment.
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Figure 5—Sand Lift Operation – representation of fluid and sand
movement when the ESP shuts down and when it starts back up

Design and Applications

One of the main design variables is the amount of fluid expected and the pressure drop across the tool. This
process is done through computational models and requires information such as pump discharge pressure,
production flow, fluid properties and flow geometry. The Flow geometry refers to the dimensions and
internal design of the Sand Lift's flow channels. The size of the tool largely depends on the factors mentioned
above but also on the size of the production casing, the dimensions of the ESP pump cable and the size of
the capillary tube (if applicable). Figure 6 shows the modeling of downhole tool size in accordance to casing
and cable size. With this information, the pressure drops and flow rate through the tool are determined.
During installation, the tool can be lifted from the neck, which is already properly threaded from the
factory, no additional tool is needed to lift or run the Sand lift (Box - Pin). It is recommended to install the
Sand Lift directly on the pump discharge without adding pup joints, this will improve the internal sweep
efficiency on the body during pump restart. The banding procedure is performed as shown in figure 7,
securing the cable on the neck and the upper and lower section of the body.
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Figure 6—Sand Lift Dimensioning

Figure 7—Banding procedure

Field Background
The Sand Lift was installed in two Colombian fields owned by Gran Tierra Energy (GTE). Both ADN and
CH fields are producing through waterflooding as a secondary recovery method and produce heavy oil (13
– 20° API). The characteristics of the fields are summarized in table 2. The flow properties of the reservoir
are good in terms of permeability and thickness; however, the fluids are from medium to low mobility due
to the viscosity of the oil. Both fields were developed with mainly deviated wells with depths between
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7,000 and 9,000 ft. The wells are completed with 7" production casing, and the ESPs are located above the
perforations. Examples of the completion of these wells are shown in figure 8.

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Figure 8—Wellbore sketch CH & ADN Field

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Table 2—Field characteristics

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The ADN field is in the north of the Middle Magdalena Valley in Colombia (Figure 8), The Prudent
reservoir management of the waterflood has restored production to an average level of 14,967 BOPD in
Q4/21. After this rapid development, one of the challenges has been the reduction in the operation costs
mainly triggered by failures due to sand production. The company has created a "right sizing" program
focus on implement key technical initiatives to optimize the equipment designs and try proved technologies
to increase run life of the existed equipment.
The CH field corresponds to the southeastern block, where GTE became the operator in 2019 and began
the water injection process, achieving an excellent response in production.
Both assets are in the filling phase of the water injection process, and in some wells the breakthrough of
the water has already begun to affect the run life of the downhole equipment, so from now on optimization
processes seeking to increase the total accumulated production of oil and reduce well intervention and
operating costs as the field reaches maturity and water cuts increase. Table 2 summarizes the general
information of both fields

Results/Case Studies
About 20 producer wells have been completed using the Sand Lift above the ESPs. the wells have wide
production ranges that go from maximum productions of 273 BFPD to 6000 BFPD with water cuts from
2.4% to 77%. Sand productions have been recorded periodically, reporting values from 30 mg/L to more than
20,000 mg/L, which is quite a challenge for any downhole production system. Another of the characteristics
of these wells is the low API (13° – 20° API), which, when mixed with the sand particles, generates a paste-
like fluid that increases the risk of clogging both in the pump and in the accessories used at the bottom of
the well. Figure 9 shows the summary of some wells installed with the Sand Lift and their current run life.
All the wells included in this graph are running, so the data is up to date. The points on each of the bars
show the maximum production after the installation of the Sand Lift. The detailed information of each of the
wells will be reviewed below, but based on the results of the Run Life, the applications have been successful
and show excellent behavior of the pump against speed increases. The measurement of sand production was
recorded for each well and the amount of sand being produced through the pump and the Sand Lift can be
evidenced. Three of the installed wells have solids control systems below the pump, but the others were
simply installed with the Sand Lift above.
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Figure 9—Wells completed with Sand Lift

CH-7
Well completed for the first time in May 2012 and it was completed with the Sand Lift in July 2021. Current
run time of 318 days using a 538 series pump with 226 stages and a motor of 287 HP. Previous installations
were carried out by another operator and the details about the failures were not available. The average liquid
production of the well has been 3,135 BPFD with a maximum production of 5,086 BFPD and water cut
of 66% and API gravity of 18°. The maximum PIP has been 892 psi and the minimum 220 psi, while the
pump frequency has oscillated from a minimum of 47.90 Hz, a maximum of 64 Hz and an average of 52
Hz (Figure 10). No information about solids has been gathered by the operator.

Figure 10—Monitoring for CH-7

The information about the stops and downtime (hours) was gathered to evaluate the tool performance.
Figure 11 shows 77% less downtime compared to the same period before the installation of the sand
management system. This improvement was made among other reasons because of the capability to re-start
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the pump on more effective way than before the installation. This reduction in the downtime reduced the
deferred production from 103,325.85 bls to 51,766.5 bls.

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Figure 11—Downtime and deferred production for CH-7

ADN-15
Well completed for the first time in September 2017 and it was completed with the Sand Lift in July 2021.
Current run time of 316 days using a pump 538 with 172 stages and a motor XT1 With 339 Hp. The
average liquid production of the well has been 803 BPFD with a maximum production of 1573 BFPD.
The maximum PIP has been 996 psi and the minimum 491 psi, while the pump frequency has oscillated
from a minimum of 48.10 Hz, a maximum of 52.60 Hz and an average of 51.28 Hz (Figure 12). The well
produces with a water cut of 50% and with an API gravity of 14°. Regarding to sand production after the
installation, the well produces an average of 484 mg/L of sand, with a maximum production of 2,164 mg/
L and a minimum production of 72 mg/L, which can be classified as a high sand production. Compared
to the sand production before the installation (Avg. 195 mg/L), the current conditions are very harmful,
but the downhole equipment has performed well avoiding failures due to the solid production. From the
sand produced, 37% are sand particles between 25-75 microns, 39% are particles between 75-150 microns,
22% particles between 150-300 microns, and 3% particles larger than 300 microns (Figure 12 – Particle
size distribution, PSD).
The information about the stops and downtime (hours) was gathered to evaluate the tool performance.
Figure 13 shows 38% less downtime compared to the same period before the installation of the sand
management system. This improvement was made among other reasons because of the capability to re-start
the pump on more effective way than before the installation. This reduction in the downtime reduced the
deferred production from 4,115.64 bls to 2,713.15 bls.
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Figure 12—Monitoring and results for ADN-15

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Figure 13—Downtime and deferred production for ADN-15

ADN-18
This well was initially completed in November 2017 and had an average run life of 137 days before installing
the Sand Lift. Table 3 shows the details of the most recent failures and the completions used on these
installations. Different types of completions were used on this well and there were not optimal results after
the first 4 years. The well was completed with the Sand Lift in July 2021, and it has achieved a run time
of 242 days using a 538 series pump with 180 stages and a XP motor with 350 Hp. The average liquid
production of the well has been 552 BPFD with a maximum production of 917 BFPD. The maximum PIP
has been 824 psi and the minimum 359 psi, while the pump frequency has oscillated from a minimum of 40
Hz, a maximum of 63.60 Hz and an average of 46.43 Hz (Figure 14). The well produces with a water cut of
30% and with an API gravity of 18°. Regarding to sand production after the installation, the well produces
an average of 1,547 mg/L of sand, with a maximum production of 23,652 mg/L and a minimum production
of 57 mg/L, which can be classified as severe sand production. These conditions have changed drastically
after the installation since the average sand production before installing the Sand Lift was 582 mg/L with a
maximum of 1,764 mg/L. From the sand produced, 19% are sand particles between 25-75 microns, 32% are
particles between 75-150 microns, 43% particles between 150-300 microns, and 7% particles larger than
300 microns (Figure 14 – Particle size distribution, PSD).

Table 3—Intervention Summary ADN-15

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Figure 14—Monitoring and results for ADN-18

During the diagnostic phase, it was proposed to carry out an installation with a double sand control system
above and below the pump that includes a 300µ mesh. Additionally, the granulometric distribution of the
sand allowed separating up to 50% of the sand production before entering the pump without affecting the
14 SPE-209734-MS

liquid production due to pressure drop. This comprehensive sand control system has exceeded the average
historical run life of the well.
The information about the stops and downtime (hours) was gathered to evaluate the tool performance.
Figure 15 shows 54% less downtime compared to the same period before the installation of the sand
management system. This improvement was made among other reasons because of the capability to re-start
the pump on more effective way than before the installation. This reduction in the downtime reduced the

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deferred production from 84,463.25 bls to 33,596 bls.

Figure 15—Downtime and deferred production for ADN-18

ADN-9
This well was initially completed in March 2017 and has a gravel pack installed in 2019. After this workover,
the well had an average run life of 108 days before installing the Sand Lift. Table 4 shows the details of
the most recent failures and the completions used on these installations. Different types of completions
were used on this well and there were not optimal results after the first 1.5 years. The well was completed
with the Sand Lift in December 2021, and it has achieved a run time of 92 days using a pump 538 with
40 stages and a XP motor with 250 Hp. The average liquid production of the well has been 303 BPFD
with a maximum production of 415 BFPD. The maximum PIP has been 685 psi and the minimum 169
psi, while the pump frequency has oscillated from a minimum of 43.80 Hz, a maximum of 61.00 Hz and
an average of 46.92 Hz (Figure 16). The well produces with a water cut of 35% and with an API gravity
of 18°. Regarding to sand production after the installation, the well produces an average of 163 mg/L of
sand, with a maximum production of 540.14 mg/L and a minimum production of 47 mg/L, which can be
classified as from medium to high sand production. From the sand produced, 53% are sand particles between
25-75 microns, 36% are particles between 75-150 microns, 7% particles between 150-300 microns, and 5%
particles larger than 300 microns (Figure 16 – Particle size distribution, PSD). There are no records of sand
distribution before the installation of the gravel pack, so it is likely that the sand control system is retaining
the coarser particles while the finest material is still flowing to the wellbore. Currently the well is operating
with the same frequency that before the installation of the Sand Lift and the production is increasing. The
PIP has decreased from 500 psi to 171 psi and no issues related to sand has been reported so despite the
high pressure drop and very likely the increasing sand production, no sand issues have been reported after
149 days running.
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Figure 16—Monitoring and results for ADN-9

Table 4—Intervention Summary ADN-18
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16 SPE-209734-MS

Table 5—Intervention summary ADN-9

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Conclusions
• The use of a solids management system above the pump has improved the run life more than 100%
in some wells and the performance of the ESPs, increasing the accumulated production of oil in
reservoirs subjected to water injection and production of high-viscosity heavy crude oil.
• The ADN field has had a reduction in operating expenses due to the decrease in interventions
carried out during 2021, this success was in part the result of the optimization program of the
artificial lift systems that allowed the use of proven technologies such as the Sand Lift.
• The CH field reached a production record during 2021, and as evidenced, the ability to increase
production without affecting the operation of the downhole pump was one of the key factors.
• The use of integrated solids control systems above and below the ESP pump proved to be adequate
in wells with high sand production (sand production not found in the literature) and fine to medium
solids size. although each case must undergo a rigorous evaluation that guarantees an adequate
design of the size of the slot and the required mesh length.
• Two failures have been recorded to date; one was caused by loss of isolation material in the
terminals of the pothead connector due to scale after 37 days of run life. The second failure
happened after 68 days, and the root cause hasn't been determined yet. The Sand Lifts from these
wells were inspected to provide more information about the performance of the equipment and
the failure cause.
• The downtime and deferred production were reduced after the installation of the Sand Lift. The
number of hours per stop event show a better capacity for the downhole equipment to re-start
normal operation after shutdowns.

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