In high H2S and high pressure/temperature fields, the average run life of ESPs is still limited to 3 years. Dismantle Inspection Failure Analysis (DIFA) results show that around 50% of ESP failures are directly or indirectly related to electrical delivery problems concentrated in about 200 ft between the packer and the motor. This paper presents a collaborative R&D effort to develop and trial test a Reliable Power Delivery System (RPDS) with the goal of extending the average ESP run life from the current 3 years to 10 years. The development focuses on improving reliabilities of key power delivery components including packer penetrator, Motor-Lead-Extension (MLE) cable, and cable connection with the motor. The design integrates learnings from advanced completion and subsea technology, and includes new concepts, features and materials. Field pressure-testable connections are implemented to ensure proper field connections makeup. Factory testing incorporated a robust Highly Accelerated Life Test (HALT) methodology to simulate a ten-year service life. Prototype components were designed, fabricated and tested. These components were integrated and subjected to a rigorous system integration test. After the comprehensive factory tests, a field prototype system was built and installed in an offshore well. The system has been operated and exceeds the trial test successful criteria of minimum 180 days run-life. For years, engineers and companies have battled with ESP reliability, with electrical problems at the center of many failure causes. This paper shows the development and field trial of a new generation ESP power delivery technology with the potential of extended run life.
Summary In high hydrogen sulfide (H2S) and high-pressure/high-temperature fields, the average run life of electric submersible pumps (ESPs) is limited to 3 years. Dismantle/inspection/failure-analysis (DIFA) results show that approximately 50% of ESP failures are directly or indirectly related to electrical-delivery problems concentrated approximately 200 ft in between the packer and the motor. This paper presents a collaborative research-and-development effort to develop and trial test a reliable-power-delivery system (RPDS) with the goal of extending the average ESP run life from the current 3 years to 10 years. The development focuses on improving reliabilities of key power-delivery components including packer penetrator, motor-lead-extension (MLE) cable, and cable connection to the motor. The design integrates learnings from advanced completion and subsea technology, and includes new concepts, features, and materials. Field-pressure-testable connections are implemented to ensure proper field-connections makeup. Factory testing incorporated a robust highly-accelerated-life-test (HALT) methodology to simulate a 10-year service life. Prototype components were designed, fabricated, and tested. These components were integrated and subjected to a rigorous system-integration test. After the comprehensive factory tests, a field-prototype system was built and installed in an offshore well. The system has been operated and exceeds the trial-test success criterion of a minimum 180-day run life. For years, ESP reliability has been a constant issue faced by the industry, with electrical problems at the center of many failure causes. This paper presents a completely new design approach to address this critical challenge. Field installation and testing show the potential of extended run life with this new power-delivery technology.
Electrical Submersible Pumps (ESP) are one of the most utilized artificial lift methods in the oil industry. A faster ESP replacement methodology is the ultimate solution to reduce the deferred oil production and reduce cost. This paper focuses on the lessons learned from the previous field trials of slickline deployed ESP systems, including the deployment procedure, benefits, installation challenges, reliability, and recommendations for future installations. Two different deployment concepts of slickline deployed ESP system were trial tested in mild and high H2S well environments. These systems employ a downhole wet-mate connector as a power delivery point connecting the permanent and retrievable completions to power the ESP motor. The trial test successful criteria are dictated by the proven concept of rigless ESP replacement and system reliability. Multiple elective ESP retrievals and reinstallations were performed using a slickline unit after operating for several months. The main objective was to evaluate the downhole electrical system reliability under actual production conditions. The new slickline deployed ESP concept minimized locked-in oil potential through safe and swift ESP replacement in a live well, enabling SIMOPS, and eliminating downtime time associated with the rig mobilization and flowline remanifolding. The design and reliability improvement on the electrical and mechanical systems of both concepts are essential to prolong the system's run-life in an H2S well environment. Moreover, the downhole completion strategy and metal-to-metal seal in the electrical system are believed to be key success factors to prolong the system run-life.
Producing oil at full potential with an electrical submersible pump (ESP) in a slim well remains a challenge in the petroleum industry. A conventional slim ESP system is limited in produced oil delivery rate with an associated risk of damaging the motor lead extension (MLE) of the ESP during the running in hole due to tight clearance. Finding a high rate new slim ESP technology is crucial to enable production of wells at full potential and eliminate slot recovery. This paper shares the success stories of testing two high rate slim ESP installations, and provides the advantages and disadvantages for each of the two approaches for high rate slim ESP design. The high rate slim ESP design options were assessed through field trials collaborating with different manufacturers. The slim ESP viability evaluation metrics were maximum rates, ESP performances, completion installation simplicity and surface controller compatibility. These metrics ensure eliminating unnecessary costs of ESP replacement in the field. The first design option is an inverted ESP design with an induction motor installed at the top. Such a design is advantageous in allowing a pump with a bigger outer diameter (OD), eliminating MLE installation on the pump housing due to an increased clearance, and consequently achieving a higher rate. The second design option uses a permanent magnetic motor (PMM) in a standard ESP configuration. The second design with the smaller ESP OD allows high motor speed, thus providing a higher head capacity and higher flow rate. A modification in the variable speed drive (VSD) design is required to enable controlling the PMM. The field trial result revealed multiple benefits of the high rate slim ESP systems in the field. The high-speed system that utilizes PMM retains the standard ESP configuration, which simplifies well completion and avoids installation complexity. The reduced ESP OD provides more clearance in the well, leading to minimized possible MLE damage during running in hole. Although the VSD modification is possible, the PMM maximum speed will be limited by the maximum capacity of the existing transformer installed in the platform. Finally, both systems lead to a significant cost avoidance by eliminating the need for slot recovery of the produced well at full potential in a slim-well, and avoiding unnecessary replacement of ESP surface equipment. The two systems were already successfully evaluated with a continuous run for more than 365 days without any issues.
Traditional electric submersible pump (ESP) systems have drawbacks in terms of installation speed and efficiency. To overcome these obstacles, some alternatively deployed ESP systems, including the one selected, are deployed into the production tubing, subjecting the system to the properties of the produced fluids. A novel rigless-deployed ESP system developed for use in high hydrogen sulfide (H2S)/high chloride production environment is a solution. An initial step reviewed and ranked competing alternate deployment ESP technologies available in industry along with several new concepts. A new approach to alternate deployment technology was selected. Rigorous testing was conducted to qualify the selected technology and materials for harsh production environments. Testing included a modified NACE TM0175 test due to the processing of the power cable design. Integration testing was performed in a test well to validate the integrity and deployment of the new system prior to field deployment of the rigless-deployed ESP system. The cable deployed ESP (CD ESP) employs a fit-for-purpose power cable that incorporates an exterior metal jacket, providing strength to deploy ESPs thousands of feet into the well. The TransCoil system's power cable outside diameter is roughly 40% smaller than current 2-3/8-in cable-internal, coiled-tubing (CICT) systems; therefore, it is lighter in weight and reduces tubing pressure losses compared to previous products. Product reliability is enhanced as the power cable is fabricated in a continuous manufacturing and inspection process on a factory floor. The tightly controlled manufacturing process significantly improves the product quality over CT cable systems. The power cable can be fabricated from different metallurgies ranging from carbon steel to nickel allow based on the well requirements. A nickel alloy power cable laboratory qualified to 15% H2S and 150,000 ppm chlorides was field deployed in an onshore well and demonstrated an installation time reduction of nearly 50% over rig-deployed systems. A power cable rigless-deployed ESP system solves many of the challenges that currently plague the industry including operational efficiency, rapid replacement, and product reliability in wells in harsh environments worldwide. The power cable rigless-deployed ESP system has, in particular, the opportunity to transform ESP replacement in offshore wells.
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