Electric Submersible Pump Installation and Commissioning - Challenges and Lesson Learned from Field Development

Al-Khalifa, Mohammed A.; Cox, R. L.; Saad, Hossam

doi:10.2118/177990-ms

Cited by 4 publications

(2 citation statements)

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“…This process is undesirable because it is expensive and time-consuming: the well suffers a loss of production rate, expensive equipment is required to lifting and then lowering the ESP (all this operations can take several days) [14,15]. Due to the described disadvantages, it is desirable to reduce usage of measuring devices to a minimum [16,17], which will increase the reliability of the entire installation [18]. This can be achieved through the use of indirect methods for evaluating the ESP technological parameters.…”

Section: Introductionmentioning

confidence: 99%

Software Complex for Sensorless Control of an Electrical Submersible Pump

Iudin,

Petrochenkov,

Solodkiy

et al. 2024

IEEE Sensors J.

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The article describes design principles of sensorless observing and control system of electrical submersible pump's induction motor based on dynamic state estimation using unscented Kalman filter. The artificial lift method with electrical submersible pumps in the oil industry is associated with measurements of technological parameters from which oil fluid flow rate is one of the most important. To develop sensorless control and parameters observing system the design principles of flow rate observers were proposed. The main possible scenarios for flow rate observation are considered, including those using surface-mounted sensors. The article also considers issues relating to the limitations in flow rate observation by usage pump catalog characteristics, involving control electric drive test signals changing the pump rotational speed. Overcoming these problems is proposed to the electrical submersible pump's flow rate observing system based on a machine learning model. The simulation results using a complex electrical submersible pump model confirming the efficiency of the proposed methods are provided.

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Section: Introductionmentioning

confidence: 99%

Software Complex for Sensorless Control of an Electrical Submersible Pump

Iudin,

Petrochenkov,

Solodkiy

et al. 2024

IEEE Sensors J.

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“…The stator has been reported to fail due to improper design, current overload, and overheating due to temperature. The downhole sensors are reported to fail in extreme conditions including high temperature, and hydrogen sulfide and carbonic acid corrosion (Abou-Houzifa and Ahmed 2016;Al-Khalifa et al 2015;Arteaga et al 2020;. Understanding the mechanisms of the electrical failure is imperative in reducing the component wear and tear and prolonging the life of the ESP assembly.…”

Section: Introductionmentioning

confidence: 99%

Rigorous review of electrical submersible pump failure mechanisms and their mitigation measures

Fakher

Khlaifat

Hossain

et al. 2021

J Petrol Explor Prod Technol

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Artificial lift is a vital part of the life of many oil wells worldwide. Using several artificial lift methods can prolong the life of the wells and increase oil recovery significantly. One of the most applied artificial lift methods nowadays is the electrical submersible pump (ESP). This artificial lift method has the ability to handle large volumes of hydrocarbons and is applicable under many conditions in both offshore and onshore reservoirs. Even though ESP has been applied extensively for many years, it still suffers from many failures due to electrical, mechanical, and operational problems associated with the ESP downhole assembly. Understanding the main reasons behind ESP failures and how to rapidly and effectively avoid and mitigate these failures is imperative to reduce cost and damage and improve operational and rig-personal safety. This research performs a comprehensive review on ESP failure mechanisms and analyzes these failures in order to determine the optimum conditions to operate the ESP. This can help minimize and avoid these failures. Also, should these failures occur, the research proposes several mitigation methods for each failure based on analysis of different field cases worldwide.

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ESP Reliability Lessons Learned From Three H2S Saudi Arabian Fields

Al-Khalifa

Shepler

Cox

et al. 2016

Day 1 Wed, November 30, 2016

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Previously, many Oil and Gas Production Companies elected not to develop hydrogen sulfide (H2S) producing fields, particularly offshore, in exchange for sweeter crude projects. A narrow number of H2S field developments resulted in a limited number of publications with empirical data on Electrical Submersible Pump (ESP) reliability producing in high H2S partial pressure offshore fields. This paper summarizes ESP reliability lessons learned and solutions implemented from more than 500 ESPs producing across three carbonate field wells characterized by high H2S/CO2 partial pressures, reservoir pressure and production rates; low bubble point pressure and low to mid-level water cut. This paper utilizes ESP field observations and pull failure findings from over 200 Dismantle Inspection and Failure Analysis (DIFA) to confirm H2S behavior and root causes of electrical and mechanical failures within multiple ESP components. Moreover, H2S affects where ESPs were initially idle and exposed to H2S for one to two years either in static conditions or in naturally high rate flowing wells prior to commissioning are discussed. DIFA observations over a wide range of ESP runlife was instrumental in establishing the need for technologies to slow H2S movement across ESP components inclusive of a tandem seal section. Several motor seal sections have failed mechanically from H2S attack thereby requiring upgrade to high alloy metals, ceramic radial bearings and upgraded mechanical seals. Laboratory testing of failed conductor insulations retrieved during DIFA further exposed H2S methodology in creating electrical shorts. Systematic approaches were adopted to identify any unnecessary contributors such as power quality, operational practices or human error that may have facilitated H2S attack. Following the investigation and identification of unnecessary contributors; H2S scavengers were introduced into the seal section to slow H2S migration into the motor, lead sheathed motor lead extension (MLE) was upgraded with new H2S resistant insulation materials and design along with other new technologies that were trial tested to further improve ESP reliability and run life in H2S producing wells. ESP component failure tracking and runlife statistics spanning an eleven year period are shared with the reader to validate the success of H2S resistant ESP component upgrades. Finally, methodology in calculating and measuring impact of varying degrees of H2S partial pressure and temperature from three high and two low H2S partial pressure ESP fields are provided.

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Electric Submersible Pump Installation and Commissioning - Challenges and Lesson Learned from Field Development

Cited by 4 publications

References 1 publication

Software Complex for Sensorless Control of an Electrical Submersible Pump

Software Complex for Sensorless Control of an Electrical Submersible Pump

Rigorous review of electrical submersible pump failure mechanisms and their mitigation measures

ESP Reliability Lessons Learned From Three H2S Saudi Arabian Fields

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