esp design and operation - lbcg...esp design and operation april 29 – 30, 2015 cnq ‒ an esp is...
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PROVEN EFFECTIVE STRATEGY
PREMIUM VALUE, DEFINED GROWTH, INDEPENDENT.
ARTIFICIAL LIFT CONFERENCE ESP DESIGN AND OPERATION
April 29 – 30, 2015
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CNQ
‒ An ESP is not just artificial lift tool it is an acceleration tool. ‒ Need to be able to justify the incremental cost with incremental
production. ‒ Does the increase in production result in incremental reserves or
accelerated production?
Is an ESP appropriate?
Slide 2
Pro’s Cons
Can land around corners in deviated/horizontal wells
Large pump so sensitive to dog leg severity
High capacity Major equipment downhole
Can vary speeds with VFD Need to know the well
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CNQ
• Complex system which needs to be in balance ‒ IPR/PI – need to know reservoir information as accurately as possible ‒ Pump – uses the IPR/PI information in its design ‒ Motor – matched to both the pump and the reservoir fluid ‒ Cable – matched to the motor and the required load ‒ Isolating transformer – filters dirty power, helps extend run life ‒ VFD – conditions the power to allow the motor to run at different speeds ‒ Tubing – friction losses a function of length, size and roughness ‒ Surface facilities - all sources of pressure loss increase tubing head
pressure
Production System
Slide 3
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CNQ
Production Profile
• Production characteristics are important ‒ How lively is your oil? ‒ How high is the water cut? ‒ Is GOR going up?
Slide 4
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CNQ
Well vs Pump
• Need accurate production data
Slide 5
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CNQ
• Pump design requires the most complete and accurate input information possible.
• The better the inputs, the better the design.
Typical Pump Design Data Requirements
Slide 6
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CNQ
Typical Pump Curve
Slide 7
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CNQ
Material Selection
• Corrosion potential from H2S and CO2 can shorten life - H2S leads to hydrogen embrittlement - CO2 corrosive with water
• Abrasives have a dramatic effect. • Work with the supplier to choose the best materials. • Consider stocking long lead time special material parts.
Slide 8
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CNQ
Motor Selection
• Depending where you are in the range a size up might be better. • Bigger motor will run cooler. • Might also future proof for changes in fluid gradient or rate.
Slide 9
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CNQ
Power, the Mysterious Variable
• Electric switchgear can be a major weakness.
• Poor power quality is probably a major cause of premature failure.
• Modern VFD’s have more built in power conditioning than vintage equipment.
• Other loads on the power grid can affect your power quality.
• Match your equipment.
Slide 10
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CNQ
Cable Selection
• Cable might seem like an accessory but is a major component visa vis cost.
• Cable sizing important, power losses can be significant.
• Cable failure at connections/splices or where it comes through the wellhead are common.
• Round cable is better than flat due to current underbalances characteristic of flat cable.
Slide 11
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CNQ
Running the Pump
• You are about to lower $200,000 of equipment down the well • Check rig, both equipment and personnel.
Slide 12
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CNQ
Running Cable
• Cable spooler controls speed and therefore tension.
• Need a skilled hand to coordinate with rig.
Slide 13
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CNQ
Rig Equipment
• Make sure the running equipment is appropriate
• Brief the crew on nuisances of running a pump with cable.
Slide 14
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CNQ
Amp Chart
Slide 15
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CNQ
Sensors
• Sensor is not just to hold down the motor. • If you are going to run it, use it. • Ideally tied in to monitoring system.
Slide 16
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CNQ
Listen to the Pump
• Startup data from the pump. You have to be there to get it. • This pump failed in less than 2 hours from startup. • Everything seemed to be going well until motor temperature starts to rise. • Pump failed on overcurrent, ie, got too hot. • Note temp difference between operating and failure was 25oF, probably wouldn’t
have noticed it on surface.
Slide 17
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CNQ
Generic Measurements
• Validate sensor information to increase confidence.
• Tubing temperature and pressure to confirm flow
• Casing pressure and fluid level confirm pump submergence.
• Compare bottom hole pressure calculated from fluid level/casing pressure to that from sensor. You might not like what you see.
Slide 18
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CNQ
24/7 Monitoring
• If you have enough pumps and dedication, around the clock monitoring and decision making can increase run time.
Slide 19
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CNQ
Failure Analysis
• Tear down the pump and see what failed. Remember, a bad O-ring brought down the Challenger.
• Documentation of the results will eventually result in a meaningful database
• Industry cooperation has built large databases but analysis is still tricky.
• Part of the benefit is tracking of surplus inventory.
• CNRL belongs to a group that collects data which can be reported in different ways.
• Minimum data set 38 data points, recommended data set 128 data points.
Slide 20
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CNQ
Random Points
Slide 21
• Storing cable for more than a year is not a good idea. The insulation deteriorates due to absorbed gas devolving.
• Suppliers often reserve the right to substitute materials. It takes a sharp eye to avoid becoming part of their R&D.
• Individual parts are relatively cheap, don’t avoid replacing a questionable component to “save money”.
• If you spend the money on a downhole sensor, collect and use the data. If you can’t measure it you can’t manage it.
• Seek out a corporate expert. A lot of major producers have people on staff who have an incredible knowledge base and whose interests are aligned with yours, they are not trying to sell you anything.
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PROVEN EFFECTIVE STRATEGY
PREMIUM VALUE, DEFINED GROWTH, INDEPENDENT.
THE PREMIUM VALUE, DEFINED GROWTH, INDEPENDENT.