esp presentation

The World’s First Wireline RetrievableElectric Submersible Pumping System

Neil GriffithsOptilift Technologieswww.optilifttechnologies.com

Steve BreitWood Group ESP Inc.www.woodgroup-esp.com

European Artificial Lift Forum, Aberdeen, February 28th 2008

Presentation Overview

• Business Case for WRESP• Existing ‘Retrievable’ ESP Technologies • Analysis of ESP Component Failures• WRESP System Design• Tests and Trials• Conclusions and Way Forward



The Business Case for Wireline Retrievable ESPs

Preventative Maintenance

We service and maintain cars so why not ESPs ??….. $$$$$$ to retrieve ESPs on tubing !

WRESP Preventative Maintenance• visual inspection• unblocking of intake• shaft rotation and play• oil service of motor• oil service of seal

systems run until next inspectionincreased cumulative run lifeminimal deferment

WRESP


• Preventative Maintenance• Cost-Effective Replacement of Failed Systems

Replacement of Failed Systems• ESP replacement on wireline• shorter turnaround time• shorter intervention time• safer intervention• concurrent operations (offshore)

cost and time savingminimal defermentno formation impairmentrigs better utilised elsewhere

!


• Preventative Maintenance• Cost-Effective Replacement of Failed Systems • Cost-Effective Replacement of Sub-Optimal Systems

! Replacement of Sub-Optimal Systems

• replacement before failure• ESP system optimisation• response to changing conditions• response to wear • retrieved ESP deployed elsewhere

increased productionincreased efficiencyincreased cumulative run life


• Preventative Maintenance• Cost-Effective Replacement of Failed Systems • Cost-Effective Replacement of Sub-Optimal Systems• Sacrificial ESPs

Sacrificial ESPs• temporary ESPs to clean up wells

• drilling debris• perforation debris• formation debris• stimulation debris• dropped objects

• robust debris tolerant ESP design

fewer ‘infant mortalities’increased run life


• Preventative Maintenance• Cost-Effective Replacement of Failed Systems • Cost-Effective Replacement of Sub-Optimal Systems• Sacrificial ESPs• Test ESPs Test ESPs

• temporary ESPs to measure PI• proper design of primary system • invaluable in new fields

optimal systemincreased productionincreased efficiencyfewer ‘infant mortalities’increased run life

?


• Preventative Maintenance• Cost-Effective Replacement of Failed Systems • Cost-Effective Replacement of Sub-Optimal Systems• Sacrificial ESPs• Test ESPs• Well Intervention Below

Well Intervention below ESPs

• 111/16” tool string intervention• reservoir logging• re-perforation / zonal isolation

• no Y-tool and bypass assembly• reduced complexity• retained concentricity

reservoir, completion managementincreased run life cannot PLT sub-hydrostatic wells


• Preventative Maintenance• Cost-Effective Replacement of Failed Systems • Cost-Effective Replacement of Sub-Optimal Systems• Sacrificial ESPs• Test ESPs• Well Intervention Below

. . . a step change in ESP Operating Philosophy !

Existing ‘Retrievable’ ESP Technologies

Tubing

Seal

Pump

Motor

Conventional Tubing Deployed ESPs

Shaft Coupling

Shaft Bearings

Shaft Spline

Shaft

Diffusers

Impellers

Shaft Bearings

Housing

Shaft

Shaft Coupling

Shaft Seal

Shaft Seal

ElastomerBag

Thrust Bearing

Labyrinth Chamber

Shaft Spline Shaft Spline

Thrust Bearing

Pothead

WindingEnd-turns

Rotor Bearings

WindingEnd-turns

Stator

Rotor Bearings

Shaft Spline

Rotor

Windings

Shaft

Oil Sump

Recirc.Oil Filter


Conventional Tubing Deployed ESPsCable Deployed ESPs

Cable Deployed ESPs• cable run with tension cable• downhole packer and pod• landing nipple and seal• fluids produced through annulus

quicker installation/retrievalcannot access annulusproblems with cable strapsrecirculation potential

TorqueBalancedCable

Seal

Pump

Motor

Latch / Nipple

Packer

Discharge


Tubing

Seal

Pump

Motor

CoiledTubing

Seal

Pump

Motor

Conventional Tubing Deployed ESPsCable Deployed ESPsCoiled Tubing Deployed ESPs

Coiled Tubing Deployed ESPs• analogous to conventional ESP • cable strapped to outside of coil• fluids produced through coil

quicker installation/retrievallimited tubing size (high dp)limited pull (e.g. to retrieve packer)cable/clamp slippagedifficult to splice coil if damaged


PoweredCoiledTubing

Seal

PackerSeal Bore

Motor

Pump

Conventional Tubing Deployed ESPsCable Deployed ESPsCoiled Tubing Deployed ESPsPowered Coiled Tubing ESPs

Powered CT Deployed ESPs• cable run inside coil tubing• ESP inverted (motor on top)• packer and sealbore downhole• fluids produced through annulus

quicker installation/retrievalcannot access annulusvery heavy coilcable support inside coil ?motor runs hotter


Seal

W/L Pump

Motor

Conventional Tubing Deployed ESPsCable Deployed ESPsCoiled Tubing Deployed ESPsPowered Coiled Tubing Deployed ESPsThrough Tubing Deployed Pumps

Through Tubing Deployed Pumps• motor / seal permanently deployed• pump retrievable on wireline

quicker installation and retrievalcan inspect and maintain pumpcan optimize pump design‘sacrificial’ and ‘test’ pumps cannot retrieve seal or motorcannot maintain seal and motoraddresses few failure modes


So how manyfailure modesdo these systemsaddress ?

ESP System Component Percentage of(Primary Failed Item) total failures

Assembly (non-specific)CableSensorGas HandlerMotorPumpIntakeSeal/ProtectorOther

1211132304101

Conclusion:

TT ESP is likely to address35% of system failure modes

WRESP is likely to address76% of system failure modes

WRESP System Design

Penetrator Can

ESP Cable

Lubricator Valve

9 5/8” Casing

W/L Re-Entry Guide

Seal BoreLanding Nipple

Per

man

ent C

ompo

nent

s

Ret

rieva

ble

Com

poen

ts

Seal Mandrel

G-Stop W/L Profile

Lock RatchetSpace-Out Tubing

Pump

Seal

Motor

Motor Connector

Connectors

Adjustable Union

WRESP System Design

Design Considerations / Challenges

• Downhole electrical connection• Alignment /space-out of connectors• Prevention of ESP movement• Prevention of ESP rotation• Variation of ESP length• Prevention of re-circulation• Intervention below ESP• Safety and well control

WRESP Connector Tests

Shell Sponsored Development and Testing by Diamould Ltd.• make / break / misalignment tests

• insulation resistance / continuity tests / proof voltage / high current tests

• pressure / temperature / debris / endurance tests

Specifications:

pressure rating 5000 psitemp rating 121 ºCvoltage (cont.) 5 kVvoltage (60 sec) 22kVcurrent (cont.) 125 ampscurrent (30 sec) 250 amps

WRESP System Tests

Development / Testing of WRESP System by Wood Group ESP Inc.• dry tests of dummy connectors / dry and wet tests of actual connectors

• full string wireline installation and retrieval tests

• full functionality test in test well / flow loop with TE-1500 (7 stage) ESP

WRESP System Field Test in Oman

Test Well Candidate Selection

• sub-hydrostatic well with ESP history ( good quality design data )• 9 5/8” casing to pump setting depth ( 854 m TBF )• moderate inclination ( < 5 deg )• low free gas volume fraction (FGVF) at intake ( < 20 % )• low cost intervention environment• moderate production rate and high water cut (minimal deferment)

Rima-36• Pump TE5500 (35+53 stages)• Seal TR5 2BP/2L• Motor TR5 1900V, 50A 156HP• Cable AWG#2 Flat• Weight ~3900 lbs• Length ~78 ft

WRESP System Field Test in Oman

Field Test Completed in Rima-36, June 2007

• safety / integrity issues• no safety incidents, LTIs, recordable cases throughout entire project

• installation engineering / mechanical functionality• all components made-up and installed successfully

• wireline installation / retrieval functionality• landed, latched, ratcheted, unlatched, retrieved successfully

• wet connector mechanical / electrical functionality• orientated, spaced-out, mated, tested successfully

• ESP start-up / hydraulic functionality• electrical integrity lost prior to ESP start-up

Systems retrieved and dispatched for Teardown in OKC

WRESP - Look Ahead

Teardown and FMEA

• Complete thorough FMEA• Implement minor design modifications and QA/QC procedure

Repeat WPESP Field Test• Test well in USA

Downsizing Project (ongoing)

• Connector size is critical• All facets of business case except ‘throughbore’ intervention

Commercialisation (ongoing)

Conclusions

• Clear business case for WRESPs• Step change in ESP Operating Philosophy• Successful test in shallow test well• Partial success of field test in Oman• To be re-tested in USA soon • Downsizing project ongoing• To be commercialized soon



Acknowledgements

• ESP-RIFTS JIP Participants• Wood Group ESP Inc. Staff and Management• Shell International Exploration and Production• PDO Management and Staff• OptiLift Technologies



Any Questions ?

Neil GriffithsOptilift Technologieswww.optilifttechnologies.com

Steve Breit Wood Group ESP Inc.www.woodgroup-esp.com


esp presentation

Documents

failed systems cost

failed systems

failure modes

shaft bearings

esp start

9 5 8 casing

february 28th 2008

business case