GE Oil & Gas

Zenith™ ESP Bypass Completion SystemsAccess to perforations and logging operations below the ESP without workover

In a cost-conscious industry, gaining access below the electrical submersible pump (ESP) without the expense of workover and associated downtime is crucial; production logging, memory gauge deployment or other wireline and coiled tubing operations essential for effective reservoir management cannot be achieved with the pump blocking access below.

The Zenith ESP bypass system’s Y-Tool technology offsets the pump in the well bore and provides a parallel, unobstructed straight-line conduit for well intervention below the ESP with wireline or coiled tubing, or for the deployment of dual ESP completion systems.In addition, unique features in the re-engineered Zenith system enable simpler, safer installation, adding significant rig time and cost savings over traditional ESP bypass installations — even before any operating gains are achieved from increased uptime with the ESP bypass system in place.

Easy access below ESPThe Zenith ESP bypass system offers a well-proven means of achieving access below the ESP without the need for workover. Wireline and coiled tubing operations can be carried out without pulling the ESP — cost of downtime is avoided.

Operators are able to carry out logging, perforation, well treatment and stimulation operations with the artificial lift system in place, effectively managing production operations and reservoir performance without pulling the ESP.

Access to perforations below the ESP

Add perforations.

Formation treatments: solvents, scale inhibitor.

Logging with coil tubing or wireline

Memory gauge deployment.

Sample collection.

Identify water and oil zones.

Operator savings

Simpler, safer system installation

The re-engineered, new-technology design of the Zenith ESP bypass system with patented Saddle Assembly™ has revolutionised the way ESP bypass systems are installed; halving regular bypass installation times and significantly reducing rig costs and time-to-production delays.

Risk of dropped bypass tubing and danger of slippage are also eliminated.

Zenith completions’ unique system design also allows for thermal expansion of the ESP assembly, preventing subsequent damage which may be detrimental to the continued operation of the ESP, maximising pump pro tection.

Zenith completions from GE combine industry experience with cutting-edge technology to deliver innovative systems that overcome well constraints and enhance oil recovery.

Designed in response to industry demand for high-quality, time-saving, reliable oilfield equipment, the user-friendly Zenith ESP bypass (y-tool) system has been selected by many operators worldwide, delivering sizable reductions in installation time and related costs while enabling simplified reservoir access and minimised downtime in over 2,000 electric submersible pump wells.

“The new-technology design of the Zenith™ ESP bypass system from GE Oil & Gas has simplified and revolutionised the way ESP bypass systems are installed.”William Beveridge, Electro-Mechanical Sustaining Manager

1 | Zenith™ ESP Bypass Completion Systems

Challenge

Benefits

Solution

Regular Install

Zenith Install

Time Saved

Operator A 12hrs 5hrs 7hrs / 58%

Operator B 8hrs 3.5hrs 4.5hrs / 56%

Operator C 17hrs 9.5hrs 7.5hrs / 44%

58%

7 hours

sav

ed

56%

4.5 hour

s sa

ved

44%

7.5 ho

urs s

aved

400

Am

eric

as

1100

Mid

dle

East

380

Asi

a Pa

cific

120

Euro

pe &

Afr

ica

9-5/8" Bypass system*3 1/2" threads on the Y-Tool's upper and two lower connections.

7" Bypass system*2 3/8" threads on the Y-Tool's connections allow for application in slimline casing.

*Other system sizes available on request.

Auto Y-Tool systemReplace the standard Y-Tool with Auto Y-Tool alternative for interventionless operation; removing the requirement to set and pull plugs to switch between production and intervention operations.

A. Standing Valve Used to pressure-test tubing or set hydraulic packers.

B. Blanking Plug Prevents recircula-tion of fluid around the bypass when the ESP is pumping

C. Isolation Sleeve Isolates the ESP from fluid during pumping operations.

D. Smart Plug Acquires pump intake and discharge pressure, temperature and vibration in wells with no or failed monitoring system.

System options

Zenith™ ESP Bypass Completion Systems | 2

Zenith™ ESP Bypass (Y-Tool) system profile1. 2. 3.

System benefits

Challenge Solution Benefit

Risk of dropping bypass tubing downhole during install. Danger of slippage, lost rig time and fishing.

The Zenith Bypass Saddle prevents bypass tubing from falling.

Eliminates risk. Quicker to run. Saves rig time.

Temperature changes result in expansion leading to damaged motor and clamps. Reduced run life.

Bypass Saddle allows for different expansion rates by allowing the bypass tubing to move unrestricted.

Prevents damage to the ESP equipment.

Traditional systems need to be exactly spaced out to allow compo-nents to fit together.

Zenith Bypass Saddle allows for 8ft of tubing movement.

Eliminates complicated space out.

Difficulty handling tensile or com-pression forces due to tailpipe or completion equipment below pump.

The Zenith Bypass Saddle passes all compression forces onto the Y-block.

No load on the ESP.

Different sizes of clamps required for different ESP, cable or casing size. Difficult to change ESP or cable.

Unique design allows clamps to fit multiple equipment sizes.

Minimised inventory and flexibility.

Zenith Auto Y-Tool operation

Fig 1. Pump switched on: Auto Y-Tool isolates bypass leg, opening flow path above ESP leg, allowing production to surface while preventing recirculation.

Fig 2. Pump stopped: Auto Y-Tool allows passage of intervention tools and fluids past the Y-tool and through bypass tubing.

Fig 3. When installed in a dual ESP completion, production from lower ESP can be produced via the bypass tubing.

CouplingConnection to operator tubing

CrossoverFor ease of handling of the bypass during assembly on the rig floor

Top NippleEnables setting of standing valves or isolation sleeve

Y-BlockOffsets ESP in the wellbore to allow access below through bypass tubing

CrossoverConnects Y-block to the pump discharge head

Bypass plugs

Cable Support Clamp & ClipsHold the bypass tubing in line with

the ESP and secure cables and lines

Saddle AssemblySimplifies and reduces assembly time

Tail PipeBypass tubing suspended below ESP

Re-entry GuideEnables unobstructed access for logging tools to enter bypass tubing

Swivel NippleFor setting of plugs

Bypass TubingConduit for bypassing the ESP with

logging tools and slickline operations

A. B. C. D. 2,000 Bypass systems installed globally

Logging experiencePERFORATING

STIMULATION/ACIDISING

NITROGEN INJECTION

EXTENDED TAIL PIPE

NATURAL FLOW

RUNNING LOB

PLT LOGGING>6

Syst

ems

achieving runlives >6 years

For system sizes not listed above, please contact your local GE

Oil & Gas representative.

Imagination at work

GE Oil & Gas Zenith Downhole Monitoring & Completion Systems Thainstone Business Park Inverurie, Aberdeenshire, AB51 5GT, UK +44 (0) 1467 628866 www.geoilandgas.com/artificiallift

Zenith Oilfield Technology Ltd. is a subsidiary of the General Electric Company. The GE brand and logo are trademarks of the General Electric Company. © 2016 General Electric Company. Trademarks pending and protected worldwide.

GEA32388

CasingMax diameter of ESP assembly (in)

3.750 4.000 4.562 5.130 5.400 5.440 5.625

Size (in) Weight (lb-ft) Drift ID (in) Available space in casing drift for bypass tubing (in)

7 23 6.241 2.491 2.241 - - - - -

7 26 6.151 2.401 2.151 - - - - -

7 29 6.059 2.309 2.059 - - - - -

7 32 5.969 2.219 - - - - - -

7 35 5.879 2.129 - - - - - -

7-5/8 26.4 6.844 3.094 2.844 2.282 - - - -

7-5/8 29.7 6.750 3.000 2.750 2.188 - - - -

7-5/8 33.7 6.640 2.890 2.640 2.078 - - - -

8-5/8 28 7.892 4.142 3.892 3.330 2.762 2.492 2.452 2.267

8-5/8 32 7.796 4.046 3.796 3.234 2.666 2.396 2.356 2.171

8-5/8 36 7.700 3.950 3.700 3.138 2.570 2.300 2.260 2.075

9-5/8 40 8.679 4.929 4.679 4.117 3.549 3.279 3.239 3.054

9-5/8 43.5 8.599 4.849 4.599 4.037 3.469 3.199 3.159 2.974

9-5/8 47 8.525 4.775 4.525 3.963 3.395 3.125 3.085 2.900

9-5/8 53.5 8.379 4.629 4.379 3.817 3.249 2.979 2.939 2.754

Bypass Tubing Size OD (in) ID (in) Drift (in)

2-7/8 2.875 2.441 2.347

2-3/4 2.750 2.362 2.268

2-3/8 2.375 1.995 1.901

2-1/8 2.125 1.869 1.775

2 2.049 1.792 1.698

Zenith™ Bypass Tubing Matrix