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Marda Vidrianto
Outline
Introduction
AL selection
AL Types
Introduction
Definitions
the use of artificial means to increase the flow of
liquids, such as crude oil or water, from a
production well (wikipedia)
Method used to lower the producing bottomhole
pressure (BHP) on the formation to obtain a
higher production rate from the well (PEH
Artificial lift section-James F. Lea)
Global surveys
Weatherford
KEY FACTS Schlumberger
23% 19% GE Oil & Gas
About 65% of the global artificial lift market is found in
the US and Canada. Over the last 10 years, artificial lift Baker Hughes
2%
has grown at a CAGR of 13%, fueled by rapidly 16%
6% Dover Corp.
increasing drilling in US oil plays over the last 5 years.
We think going forward, the CAGR will be somewhat BORETS
6% 14% 14%
lower. Novomet
The US is the worlds largest lift market, followed by Others
Canada. With over 1 million producing wells in North $18,000
America, most incur at least one artificial lift expense
per year. The fastest growing regional markets are $16,000
found in the US. These markets include the Permian $14,000
and the Rockies.
$12,000
International artificial lift tends to favor high-end ESP
Millions
$10,000
systems and high-end gas lift.
$8,000
Even gas wells use artificial lift to de-water wellbores.
Rising gas well drilling will drive more lift demand. $6,000
$4,000
Lift companies embrace international manufacturing
of components, but look to the US and Canada for $2,000
customers. $0
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
Others
WFT
SLB
GE
2014
2013
2012
Global Market Share
2011
2010
Global surveys
2009
2008
2007
2006
2005
90%
80%
70%
60%
50%
40%
30%
20%
10%
100%
0%
Summit ESP
Kudu
Companies Ranked by Total Revenues
Tenaris
Halliburton Corp.
John Crane
NOV
Cameron
Novomet
BORETS
Dover Corp.
Baker Hughes
GE Oil & Gas
Schlumberger
Weatherford
$500
$3,000
$2,500
$2,000
$1,500
$1,000
$0
Million
Global surveys
Artificial Lift Market by Type of Lift
$16,000
$14,000
10%
NoAm
$12,000
17% Other
LaAm $10,000
Plunger
Gas Lift
Millions
$8,000 Hydraulic
Eur/Afr/CIS
8% PCP
65%
$6,000 ESP
Rod Lift
ME/Asia
$4,000
$2,000
$0 2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
Global surveys
Artificial lift Selection
Artificial lift Selection
Consideration of depth/rate system
capabilities
Screening advantages vs disadvantages
Selection by NPV comparison
Sample run life information
Consideration of depth/rate
Artificial lift Selection
system capabilities
Gas lift is somewhat depth limited,
primarily from compressor pressures
required, but has a wide range of
production capacity.
Beam pump produces more from
shallower depths and less from deeper
depths because of increasing rod weight
and stretch as depth increases.
Electric submersible pumps (ESPs) are
depth limited because of burst
limitations on housings and energy
considerations for long cables, but can
produce large production rates.
Plunger lift is for low liquid rates,
although some wells can produce more
than 300 B/D. Plunger lift is not
particularly depth limited because of the
increased energy storage in the casing
annulus as depth increases.
Along with advantage/disadvantage lists, the
depth-rate charts are tools for artificial lift
selection or quick elimination of possibilities. The depth-rate charts show how hydraulic
NOTE: The depth-rate curves are only a
relative comparison of the different lift forms systems can pump from the greatest depths,
and not absolutes. For example, a jet pump
has been used to produce 25,000 bpd from because of the U-tube balancing of produced
5000 feet.
fluid pressures with the hydraulic fluid
pressure.
Screening
Artificial lift Selection advantages vs disadvantages
Electrical
Progressive Cavity
Sucker Rod Pump Gas Lift Plunger Lift Jet Pump Submersible
Pump
pump
Operating depth (ft TVD) 100-16000 2000-6000 5000-15000 8000-19000 5000-15000 1000-15000
Well deviation Vertical Horizontal Deviated <20 deg Deviated Horizontal
Operating rate (bpd) 5-5000 5-4500 200-30000 1-5 300-15000 200-30000
Operating temperature (F) 100-550 75-250 100-400 120-900 100-500 100-400
Corrosion handling Good to Excellent Fair Good to Excellent
Excellent Excellent Good
Gas handling Fair to Good Good Excellent Excellent Good Poor to Fair
Solids handling Fair to Good Excellent Good Poor to Fair Good Poor to Fair
GLR: 300
Fluid gravity (API) >8 <35 >15 scf/bbl/1000 ft >8 >10
depth
Workover/pulling Workover/pulling Wireline/workover wellhead Hydraulic or Workover/pulling
Servicing
rig rig rig catcher/wireline Wireline rig
Multicylinder or
Prime mover Gas or Electric Gas or Electric Compressor Reservoir energy Electric motor
Electric
Offshore apllication Limited Good Excellent N/A Excellent Excellent
Overall system efficiency
45-60 45-70 10-30 N/A 10-30 35-60
(%)
High for
High for power High for power
Capital cost low to moderate compressor and Moderates low to moderate
generation generation
distribution
Moderate for
Operating cost Low to moderate Moderate to High Low Low Moderate to High
power fluid pump
Large for
Facilities Footprint Medium Small Large Large Small
compressor
Flexibility Excellent Excellent with VSD Excellent Poor Good To Excelent Excellent with VSD
Selection by NPV comparison
Artificial lift Selection
A more thorough selection technique depends on the lifetime
economics of the available artificial lift methods. The economics, in
turn, depend on:
Consideration
Screening
of depth/rate
advantages vs
system
disadvantages
capabilities
http://petrowiki.org/Sucker-rod_lift
Sucker-Rod
Beam pumping, or the sucker-rod lift
method, is the oldest and most widely
used type of artificial lift for most
wells. A sucker-rod pumping system is
made up of several components, some
of which operate aboveground and
other parts of which operate
underground, down in the well. The
surface-pumping unit, which drives
the underground pump, consists of a
prime mover (usually an electric
motor) and, normally, a beam fixed to
a pivotal post. The post is called a
Sampson post, and the beam is
normally called a walking beam.
SRP common problems
http://petrowiki.org/Gas_lift
Gas Lift
Gas lift is a method of artificial lift that
uses an external source of high-
pressure gas for supplementing
formation gas to lift the well fluids.
The principle of gas lift is that gas
injected into the tubing reduces the
density of the fluids in the tubing, and
the bubbles have a scrubbing action
on the liquids. Both factors act to
lower the flowing bottomhole
pressure (BHP) at the bottom of the
tubing. There are two basic types of
gas lift in use todaycontinuous and
intermittent flow.
Gas Lift
Continuous injection Intermittent injection
GL common problems
http://petrowiki.org/Hydraulic_pump
ing
Hydraulic Pumping
Hydraulic jet pump Reciprocating hydraulic pump
free Hydraulic Pumping
The unit is pumped into the well with the standing valve closed. It
seats on the bottom, with the standing valve held open by a magnet,
ready for operation. To retrieve the pump, power fluid is reverse-
circulated down the return line, causing the pump to unseat and travel
to the surface.
HP common problems
http://petrowiki.org/Plunger_lift
Plunger lift
Whether in a gas well, oil well, or gas
lift well, the mechanics of a plunger-lift
system are the same. The plunger, a
length of steel, is dropped through
the tubing to the bottom of the well
and allowed to travel back to the
surface. It provides a piston-like
interface between liquids and gas in
the wellbore and prevents liquid
fallbacka part of the liquid load that
effectively is lost because it is left
behind. Because the plunger provides
a seal between the liquid and the
gas, a wells own energy can be used
to lift liquids out of the wellbore
efficiently.
Plunger lift
PL common problems
http://petrowiki.org/Progressing_cavi
ty_pump_(PCP)_systems
Progressive Cavity Pumps
The two key features that differentiate
PCP systems from other forms of
artificial lift are the downhole PC
pumps and the associated surface
drive systems. Although other major
components, such as the production
tubing and sucker rod strings, are
found in other downhole lift systems,
the design and operational
requirements typically differ for PCP
applications. Also, many additional
equipment components may be used
in conjunction with PCP systems to
contend with specific application
conditions.
Progressive Cavity Pumps
Installation:
Surface Rod Drive System
Downhole Electric motor System
PL common problems
http://petrowiki.org/Electrical_subm
ersible_pumps
ESP Applications
ESP Parts
Pump Pump
ESP Parts
Protector Protector
ESP Parts
Motor Motor
ESP Parts
Sensor Sensor
ESP Parts
Cable Cable
ESP Surface Equipment
ESP common problems
Operating depth (ft TVD) 100-16000 2000-6000 5000-15000 8000-19000 5000-15000 1000-15000
Well deviation Vertical Horizontal Deviated <20 deg Deviated Horizontal
Operating rate (bpd) 5-5000 5-4500 200-30000 1-5 300-15000 200-30000
Operating temperature (F) 100-550 75-250 100-400 120-900 100-500 100-400
Corrosion handling Good to Excellent Fair Good to Excellent Excellent Excellent Good
Gas handling Fair to Good Good Excellent Excellent Good Poor to Fair
Solids handling Fair to Good Excellent Good Poor to Fair Good Poor to Fair
GLR: 300
Fluid gravity (API) >8 <35 >15 scf/bbl/1000 ft >8 >10
depth
Wireline/workover wellhead Hydraulic or
Servicing Workover/pulling rig Workover/pulling rig Workover/pulling rig
rig catcher/wireline Wireline
Multicylinder or
Prime mover Gas or Electric Gas or Electric Compressor Reservoir energy Electric motor
Electric
Offshore apllication Limited Good Excellent N/A Excellent Excellent
Overall system efficiency (%) 45-60 45-70 10-30 N/A 10-30 35-60
High for power High for compressor High for power
Capital cost low to moderate Moderates low to moderate
generation and distribution generation
Moderate for power
Operating cost Low to moderate Moderate to High Low Low Moderate to High
fluid pump
Large for
Facilities Footprint Medium Small Large Large Small
compressor
Flexibility Excellent Excellent with VSD Excellent Poor Good To Excelent Excellent with VSD
Thanks
CNOOC SES Ltd Artificial Lift
Nuke Suciati
CNOOC Overview
CNOOC SES AL
Why do CNOOC use ESP for Artificial Lift?
Most cost effective solution available?
Small unmanned wellhead platforms
No space for surface facilities
Gas Compression
Hydraulic Power Pack
Insufficient gas available for gas lift
Hydraulic / Piston Pumps or Jet Pumps inefficient and not
suitable for large volume lift
PCP not suitable due to high volume lift and highly
deviated wells
So what methods are left?
ESP
Artificial lift method of last resort
CNOOC SES AL
Artificial lift method of last resort, why?
Anyone think its a good idea to put electrical equipment into liquids?
CNOOC SES AL
Artificial lift method of last resort, why?
Technical Risk
We have experience, we know what works
ESP technology has evolved and improved
Reliability
We have changed the technology to improve the run lives
Wells / performance are well understood
Intervention costs
CNOOC improvements has reduced these costs
Simplified completions
Downtime / Barge availability
Minimized through efficiency and planning
Active well inventory
CNOOC SES AL
Artificial lift method of last resort, why?
Changing production environment
VSD application
Change pump type at next intervention
Sand production
Improved pump bearing technology
Alternative metallurgy
Scale production
Chemical stimulation
High temperature fluids
Pump setting depth
Higher temperature Motor design
Hi Temp Elastomers
Historical Run life
Historical Run life
ESP Management Process
ESP challenges
Problems
ESP challenges
Pressure Depletion
ESP challenges
ESP challenges
Plugged Stages
S Holes at Pump
Housing
A Parted Shaft
N Overload (High
Start/Stop Freq.)
D No Build Up
Pressure
SUNDARI A-11
Run Life: 17 days (TRL: 718 days)
Troubleshooting History:
Tripped OL many times
Manual off due to no BUP
SUNDARI A-11
Run Life: 17 days (TRL: 718 days)
Troubleshooting History:
Tripped OL many times
Manual off due to no BUP
YANI AC-12
Run Life: 7 days (TRL: 150 days)
Troubleshooting History:
Tripped Hi Temp
Tripped SCCT, OL, Stall, LO
Cable reading P-G: low reading
Pothead burnt
S
Plugged Stages
C Parted Shaft
L No BUP
E
ZELDA D-01
Run Life: 180 days (TRL: 365 days)
Troubleshooting History:
Got loss flow problem
Restarted using VSD at various frequencies
No BUP
ZELDA D-01
Run Life: 180 days (TRL: 365 days)
Troubleshooting History:
Got loss flow problem
Restarted using VSD at various frequencies
No BUP
ZELDA D-05
Run Life: 521 days (TRL: 365 days)
Troubleshooting History:
Tripped OL
Restart with VSD on both rotation (Still OL)
ZELDA D-05
Run Life: 521 days (TRL: 365 days)
Troubleshooting History:
Tripped OL
Restart with VSD on both rotation (Still OL)
Gas Lock
G Loss Flow
Increased
A Start/Stop Number
S Cable Blown
Housing Leak
(combine with sand)
KARMILA A-04
Run Life: 281 days (TRL: 619)
Pulling finding :
Cable blown out below hanger
Flat cable burn out
GITA A-01
Run Life: 29 days (TRL: 150 days)
Pulling result:
Parted at gas separator
Flat cable burn out at parted section
GITA A-01
Run Life: 29 days (TRL: 150 days)
Pulling result:
Parted at gas separator
Flat cable burn out at parted section
LOW
Tripped Underload
I
N Tripped High
Temperature
F
Causes Protector
L Failure
U Motor Overheats
X
YANI AC-11
Run Life: 45 days (TRL: 200 days)
Pulling finding :
Protector bag broken
Protector ORing melted
YANI AC-11
Run Life: 45 days (TRL: 200 days)
Pulling finding :
Protector bag broken
Protector ORing melted
TUBING
By Corrosion and
L Erosion
K 26 Wells Suffered
Tubing Leak on
S 2015
NEIA A-14
Run Life: 387 days, Tubing since 2010 (6 years)
Pulling finding :
Tubing leak above head pump
NEIA A-14
Run Life: 387 days, Tubing since 2010
Pulling finding :
Tubing leak above head pump
CNOOC challenges
Sand bailer
Workover: Sand screen Installation
Gravel pack
Smaller tubing
(3-1/2 2-7/8)
Issues:
Tubing Stock & Quality
Tubing accessories
stock
Tubing strength issue
due to deep wells
ESP Enhancement
Wide range pump
Inconnel Shaft
Tungsten carbide
bearing
Real Time Monitoring
Observes anomalies
real time
Well adjustment by
offshore team
20+ wells monitored
Inject
CISI continuously
via control line
Spot
Encapsulated encapsulated
with tubing
Scale
Squeeze into
Squeeze the perforation
Inhibitor
zone (3 ft)
Continuous Injection Scale Inhibitor
140
900
After Scale Inhibition
PRC: 98
800 120
ppm
700
PI increased 100
Before Scale Inhibition Longer ESP Run Life
600
More stable
performance 80
500
400 60
300
40
200
PRC: 2 20
100 ppm
0 0
Produce
with lower
rate (reduce
drawdown)
Use venting
system
Venting System
Lower system pressure
Safely release gas to
atmosphere
>100 wells (SBU)
Real Time Monitoring
Observed increase in
gas (RA fluctuation)
Adjust TP to prevent gas
lock
Stimulation
Reperforation
Pressure
maintenance
Use High
Temp
Resistant
Pump
Reperforation
Add SPF on old well
From 4 to 12 SPF
ESP Enhancement
Hotline ESP
YANI AC-12
Hotline cable
Hotline motor
Hotline advance protector
Max temperature rating
of 500oF
Enhance
material
CNOOC SES
ESP General Operation Guidelines
Way forward
NBU AREA
SBU AREA
CBU AREA
Manage
operation,
reduce shut
Strict down
Standardize
Warehouse
QC Reporting
QC
Operation
Excellency
Digital
Oilfields
Real time
wellhead Multi well
Real time optimization connection
wellhead Process
Conventional monitoring Add Digital connection
wellhead surface
monitoring Add SCADA P&T Gauge
Add VSD Modified
Controller
Advance ESP
Operation Excellency
Other AL method?