+20% production gain, -40% energy saving at a group of oil fields

Results

• 20% increase in oil production;
• 40% reduction in power consumption (equivalent to nearly 50 million kWh) since 2014;
• 23% increase in equipment runlife;
• Over 15,000 cycles on average reached the wells operating in intermittent mode and complicated conditions (sand content >2,000 ppm / >2,000 mg/l) ;
• 25% reduction in Total Cost of Ownership (TCO) in comparison with competitors.

Fields’ reservoirs are found up to 9,150 ft TVD (2,785 m TVD). Oil wells are drilled from well pads up to 12,000 ft MD (3,650 m MD) and completed with 7″ (177,8 mm) and 6.61″ (168 mm) API Casing. Downhole temperatures are ranging between 195 and 240 °F (90–115 °C).

The following complicating factors stalled to reach the production measures:

• Narrow operating range of existing ESPs;
• Gas content at pump intake is above 60%;
• Sand content is above 1,500 ppm (1,500 mg/l);
• High DLS;
• High power consumption.

After doing research and detailed analysis, we proposed installing several models of Ultra-High-Speed ESPs with a nameplate operating speed of 10,000 rpm:

• Low-flow-rate UHS-200 system designed for NP flow range from 50 to 280 bblpd with 190 bblpd at BEP (from 8 to 45 m³/d with 30 m³/d at BEP);
• Wide-range UHS-500 system designed for NP flow range from 125 to 560 bblpd with 500 bblpd at BEP (from 20 to 90 m³/d with 80 m³/d at BEP);
• Power efficient UHS-600 system designed for NP flow range from 280 to 720 bblpd with 500 bblpd at BEP (from 45 to 115 m³/d with 80 m³/d at BEP).

Upon every phase of technology deployment the client evaluated obtained results. They were found stable and consistent with prior results, allowing to development of a solid economic model.

Since 2016 UHS ESP^TM systems are approved for use in group of fields under Lex engineering support and supervision. 

We offer a centralized approach to the monthly delivery of equipment for installation and maintenance, due to the compact design of our UHS ESP^TM units and minimum on-site preparation requirements. This allows us to avoid additional field workshops as the preparation of equipment can be conducted at a main repair facility and delivered directly to the field being ready for the installation (plug-and-play design).

Our results consistently demonstrate the high potential of Lex UHS ESP^TM to optimize production and provide operational advantages in harsh well conditions.

UHS ESP^TM advantages vs. conventional equipment

• Wide operating range allows you to adapt to changes in inflow whilst maintaining higher efficiency.;
• Reduction in the total length of UHS ESP^TMs (by up three times) allowing passage through high DLS wells;
• Improved gas separator efficiency leads operating with 75% gas at the pump intake;
• Reliable operation with sand content up to 2,000 ppm (2,000 mg/l) is possible due to wear-resistant stage materials.

For today, we installed more than 500 units at offshore and onshore projects worldwide.