Lex – Zero failures out of 300+ UHS ESP™ installations due to wear when 2,000 ppm of the solids content in produced fluid at fields in Western Siberia, Russia

Zero failures out of 300+ UHS ESP™ installations due to wear when 2,000 ppm of the solids content in produced fluid at fields in Western Siberia, Russia

The Cases below are based on the operating history of Lex Ultra-High-Speed ESP (UHS ESP™) in various fields with the highest recorded solids content of all wells equipped with our ESPs. The project was targeted to overcome frequent ESP failures due to the high solids content in the produced fluid.

Zero failures out of 300+ UHS ESP™ installations due to wear when 2,000 ppm of the solids content in produced fluid at fields in Western Siberia, Russia

Results

Case # 1

Reservoir Data

Static Pressure140–160 bar
Bubble Point Pressure69 bar
Solution GOR178 scf/stb (32 m3/m3)
Oil DensityAPI 30.4 (874 kg/m3)
Oil Viscosity21 cP
Reservoir Depth7,100–7,200 ft TVD (2,162–2,195 m TVD)

Operating Data 

ESP Setting Depth8,700 ft MD (2,651 m MD)
Production35–55 cmpd
WC43–49%
FBHP40 bar
Start-up Date15 March 2015
StatusPulled
Runlife1,280+ days
Max Sand Production2,080 ppm (2,080 mg/l)
Running cycles15 000+
Operating dutyPeriodic

Case # 2

Reservoir Data

Static Pressure140–160 bar
Bubble Point Pressure69 bar
Solution GOR178 scf/stb (32 m3/m3)
Oil DensityAPI 30.4 (874 kg/m3)
Oil Viscosity21 cP
Reservoir Depth7,100–7,200 ft TVD (2,162–2,195 m TVD)

Operating Data

ESP Setting Depth9,586 ft MD (2,922 m MD)
Production40–45 cmpd
WC41–45%
FBHP40 bar
Start-up Date10 July 2017
StatusPulled
Runlife364 days
Max. Sand Production2,448 ppm (2,448 mg/l)

Case # 3

Reservoir Data

Static Pressure215–235 bar
Bubble Point Pressure72 bar
Solution GOR147 scf/stb (26,3 m3/m3)
Oil DensityAPI 30.4 (874 kg/m3)
Oil Viscosity21 cP
Reservoir Depth7,160 ft TVD (2,182 m TVD)

Operating Data

ESP Setting Depth8,600 ft MD (2,623 m MD)
Production90–100 cmpd
WC10–14%
FBHP40 bar
Start-up Date02 January 2017
StatusStopped
Runlife1,242+ days
Max. Sand Production2,390 ppm (2,390 mg/l)
Operating dutyConstant

Case # 4

Reservoir Data

Static Pressure179–225 bar
Bubble Point Pressure72 bar
Solution GOR163 scf/stb (29 m3/m3)
Oil DensityAPI 30.4 (874 kg/m3)
Oil Viscosity21 cP
Reservoir Depth6,804-7,000 ft TVD (2,074–2,131 m TVD)

Operating Data

ESP Setting Depth7,310 ft MD (2,227 m MD)
Production14–35 cmpd
WC15–20%
FBHP40 bar
Start-up Date23 September 2015
StatusPulled
Runlife514 days (runlife of previously installed ESP was 94 days)
Max. Sand Production1,226 ppm (1,226 mg/l)
Operating dutyConstant

In 2017 we installed another UHS ESPTM system in this well (see below Case # 5).

Case # 5

Reservoir Data

Static Pressure179–225 bar
Bubble Point Pressure72 bar
Solution GOR163 scf/stb (29 m3/m3)
Oil DensityAPI 30.4 (874 kg/m3)
Oil Viscosity21 cP
Reservoir Depth6,804-7,000 ft TVD (2,074–2,131 m TVD)

Operating Data

ESP Setting Depth7,310 ft MD (2,227 m MD)
Production15–35 cmpd
WC15–20%
FBHP40 bar
Start-up Date05 March 2017 
StatusPulled (leakage problem)
Runlife463 days
Max. Sand Production1,794 ppm (1,794 mg/l)
Operating dutyConstant, followed by periodic mode

Case # 6

Reservoir Data

Static Pressure180–220 bar
Bubble Point Pressure72 bar
Solution GOR163 scf/stb (29 m3/m3)
Oil DensityAPI 30.4 (874 kg/m3)
Oil Viscosity21 cP
Reservoir Depth6,800-6,970 ft TVD (2,075–2,125 m TVD)

Operating Data

ESP Setting Depth8,583 ft MD (2,616 m MD)
Production8–21 cmpd
WC21-29%
FBHP40 bar
Start-up Date27 September 2015
StatusPulled (insulation failure)
Runlife420 days (runlife of previously installed ESPs was 25 and 65 days)
Max. Sand Production3,250 ppm (3,250 mg/l)

West Siberian reservoirs are found at 6,900–8,200 ft TVD (2,100-2,500 m TVD). Oil wells are drilled from well pads, ESP friendly deviated along 8,860-11,800 ft MD (2,700-3,500 m MD) and completed with 7″ (177,8 mm) and 6,61″ (168 mm) API Casing. Downhole temperatures are ranging between 176 and 212 °F (80-120 °C).

The complicating factors:

The Client contacted us to address rapid wear and frequent ESP failures due to high sand content in the produced fluid.

We have developed an innovative wear-resistant modular UHS ESPTM. Also, we created new methods of testing the heat resistance of the UHS ESPTM bearings. Also, we tested the reliability of bearings and components of the system in high sand content conditions on specially designed testing benches.

After passing extreme sand content tests, we manufactured and installed in client’s wells the following UHS ESPs:

It is considered that a higher rotational speed hurts the wear resistance of ESP components, particularly when exposed to abrasive fluids. However, advanced design features and material selection enlarged the tolerance of UHS ESPTM to solids content more than 2,000 ppm (2,000 mg/l), which outweighs the traditional standard-speed ESP 2-4 times and improved other performance properties due to a high operating speed of 12,000 rpm.

All case studies

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