Artificial Lift Systems

For Heavy Oil Production

Heavy Oil Workshop Sudan

September 19 20th 2005

Presented by: Allan Peats

1 Initials
 Presentation Outline

Artificial Lift Influences

Rod Pump
Progressing Cavity Pumps
Hotline ESP

2 Initials
 Influences That Impact AL Performance
People
Procedures Well Design

Training Completion
Artificial Lift
Systems
Operation
Well Conditions

Monitoring Installation
Technology

Quality Surface Design

Manufacture Commission Electrical

 Presentation Outline

Artificial Lift Influences

Rod Pump
Progressing Cavity Pumps
Hotline ESP

4 Initials
5 Initials
 Husky Oil Project Lloydminister

6 Initials
 Presentation Outline

Artificial Lift Influences

Rod Pump
Progressing Cavity Pumps
Hotline ESP

7 Initials
 Top Drive PC Systems
Simple and cost effective lift method
Down-hole pump components:
Rotor & Stator
Sucker rod string.
Surface drive head.
Accessories:
Torque anchor.
Rod protectors / centralizers.
Pressure Sensors
8 Initials
 PCP System Venezuela

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 Bottom Drive* - Benefits
Increased setting depth.
Progressing
Increased flow capacity.
Cavity Pump
Elimination of rod breaks, wellhead leaks and
tubing wear.
Elimination of back-spin related safety issues.
Improved well control.
Available in
tubing conveyed or
wireline conveyed versions

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* Mark of Schlumberger
 Slant Well Schematic
Pad #5 Lake Newell
8-24-17-15
Surface
casing
178mm
45 production Lake Newell
casing TVD
927m
73mm tubing
83m Perfs
2852-2856m MD
2862-2866.5m MD
927m
ESPCP 72 Oil
Assembly
Glauconite
Channel Tubing bottom
@ 2826m KB Total MD
2870m KB
9805058-11
 Presentation Outline

Artificial Lift Influences

Rod Pump
Progressing Cavity Pumps
Hotline ESP

12 Initials
 HOTLINE Production System
Two choices for thermal lift systems
Original Hotline system rated for
BHT of 175C Aflas elastomer /
540 motor / direct connect
pothead.
SAGD system Generation II 562
series motor / metal bellows
protector rated for BHT 218C.
SAFETY FACTOR TO HANDLE
SHORT TERM TEMPERATURE
EXCURSIONS TO 232C.

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 Component Temperature Rating Comparison

Component Component Continuous Maximum Operating Temperature (C)

150 162 175 190 205 218 232 245 260 274 288 300
Component Continuous Maximum Operating Temperature (F)
300 325 350 375 400 425 450 475 500 525 550 575
Pumps existing
Pumps current
Intakes AGH Poseidon existing
Intakes AGH Poseidon current
Protector existing
Protector current
MLE / Pothead existing
MLE / Pothead current
Cable existing
Cable current
Cable splice existing
Cable splice current
Motor winding existing
Motor winding current

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 HOTLINE Production System
History & Evolution of the Hotline Production System
Development began in the 1970s & 1980s
Geothermal wells
Low flow / high oil cut (reduced cooling)
1990 - 1998
Huff & Puff steam injection USA & Canada
Thermal Projects (horizontal producers, offset vertical steam
injection
2000 & beyond
Initial SAGD Pilots
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Commercial Developments
 HOTLINE Production System
562 Series Motor Key Improvements Summary

All Steel Stator

Teardrop Rotor Bars
Anti-Rotation Rotor Bearing
Shaft With Involute Splines
High Load Thrust Bearing
ARZ Base Bushing
Additional Rotor Bearing
Welded Joints
Improved High Temperature Motor Oil
Improved Insulation Materials
Special mechanical design to account for material
thermal expansion coefficients

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 Protector Options
Protector Options for temperature
and well type

Bellows style can be used in SAGD

or thermal applications. Effective
when down hole orientation is
greater than 60 degrees from
vertical.

Bag style protector with Aflas rated

for BHT of 180C. Also used in
deviated wells.

Labyrinth protector developed for

vertical steam flood wells.
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 Advanced Protector
Use of ceramic bearing to reduce
vibration.
Use dual bearing in protector head
for better stability
New abrasive resistant head design
including:
Sand shroud to protect mechanical
seal.
Seamless bearing to reduce
mechanical stresses
Elevated mechanical shaft seal
Drain holes to prevent sand / solids
from accumulating in the protector head
High pressure check valve.
Pre-shimmed protector shaft
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 Protector Technical Feature Summary
Feature High Temp H2S Abrasion

Replacement of elastomer bag with metal bellows X X

Use of metal bellows shaft seal X X

Use of high load thrust bearings with no copper parts X X

Dual head bearings for shaft seal support X X X

Ceramic journal bearing for abrasion resistance X X X

Solid shield over head bearings for abrasion resistance X X X

Use of high pressure relief valve to ensure valve closure X X X

Factory shimmed shaft to eliminate field shimming X X X

Use special High Temperature Oil X

Use of Chemraz O-rings X

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 Advanced Gas handlers
Gas & vapor handling is a
major concern in thermal
applications
AGH handles up to 40%
free gas
Poseidon up to 75% free
gas Poseidon vs AGH Performance in T est Wells

100%
aterOnly

Pose idon
re(%)
fW

ressu

AGH
ercento

P
P

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Gas Fraction (% )
 HOTLINE Production System
Pump Considerations

Abrasion Resistant Zirconia (ARZ) to protect against

accelerated wear due to abrasives also available Silicon
Carbide. 5530 stage material available, corrosion
resistance similar to 316 SS. Hardness rating of 180
220 Brinell

Mixed Flow Stage Design

Compression Style Stage

Expanded Production Range to Guard Against Less-
Than-Expected Production Rates

Engineering review of pump selections to ensure no

tolerance & thermal Growth problems.
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 Sinewave Variable Speed Drive
The Schlumberger Sine Wave Drive (SWD)
combines advanced Pulse Width Modulated flux
vector control technology with a built in
harmonic filter to produce near sinusoidal
voltage and current output waveforms ideal
for Electric Submersible Pump applications.

SWD voltage

SWD current

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815 KVA SWD
 Distributed Temperature Measurements

Using Sensa fiber optical DTS is

essential in measuring BHT and
detecting any variation in the
temperature profile
118

108

98
Temperature in Deg C

88

78

68

58
1950 1970 1990 2010 2030 2050 2070 2090 2110 2130 2150
Distance along fibre in metres
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 HOTLINE Production System Summary
Pumps Mixed flow, compression, 5530 stage material, Kevlar washers, silicon carbide,

bearings special mesh rite screen available, coatings

Intakes Options for gas & vapor handling, AGH, Poseidon, graphite impregnated bearings,

radial support, stage geometry, stage material, coatings

Protectors Metal bellows, metal seals, bearing choices, abrasion resistance head

Motors Dominator, all steel stator, SL rotor bearings, additional bearing support, new oil type

Cable Lead cable, EPDM, special high temp tape. MLE new design with Monel tubes/ HT

splice

VSD Sine wave vsd, more efficient, built in load filter reduced footprint, reduce motor heat

Monitoring
24 Initials Sensa temp & pressure / Flowatcher / software
 Hotline Application Case Study

Kerrobert Thermal Project

Prepared by: Allan W.Peats

BDM Heavy Oil Canada
 Hotline Application Kerrobert Thermal Project

Well Information
Steam injection temp. 245C
Production formation: Waseca
Depth: 811mKB TVD
KOP 565 mKB
PBTD 1462.34 mKB
Horizontal section 538 m
Ambient Reservoir Temp: 20C
API 10.5
Viscosity: 32500 cp @ 20C
15 cp @ 150C
Initial Static Reservoir Pressure: 5900 kPa
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 Initial Hotline Application
Kerrobert Thermal Project
Previous Production Method:
Pump Jack (912)
4- Tubing Pump (max displacement 550 m3/d)
Production limited to 450 m3/d max.
Target - 700-800 m3/d
As rates went up Reliability went down
Further rate increases required large capital spending
Gas Lift not an option due to well depth and low BHFP

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KB: 716.96 m
GL: 712.26 m
TD: 1470.00 mKB Well Bore Schematic
PBTD: 1462.34 mKB Case Study
KOP: 565.00 mKB Kerrobert Production Well
TVD: ~ 811.00 mKB (99 mSS)

Surface Casing: 7 jts. of 339.7 mm, 71.43 kg/m

Intermediate Casing: 73 jts. of 244.5 mm, 53.57 kg/m

Production Tubing: 91 jts. of 88.9 mm, 13.84 kg/m, J-55, EUE tubing. Total cable length 861.17 m.

Guide String: 99 jts. of 52.4 mm, 4.84 kg/m, J-55, IJ tubing landed at 986.10 mKB.

Instrumentation String: 31.8 mm, QT-70 coiled tubing landed at 1455.0 mKB.

Thermocouple Bundle: Type-K special 2 x Triplex assembly with junctions at 1454, 1354, 1254, 1154, 1054 and 954 mKB.

Bottomhole Pump: Reda 540 series GN5200 HOTLINE pump c/w 150 HP 540 series motor, AGH, and bottom
feeder intake. Pump intake landed at approx. 70 from vertical at a TVD of +/- 790 mKB.
Liner: 244.5 mm x 177.8 mm. Liner landed at 1462.34 mKB.

Liner: 244.5 mm x 177.8 mm. Liner landed at 1465.28 mKB.

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 Kerrobert Thermal Project Initial
Hotline System Installed
Production Achievement (60Hz)
700 m3/d
75 - 80% Water Cut
BHFP = 3100 kPa
BHT = 160 C
Initial run time 446 days
Cost effective application of technology
Additional Hotline systems have operated for 932 days
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 Case Study Summary
Successful field trial
3 more systems installed
Record run for well 9C9 equipped with Hotline system
9C9 run time 932 days (temperature 150 205C)
The Hotline ESP systems provide a cost effective, high
volume lift method for thermal production projects.

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 HOTLINE Experience Foster Creek Applications

Well Design Temp. Pump Landing Prod. Liner Intake to Liner Diff.
Depth Angle TVD
C mMD mTVD mTVD mTVD
AP3 180 600 79 485 489 4
BP9 200 575 82 476 479 3
CP11 180 538 68 461 482 21
DP17 180 619 76 473 483 10
DP19 180 604 83 482 485 4

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 Foster Creek AP3 (180C)

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 HOTLINE Production System
Summary and Key Advantages
Key Components Re-designed & Extensively Tested
System has safety factor to allow for short term
temperature excursions
System will operate with a bottom hole temperature of 425F
(218 C)
Reduced Steam Oil Ratio
Reduced Facilities Cost
Production Rates in excess of 1600 m3/d
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 HOTLINE Production System
Schlumberger is the Only Company with a Qualified &
Proven HOTLINE Production System

THANK YOU FOR YOUR ATTENTION

Questions?

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