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Dual ESP Completion System

Installed Successfully
S h e i l a P o p o v, K & M E n t e r p r i s e s

A dual electrical submersible pump (ESP) system has The dual ESP completion system consists of two assem-
been installed successfully in a dually completed, high- blies—one for the lower productive zone and one for the
flow-rate well. The test installation was performed at the upper (Fig. 1). The upper short string was assembled
Laguna field in Ecuador as an alliance technology project alongside the long-string lower assembly. When posi-
between Occidental (Oxy) Petroleum Corp. and tioned, the long-string tubing was clamped to the short-
Schlumberger Ltd. string ESP assembly using dual string clamps, which also
The dual ESP completion system allows simultaneous served to protect the ESP power cables and capillary tubes
but separate production streams. The cost-effective tech- used for chemical injection.
nology provides a means to maximize production rates Several innovative, technology-based solutions were
and ultimate recovery in field situations suited for this applied in the project. To isolate between the producing
method of artificial lift. zones, a Schlumberger Multiport packer was used. The
The completion uses two Russian Electrical Dynamo of packer has multiple pressure-isolated ports through
Arutunoff (REDA) ESP’s. An ESP is a multistaged cen- which tubulars, capillary tubes, electric power cables,
Te c h n o l o g y U p d a t e

trifugal pump with a downhole motor, the power for and, if needed, hydraulic control lines may pass.
which is supplied from the surface by a cable clamped to For this dual completion in particular, packer penetra-
the tubing exterior. Some ESP’s have up to 80,000 Bcf/D tion requirements included the two tubing strings, two
rate capacities. From a reservoir standpoint, they operate ESP cables, and three chemical injection capillary tubes
most effectively in low gas/oil ratio, high-fluid-productiv- (Fig. 2). Space constraints were tight. One ESP cable and
ity wells. When high production rates are desired, ESP two 3/8-in. capillary tubes penetrated each of two 1.9-in.
systems are an attractive alternative to gas lift in fields mandrel ports, which were designed with a special
lacking a reliable source of compressed, sweet gas for arti- adapter that allows passage while maintaining pressure
ficial lift. integrity between the packer and ESP cable and capillary
From an economic standpoint, the dual ESP comple- tubes. The penetration design incorporated standard
tion system serves as a cost-effective production enhance- Boston Insulated Wire (BIW) ESP packer penetrators.
ment solution that maximizes project net present value by Another key technical solution was the shroud design
enabling simultaneous, high-rate streams to be produced for the lower ESP equipment, which was created specifi-
separately from a single wellbore. Geographically, the dual cally for this project and manufactured in Ecuador. One
installation design is particularly applicable in regions ESP cable and two chemical injection tubes had to pene-
such as Ecuador, where local regulations restrict or pro- trate the ESP shroud using a BIW Trident penetration sys-
hibit commingling of produced fluids from two or tem. Again, space constraints were tight between the ESP
more zones. equipment and the 7-in. liner shroud inside diameter. An

Fig. 1—The REDA dual ESP completion system consists of short-string upper and long-string lower assemblies.

extended discharge head from the shrouded pump was
designed to incorporate an offset of the ESP equipment and
to accept five standard 3/8-in. tubing pressure seals to the
capillary and Trident tubes. The shroud penetration tubes
were fed through the ports in the discharge head as the
lower ESP assembly was run in and landed on the shroud
adapter. The outer slots in the shroud adapter improved
fluid bypass both while running in the hole and when pro-
Fig. 2—Two tubing strings, two ESP cables, and three ducing the lower zone.
chemical injection capillary tubes penetrate the dual The two ESP’s were started in sequence and achieved
Te c h n o l o g y U p d a t e

completion’s Multiport packer.

expected production rates; the lower zone produced at
4,500 Bcf/D, and the upper at
5,500 Bcf/D. Both upper and lower
ESP units operated in accordance
with design expectations.
Its successful installation, start-
up, and subsequent tests proved
the completion design’s viability
while providing valuable informa-
tion for future design modifica-
tions. This field test established
that the equipment could run suc-
cessfully into a 95/8-in. cased well-
bore. Additionally, it confirmed
that the dual completion system
pumps could be started without
any undue mechanical or electrical
problems while maintaining elec-
trical and pressure integrity. The
test also allowed tubing and com-
pletion equipment to be scruti-
nized, and the experiences have
generated lessons learned that will
further enhance future dual ESP
completion installations. This
important technical accomplish-
ment is even more significant given
the early stages of operations in
the region.