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Catalyst Specialised ESP

Completions
Schlumberger Private
Catalyst Specialised ESP Completions

Wells which are produced by an Electric Submersible


Pump, often suffer from these restrictions:-

Access to Reservoir
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Rate Limitation
Head Limitation
High Workover Costs
Unable to Control Zonal Production

Nov. 06
Y - Tool

 Coil Tubing and Wireline Logging


 Well stimulation through CT or By-Pass tubing
 Retrieval of plugs below ESP
 Bridge plugs can be set for water shut-off
 TCP guns deployed and detonated below ESP
 Memory gauge deployment below ESP
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 Wireline perforating below ESP


 Bottom hole samplers can be deployed
 Back-up ESP deployed on By-Pass Tubing

Nov. 06
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Y - Tool

Nov. 06
By-Pass Systems

Bypass tubing is clamped to the ESP. The ESP


discharge enters the tubing string via the eccentric
leg of the Y-Tool and is prevented from re-
circulating down the bypass tubing by a flapper in
the Auto Y-Tool, or a wireline blanking plug in the
standard Y-Tool.
Schlumberger Private

Where intervention is required while the ESP is


running, (e.g. production logging), a bypass logging
plug is run with the wireline or coiled tubing to
prevent re-circulation.

Nov. 06
Auto Y - Tool

Auto Y-Tool*
Auto access below your
ESP
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Nov. 06
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Auto Flow Sub

Nov. 06
Auto Diverter Valve
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Nov. 06
Auto Diverter Valve
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Nov. 06
Parallel Pumping System
Higher Production
Rates

 Realise the potential of your high


producing wells
 Get access below your high producing
ESP.
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• Increased Production
• Two separate ESPs producing from one
zone simultaneously
• Especially high productivity wells
• Overcome surface HP limitation

Nov. 06
Parallel Pumping System
Higher Production
Rates
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Nov. 06
Increased Lift Systems
UltraHi ™ Systems

 Extend your drawdown capability


 Multiply your down-hole horsepower

To deal with;
• Declining reservoir pressure
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• Increasing water cut


• Restrictive casing size
• High electrical stress
• High Shaft Load

Nov. 06
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High HP

Nov. 06
Back Up Systems
DuaLife ™ Systems

 Reduce your workover frequency


 Keep your wells producing longer

Two pumps used in a redundant configuration to extend


system run life, and tackle issues such as:
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• High rig costs


• Difficult access (subsea)
• Minimise intervention time / cost
• Deferring abandonment

Nov. 06
REDACoil

 Reduce your workover


costs
 Remove the need for an
MDU for pump change
outs
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 Improve your well


production uptime

Nov. 06
Typical ESP System
The submersible pump
MLE Cable
consists of an electric
Submersible
motor attached to a Pump
pump and protector with
other key component Intake
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parts as described in
Protector
this section which are
run into the well on
production tubing.
Motor

Nov. 06
Conventional Pumping System

Production
Power Cable Tubing
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Cable Band

Nov. 06
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Nov. 06
Cable Deployed Pumping System (CDPS)

Conceived by REDA in the late 60’s and covered by var. patents:


 1949 - USP2463590 Weight carrying cable
 1968 - USP3411454 Wireline suspended EP installation in well casing
 1969 - USP3468258 Wireline suspended EP installation in well casing
 1972 - USP3672795 Cable suspended linear-supported EP installation
 1974 - USP3853430 Cable suspended linear-supported SP installation
with locking discharge head
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 1979 - USP4171934 Cable suspended liner-supported SP installation


with locking discharge head
 1982 - USP4352394 Cable suspended well pumping systems
 1986 – USP4621689 Cable suspended SP system with safety valve
 1992 – USP5086196 Electro-mechanical cable for cable deployed PS

Nov. 06
Cable Deployed Pumping System History

Thums California, 1972 Single cable


Dow Chemical, Michigan, 1973 Single cable
ELF, France, Mid 70’s Single cable
ARCO, Indonesia, Late 70’s Single cable
Standard, Alaska, Early 80’s Single cable
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AMOCO, Texas, 1990 Double cable


LASMO, Canada, 1992 Double cable
Mobil, Oklahoma, 1992-3 Double cable
ZAFCO, Egypt, 1995 (6 systems) Double cable

Nov. 06
Coiled Tubing & Cable deployed ESP
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Nov. 06
CT Deployed - External Cable
Advantages
Faster deployment method
Mainly standard CT unit and equipment
Rigless operations

Disadvantages
• Limited to shallow depths and low
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flowrates due to CT size and


increase in friction pressure with
depth and volume
• Common CT size 2 7/8”….3 ½”
possible

Nov. 06
CT Deployed ESP
(cable external) Cable
Clamps around CT and
Power Cable
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Nov. 06
PDO Cable External

Shell/Reda
4 PDO (Shell) production wells
Oman
3.5" CT, 5.5" ESP
5,000 bpd
Cable clamped to the outside of the
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CT
Reached Average Run Life
No significant cost savings
Proved Connector Systems

Nov. 06
The Question was then asked:

Could we put the cable


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inside the coiled tubing?

*Mark of REDA

Nov. 06
Development of REDACoil

1. How to deploy the power cable?

Mechanical anchors
 Do not work well enough
 CT will always deform during a
workover
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 Anchors must withstand vibration


 Anchors must grip steel/oil/steel

Overall, not a good idea, poor chance of


success

Nov. 06
Development of REDACoil
2. How to deploy the power cable?

Dimpled CT mechanical anchors


 Complicated
 Expensive
 Requires use of large diameter CT
 CT structural strength compromised
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 CT corrosion resistance compromised


 Weld area prone to sulfide and fatigue
stress cracking
 Impossible to remove the power cable
in the event of a failure
Overall, not a good idea
Nov. 06
Development of REDACoil

3. How to deploy the power cable?

Magnetic anchors
 Complicated
 Unproven
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Overall, a good idea, difficult to perfect

Nov. 06
Development of REDACoil

4. How to deploy the power cable?

Chemical/swell mechanical anchors


 Complicated
 Unproven
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 Will deteriorate with time


 Not strong enough
 Very difficult to remove the power cable
in the event of a failure
Overall, not a good idea

Nov. 06
Development of REDACoil

5. How to deploy the power CT


cable? Heavy fluid
Buoyancy deployed:
 Simple
 Field proven, environmentally friendly Cable
Perfected by Archimedes over 2,000
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years ago
 CT structural strength retained
 CT corrosion resistance not
compromised
Overall, a good idea, easy to perfect
 However: not sufficient for complete
Nov. 06 cable support
Cable Suspension Solution – Friction
Deployed Solution
Side view

Lh3 End view

Lh2
5,000'
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Lh1

1.5" & 1.75" ID Lv


steel pipe
Nov. 06
REDACoil System - Internal Cable
Advantages
Minimize lost production by reducing well
downtime (Rigless vs. rig availability)
Lowest cost ESP deployment and retrieval
method (especially offshore)
Cable totally isolated inside coiled tubing
 No exposure to chemical or pressure
attack
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 Lowest risk of cable damage


Full pressure control
No splices / connections required
Safest deployment and retrieval method
Fastest deployment and retrieval method
Annular production
 Increased production
Nov. 06
 Reduced Power Consumption
REDACoil System - Challenges

Disadvantages / Challenges
• Weight of coiled tubing reel
• Platform / Crane space / load
limitations
• Annular production
• All the production needs to go
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through the pump….limited to low


gasrate wells

Or…use Poseidon gas


handler

Nov. 06
CT Deployed ESP

Conceived by REDA in 1992 and covered by several


patents:
 1992 – USP5146982 Coiled Tubing Electrical
cable for well pumping systems: first “REDACoil”
patent, includes hydraulic control lines embedded
within the power cable
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 1999 – USP5906242 Method of suspending an


ESP in a wellbore: covers the “floating” or “buoancy
support” of power cable inside the CT
 1999 – USP5954136 Method of suspending an
ESP in a wellbore: covers the “friction support” of
power cable inside the CT
Nov. 06
CTESP Deployment History
Mobil /Reda/Schlumberger Tatums1 1992
BP/Schlumberger Alaska2 1993
Unocal/Schlumberger California2 1993
Pentex/Reda/Schlumberger England 1994 (first REDACoil)
Shell/Reda [4] Oman1 1995
Arco/Reda/Schlumberger [4] Qatar 1996
BP/Schlumberger (2 7/8” CT) [4] Alaska1 1996
BP/Schlumberger (2 7/8” CT) [4] Alaska1 1997
Thums/Reda/Schlumberger California 1997
Arco/Reda/Schlumberger [2] Qatar 1997
BSP/REDA (2”CT) [2] Brunei 1998
Arco/Reda/Schlumberger [2] Qatar 1998
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Arco/Schlumberger Alaska 1998


Chevron/Schlumberger2 7/8”CT[13] Angola1 1999
Oxy/Reda Qatar2 2000
BP/Schlumberger [2] Alaska 2000
Shell/Reda/Schlumberger Venezuela 2001
ConocoPhillips/Reda [2] Norway 2002 Note1 External cable with coiled tubing production
2
Shell/Reda/Schlumberger Venezuela 2002 Note External cable with annular production
Anadarko [4] Qatar 2002 & 2003
Shell/Reda[Injection] [1] Sarawak 2003
QPD {1} Qatar 2005
Nov. 06
Apache {3} UKCS 2005
History - Pentex Cable Internal REDACoil

Reda/Schlumberger/ Pentex
The worlds first annulus produced CT
deployed ESP
Pentex test well in Stockbridge, UK
2.375" CT, 50hp 4.5" ESP
2,930´ pump setting depth
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1,400 bpd
Failed due to well pump off and motor
overheating after 18 months

Nov. 06
History – REDACoil THUMS

REDACoil Thumsat THUMS


Arco/Reda/Schlumberger
 Installed November 1997
 120hp 4.5" ESP
 3,400bpd
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 Pump setting depth 2,900´


 Nine workovers (for testing)
 Power cable x-rayed, all OK
100% uptime for 3 years

Nov. 06
Qatar – Cable Internal
1st Coiled Tubing ESP Field Development
(started in 1996)
Currently 12 REDACoil systems operating
Run Life Incentive (800+ days) Inclusive of
Intervention!
Schlumberger Turn Key Contractor:

 Intervention & completion including


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wellhead

2 3/8” CT – set between 3600 – 6200 ft

4k-13,000 bpd using 5.4-5.6”, 180-500 hp


ESP

Nov. 06
REDACoil at BSP - Magpie

BSP/Camco/Reda
 Two systems (+one backup)
 Operational January 1999
 140 hp, 4.5" ESP
 8,000 bpd
 Pump setting depth 3,600´
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 2.0", 90,000psi CT
 Floating cable system
Off shore permanent platform
Still runs flawlessly 1650+ days & one
cable external +VGSA+AGH
conversion
Nov. 06
Comparison of all ESP Deployed Methods
Activity Day 1 Day 2 Day 3 Day 4 Day 5
Well kill

Nipple down tree & install BOPs

Pull completion

Lay down old & make up new ESP assembly

Run in hole with new ESP

Install tubing hanger & land completion


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Nipple down BOPs

Make up surface connections

Reinstall wellhead

Start ESP, operations complete

Jointed tubing
CT with external cable
R EDA Coil

Nov. 06
Multi-Zone Systems

 Prevent crossflow
 Improve your reservoir management
 Reduce water production
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• Zone/lateral management
• Water management
• Production measurement/allocation
• Less Wells
• Prevent cross-flow

Nov. 06
Multi-Zone Systems
Commingled Production

 Improve your reservoir management


 Reduce water production

• Dedicated ESP systems for upper and lower


zones
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• Production continues after first failure


• No cross-flow during production shut down
• Ability to test each zone individually
Multi-Zone Systems
Independent Production

 Improve your reservoir management


 Reduce water production

• Independent production to surface


• Dedicated ESP systems for upper and lower
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zones
• Production continues after first failure
• No cross-flow during production shut down
• Ability to test each zone individually
Bottom Discharge System
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Typical GasStar System

Protector

Pressure Sensing Instrument (PSI)

Motor
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Protector

Injection Pump

Packer

Nov. 06
Injection Below Producing Formation
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Nov. 06
Why install a GasStar? the Benefits….

Gas wells can become more profitable


The need for a disposal well is eliminated as no
fluid is produced to surface
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No surface handling equipment to maintain


No high pressure disposal lines
No chance of saltwater leaks

Nov. 06
Catalyst Advanced Lift Systems

A range of advanced Artificial Lift completion


designs which address increasingly common
production needs:-
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Higher Production Rates


More Lift
Fewer Workovers
Management of zones/laterals
Logging ByPass
Nov. 06