In Saudi Arabia, conventional oil reservoirs have been treated using conventional stimulation methods. The challenge is that many of the formations now are tighter and require improved stimulation methods. Fracturing is a major topic discussed in the industry as of late and as such using it in this formation will serve as a trial to shift from conventional stimulation methods to fracturing when facing tighter formations. This particular acid frac was performed in a tight carbonate formation ranging in permeability from 1 - 2 md. The chosen well is a newly drilled tri-lateral producer completed with a multi-stage frac completion in the mother bore and will serve as a pilot well for this reservoir in the area. The acid frac was a seven stage completion utilizing hydraulic fracturing. Several methods using pressure and injection were used to determine reservoir fracturing response and petrophysical properties. This paper will discuss the first multi-stage acid frac performed in an oil producer in Saudi Arabia. It will examine the entire process of candidate assessment, job preparations, and execution. In addition, the paper will discuss challenges faced, solutions taken, and the post-decision results. The paper will show how an injectivity test performed pre- and post-frac was used as a benchmarking tool to analyze the effectiveness of the frac. Finally, we will discuss the flowback of the well, initial results, lessons learned, and optimization of future jobs.

Throughout the past decades, the Electrical Submersible Pumps (ESPs) have been deployed across different oil fields in an Arena of Artificial Fields. It was a proven fact that the typical run life of an ESP can exceed multiple years. However, that fact could be reversed especially in designated fields with high Hydrogen Sulfide (H2S) partial pressure; where specialized ESP design is required. The presence of the Hydrogen Sulfide (H2S) can result in various and vast forms of corrosion products attacking the ESP components which eventually resulted in an ESP shorter run life compared to average. Hydrogen Sulfide (H2S) can also react with formation water (H2O) and form Sulfuric Acid (H2SO4) or free Sulfur; which is another source of corrosion product affecting the installed ESP system. As part of continuous improvement in equipment's reliability, several Dismantle inspection and failure analysis (DIFA) were done for ESP premature failures to identify the root causes along with the recommendations and forward plan to enhance ESP run life. The results of these DIFAs indicated a common root cause of ESP failures are related to Hydrogen Sulfide (H2S) presence and well fluids entering the ESP internal components. In particular, the packer penetrator, Motor-Lead-Extension (MLE), and the pothead interface were found to be the main reasons. Consequently, an effort was rolled out to control the Hydrogen Sulfide (H2S) presences at these three locations in order to maintain the ESP reliability and prolong its run life. This presented paper will demonstrate the methodologies and fit-to-purpose ESP design that contributed in extending the ESP run life in a high Hydrogen Sulfide (H2S) pressure fields. Also, a captivated practice along with related technologies have been adapted for the sour environment which resulted in sustaining the ESP run life.

Electrical Submersible Pumps (ESPs) are widely deployed means of artificial lift methods as they are versatile and adaptable to various well conditions. However, ESP completions have significant installation and operational costs. This paper will address an in-house developed ESP Operational Excellence (OE) initiative that translated into longer run life, increased reliability, and sustained oil production. The objective of this initiative is to unleash the ESPs’ full potentials, and provide structured approach to measure its performance and sustain improvements. The Operational Excellence model is based on asset management cycle of Plan, Do, Check, and Adjust. Production Engineering Team with the support of Artificial Lift Specialty identified two major focus areas; ESP turnaround, and premature failure, as OE candidates. Each focus area was examined in two parts: 1) review of current performance, and 2) review of processes implementation. The current performance was thoroughly reviewed and immediate actions were incorporated and tracked by Key Performance Indicators (KPIs) and driven by results and improvements. In parallel, review of processes implementation was conducted to fine tune current procedure and enforce Best Practices (BPs). ESP turnaround time was significantly reduced through planning ahead required activities, desings, and equipement. This was achieved by setting agenda and streamlined communication with all concerned orginizations. ESP turnaround was done in 20% less days before OE. With the implementation of OE model, oil production was ensured in timely efficient manner without comprising quality as well HSE. The other focus area is premature failure. Once an ESP is properly designed, installed, and operated, the ESP performance is continuously monitored and maintained. The check part of the OE cycle comes into place when the ESP is confirmed failure. Then, the equipment is thoroughly checked using data collected from Dismantle & Inspection Failure Analysis (DIFA) process, with the aim of enhancing performance and deliverability. Based on the detailed investigation, the factors that affected the pump health are integrated and adjusted for the next ESP application. Through DIFA process management, quality assurance activities were conducted to ensure that lessons learned during operation and maintenance, as well as improvements to existing ESP designs are incorporated in new designs; to continuously improve ESP asset integrity and reliability. Therefore, corrective and preventive actions were implemented to resolve common factors that affect ESP performance, such as downhole electrical components including motors and pumps, seals, well conditions and human error during pump installations. By refining these factors, the ESP performance curve was improved and operational excellence was achieved. The implemented Operational Excellence model has shown its significance in optimizing process details from ESP design until operation, which consequently improved ESP run life, increased reliability and sustained oil production.