An Effective Solution to Extend the ESP Run Life in Sour Fields

Abstract

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.