Novel Electric Submersible Pump Cable Operates in High H2S Production Environment

SPE Middle East Oil &Amp; Gas Show and Conference

Abdelaziz

et al. 2017

Electric submersible pumps (ESPs) are a widely used artificial lift technology. Conventional ESP systems provide power with a cable banded to the outside of the tubing. These systems have drawbacks in terms of installation speed and efficiency. To overcome these obstacles, a novel cabledeployed (CD) ESP system developed for use in a high hydrogen sulfide (H2S) production environment is a future solution. This paper focuses on the challenges, results, and lessons learned from the first field deployment in the world of a rigless high H2S, CDESP system. A metal jacketed power cable was a key enabler to the CDESP system. The metal jacketed power cable delivers the best protection for a H2S attack and provides a smooth outside diameter that could be gripped on and sealed. The cable had been tested to withstand H2S levels up to 15% and chloride levels in excess of 150,000 ppm with an expected service life in excess of 10 years. To overcome well control concerns, a vertical cable hanger spool (VCHS) was developed enabling the ESP cable to be terminated below the master valve. In addition to the surface termination of the cable, the VCHS provided hang off and production flow through capabilities. The CDESP system, using a specialized inverted ESP, required close integration between several equipment and service providers during the development of equipment and procedures to ensure success in the installation of the system. The system's initial deployment was in a benign onshore well that offered ample workspace for the various service providers to learn the unique aspects of this rigless deployment. Of particular importance, the interface between the service providers at the surface cable termination was critical to the successful installation. For this trial test, the well completion was changed from 4½-in. tubing to 7-in. tubing to accommodate the cabledeployed 562 series ESP. Lessons learned from this field trial will be incorporated into future trials of the technology. The goal of these future trials will be to deploy the technology in offshore H2S wells where high rig costs can be significantly reduced through the use of lower cost barge coupled with increased speed, efficiency, and ease of CDESP deployment.

Field Deployment of a Rigless Cable Deployed ESP Using a Vertical Wellhead

SPE Middle East Oil &Amp; Gas Show and Conference

Abdelaziz

et al. 2017

Field Deployment of a Rigless Cable-Deployed Electric Submersible Pump Using a Vertical Wellhead

SPE Production &Amp; Operations

Abdelaziz

et al. 2018

Summary Electric submersible pumps (ESPs) are a widely used artificial-lift technology. Conventional ESP systems provide power with a cable banded to the outside of the tubing. These systems have drawbacks in terms of installation speed and efficiency. To overcome these obstacles, a novel cable-deployed (CD) ESP system developed for use in a production environment with high hydrogen sulfide (H2S) content is presented as a future solution. This paper focuses on the challenges, results, and lessons learned from the first field deployment in the world of a rigless high-H2S CD-ESP system. A metal-jacketed power cable was a key enabler to the CD-ESP system. The metal-jacketed power cable delivers the best protection for an H2S attack and provides a smooth outside diameter that could be gripped on and sealed. The cable had been tested to withstand H2S levels up to 15% in the vapor phase and chloride levels in excess of 150,000 ppm, with an expected service life in excess of 10 years, derived from laboratory testing. To overcome well-control concerns, a vertical cable-hanger spool (VCHS) was developed to enable the ESP cable to be terminated below the master valve. In addition to the surface termination of the cable, the VCHS provided hang-off and production-flow-through capabilities. The CD-ESP system, using a specialized inverted ESP, required close integration between several equipment and service providers during the development of equipment and procedures to ensure success in the installation of the system. The system's initial deployment was in a benign onshore well that offered ample workspace for the various service providers to learn the unique aspects of this rigless deployment. The interface between the service providers at the surface-cable termination was critical to the successful installation. For this trial test, the well completion was changed from 4½-in. tubing to 7-in. tubing to accommodate the CD 562 Series ESP. Lessons learned from this field trial will be incorporated into future trials of the technology. The goal of these future trials will be to deploy the technology in offshore H2S wells where high rig costs can be significantly reduced by using a lower-cost barge coupled with increased speed, efficiency, and ease of CD-ESP deployment.

Advancing Electric Submersible Pump Alternative Deployment Technology: An Overview and Case Study

SPE Annual Technical Conference and Exhibition

Windiarto

et al. 2017

Traditional electric submersible pump (ESP) systems have drawbacks in terms of installation speed and efficiency. To overcome these obstacles, some alternatively deployed ESP systems, including the one selected, are deployed into the production tubing, subjecting the system to the properties of the produced fluids. A novel rigless-deployed ESP system developed for use in high hydrogen sulfide (H2S)/high chloride production environment is a solution. An initial step reviewed and ranked competing alternate deployment ESP technologies available in industry along with several new concepts. A new approach to alternate deployment technology was selected. Rigorous testing was conducted to qualify the selected technology and materials for harsh production environments. Testing included a modified NACE TM0175 test due to the processing of the power cable design. Integration testing was performed in a test well to validate the integrity and deployment of the new system prior to field deployment of the rigless-deployed ESP system. The cable deployed ESP (CD ESP) employs a fit-for-purpose power cable that incorporates an exterior metal jacket, providing strength to deploy ESPs thousands of feet into the well. The TransCoil system's power cable outside diameter is roughly 40% smaller than current 2-3/8-in cable-internal, coiled-tubing (CICT) systems; therefore, it is lighter in weight and reduces tubing pressure losses compared to previous products. Product reliability is enhanced as the power cable is fabricated in a continuous manufacturing and inspection process on a factory floor. The tightly controlled manufacturing process significantly improves the product quality over CT cable systems. The power cable can be fabricated from different metallurgies ranging from carbon steel to nickel allow based on the well requirements. A nickel alloy power cable laboratory qualified to 15% H2S and 150,000 ppm chlorides was field deployed in an onshore well and demonstrated an installation time reduction of nearly 50% over rig-deployed systems. A power cable rigless-deployed ESP system solves many of the challenges that currently plague the industry including operational efficiency, rapid replacement, and product reliability in wells in harsh environments worldwide. The power cable rigless-deployed ESP system has, in particular, the opportunity to transform ESP replacement in offshore wells.