Mass Implementation of Ultrahigh-Speed ESP Systems Increases Reliability, Savings
Authors: Carpenter Chris 
Published: February 2020

This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper SPE 194416, “World’s First Mass Implementation of Ultrahigh-Speed Electric Submersible Pump Systems in the Salym Group of Fields, Western Siberia, Russia,” by Anton Shakirov and Yaroslav Alexeev, Lex Submersible Pumps, and Alexander Gorlov, SPE, Salym Petroleum Development, prepared for the 2019 SPE Gulf Coast Section Electric Submersible Pumps Symposium, The Woodlands, Texas, 13–17 May. The paper has not been peer reviewed.

This paper presents the results of a 3-year project aimed at mass field implementation of ultrahigh-speed (UHS) electric submersible pump (ESP) systems in western Siberia. The project had a successful outcome, with more than 200 installations performed. The project was aimed at increasing the efficiency and safety of oil and gas production and reduction of total cost of ownership (TCO).

Background

The authors discuss the project as an endeavor of a joint venture developing the Salym group of oil fields. Since the beginning of asset development in 2003, ESP technology has been used as the primary artificial-lift method. Nearly 750 ESP systems are used at the time of writing, provided by three vendors.

Field Conditions. Salym reservoirs are found at 2100 to 2500 m true vertical depth (TVD). Downhole temperatures range between 80 and 100°C. Each of the Salym fields is typical for the region, experiencing gradual water-cut increase and flow-assurance challenges such as downhole inorganic scale deposition and various corrosion processes. Frequent debris from the unconsolidated near-wellbore zone and low inflows are recognized within the region historically as the greatest challenges facing ESP systems.

Technology Trials. Challenging production conditions and increasing operating expense led to the development of a technology study in 2014 focused on researching, testing, and evaluating the latest ESP technologies that could help reduce TCO. UHS ESP was selected among others for no-cure, no-pay performance evaluation in 2014 and 2015. Field-trial results were found to be much better than target-success criteria, specifically in terms of power consumption; UHS ESP systems consumed 40% less on average compared with standard (STD) ESP systems of an equivalent flow and head.

According to TCO analysis, UHS ESP technology lowered overall ESP-related costs by 30% (through power efficiency, reduced maintenance, and workover optimization and reduction of nonproductive time).

Project Work Flow, 2016–2018. Because of the compact design, wide operating range, and minimum on-site preparation requirements of UHS ESP systems, monthly delivery and return of equipment between the field base and the central repair facility was possible without a need to construct a field workshop. UHS ESP manufacturing and repairs were centralized in Kirov, 1750 km southwest of the Salym fields. Monthly delivery with a single 12-m-long truck can accommodate up to 30 downhole strings, fully assembled, full-string tested, and ready to run in hole. Dismantling, inspection, and failure analysis (DIFA) was scheduled on a monthly basis and corrective actions were finalized within 10 days of receipt of pulled equipment in the repair center.