ESP Design Improvements Associated with Downhole Slotted Gravitational Filter and Downhole Chemical Treatment Prolong ESPs Run Life in Western Desert of Egypt: Case Study

Abstract

Abstract Electrical submersible pumps (ESPs) have become the most efficient and reliable artificial-lift method worldwide. One of the most common causes of premature failure in ESP systems is erosion or clogging from sand and solids in the reservoir fluids. These solids generate wear in pump stages, reduce its lifting efficiency and increase frequency of well interventions. Consequently, these ESP failures require reliable solutions to enhance the performance and prolong the run life of the ESP system. In subject field inside the Western Desert of Egypt, several wells were experiencing pre-mature pump failures because of plugging, sand erosion on pump stages, and broken shafts. Five previous ESPs had been run in three offset wells, all of them had failed after average run life of 150 days. A detailed discussion with a technology provider and reference case studies come up with an integrated approach utilizing ESP Design improvements including Reliable Abrasion-Resistant Pumps and upgraded shaft material. The ESP system also incorporates a downhole slotted gravitational sand filter and continuous downhole chemical injection. The slotted gravitational Sand filter is an innovative solution to take control of downhole sand problems utilizing gravitational force and filtration process. It prevents particles 100 microns and larger in size from entering and damaging the ESP system. In SWM field, Hydrocarbon recovery is mainly from one deep reservoir characterized by a high-pressure high-temperature (HPHT) environment at depths around 16000 ft, average pressure of nearly 6400 psi, temperature reaching 310 F, and considerable amounts of CO2 and H2S. The pump was set at 10000 ft to produce 2000 BPD with wellhead pressure not less than 1000 psi. In spite of, these challenging operating conditions and high withdrawal requirements, the newly designed system was capable to maintain stable ESP performance in two offset wells for more than 14 months and still ESPs are running. This solution showed significant improvement in overall system reliability and performance. Specifically, it helped to economically produce from the wells, reduce deferred production and downtime resulting from frequent pump failures, and maximize their recoverable reserves. In addition, it increased the capability of being replicated in other wells with high sand production. This paper will provide a detailed completion design process to create a robust ESP system that fits with challenging wellbore conditions in which sand production and erosion are growing concerns. This study starts from initial installations, subsequent well interventions, equipment Dismantle Inspection and Failure Analysis (DIFA), ESP configuration enhancements, and finally reaches field application performance data in which the new completion design was successfully implemented to extend ESP run life.