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

Abstract

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.