New Pillar of Mature Field Production Strategy: A Success Story of ESP Upsizing Pilot Project

Abstract

Abstract Electric Submersible Pump (ESP) upsizing project has historically an effective tool to optimize oil production. As a mature field, KS field currently was producing with average 97% water cut. Most of the ESPs installed in SK field were designed to produce 1,000 to 2,500 BLPD. Meanwhile, the potential maximum liquid rate of some wells is much higher than the current ESP rate, ranging from 8,000 to 17,000 BLPD. The oil production can then potentially be increased 3 to 5 times higher by upsizing the ESP. Hence, the objective of this study is to accelerate oil recovery from un-optimum oil well. This optimization can be achieved in 2 ways, either drill new big bore well or optimize existing well. By optimizing existing wells through ESP upsizing pilot project, we can save estimated USD 1.5 MM compared to drill a new well. The ESP upsizing project is planned into 3 phases; phase-1 pilot (2 wells), phase-2 implementation (8 wells) and phase-3 and phase-4 full-scale (33 wells). KS-XXX1 and KS-XXX2 were selected for the pilot project and upsized using ESP pump with recommended operating range 3,500 – 10,500 BLPD at 60Hz. The reservoir simulation, fractional flow evaluation, production network modelling, well performance and nodal analysis were conducted prior phase-1 execution to increase project confident level. To operate these high-rate wells, some improvements in electrical system, flowline safety devices and well test procedure are also required. Therefore, multidiscipline team was involved in this project. The pilot project phase-1 has successfully executed and currently producing 476 BOPD from initial rate 80 BOPD without significantly increasing of water cut. Estimated cumulative oil gain of these wells are 567 MBO. The successful phase-1 ESP upsizing will unlock the potency of phase-2, 3 and 4. Through maximizing liquid production and reducing number of active ESP wells, oil production is expected to increase with lower operating cost (by reducing well count). Estimated oil gain from full scale implementation is 4.93 MMBO. This paper will describe a production optimization in mature field by ESP upsizing. Increasing liquid production is established technology to improved oil recovery in mature reservoir. Application of upsizing in high water cut wells has been proven to improve production decline using low expenditure.