Copyright 1999, Society of Petroleum Engineers, Inc. This paper was prepared for presentation at the 1999 SPE Mid-Continent Operations Symposium, held in Oklahoma City, Oklahoma, March 28-31, 1999. This paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or members. Papers presented at SPE meetings are subject to publication review by Editorial Committees of the Society of Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

Abstract This paper is a follow-on to SPE 28694 (Ref. 180) which summarizes and categorizes ESP literature by a number of different topics. The intent is to list problems mentioned in various papers and a quick mention of the solutions, which are discussed in the given references. As mentioned in the previous reference, it is also an attempt to relate problems to various field conditions, however many of the field papers do not include a complete listing of field conditions, so to be able to do this from using the literature is often not possible. Introduction The first versions of this paper were compiled and presented in April 1991 and April 1992 at the SPE Gulfcoast ESP Workshops. Additionally, the most recent version was updated and presented as SPE Paper 28694 in September 1994. This edition includes papers and technical articles found or presented since the 1994 SPE paper.

This paper contains referenced categories of problems that have been encountered in field operations and the solutions that have been found to the problems. The discussion for each problem/solution set is brief, but serves as an index to the particular reference, where more detail can be found. In past papers, the discussion has been restricted to field cases. With this edition, articles that are tutorial in nature have been included. These papers may not be in the original context of field problem and solution presentations, but in most cases they do contain good technical information, which could reduce the potential of a field problem. Also, some field operational papers were not included if they presented identical information. This study was originally intended to be a review of the field cases and a summary of various failures

and their causes as a function of the conditions present. Since the publication of the first editions of these papers and a request to include the well and field conditions, it is still the exception for a given paper to list detailed field conditions. Once again, only a few contained sufficient field condition data, which would have allowed problems and solutions to be correlated to conditions.

The number of entries is some indication of where the interest is in many of the literature presentations. The following list of subjects has the number of entries listed beside the topic: Components: Pumps (5) Seal (1) Motors 8) Cable (6) Switchboard/vsd (14) Wellhead (1) Monitoring (11) ESP Applications: Harsh conditions (11) Gas (12) Heavy oil (11) Hi-temp (4) Power (6) Coil tubing (17) Horizontal wells (2) Downhole oil/water separation (9) Subsea (19) Unique configurations (7) Optimization Design (2) Optimize operations (17) Run lives (7) Misc-overall (9) Alternative Lift Studies ESPCP (9) Misc (4) New developments (4)

The above listing shows VSD’s, monitoring, problems with gas, heavy oil, and harsh conditions, use of coil tubing, downhole separation, overall optimization and use of ESPCP’s are of great interest. Subsea, coil tubing, and ESPCP

SPE 52159

ESP's: On and Offshore Problems and Solutions James F. Lea, Amoco RPM/EPTG, and John L. Bearden, Centrilift

J. F. LEA, J. L. BEARDEN SPE 52159 2

are newer areas of interest. Monitoring downhole conditions is considered more in expensive offshore installations. VSD’s have been around for a long time, but interest is still high related to transients and attempts to provide smooth power. The new concept of downhole oil/water separation has been referred to frequently. Harsh conditions, gas, and heavy oil are continuing obstacles to long run lives and proper design. ESP SYSTEM COMPONENTS Pumps are the first component highlighted. Compression pumps, hardened pumps, coated stages, synthetic impellers and high volume topics are addressed in Table 1.

Previous collections of literature showed a lot of discussion on multi-chamber seals used to extend run-lives. Although this practice continues, only one paper is shown in Table 2 from the literature.

The motor remains an expensive component of the ESP system. Tutorials, starting concerns, and topics related to cooling are referenced in Table 3.

Cable and splice failures are always addressed in efforts to achieve long run lives. A new entry reference is a heater cable used to solve problems of tubulars through permafrost zones or solidification in flowlines (See Table 4 for cable information).

A schematic of a typical one well VSD application is shown in Figure 1. Although VSD’s have been applied for some time, they remain an area of considerable interest. Comparisons of the various types of VSD’s are made, features of individual types are compared, compatibility with other components, motor heating, use with long reach wells, harmonics, and other subjects are referenced in Table 5

Table 6 has only one entry for wellheads although entries in other sections relate to wellheads..

Monitoring of downhole conditions is more common, especially in offshore expensive wells (Table 7). Monitoring of temperature, gas content of fluids and volumetric flow rate, vibration, dielectric content of motor fluids or seal leakage, and surface features to allow data recording continue to be subjects of interest. A view of the downhole completion details is shown in Figure 2 (from Reference 41) showing some downhole instrumentation used for monitoring.

ESP Application Problems Sand, scale, asphaltenes, corrosion and other harsh conditions will continue to present users of ESP systems with application problems shown in Table 8.

New developments are still surfacing, providing the user with new options to use ESP systems in gassy wells. New tests also better define and allow predictions on the effects of free gas on ESP performance. (See Table 9 for references on using ESP’s in gassy wells.)

The subject of heavy oil seems to be getting increased interest. Problems with heating, lower efficiency, wear, and general design concerns are all important in dealing with heavy oil. (See Table 10 for heavy oil concerns.)

Using ESP’s in high temperature is one of the industry’s

success stories in recent years (Table 11). In most applications, energy usage remains a high

operational cost item in the usage of ESPs. Work is still reported on the optimization of the equipment, both from an initial design and operating variables standpoint (Table 12).

ESP Applications

Use of coil tubing with ESP’s and in many other applications is becoming more common. ESP’s can be run on conventional coiled tubing with the power cable inside or outside the CT. Some CT is manufactured with the cable as an integral part of the CT, both protecting the cable , allowing for rapid deployment and retrieval of failed equipment, and allowing for live well intervention. This possibility of reduced workover costs makes the use and potential use of CT with ESP applications a popular subject (Table 13). See Figure 3, which illustrates some options when using CT with ESP’s.

A section on horizontal wells is shown in Table 14, but the use of ESP’s in inclined wells is also detailed in the Subsea section and other related topics.

Downhole oil/water separation (Table 15) is a new development, initiated by CFER and made available by ESP manufacturers. A schematic of the concept of the system is shown in Figure 4.

Subsea ESP installations (Table 16) compete with multiphase flow pumps and gaslift. Quite a number of references are presented. Figure 5 (from Ref. 132) shows the layout of an offshore ESP developed field, Figure 6 (from Ref. 132) shows some downhole completion details from a subsea ESP developed field. Figure 7 (from Ref. 137) shows an extended reach ESP completion including a “formation saver valve.”

Various unique completions including “dual” ESP completions, for both redundancy and additional lift, are referenced in Table 17.

ESP Optimization Table 18 lists a few items related to “design” only.

Optimization efforts usually result in cost effective results. Figure 8 (from Ref. 166) shows some failure concerns and percentages of failure types before a successful optimization effort was initiated. After the study, as can be seen if the reference is studied, failure concerns were reduced in frequency and in the number of types of failures occurring (Table 19).

Data on field results and how to manipulate data for useful conclusions are discussed in the references and Table 20. Table 21 lists miscellaneous overall subjects.

Alternative Lift Studies

Although not an ESP, the ESPCP uses many of the typical ESP system components. The advantages of the PCP pump (handles viscous oil, solids well, but not high temperature) are used in the ESPCP. Figure 9 shows some of the ESPCP configurations. Table 22 lists ESPCP concerns.

Table 23 lists some studies of alternate lift vs. ESP’s.

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 3

References 1. “Use of Compression Style Pumps to Handle Production

Variations in Maxus Ecuador Inc. Field Development”, C. Moreno, et al, SPE Gulf Coast ESP Workshop, May 1, 1996.

2. Coated Stages Improve ESP Runtime in the Howard-Glasscock Field of West Texas”, J. Howell, et al, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

3. “Stage Coating’s Influence on System Efficiency”, T. Lutz, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

4. “Low Cost Pumping Systems”, B. L. Wilson, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

5. “Development of a High Volume Pump System for Texaco’s Mariner Field”, S. Dover, et al, European ESP Roundtable, Feb 4-5, 1998.

6. “Seal Section Function and Application Considerations”, M. A. Swatek, et al, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

7. ESP Motor Starting”, D. Knox et al, SPE Gulf Coast ESP Workshop, May 1, 1996.

8. “Operation of ESP Systems Below the Perforations”, B. L. Wilson, et al, SPE Gulf Coast ESP Workshop, May 1, 1996.

9. Heat Transfer Between Heavy Oil Flow and Electrical Submersible Pump’s Motor”, R. Manzanilla, et al, SPE Gulf Coast ESP Workshop, May 1, 1997.

10. “ESP Motor Tests”, D. H. Cashmore, , SPE Gulf Coast ESP Workshop, Apr 29, 1998.

11. “ESP Motor Starting Torque Characteristics with and without a VSD”, T. Radcliff et al, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

12. “Flow Regime Effects on Downhole Motor Cooling”, Paul Skoczylas et al, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

13. “Fluid Recirculation System – An Overview”, D. Bell, et al, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

14. “Implementing Recirculation System Electrical Submersible Pump Operations in Gaines County Texas”, J. W. Knight, et al, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

15. “Cable Testing Technology Helps Manage ESP Cable Life”, G. Rocha, et al, Southwestern Petroleum Short Course, Apr 1994.

16. “Cable Tear Down Procedure and Results”, T. H. Wallace et al, SPE Gulf Coast ESP Workshop, Apr 26, 1995.

17. “Field Test Technology Relationships to Cable Quality”, Marcus Durham et al, IEEE Transactions on Industry Applications, Nov/Dec 1995.

18. “ESP Cables for Harsh Environments”, D. Neuroth, 4th European ESP Roundtable, Feb 6, 1996.

19. “Comparing Extruded Layers and Tapes in ESP Cables”, by D. Neuroth, SPE Gulf Coast ESP Workshop, May 1, 1996

20. Oil Well Heater Cable - A New Approach”, D. Neuroth, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

21. “Application, Control and Setup of VFD’s for ESP Applications in the Salt Creek Field Unit”, D. Henson et al, Southwestern Petroleum Short Course, Apr 19-20, 1995.

22. “Reduced Operating Harmonics on VSD Applications”, K. R. Packard, SPE Gulf Coast ESP Workshop, Apr 26, 1995

23. “Harmonic Problems on Wytch Farm Extended Reach Wells”, Y. Hepburn, SPE Gulf Coast ESP Workshop, Apr 29, 1996.

24. “Power Quality Survey for Canada’s Virginia Hills Oil Field”, M. Voytechek, SPE Gulf Coast ESP Workshop, Apr 29, 1996.

25. “Generator-Variable Speed Drive Interface Failure Investigations”, D. Shipp, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

26. Step and PWM Drives for ESP’s A Laboratory Comparison”,

T. Brinner et al, SPE Gulf Coast ESP Workshop, Apr 30, 1997. 27. “THD (Total harmonic distortion), the Effect on Electrical

Submersible Motors”, S. Breit, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

28. “VSD’s: Definitions Applications and Comparisons”, M. Leuthen et. al., SPE Gulf Coast ESP Workshop, Apr 30, 1997.

29. “The Effect of Variable Speed Drive Modulation Schemes on Motors”, B. Pelton, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

30. Medium Voltage Variable Frequency Drives with a Low Harmonic Distortion -A Field Test”, R. Lastra, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

31. “Methods to Reduce Electrical Stress in VSD Applications”, T. Brinner, , SPE Gulf Coast ESP Workshop, Apr 29, 1998.

32. “Testing a 900 HP ESP Pump with VSD on a 34,500 ft of Cable”, Y. Hepburn, et al, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

33. “Analysis of the Electrical Instability and Solutions During the Implementation of the ESP System on Ek-Alpha Platform”, J. P. Martinez, et al, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

34. “Power Quality Analysis for a West Texas Oil Field few by Adjustable Speed Drives”, by Shipp, D., SPE ESP Roundtable, Houston, TX, April 26, 1995.

35. “Wellhead Technology Saves Money”, Z. Hosler et al, Hart’s Oil & Gas World, Nov 1998.

36. “Application of Artificial Neural Networks to Performance Monitoring of ESP’s”, B. Hatamian, et al, Artificial Intelligence in the Petroleum Industry, International Conference, Lillehammer, Norway, Proc. 1995 ,11 pp.

37. “The Monitoring of ESP’s Through SCADA”, M. K. Whitaker et al, SPE Gulf Coast ESP Workshop, May 1, 1996.

38. “Water Sensors – A Progress Report”, R. Storey, SPE Gulf Coast ESP Workshop, May 1, 1996.

39. “Optimizing Artificial Lift Operations Through the Use of Wireless Conveyed Real Time Bottom Hole Data”, B. Campbell, et al, SPE Paper 36596, Oct 6, 1996

40. “Analysis of Surface and Subsurface Data Taken During ESP Pump Off “, M. M. Patterson, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

41. “Development of a Condition Monitoring and Protection Program for High Horsepower ESP Systems”, D. J. Cohen et al, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

42. “ Downhole Sensor Performance Summary”, T. Lutz, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

43. “Remote Monitoring, Control and Surveillance of ESP Wells”, C. L. Dunham, et al, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

44. “ESP Conditioning Monitoring at Wytch Farm”, D. King, 5th European ESP Roundtable, Feb 4, 1998.

45. “Uses of Reliable Downhole Monitoring in the Captain Field”, D. J. Cohen, , 5th European ESP Roundtable, Feb 4, 1998.

46. “Downhole ESP Instrumentation”, M. R. Berry, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

47. “ESP SCADA Experience in South Oman”, C. Norris, et al, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

48. “Increasing the Run Life of ESP’s’ in the Wimborne Field High H2S Environment”, T. P. Comeau, et al, SPE Gulf Coast ESP Workshop, Apr 26, 1995.

49. “Coated Stages to Eliminate Asphaltenes”, John Kohtala, Amoco Artificial Lift Forum, Sept 1, 1995.

50. “Analysis Technique to Quantify CO2 Corrosion

J. F. LEA, J. L. BEARDEN SPE 52159 4

Susceptibility”, B. Crutchfield, et al, SPE Gulf Coast ESP Workshop, May 1, 1996.

51. “Offshore Asphaltene and Wax Deposition: Problems and Solutions”, K. J. Leontaritis, World Oil, May 1996

52. “Reducing Asphaltene Deposition in ESP’s”, A. Peats, , SPE Gulf Coast ESP Workshop, May 1, 1996.

53. “Small Change in Scale Inhibitor Leads to Severely Plugged Pumps”, B. Lindros, SPE Gulf Coast ESP Workshop, May 1, 1996.

54. “Dealing with Harsh Pumping Conditions in the dos Cuadras Field, Offshore California”, R. J. Krupa, et al, SPE Gulf Coast ESP Workshop, Apr 30,1997.

55. “Downhole Desander Performance in the Long Beach Unit”, Randy Harris, SPE Gulf Coast ESP Workshop, Apr 30,1997.

56. “ESP Operation Problems in Vanyoganneft Field in Siberia, Russia”, Y. Berdnikov-Vanyoganneft, SPE Gulf Coast ESP Workshop, Apr 30,1997.

57. “ESP for Applications in High and Severe Sour Environment”, A. W. Limanowka, et al, SPE Gulf Coast ESP Workshop, Apr 30,1997.

58. “ESP’s in Chevron Canada’s Fox Creek BHL A Pool: The Operational Challenge”, S.G. Noonan, SPE Gulf Coast ESP Workshop, Apr 30,1997.

59. “Recycle System to Extend ESP Run Lives”, K. Kusumamulya, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

60. “Production with ESP’s in Gassy Wells”, B. L. Wilson, Southwestern Petroleum Short Course, Apr 1994.

61. “Gas Separation Efficiency in Electrical Submersible Pump Installations with Rotary Gas Separators”, S. R. Sambangi, Master of Science Thesis, 1994.

62. “An ESP System for High GOR Wells”, P. Kallas, SPE Gulf Coast ESP Workshop, Apr 26, 1995.

63. “New Design for Compact Liquid-Gas Partial Separation: Downhole and Surface Installations for Artificial Lift Applications”, J. S. Weingarten, et. al., SPE Paper 30637, Oct 22, 1995.

64. “Analysis of ESP Pump Performance in High Flow rate, High Free Gas Conditions”, P. Lawson, et. al., 4th European ESP Roundtable, Feb 6, 1996.

65. “Free Gas and A Submersible Centrifugal Pump- Application Guidelines”, K. Sheth et. al. , SPE Gulf Coast ESP Workshop, Feb 1, 1996.

66. “Downhole Gas/Water Separation, A JIP”, C. Mathews, Amoco Artificial Lift Forum, Aug 1996.

67. “Field Tests of a Decentralized Downhole Gas Separator”, J. N. McCoy, SPE Paper 36599, Oct 6, 1996.

68. “The Inverted Shroud as a Solution to Gas Slugging”, B. L. Wilson, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

69. “Gas Handling Centrifugal Pumps”, B. L. Wilson, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

70. “Successful Test of New ESP Technology for Lake of Maracaibo Gassy Oil Wells”, M. Castro, et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

71. “Submergible Pumping System Technology for Production Optimization in Gassy Well Conditions”, by Kallas, P., and Way, K., SPE ESP Roundtable, Houston, TX, May 26, 1995.

72. Numerical Simulation of the Gas-Liquid Flow in a Rotary Gas Separator by Lackner, et. al., ASME JERT, March 1998, Vol. 120, pp 41-48.

73. “Experience with ESP’s in Heavy Crude Oil (Boscan Field)”, L. L. Bortolin, SPE Paper 26986, Apr 27, 1994.

74. “Producing Extra Heavy Oil from the Orinoco Belt by ESP’s, A

Pilot Test”, R. Gonzalez et. al., SPE Paper 26987, Apr 27, 1994.

75. “Beta Field History: Submersible Pumps in Heavy Crude”, D. E. Carpenter, et. al., SPE Paper 29508, Apr 2, 1995.

76. “Modeling Field Performance of ESP Systems with Viscous Crude and Emulsions”, D. J. Cohen, SPE Gulf Coast ESP Workshop, Apr 26, 1995.

77. “Crude Effect – How ESP’s Cope with Viscous Crude”, M. Scruton, EurOil, June 1995.

78. “Gas Handling and Low API Crude Down Hole Pumping”, A. L. Esson, et. al., 4th European ESP Workshop, Feb 6, 1996.

79. “Influence of Increased Pump Frequency in the Production of the Orinoco Belt Foamy Extra Heavy Crude Oil”, R. Gonalez et. al., SPE Gulf Coast ESP Workshop, May 1, 1996.

80. “ESP Lab Test with Heavy Oil at Intevep’s Artificial Lift Simulator Facility”, S. Caicedo, et. al., SPE Gulf Coast ESP Workshop, May 1, 1997.

81. “Operating Electrical Submersible Pumps in Heavy Oil Fields”, D. Christmas, Heavy Oil Conference – Aberdeen Scotland, Sept 29, 1997.

82. “Production Technologies Applied in Heavy Crude Oil of the Orinoco Belt”, R. Gonzalez, Heavy Oil Conference – Aberdeen Scotland, Sept 29, 1997.

83. “Sizing and Selecting ESP for Heavy Crude Oil Applications”, C. Tovar A., et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

84. “Successful Lifting of Gassy, Abrasive, Heavy Oil”, B. S. Crutchfield, et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

85. “The Use of Downhole Submersible Pumps in a High Temperature Steam Flood “, M. C. Wood, et. al., SPE Paper 29507, Apr 2, 1995.

86. “Artificial Lift Use in Wolf Lake, Alberta High Temperature ESP Installation”, B. Thornton, et. al., Amoco Artificial Lift Forum, Sept 1, 1995.

87. “Electrical Submergible Pumps for Geothermal Applications”, S. Breit, Geothermal Pump Workshop, Mar 18, 1996

88. “ESP’s in Cyclic Steam Injection Wells”, R. Gonzalez, et. al., SPE Paper 39084, Aug 30, 1997.

89. “Research on Energy Balance Test of ESP”, Cui Zhen-hua Zhu Jun, SPE Paper 29511, Apr 2, 1995.

90. “Power Quality Analysis for a West Texas Oil Field Fed by Adjustable Speed Drives”, D. Shipp, SPE Gulf Coast ESP Workshop, Apr 25, 1995.

91. “ESP Motor Voltage Adjustment for Maximum Profits”, J. F. Lea, SPE Gulf Coast ESP Workshop, Apr 29, 1997.

92. “Electric Submersible Pump System Efficiency”, T. S. Lutz, SPE Gulf Coast ESP Workshop, Apr 29, 1997.

93. “ESP Power Cost Management Plan”, J. Liu, SPE Gulf Coast ESP Workshop, Apr 29, 1997.

94. “Energy Management in ESP Wells”, A. Simpson, 5th European ESP Roundtable, Feb 4, 1998.

95. “Development and Field Experience of a Coiled Tubing Deployed ESP Completion System”, J.J. Tovar, Drilling & Well Technology Conference – Aberdeen Scotland, Nov 22, 1994.

96. “ESP Deployment on Coiled Tubing with Internal Power Cable”, P. Head, 3rd International Conference & Exhibition on Coiled Tubing Technology: Operations, Services, Practices, Mar 13, 1995.

97. “Field Installation of CT ESP Completions”, J. J. Tovar, SPE Gulf Coast ESP Workshop, Apr 26, 1995.

98. “Interesting Past, Glittering Future”, A. Cambell, Offshore

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 5

Engineer, May 1995. 99. “Reel ESP Deployment”, Offshore Engineer, May 1995. 100. “Technical and Economic Considerations for CT Deployed ESP

Completions”, J. J. Tovar, 3rd Annual International Conference on Emerging Technology – Coiled Tubing – Horizontal Wells – Extended Reach & Multilaterals – Aberdeen Scotland, May 31, 1995.

101. “Field Installation Proves Coiled Tubing ESP Completions Successful”, J. J. Tovar, Petroleum Engineer International, June 1995.

102. “Coiled Tubing Riser for Subsea ESP Deployment”, P. Head, 4th European ESP Roundtable, Feb 6, 1996.

103. “Auk Coiled Tubing Deployed ESP “,4th European ESP Roundtable Feb 6, 1996.

104. “Application of ESP’s Deployed on Coiled Tubing”, R. Penny, 4th International Conference on Coiled Tubing Technology, Mar 4, 1996.

105. “Coil Tubing Deployed ESP on the Auk Platform”, D. W. Stewart, et. al., OTC Paper 8225, May 6, 1996.

106. Coiled Tubing Completions in PDO”, S. A. Hookani, et al, SPE Paper 36261, Oct 13, 1996.

107. “An Alternative Method for Deploying ESP’s in Offshore Environment”, P. Nepia, Offshore Mediterranean Conference & Exhibition, Mar 19, 1997.

108. “Power CT – Coiled Tubing Deployed ESP’s (using internal power cable)”, P. Head, 5th European Union Hydrocarbons Symposium, 1997.

109. “World’s First ESP Completions Deployed on New “Powered” Coil Tubing”, Petromin, Nov 1997.

110. “Coiled Tubing Operations Performed from a Vessel”, J. E. Pearson, et. al., SPE Paper 46049, Apr 15, 1998.

111. “Advances in Electro Coiled Tubing Deployed ESP Systems”, D. H. Neuroth, et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

112. “Converting the Yme Field from Conventional-Rig to Coiled-Tubing Operations”, A. Baklid, Journal Petroleum Technology, June 1998.

113. “Producer Uses ESP in Horizontal Well”, Y. S. Kirkwood, American Oil & Gas Reporter, June 1996 ( also SPE Gulf Coast ESP Workshop, May 1, 1996.).

114. “Successful Lift of Horizontal Wells in an Unconsolidated Reservoir”, J. S. Johnston, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

115. “Downhole Oil/Water Separation System-Field Cases and DOWS System Capabilities”, T. Collen, 5TH European ESP Roundtable, Feb 4, 1998.

116. “Downhole Water-Oil Separation and Water Reinjection Through Well Branches”, T. Kjos, et al, SPE Paper # 030518, Oct 22, 1995.

117. “Downhole Separation of Oil and Water “, J. F. Michelet, et al, 4TH European ESP Roundtable, Feb 6, 1996

118. “Downhole Oil/Water Separation Systems (AQWANOT) JIP”, S. C. Sloanki, et al, SPE Gulf Coast ESP Workshop, May 1, 1996.

119. “Joint Industry Development of the Downhole Oil Water Separation System – Field Case Study”, P. J. Schrenkel, et al, SPE Gulf Coast ESP Workshop, May 1, 1996.

120. “Application of Downhole Oil/Water Separation Systems in the Alliance Field”, C.M. Matthews, SPE Paper 35817, Jun 9, 1996.

121. “Exploiting Multiple Horizons: Downhole Oil/Water Separation”, Amoco Gas Well & Artificial Lift Forum, Aug

27, 1996 122. “Application of ESP Oil Water Separation System in the Swan

Hills Unit One Field-A Case Study”, A. Peats, SPE Paper 39079, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

123. “Downhole Oil/Water Separation Moves into High Gear”, B. R. Peachey, presented at the 48th Annual Tech. Mtg. of The Petroleum Society , Calgary, Alberta, Canada, June 8-11, 1997 Paper 97 – 91

124. “Completion Design for Downhole Water and Oil Separation and Invert Coning”, A. Loginov, SPE Paper 38829, Oct., 1997.

125. “Downhole Pumping in Brazil”, Application Feature, Sea Technology Magazine, Oct 1994.

126. “First Installation of an Electrical Submersible Pump in a Subsea Well”, J E. Mendonca, et. al., SPE Gulf Coast ESP Workshop, Apr 26, 1995.

127. “Horizontal Subsea Trees Allow Frequent Deepwater Workovers”, M. Krenek, Oil and Gas Journal, May 1995.

128. “Subsea Innovative Boosting Technologies on Deep Water Scenarios – Impacts and Demands”, E. F. Caetano, et. al., OTC Paper 7902, May 1, 1995.

129. “Design Considerations for ESP Subsea Horizontal Trees”, M. Pritchett, 4th European ESP Roundtable, Feb 4, 1996.

130. “Subsea ESP Electrical Connectors, Field Experience and Further Development”, by Tronic (co. name) 4th European ESP Roundtable, Feb 4, 1996.

131. “Visund; An Introduction to New Subsea Concepts and Integration Test”, P.O. Queseth, 4th European ESP Roundtable, Feb 4, 1996.

132. “Liuhua 11-1 Development – Downhole Completion Program with ESP’s and Wet-Mateable Electrical Connectors”, J. M. Rohloff, et. al., OTC Paper 8176, May 6, 1996.

133. “New Design of a Guideline-less Horizontal Tree for Deepwater ESP Wells”, L. A. Olijnik, et. al., OTC Paper 8062, May 6,1996.

134. “The Development of a Subsea Power Transmission System for Deep Water Boosting Applications”, C. A. Godinho, OTC Paper 8061, May 6, 1996.

135. “The Impact of Subsea Boosting on Deepwater Field Development”, O. J. S. Ribeiro, et. al., OTC Paper 8063, May 6, 1996.

136. “Horizontal Trees Come of Age”, Offshore Engineer, Aug 1996.

137. “Advances in the Completion of 8km Extended Reach ESP Wells”, J. Jariwala, et. al., SPE Paper 36579, Oct 6, 1996.

138. “Deepwater Installation of an ESP in Campos Basin, Brazil”, J. E. Mandonca, OTC Paper 8474, May 5, 1997.

139. “Subsea Electrical Submersible Pumps at Large Step-Out Distances”, A. Al-Mashgari, et. al., SPE Paper 38537, Sep 9, 1997.

140. “Gannet E ESP’s”, D. Christmas, Offshore International, 1997. 141. “Gannet E: The world’s Longest Subsea ESP Tie-Back”,

J. S. MacFarlane, SPE Paper 38534, Sep 9, 1997. 142. “Subsea Electrical Power Distribution System (SEPDIS)”,

N. A. Soelvik, 5th European ESP Roundtable, Feb 4, 1998. 143. “Shell Gambles on ESP for Long Gannet Step-Out”, S. Wilson,

Offshore, May 1998. 144. “New Packer Design Offers Completion Flexibility in Thermal

Completions, ESP, Downhole Monitoring Systems, and Annular Safety Systems: Case Histories”, P.M. White, et al, SPE Paper 27893, Mar 23, 1994.

145. “The Utilization of a Cable Deployed Pumping System – Gulf of Suez, Egypt”, G. Dublanko, et al, SPE Gulf Coast ESP

J. F. LEA, J. L. BEARDEN SPE 52159 6

Workshop, May 1, 1995. 146. “Dual ESP Completion to Reduce Well Service Costs in

Remote Areas”, A. Kamal, et al, Proceedings Indonesian Petroleum Association, 24th Annual Convention, Paper IPA95-2.3-094, Oct 1995.

147. “Application of a Unique Deepset Safety Valve Below an ESP in a Naturally Flowing Offshore Gulf of Mexico Well”, C. Middleton, et al, SPE Gulf Coast ESP Workshop, Apr 29, 1997.

148. “Combined Artificial Lift System – An Innovative Approach”, L. Saputelli, SPE Paper 339041, Aug 30, 1997,

149. “Case History: Multiple ESP Deployment”, D. Smith, 5th European ESP Roundtable, Feb 4, 1998.

150. “Dual ESP Production / Injection Well”, J. Davies, 5th European ESP Roundtable, Feb 4, 1998.

151. “Applicability of Published Pump Performance Curves to Live Crude Mixtures”, M. Berry, SPE Gulf Coast ESP Workshop, May 1, 1996.

152. “Select Which Gas Lift Wells Can Produce More With ESP’s”, J. F. Lea , et. al, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

153. ”A Case Study of the Use of Corrective Action Teams to Optimize on the Performance of a Water Injection System”, A. M. Al-Kindy, , 6th Abu Dhabi International Petroleum Exhibition & Conference, (ADSPE #42), Oct 16, 1994.

154. ”Optimized Electric Submersible Pumping to Extend Economic Oil Production in a High Water Cut Environment”, D. J. Galles, et. al., SPE Paper 29505, Apr 2, 1995.

155. HP in Yeman’s Masila Block”, Efrm Yildirim, SPE Gulf Coast ESP Workshop, Apr 26, 1995.

156. ”Chevron Alba N. Sea UK ESP Operations One Year On”, R. Gilbert, et. al., SPE Gulf Coast ESP Workshop, Apr 26, 1995.

157. ”Swan Hills Submersible Pump Synergy Effort: An Example in Co-operation”, T. Comeau, et. al., SPE Gulf Coast ESP Workshop, Apr 26, 1995.

158. ”ESP Run lift Maximization for the Xijiang Field Development”, W. R. Heuman, et. al., SPE Paper 29970, Nov 14, 1995.

159. ”Operational Reliability of Centrifugal Electric Pumps for Petroleum Extraction in Western Siberia”, Y. Mesenzhnik, Allerton Press, ISSN 0038-5379, 1995.

160. Texas ESP Operations Overview”, Keith Cheatham, Amoco Artificial Lift Forum, Aug 1995.

161. “ESP Operating Experiences in Yeman’s Masila Block”, D. Wilkie, SPE Gulf Coast ESP Workshop, May 1, 1996.

162. ”Joint Effort in Optimizing the Use of ESP’s in a Siberian Environment”, Mkkhail Stavsky, et. al., SPE Gulf Coast ESP Workshop, May 1, 1996.

163. ”Operating Experience of ESP’s in South Oman”, C. Norris, SPE Gulf Coast ESP Workshop, May 1, 1996.

164. ”High Volume Pilot ESP Installation in the AKAL Reservoir-Gulf of Mexico”, S. G. Almazo, et al, 5th European ESP Roundtable, Feb 4, 1998.

165. ”Statoil Experience with ESP at YME”, T. H. Berge, 5th European ESP Roundtable, Feb 4, 1998.

166. ”Technology Development in Pancanadian’s Cohasset Project”, L. Huskins, et. al., 5th European ESP Roundtable, Feb 4, 1998.

167. ”ARCO Indonesia ESP Operation, The Optimizations and Results”, Septo A. Sudiro, et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

168. ”Cost Reduction Benefits Utilizing Wide Range Pumps and Standard Sized Equipment”, R. Mounce, et al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

169. ”Design and Implementation of A Reliable and Flexible ESP System for the Tchatamba Development”, K. Fangmeier, et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

170. ”Series Boosting Techniques Achieve 1,200 to 2,000 Horsepower Electric Submersible Pump Deployment”, C. Moreno, et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

171. “The Application Experience of Electrical Submersible Pump (ESP) in Off-shore Oilfields, Bohai Bay, China”, L. Kuiyuan, SPE Paper 29952, Nov 14, 1995.

172. “BP ESP Run Lives: Summary of Field Conditions”, 4th European ESP Roundtable, Feb 6, 1996.

173. “Development of ESP System Life on Forties Field”, A. Robertson, 4th European ESP Roundtable, Feb 6, 1996.

174. “How Do You Measure Run Life”, E. Brookbank, SPE Gulf Coast ESP Workshop, May 1, 1996.

175. “Analysis of ESP Failure Data from the Northeastern Pole of the Campos Oil Basin”, L. F. Oliveira, et. al.SPE Gulf Coast ESP Workshop, Apr 30, 1997.

176. “Electrical Submersible Pump System Failure Analysis”, M. A. Swatek, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

177. “Estimating MTPB Using Survival Analysis Techniques”, R. Lastra, SPE Gulf Coast ESP Workshop, Apr 30, 1997.

178. “Submersible Pump Innovations Mean Lowered Operating Costs”, R. Lannom, et. al., The American Oil & Gas Reporter, Jun 1994.

179. “New and Expected Developments in Artificial Lift”, J. F. Lea, SPE Paper 27990, Aug 22, 1994.

180. “Electrical Submersible Pumps: On and Offshore Problems and Solutions”, J. F. Lea, et. al, SPE Paper 28694, Sep 1, 1994.

181. “Compendium of Electrical Submersible Pump Systems Testing Criteria”, M. Durham, et al, SPE Paper 29506, Apr 2, 1995.

182. “Production Logging Below Submersible Pumps - A New and Reliable Approach”, F. X. Budianto, Proceedings Indonesian Petroleum Association, 24th Annual Convention, Paper IPA95-2.3-135, Oct 1995.

183. “ESP Production Testing”, D. Christmas, 4th European ESP Roundtable, Feb 6, 1996.

184. “Innovative ESP Completions for Liverpool Bay Development”, D. Stewart, 4th European ESP Roundtable, Feb 6, 1996.

185. “Dewatering of Gas Wells with Electrical Submersible Pump Downward Water Injection”, A. C. Hadaway, et. al., SPE Gulf Coast Workshop, May 1, 1996.

186. “Electric Submersible Pumps for Oil Production in the Middle East”, R. Lannom, SPE Gulf Coast Workshop, May 1, 1996.

187. “Bottom-Drive Progressing Cavity Pumps in Horizontal Wells”, B. Karpuk, et. al., Amoco Artificial Lift Forum, Aug 1. 1995.

188. “Experience with Progressive Cavity Pumps Driven by ESP Motors”, J. Leibfreid, SPE Gulf Coast ESP Workshop, Apr 26, 1995.

189. “Progressive Cavity Pumps with ESP Motors – Update”, T. Lutz, SPE Gulf Coast ESP Workshop, Apr 27, 1996.

190. “Unexpected Advantages of the ESPCP that have Lowered Lifting Costs”, K. Cozzens, et al, SPE Gulf Coast ESP Workshop, Apr 27, 1996.

191. “Updated Field Case Studies on Application and Performance of Bottom Drive Progressing Cavity Pumps”, C. G. Haworth, SPE Gulf Coast ESP Workshop, Apr 29, 1997.

192. “Wireline Retrievable ES Progressive Cavity Pump”, T. Lutz, SPE Gulf Coast ESP Workshop, Apr 29, 1997.

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 7

193. “Operating Do’s and Don’ts for Progressive Cavity Electric Submersible Pumps”, J. S. Johnston, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

194. “Wireline Retrievable Progressing Cavity Electric Submergible Pumping System Updated Field Case Study”, J. Mann, et. al., SPE Gulf Coast ESP Workshop, Apr 29, 1998.

195. “High Volume Downhole Progressing Cavity Pumps in Viscous Applications with Electric Submersible Motors”, M. Delpassand, SPE Gulf Coast ESP Workshop, Apr 29, 1998.

196. “Economic Comparison of ESP vs. Hydraulic Lift in the Priobskoy Field in Siberia”, Hans Kol, et. al., SPE Gulf Coast ESP Workshop, Apr 26, 1995.

197. “Total System Cost Comparison (ESP vs. Beam Pump) in Amoco’s Northern Permian Basin Operating Area”, K. Cheatham, SPE Gulf Coast ESP Workshop, May 1, 1996.

198. “Artificial Lift Alternatives Offer Operators Options for Best Production at Low Cost”, R. Duey, Hart’s Oil & Gas World, Mar 1996.

199. “Multistage horizontal Centrifugal Pumping Systems vs. Positive Displacement Pumps for Offshore Oil Pipeline Service “, W. Bolin, , SPE Gulf Coast ESP Workshop, May 1, 1996.

200. “What’s New in Artificial Lift, Part 2”, J. F. Lea & H. W. Winkler, World Oil, May 1995.

201. “What’s New in Artificial Lift, Part 2”, J. F. Lea & H. W. Winkler, World Oil, May 1996.

202. “What’s New in Artificial Lift, Part 2”, J. F. Lea & H. W. Winkler, World Oil, May 1997.

203. “What’s New in Artificial Lift, Part 2”, J. F. Lea & H. W. Winkler, World Oil, May 1998.

J. F. LEA, J. L. BEARDEN SPE 52159 8

Table 1. PUMPS

Ref #ESP Yr Location Problem Solution 1 31 96 Ecuador Handling variations in H2O cut,

viscosity, pump range, & sand Used compression style pumps for the application

2 2 of 12 97 Texas Iron sulfide scale Used pumps with hardened radial bearings, compression stages, and coatings for erosion wear.

3 13 97 California Reduce electrical consumption Approx. 3% performance gain when 700 – 3,000 bpd pump stages were coated to reduce friction.

4 N/A 98 N/A Efficiency, scaling, & corrosion Synthetic impeller stages 5 1 98 N. Sea Maximize production for field

development economics Developed a pump to produce 15,000 – 40,000 bpd

Table 2. SEAL SECTION, EQUALIZER, PROTECTOR Ref #ESP Yr Location Problem Solution 6 ? 97 N/A Selection of proper motor protection options Application guideline

Table 3. MOTORS Ref #ESP Yr Location Problem Solution 7 ? 96 N/A Motor starting requirements for reliable

operation Tutorial & Guideline

8 2 96 N/A Proper motor cooling when setting below perforations

Two field cases of ESP w/ recirculating pump system set below perfs

9 ? 97 Venezuela Motor cooling in heavy oil application Theoretical model developed to simulate application

10 ? 98 N/A Motor performance Guide to engineering tests on motors 11 ? 98 N/A Motor starting torque characteristics Tutorial on motor starting characteristics with &

without VSD 12 ? 98 N/A Motor cooling Theoretical model to calculate motor cooling 13 3 98 Oklahoma Motor cooling Implemented the test of ESP’s w/ recirculation

systems set below perfs 14 2 98 Texas Motor cooling Tested ESP system with recirculation system set

below perfs

Table 4. CABLE Ref #ESP Yr Location Problem Solution 15 ? 94 West

Texas Cable failures Developed testing program which decreased cable

relate short runs 16 ? 95 N/A Cable failures Teardown evaluation guideline 17 ? 95 N/A Determining status of used cable Discusses methods & limitations of various

techniques 18 ? 96 N/A High temp & GOR, corrosion, &

deviated applications Selection guide & discussion

19 ? 96 N/A Gassy well application Extending cable life by adding protective coatings over conductor insulation.

20 ? 97 Alaska Production tubing hydrate formation in permafrost zone

Use of tubing mounted heater cable

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 9

Table 5. Switchboards/Variable Speed Drives

Ref #ESP Yr Location Problem Solution 21 N/A 95 Salt Creek

Field, TX How do you size VSD’s for field ESP applications? What are available controls and transformer tap settings?

Field examples are given to answer the problem questions and allow for flexibility in field operations.

22 N/A 95 N/A What type of drive provides reduced harmonics?

Tests and calculations promote the PWM drive over others.

23 N/A 96 Wytch Farms Extended reach wells with VSD’s experience harmonics.

Systems that produce more of a sinusoidal output are suggested.

24 12+ ?? Virginia Hills Field, Canada

ESP failures: power quality suspected. Team formed and recommended studies related to drive tune-ups, grounding, address harmonics, transformer resonance, etc.

25 N/A 97 N/A Failures due to incompatibility of generators and VSD’s

Paper shows need for guidelines on generator-VSD compatibility

26 N/A 97 N/A Is 6 step VSD or PWM drive best suited for ESP applications?

Laboratory tests with cable tests attached made to compare motor losses, transients, ringing, etc.

27 N/A 97 N/A What is the effect of harmonic distortion of power on motor components of an ESP?

Measurement and conclusions on motor heating are presented and discussed

28 N/A 97 N/A Information needed on definitions/applications/ comparisons of VSD’s

Present tutorial on VSD’s

29 N/A 98 N/A What are the effects of newer VSD switching schemes on both surface and submergible motors?

PWM is recommended over 6 step. If PWM has adjustable carrier frequency, the highest value should be used that does not excite cable resonance.

30 N/A 98 Cano Limon field in

Colombia

Is there alternative to conventional VSD technology to reduce harmonics?

Test results of a Medium Voltage Low Harmonic Variable Frequency Drive (LH VFD) are shown indicating improvements

31 N/A ?? N/A Are over-voltages and current oscillations a problem with VSD/ESP applications?

Several solutions with variations in VSD’s and VSD/filters at the surface are suggested.

32 1 98 Wytch Farm UK

Can VSD be applied with 900 hp motor and 34,500’ of cable

Tests prior to installation: Max torque, effects of LCM in pump, voltage and current waveforms and more.

33 26 98 Ek-Alpha platform, Mexico

Electrical instabilities found Generators, transformers, filters designed to work with VSDs’.

34 N/A ?? W. Texas What is the cause of failures reported on ESP wells with ASD’s?

Proper grounding, tuned ASD’s and some use of commutating reactors, reduced failures.

Table 6. WELLHEADS Ref #ESP Yr Location Problem Solution 35 N/A 98 Various What are advantages of horizontal well

surface wellhead? Details of horizontal surface wellhead system to allow ESP to be deployed on special CT string

J. F. LEA, J. L. BEARDEN SPE 52159 10

Table 7. Monitoring Ref #ESP Yr Location Problem Solution 36 2 ? N. Sea Performance monitoring of ESP

wells Demonstrated the use of Artificial Neural Networks (ANN) for analyzing and predicting ESP performance

37 22 96 S. Florida Monitoring of remote, highly productive wells

Describes the development and use of a SCADA system

38 19 96 Colorado Motor failures (burns) due to leakage of production fluids into the motor

Use of two types of sensors to detect water inside the motor for preventative maintenance, dryout vs burn.

39 1 96 Alberta, Canada Efficiency improvement & fluid production optimization

Testing of downhole telemetry tool to monitor and control operation of ESP with feedback loop

40 1 97 W. Texas Well pump off Tests to determine parameters which could determine or predict ESP pump off.

41

7 97

N. Sea, Captain Field

Protection of high horsepower, high flow rate, offshore ESP systems

Development of monitoring system ( downhole flow, pump head, motor temp) for protection & system optimization.

42 24 97 California, THUMS

Monitoring of downhole temp & pressure for ESP’s & ESPCP’s

Test evaluation of 3 types of instruments – reliability & cost effectiveness

43

220 97

Oman Management of ESP Systems Description of Shell’s Supervisory Submersible Pump Control (SSUB) for remote monitoring, control, & surveillance

44 37 98 U.K., Wytch Farms

ESP monitoring systems Description of 2 types of downhole gauges, including fiber optic communication line.

45 98 U.K, Captain Field

Describes ESP monitoring system System includes venturi, PIP and temperature, motor temperature and vibration measurements

46 N/A 98 N/A ESP Monitoring A review of all (20) the downhole monitoring packages

47 250 Oman ESP Monitoring experience Experience on system described in Reference 43

Table 8. HARSH CONDITIONS ( Sand, Scale, Corrosion ) Ref #ESP Yr Location Problem Solution 48 45 95 Canada H2S corrosion Testing of H2S scavengers internal to ESP equipment 49 26 95 Wyoming Asphaltene pump stage plugging Successful use of synthetic impellers in cast diffusers. 50 439 96 California CO2 corrosion Innovative analysis technique for identifying wells with

corrosion problems 51 N/A 96 N/A Asphaltene & Wax deposition Presents ideas & methodologies on how to predict,

diagnose, prevent, or mitigate problems from organic deposition.

52 1 96 Canada Pump plugging - Asphaltenes Coated stages provide reduced run time 53 46 96 California Scale plugging of pumps A change in scale inhibitor reinitiated scale problem 54 9 97 California Pumping of abrasive fluids Initiated use of modular abrasion resistant pumps 55 6 97 California Pumping of abrasive fluids Use of a downhole desander, sand separating device. 56 150 97 Siberia Sand, scale, & corrosion problems Developed improved design techniques 57 13 98 Canada H2S corrosion Discusses equipment with modified metallurgies and

its application 58 1 98 Canada 8% H2S & high temp application.

Cable failures w/ PWM VSD Modified equipment materials for downhole conditions. Attached filters to PWM VSD

59 440 98 Sumatra Calcium carbonate scaling of pump Inhibitor squeeze, motor shroud filled w/ scale inhibitor capsules, & continuous injection all failed. A inhibited production fluid recycling system was successful.

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 11

Table 9. GAS

Ref #ESP Yr Location Problem Solution 60 N/A 94 N/A Pumping gassy fluid Tutorial on handling gas w/ ESP 61 N/A 94 N/A Pumping gassy fluid Lab testing and experimental results on one manfac’s

rotary type separator. 62 N/A 95 N/A Pumping gassy fluid Development of a gas handling pump w/ special stage

designed in first section. 20 – 30% free gas by volume. 63 1 95 Alaska Pumping gassy fluid Development and field testing a downhole, static auger

(vortex) type separation system. Tested on a flowing well.

64 N/A 96 N. Sea Pumping gassy fluid Lab testing of a 20,000 bpd pump under 400 – 1,000 psi and up to 40% free gas by volume. Resulted in expansion of Turpin Correlation.

65 N/A 96 N/A Pumping gassy fluid Tutorial – Application guideline 66 N/A 96 N/A Pumping gassy fluid Discussion of JIP to investigate several novel

application configurations. 67 1 96 Texas Pumping gassy fluid Design of decentralized pumping (beam) system and

successful field test results. Should be applicable to an ESP system.

68 1 97 Canada Pumping gassy fluid Field test of an ESP w/ and inverted shroud system. 69 N/A 98 N/A Pumping gassy fluid Lab tests on a modified centrifugal stage which

showed improvement of gas handling. 70 1 98 Venezuela Pumping gassy fluid Testing of an ESP system w/ an Advanced Gas

Handler (AGH) pre-staging and rotary separator intake under field conditions.

71 1 95 Texas Pumping gassy fluid Field performance of gas handling pump (20-30% free gas) compared to lab results.

72 N/A 98 N/A Modeling rotary separator performance

A numerical model of the performance of a rotary gas separator is presented

Table 10. HEAVY OIL Ref #ESP Yr Location Problem Solution 73 10 94 Venezuela Production of 10 API crude ( 544 cp

at 180 deg F) ESP’s proved successful as lift means. Problems attributed to melting of synthetic impellers in pump

74 24 94 Venezuela Production of 9.2 API crude ( 238 cp at 137 deg F)

1,130 bopd @ 60 Hz w/o diluent Maximum production was 2,160 bopd w/ diluent mixture of 19 deg API.

75 55 95 California Production of 10 – 19 API crudes 30 – 500 cp @ 170 deg F

Discusses completion design & ESP sizing. Rate, Head, & BHP correction factors developed from field experience.

76

77

6 95 N. Sea Production of 19.7 API crudes 88 cp @ 87 deg F

Involved well appraisal testing. Attempted to evaluate ESP performance degradation. ESP created water in oil emulsions, but did not indicate significant degradation

78 N/A 96 N. Sea Production of gassy, viscous crude Lab tests on a hydraulic turbine driven centrifugal pump indicated good results on gassy, viscous fluid. For application in ref #75.

79 48 96 Venezuela Production of foamy, extra-heavy crude, 6 to 16 API, 140 to 2,100 cp @ 140 deg F

For max production: 40 – 45 Hz Frequency. Developed pump performance correction factors from field experience.

80 N/A 97 Venezuela Production of viscous crude Lab testing of centrifugal pumps and viscous crude w/ & w/o diluent to develop performance characteristics

81 90 97 Venezuela Production of 9.2 API crude ( 238 cp at 137 deg F)

Describes different technologies being utilized. ESP run life increased from 9 mos to 16 mos in 5 yrs. Experience w/ multiphase flowmeter.

82 N/A 97 N/A Production of viscous crude Tutorial on ESP’s & viscous crude. 83 1 97 Venezuela Production of viscous crude Design Tutorial w/ an actual field example for 12 API (

300 cp). 84 450 98 California Production of viscous crude w/

cycling & gas locking, high fluid levels.

Pump design utilizes large vane opening impellers w/ abrasion resistant technology w/ gas separators.

J. F. LEA, J. L. BEARDEN SPE 52159 12

Table 11. HIGH TEMPERATURE

Ref #ESP Yr Location Problem Solution 85 4 96 California Can ESP’s produce wells above

400F? 2 manufacturer’s ESP systems evaluated

85 1 ?? Wolf Lake , Alberta

Lift needed for viscous wells that are periodically steamed for stimulation

Hi temp ESP installation is presented. Other lift methods discussed.

87 1 96 Power plant

ESP needed for hot well applications REDA hot well equipment described. Case history presented

88 80 97 Venezuela ESP’s for hot and cold viscous production (9 API)

Use of ESP’s for cold viscous production and for cyclic steam production presented

Table 12. POWER Ref #ESP Yr Location Problem Solution 89 N/A 95 Daqing,

China Determine energy efficiency of all components of ESP

Tests are made to determine component efficiencies

90 ? 95 W. Texas Power system problems Power quality analysis covering harmonics, grounding, voltage transients, VSD application, & lightening.

91 N/A 97 N/A Determine motor voltage settings for max. profits (low cost, hi production)

Motor performance as function of voltage modeled under various loads

92 500 79 Thums How to measure field efficiencies Efficiencies from data show trends with production, VSD’s, equipment size, etc.

93 50 97 W. Texas How to reduce energy costs Plan enabling rapid power cost evaluation of ESP wells developed

94 N/A 98 Sub sea Manage energy to avoid heavy oil, wax, arrival temperature and total facilities required.

Careful design, consider insulated pipelines, use best software, etc.

Table 13. COILED TUBING DEPLOYMENT Ref #ESP Yr Location Problem Solution 95 N/A 94 N/A Alternate ESP deployment system Describes the EEC funded project for Coiled Tubing

deployment of ESP’s. 96 N/A 95 N/A Alternate ESP deployment system Technical & economic reasons for CT deployment 97

98

N/A 95 N/A Alternate ESP deployment system Describes main technical characteristics and cost implications of new CT deployment system

99 N/A 95 N/A Alternate ESP deployment system Discussion on composite CT 100 N/A 95 N/A Alternate ESP deployment system Short discussion of first CT deployed ESP system. 101 N/A 95 N/A Alternate ESP deployment system Discusses the equipment configuration & installation of

the first field test. 102 N/A 96 N/A Alternate ESP deployment system Presents the concept of reeled riser, subsea

intervention from a vessel. 103 104

1 96 Auk N. Sea

Alternate ESP deployment system Describes the first offshore CT deployed ESP system

105

106

4 96 N/A Alternate ESP deployment system Planning described for CT deployed ESP’s by ARCO in Qatar.

107 4 96 Oman Alternate ESP deployment system Evaluation of 3.5” CT deployed ESP systems. Technical success, economics equivalent to normal workover rig.

108 N/A 96 N/A Alternate ESP deployment system Discusses the theoretical merits of CT deployed ESP’s. Live well interventions & subsea applications.

109 4 97 Qatar Alternate ESP deployment system Describes the installation & start up of the first CT deployed ESP’s w/ power cable inside the CT.

110 N/A 97 N/A Alternate ESP deployment system Overview of justification, technicalities, considerations, & constraints for CT deployment from a vessel.

111 N/A 98 N/A Alternate ESP deployment system Describes the development & testing of a method of anchoring ESP power cable inside CT.

112 N/A 98 Norway Workover costs Formation damage

Plan for CT deployment for capability of live well intervention and reduction in workover costs.

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 13

Table 14. HORIZONTAL WELLS

Ref #ESP Yr Location Problem Solution 113 1 96 California Increase wellbore production with

ESP & horizontal wellbore Describes the well design for a horizontal ESP completion. Initial problems and startup

114 24 98 California Increase well productivity Recover bypassed oil

Describes the design process for ESP’s in horizontal, unconsolidated wellbores.

Table 15. DOWNHOLE OIL/WATER SEPARATION Ref #ESP Yr Location Problem Solution 115 17-39 98 Canada

USA other Minimize effects of excess water production

Application, discussion of the Aqwanot DOWS ( downhole oil/water separation presented

116 N/A 95 various Minimize effects of excess water production

Discussion of cyclonic downhole separation of oil/water

117 N/A ? various Minimize effects of excess water production “

Discussion of cyclonic downhole separation of oil/water

118 N/A 96 Canada Minimize effects of excess water production “

JIP for development of oil water separation system

119 N/A ? various Minimize effects of excess water production

JIP development of oil water separation system-field case study

120 1 96 Alliance Field

Canada

Minimize effects of excess water production

Use of AQWANOT system with field applications presented

121 N/A 96 various Reduce capital & operational costs Utilize: Downhole Oil/Water Separation Dual completion wells Dump floods Gas water separation & re-injection

122 1 97 Swan Hills Canada

Test feasibility of ESP designed to separate/inject/produce

Test results reported to increase oil and decrease water production

123 ? 97 Various Downhole separation of oil/water Use centrifugal separation for ESP and Pcp’s. Summary of CFER’s work and tests

124 N/A 97 various How ESP’s can be used to de-water gas wells and perform oil/water separation and injection

Field cases of HydroSep and other completion variations presented

J. F. LEA, J. L. BEARDEN SPE 52159 14

Table 16. SUBSEA

Ref #ESP Yr Location Problem Solution 125 1 94 Brazil Subsea installation Discussion on plans for first subsea ESP installation 126 1 95 Brazil Subsea installation Details of subsea ESP installation in Oct 1994 in 90m

of water. 127 21 95 S. China

Sea SubSea workovers Horizontal tree allows easy access for installation &

retrieval. 128 N/A 95 Brazil Deepwater production Discusses PetroBras plans for subsea ESP production

wells, separation systems, & multiphase flow pumping systems.

129 N/A 96 N/A Subsea tree access & reliability Presentation on a subsea horizontal tree design. 130 2 96 Brazil

S China Sea

Wet-matable electrical connectors Discussion on experience with wet-matable connectors in ESP applications

131 N/A 96 Norway Marginal reservoir, floating production facility, maximize sea bed usage

Development plans for subsea installations.

132 N/A 96 S. China Sea

Subsea installation Planning discussion on first subsea ESP installation in S. China Sea

133 1 96 Brazil Diverless subsea tree intervention Design & development of guideless horizontal tree. 134 N/A 96 Brazil Subsea electrical power Design & development plans for subsea transformers,

cable, & variable speed drives for 1000 ft water depths.

135 N/A 96 Brazil Subsea boosting Discussion on the impact subsea boosting will have on deepwater developments

136 7 96 Gulf of Mexico

U.K.

Subsea horizontal tree Development & installation of subsea trees

137 9 96 U.K. Production in sensitive area Extended reach wells versus platform in sensitive nature area. Max TMD is 8,035m.

138 1 97 Brazil Subsea installation Report update on the 2 year run for the first subsea installation.

139 N/A 97 N. Sea Marginal reservoir development Discussion on technical issues related to operation of ESP’s on long cable lengths

140 141

N/A 97 N. Sea Marginal reservoir development Discussion of plans for ESP installation on Shell’s Gannet E.

142 N/A 98 N. Sea Subsea electrical power Project status update on SEPDIS, installation of all electrical gear on sea bed.

143 1 98 N. Sea Short update on the installation & startup of the first ESP on Shell Gannet E (See 134-5)

Table 17. Unique Configurations Ref #ESP Yr Location Problem Solution 144 N/A 94 N/A Limitation on packer use Design & field test a variable bore packer. Shorter than

conventional multi-bore packers. 145 4 95 Egypt Workover cost, production downtime Describes the design and deployment of ESP systems

on cable. 146 2 95 Indonesia Production downtime, remote sit

access Successful deployment of dual ESP systems. 1 primary and 1 backup. Allows for orderly workover scheduling.

147 1 97 Gulf of Mexico

Well control, formation damage Utilized a surface controlled sub-surface safety valve.

148 N/A 97 Venezuela Efficiency improvement in gassy wells

Combined configuration of ESP and gas lift system to minimize total lifting costs.

149 N/A 98 Venezuela High water cut Utilize a dual ESP system to Control the water cone, produce independently from 2 different zones, increase production when horsepower limited.

150 1 98 U.K. Water disposal Completion design to have tubular production & annular water disposal thru a cross-over packer in the same wellbore.

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 15

Table 18. DESIGN

Ref #ESP Yr Location Problem Solution 151 N/A 96 N/A Pump performance corrections Testing of ESP’s on 14, 20,31, & 39 API crudes w/

water and gas. 152 N/A 97 N/A Application design Method for determining the application boundary

between Gas Lift & ESP’s.

Table 19. Optimize Operations Ref #ESP Yr Location Problem Solution 153 42 94 Abu Dhabi Optimize operations Use of CAT (corrective action team) to make

recommendations 154 ? 95 Unitah

Basin High water cut, need to reduce electrical power demand

Increase flow line diameter, install capacitor bank, re-space wells, proper designs, analyze teardowns, 3 chamb seal, etc

155 10 97 Yemen Need high volume, hi HP lift Use of 750 HP units have paid out in matter of weeks 156 23 95 Alba Field Improve sizing/selection, handling,

installation, operations, troubleshooting

Standardize, direct shipping, reduce protection devices, clean wells, use monitoring devices

157 377 95 Swan Hills Work cooperatively with groups responsible for ESP operations

Cable repair, location of operators, testing, inventory sharing, negotiate with power companies, etc.

158 95 S. China Sea

Apply Quality Control Planning, design, installation, use of teamwork, etc. overview

159 ? 94 W. Siberia Short run lives of CIS ESP’s Should seal stator windings, use heat stable cables, prepare wells

160 178 95 W. Texas Optimize operations Reduce redundant work, standardize eqpt., alliance, calc. System cost

161 55 96 Yemen Improve operations with VSD’s, motors, sand, cable maintenance, teardown, logistics

410 days run life, rebuilds costlier than new, 25% consignment excess needed

162 150 96 Siberia Low temp, short run lives in similar applications

Review application, program to size, install and maintain prior to installation of first well

163 145 96 Oman Emulsions, hi viscosity Good results achieved, better expected with SCADA 164 1 97 Akal

Resvr, Mex

Need high volume , 10,000 bpd production. Free gas present

Used high volume pump with AGH. Achieved more than gaslift but less than design

165 5 98 YME, UK Minimize workover costs, avoid resv. Damage during workover, water production, perm contrasts

Plan to use monobases well design, use CT ESP’s, use CT drilling through completion

166 12 98 Nova Scotia

Sand, short run lives Dual ESP’s for immediate use after failure of one unit

167 120 98 Indonesia Improve performance Use of ARA pumps, premium cable, double bag protectors, hi temp motors, gas separators, mix matching, cable reconditioning

168 30 98 N. Mex. Achieve cost reduction Standardize, inventory reduction, Immediate use, re-rate for load/temperature

169 2 98 Offshr, Gabon

Coordinate design, sizing, planning, deliverability of clean power, etc

Perf with ESP out of well, have spares, test in advance and have results for previous units for 1 year, use bands, design for clean power, etc.

170 3 97 Ecuador Need high volumes Use series boosting to get 20,000 bpd with 1200-2000 hp. Higher values planned.

J. F. LEA, J. L. BEARDEN SPE 52159 16

Table 20. RUN LIFE

Ref #ESP Yr Location Problem Solution 171 ? Offshore

China 1. Run life Match ESP system to well productivity, establish

diagnostic technique, maintain standbys, & strengthen QC.

172 ? 96 N. Sea Summary of Wytch Farm, Forties, Beatrice and Milne Point run lives

Data presented

173 ? 96 N. Sea Hot, CO2, erosive, stop/start Team, new motors, ARA pumps, larger systems, increased sand production

174 N/A 96 N/A How to measure run life? Develop MTBF program 175 34-

110 97 Campos

Basin Infant mortality failures, manufacturer differences in run lives

Installation main infant mortality cause. New and used equipment affected by infant mortality

176 N/A 97 N/A Determine system failure analysis Collect evidence, determine root cause of failure 177 N/A 97 Cano

Limon Field

How to estimate MTBF Survival analysis compared to direct estimation and Poisson pure death process

Table 21. MISCELLANEOUS - OVERALL Ref #ESP Yr Location Problem Solution 178 N/A ? N/A List new developments New features for ESP components are detailed 179 N/A 94 N/A List new developments in artificial lift New and needed developments for Beam, PC, ESP,

Hydraulic and other lift presented 180 N/A 94 N/A Learn from publications prevalent

problems and their solutions Problems and solutions presented and categorized from literature

181 N/A 95 N/A Compile list of ESP testing criteria from industry sources

References and examples on testing criteria for various areas of ESP testing presented

182 7 95 Sumatra Production log below ESP’s Team has developed reliable method to log be low ESP’s

183 N/A 96 N. Sea and other

Details require attention before ESP drill stem testing

Testing with ESP’s over-viewed. Only method of testing some heavy oil reservoirs at high rate?

184 2-6 96 Liverpool Bay, N. Sea

Innovative designs planned for offshore wells

Details of using Horizontal Trees and a Fluid Loss Device with completion sequence presented

185 96 Krider field , TX

Need to inject water so gas wells can flow

Use of downward injecting ESP’s to “de-water” gas wells presented.

186 ~75 ?? Saudi Arabia

Need for two company agreement to supply ESP’s for middle East location.

Partnership approach to planning, use of new technology, service, testing, etc for new area

Table 22. ESPCP Ref #ESPCP Yr Location Problem Solution 187 5 95 Canada Heavy oil & sand, rod breaks,

deviated well Field tests on ESP motor driven PC pumps

188 5 95 California Heavy oil & sand, rod breaks, deviated well

Field test data on ESPCP trials

189 10 96 California Heavy oil & sand, deviated wells. Successful where conditions limit ESP runs to less than 400 days. Economics are still questionable.

190 8 97 Various Heavy oil & sand, deviated wells. Case study on the economics of 8 different wells with ESPCP’s.

191 5 97 Canada Surface drive PC’s in deviated wells, reliability

5 case studies of successful applications.

192

193

1 97 California Premature PC pump failure on ESPCP systems

Development & testing of wireline retrievable PC pump system. Tubing hung motor & seal.

194 5 98 California Heavy oil & sand, deviated wells. Discusses operational experience with ESPCP’s 195 N/A 98 N/A High volume viscous production Design of a high volume, multi-lobe PC pump for

ESPCP systems.

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 17

Table 23. LIFT ALTERNATIVES Ref #ESP Yr Location Problem Solution 196 N/A 95 Siberia

field is studied

Which of ESP vs. Hydraulic is more suited for pad development

Economic study suggests when certain methods of list should be used.

197 355 96 W. Texas What conditions is use of ESP’s more economical than using beam?

Depth and rates established as to when to use ESP vs. Beam Pump considering total cost

198 N/A 96 N/A When to use Beam/Long Stroke/ESP/Plunger lift/PCP/ Hydraulics

Discussion of merits of various methods of lift

199 N/A 96 N/A Is multi-stage centrifugal or positive displacement pump best for offshore pipeline service?

Details of each system presented.

J. F. LEA, J. L. BEARDEN SPE 52159 18

Figure 1: Typical VSD Layout (from Reference 21).

Figure 2: Completion below packer in Captain field showing instrumentation and other features (from Reference 41).

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 19

Figure 3: Coil Tubing Options: (a) Standard installation with cable banded to tubing, (b) CT with cable inside, (c) inverted unit with cable banded, and (d) inverted unit with cable manufactured inside the CT. Ref (111)

J. F. LEA, J. L. BEARDEN SPE 52159 20

Figure 4: Schematic of downhole oil/water separation unit (i.e., AQWANOT, DHOWS, initiated by CFER) from Reference 123.

Figure 5: Schematic of offshore Liuhua installation (from Reference 132).

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 21

Figure 6: Downhole Subsea Completion Details: S. V., ESP, Packer, etc. (from Reference 132).

J. F. LEA, J. L. BEARDEN SPE 52159 22

Figure 7: Extended reach installation showing formation saver valve (from Reference 137).

Figure 8: Summary of failures present before an optimization study was initiated from Reference 166. After the study and reductions of failures, failure concerns are reduced to fewer concerns as can be seen in the reference.

SPE 52159 ESP'S: ON AND OFFSHORE PROBLEMS AND SOLUTIONS 23

Figure 9: Conventional ESPPC, through-tubing-conveyed ESPPC, coiled tubing ESP (References 199-194, 203).