OMV Upstream
EuALF 2018
Maximize artificial lift
systems reliability due to
continuous in-house failure
analysis and optimization
Bernd Kometer
Michaela Hoy
Michael Nirtl
Aberdeen, 13. June 2018
2 | OMV Upstream, Kometer Bernd, 4 July 2018
Introduction
OMV Austria
Artificial lift systems
Failure analysis
Optimization
Sucker rod pump
Electrical submersible pump
Results
Summary
Agenda
3 | OMV Upstream, Kometer Bernd, 4 July 2018
Production ~28,000 boe/day
10% of the Austrian oil and gas demand
50 fields
600 employees
Technology center of OMV group
120 WI per year
IntroductionOMV Austria
700115
90
165
Oil wells
Gas wells
Water Injectors
Storage
4 | OMV Upstream, Kometer Bernd, 4 July 2018
IntroductionArtificial Lift Systems
0
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
10.000
0 500 1000 1500 2000 2500 3000
Pu
mp
/ In
sta
llatio
n s
ett
ing
de
pth
[ft
]
Gross production [bbl/d]
Depth vs. rate
SRP
Continous GL
Intermittent GL
ESP
Ref: ISBN 978-3-941721-86-9
5 | OMV Upstream, Kometer Bernd, 4 July 2018
Failure AnalysisInformation
Ref: SPE-190958-MS
6 | OMV Upstream, Kometer Bernd, 4 July 2018
Failure AnalysisDocumentation
Artificial Lift System
ALS Subsystem
Equipment
Cause
Primary Cause
Severe
Moderate
7 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization SRPEquipment
43%
19%
18%
11%
6%3%
SRP downhole pump
Valve
Barrel
Seating assembly
Plunger
Valve rod
On/Off tool
57%
29%
14%
SRP subsystem
SRP downhole pump
Tubing string
Sucker rod string
Ref: ISBN 978-3-941721-86-9
8 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization SRPEquipment and Cause
RCFARCFARCFA RCFA
Ref: SPE-190958-MS
9 | OMV Upstream, Kometer Bernd, 4 July 2018
OMV TECH Center & Lab & AC²T research
Barrel: Honing scratches in chromium layer as
starting point for corrosion
Plunger: Quality and thickness of spray metal
coating
Improved OMV Specification for SRP and
quality assurance by factory acceptance tests
Valve
Valve deformation main driver
No corrosion detected
No erosion by dispersed sand
No sand particles embedded
Optimization SRPRoot Cause Failure Analysis
Ref: SPE-190958-MS
10 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization SRPCustomization
Ref: SPE-190958-MS
11 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization ESPALS Subsystem
36%
29%
21%
7%
7%
ESP subsystem failure frequency
Motor
Gas separator
Pump
Cable
Intake
Ref: ISBN 978-3-941721-86-9
12 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization ESPEquipment and Condition Monitoring
primary cause
severe
moderate
0
1
2
3
4
bearing shaft housing
Gas Separator
Ref: ISBN 978-3-941721-86-9
13 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization ESPGas Separator
14 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization ESPEquipment and Condition Monitoring
primary causesevere
moderate
0
2
4
6
8
10
12
14
shaft bearing diffusers impeller housing
Pump
Ref: ISBN 978-3-941721-86-9
15 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization ESPPump
Ref: Schlumberger
16 | OMV Upstream, Kometer Bernd, 4 July 2018
Optimization ESPCustomization
Pump
Mixed flow
1 tungsten carbide bearing per ft
Compression pumps
Intake
Change from gas separator to intake
Tungsten carbide bearings
Protectors
Tandem protector with up to 6 seals
Motor
Single motor
Cable
Lead cable with factory spliced MLE
Ref: Schlumberger
17 | OMV Upstream, Kometer Bernd, 4 July 2018
ResultsSRP Downhole Pump - Failure Recurrence Index
0%
10%
20%
30%
40%
50%Barrel
On/Off tool
Plunger
Seatingassembly
Valve
Valve rod
SRP Downhole Pump
FRI 2015
FRI 2016
FRI 2017
Ref: SPE-190958-MS
18 | OMV Upstream, Kometer Bernd, 4 July 2018
ResultsSRP - Mean Time Between Failures
0
10
20
30
40
50
01.01.2016 01.04.2016 01.07.2016 01.10.2016 01.01.2017 01.04.2017 01.07.2017 01.10.2017
MT
BF
im
pro
vm
em
en
t [%
]
Normalized MTBF moving average
Ref: SPE-190958-MS
19 | OMV Upstream, Kometer Bernd, 4 July 2018
ResultsSRP - Life Cycle Cost
70%
75%
80%
85%
90%
95%
100%
105%
110%
115%
120%
0% 2% 4% 6% 8% 10% 12% 14% 16%
To
tal L
CC
an
d B
EP
Well intervention cost increase
Total life cycle cost and break even point analysis
Total LCC runlife increase 10% Total LCC runlife increase 50% BEP low oil
Ref: SPE-190958-MS
20 | OMV Upstream, Kometer Bernd, 4 July 2018
In-house failure analysis serves as the fundament for continuous
artificial lift system optimization
Quality assurance by factory acceptance tests at the pump
manufacturer and laboratory inspection of failed parts ensures high
quality of equipment
Root cause failure analysis is a vital method to mitigate severe and
recurring problems
Economics: Increase of runlife leads to a decreasing amount of well
interventions thereby decreasing life cycle costs
Shift from standardization to customization of equipment for specific
well conditions
Summary
21 | OMV Upstream, Kometer Bernd, 4 July 2018
SPE-190958-MS (August 2018)
SPE-185770-MS
ISBN 978-3-941721-86-9
API RP 11S1
API 11AX
References
22 | OMV Upstream, Kometer Bernd, 4 July 2018
This presentation is prepared in order to outline our expression of
interest. Nothing in this presentation shall be construed to create any
legally binding obligations on any of the parties. Neither party shall be
obligated to execute any agreement or otherwise enter into, complete or
affect any transaction in relation to this presentation.
All figures and information in this presentation are strictly confidential,
they are by no means binding and thus indicative only.
© 2017 OMV Aktiengesellschaft, all rights reserved, no reproduction
without our explicit consent.
Legal Disclaimer
23 | OMV Upstream, Kometer Bernd, 4 July 2018
OMV Exploration & Production
ContactBernd Kometer
EATTP-T Production Technology
OMV Austria Exploration & Production
Protteserstraße 40
2230 Gaenserndorf
Austria
www.omv.com
