This paper will outline and discuss the processes involved from planning to conceptual design, detailed design, equipment preparation and onsite execution that has contributed to the successful offshore installation of Malaysia's first dual ESP system. It will also highlight the challenges and issues encountered throughout the project. The well was originally completed in 1989 as a single producer with gas lift. It is closed in 2004 due to high solid production. A workover operation was carried out in end of May 2011 to revive the well. The current producing zone was plugged and abandoned and the shallower producing interval is opened up and completed. Instead of continuing with the status-quo, gas lift strategy the well is completed with a Dual ESP system with bypass tubing, making it the first ever dual ESP installation in Malaysia.
Gas lift has been predominantly used as the main artificial lift strategy in the region. It's relatively ‘cheap’ resources and simple application has been the main driver for oil operator to continue using it as their preferred option. However as the water cut increases and lift gas supply become limited there is a need to have a look on the so called ‘commodity’ artificial lift application. ESP has been seen as one of the most attractive alternatives. The field's first conventional ESP installation with a backup gas lift system in 3 wells was installed in late 2008. In 2010 another ESP with pod configuration was installed. Ever since then, Bokor Project Management team has started to explore on the advancement of ESP system in order to find the optimized design for Bokor Field. However there are several challenges to be addressed.
Justification to use a dual ESP system rather than a conventional gas lift system or single ESP configurations that has been done previously in 4 other wells, especially in term of initial cost.
The complex installation of a dual ESP system complete with bypass tubing and gas lift backup system which is not a common practice in the area
Design considerations and challenges for a successful installation. A complete design of a dual ESP for well specific application.
Installation challenges of Dual ESP system with bypass tubing and backup gas lift system utilizing a hydraulic workover unit which has limited handling capacity compared to a conventional rig.
Surface requirement and limitations of the existing facility for ESP commissioning and startup.
Among others, the paper will discuss on the justification and technical solutions that have been proposed for the installation of the dual ESP system in Bokor field. Lesson learned from the project is also compiled in this paper for any future similar installation in the field