This paper presents the results of a three-year project at Salym Petroleum Development (50:50 joint venture between Shell and GazPromNeft), aimed at mass field implementation of innovative Ultra-High-Speed (UHS) ESP Systems, with over 200 installs having been done. The project was targeted to produce oil and gas safely and efficiently and to reduce Total Cost of Ownership (TCO).
Based on the previous study , the key elements, identified to evaluate the technology performance include: equipment, services and operating costs, reliability, production and HSE optimization. Continuous analysis made during the project incorporated a few phases, with each phase followed by a detailed technical and economical assessment. Monitoring, analysis, and optimization methodologies are detailed in several case histories demonstrating principal outcomes of the technology implementation and pointing out its advantages vs counterparts in use as well as limitations and recommendations.
The results of the study proved high potential of Ultra-High-Speed ESP Systems to optimize production and to provide operational benefits under a range of production and well-fluid conditions.
Close study of project results revealed significant savings in power consumption by 40 % at an average, improved runlife in challenging operating conditions (20% increase over other ESP suppliers), and field operating efficiency, with installation time being reduced by 60 %.
The successful results have been achieved through the use of Ultra-High-Speed Permanent Magnet Motor operating in a speed range from 1,000 to 12,000 rpm. Wide speed control facilitates operational adaptation in changing conditions. Due to its high nameplate frequency (10,000 rpm) the system has shorter length allowing for flexible setting depth selection. Innovative design along with precise manufacturing techniques made the system tolerant to harsh environment, including solids, corrosive and gassy fluids.
As a result, UHS ESP Technology allowed for reducing TCO and improving business results in a safe and efficient manner.
The UHS ESP systems studied in this paper represent an innovative technology targeted to provide capital and operational savings. Project findings helped determine a target application range of the technology. The conclusions of this paper are intended to develop guidance for selection of an artificial lift technology in challenging operating conditions.