Summary
Firebag SAGD (Steam Assisted Gravity Drainage) asset has shown steady growth in well count, with ESPs (Electric Submersible pumps) as the primary mode of lift. In the high temperature environment, robust design and material selections are important considerations to achieve long run lives. However, key constraints such as economic conditions, increasing well count and changing well performance require solutions that optimize cost and reliability. This is critical to offering flexibility in approaches to addressing the top failure modes of the ESPs at Firebag. The paper discusses Suncor's efforts to prioritize not only prevention, but also management of the key failure modes to optimize reliability and cost in the SAGD environment by developing a better understanding of the problem. This includes novel approaches to treat an installed ESP as a repairable system through cable-only replacement (non-serviced motor reruns) and re-landing an ESP as-is when a cable failure is located close to the surface. Risk mitigation is done primarily through data analysis of teardown information and statistical survivability rates at both the system and sub-component level. This risk mitigation includes building the foundation for information gathering through a clear teardown process on every ESP pulled from service, gaining insights on failures, challenging traditional assumptions based on the data obtained, and driving focused trials and initiatives.
