Summer 2017
THE SAUDI ARAMCO JOURNAL OF TECHNOLOGYA quarterly publication of the Saudi Arabian Oil Company
Saudi AramcoJournal of TechnologyField Deployment of a Rigless, Cable Deployed ESP Using a Vertical Wellheadsee page 2
Offshore Drilling Operation Time Optimization Using PDC Bit Shear Cap Technologysee page 36
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Omar S. Al-Husaini General Manager, Drilling & Workover Operations
Abdul Hameed A. Al-Rushaid Chief Drilling Engineer
Nabilah M. Tunisi Chief Engineer
Ammar A. NahwiManager, Research and Development Center
Ali A. MeshariManager, EXPEC ARC
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EDITOR
William E. BradshawThe Saudi Aramco Journal of Technology C-11B, Room AN-1080North Admin Building #175Dhahran 31311, KSATel: +966-013-876-0498E-mail: [email protected]
Unsolicited articles will be returned only when accompanied by a self-addressed envelope.
Amin NasserPresident & CEO, Saudi Aramco
Nasser A. Al-NafiseeVice President, Corporate Affairs
Abdulla I. Al-IsaGeneral Manager, Public Affairs
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Richard E. Doughty
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ISSN 1319-2388.
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EDITORIAL ADVISORS
Ibraheem M. AssaadanVice President, Exploration
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Khalid M. Al-Abdulqader General Manager, Unconventional Resources
On the Cover
Alternate deployment methods for electric submersible pumps (ESPs)
reduce well intervention cost and production deferral by decreasing the
use of workover rigs. Saudi Aramcos high hydrogen sulfide (H2S) cable
deployed ESP system advances alternate deployment technology through
robust design and simplification of the overall system. On the cover is the
first installation of this new technology in an onshore well.
Some of the many team members who made the field installation a success.
Summer 2017
THE SAUDI ARAMCO JOURNAL OF TECHNOLOGYA quarterly publication of the Saudi Arabian Oil CompanyJournal of Technology
Saudi Aramco
Contents
Field Deployment of a Rigless, Cable Deployed ESP Using a Vertical Wellhead 2Brian A. Roth, Dr. Jinjiang Xiao, Mohannad Abdelaziz, John Mack, Yahya Sarawaq, Richard Reid and Andrew Helvenston
In Situ Steam Generation: A New Technology Application for Heavy Oil Production 12Ayman R. Al-Nakhli, Luai A. Sukkar, Dr. James O. Arukhe, Abdulrahman A. Al-Mulhem, Mohannad Abdelaziz, Dr. Muhammad Ayub and Mohammad Arifin
First Worldwide CT Stimulation of a Quad-Lateral, Extended Reach Power Water Injector Using a Multilateral Tool with Gamma Ray and Distributed Temperature Survey 25Hasan M. Al-Jassem, Ayedh M. Al-Shehri, Nayef S. Al-Shammari, Salman D. Al-Gamber, Khaled M. Al-Mutairi, Rifat Said, Souhaibe Barkat and Danish Ahmed
Offshore Drilling Operation Time Optimization Using PDC Bit Shear Cap Technology 36 Musab A. Al-Jamea, Hatem M. Al-Saggaf, Hocine Boussahaba and Bruno Cuillier de Maindreville
Best Practices in Pre-Fracturing Coiled Tubing Intervention Operations Increase Success Rate of Hydraulic Fracturing Treatments 44Pablo H. Guizada, Dr. Zillur Rahim, Adnan A. Al-Kanaan, Rifat Kayumov and Mohammad Arifin
Intelligent Completion in Laterals Becomes a Reality 52Brett W. Bouldin, Robert J. Turner, Isidore Bellaci, Yousif M. Abu Ahmad, Steve Dyer, Thales De Oliveira and Ali Bin Al-Sheikh
From a Technology User to an Innovation Leader 63Julie L. Springer
creo
2 SUMMER 2017 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
ABSTRACT
Electric submersible pumps (ESPs) are a widely used artificial lift technology. Conventional ESP systems provide power through a cable banded to the outside of the tubing. These systems have drawbacks in terms of installation speed and ef-ficiency. To overcome these obstacles, a novel cable deployed (CD) ESP system, developed for use in a high hydrogen sulfide (H2S) production environment, was formulated as a future solution. This article focuses on the challenges, results and les-sons learned from the first field deployment in the world of a rigless, high H2S CDESP system.
A metal-jacketed power cable was a key enabler to devel-oping the CDESP system. The metal-jacketed power cable delivers the best protection against a H2S attack and provides a smooth outside diameter that can be gripped on and sealed. The cable has been tested to withstand H2S levels up to 15% and chloride levels in excess of 150,000 ppm with an expected service life in excess of 10 years.
To overcome well control concerns, a cable hanger spool was developed enabling the ESP cable to be terminated below the master valve. In addition to the surface termination of the cable, the cable hanger spool provides hang-off and production flow through capabilities.
The field deployment of the CDESP system, using a spe-cialized inverted ESP, required the close integration of several equipment and service providers during the development of the equipment and procedures to ensure success in the installation of the system. The systems initial deployment was in a benign onshore well that offered ample workspace for the various ser-vice providers to learn the unique aspects of this rigless deploy-ment. Of particular importance, the interface for the service providers at the surface cable termination was critical to the successful installation. For this trial test, the well completion was changed from 4 tubing to 7 tubing to accommodate the cable deployed 562 series ESP.
Lessons learned from this field trial will be incorporated into future trials of the CDESP technology. The goal of these future trials will be to deploy the technology in offshore H2S wells where high rig costs can be significantly reduced through the use of a lower cost barge coupled with the increased speed, efficiency, and ease of CDESP deployment.
INTRODUCTION
A majority of electric submersible pumps (ESPs) installed today are installed with tubing. The ESP is installed as part of the tubing string, and the cable that provides power to the ESP is banded or clamped to the tubing. This method has been in use since the beginnings of ESP installations back in the 1930s.
Since the 1970s, several types of alternative deployment methods have been developed. These are represented by var-ious technologies, including a cable suspended submersible pump system1, cable internal coiled tubing (CT) deployed submersible pump system2 and umbilical system3. A significant amount of learning was achieved in the use of these alternative deployment systems; however, each of these systems had draw-backs that prevented widespread adoption of the alternative deployment technology.
ALTERNATIVE DESIGN APPROACH
Saudi Aramco, with a large installed ESP base, sought alterna-tives to conventional rig deployed ESP installations. A key ben-efit of alternative deployed ESPs is that workover rigs are freed up for other well activities.
A number of alternative deployed ESP technologies have been field tested over the past few years with limited success. One major concern with the current alternative deployed ESP options is that those systems cannot survive long-term in high hydrogen sulfide (H2S) environments.
A new alternative deployed ESP system able to function long-term in high H2S wells was considered and developed as a collaborative project involving Saudi Aramco, Baker Hughes and GE. Some of the challenges in the development were the need for a high H2S cable, for compatibility with Saudi Ar-amco well control requirements and for a cable hanger inter-face, as well as issues with the deployment of the new technol-ogy. Each of these challenges will be discussed further.
TECHNICAL CHALLENGES
High H2S Cable
Saudi Aramcos wells can be particularly hostile, with up to
Field Deployment of a Rigless, Cable Deployed ESP Using a Vertical Wellhead
Brian A. R
