Imagination at work

Survivability and long-term reliability of High-Temperature monitoring Systems

Dave Shanks, GE Oil & Gas – Artificial Lift Automation

SPE EuALF, Feb 18, 2014

Today’s Presentation

• Historical development of gauges

for rising temperature requirements

• Zenith projects to develop extended

operating temperature gauge systems

• Why we did it

• What our thinking was

• What we have done

• Field experience

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Complex thermal production is currently run blind — this project gives our customers tools

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Measurement solutions do not provide sufficient visibility on the process!

HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Measure injection

pressures and

fluid quality.

Measure thermal

effectiveness,

heat transfer. Measure flow rates,

fluid present

(steam front arrival)

Thermal oil recovery is increasing.

High Temperature History

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Permanent Gauges

• Wireline gauges survive high

temperatures — life is in hours.

• Extreme temp still relies on flasks.

• Electronics still 200°C despite

years of work.

• Electronic gauges at >175°C have

life expectancy of months.

• Optical Fibre solutions have

limitations of construction,

and lack a viable pressure sensor

at temperature.

The General Approach

• Industry needs tools that will survive.

• Shot term electronics free.

• Cable, electrical connections, pressure seals.

• Up to 300°C existing technology will operate

— HT will stretch existing technology to its limit.

• 500°C technology does not exist so we will need to develop

it — this is XT.

• Keep it very simple.

• HT system is ready.

• Will inherit elements of XT once ready.

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

HT Monitoring System: Specifications

• All downhole parts operational

to 500°F

• Calibrated 0 — 500°F, 0-

5,000psi

• Accuracy 0.1% FS (5psi)

• Resolution 0.1psi

• Temperature resolution 0.1°C

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

HT Monitoring System: Development

• In development since 2005

• First prototype in 2007

• First installations 2008

• Max run life so far:

>1,000 days at 250°C

• Currently building 10/month

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Use of HT Sensors

• Allows real time monitoring of well bore temp and pressure.

• Improved decision making when to stop injection and start producing.

• Improved control of steam injection pressures.

• Allows vision across reservoir, enabling better decision making on

which wells to inject.

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

HT Monitoring System: It’s Tough!

• Pressure and temperature cycling in manufacturing process.

• Thermal cycling from 30 to 250°C and back.

• Pressure cycle at each temperature.

• 2 weeks at 250°C prior to test to remove any errors caused by

metalwork.

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Development of HT Systems

• All steam injection projects

• Some issues with cable near injection lines

• Total operating days 8,788 so far

• Cable, sensor, electronics all evolving

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Location of installations

Oman

Turkey

Kuwait

Installation

• Installs like regular permanent gauge

• Gauge carrier, cable clamps, surface logger

• ¼ inch OD high temp cable

• Option for XT cable

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

XT Well Depths in Metres

13

0

200

400

600

800

1000

1200

1400

1600

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OPTIONAL RUNNING HEADER IS ALL CAPS

Gauges in Two Forms

ESP Configuration Tubing Configuration

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

0

500

1000

1500

2000

2008 2009 2010 2011 2012 2013

Runlife Max Run

Experience with 260°C Systems

1. Early installs on metal PCP problematic

2. Pressure seals re-design caused problems 2011

3. Recent installs on ESPs working well

4. Steam injector well gauges working well

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Runlife – ideal and actual

Recording Steam Injection

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS

Conclusion

GE are trailblazing the development of reliable

downhole sensor technology for all high temperature

well monitoring.

• We have extended existing technology to 250°C successfully.

• We are developing up to 500°C pressure sensor with cable,

housings and connections.

• We plan a suite of 250-500°C permanent monitoring products

including flow and fluid sensors.

• We will require the ongoing support and involvement of operators.

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HIGH TO EXTREME TEMPERATURE DOWNHOLE MONITORING SYSTEMS