GE Oil & Gas

Zenith™ Dual ESP & Specialist CompletionsCompletion systems designed to address specific well parameters, constraints and production objectives

GE Oil & Gas

Dual zone ESP completion halves drilling

costs & eliminates deferred production

Multi-zone production capabilities of the Zenith™ dual concentric ESP

completion system cut drilling costs and reduce well intervention time,

saving the operator over $2MM before start up.

GE Oil & Gas

Novel specialist completion system enables injection while producingIndividually engineered to suit specific operator requirements, a hybrid

Zenith™ ESP bypass system with concentric tubing configuration

provides an effective solution to this complex challenge.

Production from wells with a single ESP can be limited by factors including the amount of horsepower attainable downhole, the maximum available ESP flow rate, high workover costs, casing corrosion considerations and limited control over production zones.

Our Zenith team have many years' experience backed by the engineering know-how to design dual ESP and bespoke specialist completion systems that integrate with all manufacturer ESPs to effectively deliver on each well's specific production requirements.

“Each Zenith™ specialist completion system from GE Oil & Gas is designed to suit specific operator requirements based on their well parameters and production objectives, addressing constraints that can occur with standard ESP deployment.”William Beveridge, Electro-Mechanical Sustaining Manager

1 | Zenith™ Dual ESP & Specialist Completions

Challenge

Benefits

Solution

Casing protection ESP systems

For wells with casing integrity issues and corrosive fluids (fig 1)

The ESP system is housed in a pod which is stabbed into a lower packer. The pod and packer isolate the upper casing from the well fluid, protecting it from corrosive well fluids. The pod enables the ESP to produce from below the packer by routing well fluid directly into the intake of the pump via the sealed pod unit. The pod has a penetrator system incorporated in the pod hanger to allow the ESP cable to exit through a pressure-tight connection. Multiple pods may be deployed to provide redundancy in the event of ESP failure.

Protect casing from corrosive well fluids

Protect ESPs during deployment

Parallel ESP systems

For wells that have high productivity indexes and therefore high potential rates (fig 2)

The parallel system uses two electrical submersible pumps to maximise flow rate where a single ESP would not be capable of handling the well potential rate due to casing size, pump rate or power supply constraints. Production from two ESPs is combined at the Y-block in the upper ESP bypass assembly. The bypass assembly suspends the lower ESP on its bypass tubing.

Each ESP can produce to the surface independently at a reduced rate in the event that a pump should prematurely fail. This allows continued production, albeit at a lower rate, until workover is feasible.

Achieve maximum flow rates

Zenith™ Dual ESP & Specialist Completions | 2

Zenith™ specialist completion schematics1.

Pod Assembly

Upper ESP Assembly

Packer

E-Series Sensor

Auto Flow Valve

Y-Block / Auto Flow-Through

Swivel Nipple Assembly

Cable Support Clampc/w cable clip for MLE cable

Upper ESP Assembly

Bypass Tubing

E-Series Sensor

Pump Support

Lower ESP Assembly

E-Series Sensor

2. 3.

Pod Assembly

Auto Flow Valve

Upper ESP Assembly

E-Series Sensor

Auto Flow Valve

Lower ESP Assembly

E-Series Sensor

Dual boost ESP systems

For wells that have lower productivity index values and require a large draw-down to overcome high back-pressure (fig 3)

Two ESPs are combined in series, sharing the number of stages and required horsepower. Pods are used to configure two ESPs in series, the lower ESP boosting the intake pressure of the ESP above it. The configuration enables two smaller ESPs to perform the job where a single large ESP would normally be infeasible due to casing size, horsepower or shaft strength limitations.

If a single pump will not produce to surface then a third ESP can be included in the completion as a redundancy measure for the failed pump. The Zenith Auto Flow Valve ensures that the lower pumps can be run without having to produce through the upper pump stages. The valve opens and closes automatically depending on which ESP is running.

Achieve maximum draw-down

Zenith™ ESP monitoring systems installed on each pump allow reliable, realtime assessment of well and artificial lift system performance. Accurate measurements from each ESP provide confidence in pushing each system to its optimum performance, enabling maximum production with the knowledge that the pump is running within its specified limits.

Dual back-up ESP systems

For wells with high workover costs or difficult access (fig 2)

In the event of an ESP failure, a back-up ESP already deployed in the well can be immediately switched on to maintain production. The second ESP is suspended below the upper ESP with a bypass assembly. The bypass tubing provides a production path for the lower ESP.

Normally the upper ESP is run first to prevent temperature effecting the backup system runlife. The lower ESP can be appropriately sized to accommodate changes in well performance such as decreasing reservoir pressure or increasing water cut.

Replace the Y-Tool with the Zenith Auto Y-Tool for automatic switching between upper and lower ESPs. The Auto Y-Tool also prevents circulation from upper to lower ESP and vice-versa, and protects the pumps from descending solids on shut-down.

Minimise lifetime intervention costs

Reduce downtime and deferred production when ESP failure occurs

Dual zone ESP systems

For multiple zone wells that require control of zonal contribution (fig 4)

Dual zone completions enable production from multiple zone wells. A dedicated ESP for each zone gives independent control of draw-down. This allows improved zone management, prevents cross-flow between zones, allows improved water management and enables individual production well tests on each zone independently. If used effectively during field planning, these systems can decrease the number of wells required to be drilled.

Enables simultaneous production of incompatible fluids from separate zones

Prevents water coning, maintaining well asset viability

Allows simultaneous production and injection through a single well bore

Reduces topside separator capacity requirement

Drill fewer wells

Test zones independently

Reduced deferment: the second ESP provides back-up should one system fail

Dual zone systems are available in two configurations:

Commingling systems

Combines production from dedicated ESPs for upper and lower zones

The lower ESP is housed in a sealed pod which is stabbed into a permanent packer that isolates the upper and lower zones. Production from the lower zone is produced by the ESP inside the pod. The upper ESP is installed above the pod using a bypass system. The lower zone is produced via the bypass tubing and its production commingled with production from the upper zone at the Y-block.

Zones can be produced either simultaneously or independently by running upper, lower, or both ESPs. Cross-flow between zones during production shut-down can be prevented, and well tests of individual zones can be carried out to provide improved well testing. This is achieved by running each ESP individually thereby producing only the relevant zone for testing.

Dual concentric systems

Dedicated ESPs for upper and lower zones that isolate zone contribution to surface production facilities

The dual concentric system is similar to the commingled system described above but produces the zones independently to surface using concentric production strings. This system is particularly useful where complete isolation of production zones is a requirement.

Fluid from the lower zone is produced to surface through a flow crossover tool which routes the fluid through the inner production tubing string. Fluid from the upper pump flows through the inside of the flow crossover tool and to the surface through the annulus between the inner and outer production strings. The two separate production strings exit the well through a concentric well head that allows flow through two separate production flow lines.

3 | Zenith™ Dual ESP & Specialist Completions

Zenith dual zone ESP system profile

Zenith™ Dual ESP & Specialist Completions | 4

4.

Y-Block/Flow XOver Assembly

Swivel Nipple Assembly

Auto Flow Valve

Discharge Pressure Assembly

Cable Support Clampc/w cable clip for MLE cable

Upper ESP Assembly

E-Series Sensor

Bypass Tubing

Pump Support

Cable Penetrator

Rotary Offset Assembly

Pod Assembly

Auto Flow Valve

Discharge Pressure Assembly

ESP Centraliser Clamp

Lower ESP Assembly

E-Series Sensor

Install cost analysis

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Cost Analysis Per Phase ($MM)

2 x 7" Wells 9-5/8" Dual Well

-50% -50% -29% +21% -14%

Cost per phase ($MM)

$1.17MM saving

on well drilling processes with Zenith™ dual zone ESPA 37% saving on drilling two single 7" wells.

$725,000 saving

on whole system processTotal cost of Zenith dual zone ESP system preliminary, mobilisation, drilling and completion vs two single 7" wells.

10,000 hours

time saving could add up to:

Install time analysis

2 x 7" Wells 9-5/8" Dual Well

12,000 hrs 10,000 hrs saved

22,000 hrs

>90% of human resource investment/time to drill

and complete another well gained back

50% less environmental impact

150,000 bbls

gained by eliminating deferred production

based on 800bopd from 2 zones, that's...

$7,500,000 @ $50 per barrel

production from 2 x 7” wells @ 22k hours

production from 9-5/8” dual well @ 22k hours

46% less exposure to risk for oilfield personnel

Zenith ZenWell completion systems take specialist and dual ESP completion designs to the next level, combining unique tools and technologies engineered to interact in a fully integrated completion surrounding the artificial lift system.

Systems deliver all the monitoring and protection benefits of individual Zenith technologies within a specialist ESP well completion.

ZenWell™ completion systems employ various Zenith technologies such as tubing drain valves, fluid loss relief valves, E-Series ESP monitoring and Z-Sight auto well surveillance systems to unlock tangible benefits from customer operations.

“Zenith™ ZenWell™ completion systems focus on the bigger picture with a whole-well approach to system design, unlocking significant monitoring and protection benefits.”Greg Davie, General Manager

5 | Zenith™ Dual ESP & Specialist Completions

Challenge

Benefits

Solution

Tubing drain valves (TDV)

Production solids management for protection of artificial lift systems.

The efficient solids management system in all Zenith TDVs is engineered to ensure increased pump runlife by providing an innovative solution to costly pump damage.

Defends against equipment damage or blockage on pump shut down.

Protects from pump off situations.

Prevents damage to pumps by channelling natural flow through annular ports.

Prohibits back-spin, motor shaft or pump rotor breakage at start up.

Fluid loss relief valves (FLRV)

For fluid loss applications and maintenance of defined fluid head in the tubing.

The Zenith fluid loss relief valve (FLRV) is a development of the field-proven tubing drain valve, configured as a fluid loss valve with pump-through capability.

Cracking pressure can be adjusted to suit the particular application.

When injection is stopped, valve returns to default position as fluid loss device.

Interventionless operation with no control lines or wireline intervention required.

E-Series ESP monitoring systems

For enhanced oil recovery and prolonged ESP run life.

Zenith E-Series gauges are installed below the ESP motor providing reliable well and pump surveillance via direct measurement of key parameters surrounding the motor and pump.

Maximise runlife while reducing cost.

Optimise production.

Reliable source of data for analysis.

Z-Sight auto well surveillance

Automated well and field management and optimization.

The Z-Sight auto well surveillance system performs automatic data analysis, diagnosis, optimization and protection at the well site in real-time.

Automates time-consuming data analysis and optimization processes.

Enables remote access and control.

Efficient field-wide management.

Instantly recognize and prioritize wells requiring attention.

Zenith™ Dual ESP & Specialist Completions | 6

Zenith™ ZenWell™ ESP system schematic

Y-Tool / ESP Bypass Systemoffsets the ESP in the wellbore to allow access through bypass tubing

Crossoverconnects the Y-Tool to the pump discharge head

Swivel Nipplefor setting of blanking and logging plugs

Fluid Loss Relief Valvefluid loss valve with pump-through capability - for fluid loss applications and maintenance of fluid head

Zenith E-Series ESP Gaugepump surveillance and well analysis using key parameters - options incl. hi temp and ground fault immune

Bypass Saddle Assemblyenables simplified, safe and cost effective bypass installation

Re-entry Guideenables unobstructed access for logging tools to enter bypass tubing

Discharge Pressure Assemblyconnects pump discharge pressure to the transducer in the gauge

Tubing Drain Valveprevents solids descending into pump on shut down, allows flow to surface when pump is switched off

Bypass Tubingconduit for bypassing the ESP with logging tools and slickine operations

Discharge Pressure Line

Discharge Head

Pump

Motor Base Crossover

Motor

Seal

Packer

Surface equipment

ChokePanel

Remote Access

Zenith interface unit (ZIU)

interfaces downhole gauge signal to data output for use on a drive or SCADA remote terminal unit.

Zenith surface panel (ZSP)

provides on-screen data charting, alarms and trips, analogue and data communication signals.

Zenith surface panel plus (ZSP+)

includes touch-screen display, well info dashboard, live/historical data trending, pump curve with real time operating point, virtual well test, auto alarm setting.

Z-Sight™ auto well surveillance

provides automated analysis and production recommendations of well site data in real time; multiple communications ports to interface with VSD, switchboards and well site gauge data.

GE Field Vantage™

360-degree view of your wells — real-time data and info, in one format, in one place.

Bespoke systemsShare your specific production objectives and requirements with your local GE Oil & Gas representative to see how a Zenith specialist completion or ZenWell system could overcome your artificial lift operation challenges.

Gauge parameter listMeasurement

Primary Parameters for essential pump & well surveillance & protection

pump intake pressure

pump discharge pressure

intake temperature - standard temp

intake temperature - high temp

discharge temperature

motor oil / motor winding temperature

vibration - x axis

vibration - y axis

Predictive Parameters for preventative maintenance & workover management

current leakage

wye point voltage

Intelligent Parameters for advanced well & field management & optimisation

bottom hole flowing pressure*

fluid level above pump*

wellhead pressure

total liquid flow rate*

water cut*

real time pump curve & live op point*

parameter included as standard

optional addition or alternative

* calculated

Zenith E-Series ESP gauge

Accurate, real-time measurements enable fast, confident assessment of well and lift system performance.

Zenith GFI™ ESP gauge

First ground fault immune ESP gauge to deliver unshakable surveillance despite ground fault conditions.

Zenith HT ESP gauge

Extends downhole ESP gauge temperature limitations, operating reliably up to 260°C.

Downhole gauge options

Imagination at work

GE Oil & Gas Zenith Downhole Monitoring & Completion Systems Thainstone Business Park Inverurie, Aberdeenshire, AB51 5GT, UK +44 (0) 1467 628866 www.geoilandgas.com/artificiallift

Zenith Oilfield Technology Ltd. is a subsidiary of the General Electric Company. The GE brand and logo are trademarks of the General Electric Company. © 2015 General Electric Company. Trademarks pending and protected worldwide.

GEA32487