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  • Wells in X-ray area of Northwest Java Production Sharing Contract were all produced by Electrical Submersible Pump (ESP) system until a gas zone was discovered in XM area in 1987. During development drilling in X-ray area Gas zone, XM-27B discovered in XM structure 4 miles from the southern portion of XA field. The zone was tested and proved to be sufficient in terms of pressure and gas volume to the support gas lift for XMA wells of pressure and gas volume for the support of all the XMA wells
  • In Xray flow station, there are 4-gas power generators with capable of supplying 3 x 900 KWatt with one unit stand by as a back up. The electrical power is transmitted to remote platform XB, XD including XMA platform through 4180-Volt sub sea cable to a primary transformer down to 480 Volt Depending upon the ESP stock available, we may substitute the ESP assembly as necessary. It is common to have a mixed match for two brands of ESP in one assembly to anticipate stock availability . A down hole completion assembly was designed to allow us converting gas lift mode to ESP wells. In case of multiple zones and possibly stimulation work, we installed the ESP with Y-block. In wells which capable of flowing naturally; we install vent packer and sub surface safety valve. Typical ESP capacity installed in this area is about 1000-5000 BFPD with the horsepower motor from 100 to 180 Hp to generate total head of about 3000 ft. Some wells were also equipped with pressure and temperature data acquisition system.
  • The ESP-GL hybrid system offers numerous possibilities for optimizing the production rate and ensuring uninterrupted production operation with a limited source gas for gas lift operation. ESP well is equipped with gas lift mandrels where a production rate can be maintained by gas lift operation until the ESP operation resumed.
  • The equipment required for hybrid system should fulfill the used for both ESP and GL system. Gas lift system : knock out drum to separate gas and liquid in the gas lift gas and gas lift manifold to distribute the gas lift gas into each well. ESP system : related to the electrical system such as the power generator, cable transmission, primary and secondary transformer, electrical panels, junction box and tail cable which go to the well head.
  • Description of equipment’s used in the installation: SSSV (Subsurface Safety Valve). Flapper type of SSSV, allow us having full tubing opening. Gas lift mandrels and valves. Side pocket gas lift mandrels are selected instead of concentric mandrels to avoid tubing restriction during wireline or ESP operation. Dummy valves are installed during ESP operation. Casing operated gas lift valves are preferably installed to avoid tubing pressure influences during ESP mode. Y-block. equipped with the SSD to isolate tubing and annular communication during gas lift mode. In the ESP mode the SSD in the Y-block need to be in opening position. A blanking plug installed in the nipple slightly below Y-block during ESP mode. The plug should be ensured properly set, otherwise the liquid will not pumped to the surface. To switch to gas lift mode, the plug need to be removed and the SSD intake pump need to be closed
  • The completion must be capable of fulfilling both requirements : ESP has to be hung on the Y-block and the GL mandrel installed above the Y-block. A blanking plug and intake SSD have to be installed below Y-block. To enable of lifting using gas lift gas. The plug has to be pulled out , the SSD needs to be closed and gas lift valves need to be installed.
  • Due to space limitation inside the casing (9-5/8” OD), a slim body ESP need to be used with a small tubing (2-7/8” OD) opposite to the ESP below Y-block. To monitor pumping performance, a down hole pressure and temperature sensor are installed. Since all wells in XMA area are not capable of flowing naturally, subsurface safety valve and vent packer are not installed. In other ESP-GL hybrid application where the well is capable of flowing by itself, SSSV and vent packer are needed.
  • An electrical sub sea cable and surface facilities were installed for the ESP artificial lift production at the same time as the nine wells were drilled in 1987, these ESP tools were not used until 1998 where ESP-GL hybrid was firstly introduced. To prepare for future operation (ESP-GL hybrid system), casing operated valves were installed to prevent valves from opening during ESP operation.
  • Transcript

    • 1. Gas-Lift Hybrid Application in Offshore Northwest Java Production Sharing Contract B.T.Santoso Maxus Indonesia , P.Priyandoko ARCO Indonesia, Boyke Harahap ARCO Indonesia
    • 2. Agenda <ul><ul><li>Background </li></ul></ul><ul><ul><li>Overview </li></ul></ul><ul><ul><li>“ Theory” ESP vs ESP G/L Hybrid </li></ul></ul><ul><ul><li>Field Example </li></ul></ul><ul><ul><li>Conclusion </li></ul></ul><ul><ul><li>Recommendation </li></ul></ul>
    • 3. JAKARTA BIMA ARDJUNA ARIMBI AV AVS A A MX MQ MR MM MB LL L BZZ B Y K U E EQ-EZ ES F FF HZE ZU P XM X KLX KLY KNA KL KK APN A R I I O Y LES/KKN GG CIREBON ARCO Indonesia ONWJ XM Location 0 25 50 KM KALIMANTAN SULAWESI SUMATERA J A V A
    • 4. Background <ul><ul><li>All wells in the X-ray area were originally produced by Electrical Submersible Pump ( ESP ). </li></ul></ul><ul><ul><li>Gas zone discovered in the XMA area in 1987. </li></ul></ul><ul><ul><li>Tested and proved to be sufficient in terms of pressure and gas volume to the support gas lift for XMA wells. </li></ul></ul>
    • 5. X-RAY SIMPLIFIED FLOWLINE DIAGRAM CRUDE TO BALONGAN OIL GAS THREE PHASE LINE 4180 V CABLE XMA P/F XD P/F XA P/F XB P/F X PROS X L/Q 4 MILE 16” 1 MILE 8” 4 MILE GAS 8” OIL 12” 21 MILE 16” V-002 TEST SEPARATOR V-002 TEST SEPARATOR V-002 TEST SEPARATOR V-002 TEST SEPARATOR
    • 6. XMA ESP Background <ul><ul><li>Requires significant power </li></ul></ul><ul><ul><li>Two brands of ESP used due to stock availability </li></ul></ul><ul><ul><li>Completion originally designed for eventual G/L conversion </li></ul></ul><ul><ul><li>General design capacity is 1000-5000 BFPD </li></ul></ul><ul><ul><li>Pressure and temperature data acquired </li></ul></ul>
    • 7. ESP GL Hybrid Benefits <ul><li>Optimize of production rate </li></ul><ul><li>Ensuring uninterrupted production operation with a limited source gas for gas lift operation . </li></ul><ul><li>. </li></ul>
    • 8. ESP-GL Hybrid <ul><li>Equipment required for hybrid system is common to both ESP and GL systems. </li></ul><ul><li>Gas lift system : </li></ul><ul><ul><li>knock out drum </li></ul></ul><ul><ul><li>gas lift manifold </li></ul></ul><ul><li>ESP system : </li></ul><ul><ul><li>the power generator </li></ul></ul><ul><ul><li>cable transmission </li></ul></ul><ul><ul><li>primary and secondary transformer </li></ul></ul><ul><ul><li>electrical panel </li></ul></ul><ul><ul><li>junction box and tail cable </li></ul></ul>
    • 9. XMA SIMPLIFIED PROCESS FLOW DIAGRAM MAIN TRANSFORMER SUBSEA CABLE F/ XA PRODUCTION HEADER WELL XMA 1-9 Z-35 WATER DISPOSAL CAISSON BLPD, MCFD TO XAPV-1B 8” 1 mi pipeline POWER DISTRIBUTOR TEST HEADER GAS LIFT Manifold PRODUCTION SEPARATOR XMA-MD-9 SLOP PUMP SECONDARY TRANSFORMER DOWN FROM 4180 TO 480 VOLT DOWN FROM 4180 TO 480 VOLT KO Drum XMA-6S Description Test Sep Prod Sep MOL Design, psi 230 600 230 Operate, psi 110 100 100 MAWP 275 PSH, psi 200 200 175 PSL, psi 10 10 10 Cap, MPLPD Cap, MMCFPD V-002 TEST SEPARATOR XMA-MD-8 CAISSON PUMP XMA-V-7 SLOP TANK
    • 10. ESP-GL Hybrid <ul><li>Equipment necessary : </li></ul><ul><ul><li>SSSV (Subsurface Safety Valve) </li></ul></ul><ul><ul><li>Gas lift mandrels and valves </li></ul></ul><ul><ul><li>Y-block </li></ul></ul><ul><ul><li>A blanking plug </li></ul></ul>
    • 11. ESP-GL Hybrid <ul><li>The completion must be designed to easily adapt to both systems : </li></ul><ul><li>ESP </li></ul><ul><li>ESP has to be hung on the Y-block </li></ul><ul><li>GL mandrel installed above the Y-block </li></ul><ul><li>A blanking plug and intake SSD have to be installed below Y-block. </li></ul><ul><li>Gas lift </li></ul><ul><li>The plug has to be pulled out </li></ul><ul><li>SSD needs to be closed </li></ul><ul><li>Gas lift valves need to be installed. </li></ul>
    • 12. ESP-GL Hybrid : Specific Issues <ul><li>Slim body ESP required </li></ul><ul><li>Down hole pressure and temperature sensors </li></ul><ul><li>Vent packer and SSSV installed as necessary </li></ul>
    • 13. ESP Mode 800' 1399' 1969' 2505' GL mandrel ` 2982' 3363' 3682' 3966' Opened 4570' Y -block with SSD Plugged 4579' Nipple 4562' SSD Intake ESP 4698' On off tool 4699' Packer 4738' SSD 4750' Nipple 9-5/8 Casing 3363' 3682' 3-1/2” Tubing 3966' Opened 4570' Y -block with SSD Plugged 4579' Nipple 4562' SSD Intake ESP 4698' On off tool 2-7/8” Tubing 9-5/8” Casing Detailed Completion
    • 14. ESP-GL Hybrid Completion XMA-8 Completion XMA-8 Completion ESP Mode GL Mode 800' 800' 1399' 1399' 1969' 1969' 2505' GL mandrel 2505' ` 2982' 2982' 3363' 3363' 3682' 3682' 3966' 3966' Opened Closed 4570' Y -block with SSD 4570' Plugged Unplugged 4579' Nipple 4579' 4562' SSD Intake 4562' ESP 4698' On off tool 4698' 4699' Packer 4699' 4738' SSD 4738' 4750' Nipple 4750' Baturaja 4802'-4841' 4852'-4864' 9-5/8 Casing GL Gas Formation Gas
    • 15. ESP-GL Hybrid Completion Other Completion Other Completion ESP Mode GL Mode GL mandrel ` Opened Closed Plugged Unplugged ESP GL Gas Formation Gas
    • 16. Field Example <ul><ul><li>After more than 8 years providing gas lift gas to XMA wells : </li></ul></ul><ul><ul><li>The source gas in XMA area has depleted. </li></ul></ul><ul><ul><li>Many wells needed to be selectively shut in. </li></ul></ul><ul><ul><li>The conversion from gas lift (GL) to ESP wells is required to maintain production. </li></ul></ul><ul><ul><li>ESP-GL hybrid was proposed to use the limited source gas availability if necessary. </li></ul></ul>
    • 17. XMA-6S FTP & PRODUCTION 10 100 1000 10000 '86 '88 '91 '94 '97 '99 Gas Production , MCFPD 0 500 1000 Pressure, psia Gas Prod Pressure
    • 18. Field Example <ul><li>The XM-27B zone was tested at 920 psi FTP with gas rate of 2360. </li></ul><ul><li>The minimum gas lift injection pressure required to lift the liquid from the well is 600 psi. </li></ul><ul><li>XM-27 B supplied gas lift gas to 9 wells for 8 years. </li></ul><ul><li>Recently, the gas supply can only support 3 wells due to pressure depletion . </li></ul>
    • 19. Gas Source Well Completion XMA-6 Completion GL Gas Source XM-27B Baturaja Baturaja At the surface liquid produced from the gas zone was drained in the knock out drum and the dry gas was then distribute to each well through gas lift manifold .
    • 20. XM-27A XM-27B XM-34 ( Baturaja ) Gas Lift Gas Source Log Oil Zone Log
    • 21.  
    • 22.  
    • 23.  
    • 24. Field Examples <ul><li>Original facility & well design allowed for GL to hybrid conversion </li></ul><ul><ul><li>Cable for ESP power laid down at time of installation </li></ul></ul><ul><ul><li>G/L designed for flexibility </li></ul></ul><ul><li>ESP G/L Hybrid system was implemented on two XMA wells (XMA-7 and XMA-8) </li></ul><ul><li>Hybrid system allowed production to continue until the ESP was replaced </li></ul>
    • 25. Field Examples : Result XMA-7 Well Test History 1 10 100 1000 10000 Feb -98 Mar-98 Apr-98 May-98 Jun-98 Jul-98 Aug-98 Sep-98 Oct-98 Oct-98 Nov-98 Dec-98 Jan-99 BOPD/BFPD (BFPD) (BOPD) ESP Down ESP Down GLV's Installed Hybrid Installed XMA-8 Well Test History 1 10 100 1000 10000 Feb-98 Mar-98 Apr-98 May-98 Jun-98 Jul-98 Aug-98 Sep-98 Oct-98 Oct-98 Nov-98 Dec-98 Jan-99 BOPD/BFPD (BFPD) (BOPD) ESP Down ESP Down GLV's Installed Hybrid Installed <ul><li>System was tested when ESP failed : XMA-7 and 8 </li></ul><ul><li>Hybrid system allowed continued production </li></ul>
    • 26. Economic Evaluation Conventional Hybrid 300 BOPD 200 BOPD Down Time 80 days 3 months 2 days 7 days Items US$ US$ ESP change out 100,000 100,000 40,000 one time “charge” 2,000 wire line -------------------------------------------------------------------------------------------------- Production Bbls Bbls Normal 81,000 81,000 Down time 0 16,000 Total 81,000 81,000 -------------------------------------------------------------------------------------------------- US$ US$ Revenue 1,215,000 1,455,000 Profit 1,115,000 1,313,000 Benefit $ 198,000 /well
    • 27. Conclusion 1. ESP-GL hybrid technique can be applied mainly in an operation where both electrical power and a high-pressure gas source are available. 2. The ESP-GL hybrid system offers numerous possibilities for optimizing the production rate and ensuring uninterrupted production operation in many wells. 3. The GL in ESP-GL system provides a back up lift system in the event of an ESP failure. 4. ESP-GL prevents a longer down time period prior to rig schedule availability. 5. By applying ESP-GL hybrid technology ARCO has prevent loss production of approximately 400 BOPD during the event of ESP failure.
    • 28. Recommendations 1. Casing operated valve is recommended to be installed in the mandrels to avoid valves opening during ESP operation. 2. All reservoir fluid production through an ESP during GL operation can be avoided by installing Y-tool with a sliding sleeve above the pump.

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