Expands ESP system operating range in unconventional oil wells
The new Centrilift FLEXPumpER™ extended range pump provides an unmatched operating range for steep production declines. This pump is designed to expand the operating range of the ProductionWave™ FLEXible production solution for unconventional oil wells.
As unconventional production rates decline, operators typically switch out pumping units or artifi cial lift production methods. The FLEXPumpER pump eliminates this requirement with a flow range from 2,900 to 50 barrels per day—the industry’s widest operating range for a single pump. The innovative stage design maximizes production while extending electrical submersible pumping (ESP) system run life.
Improving efficiency with ATM design
The production stream in unconventional oil plays typically contains high levels of gas entrained in the fluid. The advanced design of the FLEXPumpER pump stages features patentpending advanced turbulence mitigation (ATM) technology to increase pumping effi ciency and reduce gas locking.
A re-designed bearing system allows the pump to withstand elevated temperatures generated during short-term operations with gas slugs. In addition to these features, particle swirl suppression ribs in the diffuser provide abrasion resistance by reducing the buildup of abrasives that can cause erosive wear.
This pump design expands the ESP system’s operational fl exibility for the duration of an unconventional oil well’s production cycle. This pump operates more effi ciently in a wider flow range to reduce operating costs, improve reliability, and optimize production in changing downhole conditions.
Applications
- Unconventional resource plays；
- Wells with quickly changing flow rates, high gas/oil ratios (GOR), and high solids content.
Location: East Texas
An operator in East Texas had a well that experienced frequent electrical submersible pumping (ESP) system shutdowns, sometimes multiple times a day, as a result of gas slugs and elevated bottomhole temperatures. Gas/oil ratios (GOR) and water cut varied daily, which led to downthrust issues and poor reliability rates.
The operator approached Baker Hughes for an ESP system solution to increase reliability and handle flexible flow rates with frequent gas slugs. Baker Hughes installed a CENesis™ ESP system with FLEXPumpER™ technology, WellLIFT™ H sensor, MVP™ gas handling pump, Electrospeed Advantage™ variable speed drive, and vortex gas separator. Production rates began at 2,000 BFPD with 60% water cut. Reliable operations continued even when production dropped as low as 800 B/D. The ESP system maintained operations and provided superior downthrusthandling capabilities. Gas averaged 650 MCF with some significant slugging but operations continued. WellLIFT H sensor monitored discharge pressure as dynamic reservoir conditions changed frequently.
The CENesis ESP system with FLEXPumpER technology maintained steady drawdown while running at a slow speed of 46 Hz. Production averaged 1,034 BFPD, which represented a 20% production increase over the previous ESP system.
The operator was so pleased with the performance of the FLEXPumpER technology that 2 additional systems were installed within 6 weeks. The CENesis ESP system handled changing densities in the well fluid, variable flow rates, and frequent gas slugs while production rates increased 20%.
Location: Oklahoma
Unlike conventional oil wells, the production decline from an unconventional reservoir is dramatic—going from an initial production rate of 3,000 B/D or more, to less than 50 B/D in just a year or two.
Traditionally, producers install an electrical submersible pumping (ESP) system when production is high and then switch to rod lift when the production rate declines because traditional ESP systems typically cannot handle a wide and varying flow range.
Recently, an operator in Oklahoma met with Baker Hughes to discuss artificial lift options for a well characterized by high levels of sand and other abrasives entrained in the fluid, and low flow rates. Initially, the operator opted to deploy an ESP system to effectively draw down the well; however, issues arose related to high gas volumes and excessive sand in the ESP system.
To combat these issues, Baker Hughes installed an ESP system featuring a FLEXPumpER? extendedrange mixed-flow pump and a Gas Avoider™ gravity-cup intake. This new system configuration was able to handle flow ranges as high as 344 B/D and as low as 13 B/D with an average flow range of 80 B/D. The mixed-flow stage design and particle swirl suppression ribs in the diffuser provided better abrasion resistance to the high levels of sand entrained in the fluid.
When production rates declined as low as 13 B/D with a pump intake pressure under 100 psi, the system maintained production with no reliability issues, eliminating the need for an artificial lift system change out.
This innovative, flexible pump design improved reliability and maintained production at extremely low flow rates with average water cut of 78.5%. The operator was pleased that the ESP system with FLEXPumpER technology maintained production after rapid production declines and eliminated the need for a system change out. This system solution extended run life despite excessive levels of gas and sand and extremely low flow rates.
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