Production enhancement and gas saving opportunities in

Indian offshore wells . A case study on conversion of mode of

artificial Lift to ESP from Gas lift .

27 wells were studied for conversion of lift mode from gas lift to ESP. The
had a good productivity index ranging from1 barrel /day/psi to 6.9
barrel /day /psi. These well have a lower bubble point pressure than the
formation pressure itself and thus pose a gas interference challenge.
Thus the study was carried out to mitigate the effect of gas interference in
ESP

Extreme difference in the densities of the liquid and gas create a low
pressure in the
Impeller eye, resulting in gas accumulation. Free gas in the stages of the
impeller displaces liquid and restricts volumetric efficiency of the pump.
Different methods of practices for handling gassy wells practice worldwide
were studied and their application was done during the study

1. Standard ESP: A standard unmodified ESP can be utilized in gassy

application if the free gas to liquid ratio falls within acceptable limits. The
Turpin and Dunbar correlation can be used as general guidelines. Since
the boundary between stable and unstable operation will vary and
depends on stage type, fluid characteristics and well bore geometry.
2. Tapered Pump-: Another technique that has been successfully used
since the 1960s is the use of tapered pumps. A tapered pump involves
the use of several different pump stages to achieve a volumetric taper
in the same pump. Basically higher volume capacity stages are used in
the first part of the pump with lower volume stage in subsequent section
as needed
3. ESP with VSD : With the introduction of use of variable speed drive
(VSD) with ESP, another application method available to the designer. VSD
provides the ability for varying the speed of the down hole unit. It has
been shown through some limited lab testing and actual field experience
that the gas handling capability of the pump can be improved by running
the unit at higher speed. Using this attribute, the VSD can be used to
sense the onset of gas interference, speed up to improve the pumps
chance of running through the gas interference, and return to its present
operating speed.
4. ESP Shrouds- : Shrouded ESP units in various configurations are also
used for enhanced gas handling. Simply stated, a shroud is used to
change the direction of flow to utilize the buoyancy effect of the gas
separation from heavier liquids and vent up through annulus or away from
the pump intake.
5) Multi vane pumps can be used to handle 70% gas at the pump
intake. These pump can be used as charge pump or standalone pumps for
superior lift characteristics and efficiency
Well completion was one of the key area which could help in handling
excessive gas at pump intake Maximum deviation for the non-
horizontal wells was 50 degrees and deviation profile appeared to be
no hindrance for these wells as far as ESP installation was concerned
.In-order to reduce gas interference and higher suction three
completion philosophies were counted upon

Case I:
In 9 5/8 casing, ESP will be installed below perforations with 7
shroud
Case II:
In 7 casing, ESP will be installed just above the 7 liner top with
suction point below the perforation through a7 shroud and a 3
tubing ahead of the shroud
Case III:
In 7 casing, where perforation depth is high more than 250 meters
from 7 liner top. 400 series ESP will be installed below perforations.

Methodology
During the study for suitability of ESP for the above wells a screening
Rule of Thumb was created as a simple guide for prioritizing ESP
candidate. The selection criteria focus on feasibility of installation,
operability condition and operating practice to maximize run life.

Feasibility of installation- this factor includes reservoir quality, well

inflow performance, produced fluid characteristics, well completion
etc. The standard practise for well completion is maximum
deviation < 85 deg, dog-leg severity < 6 deg/100 ft above set depth
,sufficient tangent section of < 1 deg /100 ft for landing ESP is
required
A bottom hole temp, 250 deg F is ideal as it allows for successful
application of standard design, material and operating practise. A
detail temp profile considering fluid velocity across the motor also
analysed in detail for smooth run life.
Gas volume fraction (GVF)- Improved ESP performance and
equipment run life is achieved at lower free gas volume. The ideal
condition is where the GVF is < 20% at the pump depth. Up to 70%
GVF can be handled effectively if special steps are taken in design,
selection of suitable Gas handlers and operation of ESP equipment.
The thumb- rule is to keep the pump- intake pressure above the
bubble point pressure where ever possible. A details analysis was
done to select most suitable gas handling efficiency for smooth
operation of the ESP for all the wells studied,
A safe pump intake pressure of 500 psi was considered for the
design to check the optimum possible increase in liquid production
 Common parameters such as the well productivity PI, pump setting
depth and total production rate are used for screening the
candidate wells.
Software was used for the indicative design and equipment from
the data sheet of the software has been used in the study

After analysing the well through the above guidelines, it can be deduced
that conversion from Gas lift to ESP for the studied 27 wells can be
categorized as:

a) Potential for oil gain : 15 wells with 2011 BOPD envisaged oil
gain and 6,55,000 SCM gas saving on account of conversion of gas
lift wells to ESP mode of lift
b) Wells identified with low gain but significant injection gas
savings: 2 wells with 133 BOPD envisaged oil gain and 1,20,000
SCM gas saving
c) Wells not suggested for conversion: 10 wells were not found
to be economically feasible.

Moreover there are 7 Horizontal drain hole wells and the same
completion philosophy was applied while installing the pumps with
suction at the start of the drain hole itself.

The indicative designs thus established gave a gain of 2144 BOPD

and a gas saving of 775000 SCMD on account of change in mode of
lift to ESP from Gas lift.

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