Driving Optimization through a Full Artificial Lift Well Cycle · PDF fileDriving Optimization...

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Driving Optimization through a Full Artificial Lift Well Cycle

Olivier Leclerc, Europe ESP Sales leader

Julian Cudmore, Senior Product Manager - Upstream Digital Solutions

Scott Raphael, VP Product Management - Upstream Digital Solutions

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Agenda

• Product Solutions with focus on recent ESP technology

developments by Olivier Leclerc

• Zenith gauges – and recent tech developments in monitoring tech

(GFI gauge, Downhole Water Cut Monitor & ESP Power Optimiser)

by Julian Cudmore

• APM & Demo by Scott Raphael

• Q&A

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ESP Technology

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ESP OverviewAutomation and Production Optimization

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Offering full range of artificial lift

Integrating automation and production optimization

software

Refining GE’s oilfield operating model

Wood Group ESPs + Lufkin + GE Technology … Automation & Field Optimization

+ +

Artificial Lift

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ESPs in Unconventional wells

Key Challenges

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ESPs in Unconventional wells: Key Challenges Gas production

Ace +Gas Separators Advanced Gas Handlers

Handles 75% of free gas

without gas locking at low

intake pressures

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ESPs in Unconventional wells: Key Challenges Solids Production

AR Modular Pumps GE PLUSCoat

Abrasion Resistance

• Proprietary plating process

• Chemistry for O&G environment

• Structure designed for strength

• Additives for superior wear resistance

• 6-7X > performance Ni-resist Type 1

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ESPs in Unconventional wells: Key Challenges Rapid Decline Rate

Q+ Pump design

Lift Plus Q+ 675

Lift Plus Q+ 1000

Lift Plus Q+ 1750

50 – 1200 BPD

300 – 1750 BPD

500 – 2730 BPD

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ESPs in Unconventional wells: Key Challenges Wellbore access for ESP systems

Permanent Magnet Motor

70 ft.

30 ft.

13 ft.

PM Motor Highlights

• +15 Points Efficiency

• Higher Power Density

• ~ 1/3 IM length

• > 3 Times Torque

• Higher Power Factor

• Smaller Power Cable

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Zenith® E-Series ESP Gauges

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Zenith Downhole Monitoring Systems

Enabling customer reserves to be produced in the most efficient and profitable manner, the Zenith name has

become synonymous with reliable downhole monitoring systems.

ARTIFICIAL LIFT MONITORING

ESP Monitoring

Zenith E-Series for ESP

Zenith GFI ESP Gauge

Zenith Hi-Temp for ESP

Zenith E7/8+ Intelligent Monitoring

Zenith ESP Motor

DIagnostic

PCP Monitoring

ZenithC-Series for PCP

Zenith PCP Protection

System

ZenithHi-Temp for PCP

Gas Lift Monitoring

ZenithC-Series

for Gas Lift

Beam Pump Monitoring

ZenithC-Series for Beam Pump

High Temperature Monitoring

Zenith HT Hi Temp

Monitoring

Zenith ST Severe Temp

Monitoring

Zenith XT Extreme Temp

Monitoring

RESERVOIR MONITORING

Zenith R-Series Quartz Reservoir Monitoring Zenith ZTORM™ True Oil Rim Measurement

Over 13,000 Zenith monitoring systems installed worldwide

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Zenith® E-Series Gauge

• # gauges installed

• 10,000• 2005-2015

• Longest running

• >10 years• Saudi Arabia | Sept 2005 - present

• Mean time to failure

• 5.4 years• Based on 223 installs in Middle East

Regional reliability:

96.47 100 97.5392.56

98.54 96.78 94.27

0

20

40

60

80

100

Asia Pacific Europe Middle East N Africa N America S America Sub Sahara

No. Gauges Tracked:

Asia Pacific 963

Europe 12

Middle East 2,022

North Africa 242

North America 137

South America 751

Sub Sahara 297

Stats correct @ June 2015. Gauge reliability rates calculated from tracked installs vs known gauge issues.

Cable issues and gauges with status unknown removed from calculation to allow a true picture of gauge reliability.

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Zenith® GFI ESP GaugeGround fault immune monitoring system

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Zenith® GFI ESP GaugeGround fault immune ESP monitoring system

Challenge

• ~15% of downhole ESP monitoring systems fail

due to ground faults on the ESP cable – GFI doesn’t.

• Faults on the ESP cable cut off all data to surface

• With no downhole data available, operators are

faced with full workover or running motors at

lower pumping rates to ensure safe operation.

25% reduction in output from 800BOPD well = $2.92MM* per year lost revenue

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Zenith® GFI ESP GaugeGround fault immune ESP monitoring system

GFI ensures maintained optimised production:

operators continue to receive data as long as ESP cable is operational

Solution

• Runs unique power/communications system

Cable faults will not short the system.

• Transmits data very quickly (~0.5s per reading)

• Delivers indication of cable fault location

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Zenith® GFI ESP GaugeGround fault immune ESP monitoring system

Operators are benefiting from higher-speed, higher-accuracy data

despite cable faults; detecting faults & delivering diagnostics on the source.

Benefits

Real-time data available despite ESP electrical fault

Electrical diagnosis assists in predicting ESP failure

Electrical diagnosis assists in establishing root cause of ESP

failure

Depth of fault information enables faster workovers

Depth of fault information improves cable inventory

management

Insight into power management prolongs ESP runlife

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Zenith® GFI ESP Gauge

Ground fault immune ESP monitoring system

Experience

1. Accurately located cable fault measurement accurate to <60ft & gauge continued to record data

2. Identified power line fault avoiding early failure of the power system & unscheduled down time

3. Detected, measured & operated through dead short detected during run in hole & continued to recover data

4. Enabled decisions despite cable fault in live production operations completion would have been pulled or operated blind & unoptimised

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Zenith® ESP Motor DiagnosticsBalancing power usage with production

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Zenith® E-Series Gauge

with wye-point voltage monitoring

Solution

• Direct measurement of AC at motor wye point

with the Zenith E-Series ESP monitoring system

• Insight into electrical system issues BEFORE

they pose any immediate operational threat

• Knowledge of deterioration and potential failure

means timely, informed decisions can be taken

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Zenith E-Series gauge data

Example of wye point voltage monitoring

A healthy ESP electrical

system would maintain a

generally steady AC

voltage reading.

This visible increase

in AC voltage

highlights issues in

the ESP electrical

system.

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Zenith® E-Series Gaugewith wye-point voltage monitoring

Benefits

Minimise losses through predictivity of downtime:

• Wye-point voltage monitoring delivers a clear

indication of fault/imbalance in the ESP system

• Early-warning diagnostic measurement with

auto-alarm allows time to:

Assess well and field priorities

Action appropriate frequency adjustment

Prolong ESP pumping system runlife

Initiate effective workover planning

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Zenith® ESP Motor Diagnostics

Balancing power usage with oil production

Challenge

Energy required for extracting oil from wells is increasing as resources decline

and operations go deeper

Despite high energy costs, many operations use energy inefficiently,

prioritising production over efficiency

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Zenith® ESP Motor DiagnosticsBalancing power usage with oil production

Solution

Downhole power optimization from a standard

ESP gauge:

Real-time power analysis at downhole & surface

wye-points monitors ESP power

Downhole electrical measurements sent to

surface with traditional parameters

Conventional gauge surface logger displays/logs parameters

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Zenith® ESP Motor Diagnostics

Balancing power usage with oil production

Benefits

Unlocks key ESP parameters allowing maximised efficiency:

Measurement Benefit

Motor frequency Actual operating point

Slip rate Actual RPM

PF Actual effective power

Torque & HP Actual load at motor

DH volts & amps Losses & fault indication

Motor efficiency Real-time motor performance monitoring

Shaft rotation direction Reduce start-up delays

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Zenith®

Downhole Watercut MeterDirect real-time measurement for optimised well performance

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Zenith® ESP Motor Diagnostics

Balancing power usage with oil production

Challenge

Downhole water cut measurement is essential for true optimised well

performance

Several surface tools and techniques are available

Limited options for direct real-time downhole measurement — all of which

carry a high price

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Zenith® Downhole Watercut Meter | Direct real-time

measurement for optimised well performance

Solution

Permanent continuous measurement of water cut

from an industry-standard downhole gauge

•Downhole water cut range

•Accuracy

• Temperature rating

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Zenith® Downhole Watercut Meter

Direct real-time measurement for optimised well

performance

Benefits

Provides real-time understanding of changes in the

well and reservoir

Enables efficient and reliable water management

for effective production optimisation

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Digital Upstream

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Revolutionizing Upstream through Software

Field Vantage

• Artificial Lift Focus• Monitor Advise

Optimize

Digital Maturity

En

terp

rise

Valu

e

Digital Upstream

Unified, holistic view

Full asset optimization

Connected workflows

Enterprise scalability

Quick deployment

Always up to date

Managed Service

32

Delivering outcomes that matter…

Optimizeproduction

ImproveReliability

• Recovery Factor (OOIP Conventional)

• Utilization Ratio(CO2 EOR)

• Utilization Ratio(SAGD SOR)

• Gas Lift Production Gain

• Power Quality Deferments

• Unplanned Downtime

• Planned Downtime

• Failure Rate

KPI Potential Impact

5% - 10%

1 Mscf / bbl

5% - 15%

10%

50%

10% - 40%

15% - 45%

10% - 20%

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O&G Vertical Product Suites

Visualization &

Collaboration

Incident

Management

Inspections

On-ramp

System 1

On-rampEdge

SimulationAsset Services

Connectivity

Data

Management

Analytics

Orchestration

Risk

Management

System Health

Workflow

Optimization

Operations

Optimization

Maintenance

Optimization

Core Services

Digital Twin Foundation

Edge & On-Ramp Services

Digital

Inspections

LNG/FPSOUpstream DownstreamMidstream• Onshore

• Offshore

• Subsea

• LNG

• FPSO

• FLNG

• Refinery

• Petrochemical

• Fertilizers

• Pipelines

• Storage• Non-

Productive

Time

Avoidance

• Production

Optimization

Customer

Outcomes

Predix + APM + Digital Twins = A Step Change

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Digital Upstream Roadmap

ExplorationField

Development ProductionGathering &

Processing

Abandonment

& Remediation

Life Cycle

Optimize Production

Improve Reliability

Operational Intelligence

Phase 1 Phase 2 Phase 3

• Performance & KPIs

• Surveillance• Open Analytics Engine

• Well Optimization

• Lift Optimization

• Equipment Health

• Power Management

• Prognostics & Lifing

• Reliability Centered

Maintenance

• Process Visualizer

• Flowback Advisor

• Flood Optimization

• Network Optimization

• Process Visualizer

• Economic Decision

Support

• Flow Assurance

• Equipment Lifecycle

Management