Multiple ESP solutions help operator dewater gas well

Overview

A European operator was challenged to efficiently dewater a well with high gas volumes. Previous attempts using a sucker rod pump were unsuccessful due to high sand volumes. When the well stopped producing, the operator considered abandoning it.

Challenge

Electric submersible pump (ESP) systems offered the best solution to bring the well back online, but substantial water volumes would challenge them during startup and significantly lower volumes once gas flow resumed. Additionally, they would have to contend with the possibility of high gas volumes and potentially producing sand that had accumulated at the bottom of the well.

Solution

Drawing from the operator’s expertise in dewatering gas wells and the extensive experience Summit ESP®- A Halliburton Service brought with ESPs in challenging gassy and sandy environments, a novel pump design emerged. Strategically installed below the perforations and incorporating a shroud, the specialized Tiger Shark® pump ESP system with an exceptionally broad operating range would ensure stability even during fluctuating liquid inflow conditions. Erosion Buster® stage technology and robust tungsten carbide bearings were incorporated to tackle sand production.

During startup, gas separators, and handlers adeptly managed high water rates while handling high gas production at later stages. An ACS-15® variable speed drive, equipped with gas-lock mode, managed the ESP during periods when taking on high gas volumes.

The Intelevate™ digital platform provided 24/7/365 cloud-based monitoring to assist in finding stable operating conditions, real-time power consumption tracking and enhancement, performance audits, and remote control of the ESP. Optimization settings were identified for surface gas and water adjustment valves based on real-time, high-resolution data, which allowed rapid data-driven decisions to recover maximum gas production. Team members used an optimization playbook with gas dewatering troubleshooting techniques and an engineering manual with best practices for extending ESP equipment integrity.

Result

After installing the ESP, gas production increased by an average of 200-m3/h; however, higher gas rates were not achieved due to reservoir constraints. All other targets were met, including dewatering volumes, bottom hole wellbore flowing pressure, and stable ESP operation. Due to this success, additional wells are being evaluated for dewatering with ESP to bring back gas production. Additionally, the customer now uses the Intelevate digital platform as a reliable online service for controlling the ESP system remotely and is satisfied with the team’s continuous collaboration efforts to optimize operating parameters.