Summit ESP® successfully replaces rod lift system in low-flow well

Overview

An operator in the Bakken formation initially used an electric submersible pump (ESP) system and became displeased with the costs compared to other lift solutions. The operator switched to rod pumps, but higher gas rates and drawdown issues caused production rates to drop. Given the conditions, the operator used ESPs over rod lift systems to achieve more incredible production results.

Challenge

Rod lift systems have challenges, especially in extreme conditions with excessive gas and high depths. Gas is compressed within the pump itself before actually producing liquid. Solids fallback is also an issue, particularly in the Bakken formation. The client had wells with pump set depths ranging from 8,500 feet to 9,800 feet (2,591 meters to 2,987 meters) and bottomhole temperatures around 190°F (88°C). The desired results were not achieved with rod pumps, so the client reconsidered ESPs using the latest technology from Halliburton.

Solution

The Tiger Shark® SF320 pump was chosen for its larger shaft diameter to achieve production goals. The giant shaft allows for greater torque for the flow range, thus mitigating shaft breakage. The volute design diffuser provides high efficiency, while the wide vane configuration handles gas and solids more effectively. Liberator™ gas separators were used to separate as much gas as possible from the fluid before entering the pump.

The Tiger Shark SFGH2500 gas handler was used for its open impeller stage design, which handles a higher percentage of free gas going into the pumps and requires less horsepower than competing gas handlers. The Defender® super sand seal was added to this multi-technology solution for extended reliability. The super sand seal has exit ports at the top of the mechanical seal to prevent the swirling effects of abrasives, which destroy shaft seals and radial bearings.

Result

Extensive experience in deep, low-producing wells allowed Summit ESP to achieve well drawdown better than previously used methods and keep the production numbers up compared to a rod pump solution. In just six months, the increased production generated approximately USD 1.4 million in revenue for the operator.