Trial experiment of dual ESP production technologies application for multi-reservoir fields of Lukoil-West Siberia

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This work represents the results of dual production technologies introduction at Urayneftegaz oil fields which allowed, under the conditions of low permeable reservoirs.

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Nội dung Text: Trial experiment of dual ESP production technologies application for multi-reservoir fields of Lukoil-West Siberia

International Journal of Mechanical Engineering and Technology (IJMET) Volume 10, Issue 03, March 2019, pp. 1038-1043. Article ID: IJMET_10_03_104 Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=3 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed TRIAL EXPERIMENT OF DUAL ESP PRODUCTION TECHNOLOGIES APPLICATION FOR MULTI-RESERVOIR FIELDS OF LUKOIL- WEST SIBERIA Valeriy A. Kostilevsky Deputy CEO of LUKOIL-West Siberia OOO, PhD in Engineering Oleg V. Bikbulatov Head of Oil Production Department of Kogalymneftegaz TPP ABSTRACT This work represents the results of dual production technologies introduction at Urayneftegaz oil fields which allowed, under the conditions of low permeable reservoirs, to:  increase the sweep and intensity of multi-reservoir field development by isolated development of certain layers;  ensure produced fluid accounting from each of the reservoirs;  efficiently manage the range of bottomhole pressures;  extend the field’s economic development time  reduce operational costs. Keywords: dual production; multi-reservoir oilfields; ESP production technology Cite this Article Valeriy A. Kostilevsky and Oleg V. Bikbulatov, Trial Experiment of Dual Esp Production Technologies Application for Multi-Reservoir Fields of Lukoil- West Siberia, International Journal of Mechanical Engineering and Technology, 10(3), 2019, pp. 1038-1043. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=3 A number of fields developed by LUKOIL-West Siberia have entered the late stage of development. The majority of residual hard recoverable reserves are located in low permeable reservoirs and their isolated development is not economically efficient. Maximizing the recovery requires development of all existing reservoirs in one well, however the license obligations for subsoil development should be observed [1-6]. Drilling of a separate well will be economically efficient only if production rate is minimum 60 m3/d [5-9].  The first steps towards dual oil production by Urayneftegaz TPP were made in 2011. The Company had to resolve the related issues such as: http://www.iaeme.com/IJMET/index.asp 1038 editor@iaeme.com
Valeriy A. Kostilevsky and Oleg V. Bikbulatov  increase the sweep and intensity of multi-reservoir field development by isolated development of certain layers;  ensure produced fluid accounting from each of the reservoirs;  efficiently manage the range of bottomhole pressures;  extend the field’s economic development time  Reduce operational costs. The task set to the technical teams was to ensure feasibility of individual control of the following parameters for every layer: Pump intake pressure (for bottomhole pressure calculation), fluid rate and water cut. The technology was first time introduced at Urayneftegaz TPP fields with TatNIPIneft representatives using the equipment of OOO Packer, Bugulma. The first candidate wells: 134p of Krasnoleninskoe field and 10700P of Novomostovskoye field, proposed by geologists for dual completion, had the following peculiarities. The well 134P contained two reservoirs (UK and VK formations), with the lower one having low productivity. The well was equipped with a single-lift, dual packer assembly with an ESP for the upper layer development and a sucker rod pump for the lower one. The well was started up on 25.04.2011. It was a new completion. After the dual oil production assembly was introduced, 4 workovers were conducted with the average MTBF of 99 days (96, 24, 192, 85 days). The well 10700P contained two reservoirs (USH2 and USH5 formations), with the upper one having low productivity. The well was equipped with a single-lift, single packer assembly with an ESP for the lower layer development and a sucker rod pump for the upper one. The well was started up on 02.08.2011. The well had been operated by ESP. After the dual oil production assembly was introduced, 2 workovers were conducted with 37 days MTBF. After the dual production assembly was started, in both cases a leakage was identified on the packer-nippel joint. Based on the analysis the material of the sealing rings of the packer case was identified as a bad actor (Fig.1). During the well servicing the polyurethane gasket of the nipple was replaced with a rubber one which allowed to achieve the leak tightness of the system. Based on the results of dual production application on these wells high water cut of the lower reservoir was established. Later, the lower perforation intervals were isolated in both wells. The next step was introduction of dual production technology with ESP+sucker rod layout with single-lift, dual packer assembly on the well 5632 of Krasnoleninskoe field. Manufactured by OOO Packer, Bugulma. Unreliable packer case was replaced with PRO-YaT-O packer. It allowed to enhance the reliability and effectiveness of the process. During the dual oil production assembly operation, 3 revisions of the downhole pumping assembly without packer pickup were conducted with the MTBF of 134, 112, 185 days respectively. All failures were caused by the tubing abrasion by the rods in the interval 600-830 m. It should be noted that operation of two pumps – ESP and sucker rod pump on a single lift causes restriction to using rods with centralizers, therefore the assemblies contained the rod with no centralizer. http://www.iaeme.com/IJMET/index.asp 1039 editor@iaeme.com
Trial Experiment of Dual Esp Production Technologies Application for Multi-Reservoir Fields of Lukoil-West Siberia The next trial was conducted on the well 9824 of Novomostovskoe field. ELKAM NEFTEMASH TD LLC equipment was used. The similar ESP+sucker rod layout to the one used in Urayneftegaz TPP, was applied (Fig.1). A weak point in the process scheme turned out to be the isolation shell. It functioned as a rod inserted pump sitting nipple, surrounded by a number of holes for the fluid passage from the lower ESP. Setting of a rod inserted pump into the shell is not process efficient if set in a sitting nipple, besides in case of leakage of this joint there is a risk of fluid interflow supplied by the ESP to the above-the-packer space. With such a failure the whole system should be shut down. Figure.1. – Dual production ESP+sucker rod pump layout on the well 5632 1 - ESP (complete set); 2 – Three-way check valve; 3 – Knock-off valve; 4 – Packer with cable duct; 5 – Isolation shell; 6 – Insterted sucker rod pump; 7 – Pumping rods string; 8 – Wellhead equipment for sucker rod pump; 9 – Power cable for downhole electric motor. http://www.iaeme.com/IJMET/index.asp 1040 editor@iaeme.com
Valeriy A. Kostilevsky and Oleg V. Bikbulatov As soon as West-Turgovskoe field development started, it became necessary to develop the reservoirs having sufficient productivity for the ESP+ESP dual production layout. Under the trial performed on the wells 4667 and 4685 in 2013 the full-set dual ESP+ESP production assemblies produced by Novomet-Perm CJSC were introduced. The fundamental difference was application of size 3 progressive cavity pump. Reduced diameter of the pump allowed the manufacturer to re-distribute the load from the assembly weight to the bypass line. The ESP included multiphase pump sections. The technology was introduced in the well 4667 in April followed by the well 4685 in June. The structural reliability of the downhole part of the equipment in these layouts "suffered" from the control stations. During the trial, the control stations of ESP size 3 failed multiple times. Representatives of Novomet-Service were called to recover the stations. The dual production layouts use ESP bypassing systems with Y-Tool. They are primarily designed for: - logging activities; - flexible pipe operations; - production string perforation; - chemical treatment of the reservoirs; - usage of two pumps; - RIH of fiber optic measuring systems. Tables 1 and 2 represent various layouts of dual systems with ESP. Table 1 Casing diameter 146 168 178 245 Size 3 3 3 Up to 5А 4 Outer diameter of the 122 142 152 210 assembly Upper ESP Bypass pipe diameter 42 / 26 56 / 40 56 / 40 73 / 50 (outer/inner), mm Capacity, m3/d 400 400 400 до 800 200 Size 5, 5А 5, 5А 5, 5А 5, 5А Lower ESP Capacity, m3/d 800 800 800 Up to 1000 Table 2 Casing diameter 146 168 178 245 3 Size 3 3 Up to 5А 4 Outer diemeter of the 122 142 152 210 assembly Upper ESP Bypass pipe diameter 42 / 26 56 / 40 56 / 40 73 / 50 (outer/inner), mm 280 Capacity, m3/d 400 400 до 800 200 3 Lower ESP Size 3 3 до 5А 4 http://www.iaeme.com/IJMET/index.asp 1041 editor@iaeme.com
Trial Experiment of Dual Esp Production Technologies Application for Multi-Reservoir Fields of Lukoil-West Siberia Case diameter 121 / 100 121 / 100 121 / 100 190 / 140 (outer/inner), mm 140 / 117 400 Capacity, m3/d 400 400 Up to 800 200 The main drawback of this layout is high cost of equipment. This is caused by application of ESP pumps of size 3. These pumps are produced only by order in small batches, the revision of the equipment is time-consuming even if performed at the manufacturer's site. On the other hand, the reduced diameter of the pump allowed the manufacturer to increase the diameter of the pipes used in the dual system and redistribute the load from the assembly weight onto the bypass line. Generally, the dual production conditions were met. The assembly remains operational if one of the pumps fails. Fig.2 shows a graph of changing production rate of the well 2081 of East-Surgutskoe field where dual ESP-ESP production layout was applied. Almost double growth of the production rate after the technology introduction can be observed. Figure.2. Changing production rate of the well 2081. REFERENCES [1] Badianov V.A., Baturin Yu.E., Efimov E.P., Ponomareva I.A., Pravednikov N.K. Sovershenstvovanie system razrabotki neftyanykh mestorozhdeniy Zapadnoi Sibiri [Enhancement of development systems for Western Siberia fields]. Sverdlovsk, Middle Ural Publishing, 1975, pp. 175. [2] Garipov O.M. Neftyanoe khozyaystvo - Oil Industry, 9, 2009, pp. 58-61. [3] Diyashev R.N. Sovmestnaya razrabotka neftyanykh plastov [Combined development of oil reservoirs]. Nedra, 1984, pp. 208. [4] Leonov V.A., Donkov P.V. 2001. Dual oil production in multiple reservoirs at Vanjegan field. Proceedings of the Conference “Ways of unlocking oil and gas potential in KHMAO”, Khanty-Mansiysk, November 14-18. http://www.iaeme.com/IJMET/index.asp 1042 editor@iaeme.com
Valeriy A. Kostilevsky and Oleg V. Bikbulatov [5] Medvedev P.V., Muslimov E.Ya., Movsesyan M. H. Engineering practice,2, 2012, pp. 52- 62. [6] Muslimov E.Ya. Overview of TNK-BP experience in dual production technologies, Proceedings of SPE Moscow Section Meeting, Moscow, 2012, January 17. [7] Afanasyev I.S., Pasynkov A.G., Khudyakov D.L., Gabdulov R.R., Nikishov V.I., Slivka P.I. Simultaneous - Selective wells operation. Smart well creation, Neftyanoe khozyaystvo - Oil Industry, 11, 2008, pp. 66-70. [8] I. Yu., Kazantsev, A. O. Gordeev, I. A. Vakhrusheva, A. A. Lutsenko. Experience of dual production technology application in the fields of TNK-BP OJSC. Proceeding of “Designing of oil and gas fields development in Western Siberia” conference, Tyumen, 2010, February 10. [9] A. R. Latypov, V. I. Nikishov, P. I. Slivka, A. A. Slabetsky. Neftegazovoye Delo, 6, 2008, pp.59-62. http://www.iaeme.com/IJMET/index.asp 1043 editor@iaeme.com