This paper describes the implementation of a performance analysis (PA) review and a comprehensive root cause failure analysis (RCFA) for the artificial lift system (ALS) failures in heavy oil wells. The subject wells, located in Egyptian Eastern Desert (EED), have been operated by Canadian-Egyptian joint venture. Progressive cavity pump (PCP) and beam pump (BP) have been selected as the preferred ALS methods. With the objective of improving ALS performance, RCFA identifies the main causes of ALS failures and proposes guidelines and recommendations with a new open source service for the current and future development for EED Oil companies.
PA has been applied using some Key Performance Indicators (KPI), such as: failure index, recurrence index, and average run life in order to track all failed and crucial issues. RCFA has been applied to different ALS, such as: BP and PCP. Therefore, the definition or limitation of the boundaries of each system and the classification of failures were performed. RCFA covered failures between 2012 and 2018 for average 150 active wells and 622 failures. Finally, the new open source service applied as a trial to evolve the failure tracking and decision making methodology.
PA review showed a high failure and recurrence index that reached 3.0 and 3.7, respectively, in 2014 then declined to 1.0 and 1.7, respectively, in 2017 as a result of comprehensive corrective actions implemented. RCFA showed that rod string failure in BP was and still is a dominant failure with 200 failures over the last six years. Moreover, Down-hole pump failure in PCP was the major PCP failure system although its failures declined from 80 failures in 2014 to 14 failures in 2018. Several field cases were presented to cover the dominant cause of failures for both BP and PCP wells. Most wells had a significant improvement in their mean time to failure (MTTF) after reviewing design, installation and operation procedures.
The procedure for carrying out this methodology and implementing lessons learned has been presented in this paper. In addition, the new open source integration service provides an increased visibility about individual well performance issues and more broadly, about field performance and ALS failures.
Progressive Cavity Pumps (PCPs) are the predominant form of artificial lift method deployed by Australian operators in Coal Seam Gas (CSG) wells. With over five thousand CSG wells [
It is possible to gauge the holistic production performance of PCPs with the aid of real-time data, as this allows for pro-active and informed management of artificially lifted CSG wells. Based on data obtained from two (2) CSG operators, this paper will discuss in detail how features extracted from time series data can be converted to images, which can then aid in autonomously detecting abnormal PCP behavior.
Data-driven, or top-down, modeling uses machine learning and data mining to develop reservoir models based on measurements, rather than solutions of governing equations. Seminole Services’ Powerscrew Liner System is a new expandable-liner hanger that is set with torsional energy from the topdrive. Stuck pipe has traditionally been a challenge for the oil and gas industry; in recent years, operators have become even more determined to reduce the effect of stuck-pipe issues. The primary purpose of this study is to develop a method that overcomes the restrictions of rock-mechanics tests with respect to unconventional shale formations. The Earth is complex in all directions, and hydrocarbon traps require closure—whether structural or stratigraphic or both—in three dimensions.
ExxonMobil’s hot streak of offshore discoveries have sparked investor interest in the Guyana-Suriname basin. How did the company get there, and why do industry representatives feel optimistic about future deepwater prospects in the region? In the 30 years of operations on Suriname’s Tambaredjo field, the prime mechanism for lifting the 15.6 °API crude to surface has been that of progressing cavity pumps (PCPs).
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This course is designed to give trainees an overview of various artificial lift solutions and related production optimization concepts. After introducing participants to the need for an artificial lift system, training will focus on each of the following lift methods: Gas lift, Reciprocating Rod Lift, Progressing Cavity Pumping, Hydraulic Pumping, Electrical Submersible Pumping, Plunger and Capillary System. For each lift type, the course covers main components, application envelope, relative strengths and weaknesses. Animations, field cases, and example-calculations are used to reinforce concepts. A unique feature of this course is discussion on digital oil field as applicable to lift optimization.
A progressing cavity pump (PCP) system includes a variety of components. The basic system includes downhole PC pumps (and appropriate elastomers), along with sucker rod and production tubing strings and surface drive equipment(which must include a stuffing box). Surface-driven PCP systems require a sucker-rod string to transfer the torsional and axial loads from the surface drive system down to the bottomhole PC pump. Several different rod-string configurations are commonly used in PCP applications. These include continuous rods, standard rods with couplings (including hollow rods), standard rods with centralizers, and standard rods with bonded/molded rod guides. Within these categories are numerous additional variations resulting from differences in centralizer and rod guide design. The centralizers can be divided into two groups based on functionality. The first group consists of "coated" centralizers that have a urethane, plastic, or elastomer sleeve bonded to either a coupling or the rod body. The second group consists of "spin-thru" centralizers that have an outer stabilizer that is free to rotate on either an inner core or the rod body. With the spin-thru design, the rod string rotates inside the stabilizer, which remains stationary against the tubing.
In downhole applications, most progressive cavity (PC) pump failures involve the stator elastomer and often result from chemical or physical elastomer breakdown induced by the wellbore environment. Successful use of PC pumps, particularly in the more severe downhole environments, requires proper elastomer selection and appropriate pump sizing and operation. PC pump manufacturers continue to develop and test new elastomers; over time, these efforts have resulted in performance improvements and an expanded range of practical applications. Despite this success, the elastomer component still continues to impose severe restrictions on PC pump use, especially in applications with lighter oils or higher temperatures. The performance of an elastomer in a PCP application depends heavily on its mechanical and chemical properties.
Several nonstandard Progressing cavity pumping systems have been developed by various companies to improve pumping capacity, performance, and serviceability for certain applications. These nonstanard PCP systems includes a number of different downhole drive systems that inherently eliminate tubing wear problems and reduce fluid flow losses. Rod-insert PC pump designs are available that preclude the need to pull the tubing string for pump replacement. Charge pumps and fluidizer pumps are currently being used to increase the gas- and solids-handling capabilities of PCP systems. The following sections provide a brief description of the rationale for developing each hybrid system and a description of the basic operating principles of the product where applicable.