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Successful Installation of The First Dual Concentric Completion System On 9 5 8inch Casing ESP ESP Type in Colombia
Successful Installation of The First Dual Concentric Completion System On 9 5 8inch Casing ESP ESP Type in Colombia
Abstract
The Oil and Gas industry is always looking for methods that reduce costs associated with the drilling process and, over the
last decade, eliminate the environmental impact of well preparation. One new technology provides an option for oil and gas
producers to achieve that goal allowing installation of two sets of electrical submersible pumps (ESP) on the same well bore
but producing two sands separated by a packer.
The purpose of the following paper is to to present a real example of the successful installation of a Dual Concentric
Completion System in COPA ASUR3 , allowing two ESP systems to produce two different sands on the same well bore
separated by a packer, and to demonstrate the economic effects of its use, reducing by 38% the costs associated with the
drilling process, 14% on the total drill/completion investment and 50% on the environmental impact in COPA field
(Colombia). The design and installation of the system were carried out taking into consideration Local Governmental
regulations requiring both production zones remain insulated from each other.
Evidence explained on this paper helps to conclude that Dual Concentric Systems are proven to be applicable for specific
fields with adequate sand distribution and fluid characteristics, also the use of Dual Concentric Systems complies with
Government regulations keeping production from both zones isolated when applying the right integrity test procedure and
that the use of Dual Concentric Systems significantly reduces costs and environmental impact associated with the drilling
process and surface facilities configuration requirements.
Keywords: Dual concentric completion, Electric submersible pumps, ESP, Artificial Lift.
Introduction
Increasing demands from the Oil and Gas industry for economic and viable ways to reduce costs on hydrocarbon extraction
processes have, since the 1950s, pushed the industry to consider dual concentric completions for multiple applicationsi. In
cases where multiple stratified oil reservoirs are present and the general downhole conditions (formation characteristics,
downhole pressure, fluid properties, etc) demand the development of each reservoir separately by local regulations, the
traditional solution was to increase the number of wells to be drilled in order to recover fluid from all zones simultaneously,
or produce different zones from the same well bore by single zone selection using sleeve/valve methods to allow the selective
production.
Multiple drilling processes increases CAPEX figures considerably and is commonly considered as the only solution for
multiple zones production, and important financial effect is add by the deferred production consequence of the drilling and
completion period invested until fluid is obtained and the safety and environmental footprint caused by each wells
preparation. On the other hand, selective zone production using SSD forces a production delay or reservoir production slow
down, which has a negative impact on the operators extraction expectations, always sacrificing the input from the less
productive zone.ii
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Field History: On 26th Jun 2012 Copa 5 well was completed with the first dual concentric system in Cubiro field, aiming to
produce two different zones on the same well bore. The installation was successfully achieved, however production tests after
start up showed unsatisfactory results on the
the fluid composition of the lower sand (C7) leading to a shutdown of the lower
system leaving only the upper ESP assembly in production. (Figure 3)
Figure 3 DHG Data from both ESP system during start up in COPA
This successful first installation experience with dual concentric systems provided the operator and all service companies
involved with a full understanding of the potential that this technology represents for the future development of the field and
the positive impact on the operators financial and QHSE figures.
General System Design: COPA ASUR3 is an exploration well which is expeted to provide information to define, characterize
and determine the existing reserves for this carbonated area (C5 and C7), reason why is necessary to flow both reservoirs on
different paths.
COPA A3SUR was drilled on 15th Jan 2013 and zones tested confirming C5 and C7 as the productive zones to be considered
for a dual completion design. The system needed to be designed to produce C5 & C7 zones with adequate insulation. In
order to confirm and prove this insulation, specific integrity tests were planned for the installation process to guarantee such
conditions.
Using previous experience in COPA5 and worldwide recommendations and information, the criteria used for this application
to select and design the system configuration and installation procedure were based on the following aspectsiv
1.
Mechanical considerationsv
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Casing Information
ID
Drift
Weight
TOP
Bottom
9 5/8
8.755
8.599
43.5 lbs/ft
Hanger
5615 ft
Qty
1
1
1
1
1
1
1
2
2
1
2
2
1
1
1
1
2
1
1
7
Weight Table
Item
ESP System
Sensor Discharge Sub E7
AFV
Crossover 3 1/2" EUE x 2 7/8" EUE
HEAD,PUMP BO TR4 2-7/8 8RD
PUMPs,TD2200 CMP 49/11B #06
PUMP,TD2200 CMP 100/21B #12
INTAKE,PUMP BO TD AR STL
SEAL,TR4 DBG PFDB AR HL-HT
SEAL,TR4 DBG PFDB AR HL-HT
MOTOR,TR4-92 120\1625\ 46 UT
Motor base crossover
E7 Sensor with Discharge Pressure
GAS,SEPARATOR TR4 MAGS-3
MOTOR,TR4-92 80\1085\ 46 UT
PUMP,TD1250 AR CMP 87/11B
CENTRALIZER 4.65 OD TR4
Tubing
3 1/2" EUE #12.95
Dual
POD Assembly+tail pipe
Saddle Assembly
By pass tubing THS blue + Crossover
Total
Weight Pounds
3083
65
75
25
23
350
350
25
110
110
750
25
20
30
750
320
55
777
777
3170
3412
261
274.16
7870
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2.
Location
Back up System
Pre-shipment installation checks.
Flexibility
Considering the distance between the ESP and Dual system providers
providers warehouse and the field location, a complete backup
system was requested to overcome any design change or component failure during the installation.
All the equipment was physically checked by the ESP Company and the dual completion system provider prior to installation
in order to confirm measurements and neck sizes for clamp installation. This process highlighted neck size differences
between nominal and real value. This was rectified prior to installation.
For this project a Bypass System with saddle assembly option was selected which allows flexibility in the space out
procedure when connecting the Y-Block. This was suggested in order to avoid delays matching by pass tubing and pump
ends on the top connections during the RIH
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3.
Fluid Properties
Material
Ranges
Maximun Temperature
180 F
800 psi
CO2
N/A
H2S
N/A
N2
N./A
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L1
Sensor - Motor
2.87
4.56
2.56
Motor - Seal
2.875
4.5
2.26
Seal - Seal
2.875
4.5
3.05
1.463
Seal - Intake
2.25
3.75
Intake Pump
2.63
1.125
Pump Discharge
2.63
1.125
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Clamping the ESP neck to the By Pass tubing will be done by using adjustable clamps type 1 which offers a range of
adjustment from 2.250 up to 3250 1, covering all necks to be installed specified on table 5. The use of Adjustable clamps
is a method which simplifies the preparation of the system allowing quick changes in design without affecting delivery times
or installation duration of the system
Operative scenarios
Tools required (lifting, work tables)
Procedure review for specific project.
Dual Completion ESP-ESP Type on 9 5/8 Casing Final Design: Only after a thorough review of the system requirements
and consideration between all parties involved, the final design was approved and the dual completion tools and accessories
were moved to the location to be installed in COPA A3SUR
Bottom Assembly:
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Primary Purpose: To provide a seal between C5 and C7 Zone and Stinger connection port for the upper assembly to be
connected.
Consists of the following items:
Qty
Description
Length
Depth
61.02
5,390.02
Safety Joint
1.04
5451.04
31.00
5,452.08
21.62
5483.08
16.20
5504.70
1.09
5520.90
1.02
5521.99
0.27
5523.01
5.12
5523.28
19.10
5528.40
0.54
5547.50
1.82
5548.04
0.70
5549.86
36.10
5550.56
5.5" 17#L80,BTC,316L
(PremiumNet)
37.70
5586.66
0.73
5624.36
0.91
5625.09
3.24
5626.00
10
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11
Qty
Description
Crossover 11450041201
Length
4.65
1.44
9.65
Dept
h
7,405
.12
7,406
.56
7,416
.21
5.00
7,421
.21
0.50
7,421
.71
18.90
7,440
.61
1.10
7,441
.71
12.60
7,454
.31
19.70
7,474
.01
3.62
7,477
.63
13.00
7,406
.56
20.00
40.00
11.00
7,426
.56
7,466
.56
7,477
.56
12
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13
Qty
1
Description
Coupling and Cross overs
Length
Depth
0.77
7,240.04
3.48
7,251.14
9.53
7,260.67
4.85
7,263.97
60.00
7,323.97
n/a
n/a
5.00
7,261.67
0.50
7,262.17
14.40
7,276.57
3.10
7,279.67
12.60
7,292.27
19.70
7,311.97
E7 DHG Sensor
2.80
7,314.77
9.20
7,323.97
Saddle assembly
15.50
7,339.47
14
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Operational guidelines. The following section contains a detailed installation procedure and pressure test guidelines in order
to understand and consider all operational aspects of a Dual concentric installation.
On surface and before starting to run completion
A. Manual set 2.750 Blanking Plug in Pod bottom crossover
B. Manual set 1.875 Standing Valve in Pod Hanger
Run completion tailpipe assembly:
1. Build Zenith Pod assembly
2. Pressure test pod assembly against 2.75 plug Test to 3600psi max
3. Rig up wire line
4. RIH and pull 2.75 plug
5. Rig down 2.75 Blanking Plug Redress Blanking Plug
6. Rig down wire line
7. Build Pod ESP
8. Make up pod hanger - Test between pod hanger seals using hand pump 3000psi max
9. Build Intermediate tubing and By-pass system
10. Make up Y tool and run 1 or 2 joints tubing
11. Rig up wire line
12. Make a 1.901 drift run through Y-tool/By-pass/Intermediate tubing - Drift to Pod
Hanger nipple/1.875 Standing Valve
13. Rig up Isolation Sleeve/Standing Valve on wire line - RIH and set 3.75 x 3.555
Isolation Sleeve across Y-Tool Top Nipple/Teleswivel Nipple
14. POOH and rig down wire line
15. Pressure test By-pass/Intermediate tubing against 1.875 Standing Valve Test to
3600psi max - (Testing through Isolation Sleeve)
16. Space out by pass Assembly as per procedure
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Pd
Psi
Ti
Deg C
Tm
Deg C
1581.0
2086.0
171.9
177.4
Pi
Psi
Pd
Psi
Ti
Deg C
Tm
Deg C
1560.9
1998.5
180.0
185.0
Figure 14 shows the data from the DHG installed on the well, Pi & Pd behaivor during the start up with fluid in surface
confirms the sucess of the installation and the integrity of the system.
Lower Reservoir
Upper Reservoir
Start Up
16
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QHSE Results
Financia Results.
138K$
483K$
1371K$
2560K$
DISCUSSION
Operational. Dual concentric system installation meets the project expectation. Having tested both strings for leaks and
having fluid to surface from each system it can be considered a successful installation. The installation added an efective 25
hrs compared with a traditional installation of a BES on 7 Casing with By-pass System.
QHSE. Man hr worked reduction affects directly the likelihood of having a incident/accident while performing oil field
operations. On COPA ASUR3 the 12000 Hrs required to achieve two zones production (drilling&completion) could be
compared with the human resource investment necessary to drill and complete two different wells and obtain the same
production results.
Standard drilling/completion process takes around 11000 hrs (on average) on each 7 well completed in Copa Field,
suggesting that the use of this type of system could reduce the exposure of field personnel by almost 50%.(46%)
Financial. Efective cost associated with the project is compared with the previous standardized and accepted option which
consist on the drilling of two 7 casing separated wells being completed with one ESP system per hole. The analisys is
carried out taking in consideration the following aspects:
-
Preliminary and Mobilization: Location preparation for the intervention, well area adecuation, surface equipment,
personnel involved, surface facilities and Rig mobilization.
Drilling Surface Hole: First stage on the drilling process including material and personel involved.
Drilling Production Hole: Second stage on the drilling process, consisting on the 9 5/8 hole perforation, casing
installation, material used and the personnel involved on the operation.
Completion: Include Rig time used during the installation of the completion on the well, completion elements and
material, personnel.
Table 8 shows a comparative method to determine the benefit of the technology between the perforation and completion of
two 7 Casing Well (previous alternative) against the cost associated with the drilling and installation process of one 9 5/8
casing well with a Dual Concentric Completion
Description
PRELIMINARY AND MOBILIZATION
DRILLING SURFACE HOLE
DRILLING PRODUCTION HOLE
COMPLETION
TOTAL
2 x 7" WELLS
$ 276,178
$ 964,445
$ 1,926,003
$ 2,111,238
$ 5,277,864
DUAL
$ 138,089
$ 482,933
$ 1,371,245
$ 2,560,216
$ 4,552,483
Difference
$ 138,089
$ 481,512
$ 554,758
-$ 448,978
$ 725,381
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Thousands
$ 5,278
2 x 7" WELLS
$ 4,552
DUAL
$ 5,000
$ 4,000
$ 2,560
$ 3,000
$ 2,111
$ 1,926
$ 2,000
$ 1,371
$ 964
$ 483
$ 1,000
$ 276 $ 138
$0
PRELIMINARY AND
MOBILIZATION
DRILLING SURFACE
HOLE
DRILLING
PRODUCTION HOLE
COMPLETION
TOTAL
Saving figures:
Drilling process: 37% (1.17MM$)
Overall process: 14% (726K$)
Economic analysis is carried out without tacking in consideration savings on differed production obtained 15 days eaerlier on
one of the wells. Also there is a risk involved and not considered on this analysis, which is that on standard drilling and
completion process there is a chance of not obtaining good results on a specific reservoir that was planned to flow.
RECOMENDATIONS
To develop a strategy and future recomnedations for Dual Concentric Systems in 7 Casing applications. This could
represent an increment on the saving figures from 37% up to 45% (around 1.5MM$) to be used on lower flow rate
wells (smallers pump)
To consider the differed production financial implicati
implication
on of the use of this technology
To use adjustable systems which accommodate different type of pumps and allows reacting to ESP desing changes
as consequence of specific well conditions discovered on the drilling process.
To install Auto Flow Valves eliminates the requirement for SSD valves when recirculation is required, also is
expected to improve the runlife of the ESP system avoiding early workover manubers.
To use discharge pressure gauges in order to identify pump efficiency during the runlife of the ESP equipment
helping to optimize its use.
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REFERENCES
i
Concentric copletions of Oil and Gas Wells - 1959 G.M Harper Jr., Union Oil Co. of California
ii
Experience with dual completions in TNK-BP 2012 E. Muslimov, P. Medvedev / JSC TNK-BP Managrment
iii
Completacion dual Concentrica con Bomba Electrosumergible y Flujo Natural de un pozo en el Oriente
Ecuatoriano para Revestimiento de 9 5-8y liner de 7 2010 E. Peralta, E Baquerizo, H. Roman.
iv
Diseno de completacion dual concentric BES-FN para Casing de 9 5/8 2011 J. Soto, C. Salazar
Completacin Dual Concntrica, Pozo Sacha-165D. Anlisis de Factibilidad. H. Romn, G Echeverra e J. Chiriboga.
PETROPRODUCCION, 2004
* News Release Petromagdalena News http://www.prnewswire.com/news-releases/petromagdalena-announcesexploration-update-147524255.html
* Zenith Oilfield Dual concentric Manual and procedure - Ian McConnachie 2010
* Allange Energy Corp. ESP system design information Production department - 2012