ESPs with Permanent Magnet Motor (PMM)

in Salym, West Siberia (Russia)

Anton Bydzan, Production Technologist, Subsurface Team, SPD

Co-authors: A.Strokolist, CJ Affeld, A.Hagelaars, A.Zanimonsky, A.Mabian, Y.Nikulin,

February 2008
European Artificial Lift Forum 2008, Aberdeen
Quick overview of Artificial Lift in SPD
PMM advantages
SPD experience with PMM-ESPs
Looking forward

2
 About SPD

Joint Venture:
Shell 50%
Evikhon (Sibir Energy) 50%

Export
pipeline
West Salym

Main operational facilities:

CPF, MPS, PGP

• 3 fields
West Salym STOIIP ~ 320 MM m3
Upper Salym STOIIP ~ 70 MM m3
Vadelyp
Vadelyp STOIIP ~ 70 MM m3

Upper Salym

3
 About SPD

Operations:

• 4 drilling rigs
(adding ~100 wells per year)
• 6 hoists
• over 200 producers
(all ESP lifted)
• 70 injectors
Production Rate, m3/d

Injection Rate, m3/d

Water

Oil

Water injection

4
 About SPD

Reservoir: Lower Cretaceous consolidated sands

Depth 2100-2200 m TVDSS
Pres = 218-225 bar (hydrostatic)
Tres = 85-95 deg C

Fluids: Oil: Pb = 70 bar, SG=0.802, Viscosity 2 cP, GOR=32 m3/m3

Water: salinity 15 g/l,
Solids: 50-300 mg/l

Wells: Casing: 7” OD, L-80

Tubing: 3-1/2”; 2-7/8”, L-80
Well trajectory: - S shape : 0-10 deg dev.
- J shape : 0-60 deg dev.
- high angle wells: 80-85 deg dev.
ESP setting depth: 2000-2100 m TVDSS

5
 Quick overview of Artificial Lift in SPD
ESP stock in SPD

Main ESP vendors: Borets (Moscow, Russia)

Novomet (Perm, Russia)

Well potentials (End 2007) ESP capacity and lifetime (2007)

600 40 1200
37
36
35
1020 1005 1000
500
950
30 918
840 834 819

Quantity of pum ps
400 800
Flowrate, m3/d

Gross rate, m3/d 25 746

Net rate, m3/d 19
300 20 600
541 16
15
12 402 400
200
9 9
10 8
7
146 5 200
100
5 3
2
1
0 0 0
1 51 101 151 201 15 25 30 50 80 125 160 200 250 280 320 400 500

wells Nominal ESP rate, m3/d

6
 Quick overview of Artificial Lift in SPD
ESP Failure Analysis
All ESP sizes
Lifetime > 500 days
14%

Tubing leak
2%
Solids deposition
7%

Wear Scale deposition

4% 49%
Wax deposition
2%
R=0 in cable
9%

R=0 in motor
Scale deposition in ESP
13%
ESP-50 and smaller ESP-80 and bigger
Lifetime > 500 days
Lifetime > 500 days
14%
15%
Scale deposition
Tubing leak 25%
Tubing leak
0%
3%
Solids deposition
Solids deposition 5%
8% Wear
5%
Wear Wax deposition
3% 0%
Wax deposition
3% Scale deposition
63%
R=0 in cable
0%
R=0 in cable R=0 in motor
R=0 in motor 25% 25%
6%

7
 Quick overview of Artificial Lift in SPD

ESP technologies applied in SPD

Scale inhibitors Y-tool completion Permanent

(downhole containers and (PLT logging under ESP) Magnet
wellbore injection)
Motor ESP
Completion
Gun Anchor System Smart well for PBU testing
(underbalance perforation (downhole production
with ESP installed) allocation) (downhole closure and
PDHG under ESP)

8
Quick overview of Artificial Lift in SPD
PMM advantages
SPD experience with PMM-ESPs
Looking forward

9
 PMM advantages
Cross-section of a rotor
Main features of PMM
Permanent magnets

Design:
• Permanent magnets made from sintered materials in a rotor
• No sliding contacts on the rotor
• Similar design of a stator like in induction motors

Motor Shaft

Performance:
• Higher efficiency, lower power consumption
• Smaller motor dimensions at the same shaft power
• Wide RPM range: 250-2000, 500-3500, 2000-6000 rpm
• Lower heat generation
• No harmonic effects

10
 PMM advantages

Induction Motor vs Magnet Motor

Comparative Performance

Down-hole motor
Parameter Induction motor Magnet motor
Ratio
EDB36-117B5 1VEDB36-117B5

Nominal shaft power, kW 36 (50 Hz) 36 (50 Hz)

Nominal rotation frequency, RPM 2910 3000

Nominal required current, A 27,2 23.5 14% lower

Current at zero rate, not more, А 12,5 2,0 84% lower

Efficiency under shaft nominal power, % 83,0 91,5 10% higher

Power factor, COS Ф 0,84 0,96 14% higher

Length of motor, mm 3895 2375

40% shorter
(117 mm OD) (117 mm OD)

Weight of motor, kg 271 155 43% lighter

11
 PMM advantages

Induction Motor vs Magnet Motor:

Bench Test Results
Induction motor Magnet motor

Current, A

Efficiency, %

Power factor, COS Ф

Shaft Power, kW 12
Quick overview of Artificial Lift in SPD
PMM advantages
SPD experience with PMM-ESPs
Looking forward

13
 SPD experience with PMM-ESPs

Vendors (in Russia): Ritek, Alnas, Borets

Operators (approx. number of trials):

450

400
> 400 (since 2001)

350

300

250

200

150
(2005-2007)
100 69
(2007)
50
15 9 3 2
0
Company A Company B Company C Salym Company D Company E
(Russia) (Russia) (Russia) Petroleum (Russia) (Russia)
Development

14
 Number of installations

0
25
50
75
100

5
In operation

83
Retrieved

2
13
operational

R=0 in cable

12
ESP head

9
2
decline
Other Operators

ESP failure
Retrieved
SPD

Other reasons
SPD experience with PMM-ESPs

Not retrieved
ESP-PMM installations manufactured by Borets

R-0 in motor
15
 SPD experience with PMM-ESPs

SPD statistics for PMM-ESP lifetime (Feb 2008)

in operation
1361 34
in operation
1031 96
in operation
1014 164
in operation
1532 210
Well name

216
in operation
1531

190 ESP failure

1141
82 ESP failure
1048

1243 153 Retrieved operationa

1201 66 Retrieved operationa

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

Time, days

No PMM failures observed to date

16
 SPD experience with PMM-ESPs

SPD power consumption

other
other
CPF 7%
5%
CPF
8%
ESP
29% Rigs
31%
0%

ESP
54%

WI
Rigs WI
26% 31%
9%

2008:~ 35 MW 2020: > 40-45 MW

17
 SPD experience with PMM-ESPs
Specific power consumption
(per volume of lifted liquid)
30

25

20

kW*h/m3
15

10
Absolute power consumption
70 5

0
60 ESP-30 ESP-30 ESP-50 ESP-50
with PMM with PMM
50
ESP-50
Power Consumption, kW

ESP-50 with PMM

40
ESP-30
ESP-30 with PMM
30
30+50
30+50 PMM
20
Linear (30+50)
Linear (30+50 PMM)
10

0
0 20 40 60 80 100
Gross Rate, m3/d

18
 SPD experience with PMM-ESPs
Cost comparison:
Regular ESP system vs PMM/ESP system

%
110
~ 50 k$
100

90

80 VSD
Control Panel

70

60 Control Panel

50
ESP
ESP
40
Gas Separator
Gas Separator
30 Protector Protector

20 Induction
PMM
Motor
Regular ESP system PMM/ESP system
10
DHG DHG
0
ESP-50 ESP-50 with PMM
Similar price for ESP-50 installations 19
Quick overview of Artificial Lift in SPD
PMM advantages
SPD experience with PMM-ESPs
Looking forward

20
 Looking forward

PMM will become standard when PMM Servicing is available

in the area (since 2008)

PMM/ESP testing in high rate conditions

- more power savings per well;
- 1 sectional motor for bigger ESP (to date 200 kW is available in 117 mm OD)

PMM/PCP testing in low rate conditions (planned for Q1 2008)

- PCP with 2000 m nominal head;
- optimal RPM range for PCP (200…500 rpm);

PMM/ESP testing in cyclic mode in low rate conditions

- high capacity ESP (less sensitive to scale deposition);
- cyclic operation to keep FBHP at target level

21
Thanks for Attention!

Anton Bydzan

22