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G r a n d H y a t t R i o d e J a n e i r o • R i o d e J a n e i r o , B r a z i l • 3 - 4 M a r c h 2 0 2 0
ESP Technology Improvements in Peregrino FieldAntonio Alfonzo
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | Production
• Development plan in partnership with Sinochem.
• Over 170 million barrels of oil produced since
2011.
• Field structure consists of 2 drilling capable fixed
platforms and 1 FPSO.
• Current field production: 60-80k BOPD.
• Third fixed platform was commissioned in 2019
with first oil in 2020.
• Phase II will add 273 million barrels of oil in
recoverable reserves.
2
Source: ANP monthly report January/2019
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | Well Completion Design
• Open hole gravel pack lower completion design.
• Production packer above the ESP.
• 1100HP tandem 725 series motors.
• 675 series pumps.
• Two independent chemical injection systems.
• Isolation valve installed below the ESP.
• Diverter valve above the ESP discharge.
• Maximum packer setting depth: 4500m MD.
3
1 x 1/4” Hydraulic control line for DHSV
1.41" ESP power cable
(with 2 x 3/8" chemical injection lines)
MLE Cable
2 x 3/8" Chemical lines
Control lines:
1 x ¼” Hydraulic control line for setting the packer
1 x ¼” Hydraulic control line for discharge pressure
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | Well Completion Design
• ESP string installed inside a 7-5/8” casing.
• Triple tandem 562 series motors with 999HP.
• 562 or 538 series pumps.
• Removal of production packer above the ESP.
• Tailpipe below capsule seals inside middle completion packer.
• Reduction of mechanical stress applied to ESP components due to tail weight.
• Maximum packer setting depth: 5800m MD.
4
1 x 1/4” Hydraulic control line for DHSV
1.41" ESP power cable
(with 2 x 3/8" chemical injection lines)
MLE Cable
2 x 3/8" Chemical lines
Control lines:
1 x ¼” Hydraulic control line for discharge pressure
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Failure Types
5
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | ESP Teardown History
• Created by chemical instability between dielectric oil and heavy crude.
• Bag expansion capacity is reduced.
• Check valves plugged.
• Mechanical shaft seal operation is compromised.
• Limited sealing capacity leads to motor oil
contamination.
6
Asphaltene Precipitation
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | ESP Teardown History
• Loose Upthrust Bearing Pads
o Many upthrust bearing pads found loose in thrust chamber.
o Caused by impacts from runner during rotation speed variations.
o The issue hasn´t been identified as failure root cause yet.
• Pump Spinning Diffusers
o Pump diffusers spinning against housing caused pump to loose efficiency.
o Excessive thermal expansion created contact wear between impellers and diffusers.
o Pressure and temperature oscillations caused pump stages to loose compression.
o Excessive load in pump shaft.
7
Mechanical Failures
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | ESP Teardown History
• Wear between rotor end and carbide washer.
• Rotor ends severely worn.
• Excessive metallic particles contamination in motor oil decreasing motor dielectric strength.
• Compromised bearing lubrication due to oil contamination.
• Rotors strike against stator leading to short
circuit.
• Accumulation of hard material limits rotation capability of rotor stack which results in higher amperage.
8
Rotor’s Motor Bearing Failure
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | ESP Teardown History
• Epoxy with cracks leading to phase-phase
and/or phase-ground failures.
• Fluid contamination from the upper part of the
penetrator.
• Signs of overheating noticed during teardown.
• Possible root causes analysed:
o Incorrect installation or equipment handling.
o Improper annulus bleeding procedure.
o Power quality issues.
o No flow condition.
o Temperature and pressure oscillations due to emulsion production.
9
Packer Penetrator Failures
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Technology Improvements
10
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | ESP Technology Improvements
• Seal developed to increase reliability in an environment rich in asphaltene.
• Particle expulsion holes in top chambers in upper section.
• Communication holes in the housing replace communication through
head.
• Backup check valve in upper guide with parallel bags.
• Special non-sticking coating for head, upper two chambers and guides.
• Bag top cap and special neck clamp.
• High pressure single premium check valve.
11
ASP Seal
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | ESP Technology Improvements
• 725 series new design proposed for Peregrino application.
• Key improvements:
o Extended sleeve bearing.
o Thermoplastic thrust washer with larger ID.
o Sled key.
• New Motor design to deliver a smoother contact between end rings and washers.
• Stack weight is transmitted through the bearing sleeve.
• 42 strings with the new motor design were already deployed in the field without any failure up to date.
12
New Motor Design
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | ESP Technology Improvements
• Packer penetrator pressure ratings improved to 10k psi (absolute) and 5k
(differential).
• Temperature rating increased to 1800 C.
• Key enhancements:
o Lock ring uprated to high strength alloy.
o Pressure barrier sealing with compression ring face seals and FFLKM o-rings.
o Pressure barrier moulded with upgraded thermoset polymer.
o Lead sheet encasement instead of tape encasement.
o Bodywork improved to higher tensile steels.
o Upgraded thermoset moulds and insulation material.
• 29 HPHT penetrators already installed in the field without any failure up to date.
13
HPHT Packer Penetrator Design
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | Key Performance Indicators
• Track reliability using consistent metrics is
paramount to evaluate ESP performance.
• Data quality and detailed failure analysis is
important.
• Mean-time to Failure (MTTF)
o Widely used metric in ESP industry.
o Allows meaningful conclusions even when a limited
portion of the population has experienced a failure.
o Earlier measurement of performance impact after
design changes.
o Forward tracking method.
14
Mean Time to Failure
Day
s
ESP Run Life KPIs
HPHT Penetrator
Vanguard Pump Technology
New Motor Design
ASP Seal
1538 days
Source: ESP Run Life Control KPIs - BH
PSU Motor
Q1 Traceability
Type 4 Seal
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
Peregrino Field | Key Takeaways
• Collaboration between operator and vendor is essential for improving ESP performance.
• Equipment customization is required in challenging applications.
• Detailed failure analysis drives equipment improvements.
• Ongoing actions to increase ESP reliability:
o Performance based contracts.
o Audits in Manufacturing Center to improve quality control.
o Focus on equipment testing prior to offshore mobilization.
o Partnership with Research Center and universities to better understand application challenges.
o Implementation of recognized industry standards (ISO 15511).
o ESP operation digitalization.
15
Conclusion and Way Forward
© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C
ESP Technology Improvements in Peregrino Field - SPE-194401-MS
Acknowledgements