Gas Well De-Watering Techniques Using Electric Submersible Pumps

J.W. Knight & B.L. Wilson Baker Hughes Centrilift

Gas Well De-Watering Workshop, Denver, CO, USA March 3-5, 2003

Presentation Outline

Introduction Description of Technique Case History

Conclusions

Introduction

ESPs well suited for

high volume / low head apps (i.e., water wells, mine de-watering, surface liquid transfer)

low volume / high head apps (i.e., typical deep onshore U.S. oil wells)
high volume / high head apps (i.e., deep or extended reach offshore wells) minimizing FBHPs (thus maximizing well inflow)

Gas Well De-watering can involve

producing large quantities of water from significant depths (i.e., high volume / high head app)

potentially large volumes of gas which must be handled; thus annular separation usually key to success
setting the ESP system below perforations (sumping) in order to take advantage of annular gas/liquid separation the need to significantly reduce FBHP

Technique #1

Recirculation System
maximize well drawdown
minimize gas interference improve motor cooling in low volume wells provide an alternative to slim-line equipment patent protected technology

Original Style Recirculation Tube

Midland Style Recirculation Tube

Argentine Style Recirculation Tube

Recirc Pump Head / Tube / Cap

Recirc Tube and Protective Clamp

Case History #1

Well Data Summary

Static pressure, psi Producing GOR, scf/stb 1,200 6100

Water cut, % Bottomhole temp, F Oil gravity, API Water gravity Gas gravity Casing size & weight Tubing size Perforated interval, ft TVD Well depth, ft TVD

93 156 43 1.03 0.63 7-in., 23 lb. 3.5-in. 7,528 7,767 8,262

ESP Unit Comparison

Unit Pump
163 stg, 513-series, 4100 BFPD 207 stg, 513-series, 6100 BFPD

Recirc pump
N/A

Seal
400-series

Motor
450-series, 350 hp (re-rate), with 5.5 shroud 562-series, 570 hp

Pre-recirc

Recirc

9 stg, 513-series, 10000 BFPD w/ 64 ft recirc tube

513-series

Pre and Post-recirc Production

7 6

Gas Prod., MMcfd Oil Prod., BPD x 100 Water Prod., BPD x 1000

5 4 3 2 1 0 Gas Oil Water Pre-recirc Recirc

Note: estimated monthly oil & gas revenue increase = US $200K based on $18/bbl oil price and $2/Mcf gas price

Technique #2

Shrouded ESP System

not a new concept
common arrangement when sumping unit also used above perfs in low flow scenarios relatively simple system w/ minimal hardware drawback limits motor OD per given casing size

Case History #2

General field/reservoir/fluid data

Formation Name Rock Type Upper Pennsylvanian Dolomite

Subsea Depth Porosity Permeability Reservoir Pressure Reservoir Temperature Oil Gravity Gas Gravity Water Cut

-3500 SS to -4100 SS 4% to 30% 2 md to 2000 md 900 psi to 1200 psi 140 F 40 API 0.65 80% to 98%

Hydraulic requirement

+/- 10000 BFPD 6938 ft. TDH Delta pressure across pump = 3035 psi 7-in. versus 9.625-in. casing?

Shrouded ESP system configuration

74 stage 3X tandem HC12500, ARC trim

513 seal double bag seal w/ HS shaft

836 hp 562 series motor w/ HS shaft 7-5/8 motor shroud Instrumentation

Results for two Big-Holes

Gas rates 2.5X higher than previous best 7 wells Initial BWPD > 11,000

Economic Comparison 7 in. vs 9-5/8 in.

Parameter CAPEX 7 in. casing $1,500,000 9-5/8 in. casing $2,000,000

Monthly OPEX Avg Gas Rate Avg Oil Rate Avg Water Rate AFIT ROR AFIT NPV/I @ 10% Capital/BOE

$20,000 3500 MCFPD 200 BOPD 3000 BWPD >100% 1.45 $3.41/BOE

$35,000 5300 MCFPD 350 BOPD 5000 BWPD >100% 1.81 $2.90/BOE

Technique #3 Inverted Injection ESP

electric submersible pump system for de-watering
gas wells inverted system to pump water through a packer into a lower disposal zone eliminate surface water disposal costs VSD required (normally) Centrilift system known as GasProTM

Case History #3

Economic Overview

Gas well economics at unprecedented levels Gas price Mean predicted at $3.50 USD/MMSCF (Spear & Associates) 1 MMSCF/day of incremental Production Incremental revenues $3,500 USD/d ($105,000 USD/month) ESP Cost estimated at $105,000 USD Work over/completion cost estimated or $105,000 USD Pay out estimated at 2 months Assumption is that 6 month pay out is the economic threshold for project approval ESPs now a cost effective de-watering method

GasProTM System Configuration

115 stage 450-series RA7 pump (700 BPD) 400-series expansion chamber 400-series thrust chamber 77 horsepower 450-series motor Flow meter, check valve, on/off tool above packer

Before GasProTM
Stranded asset No production No revenue Well liquid loaded

Casing not tied in

After GasProTM
Bookable reserves 3.85 MMcf/day gas

$11,809 USD per day (@ US $3.07/Mcf)

Well unloaded Casing tied into gathering system

Conclusions
1. Electrical submersible pumps provide a viable gas well de-watering option, particularly at high Q/H requirements 2. All three techniques described have been successful for gas well de-watering

3. Sumping the ESP below perforations is oftentimes a key factor for success

4. Project economics can be quite favorable

References
1. SPE 75711 (for recirculation system case history) 2. SPE 77733 (for shrouded system case history), 3. SPE 37451 (for more info on recirculation system) 4. For more info on inverted ESP injection for gas well de-watering, see Hadaway and Oelke paper from 1996 ESP Workshop, Houston, TX, May 1-3 5. Recirculation Pump For Electrical Submersible Pump System, U.S. Patent No. 5,845,709 (1998), Mack, J.J. and Wilson, B.L.