In line with its reputation of using the best technology to address its business challenges, Brunei Shell Petroleum (BSP) recently installed two 7" ESP Shuttle Systems from ZEiTECS. The Shuttles were installed in wells S-746 and S-747 in the onshore Darat field. These wells have 9 5/8" casing and were completed with 7" tubing. Both wells are now producing and are currently making over 700 BOPD.
The Shuttle technology permits the rapid retrieval and redeployment of an electric submersible pump (ESP) system through tubing using standard oil field technology. After the initial well completion or workover to install the ESP components all future operations avoid the use of a rig or hoist to retrieve the ESP. The ESP's supplied by Wood Group ESP and conveyed by wireline have been successfully started and are operating as expected. These installations were the second and third commercial installations in the world.
Typically ESP's are installed in wells on tubing and recovered when the system fails by means of a rig or hoist. BSP is planning a multi-billion dollar redevelopment of the Champion Field, offshore Brunei. Darryl Williams, Senior Production Technologist and Shuttle Project Leader stated that, "The green field area of Champion Waterflood project is reliant on the production continuity of ESPs. Over field life ESP failures remain inevitable and unpredictable and have the potential to cause significant production deferment, loss of reserves and increase operating expenditure. Although manufacturers have succeeded in extending run life, the fact is that operators still experience ESP failures even with the best operational practices."
Louis Huizinga, Champion Waterflood Project Manager commented that, "BSP has recognised that seeking solely ESP systems with improved run life potential alone does not put an end to costly, disruptive rig workovers required to replace the unscheduled failed or sub-optimal ESPs. To maximise the value of the Champion Waterflood project, BSP has assessed all current and new technologies, which would permit a more expedient, safe and economic means of retrieval and replacement. The ZEiTECS Shuttle met BSP's technical requirements and these installations are taking place to build up technical and operational expertise prior to the potential deployment of this technology offshore." The estimated value that this technology will add to the project is approximately US$25 million per year. This figure is based on a reduction in opex associated with rig-less ESP workover costs and a decrease in deferred oil when compared to the time required to deploy Coiled Tubing ESPs.
The successful and safe implementation of this technology has been due to the tight integration and support of many parties across BSP and between BSP, ZEiTECS and Wood Group ESP. This project was completed on time and within budget. In particular the Darat subsurface and operations teams, TSW/4, PPA, SEN, and TWD teams are thanked for their great efforts. Testing these systems in Darat was a "Win/Win" for both the Champion Waterflood Team and the Darat Asset Unit. The wells chosen for this trial had been previously closed in for HSE related issues. These wells were previously gas lift wells that were required to be shut-in because they were near the Panaga Clinic and a new housing development. These trials allow BSP to put these wells back into service by replacing the high pressure gas lift system with an environmentally friendly ESP.
BSP would also like to thank Brunei's Petroleum Unit (PU) for showing such and interest in this technology. During the installation of these systems, BSP was able to conduct a field trip with several new members of the Petroleum Unit to present this new technology.
The Zeitecs Shuttle technology consists of three main elements: i) a permanent downhole power installation; ii) a conveyance system for the retrieval and replacement of the total ESP system through tubing; and iii) a downhole docking station. In addition the Shuttle has a unique patented docking system that connects the pump to the fixed downhole power supply. This 'plug and play' technology will allow BSP to be able to install any manufacturer's ESP to match prevailing well production conditions. BSP has yet to issue tenders for the project and Shuttle technology will allow the company to invite a wide range of ESP vendors to submit bids. An equally important factor for BSP operations is that ESP change-out by means of Shuttle using wireline presents far fewer risks and lower HSE impact than a traditional workover.
In April 2010 BSP will be running a newly designed smaller system (550 series ZEiTECS Shuttle) for ESP recovery through 5 ½" tubing. This installation will be the first of its kind and will provide BSP the potential to use the technology widespread across its assets.
Article from BSP Company Magazine " Salam". Reproduced with the permission of BSP.
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