ESP Performance Enhancement and Premature Failure Reduction Through Esp Equipment Reliability Project in a West Kuwait Field - Case Study From Kuwait

Abstract

Most of wells in the major oil fields of West Kuwait Asset are producing with Electrical Submersible Pump (ESP). During 2012- 2013, the ESP premature failures reached high percentages of up to 30% of ESP population with high deferred oil. In order to enhance the ESP performance and reduce the number of premature failed ESP, FD (WK) has initiated ESP Equipment Reliability Project in 2014. The main objective was to define a proper workflow that will be capable to identify the root cause of ESP premature failures, find the way forward and mitigation actions to overcome the issue. All ESP business partners from KOC and service providers were involved in the project. Series of technical workshops following the API and KOC standards were conducted by the team members to analyze the ESP performance and premature failures where the team was able to define analytical workflow in the early review sessions to conduct the required work. The workflow takes in consideration the reservoir parameters and conditions, ESP performance with all tags and signatures, ESP systems from the overhead electrical line or generator, surface equipment down to ESP down hole equipment specifications, installation and pull-out procedures, and ESP operating conditions. Also attending the tear down of the failed wells to ensure the vendors procedures and the reported findings. In-addition, well models were utilized to find the deviation between the design and actual parameters and surface network model was utilized to define the impact of the pipeline issues on the ESP performance. Based on this study, the root cause of the ESP premature failures were found to be mainly due to; Power Quality, Sour condition, External sand source, Down hole emulsion, and some Equipment quality / specifications that were not designed to handle the down hole conditions of UG wells. A mitigation plan and list of recommended actions were concluded and implemented with a measure of the outcome and results in addition to some modifications that were applied within time. The project shows excellent results with time where the premature failures reduced from 30% in year 2012- 2013 to 12% in year 2018. Also the ESP showed enhanced performance over time. Extra room for improvement can be chieved by enhancing the power quality of the overhead lines and generators. Applying the mentioned workflow with the proper project structure form will help ESP stakeholders to identify the root cause and not the failure reason, Hence reduce premature failures. This will lead to reduce deferred oil, reduce cost per barrel, and avoid equipment compensation fees.