Baker Hughes XPVision Service Prevented ESP
Case History
Baker Hughes XPVision Service Prevented ESP Failure and Reduced Downtime Saved operator USD 790,000 by preventing workover costs and equipment replacement
Benefits XPVision
service optimized ESP run life
Prevented Saved
ESP system failure
workover costs
Reduced
deferred production
Project background and challenges Well
located on West Coast
Well
experienced multiple shutdowns
ESP
system had high motor operating temperatures
Bottomhole
temperatures were high
Asphaltenes
were present
Well
experienced constant cycling
Downtime
increased
Baker Hughes solution and results Baker Hughes personnel identified
operating problems with the ESP system and offered best-in-class solutions XPVision
service was implemented
XPVision
engineer monitored the well
Engineer
observed excessive motor temperature fluctuations
Engineer
recommended changing the drive set points remotely
Change
reduced ESP stress and optimized the system
Proactive
well management let engineer catch anomalies quickly
ESP failure risk A West Coast operator had several wells with electrical submersible pumping (ESP) systems in a field with dynamic downhole operating conditions. One well in this field experienced multiple shutdowns and a failure due to these challenging operating conditions. Some of these challenging well conditions included bottomhole temperature (BHT) that was higher than average due to deep pump setting depths. The addition of scaling also added to the heat buildup. The well had gas and corrosion, which meant that ESP operating expenses were higher than normal. Well conditions required the addition of Monel® coating on the ESP. Due to the field’s challenging operating environment and recent ESP failures, the operator implemented XPVision™ service for several problem wells in their field. An XPVision engineer began monitoring the
wells remotely and recommended changes to the ESP operating systems. One specific well’s new ESP was brought online and immediately began experiencing the same operating conditions that had led to the previous ESP system failure. Well cycling and high motor temperatures put the new ESP at risk of failure.
Baker Hughes solution With remote monitoring, the engineer observed frequent shutdowns due to high motor temperatures and sudden changes in intake pressure. The XPVision engineer had two recommendations for the operating set points. The first recommendation was to change the proportional integral derivative (PID) gains of the intake pressure set point to 275 amps. The second recommendation was to raise the low speed clamp from 45 Hz to 50 Hz and lower the high speed clamp from 60 Hz to 55 Hz dialing in the range of operation.
After the engineer made adjustments to the operating set points, the ESP began operating within range and without motor temperature fluctuations and multiple shutdowns. The changes made by the XPVision engineer ultimately increased run life and reduced stress on the ESP equipment by eliminating shutdowns and increasing uptime.
Multiple Shutdowns
XP Engineer
Because of the expert knowledge and remote monitoring capability of the XPVision engineer, an ESP failure was prevented. The operator saved USD 290,000 by avoiding ESP equipment replacement and USD 500,000 in workover costs.
www.bakerhughes.com XPVision is a trademark of Baker Hughes Incorporated. Monel is a registered trademark of Special Metals Corporation. Disclaimer of Liability: This information is provided for general information purposes only and is believed to be accurate as of the date hereof; however, Baker Hughes Incorporated and its affiliates do not make any warranties or representations of any kind regarding the information and disclaim all express and implied warranties or representations to the fullest extent permissible by law, including those of merchantability, fitness for a particular purpose or use, title, non-infringement, accuracy, correctness or completeness of the information provided herein. All information is furnished “as is” and without any license to distribute. The user agrees to assume all liabilities related to the use of or reliance on such information. BAKER HUGHES INCORPORATED AND ITS AFFILIATES SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, PUNITIVE, EXEMPLARY OR CONSEQUENTIAL DAMAGES FROM ANY CAUSE WHATSOEVER INCLUDING BUT NOT LIMITED TO ITS NEGLIGENCE. © 2013 Baker Hughes Incorporated. All rights reserved. 37660. 01/2013
Baker Hughes XPVision Service Prevented ESP Failure and Reduced Downtime Saved operator USD 790,000 by preventing workover costs and equipment replacement
Benefits XPVision
service optimized ESP run life
Prevented Saved
ESP system failure
workover costs
Reduced
deferred production
Project background and challenges Well
located on West Coast
Well
experienced multiple shutdowns
ESP
system had high motor operating temperatures
Bottomhole
temperatures were high
Asphaltenes
were present
Well
experienced constant cycling
Downtime
increased
Baker Hughes solution and results Baker Hughes personnel identified
operating problems with the ESP system and offered best-in-class solutions XPVision
service was implemented
XPVision
engineer monitored the well
Engineer
observed excessive motor temperature fluctuations
Engineer
recommended changing the drive set points remotely
Change
reduced ESP stress and optimized the system
Proactive
well management let engineer catch anomalies quickly
ESP failure risk A West Coast operator had several wells with electrical submersible pumping (ESP) systems in a field with dynamic downhole operating conditions. One well in this field experienced multiple shutdowns and a failure due to these challenging operating conditions. Some of these challenging well conditions included bottomhole temperature (BHT) that was higher than average due to deep pump setting depths. The addition of scaling also added to the heat buildup. The well had gas and corrosion, which meant that ESP operating expenses were higher than normal. Well conditions required the addition of Monel® coating on the ESP. Due to the field’s challenging operating environment and recent ESP failures, the operator implemented XPVision™ service for several problem wells in their field. An XPVision engineer began monitoring the
wells remotely and recommended changes to the ESP operating systems. One specific well’s new ESP was brought online and immediately began experiencing the same operating conditions that had led to the previous ESP system failure. Well cycling and high motor temperatures put the new ESP at risk of failure.
Baker Hughes solution With remote monitoring, the engineer observed frequent shutdowns due to high motor temperatures and sudden changes in intake pressure. The XPVision engineer had two recommendations for the operating set points. The first recommendation was to change the proportional integral derivative (PID) gains of the intake pressure set point to 275 amps. The second recommendation was to raise the low speed clamp from 45 Hz to 50 Hz and lower the high speed clamp from 60 Hz to 55 Hz dialing in the range of operation.
After the engineer made adjustments to the operating set points, the ESP began operating within range and without motor temperature fluctuations and multiple shutdowns. The changes made by the XPVision engineer ultimately increased run life and reduced stress on the ESP equipment by eliminating shutdowns and increasing uptime.
Multiple Shutdowns
XP Engineer
Because of the expert knowledge and remote monitoring capability of the XPVision engineer, an ESP failure was prevented. The operator saved USD 290,000 by avoiding ESP equipment replacement and USD 500,000 in workover costs.
www.bakerhughes.com XPVision is a trademark of Baker Hughes Incorporated. Monel is a registered trademark of Special Metals Corporation. Disclaimer of Liability: This information is provided for general information purposes only and is believed to be accurate as of the date hereof; however, Baker Hughes Incorporated and its affiliates do not make any warranties or representations of any kind regarding the information and disclaim all express and implied warranties or representations to the fullest extent permissible by law, including those of merchantability, fitness for a particular purpose or use, title, non-infringement, accuracy, correctness or completeness of the information provided herein. All information is furnished “as is” and without any license to distribute. The user agrees to assume all liabilities related to the use of or reliance on such information. BAKER HUGHES INCORPORATED AND ITS AFFILIATES SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, PUNITIVE, EXEMPLARY OR CONSEQUENTIAL DAMAGES FROM ANY CAUSE WHATSOEVER INCLUDING BUT NOT LIMITED TO ITS NEGLIGENCE. © 2013 Baker Hughes Incorporated. All rights reserved. 37660. 01/2013
