Gas-Lift Hybrid Application in Offshore Northwest Java Production Sharing Contract

B.T.Santoso Maxus Indonesia , P.Priyandoko ARCO Indonesia, Boyke Harahap ARCO Indonesia

Agenda

● Background

● Overview

● “Theory” ESP vs ESP G/L Hybrid

● Field Example

● Conclusion

● Recommendation

JAKARTA

BIMA

ARDJUNA

ARIMBI

AV

AVS

AA

MX

MQ

MR

MM

MB

LL

L BZZ

BY

KU

E

EQ-EZ

ESF

FF

HZE

ZU

P

0 25 50 KM

XMX

KLXKLY

KNAKL

KK

APN

A R I I

O

Y

KALIMANTAN

SULAWESI

SUMATER

A

J A V A

LES/KKN

GG

CIREBON

ARCO Indonesia

SAFE

ARCOINDONESIA

ONWJ

XM Location

Background

• All wells in the X-ray area were originally produced by Electrical

Submersible Pump ( ESP ).

• Gas zone discovered in the XMA area in 1987.

• Tested and proved to be sufficient in terms of pressure and gas

volume to the support gas lift for XMA wells.

V-002 TEST

SEPARATOR

V-002 TEST

SEPARATOR

V-002 TEST

SEPARATOR

V-002 TEST

SEPARATOR

X-RAY SIMPLIFIED FLOWLINE DIAGRAM

CRUDE TO BALONGAN

OIL

GAS

THREE PHASE LINE

4180 V CABLE

XMA P/F

XD P/F

XA P/F

XB P/F

X PROS

X L/Q

4 MILE 16”

1 MILE 8”

4 MILE GAS 8”

OIL 12”

21 MILE 16”

XMA ESP Background

• Requires significant power

• Two brands of ESP used due to stock availability

• Completion originally designed for eventual G/L

conversion

• General design capacity is 1000-5000 BFPD

• Pressure and temperature data acquired

ESP GL Hybrid Benefits

• Optimize of production rate

• Ensuring uninterrupted production operation with a

limited source gas for gas lift operation.

.

ESP-GL Hybrid

Equipment required for hybrid system is common to both ESP and GL

systems.

Gas lift system :

• knock out drum

• gas lift manifold

ESP system :

• the power generator

• cable transmission

• primary and secondary transformer

• electrical panel

• junction box and tail cable

XMA SIMPLIFIED PROCESS FLOW DIAGRAM

MAIN TRANSFORMERSUBSEA CABLE

F/ XA

PRODUCTION HEADER

WELL XMA1-9

Z-35WATERDISPOSALCAISSON

BLPD, MCFDTO XAPV-1B

8” 1 mi pipeline

POWER DISTRIBUTOR

TEST HEADER

GAS LIFT Manifold

Description Test Sep Prod Sep MOLDesign, psi 230 600 230Operate, psi 110 100 100MAWP 275PSH, psi 200 200 175

PSL, psi 10 10 10Cap, MPLPDCap, MMCFPD

PRODUCTIONSEPARATOR

V-002 TEST

SEPARATOR

XMA-MD-8CAISSON PUMP

XMA-V-7SLOP TANK

XMA-MD-9SLOP PUMP

SECONDARYTRANSFORMER

DOWN FROM

4180 TO 480 VOLT

DOWN FROM

4180 TO 480 VOLT

KO Drum

XMA-6S

ESP-GL Hybrid

Equipment necessary :

① SSSV (Subsurface Safety Valve)

② Gas lift mandrels and valves

③ Y-block

④ A blanking plug

ESP-GL Hybrid

The completion must be designed to easily adapt to both

systems :

ESP

• ESP has to be hung on the Y-block

• GL mandrel installed above the Y-block

• A blanking plug and intake SSD have to be installed below Y-block.

Gas lift

• The plug has to be pulled out

• SSD needs to be closed

• Gas lift valves need to be installed.

ESP-GL Hybrid : Specific Issues

•Slim body ESP required

•Down hole pressure and temperature sensors

•Vent packer and SSSV installed as necessary

ESP Mode

800'

1399'

1969'

2505' GL mandrel `

2982'

3363'

3682'

3966'

Opened

4570' Y -block with SSD

Plugged4579' Nipple

4562' SSD IntakeESP

4698' On off tool

4699' Packer

4738' SSD

4750' Nipple

9-5/8 Casing

3363'

3682'

3-1/2” Tubing

3966'

Opened

4570' Y -block with SSD

Plugged4579' Nipple

4562' SSD IntakeESP

4698' On off tool

2-7/8” Tubing

9-5/8” Casing

Detailed Completion

ESP-GL Hybrid CompletionXMA-8 Completion XMA-8 Completion

ESP Mode GL Mode

800' 800'

1399' 1399'

1969' 1969'

2505' GL mandrel 2505'`

2982' 2982'

3363' 3363'

3682' 3682'

3966' 3966'

Opened Closed

4570' Y -block with SSD 4570'

Plugged Unplugged

4579' Nipple 4579'

4562' SSD Intake 4562'ESP

4698' On off tool 4698'

4699' Packer 4699'

4738' SSD 4738'

4750' Nipple 4750'

Baturaja4802'-4841'4852'-4864'

9-5/8 Casing

GL Gas

Formation Gas

ESP-GL Hybrid CompletionOther Completion Other Completion

ESP Mode GL Mode

GL mandrel `

Opened Closed

Plugged Unplugged

ESP

GL GasFormation Gas

Field Example

After more than 8 years providing gas lift gas to XMA

wells :

• The source gas in XMA area has depleted.

• Many wells needed to be selectively shut in.

• The conversion from gas lift (GL) to ESP wells is required to

maintain production.

• ESP-GL hybrid was proposed to use the limited source gas

availability if necessary.

XMA-6S FTP & PRODUCTION

10

100

1000

10000

'86 '88 '91 '94 '97 '99

Ga

s P

rod

uct

ion

, M

CF

PD

0

500

1000

Pre

ss

ure

, p

sia

Gas Prod

Pressure

Field Example

•The XM-27B zone was tested at 920 psi FTP with gas

rate of 2360.

•The minimum gas lift injection pressure required to lift

the liquid from the well is 600 psi.

•XM-27 B supplied gas lift gas to 9 wells for 8 years.

•Recently, the gas supply can only support 3 wells due to

pressure depletion.

Gas Source Well Completion

XMA-6 CompletionGL Gas Source

XM-27B

Baturaja

Baturaja

At the surface liquid produced from the gas zone was drained in the knock out drum and the dry gas was then distribute to each well through gas lift manifold.

XM-27A

XM-27B

XM-34

( Baturaja )

Gas

Lift

Gas

Sou

rce L

og

Oil Zone Log

Field Examples

•Original facility & well design allowed for GL to hybrid

conversion

✦ Cable for ESP power laid down at time of installation

✦ G/L designed for flexibility

• ESP G/L Hybrid system was implemented on two XMA wells

(XMA-7 and XMA-8)

• Hybrid system allowed production to continue until the ESP

was replaced

Field Examples : Result

XMA-7 Well Test History

1

10

100

1000

10000

Fe

b-98

Ma

r-98

Apr

-98

May

-98

Jun-

98

Jul-9

8

Aug

-98

Sep

-98

Oct

-98

Oct

-98

Nov

-98

Dec

-98

Jan-

99

BO

PD

/BF

PD

(BFPD)

(BOPD)

E S P D o w n E S P D o w n

' G LV s In s t a lle d H y b r id In s t a lle d

XMA-8 Well Test History

1

10

100

1000

10000

Feb

-98

Mar

-98

Apr

-98

Ma

y-9

8Ju

n-9

8Ju

l-98

Au

g-9

8S

ep-9

8O

ct-9

8O

ct-9

8N

ov-9

8D

ec-9

8Ja

n-99

BO

PD

/BF

PD

(BFPD)

(BOPD)

E S P D o w n

E S P D o w n

' G LV s In s t a l le dH y b r id In s t a lle d

• System was tested when ESP failed : XMA-7 and 8

• Hybrid system allowed continued production

Economic Evaluation

Conventional Hybrid300BOPD 200 BOPD

Down Time 80 days3 months

2 days 7 days

Items US$ US$

ESP change out 100,000 100,000

40,000 one time “charge”

2,000 wire line

--------------------------------------------------------------------------------------------------

Production Bbls Bbls

Normal 81,000 81,000

Down time 0 16,000

Total 81,000 81,000

--------------------------------------------------------------------------------------------------

US$ US$

Revenue 1,215,000 1,455,000

Profit 1,115,000 1,313,000

Benefit $ 198,000 /well

Conclusion

1. ESP-GL hybrid technique can be applied mainly in an operation where both

electrical power and a high-pressure gas source are available.

2. The ESP-GL hybrid system offers numerous possibilities for optimizing the

production rate and ensuring uninterrupted production operation in many

wells.

3. The GL in ESP-GL system provides a back up lift system in the event of an

ESP failure.

4. ESP-GL prevents a longer down time period prior to rig schedule availability.

5. By applying ESP-GL hybrid technology ARCO has prevent loss production of

approximately 400 BOPD during the event of ESP failure.

Recommendations

1. Casing operated valve is recommended to be installed in the mandrels to avoid

valves opening during ESP operation.

2. All reservoir fluid production through an ESP during GL operation can be

avoided by installing Y-tool with a sliding sleeve above the pump.