Shauna Noonan is the Completions Technology Manager for ConocoPhillips in Houston.

She has worked on artificial lift projects and technology development worldwide at ConocoPhillips and previously Chevron for over ! years. She has chaired many industry artificial lift forums and authored " co#authored numerous papers on the su$ject of artificial lift. She was the chair of the %S& standard committee for PCPs and is the current chair of the %S& standard for 'SPs. She is the () ( * () + Technical ,irector for Production and &perations on SP'-s %nternational .oard of ,irectors and serves on the /PT 'ditorial Committee. . Shauna $egan her career working for Chevron Canada 0esources and holds a ..Sc. in Petroleum 'ngineering from the 1niversity of 2l$erta.

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ESP Reliability
Shauna Noonan April 10, 2013

Outline
ESP Reliability
Is it an issue? What fa tors influen e reliability? Reliability statisti s What is the in!ustry !oin" to i#pro$e ESP reliability? Su##ary

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Poll %1& Who is parti ipatin" in this 'ebinar?

Sele tion fro#& ESP (anufa turer ESP )istributer Operatin" *o#pany A a!e#ia +in lu!in" stu!ents, Other

Result fro# Poll %1

Reliability
- the ability of a syste# or o#ponent to perfor# its re.uire! fun tions un!er state! on!itions for a spe ifie! perio! of ti#e/
Source: Wikipedia

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Poll #2:

How would you rate the reliability of current ESP technology?

Answers: Excellent Good Average Below average Very poor

Result of Poll %2

Is ESP Reliability an Issue?

What is the urrent i#pa t of ESP run life on your e ono#i s an! 'hat is the 0 $alue of ESP reliability to you? What is the reasonable tar"et run life for your spe ifi appli ation? )o you un!erstan! the root ause of your ESP failures an! are you bein" li#ite! by e1istin" te hnolo"y?

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Example !
Proble#& E1 essi$e !o'nti#e an! ESP failures pro#pte! #ana"e#ent to re.uest an in$esti"ation an! !e$elop#ent of ne' ESP te hnolo"y2 E$aluation& (ost of the ESP failures 'ere ause! by san! settlin" on top of the pu#p after unplanne! shut!o'ns2 Re o##en!ation& Priority nee!s to be on re!u in" shut !o'ns !ue to surfa e #ultiphase pu#p failures an! ele tri al e$ents2

Example "
Proble#& In one fiel! an ESP failure 'as o urrin" al#ost !aily2 3he urrent 'or4o$er ri"s oul! not han!le the $olu#e of inter$entions an! !o'nti#e 'as in reasin" as a result2 (ana"e#ent for#e! a tea# to in rease ESP run life2 E$aluation& A$era"e ESP run life 'as 2 years, 'hi h is a reasonable tar"et for this appli ation2 3his fiel! ha! 5 600 ESPs, of 'hi h an ESP failure ea h !ay shoul! ha$e been e1pe te!2 Re o##en!ation& Operations nee! to ontra t enou"h 'or4o$er ri"s to han!le a 2 year a$era"e ESP life2

000000000 Nee! to 4no' finan ial i#pli ations of ESP reliability on your operations +si7e of the pri7e,
This will help to determine target run life and the amount of effort that must be made to achieve it.

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8et9s be Realisti 'ith Settin" 3ar"ets

This years goal is to increase average run life from 1 year to 2 years. Reality& On :anuary 1st, if you 'ere to repla e all pu#ps 'ith ones that 'ere #ore reliable, this "oal oul! not be #et by )e 2 31st2 Reality& We 'oul! typi ally repla e syste#s as they faile!2 3he entire population 'oul! not be repla e! 'ith the better syste#s until the en! of that year2 It #ay ta4e 3 years or #ore to a hie$e this "oal2

E1a#ple ti#eline for intro!u in" a step han"e in ESP te hnolo"y to in rease reliability for e1tre#e hi"h te#perature
2008 or earlier
Design concept

3Q 2009
Validation testing of prototype

Sept 2010
Prototype field trials

Sept 2012
Achieved two years runtime

4+ years from concept to achieving a 2 yr runtime

;a tors that I#pa t ESP Reliability

(these are just some of the ones we have influence over)
Installation practices Material selection Equipment qualification and testing Operating practices

Is there anything you can be doing Sizing and selection of equipment differently right now that will result in Relationship between the supplier / manufacturer and the enduser improving ESP run life and project New versus used equipment DIFA procedures economics? Data quality
Fit for purpose design Quality of manufacturing Quality of completion: hole size, deviation, dogleg severity

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Its not only about ha$in" the ri"ht e.uip#ent for the appli ation<
It is also about who is installing and operating it.

#ommunication between the enduser and supplier $ manufacturer is critical - Reliability& the ability of a syste# or o#ponent to perfor# its re.uire! fun tions un!er state! on!itions for a spe ifie! perio! of ti#e/
Source: Wikipedia

Reliability Statisti s

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Average Run Time MTTF

A BC DE FG H I J K LM N

A B C DE F G H I J K L M N

Instantaneous Run Time Each of these metrics use a different formula to calculate run life. Next time you see a run life number quoted, ask how it was calculated..
A BC DE FG H I J K LM N

All run life metrics are a function of the ESP population whether it is total records, installations still running and / or units that have failed.

(33;? Not al'ays a "oo! #etri

MTTF

How do you know which one to use?

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Run life #etri s& One is not enou"h

Interpreting the trends in ESP run life statistics is impossible without understanding your data population. Its not a matter of knowing what your ESP run life metrics are, it is also having the data to be able to answer why.

If you 'ant to "et serious about ESP reliability, you nee! to "et serious about !ata olle tion an! e$aluation2

What is the ESP In!ustry )oin" No' to I#pro$e Reliability?

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As of April, 2013, this industry ESP database contains ~ 104,179 records from approximately 750 fields representing 22 operating companies.
For more information www.esprifts.com Related paper: SPE 148333

%ailure &ata Structure

Reason for Pull ;aile! Ite#+s, Pri#ary ;aile! Ite# ;ailure )es riptor+s, ;ailure *ause

Document can be downloaded at www.esprifts.com

Examples of Poor %ailure #ause &ocumentation

Pump NFG

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'PI Recommended Practices (RPs)

!!S& Operation, (aintenan e = 3roubleshootin" of ESP Installations !!S!& ESP 3ear!o'n Report !!S"& ESP 3estin" Pumps !!S*& ESP Installations !!S+& Si7in" = Sele tion of ESP Installations !!S,& Appli ation = ESP *able Syste#s !!S-& 3estin" of ESP *able Syste#s !!S.& Appli ation = 3estin" of ESP Seal *ha#ber Se tions !!S/& ESP Syste# >ibrations

How did your ESP manufacturer develop their pump ratings and performance curves?

In!ustry Stan!ar!s for ESPs

ISO 15551-1 ESP Systems - Draft document is complete and submitted to ISO / OGP for approvals.

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IS0 !,,,!1!
ISO spe ifi ation for !o'nhole oilfiel! ESP o#ponents that !efines re2uirements for&
? )esi"n $erifi ation = $ali!ation ? (anufa turin" Engineering design of the component, ? Perfor#an e ratin"s not the application design for a specific ? ;un tional e$aluation
well.

3hat ESP components are co4ered in IS0 !,,,!1!?

entrifu"al pu#ps in lu!in" "as han!lin" !e$i es, !is har"e hea!s, seal ha#ber se tions, bolt@on inta4e syste#s, #e hani al "as separators, in!u tion #otors, (8E, pothea!s an! po'er ables2 asse#ble! ESP syste#s

3hat this IS0 document is 506

It is not a ontra t 'ith the #anufa turer2 It !oes not "uarantee or be o#e an issue of e.uip#ent 'arranty2 A #anufa turer !oes not ha$e to be o#pliant 'ith ISO 1AAA1@1 unless they ha$e a"ree! upon re.uest of the en!user2 3his is not a !o u#ent that only has re.uire#ents for the #anufa turer B there are re.uire#ents by the en!user2 Pro$isions ha$e been 'ritten to han!le le"a y C e1istin" pro!u t lines so that they 'ill #eet so#e part of this stan!ar!2

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Poll Duestion %3 Eo' 'ell !o you thin4 the fun!a#ental s ien e of ESP fun tionality are un!erstoo!? What F of un!erstan!in" !o you thin4 the in!ustry is at?
Ans'ers& A2 2AF G2 A0F *2 HAF )2 100F

6he industry is still on the learning cur4e7

Pu#ps Ias han!lers
Steam handling studies may also uncover new information about gas handling capabilities. ISO testing will result in lots of new data collected.
Manufacturers are beginning to test via ISO methods.

(e hani al Ias Separators Seal Se tions (otors

At ESP Workshop, preliminary results from an extensive seal section test program will be presented.

High temperature ESP developments have led to better understanding of ESP internal motor operating conditions.

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www.espworkshop.com

Wrapping Up ESP reliability is not something you can buy or get from a reading a publication
This should be obvious but

Reliability of ESPs is a function of many things, such as: 3e hnolo"y #aturity Eu#an fa tor *o##uni ation an! "oo! relationship 'ith $en!or Realisti tar"ets an! e ono#i s Pra ti es an! pro e!ures Operatin" en$elope ! knowing where you are and
where you should be

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;inally, let9s be realisti

)e isions are routinely #a!e by the en!users that ne"ati$ely i#pa t ESP reliability, su h as&
)esi"n 'ith $ery little !ata Run repla e#ent syste#s 'ithout un!erstan!in" the root failure ause of the ori"inal pu#p Sele t $en!or C e.uip#ent base! on pri e Operate e.uip#ent outsi!e of its re o##en!e! ran"e to #eet pro!u tion tar"ets2J
Economics may justify other actions over pump reliability

Duestions?

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