Artificial Lift in the Montrose Field,
North Sea
E.G. Jacobs, * SPE, Amoco (UK) Exploration Co.
Summary. Electric submersible pumps (ESP's) have been in operation in the Montrose field since 1979. Initially, very low run lives
were reported, but continued efforts have increased these run lives significantly. A hydraulic-jet-pump pilot scheme implemented in the
field is operating satisfactorily.
Introduction
ESP's were introduced in the Montrose field in 1979 as the most
feasible means of artificial lift. Increases in water cut necessitated
some form of lift because the reservoir pressure could not sustain
production. A nonideal environment pushed ESP technology to its
limits. Very short run lives resulted.!
Significant improvements have since been made in the sizing,
handling and operating procedures, and materials and manufacture
of ESP's. Close contact and feedback were required from office
staff, field personnel, and ESP manufacturers.
All facets of the operation of ESP's and the ongoing evaluation
of run lives and failure modes are discussed, as well as the actions
to improve run life further through both pump technology and the
electrical system. The completion and operation of the hydraulic-
jet-pump pilot scheme is discussed and current results are given.
Montrose Field
The Montrose field is located in the North Sea, U.K. Blocks 22/17
and 22/18, 130 miles [209 km] east of Aberdeen. The field was
discovered in Sept. 1969. Development drilling began during 1976,
and the first production started in July 1976. The initial development
program consisted of 16 producers and 4 water injectors. This
program was completed in Dec. 1979. Another producer was drilled
and placed on production in 1984.
The Montrose Alpha platform is an 8-1egjacket positioned in 150
ft [46 m] of water in Block 22/17. The platform has 24 slots, all
of which can be reached by a permanently installed drilling I
workover rig. All facilities for the handling of oil, water, and gas
are installed on the platform. Oil was initially exported by shuttle
tankers. A pipeline to the Forties field, from which the oil is trans-
ported to shore, was installed during 1984.
Production is from a Paleocene sandstone. The reservoir is
situated in a large structural anticline of low relief (Fig. 1). The
two lobes both have longitudinal axes in a northwest/southeast orien-
tation. High-permeability channels exist in the same direction. An
active waterdrive is present in the west lobe. The drive mechanism
in the east lobe is less active, and three of the four water injectors
are located in this part of the reservoir. Water injection is for
pressure support in the aquifer only. The reservoir is not being
flooded.
Table 1 lists some important reservoir parameters. The reservoir
temperature of 255°F [124°C] is high for the reservoir datum of
8,150 ft [2484 m] subsea. The fluid properties for both lobes are
listed in Table 2, which shows that the properties are slightly
different between the lobes, with a notable difference in bubblepoint
pressure and gas gravity.
Production
The maximum oil production from the field was 46,144 BID [7336
m 3 /d] during 1979. Present field production is 15,000 BID [2385
m 3 /d] with an average water cut of 57 %. Water injection is 27,000
BID [4293 m 3 /d].
The field initially had an intermittent export system. Crude oil
was transported to shore by shuttle tankers. With little storage fa-
cility provided on the platform, production was shut down regu-
larly, especially during the winter months when the tankers
frequently had to leave the export buoys because of weather con-
ditions. Production downtime averaged 22 % over the year, reaching
'Now with Amoco Netherlands Petroleum Co.
Copyright 1989 Society of Petroleum Engineers
SPE Production Engineering, August 1989
82 % in the winter months. Since the installation of the pipeline to
the Forties field, downtime has been virtually eliminated, except
for scheduled maintenance. A small surge tank provides enough
storage to accommodate short pipeline-system shutdowns.
Gas and water are separated from the crude oil in either of the
2 two-stage separation trains. The high-pressure train provides fuel
gas for the utilities and electricity generation. The remaining gas
is flared because no export facilities for gas exist on the platform.
The produced water is cleaned and dumped into the sea.
Artificial Lift
It became obvious early in the life of the field that some form of
artificial lift would be required to continue production with in-
creasing water cuts. During 1979, the relative merits of ESP's and
gas-lift and hydraulic jet pumps were evaluated. A full system of
jet pumps for 16 producing wells was discarded in view of the ex-
tensive fluid-handling capacity required. ESP's were preferred over
gas lift because of the easy installation of surface facilities and the
abundance of electrical power on the platform.
The first ESP was installed on the platform in 1979. Since then,
87 ESP's have been installed in 14 production wells (May 1986).
Mechanical Completion. In a typical Montrose well, 9%-in. [244-
mm] casing is set above the pay zone and a 7-in. [178-mm] liner
is set through the pay (Fig. 2). The flowing well completion in-
cludes a permanent packer with a tailpipe set above the top of the
7-in. [178-mm] liner. The 4V2-in. [l14-mm] tubing is stabbed into
this packer with a seal assembly. The tubing is hung with a ratch-
latch stinger and tubing hanger at about 500 ft [152 m] below rotary
kelly bushing (RKB) or, more recently, is hung off at the wellhead
surface. The completion also includes a sliding sleeve (not included
in recent wells) above the downhole packer and the required nipples.
A tubing-retrievable mudline safety valve is located above the tubing
hanger at 480 ft [146 m] below RKB.
The completion for an ESP-lifted well is completely different (Fig.
3). A high-set, vented packer is used to allow free gas to be vented
to the surface.
The completion is discussed from top to bottom. The tubing
bonnet is eccentric to allow the installation of a wellhead penetrator
for the electric cable. The boll-weevil-type hanger for 41/2-in. [114-
mm] tubing is also eccentric. An adjustable union is placed below
the tubing hanger to facilitate the spacing for the fixed-length cable
between the packer and the wellhead. Tubing (4 1/2-in. [1l4-mmD
is run to' about 600 ft [183 m] below RKB, where the vented dual
hydraulic packer is located.
The wireline-retrievable safety valve is located in a nipple above
the packer. The ball-type subsurface safety valve is controlled by
a hydraulic control line. The 9%-in. [244-mm] -OD packer is a dual
41/2 X 2Ys-in. [114 X 60-mm] tubing-retrievable packer, whose
secondary side is adapted for cable feed-through. The secondary
side also incorporates a gas vent that is opened and closed with a
sleeve (Fig. 4). This sleeve operates in conjunction with the mudline
safety valve.
A nipple located three joints below the packer is used to set a
plug for setting the packer. Below the nipple, the tubing size is 4 V2,
3Y2, or 2Ys in. [114, 89, or 73 mm], depending on production rates.
The ESP assembly (Fig. 5) has an OD of about 5V2 in. [140 mm]
or, for the lower-rate wells, 4 in. [102 mm]. It consists of several
pump sections, a static gas separator or standard intake, a tandem
protector section, and either a single or tandem motor. A downhole
313
 TABLE 1-MONTROSE FIELD RESERVOIR PARAMETERS TABLE 2-MONTROSE FIELD
RESERVOIR-FLUID PROPERTIES
Reservoir datum, ft subsea 8,150
Reservoir pressure, psia East Lobe West Lobe
Original 3,700 Oil gravity, °API 39 39
Present 2,900 Gas density (air = 1) 0.85 0.75
Reservoir temperature, of 255 Bubblepoint, psig 2,737 2,348
Oil gravity, °API 39
Solution GOR, scf/bbl 600 to 800 Solution GOR, scf/STB
At bubblepoint 800 600
At 2,000 psia 569 488
pressure sensor is usually located below the motor, and a motor At 1,000 psia 349 288
guide is run. This motor guide also acts as a centralizer to prevent Oil FVF, RB/STB
the motor from lying against the casing, which could cause localized At bubblepoint 1.557 1.467
overheating. At 2,000 psia 1.432 1.412
At 1,000 psia 1.265 1.254
The 4-in. [102-mm] -OD ESP assemblies have a 7-in. [178-mm]
shroud and gas anchor. This shroud increases the flow velocity past Gas compressibility factor
At bubblepoint 0.91 0.89
the motor and therefore enhances cooling. The motors in use are
At 2,000 psia 0.89 0.88
between 831h and 350 hp [62 and 261 kW] at the standard frequency At 1,000 psi a 0.91 0.89
of 50 cycles/sec [50 Hz]. Whenever possible, motors modified for
high temperature are run because of the relatively high ambient tem- Formation-water specific gravity 1.06 1.06
perature in the wells. The tandem protector section provides a
pressure equalization between the inside and outside of the motor. from the annular area to the central intake at the pump section. The
It also separates the motor oil and the well fluids. pump discharges into the tubing string. Check and drain valves were
The majority of protector sections in use in the field are of the run in the Montrose field on initial installations to avoid back-
labyrinth type. A tortuous path prevents the well fluids from en- spinning of the motor but are now omitted. When the ESP was
tering the motor. Some bag-type protectors, which provide a positive stopped, sand would drop on top of the valve, preventing the valve
separation between well fluids and motor oil, are also run. from opening upon startup.
In the static-type downhole gas separator, the flow of well fluids
is inverted twice, to aid separation of the gas from the liquid phases. Electric Completion (Fig. 6). The platform generators produce
This separator also acts as a pump intake, and well fluids are diverted 3.3 kV, too much voltage for the ESP motors, which require a

r-----------------------------~r_------------------------~7°~O'N
• PROOUCING WELLS
, WATER INJECTORS
~ ESP WELLS

~7° 27'N

~ ____________ ----------------~~ ________________________ ~~7°24'N

IOIS'E I024'E 1° 29' E

STRUCTURE IN DEPTH (FT)

o 2
I I

MILES

Fig. 1-Montrose field, top Paleocene sand.

314 SPE Production Engineering, August 1989

 ~===
MLSV AT :I: 480ft RKB
r
~-I
~ J-! -2

r--- 3
RA TCH LA TCH STINGER
r--- 4 EQUIPMENT
TBG HANGER AT % SOOft RKB
NO COMPONENT
5
r--- 6
tg -7 2
~
1 I Cable and Wellhead Penetrator
Boll Weevil Hanoer
~ Packer 10 Wellhead Cable - 125 Amp
r--- 8 Connectors
4 4 1k" Tubino. Bonded onty
-r--- 9
5
3. 7S" NIPPLE AT i: 2000ft RKB
...... -r---IO 6
No - Go type MLSV
jl Packer Penetrator
CSG.
7 Dual Vented Packer
a Splice

9 ~ Moln Coble N! I AWG

10 TubinQ I I Coble Protector per Join'
-I- SLIDING SLEEVE AT i: 99S0ft RKB I-r--- Ii II Spite.
12 MLE Coble

LOCATOR AND SEAL ASSEMBLY r--- '2 I~ Pump Assembly

r---i3 14 Downhole pressure sensor
t---
RETAINER PACKER AT ± 70000ft RKB t---

f--
'--
r-r- '4

TAILPIPE

7"

~
LINER

9 $/8 " CSG 47/b/ft Fig. 3-ESP well completion.

PERFORA TlON
penetrator /plug _ __
xxx PBTD
system
'iT'
7" LINER 291b/ft I I
I I --~-- 3'813· nipple
Fig. 2-Flowing well completion. I I
I I
I I I
I I
downhole voltage between 1,800 and 2,200 V. The direct on-line Y." hydraulic line ---+-HI~ I
isolation transformers (50 cycles/sec [50 Hz]) have a secondary side II II
of 2.1 kV with tap settings of ±5 and 10% so the correct surface I I
voltage can be selected. ESP switch gear is used to start and stop I I - - - - pocking element
the pump, to provide the necessary protection, and to monitor its
2~" EUE tubing _ _
I I
performance. From the switch gear, the power is fed to the junction I I
box in the wellhead area. I I
r-t
Alternatively, the main power at 3.3 kV is transformed to 480
(I I 'Itt-""t-----ball valve
V to power a variable-frequency drive (VFD). A VFD is used when
\1'-/
it is required to operate the pump at a frequency differing from
50 cycles/sec [50 Hz]. After the frequency change, the voltage is
I I
I I
raised again. The output voltage is determined by the setting of a I I
voltage-to-frequency ratio on the VFD to give the required voltage I I
at the frequency to be used. A cable connection is made to the I I
junction box, as in a direct on-line installation. The remainder of I I
the completion is identical for both installation types.
Power is introduced through the wellhead feed-through, which ~ ......
t%
~ II %
I el v:
penetrates the tubing bonnet and the tubing hanger. The top end t;:;; l"7r-j,gI'-V
of the feed-through has a pigtail that connects to the junction box. Annular safety
gas vent sleeve---t'74-1-1-'Vj7'l .1N
V v:: F. I v;:
"'.
- mud line packer

The bottom end of the wellhead feed-through has a male connector.

The 500- to 6oo-ft [152- to 183-m] -long packer-to-wellhead cable :% ~
has connectors at both ends. The connectors currently in use are ~ ~
of the field-attachable type. The lower connector connects to the ;% ~
packer penetrator. This penetrator, located in the secondary side ~ V
of the dual packer, has a 40-ft [12-m] pigtail at the bottom end. %: V 4~'
Currently, several types of packer penetrators are octasionally in ::::: ~ tubing
use, some with pigtails at both ends. electncal coble ---r.....
...,.. ~
The main cable run is spliced to the bottom pigtail on the rig floor
with a vertical splice. The main cable in use is round or flat No.
Fig. 4-Mudline packer and safety-valve assembly.
1 AWG cable. Although for most installations No. 1 cable is not

SPE Production Engineering, August 1989 315

 3·3 KV RIG POWER

STEP DOWN
~ _ _ _ _ TUBING TRANSFORMER

VARIABLE
. .~_ _ _ BOLT -ON HEAD FREQUENCY
DRIVE

STEP UP
TRANSFORMER

JUNCTION BOX
P
WEl...Lt-EAD
FEEDTHROlXlH
PACKER TO
WELLHEAD CABLE
"'r--~I--_FLAT CABLE EXTENSION
PACKER
FEEDTHROUGH
SPLCE TO
MAIN CABLE

MAIN CABLE
. . .f---_ _ _ GAS SEPARATOR/INTAKE

.....I--_ _ _ CASING SPUCE TO

MOlORLEAD EXTENSION

POTHEAD

MOTOR

Fig. 6-ESP electrical completion.

" - RECOMUENDEC RANGE""-I Dulin ...... 0

I
1
I
I ,,~
-.--.--_._---. ~I at Intake Condition_
.......
'I

J.... ". I I
HEAD r - - - -__ ,/'1 '\~ f

: i
R t /. ;'
"I'
" 1'\,
! \\
\
I i______________ , ~
,/.~..!!:J \'"

H
Eff.

_ _ _ _ PRESSURE SENSOR
~_ _ _----"'luTOR GUIDE
t I '
,
'//
,/ $
I :
\'"
\ :

L ___.____.l.___________ ~ ___.J
(/ : : ' r

---. Q

Fig. 5-ESP assembly. Fig. 7-ESP performance curve.

required for electrical reasons, it was selected because of its higher
mechanical and electrical strengths. Its use has reduced the number
of mechanical and electrical cable failures.
A motor lead extension cable, No.4 or NO.5 AWG cable with
a pothead, is spliced to the main cable. This splice is usually made
onshore; therefore, only one or two field splices have to be made,
depending on the type of packer penetrator.
The high-temperature cable allows the breathing of gas. This ca-
pacity is required because gas is vented up the annulus and the cable
is in a gassy, hydrocarbon-type environment.
The cable is protected by cable protectors, one per joint of tubing,
located below the coupling. A type of cable protector initially was
used that protected the cable only against "crunching" between
the tubing and the casing inner wall. The cable was held in place
and supported by stainless steel bands above and below the pro-
tector. Rubbing of the cable would often result in displacement of
the banding and cable stretch. This problem was mostly solved when
a newer type of protector became available. The newer type not
only protects the cable, but also supports the weight of about 100
ft [30 m] of cable by a cable guard door closed tightly around the
cable. The profile of the inside of the door fits inside the grooves
of the cable armoring. No banding is required around the protector.
The motor amperage of all ESP assemblies is recorded continu-
ously to allow trouble-shooting of the installations.
Setting Depths. The ESP's in the Montrose field are set above the
top of the 7-in. [l78-mm] liner. A location is selected with a dogleg
severity ofless than 0.5° 1100 ft [0.5°/30 m]. If such a dogleg-free
section cannot be found, then a dogleg of up to I 0/100 ft [I 0/30
m] is considered acceptable. Although the hole section in which
the ESP is set is relatively straight, the actual angle of the hole can
be up to 60 0 from vertical and severe doglegs may have to be passed
during the installation of the pump.
ESP installation inside the 7-in. [l78-mm] liner has been con-
sidered. The clearance between the pump plus motor lead extension
cable and the inside of the 7-in. [l78-mm] casing, however, is not
enough to guarantee trouble-free installations when going through
the liner top.

316 SPE Production Engineering, August 1989

 LEGEND
ELl ,.£RIOD AVERAGE
b.Sl CIIMULATIVE AVERACE
.
: 110
~oo
Fig. 8-ESP run-life analysis.
By setting the ESP's lower and inside the 7-in. [178-mm] liner,
lower flowing bottomhole pressure can be achieved, resulting in
higher flow rates from the well. Examination of the strength of the
9%-in. [244-mm] casing showed, however, that this one is under-
designed from about 6,000-ft [1830-m] true vertical depth; thus,
the most critical area is at the top of the liner. A minimum pump
intake pressure must be adhered to for the casing to be protected
from possible collapse. This largely offsets the gains obtainable from
a more deeply set ESP.
The economics of deep vs. shallow setting of ESP's in the 9%-
in. [244-mm] casing was discussed in Ref. I. Way and Hewett
showed that the deepest setting in the 9%-in. [244-mm] casing will
yield the highest returns.
ESP Sizing. The EPS' s are sized following established methods. 2
The selection of a pump intake pressure depends on the maximum
pressure required to prevent a potential collapse of the 9%-in. [244-
mm] casing and to limit the amount of free gas entering the pump.
Until recently, the allowable amount of free gas was limited to 10
to 15 vol %. During ESP runs in the Montrose field, however, free-
gas percentages of 30 to 50% going through the pump were estab-
lished without any obvious detriment to pump or well performance.
Similar results were also concluded from work reported by Lea
and Bearden. 3 At an intake pressure of 400 psi [2800 kPa], free-
gas percentages of up to 40 vol % were found to be allowable without
any significant effect on pump performance. Extrapolation of these
results shows 50 to 55 % free gas to be allowable at intake pressure
of 1,000 psi [6900 kPa] and higher.
The total volumetric flow rate (liquid and gas) at intake conditions
is used to select the pump type. Whenever possible, pump types
are selected to operate at the higher end of, or even outside, the
recommended range. Experience in the Montrose field has shown
that pumps operating at the high end experience less wear, which
extends run life (Fig. 7). While the mixture pressure is increased
in the pump, the actual flow rate decreases because of gas com-
pression and dissolution in the oil. Selecting the pump types as de-
scribed ensures that most of the pump's stages will operate within
the recommended range.
When the motor horsepower is determined, 10% is added to allow
for the high ambient temperatures in the Montrose field. Although
motors specially developed for higher temperatures are frequently
used, it is believed that this effective derating gives extra protection
against potential overheating.
The difference between the perforation depth and the pump setting
depth can make the temperature at the pump quite different from
that at the perforations. The temperature at the perforations is
assumed to be the same as the reservoir temperature (255°F
[l24°C]). Downhole pressure and temperature sensors have indi-
cated that the temperature of the fluid at the motor may be as low
as 190°F [88°C].
In the Montrose field, the fluid may pick up between 2 and 20°F
[l and 11°C] while going past the motor and will be heated more
SPE Production Engineering, August 1989
D.'
D.'
D.'
D.4
D.'
D.2
D.I
____ ______________
D~--~----~----~
"7' '''0 ", f ",z JUIJ
YEARS
~
18'4 ....~
Fig. 9-ESP failure distribution per time.
by the efficiency losses in the pump. Depending on several param-
eters, this can lead to high pump-discharge temperatures. If this
effect is not considered, the results of computer-calculated
multiphase-flow correlations for the tubing pressure drop can be
greatly in error. Also, a good estimate must be made of the surface
temperatures that are expected from ESP wells, which will be
different from the surface temperature of a naturally flowing well.
In Montrose, surface temperatures between 120 and 220°F [49 and
104 0c] have been recorded.
Before the design is finished, a final check of the pump's total
flow rate at discharge conditions is made. This step is important
when larger amounts of free gas are allowed to enter the pump.
Thus, the discharge volume is ensured to be within the recommended
range of the selected pump.
Run-Life Analysis. The operating run lives of ESP's in the Mon-
trose field have improved since they were reported in Ref. I. The
average run life of all pumps reported in Ref. I was 28 days. The
average run life of all pumps currently has increased to 97 days.
Fig. 8 shows the general improvement on the bar chart, where both
the average run lives of all pumps (cumulative average) and of
pumps installed during a certain period (period average) are shown.
The periods are 6-month summer and winter intervals. These in-
tervals were initially chosen to allow for the effect of weather
downtime in the production system while crude oil was exported
by shuttle tankers.
Another way to indicate improvement in run life and installation
of ESP's is to express it as a number of failures per time period
per well. Fig. 9 gives those results of ESP's operated in the Mon-
trose field and shows clearly the improvements made over the past
5 years.
A new method to evaluate run lives recently has been adopted.
A running average of the run lives of the 10 ESP's that failed most
recently is determined. When another ESP fails, it is included for
the running average, while the earliest ESP failure is deleted. This
method gives a good impression of the actual current run-life per-
formance of the ESP system. The run-life averages until June I,
1986, are plotted vs. the number of ESP's failed in Fig. 10. A time
scale is also included. A general increase in run-life average can
be seen clearly.
Several factors contributed to this general increase in run life.
A major factor probably was the installation of the pipeline that
became operational in mid-Nov. 1984. Run life had already im-
proved, however, between April and Oct. 1984, apparently because
the weather downtime was already practically nil and the number
of forced ESP shutdowns was therefore very limited.
Apart from the effect of the pipeline, improved installation
procedures, improved ESP design, improved sizing and optimizing
of operating conditions, and the installation of four VFD's on the
platform greatly contributed to the improvements. Installation
failures have now virtually been eliminated. Although no major
changes have been made in the installation procedures, the decrease
317
 o
: 2001--1--t---j- ---I---+-~--+---+_-th+--+_---1
.~

~~ f\ /
l-tt-+(+--+-----I
150-1----1----1------11------1-~_j-_j~--+

j 100.t------t----t---t--- rV L
;
w
fV1 Irfi
50r-~~~AM~~~/T__r~--r_~~
o
V V vy Fig. 11-ESP failure analysis.

o+--+---+--+---+---I-----I------1I------1--~--~
o 10 20 30 40 50 60 70 80 90 100
UI3 1'14 1... U"
No. of ESP'. Failed
Fig. 10-Running average of 10 ESP's.
in failures results mainly from the continuous attention paid to ESP
installation by the rig crew. Also, the switch to a different type
of cable protector eliminated initial problems with cable stretching
and damage.
The ESP design mainly in use in the Montrose field has 'been
changed to combat abrasive wear. This design also helps reduce
the rate of downthrust wear in general. The design modifications
were achieved by establishing the areas in the pump stages suffering
most from wear and by strengthening these areas. The modifications
are proprietary to the individual manufacturer. When the modifi-
cations included the strengthening of the balancing skirts in the pump
stages, a general reduction of the rate of downthrust wear was also
observed.
The sizing and operating philosophy of ESP's has become much
more sophisticated. Initially, the design was based largely on the
production of a full water column, where free gas was allowed for
by overstaging the pump. The need for free gas to be accounted
for in the downhole volume and used in pump selection is now fully
appreciated. , out motors caused by well-fluid ingress and overheating. The Well
Whenever possible, sizing will take place around the upper limit
of the recommended range and, if required, for an even higher flow
rate. This leads to a decrease of the downthrust force for that pump
type. Most of the pumps in use in the Montrose field have the zero-
downthrust force point toward the high end of or outside the rec-
ommended range. When downhole pressure information is available,
ESP's are operated toward the upper limit of the recommended range
whenever possible. No significant changes in operating conditions
are made when this information is not available.
The first VFD was installed during 1982 and three more during
1984. A separate analysis has shown that ESP's operated by a VFD
show a 30% increase in run life compared with the overall average.
This is attributable to the soft-start option and the chance to find
the best possible operating point for an ESP installed in a well. The
VFD's have also contributed to production increases. Because of
the inaccuracies inherent in the ESP sizing procedure, installed
pumps may not be perfectly suited for their actual duty, often re-
sulting in lower-than-anticipated flow rates. Through the use of
VFD's, an increase in oil production of 500 BID [80 m 3 /d] is
generally realized.
Failure Analysis. Fig. 11 shows the distribution of typical failures
in ESP installations in the Montrose field. Failures are divided into
five major categories. The largest number of failures occurs in the
Electrical Components category, which includes the electrical com-
ponents (splices, penetrators, connectors, and cable length) between
the junction box at the surface and the pothead where the electrical
conduit and the motor join.
The next-largest category is Worn and Seized Components, which
eventually led to assembly failure. This type of failure can result
from heavy downthrust, seized impellers andlor shafts, or seized
components in the other parts of the assembly, such as the down-
thrust bearing. The Motor Failure section includes mainly burnt-
Inflow category contains mainly problems caused by scale formation
in the near-wellbore region or wellbore damage resulting from the
workover fluid. Other Failures contains a variety of nonspecific
ESP assembly-related failures, such as tubing holes, casing col-
lapse, sand ingress, or unexplained shaft failures.
This simple failure summary shows that the electrical aspect of
the installation requires the most attention and improvement. The
chart covering the more recent period shows no significant change
in the distribution of failure types.

FAILURE MODE NUMBER OF OCCURRENCES

WORN PUMPS
SEIZED PUMPS
SEPARATOR WORN/SEIZED
PROTECTOR FLUID INFLUX
PROTECTOR THRUST BEARING
PROTECTOR MECHANICAL SEAL
MOTOR FLUID INFLUX
MOTOR TORQUE
MOTOR THRUST BEARING
MOTOR WINDING/OVERHEATING
DOWNHOLE P.T. SENSOR
BLOWOUT PACKER TO WELLHEAD CABLE
BLOWOUT MAIN CABLE
BLOWOUT MOTOR FLAT CABLE
CABLE SPLICE
POTHEAD
CABLE CONNECTOR
CABLE FEEOTHROUGH
INSTALLATION FAILURE
WELL FAILURE PROBLEMS
MISCELLANEOUS COMPLETION EQUIPMENT

Fig. 12-ESP failure·mode distribution.

318 SPE Production Engineering, August 1989


Fig. 13-Jet-pump operating principle.
A further breakdown of equipment failure is given in Fig. 12.
For this advanced analysis, 37 failure areas were established. Each
installation was analyzed and, when more than one area showed
problems, they were all listed and cross-referenced. This procedure
allowed the problems to be sorted so that a better relationship be-
tween cause and result could be obtained. This analysis shows that
the main cable, which used to be a great cause for concern, ac-
tually contributed much less to the overall number of failures than
was assumed previously. The origin of many cable faults was in
the splice, as explained in the Scope for Improvement section. Fig.
12 shows only the types of failures occurring most frequently.
Well Problems. Two wells, Wells 22/17-A2 and A4, had to be
abandoned after pulling the ESP after a failure proved impossible.
In both cases, this was most likely the result of the well being
pumped off.
As discussed earlier, the 9%-in. [244-mm] casing is under-
~esigned. It is therefore suspected that the pump intake pressure
In those two wells went well below that acceptable level, causing
the casing to collapse. Both wells have been sidetracked to a neigh-
boring area. One of the wells is currently pumping with a hydraulic
jet pump; the second well recently had an ESP installed.
It was not possible to pull the ESP in Well A 19. The ingress of
large quantities of sand has plugged the annular space between the
pump and the casing; therefore, the ESP could not be pulled out
again or the casing has again collapsed. This well was temporarily
suspended awaiting further action.
Potential problems with workover fluid have already been indi-
cated and a program to improve the quality of the workover fluid
was initiated. The type of workover fluid was changed during late
1985, and initial results are encouraging. Also, performance has
been hampered after inhibitor squeeze treatments.
On two occasions, performance at the surface was seen to be
decreasing and, upon pulling of the completion, holes were found
in the tubing, causing downhole recirculation of fluids.
Original sand production in the field was reported to be 30
Ibm/l,OOO bbl [0.086 kg/m3] and higher. Over the last year, sand
production seems to have diminished. During 1983, a test was done
with a gravel prepack hung off from a packer installed below the
ESP. This test was unsuccessful because calcium chloride scale,
most likely originating from the workover fluid, plugged the gravel
pack. The test was not repeated because it would be only a tem-
porary measure.
With the reduced san~ production today and more continuous op-
eration, the amount of sand produced through the ESP is not con-
sidered to be a real problem any more. Recent workovers have
shown very minor changes in fill depths on ESP wells. The only
time the wells appear to have problems is on the initial ESP instal-
lation, when the well experiences a sudden increase in drawdown.
Scope for Improvement. Amoco has, on behalf of the Montrose
operating group, been involved for some time in R&D related to
abrasion-resistant ESP's. It was recognized early that the combi-
nation of problems in the Montrose field created a specific envi-
ronment. The combination of hot, gassy fluids, deviated holes, some
sand production, and an intermittent production schedule caused
pumps to fail earlier than in wells where only one or two of the
SPE Production Engineering, August 1989
POWER FLUIO
\ A ) - - r - XMAS TREE
~~~-t-~~!::1= BOll WEEVIL TBG HANGER
_ EXPANSION JOINT
SUBSURFACE SAFETY VALVE
h.ll-Il.;=:;t---- ANNULAR SAFETY VALVE
~>4-p.<:::"l---- PACKOFF TBG HANGER
1 - - + - - - - 3 '-7' TBG
- + - - - - J E T PUMP BOTTOM HOLE ASSEMBLY
. - + - - - - N I P P L E PROFILE
SEAL LOCATOR
k-,,.§l.;;:::;t---- SEA L S
r:::::T-El<r=o>(---- PROOUCTION PACKER
J + - + - - - S E A L BORE EXTENSION
MILL OUT EXTENSION
,
V---I---- WIRELINE ENTRY GUIOE
Fig. 14-Hydraulic-jet-pump completion.
factors were present. Therefore, R&D in cooperation with ESP
manufacturers or outsiders was initiated early.
The first pump resulting from this cooperative effort has been
installed. A failure in the electrical system made the installation
fail after 296 days, but the pump itself was in excellent condition.
This pump design tackled the problems of sand abrasion and heavy
downthrust.
The second pump developed by a manufacturer not earlier in-
volved in ESP's became available in 1986. This pump design tries
to overcome the combination of problems.
Research on downhole cable was also carried out because the
electrical system seemed to present the majority of failures. It was
found that a significant part of the cable failures took place in an
area close to the splice of the motor lead extension cable. Typi-
cally, a blowout in the cable would occur between 5 and 30 ft [2
and 10 m] above the splice. This type of failure was initially at-
tributed to the main cable itself. During 1984, several splices were
evaluated with both X-ray and thermography. The splices evaluated
were both field- and shop-made splices, most of them coming from
wells but some made especially in the shop for comparison purposes.
The results of both the X-ray and thermography investigations
showed that several splices generated a very high temperature, ul-
timately resulting in a nearby cable failure. Therefore, quality
control at the splice makeup is of utmost importance, and special
attention is given to crimping the connecting sleeve to the con-
ductors.
An R&D project was recently initiated to test all electrical com-
p~nents as they are used in an ESP installation. New equipment
wIll also be tested before installation. The result of the project will
be a quality test and recommendations on electrical field testing
and/or equipment modifications.
A new type of cable is also being evaluated in the field. The cable
has a high mechanical strength and is designed specifically for a
gassy environment. A metal encapsulation around the conductor
and insulating material reduces the detrimental effects of the decom-
pression of gas, captured in the insulator. The cable has now been
used satisfactorily for more than 1 year.
319
 Continuous efforts are in progress to improve the sizing procedure psi [26.2 MPa]. Increasing the surface injection pressure and thereby
for ESP's. In general, an elaborate sizing procedure is being fol- the rate of the power fluid results in a higher production rate from
lowed that will probably yield the best results, although some further the well.
refinements are still possible. The more size refinement an ESP Retrieval and inspection showed no damage to the nozzle and
has, plus performance simulation compared with actual well con- the throats. For the test period, this was not expected. The major
ditions, the more options exist for optimizing well production. problem in this arrangement appeared to be the maintenance to the
The latest addition to the refinement was a method of more ac- mud pump: maintenance was required every 2 to 3 days, mainly
curately determining downhole temperatures at any particular point because of the use of water as the power fluid and the high oper-
in the well. The use of inaccurate temperature information can sig- ating pressure.
nificantly affect the calculated pressure drop in the tubing, the After the test program in Well 22/17-A5 was finished, the com-
downhole volume, and in the head generated by the pump. A flowing pletion was pulled and installed in Well 22/17-A21. This well al-
temperature gradient was established with the help of the downhole ready had 7-in. [178-mm] casing installed to surface, and special
pressure and temperature sensor between the perforations and the ESP equipment was designed for operation in this well. However,
pump. This gradient depended mainly on flow rate. Calculating the lead times for several pieces of the completion equipment left this
temperature rise through the pump and applying the flowing tubing well shut in for some time, and production could be regained earlier
gradient results in a good estimate of flowing surface temperature. by installation the jet pump.
The temperature profile throughout the well is now known, giving The jet pump has been in operation in this well since Aug. 1985
a much better result of the vertical multiphase-flow equation used and is performing according to predictions. Current total production
to determine the head to be delivered by the pump. is 500 B/D [80 m 3 /d], with a water cut of 63%. Power fluid is
injected at a rate of 2,000 B/D [320 m 3 /d], with a surface pressure
Hydraulic Jet Pump. In 1983, we decided to evaluate another of 3,400 psi [23.4 MPa].
means of artificial lift in the Montrose field. At that time, the in- The power-fluid-to-produced-fluid ratio of 4: 1 is inefficient. It
crease in average run life of ESP's was not as great as anticipated. has been determined, however, that with a different, more efficient
The interest was focused on systems that could be operating in only throat/nozzle combination, no increase in production could be ex-
a few wells in the field, notably in those wells that were very difficult pected. Further, no new parts were ordered for this project because
to operate with ESP's. Well 22117-A21 is awaiting conversion to a water injector.
Gas lift, which requires huge initial initial investments, long-term
fuel gas, and ample space to locate the gas compressor, was ex- Conclusions
cluded as a possible alternative. The best alternative was found to 1. ESP's have become a viable means of artificial lift in the Mon-
be hydraulic jet pumping. A pilot scheme was designed to evaluate trose field.
this system. Special interest was given to the handling of sand and 2. ESP run lives continue to increase because of improved
gas by the jet pump. procedures in handling, sizing, design, and operation.
In ajet pump, the nozzle converts the high pressure of the power 3. The majority of failures take place and originate in the elec-
fluid to a low pressure at the pump intake by changing its velocity. trical system, which requires and is getting further attention.
The power and well fluids are mixed in the pump throat, and the 4. The initial results of R&D into special abrasion-resistant ESP's
discharge pressure is obtained by the diffuser, where the low are very encouraging, with satisfactory results obtained from the
pressure is increased. The combined fluids are produced back first such ESP.
through the casing/tubing annular area. This pumping system has 5. Hydraulic jet pumping can provide a suitable alternative to
no moving parts (Fig. 13). Further information on the operating ESP's on a one-off basis.
principles can be found in Refs. 2 and 4.
Well 22/17-A5 initially was selected for this pilot scheme. An Acknowledgments
ESP used to be operated in this well but the well was shut in after
the water cut had increased to more than 95 %. I thank Amoco (UK) Exploration Co., Enterprise Oil pic, Amerada
Fig. 14 is a completion diagram for this well. To provide the Hess Ltd., and Texas Eastern North Sea Inc. for permission to
best annular area for the return fluid, the 7-in. [178-mm] liner was publish this paper.
extended to surface. The tubing is 3 1/2 in. [89 mm], with great care
being taken to provide a smooth bore between the wellhead and References
the jet pump bottomhole assembly. \. Way, A.R. and Hewett, M.A.: "Electrical Submersible Pumps for the
A special wellhead was designed for this pilot that allowed the Montrose Field-Their Application and Post Operational Experience, "
power fluid to be pumped either through the tubing in normal op- paper SPE 10388 presented at the 1981 SPE Offshore Europe Con-
erations or through the annulus when the jet pump has to be pumped ference, Aberdeen, Sept. 15-18.
out. One of the major advantages of the jet pump over the ESP's 2. Brown, K.E.: The Technology of Artificial Lift Methods, Petroleum Pub-
is that the pump can be retrieved merely by pumping out, rather lishing Co., Tulsa (1980) 2b, 58-92.
3. Lea, J.F. and Bearden, J.L.: "Effect of Gaseous Fluids on Submer-
than pulling the tubing string. sible Pump Performance," JPT (Dec. 1982) 2922-30.
The completion incorporates a tubing hanger/annular safety valve. 4. Wilson, P.M.: Introduction to Hydraulic Pumping, Kobe Inc., Hun-
Above the tubing hanger is the tubing-retrievable mudline safety tington Park, CA (1976).
valve. Both safety valves are hydraulically operated from surface.
Produced water was used as power fluid. To limit modifications 51 Metric Conversion Factors
to the surface system, an open system was selected for this pilot. °API 141.5/(131.5 + ° API) g/cm 3
The power fluid is taken from the high-pressure separation train, bbl x 1.589 873 E-Ol m3
which handles most of the produced water. The gas is vented and ft x 3.048* E-Ol m
the water dumped into an allocated pit by a separate vessel. An OF (OF-32)/1.8 °C
oxygen scavenger, scale inhibitors, and corrosion inhibitor are added in. X 2.54* E+OO cm
to the power fluid before it is pumped into the well. From the pit, lbf x 4.448222 E+OO N
the power fluid is pumped down the well by one of the mud pumps Ibm x 4.535924 E-Ol kg
available on the platform. The combination of produced fluids and miles x 1.609344* E+oo km
exhaust power fluid is returned through the annulus into the low- psi x 6.894757 E+OO kPa
pressure separation train. scf/bbl x 1.801 175 E-Ol std m 3 /m 3
An extensive test program to evaluate different combinations of
nozzles and throats was performed. With this system, the well would • Conversion factor is exact. SPEPE
still produce 3,000 BID [477 m 3 /d] of fluid, an amount similar to
Original SPE manuscript received forreview Sept. 18. 1986. Paper accepted for publication
that produced with an ESP. To do this, about 6,000 BID [954 Nov. 22, 1988. Revised manuscript received June 27, 1988. Paper (SPE 15869) first
m 3 /d] of power fluid was required at a surface pressure of 3,800 presented at the 1986 SPE European Petroleum Conference held in London, Oct. 20-22.

320 SPE Production Engineering, August 1989