SPE-186250-MS

Overcoming Electrical Submersible Pumping Production Challenges in

Highly Deviated Wells

Reda El Mahbes, Regulo Quintero, and Antoni Malino, Baker Hughes

Copyright 2017, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE/IATMI Asia Pacific Oil & Gas Conference and Exhibition held in Jakarta, Indonesia, 17-19 October 2017.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Deviated wells with a high dogleg severity (DLS) or buildup rate present major challenges for electrical
submersible pumping systems(ESP) and often prevents the installation of ESPs at the deepest possible
setting depth (El Mahbes, 2016). Passing ESP systems through a tight bend radius can reduce system
reliability and limit how deep the system can be set to achieve maximum oil recovery. This paper highlights
the benefit of using a newly designed ESP system for five highly deviated wells.
The new tight-radius ESP system is designed to pass through buildup rates of up to 25° per 100 ft. with no
impact on reliability. This capability means the ESP can be placed at the lowest possible setting depth closer
to the production zone, which permits greater reservoir pressure draw down, enhanced overall production,
and improved reserve recovery. In addition, tight-radius ESP system reduces the equipment installation time
by more than 50% and eliminates the potential of dropping bolts in the wellbore during installation.
This paper presents a comparison between using conventional ESP systems and the new tight-radius ESP
design in highly deviated wells and wells where the buildup rate is very high for conventional ESPs to pass
through. This technology was applied in multiple wells and results showed that the new ESP design helped
extend ESP run life and allowed the operator to set the system deeper in the well, closer to the producing
zone, to increase production and maximize reserve recovery.

Introduction
Drilling and well construction are considered the most expensive stages in the lifecycle of any oil and
gas well. Directional drilling introduces more challenges and cost to the lifecycle of the well and may
reduce reserve recovery due to artificial lift technology limitations based on the construction of a deviated or
horizontal well. To maximize production in unconventional resources, wells need to be drilled horizontally
at the pay zone area; this maximizes reservoir contact, which is necessary to maximize oil and gas production
from tight sands. Drilling unconventional wells with a low dog leg severity (DLS) and a long tangent is very
challenging and expensive. Therefore, the majority of operators opt to drill long tangents below the well
kickoff point (KOP) because it is a more cost effective solution and more convenient for current artificial
lift technologies. The following schematic shows a typical unconventional well drilling and construction
in US land.
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Figure 1—Typical Unconventional oil and gas wells in US land

Directional drilling can limit where to set artificial lift systems; for instance, passing an ESP system
through a high DLS can cause permanent damage to the ESP equipment, leading to premature failure. The
industry standard for conventional ESP systems to pass through DLS or deviation rate is 6°per 100 ft. which
requires stringent steering control and reduced drilling speed which significantly increase drilling costs.
Placing the ESP system at the deepest allowable setting depth enhances production by having more fluid
above the pump intake and potentially accomplishing greater pressure drawdown and less possible gas slugs
due to undulations in the lateral section of the wellbore. Therefore, the need for an ESP system that can pass
through higher buildups or deviation rates is vital to improve the economics for deviated wells in general
and unconventional wells specifically.

New ESP System

A new ESP system designed to maximize production by allowing ESP system to reliably pass through a
high deviation rate or DLS without the stresses typically produced on a conventional ESP. Additional stress
as an ESP passes through a tight radius can cause a break at the weakest points in a traditional ESP, causing
permanent ESP damage and accelerating ESP failure. The new tight-radius ESP configuration strengthens
the weak points, allowing for easier entry with reduced installation time.
The new ESP system was tested to pass through 25° per 100 ft.at the research and technology laband
passed through buildup rates of 21° per 100 ft. in the field. Moreover, the system was designed to increase
tensile strength, successfully handling up to 120,000 lb tensile vs. 35,000 lb with a traditional ESP design.
Figures 2, 3 & 4 show tests of the tight-radius ESP passing through a buildup rate and being tested for
tensile strength respectively.
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Figure 2—Traditional ESP vs. tight-radius ESP

Figure 3—Tight-radius ESP system passing through 25° per 100ft buildup rates

Figure 4—Tight-radius ESP connections tensile test

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Case Histories Background

Current unconventional well architecture in Permian and Uinta basin have an average of 8,000 ft. total
vertical depth (TVD) and KOP typically from about 5,000 to over 10,000 ft. TVD. The buildup rate varies
based on operator's business drivers. The operators deploy different types of lift in both basins, including
gas lift, rod lift, and traditional ESP systems. However, some of the wells are very challenging to improve
production and enhance reserve recovery by setting the artificial lift system closer to the producing zone due
to the limitations the well construction present. For instance, gas lift can be inefficient in high inclination
wells due to gravitational differences between liquid and gas. The injection in these types of well will
not be as efficient as vertical wells. Therefore, setting the gas lift mandrels at the inclination can limit
well drawdown and production. The other disadvantage of setting the mandrel at the horizontal or high
inclination is workover challenges to replace valves with wireline. This process is very problematic and can
significantly increase the time and cost of workover operation.
Similar to gas lift, deploying rod lift systems is very limited for applications where well inclination and
buildup rate are high. The majority of rod pumps are set in the vertical section above the KOP which can
significantly reduce desired drawdown and production. Setting rod lift systems at the high inclination build
section can increase rod wear and tubing wear which leads to frequent rod lift system failures and tubing
failures.
Conventional ESP systems are sensitive to deviation and high buildup rates. Passing an ESP system
through a high buildup rate may cause permanent damage to the ESP system, leading to premature failure.
Therefore, it is recommended to run stress analysis for conventional ESP systems to pass through DLS
higher than 6° per 100 ft. to check the feasibility of passing the system without causing permanent
deformation or crushing the motor lead extension. In addition, setting the ESP system deeper and at the
deviated section can help with handling gas slugs that are created by natural gas accumulating on the high
side of the undulations in the lateral section of the wellbore. Setting the ESP system deeper than the gas
cap can exponentially increase system efficiency and run life. Figure 5 shows an illustration of setting ESP
system deeper than the gas caps.

Figure 5—Gas cap formation

The operators in the Permian and the Uinta Basins opted to run the new tight-radius ESP system to
overcome these previous challenges and to enhance reserve recovery. The following case studies describe
the results ofdeploying the new ESP system in wells where other forms of artificial lift do not achieve the
desired draw down and improved reserve recovery.

Case Study Number One

One operator in the Permian Basin experienced multiple ESP premature failures due to attempts to pass
the systems through a deviation of 16.5° per 100 ft. The ESP systems were planned to set below KOP to
maximize production and reduce the failure rate due to the high buildup rate. Table 1 shows the drilling
survey for the well and the buildup rate, which the ESP needed to pass through to land at the operator
desired setting depth.
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Table 1—Permian Basin Well #1 drilling survey

Measured Depth (ft.) Total Vertical Depth (ft.) DLS (°/100 ft.) Remarks

8689 8686.64 0.61 Kick off Point

8720 8717 9.49

8752 8749.36 14.38

8784 8780.69 16.55

8815 8810.43 13.4

8847 8840.54 8.78

8879 8870.03 10.57

8910 8897.72 14.42

8942 8925.16 13.72

8974 8951.42 11.16

9005 8975.81 9.94

9037 8999.8 11.01

9069 9022.38 12.13

9100 9042.6 14.53

9125 9057.54 14.16

9156 9074.53 11.45

9188 9091.19 3.15

9220 9107.8 3.55

9251 9123.77 4.61

9282 9139.13 6.79

9314 9153.72 9.96

9346 9166.49 12.75

9377 9176.76 14.08

9409 9185.03 13.75

9441 9190.82 14.89

9472 9193.98 15.19

9504 9194.98 13.93

9536 9194.37 12.64

9567 9193.3 9.9

9599 9192.3 7.68

9631 9191.56 9.22

9821 9188.12 0.73 Desired ESPSetting Depth

9916 9187.1 0.33

10011 9186.15 1.72

10105 9186.8 2.43

10200 9189.07 0.18

10295 9191.33 0.25

10390 9193.81 0.14

10485 9196.15 0.67

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Measured Depth (ft.) Total Vertical Depth (ft.) DLS (°/100 ft.) Remarks

10580 9198.19 0.16

10675 9200.02 0.37

10770 9201.48 0.32

10865 9202.72 0.17

10960 9203.67 0.38

Figure 6 shows atwo-dimensional representation of Well #1 using stress analysis simulation.

Figure 6—2D Well Profile

Stress analyses were conducted to determine the stress on the conventional ESP and the new tight-radius
ESP to determine which configuration was feasible for well #1 after 3 premature failures as shown in Figure
7. Figures 8 and 9 shows stress difference for both options passing through 16° per 100 ft.

Figure 7—Attempt to pass covenantal ESP system through 16° per 100ft build up rate
SPE-186250-MS 7

Figure 8—Well #1 stress analysis for conventional ESP system

Figure 9—Well #1 stress analysis for new ESP system

Based on the stress analysis the conventional ESP system will go under more than 50ksi stress, which
can cause permanent equipment deformation that leads to failures. The new tight-radius ESP system will
be under 25 ksiwhich is 50% less stress. The tight-radius ESP system was installed succefully at the desired
setting depth and increased oil production by 50% from previous artificial lift system which was set above
the KOP.
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Case Study Number Two

An operator in Uinta Basin drilled a new horizontal well and after the well was completed, the customer
ran a Gyro to evaluate the DLS above the desired ESP system setting depth. The Gyro results showed that
the well had a high DLS of more than 17.7° per 100 ft. Table 2 shows the drilling survey for Well #2.

Table 2—Uinta Basin Well#2 Drilling Survey

Measured Depth (ft.) Total Vertical Depth (ft.) DLS (°/100 ft.) Remarks

4800 4799.8 0.00 Kick off Point

4814 4813.79 14.25

4845 4844.71 15.34

4877 4876.29 17.70

4908 4906.38 12.86

4940 4936.78 14.86

4971 4965.49 12.08

5003 4994.32 12.45

5035 5022.25 11.71

5067 5049.33 10.47

5099 5075.70 10.01

5131 5101.43 13.65

5162 5125.72 12.45

5193 5149.62 3.43

5225 5173.84 7.08

5257 5196.90 12.84

5289 5218.38 11.98

5320 5237.66 11.95

5352 5256.01 10.78

5383 5272.23 11.88

5415 5287.23 11.92

5447 5300.55 9.84

5478 5311.96 10.35

5510 5322.12 10.36

5542 5330.66 9.34

5573 5337.15 12.21

5605 5341.72 12.41

5636 5344.29 9.48

5700 5347.50 1.47

5795 5351.44 0.27

5891 5354 1.61 Desired ESPSetting Depth

5986 5354.55 1.58

6081 5354.13 0.12

6176 5354.20 0.19

6271 5353.62 0.74

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Figure 10 Atwo-dimensional representation of Well #2 using Stress analysis simulation.

Figure 10—2D well profile

The first ESP was installed above the KOP, which limited fluid drawdown and reserve recovery. After
the first ESP system failed, the operator wanted to set the ESP system deeper below the KOP to maximize
production and well recovery. A stress analysis was conducted to determine the stress on the ESP equipment
and to evaluate the feasibility of passing a traditional ESP system through 18° per 100 ft. buildup rate. The
following graph (Figure 11) shows the stress analysis of a conventional ESP system passing through 18°
per 100 ft.

Figure 11—Well #2 stress analysis for conventional ESP system

Based on the stress analysis, it was determined that passing the ESP system through the well #2 buildup
rate would damage the ESP equipment.
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The new tight-radius ESP system was introduced to the operator as a solution to set an ESP at the desired
setting depth. A stress analysis was simulated to evaluate the stress on the ESP equipment and to evaluate the
feasibility of passing the new design through the high DLS without damaging the ESP. The following graph
(Figure 12) shows the stress analysis of the new ESP system passing through a bend radius of 18°per 100 ft.

Figure 12—Well #2 Stress Analysis for Boltless Flange ESP system

The stress on the tight-radius ESP equipment was it passed through 18° per 100 ft. is around 27 ksi which
is 50% less than stress on conventional ESP system. After the stress analysis, the system was installed
successfully and increased oil production by 30%.

Summary of Case Studies

Table 3 shows a summary of the advantages of deploying the new tight-radius ESP system design over a
conventional ESP system and other forms of artificial lift.

Table 3—Tight-radius ESP system case histories summary

Vertical Setting Depth [ft.] OIL PRODUCTION [bopd]

DLS CASING Before After Before After

Well # Tight- Tight- Tight- Tight- INCREM.
[°/100FT] SIZE
radius radius radius radius [%]
System System system System

1 16.5 5.5" 17# 8486 9187 61 120 49%

2 18 5.5" 17# 4699 5354 265 340 28%

3 (New
15.81 7" 26 # N/A 6066 N/A 183 N/A
Drill)

4 12.59 7" 26 # 8060 8494 183 248 36%

5 (New
13 7" 26 # N/A 6947 N/A 78 N/A
Drill)
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Conclusion
The tight-radius ESP configuration strengthens the ESP system, making the system stronger to allow the
ESP system to pass through buildup rates up to 25° per 100 ft. Passing through high buildup rates allows
the ESP to be set deeper and closer to the producing zone to improve production and recovery. In addition,
the tight-radius ESP system minimizes installation time, which reduces OPEX and eliminate the potential
of dropping equipment downhole (Bridges, 2016).

Nomenclature
DLS = Dogleg Severity
ESP = Electrical Submersible Pump
KOP = Kickoff point
OPEX = Operational Expenditure
TVD = Total Vertical Depth

References
1. Bridges, J., Fougerdi, M., "Production optimization in highly deviated unconventional wells,"
SPE North America Artificial Lift Conference and Exhibition, 2016. SPE-181225-MS
2. El Mahbes, R., Quintero, R., Larez, A. "Artificial Lift Production Systems Sizing and Simulation
Software" Abu Dhabi International Petroleum Exhibition & Conference, Abu Dhabi, UAE, 2016.
SPE-183534-MS