Fighting, Mitigating, and Surviving Againstasphaltenes with a Special Electrical Submersible Pump Design

Abstract

Abstract Over the years, Electric submersible pumps have been proven to be a reliable artificial lift method in different fields of the world for a broad range of flow production and different well fluid types. However, harsh environment such as heavy oil, high temperature, asphaltene formation and severe fluid properties generate problems inside the equipment reducing their operating run life. During the normal operation of the ESP, asphaltenes formation inside protectors are one of the major problems that the operators suffer and due to this, premature failure could occur. This failure usually follows the same pattern and consist in formation and accumulation of solids inside chambers, bags will collapse due to incorrect function of expansion and contraction of the oil due to temperatures (due to frequent shutdowns), and contamination though all internal chambers reaching thrust one, usually resulting in mechanical failure due to a shaft fatigue at the runner level or in an electrical failure due to motor contamination with well fluid. Chemical injection and low drop pressures have been considered to control this effect, however, there is not an ESP configuration developed to mitigate and combat to the presence of asphaltenes inside protector chambers. The main objective of this paper is to share the results and conclusions of a full study that considers the main reasons for formation, accumulation, and mitigation of asphaltene effects inside ESP systems. This study explains in detail all the root failure analysis, laboratory investigation, R&D process and new ESP design solution, proved at laboratory and in field, that will allows the customerto extend the run life of the ESP systems.