Performance Evaluation for the Combination of Vortex Desander and Hybrid Sand Flowback Device for use with ESP in the Permian Basin

Abstract

Abstract This paper introduces technologies for handling solids above and below the ESP which increase ESP run time, decreases premature failure by pump plugging or damage, and thus contributes to the reduction of carbon emissions and environmental impact from well in interventions. A hybrid sand flowback device was engineered to allow fluid injection through the tubing while also allowing dissembling the components when pulled out of the hole, providing the operators with valuable information about downhole conditions. A vortex desander run below the ESP processes the majority sand before it enters the ESP pump intake. The hybrid device used to control the sand above the pump discharge is designed with the fundamental purpose of controlling the sand, to allow injection from the surface through the tubing, and to allow the inspection and repair of its components after retrieval from the well. The sand regulation system permits flow rates up to 15,000 BPD and has handled sand volumes up to 23,000 mg/L (0.19 ppg or 1.44 lbs/cu.ft. or 8.06 lbs/bbl). It also permits an injection rate through the tool up to 8 BPM while maintaining a surface pressure of less than 600 psi. The operational and performance advantages of this device have enabled its successful use in several Permian Basin wells. Artificial lift equipment run time have maintained high values to reduce the frequency of well interventions, as well as the replacement of the pump equipment, thus reducing the carbon footprint. Additionally, ESP sensor variables remained stable to contribute to a higher cumulative production compared to production periods where the pump was off line excessively or under well maintenance because of sand production. Furthermore, each combination tool pulled has been inspected and re-used to maximize the initial investment economics. This innovative technology protects the ESP against solids during shutdown events, allows flushing operations, and is easy to inspect and repair. Aided by use of premium materials with a special assembly system make it a tool for a long useful life. The successful application of complementary systems helped to extend the run-life of the wells until the ESP needs to be resized to match the reservoir inflow capacity. The sand challenges need to be approached by gathering data starting from expected fluid production (Oil, Water, Gas) and hydraulic fracturing design (frac sand size). This paper also proposes a new method to mitigate ESP sand problems through the use of a vortex desander comprised of an isolation method and sand control system. The isolation method separate the vortex desander intake from the casing fluid using cup packers, mechanical packers, or shrouds. The sand control portion considers static and dynamic principles of physics whose length, open cross-sectional area, and separation efficiency depend on the particle size distribution, well completion, and fluid characteristics.