Technology

What’s the cost of being reactive vs. proactive?

Unplanned interruptions to Artificial Lift production are a $100 billion/year problem.

AVERAGE RUN LIFE OF AN ESP

1.2 years

OPTIMAL RUN LIFE OF AN ESP

5 years

AVERAGE DOWNTIME

0 Days

Typical downtime for ESP repair after failure

AVOIDABLE OR EARLY FAILURES

0%

40% are Pump Failures + 20% are Motor Failures

AVOIDABLE YEARLY REVENUE LOSS

0 Bil. USD

Amount to be gained industry-wide by extending ESP life by 30%

OspreyData identifies how problems evolve

Every form of artificial lift is prone to failure when subjected to different types of reservoir conditions. Problems like scale, low static bottom hole pressure, overload and rod string failure are the result of machines encountering gas, sand, H2S and CO2 corrosion and other subsurface conditions.

The early evolution of these reactions is absolutely detectable. OspreyData’s machine learning technology and robust architecture alerts you to problematic changes in these sensors early so that your operators can take preventive action immediately.

CYCLING GAS LOCK

Cycling Gas Lock is a transient state that may not result in an equipment failure, but kills production results. Cycling Gas Lock can persist for days and result in as much as 80% reduced production if not identified. OspreyData can identify Gas Lock in minutes and can escalate the problem if the state at its onset. The handling of gas lock is quite simple; it usually can be resolved by slowing the pump or turning it off to allow pressure to build back up in the reserve, re-establishing normal flow.

SCALE

Scale acts as an insulator to the ESP motor, causing an increased spread between actual and predicted temperature. Scale also coats the impellors, causing an increasing negative spread between actual and predicted efficiency.

Scale is a very destructive but treatable occurrence, currently managed with a proactive chemical regimen that is effective but not efficient. OspreyData can identify scale and escalate the application of a more effective chemical treatment that significant reduces the cost of maintenance.

SAND EROSION

Sand erosion occurs on impellors over time and is detected by an increasing negative spread between actual and predicted efficiency, without a noticeable spike in temperature. Erosion slowly robs the pump of its efficiency, resulting in lowered production outcomes compared to the designed potential. OspreyData can identify and predict the best time to schedule impellor replacement to maximize a pump’s use.

IRON SULFATE BUILDUP

Iron Sulfate has four times the specific gravity of sand and tends to rest in the ESP tubing string, which causes an increasing negative spread of efficiency between actual and predicted. Iron Sulfate also causes vibration as the pump struggles to move the product. A slight increase in temperature also occurs.

Iron Sulfate can cause a plugging effect that results in an immediate pump shutdown. This can be treated by using a chlorine dioxide stimulation process to remove the sulfate by oxidation. We identify the best time to schedule this procedure, preventing major destruction to the pump.

These are just a selection of the problems OspreyData has been able to identify for clients.
To discuss your goals for production and optimization, contact us.

Artificial Lift is just the beginning.

Opportunities for event prevention and response in Oil & Gas are increasing as companies pursue unconventional, high-risk and highly sophisticated drilling techniques and forms of artificial lift. OspreyData’s predictive analytics and escalation capabilities will readily extend to serve this wider range of installations. These cases show just the starting potential of uses in the Oil & Gas industry:

ARTIFICIAL LIFT

ESP
ROD PUMPS
GAS LIFT COMPRESSORS
(Natural Gas)

ENHANCED OIL RECOVERY

ESP
STEAM INJECTION

DRILLING + COMPLETION

FRACKING
DRILLING DYSFUNCTION