AVERAGE RUN LIFE OF AN ESP
OPTIMAL RUN LIFE OF AN ESP
Typical downtime for ESP repair after failure
AVOIDABLE OR EARLY FAILURES
40% are Pump Failures + 20% are Motor Failures
AVOIDABLE YEARLY REVENUE LOSS
Amount to be gained industry-wide by extending ESP life by 30%
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 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 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 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.
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:
GAS LIFT COMPRESSORS