By using Rod Lift Advisor to remotely monitor and control wells, production engineers were able to quickly analyze contextualized pump condition data to take corrective actions with no delays.

THE CHALLENGE

An operator in the Permian Basin had a challenge to reduce the frequency of field visits to remote wells while improving ESP uptime. With about 365 ESP wells in their field, this operator has been experiencing the challenges of maintaining oil production in unconventional wells. Their engineers were accustomed to frequent ESP downtime caused by issues. ESP critical events required a rapid intervention to reduce stress on ESP components and maintain the system’s run life.

However, mobilizing field service personnel to the remote wells (100 to 180 miles from the nearest field service experts) incurs risks and takes time—about 7 hours per event. Even for planned shutdowns, service hours and deferred production can accumulate rapidly.

To minimize the costs and risks of wellsite visits as well as reduce the ESP downtime, the operator sought an alternative means of intervening in their operations

THE SOLUTION

In collaboration with the ESP provider, the AgoraGateway and edge platform were installed on every well site to enable a real-time monitoring and control solution. The solution not only allowed all the ESPs to be monitored but also to be controlled remotely in real-time leveraging cellular network in the area. The high-frequency data was also delivered to the ESP provider for production life cycle management service which provides insights for optimized ESP performance, condition-based maintenance, and future design improvements. This critical service which incorporated 24/7 monitoring and surveillance by dedicated ESP engineers, was deployed for 23 wells prone to frequent shutdowns requiring unplanned field trips by the operator.

THE RESULTS

The overall solution allowed the operator to achieve 91% ESP uptime in critical wells with 24/7 surveillance and remote interventions, compared with 57% uptime in wells monitored with data visualization only.

A dedicated ESP engineer remotely intervened 124 times in wells protected with the 24/7 surveillance. Most importantly, 31 critical events were addressed within 20 minutes of its occurrence, which used to take on average of 7 hours to mobilize personnel to begin the investigation and intervention work.

For the 23 critical wells, remote operation became the accepted practice for every remedial activity like elective stop, troubleshooting events, startup of ESPs. As a result, the operator avoided 1,800 bbl of deferred oil production and eliminated 800 hours of unplanned and unnecessary field service time—a total value of approximately USD 206,000.

Learn more about the ESP Vision app, powered by Agora.

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