G r a n d H y a t t R i o d e J a n e i r o • R i o d e J a n e i r o , B r a z i l • 3 - 4 M a r c h 2 0 2 0

ESP Technology Improvements in Peregrino FieldAntonio Alfonzo

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Peregrino Field | Production

• Development plan in partnership with Sinochem.

• Over 170 million barrels of oil produced since

2011.

• Field structure consists of 2 drilling capable fixed

platforms and 1 FPSO.

• Current field production: 60-80k BOPD.

• Third fixed platform was commissioned in 2019

with first oil in 2020.

• Phase II will add 273 million barrels of oil in

recoverable reserves.

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Source: ANP monthly report January/2019

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Peregrino Field | Well Completion Design

• Open hole gravel pack lower completion design.

• Production packer above the ESP.

• 1100HP tandem 725 series motors.

• 675 series pumps.

• Two independent chemical injection systems.

• Isolation valve installed below the ESP.

• Diverter valve above the ESP discharge.

• Maximum packer setting depth: 4500m MD.

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1 x 1/4” Hydraulic control line for DHSV

1.41" ESP power cable

(with 2 x 3/8" chemical injection lines)

MLE Cable

2 x 3/8" Chemical lines

Control lines:

1 x ¼” Hydraulic control line for setting the packer

1 x ¼” Hydraulic control line for discharge pressure

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Peregrino Field | Well Completion Design

• ESP string installed inside a 7-5/8” casing.

• Triple tandem 562 series motors with 999HP.

• 562 or 538 series pumps.

• Removal of production packer above the ESP.

• Tailpipe below capsule seals inside middle completion packer.

• Reduction of mechanical stress applied to ESP components due to tail weight.

• Maximum packer setting depth: 5800m MD.

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1 x 1/4” Hydraulic control line for DHSV

1.41" ESP power cable

(with 2 x 3/8" chemical injection lines)

MLE Cable

2 x 3/8" Chemical lines

Control lines:

1 x ¼” Hydraulic control line for discharge pressure

© G l o b a l O f f s h o r e B r a z i l S u m m i t a n d G u l f Q u e s t L L C

Failure Types

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Peregrino Field | ESP Teardown History

• Created by chemical instability between dielectric oil and heavy crude.

• Bag expansion capacity is reduced.

• Check valves plugged.

• Mechanical shaft seal operation is compromised.

• Limited sealing capacity leads to motor oil

contamination.

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Asphaltene Precipitation

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Peregrino Field | ESP Teardown History

• Loose Upthrust Bearing Pads

o Many upthrust bearing pads found loose in thrust chamber.

o Caused by impacts from runner during rotation speed variations.

o The issue hasn´t been identified as failure root cause yet.

• Pump Spinning Diffusers

o Pump diffusers spinning against housing caused pump to loose efficiency.

o Excessive thermal expansion created contact wear between impellers and diffusers.

o Pressure and temperature oscillations caused pump stages to loose compression.

o Excessive load in pump shaft.

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Mechanical Failures

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Peregrino Field | ESP Teardown History

• Wear between rotor end and carbide washer.

• Rotor ends severely worn.

• Excessive metallic particles contamination in motor oil decreasing motor dielectric strength.

• Compromised bearing lubrication due to oil contamination.

• Rotors strike against stator leading to short

circuit.

• Accumulation of hard material limits rotation capability of rotor stack which results in higher amperage.

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Rotor’s Motor Bearing Failure

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Peregrino Field | ESP Teardown History

• Epoxy with cracks leading to phase-phase

and/or phase-ground failures.

• Fluid contamination from the upper part of the

penetrator.

• Signs of overheating noticed during teardown.

• Possible root causes analysed:

o Incorrect installation or equipment handling.

o Improper annulus bleeding procedure.

o Power quality issues.

o No flow condition.

o Temperature and pressure oscillations due to emulsion production.

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Packer Penetrator Failures

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Technology Improvements

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Peregrino Field | ESP Technology Improvements

• Seal developed to increase reliability in an environment rich in asphaltene.

• Particle expulsion holes in top chambers in upper section.

• Communication holes in the housing replace communication through

head.

• Backup check valve in upper guide with parallel bags.

• Special non-sticking coating for head, upper two chambers and guides.

• Bag top cap and special neck clamp.

• High pressure single premium check valve.

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ASP Seal

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Peregrino Field | ESP Technology Improvements

• 725 series new design proposed for Peregrino application.

• Key improvements:

o Extended sleeve bearing.

o Thermoplastic thrust washer with larger ID.

o Sled key.

• New Motor design to deliver a smoother contact between end rings and washers.

• Stack weight is transmitted through the bearing sleeve.

• 42 strings with the new motor design were already deployed in the field without any failure up to date.

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New Motor Design

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Peregrino Field | ESP Technology Improvements

• Packer penetrator pressure ratings improved to 10k psi (absolute) and 5k

(differential).

• Temperature rating increased to 1800 C.

• Key enhancements:

o Lock ring uprated to high strength alloy.

o Pressure barrier sealing with compression ring face seals and FFLKM o-rings.

o Pressure barrier moulded with upgraded thermoset polymer.

o Lead sheet encasement instead of tape encasement.

o Bodywork improved to higher tensile steels.

o Upgraded thermoset moulds and insulation material.

• 29 HPHT penetrators already installed in the field without any failure up to date.

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HPHT Packer Penetrator Design

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Peregrino Field | Key Performance Indicators

• Track reliability using consistent metrics is

paramount to evaluate ESP performance.

• Data quality and detailed failure analysis is

important.

• Mean-time to Failure (MTTF)

o Widely used metric in ESP industry.

o Allows meaningful conclusions even when a limited

portion of the population has experienced a failure.

o Earlier measurement of performance impact after

design changes.

o Forward tracking method.

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Mean Time to Failure

Day

s

ESP Run Life KPIs

HPHT Penetrator

Vanguard Pump Technology

New Motor Design

ASP Seal

1538 days

Source: ESP Run Life Control KPIs - BH

PSU Motor

Q1 Traceability

Type 4 Seal

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Peregrino Field | Key Takeaways

• Collaboration between operator and vendor is essential for improving ESP performance.

• Equipment customization is required in challenging applications.

• Detailed failure analysis drives equipment improvements.

• Ongoing actions to increase ESP reliability:

o Performance based contracts.

o Audits in Manufacturing Center to improve quality control.

o Focus on equipment testing prior to offshore mobilization.

o Partnership with Research Center and universities to better understand application challenges.

o Implementation of recognized industry standards (ISO 15511).

o ESP operation digitalization.

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Conclusion and Way Forward

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ESP Technology Improvements in Peregrino Field - SPE-194401-MS

Acknowledgements