Reducing Artificial Lift Surface Conversion Costs in a Unconventional Oil Field

Abstract

The Tourmaline Oil Corporation's light oil play (The Field) utilizes electrical submersible pumps (ESP's) for the dewatering and initial production (IP) phase. Sucker rod pumps are then used as the main artificial lift technology to produce The Field. The typical procedure is to convert these wells to pump and rods after the first ESP failure or after the well ceases to flow naturally. Constant changing of the lift systems on each well incurs costs, requires manpower and creates exposure with the need for surface facilities work. The recent economic downturn applied focus on reducing costs while optimizing production. A single wellhead that could accommodate flowing wells, ESP's, rod pumps and gas lift without the need to change the flowline configuration would save money and minimize production downtime. To develop this technology Tourmaline collaborated with industry leaders in wellhead penetration and rod pumping blow out preventers (BOP's) to design and engineer such a wellhead. The multi-function BOP will master ESP, rod pumps, natural flow and gas lift. After the multi-function BOP development was complete it was trialed in a controlled environment then installed on multiple wells within The Field. The product developed consists of combination tubing hanger and production wellhead. The multi-function wellhead includes dual master valves, dual rod BOP's, ESP capillary feed-through and gas lift capabilities with two flowline outlets. The final product is only thirty one and a half inches in height, making it compact, and operationally ergonomic. There have also been efficiencies realized from this wellhead including modular wellhead skids, downhole artificial lift combination deployment and reduced servicing costs. The surface conversion costs have been reduced by 95%. Due to the unconventional well flowing regimes and artificial lift practices Tourmaline Oil faces in The Field the need for new technology was identified. By teaming up with industry leaders an innovative and unique multif-function BOP wellhead was developed. The product has been installed throughout The Field with great success and has inspired other advancements in oil field efficiency.