International Journal of Mechanical Engineering and Technology (IJMET)
Volume 10, Issue 04, April 2019, pp. 136-141. Article ID: IJMET_10_04_012
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=4
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
Scopus Indexed
TRIAL EXPERIMENT OF DUAL ESP
PRODUCTION TECHNOLOGIES APPLICATION
FOR MULTI-RESERVOIR FIELDS OF LUKOILWEST SIBERIA
Valeriy A. Kostilevsky
Deputy CEO of LUKOIL-West Siberia OOO, PhD in Engineering
Oleg V. Bikbulatov
Head of Oil Production Department of Kogalymneftegaz TPP
ABSTRACT
This work represents the results of dual production technologies introduction at
Urayneftegaz oil fields which allowed, under the conditions of low permeable
reservoirs, to:
 increase the sweep and intensity of multi-reservoir field development by
isolated development of certain layers;
 ensure produced fluid accounting from each of the reservoirs;
 efficiently manage the range of bottomhole pressures;
 extend the field’s economic development time
 reduce operational costs.
Keywords: dual production; multi-reservoir oilfields; ESP production technology
Cite this Article Valeriy A. Kostilevsky and Oleg V. Bikbulatov, Trial Experiment of
Dual Esp Production Technologies Application for Multi-Reservoir Fields of LukoilWest Siberia, International Journal of Mechanical Engineering and Technology, 10(4),
2019, pp. 136-141.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=4
A number of fields developed by LUKOIL-West Siberia have entered the late stage of
development. The majority of residual hard recoverable reserves are located in low permeable
reservoirs and their isolated development is not economically efficient. Maximizing the
recovery requires development of all existing reservoirs in one well, however the license
obligations for subsoil development should be observed [1-6]. Drilling of a separate well will
be economically efficient only if production rate is minimum 60 m3/d [5-9].
 The first steps towards dual oil production by Urayneftegaz TPP were made in 2011.
The Company had to resolve the related issues such as:
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Valeriy A. Kostilevsky and Oleg V. Bikbulatov

increase the sweep and intensity of multi-reservoir field development by isolated
development of certain layers;
 ensure produced fluid accounting from each of the reservoirs;
 efficiently manage the range of bottomhole pressures;
 extend the field’s economic development time
 Reduce operational costs.
The task set to the technical teams was to ensure feasibility of individual control of the
following parameters for every layer:
Pump intake pressure (for bottomhole pressure calculation), fluid rate and water cut.
The technology was first time introduced at Urayneftegaz TPP fields with TatNIPIneft
representatives using the equipment of OOO Packer, Bugulma.
The first candidate wells: 134p of Krasnoleninskoe field and 10700P of Novomostovskoye
field, proposed by geologists for dual completion, had the following peculiarities.
The well 134P contained two reservoirs (UK and VK formations), with the lower one
having low productivity. The well was equipped with a single-lift, dual packer assembly with
an ESP for the upper layer development and a sucker rod pump for the lower one.
The well was started up on 25.04.2011. It was a new completion. After the dual oil
production assembly was introduced, 4 workovers were conducted with the average MTBF of
99 days (96, 24, 192, 85 days).
The well 10700P contained two reservoirs (USH2 and USH5 formations), with the upper
one having low productivity. The well was equipped with a single-lift, single packer assembly
with an ESP for the lower layer development and a sucker rod pump for the upper one.
The well was started up on 02.08.2011. The well had been operated by ESP. After the dual
oil production assembly was introduced, 2 workovers were conducted with 37 days MTBF.
After the dual production assembly was started, in both cases a leakage was identified on
the packer-nippel joint. Based on the analysis the material of the sealing rings of the packer
case was identified as a bad actor (Fig.1). During the well servicing the polyurethane gasket of
the nipple was replaced with a rubber one which allowed to achieve the leak tightness of the
system.
Based on the results of dual production application on these wells high water cut of the
lower reservoir was established. Later, the lower perforation intervals were isolated in both
wells.
The next step was introduction of dual production technology with ESP+sucker rod layout
with single-lift, dual packer assembly on the well 5632 of Krasnoleninskoe field. Manufactured
by OOO Packer, Bugulma.
Unreliable packer case was replaced with PRO-YaT-O packer. It allowed to enhance the
reliability and effectiveness of the process.
During the dual oil production assembly operation, 3 revisions of the downhole pumping
assembly without packer pickup were conducted with the MTBF of 134, 112, 185 days
respectively.
All failures were caused by the tubing abrasion by the rods in the interval 600-830 m. It
should be noted that operation of two pumps – ESP and sucker rod pump on a single lift causes
restriction to using rods with centralizers, therefore the assemblies contained the rod with no
centralizer.
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Trial Experiment of Dual Esp Production Technologies Application for Multi-Reservoir Fields of
Lukoil-West Siberia
The next trial was conducted on the well 9824 of Novomostovskoe field. ELKAM
NEFTEMASH TD LLC equipment was used. The similar ESP+sucker rod layout to the one
used in Urayneftegaz TPP, was applied (Fig.1).
A weak point in the process scheme turned out to be the isolation shell.
It functioned as a rod inserted pump sitting nipple, surrounded by a number of holes for the
fluid passage from the lower ESP. Setting of a rod inserted pump into the shell is not process
efficient if set in a sitting nipple, besides in case of leakage of this joint there is a risk of fluid
interflow supplied by the ESP to the above-the-packer space. With such a failure the whole
system should be shut down.
Figure.1. – Dual production ESP+sucker rod pump layout on the well 5632
1 - ESP (complete set); 2 – Three-way check valve; 3 – Knock-off valve; 4 – Packer with cable duct;
5 – Isolation shell; 6 – Insterted sucker rod pump; 7 – Pumping rods string; 8 – Wellhead equipment
for sucker rod pump; 9 – Power cable for downhole electric motor.
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Valeriy A. Kostilevsky and Oleg V. Bikbulatov
As soon as West-Turgovskoe field development started, it became necessary to develop the
reservoirs having sufficient productivity for the ESP+ESP dual production layout.
Under the trial performed on the wells 4667 and 4685 in 2013 the full-set dual ESP+ESP
production assemblies produced by Novomet-Perm CJSC were introduced. The fundamental
difference was application of size 3 progressive cavity pump. Reduced diameter of the pump
allowed the manufacturer to re-distribute the load from the assembly weight to the bypass line.
The ESP included multiphase pump sections. The technology was introduced in the well 4667
in April followed by the well 4685 in June.
The structural reliability of the downhole part of the equipment in these layouts "suffered"
from the control stations. During the trial, the control stations of ESP size 3 failed multiple
times. Representatives of Novomet-Service were called to recover the stations.
The dual production layouts use ESP bypassing systems with Y-Tool. They are primarily
designed for:
- logging activities;
- flexible pipe operations;
- production string perforation;
- chemical treatment of the reservoirs;
- usage of two pumps;
- RIH of fiber optic measuring systems.
Tables 1 and 2 represent various layouts of dual systems with ESP.
Table 1
Casing diameter
Size
Outer diameter of the
assembly
Upper ESP
Bypass pipe diameter
(outer/inner), mm
Capacity, m3/d
Lower ESP
Size
Capacity, m3/d
146
168
178
3
4
245
3
3
122
142
152
210
42 / 26
56 / 40
56 / 40
73 / 50
400
400
до 800
5, 5А
800
5, 5А
800
400
200
5, 5А
800
Up to 5А
5, 5А
Up to 1000
Table 2
Casing diameter
146
168
Size
3
3
122
142
152
210
42 / 26
56 / 40
56 / 40
73 / 50
Capacity, m3/d
400
400
до 800
Size
3
3
280
200
3
4
Outer diemeter of the
assembly
Upper ESP
Bypass pipe diameter
(outer/inner), mm
Lower ESP
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139
178
3
4
245
Up to 5А
до 5А
editor@iaeme.com
Trial Experiment of Dual Esp Production Technologies Application for Multi-Reservoir Fields of
Lukoil-West Siberia
Case diameter
(outer/inner), mm
121 / 100
121 / 100
Capacity, m3/d
400
400
121 / 100
140 / 117
400
200
190 / 140
Up to 800
The main drawback of this layout is high cost of equipment. This is caused by application
of ESP pumps of size 3. These pumps are produced only by order in small batches, the revision
of the equipment is time-consuming even if performed at the manufacturer's site. On the other
hand, the reduced diameter of the pump allowed the manufacturer to increase the diameter of
the pipes used in the dual system and redistribute the load from the assembly weight onto the
bypass line. Generally, the dual production conditions were met. The assembly remains
operational if one of the pumps fails.
Fig.2 shows a graph of changing production rate of the well 2081 of East-Surgutskoe field
where dual ESP-ESP production layout was applied. Almost double growth of the production
rate after the technology introduction can be observed.
Figure.2. Changing production rate of the well 2081.
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