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Spe 185367 Ms

This summarizes a document discussing transitioning gas lift wells with high gas volumes to electric submersible pumps (ESPs) in an offshore Indian oil field. 27 candidate gas lift wells were studied for ESP feasibility. 13 wells were initially converted to ESPs but many failed due to high gas volumes. Lessons from failures were used to design successful ESP solutions for the remaining 27 wells. The document discusses challenges of operating ESPs in high gas volume fractions and different methods studied to mitigate gas interference, improve production, and ensure future ESP pilot project success in such fields.

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0% found this document useful (0 votes)
34 views12 pages

Spe 185367 Ms

This summarizes a document discussing transitioning gas lift wells with high gas volumes to electric submersible pumps (ESPs) in an offshore Indian oil field. 27 candidate gas lift wells were studied for ESP feasibility. 13 wells were initially converted to ESPs but many failed due to high gas volumes. Lessons from failures were used to design successful ESP solutions for the remaining 27 wells. The document discusses challenges of operating ESPs in high gas volume fractions and different methods studied to mitigate gas interference, improve production, and ensure future ESP pilot project success in such fields.

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sheenat100
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© © All Rights Reserved
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SPE-185367-MS

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Transition from Gas Lift to Electric Submersible Pump in Wells with High
Gas Volume Fraction - Avenues for Profitability in Challenging Markets - A
Novel Case Study of an Indian Offshore Field

Prasant Goel, A Kumar, H Duara, T K Mandal, Dr K R Rao, and V V Manchalwar, ONGC

Copyright 2017, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Oil and Gas India Conference and Exhibition held in Mumbai, India, 4–6 April 2017.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
27 gas lift wells of an Indian Offshore field were studied for feasibility of conversion of Gas lift mode
to ESP. The wells have good productivity indices ranging from 1 barrel /day/psi to 6.9 barrel /day /psi.
However, the production challenge was to operate these wells in a region where bubble point pressure was
higher than the formation pressure itself and thus posed problem of gas evolution at the wellbore. During
ESP operation in High Gas Volume Fraction (GVF) regions, extreme difference in the densities of the liquid
and gas lead to a low pressure area in the Impeller during the pumping operation across the stages of ESP,
resulting in gas accumulation. Free gas in these stages displaces liquid and lowers down the volumetric
efficiency of the pump. In the past, 13 offshore wells were installed with ESP and many of these ESPs
failed. Their failure analysis was used as a guiding light for designing successful ESP solution for other 27
candidate wells of the same Offshore field. Different methods & practices for handling gassy wells were
studied and their application was analyzed. This study was aimed at finding solutions to mitigate the effect
of gas interference in ESP while enhancing the production from the wells. Moreover, the paper also draws
a strategy for future ESP pilot projects in high GVF fields.

Introduction
The field was discovered in 1970's and has around 792 gas lift wells and 52 self flow wells currently. It
is one of the largest and most prolific oil field in India and has a length of 75 Km with a width of 25
Km.13 of the high producing gas lift wells from this field were converted to ESP as a pilot project. The
13 wells selected for ESP initially produced at an average of 1330 BLPD with a water cut of 79.6%. The
overall average production from the gas lift wells is 1087 BLPD with 73.7 % water cut. The self flow wells
produce at a rate of 500 BLPD with an average watercut of 54.7%. Formation GLR in the ESP wells was
close to 89 m3/m3 and was relatively lower than that of other Gas lift wells. Production enhancement and
Injection gas savings were the two major objectives for this project. The production challenge lay in the fact
that these wells had a higher bubble point pressure than the formation pressure itself and thus posed a gas
interference problem. Generally a centrifugal pump handles incompressible liquid and on the other hand a
compressor handles liquid free compressible gas. But when the liquid and the gas combine, they deteriorate
2 SPE-185367-MS

the operating efficiency of both the pump and the compressor. Thus whenever we find that the gas and
liquid are together forming a commingled flow, we should consider a few design factors like pump stage
geometry, its operating point, the pump intake pressure and the wellbore geometry and alter them to avoid
any bottlenecks during the operation of the pump in these conditions. Presence of free gas at pump intake
affects the pump performance negatively by reducing the liquid handling and pressure generation ability of

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the pump. This performance reduction may sometimes be quite severe, resulting in significant production
losses due to unstable pump operation and increased operating costs due to premature equipment Failure.
ESP can operate successfully with the pump intake gas fraction of up to 75% through use of appropriate
gas handling technologies. In this paper experience of running ESP in 13 high GVF(Gas Volume Fraction)
wells has been put across and major lessons learnt, during the failure of ESP in some of these wells, have
been highlighted. These lessons were implemented in designing the future ESP for the next 27 Gas Lift
wells. The paper further draws a strategy for future ESP pilot projects in high GVF wells.

Figure 1—field Overview


SPE-185367-MS 3

Operation of ESP in high GVF and its Challenges


The failures in the ESP due to low volume High GOR conditions is generally due to the high rate of
gas passing through the smaller size impeller conduits of the pump, which ultimately causes the pump to
cavitate. With no liquid passing through a cavitated pump, it will either trip due to under-load or the ESP
would fail due to overheat as has been observed in many field cases in our experience. In such scenario, the

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normal industry practice is to reduce the volume of the free gas at the pump intake, by putting one of the
systems to counter the excessive free gas. It may be a gas separators, gas handler, impellers with balance
holes, and other similar systems. Many a times, an effective ESP lift is not possible due to gas locking of the
pump. This may be caused by the very high free gas fractions, which are in excess of 80% at pump intake.
In an attempt to address the poor performance of the wells in one our fields, we had installed conventional
vent packer ESP completions. The vent packer completions used a rotary gas separator at the pump intake,
which separated a proportion of the free gas and exhausted it via the annulus. As a consequence, the free
gas fraction entering the gas handling ESP pumps was reduced. Vented packers, with surface controlled sub
surface safety valves were included above the pump to provide downhole isolation of the annulus flow path.
The vent packer completions was helpful in handling the gas but could not handle excessive free gas due
to various operational reasons including prescence of low pressure gas in the annulus and gas recirculation
below the vent packers. Thus the free gas in the stages of the impeller displaced the liquid and restricted
volumetric efficiency of the pump. Therefore apart from the above effort other methods for handling gassy
wells worldwide1,2,3,4,5,6 were studied and possibility of their application was explored during the study: -

1. Standard ESP
A standard ESP can successfully counter high GVF wellbore conditions if the free gas to liquid ratio falls
within acceptable limits of these ESP pumps. The Turpin and Dunbar correlations may be used to check
the compliance with the limits and accordingly the pumps may be improvised in terms of construction and
configuration if need be. There is fine line between stable and unstable operation and it varies with stage
type, fluid characteristics and well bore geometry therefore the pump improvisation analysis depends on
case to case basis.
Turpin presented two correlations that were based on the Lea and Bearden data. One of the correlation
relates to the head deterioration and depends on the stage type. This correlation predicted an exponential
decay of head with increasing free gas at the intake of the pump. The second correlation works towards
prediction of pump stability through the Turpin factor f, which is defined as:
f=2000(qg/ql)/3Pi.
Here,
qg = gas flow rate,
ql = liquid flow rate in the same units,
Pi = intake pressure in psia.
The Turpin factor predicts stable pump operation whenever the turpin factor "f" is less than 1. In such
a situation the pump may be able to handle the gas without major degradation in its performance. The
correlation presented above may be used to calculate head-capacity performance for each pump type.
Dunbar on the other hand produced a general correlation, based on experimental evidence to indicate
that unstable pump operating conditions exist at lower pressures for a given gas-to-liquid ratio. As we can
see, both the correlations show the same general trend, with the Turpin being the less conservative among
the two.

2. Tapered Pump
It is a technique that has been successfully used for countering high GVF conditions at wellbore. Such
pump involves the use of various different sizes of pump stages to achieve a taper in terms of the volume
being handled by the pump as the fluid progresses ahead through the different stages of impellers and
4 SPE-185367-MS

diffusers. Here, higher volume stages are installed in the bottom part of the pump with lower volume stages
in subsequent section as the fluid progresses up the pump based on the fluid composition and pressure
requiremenits. A tapered ESP is primarily installed in wells to pump high gas oil ratio fluid from the
reservoir. Here, the free gas is vented via a shroud or gas separator and thereafter the remaining gas is
compressed using a tapered pump with capacity stages aimed at handling high quantity of gassy fluid. Free

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gas in fluid stream being pumped leads to reduction in performance of the pump, and may cause surging
during normal operation with gas lock at extreme conditions. Here the free gas effect needs to be calculated
through a stage wise calculation incorporating operational stability in free gas region. This consideration
forms an important basis for a successful design of such pumps as otherwise the above stages may work
beyond their pressure-flow operating range and the catastrophic pump failure is inevitable. Moreover we
should operate such pumps in the region of the best efficiency point (BEP) to the maximum flow rate range
as when we go below the BEP rate for a particular head, the degeneration in terms of fluid handling capacity
and chances of cavitation increases, leading to failure of the pump.

Table 1—Input data for Initial simulation of well O#1

Well depth 2889 m GLR 70 m3/m3

Casing 9 5/8″ Des. Rate 2500 BLPD

Tubing 3½″ Pump 538P31

Res pres 1550 psi Motor 210 HP

FTHP 241 psi Freq 51 Hz

Water cut 80% Depth 2727 m

3. ESP Shrouds
Gas handling ability of a pumping configuration involving ESPs may well be enhanced through an ESP
shroud system. The basic principle involved here is to change the direction of flow, leading to relatively
heavier liquid to fall back due to gravitational effects and gas escaping up through the annular area between
the shrouded conduit and the pump. The shrouds may come in various configurations including the reverse
shroud for wells with relatively lower influx and high gas prescence. In such cases the reverse shrouds carry
a priming liquid so that the pump is not starved of fluid and the gas escapes as the pump draws the fluid
into the reverse shroud conduits from the well bore /sump.
In conventional configuration, the ESP is placed below perforations and the shroud directs the fluid from
below through the motor to the pump intake, thus leading to the additional function of motor cooling. If the
shroud systmes are not present the motors is exposed to heated stagnate fluid that does not support motor
cooling and thus leads to failure of ESP due to over heat – a very common reason for ESP failure.

4. Multi vane pumps


This pump technology may be used to pump fluid with gas occupying upto 70 % of the volumetric space
of the total fluid at the pump intake. These pumps were initially used as charge pumps but now have been
improvised to work as standalone pumps with varying vane geometry at various pump stages acroos the
length of the pump. Currently it is one of the most advanced technology available and can be customized as
per the needs to handle the various challenges arising out of free gas at pump intake. The multivane pumps
involve three basic principles and the rest of the designs configuration vary with different manufacturers
and may extend the MVP's ability to handle even 90% gas at the pump intake.

• Balancing holes – These holes lower the diffrences in the pressure across the stages and also the
loading on the thrust bearings that lead to wear of the pumps. Moreover it provides the venting
veins for the low pressure gas pockets formed near the shaft of the ESP.
SPE-185367-MS 5

• Split Vane Design – The split vane concept allows for a homogeneous mixing through turbulents
movement of the gas and liquid partcles. Now as the fluid gets more homogeneously mixed,
it is conditioned to be pumped to stages with lower volume and higher pressure rating. This
conditioning of the fluid is critical for successful operation of the MVP pumps.
• Steep vane discharge angle-The discharge angles help in delivering higher Kinetics energy to the

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pumped fluid leading to better pressure development through the diffuser stages. This helps in
covering the loss in pressure due to balancing holes and split vanes and thus delivers better pressure
development even in harsh condition with relatively lower fluid rates.

5. Gas Separators
Gas separation may be because of natural difference of densities of the gas liquid that has been discussed
in the shroud section of this paper. Moroever when we apply a mechanical means, the separation may be
classified as static or dynamic separation.
Static separators provide a tortuous part for the fluid that allows separation as the fluid velocity reduces
and the gas separates due to frictional losses and buoyancy effects.
On the other hand, dynamic gas separators impart external energy to separate the gas from the liquid. One
of the forms of dynamic separation is Vortex gas separators which creates a vortex that helps in separating
the liquid from the gas as the vortex is split due to constructional design and movement of the fluid under
the effect of the kinetic energy imparted to the fluid.

6. Gas Handlers
Gas handling may be put in two groups – first group includes centrifugal gas handler including the various
gas separators as has been discussed above and the second group that involves axial flow technology and can
be used along with rotary gas seperators (first group) to compress the gas back inside the fluid to produce
through the pump

Well Analysis
13 candidate wells had ESP installed and over 10 wells failed in the years 2013-2015. Detailed design and
subsequent failure analysis was carried out for 10 failed ESPs in these candidate wells Indicative design
analysis of one of these wells is shown in this paper and later a summary is presented(table2). The Initial
design simulation based on the input data given in table 1 above reflects a P31 series pump for rate of 2500
BLPD with best efficiency design performance of the pump (Fig 2a). Moreover the second graphs compares
the Gas Liquid Ratio (GLR) vs Pump Intake Pressure (PIP) (Fig. 2b) of an ESP well and superimposes
dunbar factor line which clearly shows the requirement of a gas separator and finally the third graph shows
GLR vs PIP curve with a gas separator efficiency of 90% (Fig. 2c). Here, we see the operating point goes
below the Dunbar factor line showing a successful operation should occur with this design of ESP for a
given GLR of 70m3/m3 and the corresponding GVF. Later when this particular well failed, the ampere
charts showed severe fluctuations (Fig 3a). Moreover the Dunbar curves showed lower separator operating
efficiency for a measure PIP and GLR point as per the sensor readings of ESP. Also we could see that the
pump had gone into severe downthrust due to starvation of fluid (Fig 3b). And this complete analysis points
to one major problem i.e. failure in handling high amount of free gasat pump intake. The overall summary
of these 13 wells mentioned with relevant details in Table 2 in annexure are as follows: -These wells were
producing between 709 blpd to 2512 blpd with water cut around 50% to 91% at the time of ESP failure.
The wells had a deviation angle in the range 42 degree to 76 degree. In wells with high deviation of the
order of 70 degree, phase separation may lead to fluctuating flow with slugs of gas and liquids at the intake.
This leads to poor pump performance and motor heating. Moreover slug flow at the bottom also does not
provide efficient cooling to the motor. These wells have Pump intake Pressure of around 512psi to 1295
psiand a GVF in the range of 18%- 79%. Out of 10 closed wells 2 wells have low influx problem, 6 wells
6 SPE-185367-MS

stopped due to loss of Electrical integrity and rest of 2 wells stopped due to sudden high intake temperature
problem. The running wells are currently producing around 1832 blpd to 3111 blpd. Above discussion and
statistical analysis in fig 4 clearly shows that ESP failed in wells due to high GVF value but if our GVF is
around 40% the well is working perfectly.

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Figure 2—Initial design simulation results
SPE-185367-MS 7

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Figure 3—Failure analysis and simulation results

Figure 4—Statistical analysis reflects that, GVF played a major role in ESP failures

Implementation Of Learnings Into New Wells


Then 27 more wells were studied for conversion of lift mode from gas lift to ESPfrom the same offshore
field. They had a good productivity index ranging from1 barrel /day/psi to 6.9 barrel /day /psi. These well
have a higher bubble point pressure than the formation pressure itself and thus pose a gas interference
challenge. Thus the study was carried out to mitigate the effect of gas interference in ESP caused due to
extreme difference in the densities of the liquid and gas leading to a low pressure pocket in the Impeller
eyeand subsequent performance deterioration.

Methodology
During the study for suitability of ESP for the above wells a screening "Rule of Thumb" was created as
a simple guide for prioritizing ESP candidate. The selection criteria focuses on feasibility of installation,
operability condition and operating practice to maximize run life.

• Feasibility of installation- this factor includes reservoir quality, well inflow performance,
produced fluid characteristics, well completion etc. The standard practice for well completion is
8 SPE-185367-MS

maximum deviation < 85 deg, dog-leg severity < 6 deg/100 ft above set depth, sufficient tangent
section of < 1 deg /100 ft. for landing ESP is required.
• A bottom hole temp, 250 deg F is ideal as it allows for successful application of standard design,
material and operating practice. A detail temperature profile considering fluid velocity across the
motor was also analyzed in detail for smooth run life.

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• Gas volume fraction (GVF): - Improved ESP performance and equipment run life is achieved at
lower free gas volume. The ideal condition is where the GVF is < 40% at the pump depth. Up to
70% GVF can be handled effectively if special steps are taken in design, selection of suitable Gas
handlers and operation of ESP equipment. The thumb- rule is to keep the pump- intake pressure
above the bubble point pressure where ever possible. A details analysis was done to select most
suitable gas handling efficiency for smooth operation of the ESP for all the wells studied,
• A safe pump intake pressure of 500 psi was considered for the design to check the optimum
possible increase in liquid production
• Well production history of more than 2000 Blpd to be preferredwhile selecting the candidate wells
for conversion of lift mode.
• Software was used for the indicative design of equipment. Application of the above learnings for
well selection also comply with the Turpin curve as a GVF of less than 40% and a pump intake
pressure of more than 500 psi puts the point of operation in the stable region as seen from Fig 5.

Figure 5—Turpin curve-GVF vs. PIP for stable ESP operation.

Well Completion Design


Well completion was one of the key area which could help in handling excessive gas at pump intake
Maximum deviation for the non-horizontal wells was 50 degrees and deviation profile appeared to be of no
hindrance for these wells as far as ESP installation was concerned. In-order to reduce gas interference and
higher suction three completion philosophies were counted upon

• Case I: In 9 5/8″ casing, ESP below perforations with 7″ shroud

• Case II: In 7″ casing liner, (perforation depth more than 250 meters from 7″ liner top). 400 series
ESP below perforations with 5 1/2 shroud.
• Case III: In 7″ casing liner, (perforation depth less than 250 meters from 7″ liner top) ESP just
above the 7″ liner top with 7″ shroud. Suction below the perforation through a 3 ½″ tubing
SPE-185367-MS 9

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Figure 6—Casing completion philosophy.

Figure 7—ESP Implementation plan.

Analysis Result
The following results compile the in-depth analysis taking into consideration the above methodologyand
the learnings. After analysing the well, it can be deduced that conversion from Gas lift to ESP for the studied
27 wells can be categorized as (details in Table 3 annexure)
a. Potential for oil gain : 15 wells with 2011 BOPD envisaged oil gain and 6,55,000 SCM gas saving
on account of conversion of gas lift wells to ESP mode of lift
b. Wells identified with low gain but significant injection gas savings: 2 wells with 133 BOPD
envisaged oil gain and 1,20,000 SCM gas saving
c. Wells not suggested for conversion: 10 wells were not found to be economically feasible.
Moreover there are 7 Horizontal drain hole wells and the same completion philosophy was applied
while installing the pumps with suction at the start of the drain hole itself. The indicative designs thus
established gave a gain of 2144 BOPD and a gas saving of 775000 SCMD on account of change in
mode of lift to ESP from Gas lift based on simulation study.
d. However taking into consideration the practical issues, 14 out of 15 wells having potential of oil
gain were selected for implementation in 2 phases. One of the well was dropped due to operational
challenges and economics.
e. Phase I of the implementation has 8 wells that aims at an envisaged gain of 958 BOPD with a gas
saving of 3.55 LCMD
f. Phase II implementation of the 6 wells that aims at an envisaged gain of 934 BOPD with a gas
saving of 2.3 LCMD
10 SPE-185367-MS

Conclusion
The 13 wells were studied for various parameters and the failure analysis showed that High GVF(more
than 40% v/v) was the major reason for the failure of ESP. Therefore, inorder to handle high GVF, pump
intake should be extended below perforation through various completion schemes established in the paper.
Moreover a thorough literature survey was done to establish the various technologies which may help deal

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with high gas volume at pump intake. Various new technologies and the learnings from the failed ESP
wells were applied in designing 27 ESP wells. Finally 14 wells of the 27 candidate wells were selected for
implementation in two phases. Envisaged gain from the implementation plans may result in an oil gain of
1892 BOPD from the 14 selected candidate wells.

References
1 Takacs, G. (2011): How to Improve Poor System Efficiencies of ESP Installations Controlled by
Surface Chokes. Journal of Petroleum Exploration and Production Technologies: Vol. 1, Issue 2,
p 89–97. DOI 10.1007/s13202-011-0011-9.
2 Aitken, K.J., Allan, J.C., Brodie, A.D. and Holmes, J.D.: "Combined ESP / Auto Gas Lift
Completions in High GOR".
3 N.K. Mitra, SPE, and Y.K. Singh, Oil & Natural Gas Corp "Increased Oil Recovery from Mumbai
High through ESP Campaign", OTC 18748.
4 J. Jedda, Said Al. Houquani, S. Wardi, "ESP installation in very high gas environment (GOR 500
m3/m3), using Multi Vane pump and Tail-pipe in PDO", SPE/IADC 148530.
5 Zhou, D., "Design Tapered Electric Submersible pumps for gassy Wells", SPE 11361.
6 A. Suat Bagci (SPE), Murat Kece (SPE), and Jocsiris Nava (SPE), "Challenges of Using
Electrical Submersible Pump (ESP) in High Free Gas Applications", Eclipse Petroleum
Technology Ltd.
SPE-185367-MS 11

Annexure

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Figure 8—detailed production analysis of 13 intial candidates reflecting relatively lower production
rates as a result of gas intrusion at pump intake that is further supported by amp charts

Table 2—Summary of 13 candidate wells that were converted from Gas Lift to ESP.
12 SPE-185367-MS

Table 3—Analysis of 27 candidate wells on ESP based on learning from the challenges faced in the intial 13 candidate ESP wells

Expected Oil Injection gas Expected Oil Injection gas


Well No. Recommendations Well No. Recommendations
Gain (BOPD) saving (SCMD) Gain (BOPD) saving (SCMD)

1N 33 – Not Recommended 12 N 92 60000 Recommended

2N 121 35000 Recommended 13 N 94 60000 Recommended

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3N – Not Recommended 14 N 117 50000 Recommended

Not Recommended
the well is not being
recommended for ESP
4N 114 35000 Recommended 15 N 138 –
installation, in view
of cement issue of
squeezed layer A2-IV.

Not Recommended
the well is not being
recommended for ESP
5N 100 35000 Recommended 16 N 138 –
installation, in view
of cement issue of
squeezed layer A2-IV.

Not Recommended
Further since the
well is planned for
6N 63 drain hole cleaning 17 N 247 75000 Recommended
with CTU which is
expected to improve
PI

7N 117 35000 Recommended 18 N 87 20000 Recommended

Recommended the Not Recommended


well may be put on Further, the well has
8N 64 60000 ESP, with Saving of 19 N 58 – high drift and may
around 60000 SCMD pose. Problems in ESP
injection gas lowering.

Recommended
However, It may
9N 433 45000 consider redesign of 20 N 59 50000 Recommended
Pump, in case fish
cannot be pulled out.

Not Recommended Not Recommended


Further, as SBHP of Well stimulation
well is lower than has been planned
other areas, falling in New improved PI
10 N 54 – 21 N 18 –
low pressure zone, to be established
further decrease after stimulation,
in SBHP may be Before taking up ESP
detrimental to ESP. redesign

Recommended
However, from
the point of view
of gas saving, the
11 N 69 60000 22 N 81 – Not Recommended
well may be put on
ESP, with saving of
around 60000 SCMD
injection gas.

Not Recommended
Setting of pump at
23 N 52 lower depths is not 26 N 70 30000 Recommended
possible as 5″ liner
exists

24 N 152 60000 Recommended 27 N 71 15000 Recommended

25 N 144 60000 Recommended

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