A Game Changer: Initiating a Massive Movement of Permanent Magnet Motor Application for Electric Submersible Pump Design in Remote Area Operation, Sangasanga Oil Field Indonesia

Abstract The application of electric submersible pumps by transforming kinetic energy into boosting pressure is widely recognized in optimizing well performance. However, it becomes challenging under remote area operations due to limited electric power supply resources. Power supply failures result in additional pump maintenance, thus shortening ESP run life and increasing operational costs eventually. This paper will introduce a solution to this challenge, i.e., innovative permanent magnet motor technology (PMM), and present successful PMM applications in the ESP system to reduce power consumption and prevent ESP failure in a mature oil field in Sangasanga, Indonesia. Permanent magnet motor (PMM) technology is designed with magnetic material and unique apparatus for in-situ re-magnetize to generate a constant rotor magnetic field, thus resulting in greater torque and maximum pump rotation and ultimately reducing the power consumption. In addition, it works under high downhole temperatures of up to 480F without de-magnetization risk. In a three-year study, ESP design with PMM technology was implemented in several oil wells. ESP performance is evaluated and compared by parameters, i.e., annual power consumption, ESP run life, and production sustainability. The parameters are presented for three different case studies which compare three production wells equipped with conventional asynchronous ESP motors (AM) and PPM motor. The campaign for PMM installation was started in 2019. Now, 40 % of ESP wells in the Sangasanga field have been equipped with PMM. With conventional AM motors, the average power consumption for ESPs is around 117,582 kWh a year. The number decreases by about 24-30% with PMM. Meanwhile, the operating cost decreases linearly accordingly. Moreover, the installation of PMM shows a promising result in securing production sustainability since it prevents unplanned shutdowns due to power shortages. As a result, the improvement has delivered an additional value of about $ 111,650 for each well annually. In addition, compared to the conventional AM motor, ESP's run life has increased from 3.5 years to 4 years by using PMM. The decrease in electricity usage also creates a domino effect on carbon emissions for better environmental sustainability.