Improving ESP reliability in Direct-To-SAGD completions: A Case Study

Summary One of the methods to establish continuous emulsion production between producer and injector wells in a steam-assisted gravity drainage (SAGD) scheme, is steaming the well-pair simultaneously. As for the producer wellbore, a typical completion implies a two-stage workover with installation of the Electric Submersible Pump (ESP) and instrumentation right after the completion of the steaming phase. A novel method of a single stage workover - going direct to SAGD with steaming past the ESP's was trialed at Suncor Energy's Firebag field in Northern Alberta. The first full direct-to-SAGD (D-SAGD) Firebag pad faced multiple challenges during steaming phase and production startup. One of them was long-term exposure of the ESP systems to the high temperature steam along with challenging temperature cycling during the fall-off tests that contributed to early failures in the power delivery system. Continued D-SAGD implementation needed a system that is capable of withstanding high-temperature steam exposure for several months along with multiple temperature cycles. After thorough engineering analysis of failure modes, a plan was established to deliver a new, redesigned system. Multiple new concepts have been developed for mechanisms and materials with the criteria to meet the reliability requirements and were successfully qualified after being subjected to extensive testing. As a result, an ESP system specific to D-SAGD style of completion was developed, deployed, and successfully started. New design has contributed to positive economic and environmental effects at both Firebag and MacKay River projects.