Technology Basis for Replacing IM with PMM for ESPs - Pathway for Decarbonizing ESP Operations, Field Case from Oman

Abstract Oman’s Journey to Net Zero by 2050 has been developed with a clear decarbonization strategy by embarking on an Energy Efficiency Program in the industrial sector. This will present a case study of one of the competitive decarbonization pathway in mature assets. A field located in north of Oman has completed ten years of oil field operation with a rising trend in energy intensity index. The OQ Alternative Energy has set a comprehensive energy efficiency program targeting the upstream business unit. The Electrical Submersible Pump (ESP) is one of the popular technologies for artificial lift systems in the oil industry, however their high energy intensity index necessitates exploration of alternative methods to reduce expenses and power consumption that can enhance overall Energy Efficiency. The Permanent Magnet Motor (PMM) stands out as an ESP technology that delivers superior energy efficiency and performance compared to conventional induction motors (IM). A key development focusing on ranking criteria developed using the Marginal Abatement Cost (MAC) that highlights the cost-effectiveness of various decarbonization initiatives adopted by the company aimed at reducing energy intensity and CO2e emissions. The most impactful project is shifting from IM to PMM for ESPs, that achieves the greatest cost savings at -$492.45 per tonne of CO2e. Similarly, ESP network debottlenecking and offsite solar-diesel generator (DG) hybrid systems also show negative MAC values, indicating cost savings alongside emissions reductions. After that the Non-technical (buildings) energy efficiency programme and solar energy project are contributing with smaller cost savings. On the other hand, flare gas recovery, while having a positive MAC of $46.79 per tonne of CO2e, is essential for mitigating methane emissions and ensuring environmental compliance despite its higher costs. Fig. 2 shows a comprehensive roadmap for ESP operations decarbonization starting with optimizing the operating condition of the ESP followed by technology upgrade towards PMM. The next step would be to consider alternative power options for ESPs, especially for cases where these are operated by diesel generators. This ESP energy efficiency roadmap would provide a pathway for optimizing ESP operations for OQ to achieve its decarbonization targets. The paper will review the business case for technology pilot and implementation of PMM technology for ESPs in the industry to understand the potential savings in replacing conventional IM technology for ESPs. The paper reviews the studies and results reported in one of the upstream Omani field regarding comparison between PMM vs IM technology for ESPs to provide framework for retrofitting IM ESPs with PMM ESPs paving the way for reducing the field energy intensity index and decarbonizing upstream operations. Savings from implementing PMM ESPs have been evaluated under different scenarios. Four wells have been identified as ring fence pilot. The selection criteria for candidate wells for pilot implementation are discussed to qualify the energy savings and establish the acceptance success criteria for deployment. There is considerable debate in the literature to substantiate the benefits and savings from PMM technology for ESPs with field testing done to confirm the savings under different scenarios. PMMs can generate two to four times the power of equivalent sized IMs. In addition, power losses with this type of motor are lower due to the zero-rotor loss and reduced iron friction/windage losses as the motors are smaller in size. This results in enhanced power efficiency exceeding 90% and can double the expected life cycle due to the high reliability and reduced mean time between failures (MTBF). PMM technology can enable reduction in energy intensity for ESP wells and enable decarbonization for ESP operations.