Project Overview
A customer in the Permian Basin Delaware approached Smart Chemical Services (SCS) with the goal of decreasing the amount of calcium carbonate (CaCO3) and iron sulfide (FeS) deposits found during ESP (Electric Submersible Pump) tear-downs in high-volume wells. These solid compounds, particularly FeS and CaCO3, were affecting the efficiency of ESPs, leading to operational issues. Through chemistry-based solutions, SCS aimed to control or prevent the formation of these compounds.
Project Timeline and Approach:
- Duration: 3 years
- Scope: 500 ESP workovers conducted over the period
- Method: On each ESP tear-down, solids were collected and analyzed for FeS and CaCO3 content. Over the course of the project, specific chemistries were developed, tested, and refined to address these issues.
Phases of Development:
Phase One: Product Implemented Targeting Corrosion, CaCO3, and FeS
- Product Description: This high-activity combination product is specifically designed to target and control corrosion, carbonate scale, and iron sulfide. By addressing these key challenges, it provides enhanced protection and efficiency in system operations, minimizing damage and maintaining optimal performance by preventing buildup and corrosion.
- Results:
- FeS: There was a 67% decrease in iron compounds within the first year, showing a significant reduction in iron sulfide buildup.
- CaCO3: While the reduction in FeS was evident, the decline in CaCO3 was not as dramatic, indicating that further intervention was needed to address carbonate scale.
Phase Two: Product Implemented With Enhanced CaCO3 Control
- Product Description: This triple combination product has been formulated to maintain the same levels of FeS and corrosion control achieved in Phase One, while also enhancing the control of CaCO3. The advanced formulation ensures continued protection against corrosion, while providing improved management of calcium carbonate buildup, contributing to more efficient system performance and prolonged equipment life.
- Results: Within 9 months of implementing SCW1894C, a 56% decrease in CaCO3 was observed, demonstrating significant improvement in carbonate scale control alongside continued success in reducing FeS.
Conclusion:
After the 3-year study, both FeS and CaCO3 were effectively reduced in the ESP system. The SCS team was able to develop and implement chemistries that significantly improved the performance of the wells, lowering the impact of these problematic solids. While the exact chemical formulations are trade secrets, SCS team members are available to discuss the findings and provide additional details regarding the results.
This project highlights SCS's commitment to providing targeted chemical solutions that optimize ESP performance and reduce maintenance costs by addressing key scaling and corrosion issues in high-volume production wells.