This study will showcase the results of developing an innovative and more compact electrical submersible pump. A compact wide-range ESP system allows increasing production by setting its intake depth deeper in high-tortuosity wells at mature fields in the Amazonas Region in Ecuador. A comparative study of this technology against a conventional ESP system highlights the lesson learned from a pilot well with the opportunity to enhance oil production (BOPD), reduce operational risks, minimize rig time, and lower carbon dioxide (CO₂) emissions. This innovative solution represents a step forward in ESP system technology for oil production in Ecuador.

The challenge started by identifying the limitations to setting a conventional ESP closer to the reservoir. A workflow was created comprising six steps: technology search, digital candidate selection, economic analysis, pilot execution, results evaluation, and finally, lessons learned. The workflow analyses approximately 250 oil wells and each one include 10 variables, involving production data, reservoir depth, well trajectory, tortuosity (deviation, dogleg severity, and bending), oil increase opportunity, economic evaluation, casing ID, production potential, rigless operations, downtime, mechanical failures, and chemical treatments. This information was incorporated into a collaborative and integral data science platform that facilitated the selection of candidate wells to install the compact wide-range ESP.

The workflow generated a portfolio of 19 ideal candidate wells for installing a compact wide-range ESP system, which, when intervened, would add an incremental production of approximately 2,000 barrels of oil per day to the mature field's output. By implementing the pilot well, the advantages of using equipment that is 70-75% shorter than conventional equipment were identified, including the ability to be installed in high-tortuosity wells (DLS >1°/100 ft) and deviation >65°. Another benefit was an 83% reduction in the installation process, decreasing the time from 8 hours to 1.4 hours. It also helped reduce the rig time by 6.6 hours, resulting in a 5% reduction in fuel consumption and, as a result, 0.17 tons of CO₂ were not emitted into the atmosphere. These results demonstrate an optimization in oil recovery using a compact wide-range ESP system for reservoirs with high depletion and low fluid levels.

The novelty of this compact wide-range ESP system is its ability to break barriers in wells with high tortuosity. This allows for deeper equipment placement and optimizes production, contributing to reducing the footprint and becoming an integral technology solution.