Advanced ESP -
Schlumberger Private
How to serve you better
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Presentation Objectives
To Introduce Artificial lift services to Audience
To Elaborate on new technologies in ESP such
as Gas handling Properties
High Horsepower /High temp Motors –hotline
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550
New Pump series – to keep up with the market
Advanced Protectors – Metal bellow protectors
ESP Watcher – Real time monitoring advantages
Medium Voltage drive
Y –tool completions & cross flow
To understand the clients needs(KPI)-
Discussion
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Title – slide 2
ESP Overview ESP helps in producing
wells that do not have
the Energy to produce
by themselves .Wells
that have been
abandoned due to low
Pwf
It is also used as a
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Booster system in
places where there is
not enough production
(but the well has the
potential )
It can also be used as
an injector of water
from shallow aquifers
into deeper reservoirs
fpr pressure
maintenance as in
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Bottom discharge
Pumps
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Title – slide 3
ESP Overview
Wide performance producing range and versatility -
Up to 50,000 bbls/day in casings ranging from 4.5”- 9-
5/8 “ or bigger)
Can operate in high angle and horizontal wells
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Most efficient and economical lift method on a cost-
per-barrel basis
Flexible production and maintenance with the VSD
Long runlife expectation of equipment when run in
normal conditions
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Title – slide 4
Advanced ESP
Gas Handling Technology Diffuser
: Upthrust
Washer
Impeller
Poseidon can handle up
to 70% free gas at intake
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Diffuser
Poseidon narrows the Spacer
barrier between gas lift Downthrus
and ESP in terms of AL t Washer
selection Diffuser
Poseidon technology is
patented by SLB and IFP
(Institut Francais du Petrole) Axial stages of a Poseidon
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Title – slide 5
Advanced ESP
Gas Handling Technology :
Inflow
InflowPerformance
PerformanceRelationship
Relationship
1.00
1.00
with Intake
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0.80
0.80
Bottom Hole Well Pressure Pwf / Ps
Mixed Flow
of P ) Pwf / Ps
0.60
0.60 with AGH Radial Flow 20 – 25 % Free
Well Pressure
10% Free Gas
(Fraction of Ps)s
Gas
(Fraction
0.40
0.40
with
Bottom Hole
Poseidon
0.20
0.20
0.00
0.00
0.00 0.20 0.40 0.60 0.80 1.00
0.00 0.20 0.40 0.60 0.80 1.00
Producing Rate q / qmax
Producing
(Fraction Rate
of q q )/ qmax
(Fraction of max
qmax) Axial Flow
70% Free
Gas
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Title – slide 6
Advanced ESP
Hotline 550 Equipment
Used in High Temp steam Injection Environment , low rate
poor cooling wells , geothermal wells , High Viscosity wells
Dominator motors technology – More HP
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Can work in BHT of 425ºF and a winding T of 550ºF
Motor insulation was changed from Kapton /Peek to a
proprietary insulation and #7 oil is used instead of #5
CHEMREZ elastomers used for motors
Metal bellows used for Protectors
Ceramic Radial bearing on the protector
Cable insulation nomenclature is KKPLB
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Title – slide 7
Advanced ESP
New series Pumps and Extreme pumps :
The introduction of the D 4300 N and the D 5800 N pumps
and the new G6200N to replace the GN 5600 and the GN
4000.
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Constant Manufacturing and Update of Equipment to meet
customer and current trend needs
Constant support of design software to meet up
manufacturing process
Ex High strength Shafts materials for pumps in very high
HP application
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Title – slide 8
Advanced ESP
Metal bellow Protectors
Replacement of elastomer bag with metal
(Inconel 625) bellows – Positive Barrier to H2S
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Use of metal bellows shaft seal
Use of high load thrust bearings with no copper
parts
Dual head bearings for shaft seal support
Ceramic journal bearing for abrasion resistance
Solid shield over head bearings for abrasion
resistance
Use of high pressure relief valve to ensure valve
closure
Factory shimmed shaft to eliminate field
shimming Bag Design Metal bellow
Use special High Temperature Oil -REDA # 7
Use of Chemraz O-rings
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Title – slide 9
Advanced ESP
Ceramic Protector bearings –reduce
vibration
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Title – slide 10
Sandy Applications
Compression Pumps
Mixed flow – Radial not good to to reduced vane opening
Larger sizing – for velocity reduction
Redalloy 5530 metal stages (boronized –optional US$70 per stage)
(Main components are: Nickel 30%, Chromium 5%, Silicon 5%,
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Molybdenum 2%. Hardness Brinnel is 180-220)
ARZ pumps – Not just ES
Silicon on Silicon bushings and sleeves for Pump and AGH (at
least every 3 stages )
ARZ bushings and sleeves for Top of protector
Bushing & sleeves : provide radial stability
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Title – slide 11
Sandy Applications
Please remember that effect of abrasives on pump life (or ESP
system life) depends on many factors such as:
1- Size of abrasives.
2- Amount of abrasives.
3- Shape of abrasive grains.
4- Hardness of material in relation to bearing material, moving
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parts, areas subject to erosion, etc.
Intouch Contents :2046760
A Standard ARZ pump per guidelines that can be accessed
through content 2046760 can handle up to 50-100 ppm. This
value is only a general guidance but it can be increased if 5530
stages and special bushings are used.
1 ppm = 1 mg/liter = 0.0003503 lb/barrel.
100 ppm = 100 mg/liter=0.03503 lb/barrel=35.03
lb/1000barrel
The sand content of the well you mention is 0.005% = 0.00005
=50 ppm.
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Title – slide 12
Sandy Applications –ARZ Vs ES
Standard Pump ES Enhanced Full ARZ Pump
Stability Pump
Benign conditions Small quantities of solids or Sand pump
Applicatio without corrosive fluids corrosion expected configuration for
n and solids abrasive conditions
Shaft (Monel or Zirconia or Silicon Carbide Zirconia sleeve or
Inconel) running sleeve running against Silicon Carbide running
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Head and
base against Ni-Resist compliant Zirconia bearing against compliant
bearing Zirconia bearing
Impeller hub running Same as standard Bearing stages
against ID of diffuser, throughout the length
Stages Ni-Resist against Ni- of pump are
Resist spaced approximately
9.5 in [241.3 mm]
For benign conditions, Since the bearings in the The unsupported shaft
the standard pedestal head and base are directly span is greatly
design with increased in the flow path, they are reduced.
thickness synthane subjected to the most wear. The stage bearings are
washers provides ARZ bearings in the heads, subjected to less wear
Benefits
excellent run life when bases and intakes of the because they are out
correctly applied. pumps greatly improve run of the flow path. This
lives. greatly increases shaft
stability.
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Title – slide 13
Sandy Applications
Material Vickers Average Corrosion Impact
Hardness Wear in 15% HCI Toughness
(HV) Coefficient
Zirconia 1200 0.19 .02% 3.5
Silicon Carbide 2600 0.045 .004% 0.5
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Tungsten 1600 0.035 > 4% 1.5
Carbide
White Iron 1000 132.4 na na
Zirconia has a wear resistance 700 times greater than most
hardened steels
Zirconia has a greater wear coefficient than Tungsten
Carbide, the difference is only a factor of four
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Title – slide 14
Sandy Applications
Reduced abrasive Zirconia (1200HV) & Silicon Carbide (2600HV)
wear is harder than sand (800HV) and the wear
coefficient is 700 times less than most white
irons. This quantum leap in technology
substantially reduces wear caused by solids in
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the produced fluid.
Reduced corrosive Radial bearings tend to suffer from erosive
wear corrosion due to the oxide film being
continuously rubbed away. Since Zirconia is a
nonmetal-based ceramic, it does not suffer
from corrosion as other hardened metals and
sintered metals like Tungsten Carbide.
Increased shaft Due to the reduced wear, the shaft is
stability stabilized and the vibration is limited. This
virtually eliminates leaks in the protector
shaft seals and eventual motor burns.
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Title – slide 15
Continued
Sandy Application
Closed rotor gas separators are less susceptible to sand the liner
and housing do not exposed to erosion and abrasion. Open rotor
and vortex designs are more exposed to direct sand erosion and
abrasion. Both these designs are improved with hard liner inside
the housing. Liners in REDA DRS-ES is hardened liner and proven.
REDA Vortex designs can easily be changed to hardened liner
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also.
Sandy application may not affect the efficiency of the separator.
It will directly affect the reliability and run life. Coarse, angular,
and hard sand will be more abrasive and erosive and may cut
through the liner, and for this application, hardened liner is a
MUST. In the case of fine and round sand application, bearings
should be ARZ and internal parts may be made of 5530 material.
In general, for sandy application, based on sand properties, ARZ
bearings, 5530 material internal parts, and hardened liner should
be considered and applied accordingly.
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Title – slide 16
Asphaltines , Paraffins
Mixed Flow stages –Radial stages are prone to plugging I.
Coating –(Possibility –Tefon-like material or Epoxy )
Teflon good for Asphaltines but does not last in Abrassive
environment
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If acid treatment is expected , use LSB protector and
may use 66L on top for redundancy
Intouch content #
3251800, 2039449, 2042761, 3908099, 2034243,
2036820, 3863991.
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Title – slide 17
Viscous Application
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Intouch content # 2060497 -Pat Kallas
viscous modeling with Design Pro
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Title – slide 18
