REDA Maximus - · PDF fileradial bearing for high-reliability operation, even in...

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REDA Maximus High-reliability plug-and-play ESP systems with integrated downhole measurement technology

Transcript of REDA Maximus - · PDF fileradial bearing for high-reliability operation, even in...

Page 1: REDA Maximus -  · PDF fileradial bearing for high-reliability operation, even in poor-lubrication conditions ... REDA Maximus ESP systems

REDA Maximus

High-reliability plug-and-playESP systems withintegrated downholemeasurementtechnology

Page 2: REDA Maximus -  · PDF fileradial bearing for high-reliability operation, even in poor-lubrication conditions ... REDA Maximus ESP systems

Applications■ All ESP artificial lift

applications including

• offshore or any other high-workover-cost applications

• arctic, rainy, and othersevere-weather environ-ments

• remote desert andjungle locations

Benefits■ Improve equipment installa-

tion time with streamlinedoperations, thus reducingnonproductive time andworkover rig costs

■ Reduce human error as asource of early pump failures

■ Extend run life with lessoil contamination

■ Maximize production capability with access to ESP performance data

■ Accurately monitorperformance of majordownhole components

Features■ Simplified, less-weather-

dependent installation withthe MaxJoint* connectiontechnology

■ ProMotor* integral motor,protector, and sensor withintegrated real-time down-hole gauges

■ MaxLok* pothead

■ Factory-filled motors andprotectors, including theProMotor* unit, meaningno oil filling is required atthe wellsite

■ Modular design of majorcomponents, enabling flexi-bility of system configuration

■ Improved modular protectorwith factory-shimmed design

■ Self-lubricating polymer-linedradial bearing for high-reliability operation, even inpoor-lubrication conditions

■ Motors with gauge-readybases (GRB) for real-timemonitoring of up to 16ESP operating parameters

■ Compatibility with allstandard REDA* pumps,gas separators, and gashandlers and Phoenix*downhole gauges

The innovative REDA Maximus ESP systemdesign enables operators to maximize pumpreliability and performance through theuse of integrated components with fewer,simpler mechanical connections. Theadvanced Maximus system offerings include■ bolt-on motor designs

■ bolt-on modular protectors

■ ProMotor integral motor, protector,and sensor systems.

The plug-and-play design of REDAMaximus motors and protectors eliminatesthe need for sensitive and weather-depend-ent critical assembly operations requiredduring conventional ESP installations.Installation operations such as oil servicingof motors and protectors and protector

shimming are now performed in thecontrolled environment of Schlumbergermanufacturing plants and service centers.Field connection of the tape-in potheadhas been eliminated.

Maximus components arrive at thewellsite ready for easy installation. TheMaximus ProMotor systems also featureoptional Phoenix downhole gauges for real-time monitoring of ESP and reservoirperformance. Maximus motors offer flexibility, because they are availablewith a gauge-ready base (GRB) that allowsdirect connection of any downhole Phoenixgauge for real-time monitoring of ESP and reservoir performance.

Schlumberger manufacturing and service personnel prepare the Maximus* motor in a controlled environment.

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Extended run lifeREDA Maximus ESP systems have beenengineered to reduce expensive early fail-ures and to extend overall system run life.

At the wellsite, the installation processhas been simplified through technologyadvances, significantly reducing the timetaken to install a conventional ESP sys-tem and virtually eliminating short-runfailures caused by human error duringequipment assembly.

The new MaxLok pothead design elimi-nates the taping of electrical connectionsto reduce the time taken to make the con-nection and maintain high performanceand reliability.

Maximus protectors and motors incor-porate the new MaxJoint ESP componentconnection technology. Oil-filled compo-nents that must be connected together atthe wellsite use MaxJoint technology topreserve the factory filling and avoid trap-ping air while making up the field connec-tions. This eliminates the risk of improperfilling under difficult field conditions andcontributes to equipment longevity,because there is minimum or no exposureof the dielectric oil to sources of contami-nation at the wellsite.

One of the life-limiting factors in ESPmotors and protectors is wear of radialbearings due to degradation of the motoroil over time. All radial bearings inMaximus systems feature hardened shaftsleeves running in self-lubricating, poly-mer-lined bushings with high load and

temperature capacity under diminishedoil lubricity. The protector head bearing ismost vulnerable because of vibration fromthe pump intake and abrasives in the wellfluid. Wear and vibration of this bearing isa common cause of well fluid leaking pastthe shaft seal. The Maximus protectorhead features the same abrasion-resistant-zirconia bearing system that has beensuccessfully used in REDA pumps forabrasive applications for more than15 years.

Operational efficiencyOperational and equipment problems,such as short runs (i.e., failures withinthe first 90 days of operation) due toinstallation problems require substantialremedial effort and nonproductive timewith a severe impact on field operations.Maximus equipment drastically reducesthe exposure to potential environmentalproblems and human errors, allowing youto focus on other operational concerns.

Wellsite operations are also greatly sim-plified, resulting in a substantial reductionin rig time expense. The installationtime can be reduced significantly whencompared to previous conventional ESPtechnology, because Maximus technologyeliminates the need for pothead tapingand because oil filling happens at thefactory, not on site.

System flexibilityThe unique flexibility of the Maximussystems enables oilfield operators toconfigure their ESP systems as needed.Maximus components are compatiblewith other standard REDA ESP compo-nents, including pumps, gas handlingdevices, and gas separators.

Maximus motors combine the industry-leading reliability of REDA Dominator*motors with the innovative MaxJointconnection technology. Factory-filled

single and tandem motors are availableto cover most ESP applications. AllMaximus motors are built with the newMaxLok pothead.

Maximus motors are available withGRB, which enables full compatibilitywith any type of Phoenix gauge. The baseallows connection of the downhole gaugein the shop or in the field without needfor refilling the motor.

Maximus protectors are built with thesame flexibility as the traditional REDAmodular protectors, but incorporate newtechnology features to increase reliabilityeven further. Maximus protectors use theMaxJoint technology for tandem combina-tions for additional sealing capabilities.

The ProMotor multifunctional com-ponent combines the motor, protector,and Phoenix gauge into one component.By using the ProMotor system, operatorseliminate the motor-protector-gaugeassembly operations at the wellsite, fur-ther reducing installation time and costs.The ProMotor unit is factory-filled andfactory-shimmed; it also incorporatesthe MaxLok pothead.

MaxJoint connection technology avoids trapping airduring makeup of oil-filled components.

All Maximus motors are built with the newMaxLok pothead.

The Maximus ProMotor unit integrates the motor,protector, and optional sensor into one unit.

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Page 5: REDA Maximus -  · PDF fileradial bearing for high-reliability operation, even in poor-lubrication conditions ... REDA Maximus ESP systems

REDA Maximus ProtectorsREDA* Maximus* protectors are plug-and-play modular components featuringMaxJoint* connection technology. Oil-filling and shimming procedures arenow performed by experts in a controlledenvironment in a Schlumberger manu-facturing plant.

Maximus protectors streamline work atthe wellsite, allowing less nonproductivetime and leading to faster production. Theseprotectors include the latest design featuresand materials to improve performance andreliability in severe environments.

Maximus protectors combine the provenreliability of REDA modular protectors withthe innovative REDA plug-and-play conceptintroduced in 2005.

Operators can customize the configurationof their Maximus modular protectors to meetthe requirements of the specific applicationby combining labyrinth and positive seal(bag) chambers in series or parallel, thrustbearing types, shaft material, and motor oiltypes.

High-reliability features include shaft sealsbuilt with wear-resistant silicon carbide facesand extended travel design, high-load-thrustbearings; a zirconia radial bearing in thehead; and self-lubricating polymer-linedradial bearings elsewhere.

Applications

■ ESP systems

Benefits

■ Reduced operating costs withcustomizable modular design

■ Improved performance inabrasive applications

■ Early startup with streamlinedinstallation and reducednonproductive time

Features

■ Simplified, reliable, and lessweather-dependent plug-and-play installation procedures

■ MaxJoint connection system,which guarantees that the motorremains filled only with the rightoil at all times, even wheninstalled in arctic conditions

■ Factory shimming to eliminatethe need for measurementand calculations of shimsat the wellsite

■ Modular design for greatflexibility of combinations oflabyrinth and positive seal(bag) chambers

■ Compatibility with all majorcomponents of REDA ESPsystems including intakes,gas handling devices, andpump configurations

■ Abrasion-resistant zirconiabearing in protector head

■ New self-lubricating polymer-lined bearing design

■ High load thrust bearings tohandle severe downthrust

■ Extended travel shaft sealswith silicon carbide faces

■ Higher-strength shaft materialsfor higher-power applications

Bubble free oil, factory prefilled to ensure improvedperformance, is displaced when the MaxJoint flangeconnector is made up at the wellsite.

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www.slb.com/artificiallift06_AL_061 August 2006*Mark of SchlumbergerOther company, product, and service names are the properties of their respective owners.Copyright © 2006 Schlumberger. All rights reserved.Produced by Schlumberger Marketing Communications

Maximus Modular Protector Specifications

Protector type Modular, multichamber Oil-filling process Factory filled; no oil servicing required at wellsiteProtector series 387 (3.87-in housing OD)

400 (4.00-in housing OD)540 (5.13-in housing OD)562 (5.62-in housing OD)

Chamber configurations Modular design that includes labyrinth- and bag-type chambers that can be connected in series or parallel

Metallurgy Carbon steelCarbon steel with Monel® trimRedalloy* high-nickel alloy

Elastomers Highly saturated nitrile (HSN) and Aflas®

Compatibility with REDA ESP components Fully compatible with Maximus motors and protectorsFully compatible with REDA intakes, gas separators,advanced gas handlers, and pumps

Incompatible with conventional modular protectors; however, conventional REDA modular protectors can be upgraded to Maximus designIncompatible with conventional or Dominator* motors; however, Dominator motors can be upgraded toMaximus design

Storage temperature –40 degC to 80 degC [–40 to 176 degF]

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Applications

■ ESP applications

Benefits

■ Better performance fromvariable-rating motors thatenable selection of motor ratingfor actual operating conditions

■ More reliable ESP operationthrough simplified, less weather-dependent plug-and-playinstallation procedures

■ Substantially reduced short- run-time ESP system events

■ Earlier ESP startup as a resultof reduced installation time

Features

■ Integrated variable-rating motorwith high efficiency and powerthroughout the operating range

■ Integrated modular protectorand downhole sensor

■ Configurable range of motor hpup to 450 hp in 5.5-in casing and675 hp at 60 Hz in 7-in casingwells

■ Single or tandem motor optionsfor a wide range of hp

■ Factory oil-filled with correctoil for the application, includingat or below freezing temper-atures; requires no oil filling atthe wellsite

■ Plug-and-play MaxLok ESPmotor pothead connector

■ Abrasion-resistant zirconiaradial bearing

■ Integrated Phoenix* real-timepressure and temperaturesensor

REDA Maximus ProMotor Unit

Integrated ESP systemsREDA* Maximus* ESP systems deliverimproved reliability and performancethrough the use of integrated componentswith fewer mechanical connections. Thisfield-friendly system reduces early-lifefailures and extends ESP run life. TheMaximus ProMotor integral motor,protector, and sensor is a key componentof Maximus ESP systems that reduces well-site installation time, enables performanceoptimization, and improves ESP systemreliability.

The multifunctional ProMotor componentcombines the motor, protector, and anoptional downhole sensor in one unit,eliminating the field procedures requiredto connect the motor to the protectorand to the downhole sensor, which savesvaluable rig time. These three componentsof the ESP system come integrated in a sin-gle factory-filled unit ready to plug and play.Oil filling of this component is carried outin the clean and controlled environment ofa Schlumberger manufacturing or servicecenter, which contributes to better long-termequipment performance. The ProMotor unitalso features the new MaxLok* ESP motorpothead connector, enabling a faster andmore reliable connection to the motorlead extension.

Tandem configurations are availablefor applications requiring more power. Anupper tandem section integrates the protec-tor and motor, and a lower tandem sectioncombines the lower tandem motor anddownhole sensor. The integral downholesensor provides real-time measurementsof key ESP operating parameters, which canbe used by artificial lift engineers to improvepump performance and increase production.

The ProMotor unit is compatible with allstandard REDA pumps, gas separators, andgas handling devices.

Maximus ProMotor* unit.

Integrated ESP motor, protector, and gauge forstreamlined and reliable ESP operations

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Operational efficiencyOperational and equipment problemssuch as short runs (i.e., failures withinthe first 90 days of operations) severelyimpact field operations because of thenonproductive time and substantialremedial effort that can result. Theadvanced reliability of the MaximusESP system can reduce the incidenceof early pump failures and extend theoverall run life of the system. Wellsiteoperations are greatly simplified,resulting in a significant reductionin rig time.

The additional informationprovided by the continuous measure-ment capability of a Maximus systemhelps operators anticipate productionproblems and closely monitor theperformance of the downhole system.Furthermore, by combining the oper-ating parameters recorded by thedownhole sensor with production datagathered at surface, the operator cananalyze the productivity of the well.

www.slb.com/artificiallift06-AL-062 November 2006*Mark of SchlumbergerCopyright © 2006 Schlumberger. All rights reserved.Produced by Schlumberger Marketing Communications

Specifications

387/456 Series 540/562 Series

Casing outer diameter (OD), mm [in] 146 [5.5] 178 [7]Oil filling process Factory-filled with REDA oil No. 5. Factory-filled with REDA oil No. 5.

(no oil servicing required at wellsite) (no oil servicing required at wellsite)Motor type Variable rating motor Variable rating motorOperating frequency, Hz 30 to 90 30 to 90Maximum winding 204 [400] 204 [400]operating temperature, degC [degF]Single section power range, 30 to 225 37.5 to 337.5hp at 60 HzTandem ProMotor max. power, 450 675hp at 60 HzConfiguration Single and tandem Single and tandemMaximum OD, in 4.56 5.62Integral protector BSL, BPBSL, LSBPB BSL, BPBSLchamber configuration†

Metallurgy‡ Carbon steel Carbon steelIntermediate radial bearings Self-lubricating Self-lubricating

polymer-lined polymer-linedTop radial bearing Abrasion-resistant zirconia Abrasion-resistant zirconiaRotor bearings Spring-loaded key with self- Spring-loaded key with self-

lubricating polymer-lined bushing lubricating polymer-lined bushing† B = Elastomer-bag modular protector design that provides a positive seal against well fluid

S = Series (two modular protectors are connected in series)L = Labyrinth modular protector designP = Parallel (two modular protector seals are connected in parallel).Other configurations may be available on request.

‡ Other material available upon request.

Optional Integral Monitoring

Measurement Range Resolution Accuracy

Intake pressure (psi) 5,000 0.1 ± 10Intake temperature, degF [degC] 302 [150] 32 [0.1] ± 34 [1]Motor temperature, degF [degC] 769 [409.5] 32 [0.1] ± 37 [2.7]Star voltage, V 3,000 -† -Local vibration x-axis, g 50 0.1 ± 0.5Local vibration y-axis, g 50 0.1 ± 0.5Local vibration z-axis, g 50 0.1 ± 0.5† Not applicable

Page 9: REDA Maximus -  · PDF fileradial bearing for high-reliability operation, even in poor-lubrication conditions ... REDA Maximus ESP systems

REDA Maximus MotorsREDA* Maximus* ESP motors are thelatest technological evolution of Dominator*motors. Maximus motors combine thestrength and reliability of the proven REDAmotor technology with an innovation plug-and-play concept.

The MaxJoint* flange connection technol-ogy ensures that the motor stays filled withthe right oil at all times, and the MaxLok*pothead eliminates the process of taping-inthe pothead terminals at the wellsite.

With this innovative motor system, thestator and some key internal componentshave been enhanced to allow reliable oper-ation in severe conditions. The new statordesign provides improved thermal conduc-tivity from the motor winding to the motorskin. All radial bearings in Maximus motorsfeature hardened shaft sleeves running inself-lubricating, polymer-lined bushingswith high load and temperature capacityunder diminished oil lubricity. Maximusmotors that include the gauge-ready base(GRB) offer the highest flexibility becausethey permit full compatibility with anyPhoenix* downhole sensor for real-time

monitoring of ESP and reservoir parameters.A temperature-sensing device directly con-nected to the end-turns of the motor windingenables real-time monitoring of the motor-winding temperature throughout all stages ofoperation. The GRB allows direct connection(no adapters required) of the downholegauge to the motor either in the shop or atthe wellsite without need for refilling themotor. Maximus motors with GRB can alsobe run without a downhole sensor if needed.

REDA Maximus motors improve total ESPsystem run time while reducing installationtime at the wellsite. The new MaxJoint ESPconnection technology permits oil filling inthe controlled environment of a Schlumbergermanufacturing plant or service center, awayfrom the potentially adverse conditions ofthe wellsite. Once at the wellsite, MaximusESP motors are installed quickly and easily,allowing earlier release of workover crewsand earlier oil production.

Applications

■ ESP systems

Benefits

■ Reduced or eliminated short-run-life events

■ Reduced nonproductive timewith streamlined installationand early ESP startup

■ Reduced operating costsbecause of optimizationcapability

Features

■ Simplified, reliable, and lessweather-dependent plug-and-play installation procedures

■ Mechanically locked-in rotorbearings and self-lubricatingpolymer-lined bearings

■ MaxLok ESP motor connector■ MaxJoint connection system,

which guarantees that the motorremains filled only with the rightoil at all times—even wheninstalled in arctic conditions

■ New stator design with betterthermal conductivity

■ Direct measurement of motorwinding temperature

■ GRB that allows quick standardconnection to any Phoenixdownhole gauge for real-timesurveillance and optimization

■ Variable rating motor with highefficiency and power factorthrough the operating range

■ High motor flexibility that allowsconfigurations with as much as540 hp in 5.5-in-casing wells

■ Involute spline shafts to providemaximum torque capacity

Variable-rated REDA Maximus motors include thenew MaxLok pothead connector for better reliability.

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www.slb.com/artificiallift06_AL_060 August 2006*Mark of SchlumbergerOther company, product, and service names are the properties of their respective owners.Copyright © 2006 Schlumberger. All rights reserved.Produced by Schlumberger Marketing Communications

Maximus 456 Series Motor Specifications

Motor series 456 (4.56 in OD)Motor configuration

Single sectionSingle section with GRBUpper tandemLower tandemLower tandem with GRB

Metallurgy Carbon steelCarbon steel with Monel® trimRedalloy* high-nickel alloy

Power range Single section: 22 to 201 kW [30 to 270 hp] at 60 HzTandem: Up to 403 kW [540 hp] at 60 Hz

Operating frequency 30 to 90 HzMaximum winding operating temperature 204 degC [400 degF]Storage temperature –40 to 80 degC [–40 to 176 degF]Head and base radial bearings Self-lubricating polymer-linedRotor bearings Self-lubricating polymer lined with spring-loaded-keyPothead design New MaxLok plug-in type potheadOil-filling process Factory-filledMotor temperature measurement Motor-winding thermocouple in all GRB motors

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A Hart Energy PublicationMarch 2007www.eandp.info

GLOBAL EXPLORATION & PRODUCTION NEWS • TECHNOLOGY UPDATES • ANALYSIS

SPECIAL BONUS:Annual Bit Records Survey

CoiledTubingDrilling

Controlled-SourceElectromagnetics

Get logging before drilling

Artificial LiftInnovation adds value

Shale GasUS hot play expands

CoiledTubingDrilling

Controlled-SourceElectromagnetics

Get logging before drilling

Artificial LiftInnovation adds value

Shale GasUS hot play expands

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www.eandp.info March 2007 | E&P

A new streamlined electrical sub-mersible pump design saves time andmoney.

AUTHORSEdison Bedoya, Petrobras; Arthur Watson

and Diego Narvaez, Schlumberger

Installation of downhole electricalsubmersible pump systems (ESP) hasfollowed a time-honored tradition for

roughly 75 years. Typically pump compo-nents are lifted one at a time with the rigcrane, then carefully lowered and con-nected to each other on the wellhead.They are topped off with motor oil andwired up to the power cable. Then theyare attached to the end of the productiontubing and run into the hole. The instal-lation procedure is labor-intensive, and insome areas it is often delayed by badweather. Even though ESPs are thought-of as being rather tough and ruggedpieces of equipment, assembling them ina downpour or other inclement condi-tions often results in operational or relia-bility problems.

Getting ESPs assembled properly in thefield also requires considerable skill onthe part of installation personnel. A typi-cal ESP consists of four components withadditional options: the pump, includingthe intake that allows fluid into thepump; a protector that equalizes the pres-sure in the motor and provides a reser-voir of motor oil; the electrical motor;and an optional gauge package contain-ing operational monitoring sensors.Among other things, field crews mustmeasure, calculate and install a series ofshims to establish the correct spacingbetween the interconnecting drive shaftsof the various components to properlytransmit thrust. Then they must assemblethe components, splice-in and seal theelectrical power cable, and refill themotor and protector with dielectricmotor oil. The connection and oil-fillingof each protector can involve more than20 steps, each requiring extreme careand precision on the part of the ESP

technician and rig crew. Any slip-up cancause the oil to become contaminated,flange sealing surfaces to be damaged orO-rings to be pinched or cut, resulting inelectrical or bearing failure.

Just performing the assembly steps fora single pump system properly can takeas much as 9 hours in the field. However,if a problem like one of those mentionedabove occurs, remediation is typicallyvery expensive and requires considerabletime. The penalty for ignoring or cuttingcorners on the established procedures is significant reduction of the pump sys-tem’s service life, or even a catastrophicfailure.

The solutionThe new REDA Maximus ESP systemfrom Schlumberger is specifically engi-neered to eliminate or drastically reducethe risks related to climatic conditionsand field operator skill and make theinstallation inherently quicker, safer andmore reliable. The new technology elimi-nates most critical steps in the ESP assem-bly/installation procedures. In a recentfield operation conducted by Petrobrasin its Palo Azul field in the jungles ofEcuador, significant savings were realized.The new streamlined procedures deliv-ered a savings of 40% in rig time andaccelerated production over conven-tional ESP systems.

At the heart of the new design is theintegration of the protector, motor andan optional downhole gauge packageinto a single unit called the ProMotorunit (Figure 1). This eliminates all thehuman-interface motor and protectorassembly steps except for the connectionof the electrical cable, simultaneouslyimproving field crew efficiency whileeliminating the possibility of humanerror. The ESP design includes newmaterials and technology such as the newradial bearing design with polymer-linedbushings and an abrasion-resistant pro-tector top bearing for added long-termreliability in adverse conditions.

The system’s motors and protectors are

ESPs get plug-and-play capability

Figure 1. Schematic of the ProMotor unitillustrates how integrated, factory-filledmotor, protector and gauge are combinedwith plug-and-play power connector toeliminate weather and skill-dependent fieldassembly procedures. (All graphics courtesyof Schlumberger)

Artificial Lift

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Copyright, Hart Energy Publishing, 1616 S. Voss, Ste. 1000, Houston, TX 77057 USA (713)993-9320, Fax (713) 840-8585

also available as individual componentswith bolt-on connections to allow evenmore flexibility in configurations thanconventional technology ESPs. Two addi-tional technological improvements arethe MaxJoint flange connection and theMaxLok plug-in electrical connection.The former allows components to bedirectly connected with no oil servicingrequired at the well site, which results ina flange connection with contamination-free oil and no air bubbles being trappedin the system (Figure 2). The latter per-mits safe and efficient connection of theelectrical cable using a combined plug-inand lock-down procedure (Figure 3).

No oil filling is required at the well site.This ensures that each component canbe filled under clean factory conditionswith exactly the right type of oil.Components are shipped to the field

with a protective compensating shippingcap that keeps the mating surfaces andO-rings from being damaged (Figure 4).Furthermore, the compensating ship-ping cap contains an elastomericdiaphragm similar to a protector bag thatcompensates for thermal expansion andcontraction of the motor oil. This main-tains the integrity of the oil charge evenwhen the equipment is exposed to largethermal cycles such as those encoun-tered during shipping and storage in thearctic or the desert.

By eliminating the possibility of oilcontamination and substantially reduc-ing the risk of human errors, the newdesign results in improved reliabilityand extended run-life. This reducesworkover costs and increases the num-ber of days the well can stay on produc-tion without intervention. Becauseinstallation is more efficient, wells canbe brought onstream faster. As anadded bonus, the new ProMotor unitcan be equipped with internal sensorsthat measure and transmit to surfacereal-time data such as pressure, temper-ature and vibration that can warn ofpotential problems or inefficient opera-tion and enable the operator to managethe performance of the ESP and pro-duction from the well. In the past, ESPsin remote fields often suffered destruc-tive failures because there was no way tomonitor their performance except byobserving production output, often toolate to prevent damage. Operationaldata are encoded and transmitted upthe power cable and used in a real-timemonitoring and surveillance system.

It’s a jungle out thereExperience on more than 300 world-wide installations to date confirms theimprovements in well site efficiency,safety and reliability. These were particu-larly valuable in the environmentallysensitive jungles of Ecuador (Figure 5).Not only are the fields remote from thesupport base, but Petrobras, the opera-tor of Block 18, is sensitive to being agood neighbor to the indigenous nativepopulation. Wells were pad-drilled tominimize the footprint of the produc-tion site. The same rig is used to drill,

case, perforate and complete the wellsto avoid a parade of noisy, dusty vehiclesand equipment running to and fromthe site. Besides the economic reasonsstated, Petrobras wanted to be as unob-trusive as possible when drilling andequipping the wells. Cumulative produc-tion from the Palo Azul and Pata fieldsaverages 40,000 b/d, most of whichcomes from wells equipped with ESPs.

Petrobras installed the first ESP pumpsystem in the Palo Azul 38 well, achievinga reduction in installation time of 40%,which resulted in a US $30,000 improve-ment in the well’s cash flow. The com-pany will monitor reliability over time toquantify expected long-term benefitssuch as reduction in maintenance costsand production uptime.

Artificial Lift

Figure 2. Upper MaxJoint flange connec-tion features sealed shaft and automaticoil communication valve, while oil-filledlower unit remains filled with pure oiland eliminates trapped air when the twoare mated.

Figure 3. Plug-and-play MaxLok electri-cal connection saves time and eliminateshuman error experienced with previousfield-spliced connections.

Figure 4. Factory crew installs compensat-ing shipping cap after topping off the unitwith clean dielectric oil.

Figure 5. Located in the lush tropical forests of northeastern Ecuador, the clean, compactdrillsites of Block 18 are examples of Petrobras’strict environmental stewardship.