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Production Lifting Technologies,

Services & Optimization Catalog


Production Lifting Technologies,
Services & Optimization Catalog
Comprehensive artificial Integrated production Domain knowledge
lift solutions performance system and expertise
Pioneering technology, services, Extensive offerings at any flow rate Understanding challenges for the life of well
and optimization Responding to changing flow rates requires Our worldwide domain experts review the
Through strategic acquisitions, Schlumberger in-depth knowledge of flow behavior and reservoir and production challenges to optimize
has brought together the best and brightest in downhole conditions. Schlumberger offers the production profile for a particular life of
the artificial lift industry. Located throughout products capable of handling any flow rate the well or field. Throughout the well’s life,
the major basins, our team offers specialized in both mild and extreme environments. there are numerous system constraints to be
expertise and complete equipment packages for evaluated, and the artificial lift experts have
every flow rate, including rod lift, progressing Our real-time surveillance services provide accumulated years of expertise to select the
cavity pumps (PCPs), hydraulic stroking units, accurate monitoring to indicate when a best lift method or improve existing methods to
electrical submersible pumps (ESPs), horizontal different form of artificial lift is required, maximize assets.
pumping systems, and gas lift. enabling operators to quickly transition to a
new system with minimal downtime. Our knowledge enables us to design artificial lift
Improve total cost of ownership by maximizing solutions that optimize production while reducing
production and decreasing downtime using Using optimization software, our experts can total cost of ownership over the life of the well.
integrated solutions that keep your operation predict when one form of artificial lift will
running at peak performance. become less efficient and choose the optimal
time to implement a different method.
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Contents
Production Lifting Technologies, Services & Optimization Catalog
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Production Lifting Technologies
Artificial Lift Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Artificial Lift Applications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Pumping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REDA HPS G3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ESP Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REDA Maximus ESP System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ProMotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Advanced Motor Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High-Efficiency Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REDA Maximus System Increases Production by 69% for Russian Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REDA Maximus with Trident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MaxFORTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REDA Continuum System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REDA Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REDA Continuum ESP Increases Production by 70% in the Bakken Shale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REDA Continuum ESP Increases Run Life by 500% in the Bakken Shale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REDA Hotline System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REDA Hotline PLus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REDA Hotline XTend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Advanced Motor Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REDA Hotline System Increases Run Life by More Than 149% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REDA Hotline System Increases Run Life by More Than 445% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
D1050N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
AGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Poseidon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Y-Tool & Bypass System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ESP Pod Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Bottom Intake Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Discharge Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Lower Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Shrouded Intake and Thrust Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Alternative Deployment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Alternatively Deployed ESP Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ZEiTECS Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
ZEiTECS Shuttle System Decreases ESP Replacement Time by 87% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Coiled Tubing ESP Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Surface Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SpeedStar 519 SWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SpeedStar 2000 Plus & SpeedStar SWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SpeedStar MVD NEMA 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SpeedStar MVD NEMA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
VariStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FixStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SCB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Instruct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Phoenix SoloConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Phoenix ArConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Production Lifting Technologies, Services & Optimization ■ Contents Next page i


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Gas Lift Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Barrier Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
MMRG-2V-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
TCBV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
R-20-02-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
O-21R-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
NOVA 15-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
02-30R-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SO2-30R-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RLC-4R-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
KBMG Series Side Pocket Mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
KBMM-R Series Side Pocket Mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
KBG Series Side Pocket Mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
MMG Series Side Pocket Mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
MMM-R Series Side Pocket Mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
MMRG Series Side Pocket Mandrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Injection-Pressure-Operated Gas Lift Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Production-Pressure-Operated Gas Lift Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Pilot-Operated Gas Lift Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Single-Point Injection Orifice Gas Lift Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
NOVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Dummy Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Conventional Reverse-Flow Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Conventional Injection-Pressure-Operated Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Conventional Production-Pressure-Operated Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Conventional Pilot-Operated Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
PerfLift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Sucker Rod Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Shores Conventional Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
TorqMax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
HG Pumping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Don-Nan Gas Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Slimhole Tubing Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Sand Diverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
On-Off Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Carbide Insert Rod Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Rod Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
UniStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
KUDU HSU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
PCP Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
KUDU PCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
All-Metal PCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
KUDU Rodless PCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Tough Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
EvenWall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
KUDU Drivehead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
KUDU Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Level 1 VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Level 2 VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Level 3 VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Advanced Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Top Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Antivibration Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Cam-Loc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Sucker Rod Centralizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Contents Previous page Next page ii


Click on entry or page number for access
Production Lifting Services
Production Lifting Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Engineered Solutions Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
ESP Well Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
ART Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Power Systems Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Rod Lift Optimization Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Production Lifting Optimization
Real-Time Monitoring and Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Lift IQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Phoenix xt150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Phoenix CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
LiftWatcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Electric Cost Optimization for ESP Saves Estimated USD 480,000 for Cepsa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
LiftWatcher Service Reduces ESP Downtime by 27% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
DesignRite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Contents Previous page Next page iii


Production Lifting
Technologies

Table of Contents Previous page Next page


Artificial Lift Applications

Schlumberger’s artificial lift products and services are engineered for demanding Subsea lift applications
environments to offer our customers the very best in technology, innovation, and ■■ Maximize production in subsea wells with the same reliable technology
optimization. used in the majority of the world’s subsea installations.
Unconventional applications Dewatering applications
■■ Produce from difficult unconventional reservoirs using the ■■ Extend the life of dewatering operations with products designed
right tools and expertise. for high-flow-rate capabilities and reliable real-time analysis.
Thermal and high-temperature applications Industrial applications
■■ Lift geothermal, thermal, and high-temperature wells with ESPs ■■ Manage the fluid flow of refining, petrochemical, and chemical
and progressing cavity pumps made to withstand extreme heat processing operations with integrated systems.
and pressure environments.

Real-time surveillance and optimization applications


■■ Enhance well performance and predict problems with advanced reservoir
monitoring, round-the clock surveillance, and real-time diagnostics.

Table of Contents Previous page Next page 6


Artificial Lift Applications Overview
Unconventional Featured products
Applications REDA Continuum unconventional extended-life ESP
Improve recovery and reliability at low flow rates and in gassy and abrasive environments with
32

the REDA* Continuum* unconventional extended-life ESP, a mixed-flow stage pump engineered
Meet the challenge of declining for unconventional flow behavior and challenging environments. Its optimized geometry,
conventional resources with new architecture, and material selection enable the pump to operate at high efficiency through a wide
operating range.
technologies. Production from
ZEiTECS Shuttle rigless ESP replacement system 60
unconventional reservoirs is now Reduce total cost of ESP ownership and eliminate the uncertainties of rig costs and availability.
possible with the right tools and The plug-and-play design of the ZEiTECS Shuttle* rigless ESP replacement system enables retrieval
and redeployment of any standard ESP assembly on wireline, coiled tubing, or sucker rods following
expertise. initial installation during a rig-supported workover.
KUDU progressing cavity pumps (PCP) 150
Produce with maximum efficiency and reduced power consumption in heavy, medium, and light
oil; coalbed methane; and dewatering applications.
Sucker rod pumping systems 129
Maintain production with advanced sucker rod pumping units and downhole equipment tailored
for low-flow wells in conventional and unconventional environments. Innovative system engineering
and automation leadership mark every component, including pumping units, downhole and
surface equipment, spare parts, and reconditioned pumping units.

Thermal and Featured products


High-Temperature REDA Hotline high-temperature ESP systems
Operate reliably in the extreme temperatures common in thermal recovery and heavy oil
35

Applications applications, including steam-assisted gravity drainage and steamflooding. REDA Hotline*
high-temperature ESP systems are designed to handle the wide swings in temperature that
result from cool surface and hot downhole operating temperatures.
Lift geothermal wells, increase fluid
All-metal PCP for thermal environments 157
pressure, and transfer fluids using high- Resist wear and maximize run life with the all-metal KUDU PCP. With specialized metallurgy, the
temperature artificial lift technologies PCP is rated for temperatures up to 662 degF [350 degC], functions in low-to-high viscosities, and
handles most solvents or chemicals.
engineered to withstand extreme heat
and pressure.

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Artificial Lift Applications  |  Technology 7
Real-time Surveillance Featured products
and Optimization Lift IQ real-time production flow rate analysis service 192
Identify changes in well and reservoir performance with Lift IQ* real-time production flow rate
Applications analysis service, which provides high-frequency liquid flow rate and water cut calculations for
any brand of ESP, at any point in the production curve.

Enhance lift system performance and LiftWatcher real-time surveillance service 197
Achieve 24-hour surveillance of artificial lift systems with LiftWatcher* real-time surveillance
eliminate potential problems through service, even in locations where access is difficult or a data acquisition system is unavailable.
reservoir monitoring, round-the-clock KUDU PCP Well Manager suite 150
surveillance and diagnostics, and Protect PCP equipment and ensure your well is always running at optimum levels. With a suite
of products ranging from a simple variable frequency drive to a fully automated and optimized
advanced lifting services. system, KUDU PCP Well ManagerTM provides scalable solutions to meet current and future needs.
Phoenix xt150 high-temperature ESP monitoring system 193
Monitor downhole pressure, temperature, current leakage, and vibration with the Phoenix
xt150* high-temperature ESP monitoring system, which provides the comprehensive data
needed to protect ESP system integrity and optimize well performance.

Subsea Lift Featured products


Applications MaxFORTE intervention-constrained high-reliability ESP system
Outrun conventional offshore ESPs with one system for thermal, deepwater, and hostile
28

environments. Designed to address the needs of remote, difficult-to-access locations,


Implement reliable, low-risk subsea MaxFORTE* intervention-constrained high-reliability ESP system provides adaptability,
lift systems with an industry leader consistency, and reliability in unpredictable situations.

you can trust. Schlumberger helped Barrier Series Gas Lift systems 88
Barrier gas lift unloading and operating valves have been developed and tested to provide strict
develop the industry’s first and quality, leak-rate, and performance criteria. Increased performance and reliability enhances
largest subsea ESP field in the South wellbore integrity and makes Schlumberger barrier systems the equipment of choice in deep high
pressure subsea gas lifted wells throughout the world.
China Sea, and played a major role in
completing the industry’s first subsea
ESP installation in the ultradeep
water offshore Brazil. Schlumberger
XLift systems and Barrier equipment
have also established gas lift as
a popular method in deep subsea
developments.

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Artificial Lift Applications  |  Technology 8
Dewatering Featured products
Pump Applications Variable speed drives to control submersible and surface pumping systems 74
Obtain reliable power, protection, and control of ESP and horizontal surface pump installations
while reducing overall operating costs, increasing total efficiency, and maintaining system
Extend the life of dewatering integrity. Schlumberger variable speed drives are tailored to the unique requirements of ESPs
operations with an effective, and horizontal surface pumping systems.

full-scale dewatering and discharge ESP systems for diverse applications and environments 13
Maximize production, increase system run life, and ultimately reduce system life cycle costs
system. With high-flow-rate with an effective and efficient ESP system. From simplifying installation to meeting the
capabilities and reliable, real- temperature and viscosity demands of each well environment, Schlumberger engineers have
accounted for every detail affecting ESP pumps.
time services, Schlumberger has
designed, implemented, and
optimized dewatering systems for
many mines throughout the world.

Industrial Applications Featured products


REDA HPS horizontal multistage surface pumping system 12
Manage the fluid flow of refining, Master harsh conditions and surface installations with a cost-effective alternative to
petrochemical, and chemical conventional industrial pumps. REDA HPS* horizontal multistage surface pumping system
features bearings made of ARZ* abrasion-resistant zirconium, which enable the system to
processing operations with powerful perform reliably in harsh conditions or surface installations.
pumping systems and integrated REDA Maximus ESP system 14
monitoring services. Achieve production goals quickly and easily with the REDA Maximus* ESP system, featuring
technology exclusive to Schlumberger. This highly reliable system features an innovative
plug-and-play design suitable for industrial water applications.

slb.com/al

*Mark of Schlumberger
Other company, product, and service names
are the properties of their respective owners.
Copyright © 2015 Schlumberger. All rights reserved. 15-AL-54822

Table of Contents Previous page Next page


Artificial Lift Applications  |  Technology 9
Horizontal Pumping Systems

Designed for years of trouble-free service


The REDA HPS* horizontal multistage surface pumping system is a cost-effective
alternative to conventional industrial pumps. Designed using ARZ* abrasion-
resistant zirconium for high-wear-resistant bearings, the pumping system
effectively handles harsh conditions, as well as surface installations.
The system’s flow capabilities range from 40 galUS/min to 1,850 galUS/min
[218 m3/d to 10,084 m3/d] with as much as 1,864 kW in a single unit.

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REDA HPS G3
Horizontal multistage surface pumping system
APPLICATIONS The REDA HPS* G3 horizontal multistage surface to a central junction box. Intake and discharge
■ Lean amine recirculation pumping system is the third generation of REDA flanges and power hookups are usually the only
■ Crude oil pipeline horizontal multistage surface pumps. A reliable, required connections. When necessary, major
cost-effective solution, the centrifugal pump components can be replaced or resized to track
■ CO2 injection
provides up to 1,864 kW [2,500 hp] in a single unit. changes in applications within 2 to 3 hours, and,
■ Mine dewatering Flexible enough to be modified in the field, the due to its modular design and factory alignment,
■ Natural gas liquids pipeline system features reliable product enhancements aligning the unit before restarting the pump is kept
■ Water injection that lessen downtime. The modular design makes to a minimum.
the unit suitable for a wide variety of applications,
■ Salt dome leaching Designed for years of trouble-free service,
from simple water injection to more complex
■ Saltwater disposal refinery services and crude oil transfer. It has also the REDA HPS G3 system requires no daily
■ High-pressure wash for refineries proven to be an efficient alternative to split-case, maintenance. There are no V-belts or packing
vertical turbine, and positive displacement pumps. to service, and a typical routine maintenance
■ Boiler feed
schedule is a quarterly lubricant change and
■ Geothermal injection Prepackaged units are provided as a whole system component check. The smooth performance
■ Industrial high-pressure facilities from a single-source vendor and are delivered extends equipment life and greatly reduces the
preassembled to a site. The skid package is chance of leakage from associated piping.
BENEFITS typically prewired with instruments and cabling
■ Saves time and minimizes cost with no daily
maintenance and ease of commissioning and
piping alignment
■ Reduces downtime and quick repair, thanks
to simple reconfiguration of pumps and
motors
■ Extends run life due to minimal vibration-
related wear and stress

FEATURES
■ Numerous API 610-specification-
compliant features
■ New bearing sections with enhanced pump- The modular design of the REDA HPS G3 pumping system provides rapid change-out capabilities
pressure capabilities and less heat generation of system components.
■ Seals
● One mechanical seal at the low-pressure
Performance Specifications Material Specifications
end of the pump Capacity, galUS/min 40 to 2,500 [0.15 to 9.5] Impellers and diffusers Ni-Resist™, 5530 alloy,
● Standard-mount single, double, [m3/min] coatings as required
and tandem cartridge seals Discharge pressure, Up to 6,650 [45,850] Shafts 17-4 PH, MONEL®,
■ Skid psi [kPa] and INCONEL®
● Adjustable clamp and motor Suction pressure,† Up to 4,000 [27,579] Intake and discharge Carbon steel and 316
mount locations psi [kPa] stainless steel
● Rigid box, steel frame construction Temperature range,‡ –20 to 280 [–29 to 138] Sleeve bearings Ni-Resist, ceramic,
degF [degC] tungsten carbide, silicon
● Standard or custom skid designs Power (single skid), Up to 1,864 [2,500] carbide, and Graphalloy®
● Intake that orients 270° in kW [hp] Flanges ANSI 150 to 2,500 RF
45° increments Testing capability, Up to 1,864 [2,500] and RTJ
kW [hp]
†Fluid dependent
‡Modifications required

*Mark of Schlumberger
Other company, product, and service names

slb.com/hps
are the properties of their respective owners.
Copyright © 2015 Schlumberger. All rights reserved. 15-AL-82708

Table of Contents Previous page Next page


Horizontal Pumping Systems  |  Technology 11
ESP Systems

Maximum power and production REDA Maximus ESP system


Maximize production, increase system run life, and ultimately reduce ■■ Increase reliability and safety with an ESP system that features
system costs with a powerful, efficient ESP system fit for any well. With a plug-and-play motor, protector, and gauge.
a range of options tailored for unconventional or harsh environments,
high-temperature wells, ultralow-volume wells, and other more common MaxFORTE intervention-constrained high-reliability ESP system
well conditions, Schlumberger ESPs deliver high production rates early in
■■ Ensure trouble-free operations with continuous monitoring using one
the artificial lift cycle. integrated system for thermal, deepwater, and hostile environments.

REDA Continuum unconventional extended-life ESP


■■ Improve recovery and reliability at low rates and in gassy
and abrasive environments.

REDA Hotline high-temperature ESP systems


■■ Increase production in high-temperature applications.

Table of Contents Previous page Next page 12


The flexibility of Maximus ESP system components enables operators to configure their ESP systems

REDAMaximus
REDA Maximus ESP System Overview
Suitable for flow rates from 200 to 96,000 bbl/d, Configuration for solids production
the REDA* Maximus* ESP system combines The standard Maximus system configuration
the best-in-class system motor and protector has two bearings fitted on the head and base of
with the REDA* ESP system’s high-efficiency the pump. An optional, enhanced version with
pump. Preconfigured to minimize environmental a fully stabilized shaft for maximum stability is
contamination and human error, the plug-and- also available. Premium metallurgy on the stages
play design of the Maximus system reduces or coating offers greater erosion resistance,
assembly time for faster deployment and lower improving reliability.
intervention costs.
System power
Flexible application The Maximus ESP system’s speed is controlled
Depending on the nature of the reservoir, by a sine-wave variable frequency drive.
the Maximus system can be fitted with Real-time operating data and the resulting data
additional components to suit various onshore plots are also available for multiple parameters,
and offshore applications. The system can also including voltage, amperage, pressure,
be modified to run effectively in H2S applications temperature, and vibration. With options for high
or handle up to 90% gas volume fraction (GVF) input voltage to low input voltage, the drives are
at the intake. available with various power ratings to optimize
system efficiency.
The available stage geometry and housing
diameter options accommodate a wide range
of flow rates and are compatible with casings
as small as 4.5 in [10.6 cm].

Table of Contents Previous page Next page


ESP Systems | Technology 13
APPLICATIONS Remote monitoring systems
■ Conventional and unconventional The Phoenix xt150* high-temperature ESP
applications for every condition, including monitoring system provides comprehensive
extreme weather dynamic downhole data such as pressure and
■ Harsh environment and high H2S temperature to help protect the ESP and achieve
optimum drawdown. LiftWatcher* real-time
BENEFITS surveillance service is available for remote
■ Improves ESP system reliability monitoring and control of the Maximus system.
with reduced risk of installation and A 24-hr surveillance team is also available for
weather-related failures fast decision-making when faced with events
■ Extends run life in harsh environments that could compromise operation of the
■ Increases production and recovery Maximus system.
while enabling pressure drawdown REDA Systems Pump Performance Curve
in high-GOR applications REDA Systems S8000N
538 Series, 1 stage at 3,500 rpm and 60 Hz
■ Reduces total cost of ownership Minimum OD Check Fluid Specific
Rev. Casing Size Clearances Gravity 1.00
FEATURES Feet E = 77.00
hp Eff
■ Plug-and-play design to simplify installation 70
P = 3.73
H = 48.54
17.50 70%
■ Reliable operation, even in harsh environments Q = 8,025
Best efficiency point
60 15.00 60%
■ Helicoaxial, multiphase stage design capable
of handling extremely high GVF 50 12.50 50%

■ Plug-in pothead connection compatible with 40 10.00 40%


MaxLok* ESP quick-plug motor lead exten-
sion or Trident* extreme-conditions motor 30 7.50 30%

lead extension
20 5.00 20%
■ Variable-rating motor with high efficiency
and power throughout operating range 10 2.50 10%

■ Flexible production capacity from


200 to 96,000 bbl/d 0 2,500 5,000 7,500 10,000 12,500
■ Dual bearing to reduce vibration and eliminate Capacity, bbl/d
bushing wear
■ Sand diverter system to protect mechanical
shaft seal
■ Ceramic radial bearing with spacing options
to fit various applications
■ Metal protector with multiple configurations
for metal bellows, elastomeric bags, and
labyrinth fluid containment chamber
■ Protector with metal bellows option for
increased resistance to gas migration

The complete Maximus ESP system improves reliability


in conventional and unconventional applications.

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ESP Systems | Technology 14
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Motors
Bolt-on single and tandem motor designs for the REDA Maximus ESP system
APPLICATIONS REDA* Maximus* ESP system motors are the latest self-lubricating, polymer-lined bushings with high
■ ESP systems across all applications and technological evolution of Dominator* submersible load and temperature capacity under diminished
conditions, including extreme weather pump motors. They combine the strength and oil lubricity.
reliability of the proven REDA* ESP system motor
BENEFITS Maximus system motors that include the GRB offer
technology with an innovative, plug-and-play
■ Improves reliability with reduced risk of the highest flexibility, as they are compatible with
concept. Maximus system motors are handwound,
installation-related failures and more robust any Phoenix system sensor for real-time monitoring
two-pole, three-phase, squirrel-cage induction type.
rotor bearings of ESP and reservoir parameters. A temperature-
Heat generated by the motor is transferred to the
■ Streamlines installation, reducing costly NPT well fluid as it flows by the motor housing, and the sensing device directly connected to the motor
and allowing early ESP startup motor thrust bearing carries the load of the rotors. winding enables real-time monitoring of the
motor-winding temperature throughout all stages
■ Optimizes production with real-time
Oil filling of the motors is performed in the of operation. The GRB allows direct connection (no
downhole monitoring capabilities
controlled environment of a Schlumberger adapters required) of the downhole gauge to the
FEATURES manufacturing plant or service center, away from motor either in the shop or at the wellsite without
■ Simplified, reliable, plug-and-play design the potentially adverse conditions of the wellsite. having to refill the motor. Motors with the GRB can
■ Prefilled and presealed to enable installation The motors are factory vacuum-filled with highly be run without a downhole sensor, if needed.
in all weather refined mineral oil to provide dielectric strength,
lubrication for bearings, and thermal conductivity. Maximus system motors improve total ESP
■ Mechanically locked-in rotor bearings with MaxJoint technology features a leak-tight seal and system run time while reducing installation time.
self-lubricating, polymer-lined a compensating shipping cap that ensures the right Once at the wellsite, Maximus system motors are
bushings amount of oil is contained at all times. Making up installed quickly and easily, allowing earlier release
■ Plug-in pothead connection with MaxLok* the pothead to the motor is now a quick and easy of workover crews and earlier oil production.
ESP quick-plug motor lead extension or plug-and-play connection with the MaxLok MLE,
Trident* extreme-conditions motor lead which eliminates the taping process of the pothead
extension (MLE) terminals at the wellsite.
■ Quick and reliable motor and protector
Along with this streamlined motor design, key
connections with MaxJoint* ESP flange
internal components have been enhanced for
connection technology
reliable operation in severe conditions. For
■ Direct measurement of motor-winding example, all radial bearings in Maximus system
temperature motors feature hardened shaft sleeves running in
■ Gauge-ready base (GRB) fully compatible
with any Phoenix* artificial lift downhole
monitoring systems sensor
■ Variable-rating motor with high efficiency
and power through the operating range
■ Involute spline shafts to provide maximum
torque capacity

Factory-filled Maximus system motors incorporate MaxJoint technology sealed with a special compensating shipping
cap to maintain the contamination-free oil during transportation and storage.

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ESP Systems | Technology 15
Motors
Maximus System Motor Specifications
Motor Series 375 456 562
Casing OD, in [mm] 3.75 [95.25] 4.56 [115.8] 5.62 [142.7]
Power range: single section 14.3 to 71.4 [8.9 to 44.4] 30 to 270 [18.6 to 167.8] 37.5 to 563 [23.3 to 350]
hp at 60 Hz [kW at 50 Hz]
Power range: max. tandem 285.6 [177.5] 540 [335.6] 1,126 [700]
hp at 60 Hz [kW at 50 Hz]
Rotor bearing type Self-locking (SLK) Self-locking and self-lubricating with SLK-PL
polymer lining (SLK-PL)
Max. winding operating 400 [204] 400 [204] 400 [204]
temperature, degF [degC]
Shipping and storage –40 to 176 [–40 to 80] –40 to 176 [–40 to 80] –40 to 176 [–40 to 80]
temperature, degF [degC]
Operating frequency 30 to 90 30 to 90 30 to 90
Metallurgy Carbon steel (CS), CS with MONEL® trim CS, CS M-TRM, Redalloy alloy CS, CS M-TRM, Redalloy alloy
(CS M-TRM), Redalloy* high-nickel alloy
Protector and tandem motor MaxJoint technology MaxJoint technology MaxJoint technology
connection
Motor lead extension MaxLok MLE MaxLok MLE MaxLok MLE, Trident MLE
connection
Sensor connection options Adaptor to sensor GRB with factory-installed motor winding ther- GRB with factory-installed motor winding
mocouple or built-in sensor thermocouple or built-in sensor
Oil-filling process Factory vacuum filled with degassed Factory vacuum filled with degassed Factory vacuum filled with degassed oil
oil specified for the application and sealed with oil specified for the application and sealed with specified for the application and sealed with
compensating shipping cap (no additional oil- compensating shipping cap (no additional oil- compensating shipping cap (no additional oil-
filling required upon installation). filling required upon installation). filling required upon installation).

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ESP Systems | Technology 16
ProMotor
Integrated ESP motor, protector, and sensor unit for REDA ESP systems
APPLICATIONS The multifunctional ProMotor* integrated ESP
■ ESP applications (456 and 562 series motor, protector, and sensor unit is compatible
motors) with flow rates from 200 to with all standard REDA* ESP system pumps,
28,000 bbl/d [30 to 4,450 m3/d] intakes, and gas-handling devices. The ProMotor
■ Production optimization programs unit is available in both 456 and 562 series with a
wide range of power (25 to 675 hp) for use with
■ Low-ambient-temperature installations
pump systems rated from 200 to 28,000 bbl/d
(Canada, Alaska, Siberia)
[30 to 4,450 m3/d].
BENEFITS
Operating efficiency
■ Simplifies installation, reducing costs
The ProMotor unit simplifies wellsite assembly,
and NPT
avoiding common operational and equipment
■ Improves pump operation and reliability problems. The unit is prefilled in a controlled
to reduce early ESP failures and extend manufacturing environment and features an
run life innovative, plug-and-play design. The ease of
FEATURES installation helps save costly rig time.
■ Factory prefilled and preshimmed The integrated Phoenix system sensor in the
system ProMotor unit measures downhole pressures,
■ Integrated protector assembly temperatures, and equipment vibrations. These
■ Plug-and-play connection of the pothead to real-time measurements can be used to improve
the motor with the new MaxLok* ESP quick- pump performance, increase production, and
plug motor lead extension anticipate production problems. Petroleum
engineering analysis can be applied to better
■ Integrated Phoenix* artificial lift downhole
understand the well’s production potential.
monitoring system sensor
Combined with the LiftWatcher* real-time
surveillance service, operators can proactively
enhance their ESP operations to improve
production and equipment run life.

ProMotor integrated ESP motor, protector,


and sensor unit.

Table of Contents Previous page Next page


ESP Systems | Technology 17
ProMotor
ProMotor Integrated Motor, Protector, and Sensor Unit Specifications
387 and 456 series 540 and 562 series
Casing OD, in [mm] 5.5 [146] 7 [178]
Oil-filling process Factory filled with REDA system oil No. 5. (no oil Factory filled with REDA system oil No. 5. (no oil servicing
servicing required at wellsite) required at wellsite)
Motor type Variable rating motor Variable rating motor
Operating frequency, Hz 30 to 90 30 to 90
Max. winding operating temperature, degF [degC] 400 [204] 400 [204]
Single section power range, hp at 60 Hz 30 to 225 37.5 to 337.5
Tandem ProMotor max. power, hp at 60 Hz 450 675
Configuration Single and tandem Single and tandem
Max. OD, in [mm] 4.56 [115.8] 5.62 [142.7]
Integral protector chamber configuration† BSL, BPBSL, LSBPB BSL, BPBSL
Metallurgy‡ Carbon steel Carbon steel
Intermediate radial bearings Self-lubricating, polymer-lined Self-lubricating, polymer-lined
Top radial bearing ARZ* abrasion-resistant zirconium ARZ zirconium
Rotor bearings Spring-loaded key with self-lubricating, Spring-loaded key with self-lubricating,
polymer-lined bushing 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 design.
P= Parallel; two modular protector seals are connected in parallel.
Other configurations may be available upon request.
‡ Other material available upon request.

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ESP Systems | Technology 18
Protector
Bolt-on modular protectors for the REDA Maximus ESP system
APPLICATIONS REDA Maximus* ESP system protectors combine The shaft seals are designed for extended travel
■ ESP systems across all applications and proven reliability with innovative, plug-and-play and built with wear-resistant silicon carbide faces.
conditions, including extreme weather design to streamline installations and enhance Other high-reliability features include high-load
production. thrust bearings, a zirconia radial bearing in the
BENEFITS
head, and self-lubricating, polymer-lined radial
■ Simplifies installation with plug-and-play Operators can customize the configuration of
bearings elsewhere.
design their modular Maximus system protectors to meet
■ Improves performance in abrasive the requirements of their specific application
applications by combining labyrinth and positive seal (bag)
chambers, in series or parallel, with thrust bearing
■ Reduces operating costs with customizable,
types, shaft material, and motor oil types.
modular design
■ Minimizes installation-related risks due to Oil-filling and shimming procedures are now
factory shimming performed by experts in the controlled environment
of Schlumberger manufacturing and service
FEATURES centers. With efficient assembly, the factory-
■ Leak-tight seal and contamination-free oil prepared protectors simplify work at the wellsite,
with MaxJoint* ESP flange connection allowing less NPT and leading to faster production.
technology
■ Combinations of labyrinth and positive seal The protectors feature MaxJoint connection
(bag) chambers for great flexibility technology, which ensures protectors are
seamlessly connected at the wellsite with leak- The upper flange connection includes an extended shaft, a
■ Compatibility with all existing REDA* ESP
tight seals. shaft lip seal, and an oil communication valve.
system pumps and accessories
■ ARZ* abrasion-resistant zirconium bearing in
Protector Specifications
protector head
Protector type Modular, multichamber
■ New self-lubricating polymer-lined bearing Oil-filling process Factory filled with purified oil; no oil servicing required at wellsite
design Protector series 325 (3.25-in housing OD), bolts onto the 375 Maximus system motor
■ High-load thrust bearings to handle severe 387 (3.87-in housing OD), bolts onto the 456 Maximus system motor
downthrust 400 (4.00-in housing OD), bolts onto the 456 Maximus system motor
■ Extended travel shaft seals with silicon 540 (5.13-in housing OD), bolts onto the 562 Maximus system motor
carbide faces 562 (5.62-in housing OD), bolts onto the 562 Maximus system motor
■ Higher-strength shaft materials for higher- Chamber configurations Modular design that includes labyrinth- and bag-type chambers that can
be connected in series or parallel
power applications
Metallurgy Carbon steel
Carbon steel with MONEL® trim
Redalloy* high-nickel alloy
Elastomers Highly saturated nitrile and Aflas®
Compatibility with REDA ESP components Fully compatible with Maximus system motors and protectors
Fully compatible with REDA system intakes, gas separators, advanced gas
handlers, and pumps
Incompatible with conventional modular protectors; however, conventional
REDA system modular protectors can be upgraded to Maximus system
design
Incompatible with conventional or Dominator* submersible pump motors;
however, Dominator motors can be upgraded to Maximus system design
Storage temperature, degF [degC] –40 to 176 [–40 to 80]

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ESP Systems | Technology 19
Advanced Motor Protector
For the REDA Maximus ESP system
APPLICATIONS The Maximus system’s advanced motor protector is a highly reliable
■ Geothermal protector with many of the features of the REDA Hotline* high-
■ Poorly cooled motor with high temperature ESP system’s advanced protector and the Maximus
viscous applications system protector. It features metal bellows and an improved shaft seal
to enable Maximus ESP systems to operate in even highly corrosive
■ Wells with abrasive fluid
environments, and it improves reliability in sandy environments. Its
■ Gassy wells plug-and-play design reduces the risk of human error and enables fast
■ Wells with corrosive fluid, including wellsite deployment, improving ESP run life and well production.
chemical treatments, H2S, and CO2
Operation
BENEFITS The protector operates reliably in highly abrasive and corrosive
■ Offers simplified and nonweather-dependent environments, such as those with H2S and CO2. It is available with
application with plug-and-play design INCONEL® metal bellows, which replace the traditional elastomeric bag
■ Saves rig time and minimizes installation- or tube and expand the environmental operating envelope of the ESP
related risk with factory shimming system to hostile or high-temperature environments. The metal bellows
also prevent motor oil displacement when operating in high gas volume
■ Improves ESP system reliability in
fraction applications.
severe application
■ Increases cash flow with an extended Application in abrasive environments
run life The advanced motor protector also features elevated shaft seals and a
■ Extends the application envelope sand diverter system in its head to enhance performance in sandy or
to improve reservoir recovery ratio solids-producing environments. The head design allows the solids to fall
from the intake back into the wellbore through the drainholes. The sand
■ Enhances performance in gassy
shield protects the top shaft seal from excessive abrasives and also
and abrasive applications
features abrasion-resistant ceramic shaft bearings that reduce wear and
■ Lowers total cost of ownership enhance shaft stability, minimizing vibration in the ESP system.
FEATURES The protector is available in two series, 540 series and 400 series. Due
■ MaxJoint* ESP flange connection to its OD, the 400 series does not feature an option with metal bellows.
technology for reduced leaks and
contamination-free oil
■ Availability in multiple configurations,
including metal bellows, elastomeric bags,
and labyrinth fluid containment chamber
■ Metal bellows option for increased
resistance to gas migration
■ Dual bearing to reduce vibration
and eliminate bushing wear
■ Sand diverter system to protect Advanced motor protector
mechanical shaft seal with metal bellows option.
■ High-pressure check valve
■ Dual elevated shaft seal for redundancy
■ Compatibility with REDA* Maximus* ESP
system motor and existing Schlumberger
pump, intake, and gas-handling devices

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ESP Systems | Technology 20
Advanced Motor Protector
Advanced Motor Protector Specifications
Protector Series 540 400
OD, in [mm] 5.13 [130.30] 4.00 [101.6]
Maximum operating temperature, degF [degC] 400 [204.4] 400 [204.4]
Housing material Carbon steel or Redalloy* high-nickel alloy, Carbon steel or Redalloy alloy, high-chrome alloy
high-chrome alloy
Elastomers Highly saturated nitrile, Aflas®, or Chemraz® Highly saturated nitrile, Aflas, or Chemraz
Bellows material INCONEL na†
Chamber configuration Metal bellows, bag, and labyrinth Bag and labyrinth
Bearing configuration Tungsten carbide Tungsten carbide
Shaft diameter, in [cm] 1.187 [30.15] 0.875 [22.22]
Compatibility with REDA system components Fully compatible Fully compatible
†Not available.

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ESP Systems | Technology 21
High-Efficiency Pumps
For
For REDA ESP electric
the REDA systemssubmersible pump system
APPLICATIONS Part of the REDA* ESP system, high-efficiency pumps can handle
■ ESP systems production rates from 200 to 96,000 bbl/d with boost pressures of up to
6,000 psi. In addition to typical applications in oil, water, and brine production,
BENEFITS
REDA pumps are used for booster service, ballast transfer, waterfloods, direct
■ Reduces power consumption with high-
injection, cavern storage, mine dewatering, fire protection, irrigation, and
efficiency designs
commercial water systems.
■ Improves reliability and extends system run
life in abrasive applications using ceramic These submersible pumps are multistage centrifugal pumps. Each stage
shaft radial bearings and premium stage consists of a rotating impeller and a stationary diffuser. These components are
metallurgy options carefully designed to deliver the best combination of hydraulic efficiency and
lift performance. Cast, high-nickel, Ni-Resist™ alloy stages are standard, and
FEATURES special metallurgies are available for optimum performance in more corrosive
■ Application flexibility with production rates or abrasive wells.
from 200 to 96,000 bbl/d
High-strength MONEL alloy shafts are standard, and optional higher-strength
■ Compression-pump design with factory
Inconel 718 material is available for higher HP applications.
shimming
■ Computational fluid dynamics (CFD) for Corrosion-resistant coatings and stainless steel construction are available for
optimized hydraulic stage design H2S, CO2, and other corrosive environments.
■ High-strength MONEL® and INCONEL® shafts Patented ARZ* abrasion-resistant zirconium pumps with zirconia or silicon
■ Radial bearings from hard ceramic materials carbide ceramic bearings are among the most reliable and technologically
with spacing options to fit various advanced submersible pumps available for sandy wells and other highly
applications demanding applications. Proprietary, compliant-mounted radial bearing
systems minimize vibration and wear.

The compression design of REDA system pumps enables the axial thrust
created by the impellers to be transferred via shaft to the high-load
hydrodynamic bearing in the motor protector, which runs in a clean and
confined oil environment. This greatly extends the application envelope of
the pumps, in terms of flow rate, and improves reliability in abrasive wells
with changing or uncertain productivity and high GOR. Factory shimming of
components ensures that the pumps can be easily connected in the field.

Full-bearing housing
configuration of a
REDA system abrasion-
resistant ESP.

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ESP Systems | Technology 22
High-Efficiency Pumps
Pump Capacity Ranges
Series OD, Min. Casing, 60-Hz Min. Flow, 60-Hz Max. Flow, 50-Hz Min. Flow, 50-Hz Max. Flow,
in [mm] in [mm] bbl/d bbl/d m3/d m3/d
A 3.380 [85.9] 4.500 [114.3] 400 3,400 53 450
D 4.000 [101.6] 5.500 [139.7] 200 7,000 26 927
G 5.130 [130.3] 6.625 [168.3] 800 12,000 106 1,590
S 5.380 [136.7] 7.000 [177.8] 1,600 16,500 210 2,186
H 5.630 [143.0] 7.000 [177.8] 5,000 36,000 660 4,770
J 6.750 [171.5] 8.625 [219.1] 4,500 25,000 596 3,313
M 8.630 [219.2] 10.750 [273.1] 12,000 32,500 1,590 4,306
N (950) 9.500 [241.3] 11.750 [298.5] 24,000 47,500 3,180 6,293
N (1000) 10.000 [254] 11.750 [298.5] 10,000 59,000 1,325 7,817
P 11.250 [285.8] 13.625 [346.1] 53,600 96,000 7,102 12,718
L 7.250 [184.2] 8.625 [219.1] 11,000 54,000 1,450 7,150

Enhanced stability configuration of a REDA system abrasion-resistant ESP.

ARZ zirconium configuration of a REDA system ESP.

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ESP Systems | Technology 23
TECH REPORT
NIZHNEVARTOVSK, RUSSIA

Field
Casing size
Van-Yogan
6.625 in [16.83 cm]
REDA Maximus System Increases Production
Pump OD 5.13 in [13.03 cm] by 69% for Russian Operator
Motor OD 4.56 in [11.58 cm]
ESP operates 1,359% longer than previous third-party installation and

REDA Maximus System Increases


Motor power 450 hp [335.6 kW]
improves run life an average of 142% in arctic conditions
Background Run Life Improvement
A Russian operator in the Van-Yogan field was

Production by 69% for Russian Operator


Run life, days
attempting to produce from a well with a production
Maximus
potential of more than 4,000 m3/d. However, Production, m3/d
system
due to casing size limitations and extreme arctic
temperatures, the well was producing only about
650 m3/d. In addition, the third-party ESP’s run life Installation 3
ranged from 61 to 457 days. The operator contacted
Schlumberger to provide a solution that would
maximize production from the well and improve the Installation 2
run life of the ESP system.
Technologies
■ REDA* Maximus* ESP system Installation 1
■ ProMotor* integrated ESP motor, protector, and
sensor unit 0 200 400 600 800 1,000 1,200
■ MaxLok* ESP quick-plug motor lead extension Facing temperatures of −27 degC [−16.6 degF], Schlumberger selected a ProMotor unit and plug-and-play Maximus system
■ GN 10000 pumps prefilled with a high-dielectric-capacity oil, which eliminated weather-dependent servicing operations and saved 3–5 hours of
installation time over third-party ESP systems. After installation, production increased 69% from 650 m3⁄d to 1,100 m3⁄d. The
Maximus system ran for 890 days—an improvement of up to 1,359% over previous third-party ESP installations—before it
was scheduled for a selective workover operation. When minimal wear was observed on either the motor or the pump, the
system was rebuilt, serviced with new oil, and sent back to the field for installation in another well.
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ESP Systems | Technology 24
REDA Maximus with Trident
Ultrareliable motor configuration for high-value wells
APPLICATIONS Combining the Trident* extreme-conditions motor
■ High-horsepower ESP systems lead extension (MLE) with Maximus system
■ 75⁄8-in [19-cm] or larger casings and pods motors maximizes ESP system reliability with
an innovative, robust design that uses advanced
■ Single- or dual-ESP completions
materials to ensure long-term, dependable
■ Offshore and onshore high-profile wells performance in the most high-power-demand
BENEFITS and run-life-critical applications. The Trident
■ Reduces operating costs with high- MLE includes three PEEK-insulated, copper
efficiency, variable-rating motor design conductor cable leads that plug in directly to
the motor through individual connectors. This
■ Improves reliability and helps eliminate The Trident MLE features innovative pothead design
design minimizes the cable manipulations usually
errors with robust plug-in design and PEEK-insulated solid copper conductors for superior
required during the manufacturing and assembly current-carrying capability and thermal stability.
■ Simplifies installation and saves rig time processes. Such additional manipulations may lead
with factory oil-filled REDA* Maximus* ESP to undetectable insulation microcracks and internal
system motor damage, which could reduce the reliability of the
product.
FEATURES
■ Three separate and individually armored Proven, field-friendly design
leads to improve phase separation, Maximus system motors and Trident MLE offer
insulation, mechanical protection, and heat operators advanced reliability features, including
dissipation the proprietary, factory-oil-filled design and high-
■ Polyetheretherketone (PEEK®)-insulated cable load radial support system with polymer-lined
leads, with extra-thick 0.04-in [1.016-mm] bearings.
lead sheaths, to protect against gas ingress
The high current-carrying capacity of Trident
and H2S corrosion
MLE single-core conductors allows for higher
■ PEEK-insulated, solid copper conductor horsepower with lower stator voltages and
cable leads to provide high current-bearing less insulation stress than previously possible.
capacity, temperature stability, and excel- Maximus system motors with Trident MLE allows
lent dielectric strength up to 1,088 hp [811 kW] at 60 Hz with only two
■ Advanced elastomers in the pothead tandem sections, and up to 1,170 hp [872 kW]
connector that accommodate wide with three tandem configurations. A variable rating Maximus ESP system with three individual Trident MLEs
temperature swings can be applied to better match the application’s installed. The robust, field-proven design of the Trident MLE
■ 61⁄4-in [16-cm] motor head OD compatible requirements to the motor and to minimize motor and the configuration’s simple plug-and-play installation
ensure superior reliability and longer run life.
with 75⁄8-in [19-cm] or larger casings and pods overheating.

The 400 series of the Trident MLE with 4 AWG conductor has the same OD as the Maximus system. The
Trident MLE with 1 AWG conductor has a 61⁄4-in [16-cm] overall OD at the thickest point, which meets the
requirement for high-horsepower applications in 75⁄8-in [19-cm] and larger casings. The OD of the motor
head is also compatible with dual-pod ESP completions in 95⁄8-in [24-cm] and larger casings, with both
systems enclosed in 75⁄8-in individual pods.

By securing the leads tightly within the OD of the system, the Trident MLE ensures that cables and
pothead connectors are protected from mechanical impact and damage while the system is being lowered
in the well.

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ESP Systems | Technology 25
REDA Maximus with Trident
REDA Maximus System Motor Specifications
Series 738 562
OD, in [mm] 7.38 [187.6] OD 6.25 [158.7] motor head OD and Trident MLE with 1 AWG
5.62 [142.7] motor head OD and Trident MLE with 4 AWG
Maximum tandem horsepower,† 60 Hz [kW at 50 Hz] 1,500 [932] 1,170 [727]
Maximum amperage, A 206 213
Maximum winding operating temperature, degF [degC] 400 [204] 400 [204]
Full load efficiency, % 88.3 87.5
Full load power factor, % 80.3 80.2
Rotor bearing type Cobalt bearing with 660 bronze sleeve Self-locking, self-lubricating with polymer lining
Operating frequency, Hz 30 to 90 30 to 90
MLE type Trident MLE Trident MLE
Housing metallurgy Carbon steel, Redalloy* high-nickel alloy (9 Cr:1 Mo) Carbon steel, Redalloy alloy (9 Cr:1 Mo)
Shaft material High-strength carbon steel 4130 hollow shaft High-strength carbon steel 4340 solid shaft
Shaft diameter, in [mm] 2.123 [53.9] 1.37 [32.2]
†Subject to motor shaft horsepower limitation. Motor rating can be varied to match the application requirement.

Trident Motor Lead Extension Specifications


Series 400 400 450 300 400 300
Conductor material 1AWG solid copper 1AWG solid copper 1AWG solid copper 1AWG solid copper 4AWG solid copper 4AWG solid copper
Maximum voltage, V 5,000 5,000 5,000 5,000 5,000 5,000
Maximum amperage, A, 225 at 200 [93] 225 at 200 [93] 247 at 200 [93] 167 at 200 [93] 128 at 200 [93] 92 at 200 [93]
at bottomhole tempera- 211 at 230 [110] 211 at 230 [110] 227 at 250 [121] 142 at 230 [110] 119 at 230 [110] 78 at 230 [110]
ture degF [degC], 200 at 250 [121] 200 at 250 [121] 201 at 300 [149] 121 at 250 [121] 113 at 250 [121] 67 at 250 [121]
Temperature range, –40 to 400 –40 to 400 32 to 450 32 to 300 10 to 400 –40 to 300
degF [degC] [–40 to 204] [–40 to 204] [0 to 232] [0 to 151] [–12 to 204] [–40 to 151]
Minimum storage –60 [–51] –60 [–51] 23 [–5] 28 [–20] –60 [–51] –60 [–51]
temperature, degF
[degC]
Conductor insulation, 0.075 [1.905] PEEK 0.075 [1.905] PEEK 0.075 [1.905] PEEK 0.075 [1.905] PEEK 0.075 [1.905] PEEK 0.075 [1.905] PEEK
in [mm]
Barrier, in [mm] 0.040 [1.016] 0.040 [1.016] 0.040 [1.016] 0.040 [1.016] 0.040 [1.016] 0.040 [1.016]
Armor MONEL® MONEL MONEL MONEL MONEL MONEL

slb.com/maximus

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ESP Systems | Technology 26
MaxFORTE
Intervention-constrained high-reliability ESP system
APPLICATIONS The MaxFORTE* intervention-constrained high-reliability ESP system integrates several Schlumberger
■ Offshore wells technologies for thermal, deepwater, and hostile environments in one system that outruns conventional
■ Remote or difficult-to-access locations offshore ESPs. Designed to address the needs of the intervention-constrained market, the MaxFORTE
system provides adaptability, consistency, and reliability in unpredictable environments.
BENEFITS
■ Extends run life Optimum design for maximum production
Every element, from engineering design to manufacturing, field operations, and ongoing surveillance,
■ Reduces early failures
has been enhanced for the MaxFORTE system. Taking advantage of breakthroughs in technology
■ Eliminates nonproductive time designed for hostile environments, the MaxFORTE system features robust, high-reliability components
■ Achieves high system uptime through that continue functioning in even the harshest conditions. Dedicated qualification and reliability
enhanced surveillance engineers validate both the hardware design and manufacturing process. After verification, component-
and system-level qualifications are conducted to stress the equipment to the extremes of operating
FEATURES
temperature and load.
■ Detailed application engineering using
DesignPro* ESP design software, PIPESIM* Rigorous testing processes
steady-state multiphase flow simulator, The MaxFORTE system is subjected to frequency and operation range sweeps to mimic varying
and transient simulation pumping regimes. Numerous start and stops are made to stress bearings, shafts, and compensation
■ High-reliability ESP resistant to abrasion, systems to ensure that the equipment can reliably withstand even continuous field restarts and
corrosion, and temperature intermittent operation.
■ Advanced protector configuration with Advanced manufacturing and assembly
metal bellows construction Components are manufactured and tested in a dedicated environment using advanced processes and
■ Fully field-testable Trident* extreme- state-of-the-art machinery. Equipment is assembled following a rigorous quality plan, fully traceable
conditions motor lead extension and audited to arrive defect-free.
■ High-temperature mine duty motor winding Secure shipping with reduced vibration
■ Phoenix xt150* high-temperature MaxFORTE system equipment is shipped from the manufacturing center to the wellsite in specially
ESP monitoring system for designed shipping boxes that reduce vibration levels by over 50%. In addition to the increased shock
motor-winding temperature and bend resistance, real-time vibration logging is done on each component during transit, with the
■ Dedicated manufacturing facility with full loggers analyzed on receipt to ensure that the MaxFORTE system is ready for use.
traceability and 100% parts inspection
■ Extensive system integration test prior to
leaving the facility
■ Secure transportation in vibration-
monitored shock- and bend-proof
shipping boxes
■ Dedicated field crews using specific
installation checklists and procedures
based on aviation methodology
■ Installation equipment with cable
spooling system for constant
electrical measurement
■ Dedicated monitoring and surveillance
with fast response time to critical events

All MaxFORTE systems are assembled and fully tested in the dedicated assembly area prior to shipment.

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ESP Systems | Technology 27
MaxFORTE
Specifications Dedicated installation technicians
General Specifications Installation is done through a Zero Fault
System temperature rating, degC [degF] 150 [302] Commissioning* approach of detailed
Maximum pressure rating, kPa [psi] 34,474 [5,000] standard work instructions and checklists.
Minimum casing size (S series), cm [in] 17.78 [7]
With the system safely commissioned, it is
Minimum casing size (H series), cm [in] 19.37 [7.625]
handed over to our real-time surveillance
center, where round-the-clock monitoring
Housing metallurgy Redalloy* high-nickel alloy
ensures trouble-free operation through the
Pump Specifications
system’s long life.
Available pump models S8000R, S11000R, HR13500, H15500R, H22500R
Frequency range, Hz 40–60 Contract availability
Stage metallurgy 5530 MaxFORTE systems are available through
Bearing construction Full bearing housing performance-based contracts to assure
Bearing type Silicon carbide keyless bearings customers they are receiving the highest
Shaft High-strength INCONEL® 718 levels of quality and service.
Sand fallback protection Shedder and retainer
Gas Handler Specifications
Available AGH* advanced gas-handling S70-100, H100-250
device models
Available Poseidon system models S50-90
Stage metallurgy 5530
Bearing type for AGH device Silicon carbide keyless bearings
Bearing type for Poseidon system Tungsten carbide keyless bearings
Shaft High-strength INCONEL 718
Protector Specifications
Protector configuration Tandem
Upper protector type Bag parallel bag series labyrinth (BPBSL)
Lower protector type Metal bellows parallel metal bellows parallel metal bellows series
labyrinth (MPMPMSL)
Shaft High-strength INCONEL 718
Shaft seals Precision-lapped silicon carbide INCONEL metal bellows
Number of shaft seals 6
Motor Specifications
Motor range at 60 Hz, hp 338–1,050
Rotor bearing type SLK-PL
Winding type High-temperature mine duty winding
Construction Snap ring per rotor
Shaft High-strength 4340 solid
Sensor connection Gauge-ready base with factory-installed motor-winding
thermocouple
Pothead connection #4 Trident extension
Field pressure testable connection Yes
Sensor
Sensor type Phoenix xt150 system Type 1
Measured parameters Pump intake pressure, pump discharge pressure, pump intake
temperature, motor-winding temperature, vibration, current
leakage
Update rate (intake pressure), s 4
Discharge pressure connection, in [cm] 0.25 [0.63]; hydraulic line
Cable
Cable construction EPDM, Lead, Braid, EPDM
Conductor size 1 AWG, 2 AWG
Armor Galvanized armor or MONEL®
slb.com/al
Conductor temperature rating, degC [degF] 204 [400]
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ESP Systems | Technology 28
The plug-and-play design of the Continuum ESP streamlines installation and eliminates the risk of human error.

REDAREDA
Continuum ESP System Overview
Continuum
The REDA* Continuum* unconventional xt150* high-temperature ESP monitoring system.
extended-life ESP system provides continuous The entire system is preconfigured for immediate
production during flow changes found in installation, saving rig time and eliminating human
challenging environments. Designed to be error and contamination of the most vital parts of
installed early in the production phase, the the system.
Continuum ESP optimizes flow throughout the
reservoir’s life cycle. Wide operating flow range
The Continuum ESP is available in three flexible
Its preconfigured plug-and-play design drastically sizing options covering a wide operating range from
reduces rig time and improves system reliability in 200 bbl/d to 7,000 bbl/d, the primary flow range
extreme all-weather conditions. Its re-engineered found in unconventional plays. It yields higher
compression design decreases stage erosion, initial production than seen with natural flow and
making it capable of handling abrasive conditions allows for faster drawdown.
and production of gas or solids. With wider vanes,
the Continuum ESP also accommodates high Continuous operation
gas volume fraction to maximize performance, As flow declines, its wide operating envelope
efficiency, and run life. enables the Continuum ESP to continue functioning
with improved uptime and reliability. Its ability to
The Continuum ESP features field-proven run even at rates beyond its recommended range
technologies in one system designed specifically decreases operating costs and eliminates the
for unconventional plays and harsh environments. expense of transitioning to a new system.
It is paired with the REDA Maximus* ESP system
motor and protector, a gas handler or Poseidon
multiphase gas-handling system, and the Phoenix

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ESP Systems | Technology 29
APPLICATIONS Enhanced reservoir recovery
■ Conventional and unconventional The ESP features mixed-flow stage pumps with wider vane openings
shale reservoirs to optimize production when there is a high percentage of free gas.
■ Casing 5.5 in or larger The system can also be installed with a helicoaxial pump, which makes
it capable of handling up to 90% free gas at the intake before separation.
■ Reservoirs with uncertain productivity
■ Wells with steep production decline Real-time monitoring
Real-time monitoring of the Continuum ESP system enables early detection
BENEFITS of pump events and downhole conditions. Proactive ESP management
■ Improves ESP system reliability prevents downtime, further reducing well intervention costs and increasing
■ Enhances performance in gassy overall production.
and abrasive conditions
Plug-and-play design
■ Accelerates production
Assembly traditionally completed onsite is performed in Schlumberger
■ Expands operating envelope manufacturing and service centers. The Continuum ESP system arrives
for continuous production at the wellsite ready for installation, reducing rig time and eliminating risks
■ Enables higher drawdown and failures caused by human errors.
■ Stabilizes operation at lower intake pressure Solids production
■ Performs in extreme all-weather conditions The Continuum ESP’s unique stage design uses a harder material
on the impeller hub to aid against the erosion caused by solids production.
FEATURES
The Continuum ESP’s distinct design mitigates the effects of erosion
■ Simplified, reliable plug-and-play design
and temperature increases on the pump.
■ Enhanced compression
■ Factory-shimmed construction
■ Wide operating flow range
■ REDA Gard* submersible pump stage design
that helps to minimize abrasive stage wear
(for the Continuum 4000)

Optimized geometry,
unique architecture, and
high-quality material
selection enables the
Continuum ESP system
to operate at high
efficiency through a wide
operating range.

slb.com/continuum

ESP Systems | Technology 30
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REDA Continuum
Unconventional extended-life ESP
APPLICATIONS The REDA Continuum* unconventional extended-life ESP, a component
■ Casing 5.5 in or larger of REDA* electric submersible pump systems, is a mixed-flow stage
■ Gassy production environments pump engineered for unconventional flow behavior and challenging
environments. Featuring enhanced compression design and wide opening
■ Abrasive production environments
vanes, the Continuum ESP improves recovery and reliability in gassy
■ Reservoirs with uncertain productivity and abrasive applications. With the ability to operate at high efficiency
■ Wells with steep production decline through a wide operating range, the Continuum ESP eliminates the need
■ Unconventional shale reservoirs for costly replacements due to production changes, reducing overall
operation expenses and optimizing uptime.
■ Conventional oil wells
Superior performance and reliability in unconventional plays
BENEFITS
Developed using computational fluid dynamics to model stage geometry
■ Improves ESP system reliability
and architecture, the Continuum ESP is engineered to deliver higher lift,
■ Increases uptime and extends system superior efficiency, and reduced power consumption. Its design further
run life improves upon the field-proven high reliability of REDA compression
■ Improves cash flow through accelerated pump designs.
production and continuous operation
The Continuum ESP was extensively tested using state-of-the-art tools
■ Reduces operating cost through superior
and proprietary techniques to model operation at different production
hydraulic efficiency
rates and fluid conditions, including at low-flow-rate and abrasive
■ Enhances performance in gassy and conditions. These solutions were validated with an instrumented string
abrasive applications test and X-ray visibility in a flow loop test and an accelerated erosion
■ Lowers total cost of ownership loop test.

FEATURES The optimized geometry, architecture, and material selection of the


■ Enhanced compression design Continuum ESP allows for a wider operating range, which improves
■ Factory-shimmed construction pump performance at low rates, in transient flow, and in abrasive
environments. Its enhanced compression design enables Continuum
■ Abrasion-resistant bearing configuration
ESPs to operate even at flow rates below the lower limit of the catalog-
for ultimate shaft support and stability
recommended operating range. The minimum flow rate of the Continuum
■ Wide operating range ESP’s operating range is determined by system constraints, including
■ Bowed vane for superior performance protector thrust bearing, motor cooling, shaft brake horsepower limit, and
■ REDA Gard* submersible pump stage system efficiency.
design that helps to minimize abrasive Enhanced stability and strength
stage wear (for the Continuum ESP 4000) The Continuum ESP offers various radial shaft-support options for a
variety of well conditions. The abrasion-resistant configurations feature
bearings with bushings and sleeves made out of tungsten carbide, evenly
spaced throughout the pump. The ceramic bushings are mounted within
diffusers on two supporting Aflas® O-rings, using the REDA systems’
patented bearing technology. These features allow the bushing to better
align to the shaft and minimize vibrations, reducing the risk of damage.

For applications with high production of abrasive materials, the full


bearing housing keyless sleeve configuration is recommended, with one
bushing and sleeve per stage made tungsten carbide. The keyless sleeve
design enables uniform stress distribution, which greatly reduces the
possibility of cracking under load or from shock impact.
REDA Continuum unconventional
extended-life ESP.

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ESP Systems | Technology 31
REDA Continuum
REDA Continuum ESP Specifications
Continuum 1000 Continuum 2500 Continuum 4000
OD, in [mm] 4.00 [101.6] 4.00 [101.6] 4.00 [101.6]
Stage geometry Mixed flow Mixed flow Mixed flow
Recommended operating range, bbl/d at 60 Hz (m3/d at 50 Hz) 200–1,350 [31.8–215] 1,000–3,200 [159–509] 3,500–7,000 [556–1,113]
Efficiency at best efficiency point (BEP), % 68.41 68.90 75.17
Head per stage at BEP, ft at 60 Hz (m at 50 Hz) 26.66 [5.86] 25.27 [5.85] 32.82 [6.95]
Burst pressure, psi [kPa] 6,000 [41,368] 6,000 [41,368] 6,000 [41,368]
Stage metallurgy Ni-Resist®, Ni-Resist, Ni-Resist,
5530 alloy 5530 alloy 5530 alloy
Housing metallurgy Carbon steel, Redalloy* high-nickel alloy Carbon steel, Redalloy alloy Carbon steel, Redalloy alloy
Shaft diameter, in [mm] 0.68 [12.27] 0.68 [12.27] 0.87 [22.23]
Shaft material and rating at 60 Hz, hp 240 (INCONEL® 718) 240 (INCONEL® 718) 492 (INCONEL 718)
Shaft radial support options ES-TT,† ARZ-TT,‡ FBH-TT,§ ARZ-TT, FBH-TT ARZ-TT, FBH-TT
FBH-TT-KS†† FBH-TT-KS FBH-TT-KS
Radial bearing material Tungsten carbide Tungsten carbide Tungsten carbide
Pump construction Enhanced compression design, Enhanced compression design, Enhanced compression design,
factory-shimmed factory-shimmed factory-shimmed
†Enhanced stability option with tungsten carbide bushing.
‡ ARZ* abrasion-resistant zirconia bearing, tungsten carbide bushing, and sleeve.
§ Full bearing housing and tungsten carbide bushing.
†† Full bearing housing, tungsten carbide bushing, and keyless sleeve.

ft BEP hp Eff ft BEP hp Eff


Flow = 984 Flow = 2,396
Head = 27.66 Head = 25.27
30 Power = 0.29 3.00 60% 60 Power = 0.65 3.00 60%
Efficiency = 68.41 Efficiency = 68.90

50 2.50 50%
25 2.50 50%

40 2.00 40%
20 2.00 40%

1.50 30%
30
15 1.50 30%
1.00 20%
20
10 1.00 20%
0.50 10%
10
5 0.50 10%
500 1,000 1,500 2,000 2,500 3,000 3,500 4,000

Capacity (bbl/d)
0 250 500 750 1,000 1,250 1,500 1,600
REDA Continuum ESP 2500 pump curves.
Capacity (bbl/d)
REDA Continuum ESP 1000 pump curves.

ft BEP hp Eff
Flow = 4,310
Head = 32.82
35 Power = 1.39 7.00 70%
Efficiency = 75.17

30 6.00 60%

25 5.00 50%

20 4.00 40%

15 3.00 30%

10 2.00 20%

5 1.00 10%

2,000 3,000 4,000 5,000 6,000 7,000 8,000

Capacity (bbl/d) slb.com/redacontinuum


REDA Continuum ESP 4000 pump curves.

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ESP Systems | Technology 32
TECH REPORT

BAKKEN FORMATION

Location
Well 1: Temperature
Bakken Shale
180 degF
REDA Continuum ESP Increases Production by 70%
Pump setting depth 8,680 ft in the Bakken Shale
Well 2: Temperature 190 degF
Pump setting depth 8,630 ft
Customer increases production while avoiding ESP replacement
Well 3: Temperature 182 degF and related costs
Pump setting depth 8,611 ft
Due to its wide operating envelope
Well 4: Temperature 180 degF Continuum ESP Exceeds Forecast Production and ability to handle production
Pump setting depth 8,432 ft decline, the Continuum ESP was
6,000 installed in the wells. The rest of the
completion included the all-weather
5,000
Background Maximus system motor and protector,
Production, bbl/d a gas handler, Vortex gas separator,
Four wells in the Bakken Shale were initially 4,000

REDA Continuum ESP Increases Production by


expected to produce 3,000 bbl/d. Although most and a Phoenix xt150 system
ESPs are available with stages for this flow rate,
3,000 multisensor gauge. The system was
configured for immediate installation
the steep production decline, solids and gas 2,000
at the wellsite, eliminating the risk of
production, and initial high flow rate made it a motor contamination and human error

70% in the Bakken Shale


1,000
challenging environment for conventional ESPs. during equipment assembly.
0
Technologies Well 1 Well 2 Well 3 Well 4
Production increased 36%–70% over
■ REDA* Continuum* unconventional Forecast production Production with Continuum ESP the initial forecast, and the Continuum
extended-life ESP ESP allowed more than 70% pressure
■ REDA Maximus* electric submersible pump drawdown. It continued operating
system
beyond its recommended flow range,
saving rig time while handling the
■ Phoenix xt150* high-temperature ESP high solids content and increase in
monitoring system gas/liquid ratio.
■ Vortex gas separator
slb.com/redacontinuum
*Mark of Schlumberger. Copyright © 2015 Schlumberger. All rights reserved. 15-AL-0049

TECH REPORT

BAKKEN FORMATION

Location
Temperature
Bakken Shale
184 degF [84.44 degC]
REDA Continuum ESP Increases Run Life by 500%
Pump setting depth 8,860 ft [2,700 m] in the Bakken Shale
Casing size 7 in [17.8 cm]
Customer experiences continuous production down to 200 bbl/d

REDA Continuum ESP Increases Run Life by 500%


Casing weight 32 lbm/ft [47.6 kg/m]
Well depth (MD) 15,200 ft [4.63 km] using one ESP
Motor OD 4.56 in [11.58 cm]
In response to these challenges, the
Pump OD 4.00 in [10.16 cm]

in the Bakken Shale


REDA Continuum ESP Run Life Continuum ESP was installed in the
well, along with the nonweather-
dependent Maximus system
Background 250 motor and protector, helicoaxial
After multiple ESP failures in an unconventional Poseidon system, and Phoenix
well, a customer needed to extend run life while 200 xt150 system gauge. The entire
improving well production. With high solids system was preconfigured and
Run life, days

content and transient flow, the environment was 150 ready for immediate installation
challenging for conventional ESPs, and only 20% at the wellsite, saving rig time
to 40% of the expected ESP run life had been 100 and mitigating the risk of motor
achieved. contamination or human error
50 during equipment assembly.
Technology
■ REDA* Continuum* unconventional 0
The Continuum ESP was able to
extended-life ESP ESP 1 ESP 2 ESP 3 ESP 4 Continuum ESP increase run life more than 500%
and continued operating down to
■ REDA Maximus* electric submersible pump 200 bbl/d, avoiding four workovers
system and the associated costs of new
■ Poseidon multiphase gas-handling system equipment and deferred production.
■ Phoenix xt150* high-temperature ESP
monitoring system
■ LiftWatcher* real-time surveillance service
slb.com/redacontinuum
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ESP Systems | Technology 33
REDA Hotline high-temperature ESP systems are designed to handle the wide swings in temperature that result with cool surface and hot downhole operating temperatures.

REDA
REDAHotline
HotlineSystem
SystemOverview
REDA* Hotline* high-temperature ESP systems applications. Thermally compensated for
are highly reliable, high-temperature ESPs deployment in high temperatures, the Hotline
designed to enable completions in high- system covers flows ranges from 200 bbl/d to
temperature reservoirs and in applications where 54,000 bbl/d [31.8 m3/d to 8,585 m3/d] at various
poor motor cooling is expected. The system is depths.
preconfigured for immediate deployment at the
wellsite to save rig time and minimize human Expanded operating envelope
error and contamination. and extended run life
Integrated downhole fluid pressure and
Temperature rating options temperature gauges near the pump intake
The Hotline system is available with two help operators produce at the optimal subcool
different temperature ratings to suit a range temperature, reduce the steam to oil ratio,
of environments and applications. Each part identify steam breakthrough, and improve overall
of the ESP system has been extensively tested pump efficiency. The ability to monitor the
to accommodate all aspects of differential motor’s internal temperature helps control the
thermal expansion for temperature ratings system’s operating point without exceeding the
of either 428 degF [220 degC] or 482 degF motor’s limitations.
[250 degC], depending on the system chosen.
Bottom-feeder gas separators are also available
System components to limit fluid entry to the low side of the casing
Hotline system components include the high- in horizontal wells, allowing steam to bypass
temperature motor and high-efficiency pump the pump on the high side of the casing and
along with optional integrated PT gauges, a extending run life.
gas separator, and a gas handler for high-GOR

Table of Contents Previous page Next page


ESP Systems | Technology 34
APPLICATION Increased drawdown and reservoir recovery
■ Oil thermal recovery The REDA Hotline System can be installed with an AGH* advanced gas-handling device to enhance
● Steam-assisted gravity drainage (SAGD) pump performance and increase reservoir recovery. The system can handle GOR up to 90% enabling
● Steamflooding a higher drawdown and therefore improving the well recovery ratio.
● Cyclic steam injection (huff and puff)
Early recovery increases the value of your asset
■ High-temperature (HT) applications Hotline system motors are rated up to 482 degF, enabling early completion in the well after steam
● HT gradient oil wells
pumping or steaming while the ESP is operating. Accelerated production improves cash flow and cost
● Geothermal wells of ownership.
■ Hot-running applications
● Low-production-rate wells
● Viscous applications with poorly

cooled motors
■ Gassy wells

BENEFITS
■ Extends ESP run life
■ Reduces human errors at wellsite
■ Optimizes reservoir drainage and production
■ Improves well cost of ownership with
● faster workovers and reduced rig costs
● minimized maintenance costs

FEATURES
■ Bottomhole temperature rating of up to
482 degF [250 degC]
■ Internal motor temperature rating up to
572 degF [300 degC]
■ Available in tighter 7-in [177.8 mm] casings to
enhance reservoir recovery
■ Single, prefilled, sealed motor with integrated
● redundant shaft seals
● thrust chamber

● fluid pressure and temperature gauges

● thermally compensated compression pumps

and gas-handling devices

slb.com/hotline

ESP Systems | Technology 35
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Copyright © 2015 Schlumberger. All rights reserved. 15-AL-66920
REDA Hotline PLus
Plus
High-temperature ESP system
APPLICATIONS The REDA* Hotline Plus* high-temperature ESP system is designed to
■ Oil thermal recovery enhance reliability in wellbores not exceeding 428 degF [220 degC].
● Steam-assisted gravity drainage (SAGD)
The system is designed with an integrated motor reengineered based
● Steamflooding
on the latest generation of REDA Hotline* high-temperature ESP
● Cyclic steam injection (huff and puff)
systems, offering the best available horsepower in a housing.
■ High-temperature (HT) applications
● HT gradient oil wells
The system enables operators to improve recovery factors and
● Geothermal wells
increase early production while reducing downtime and intervention
cost. The Hotline Plus system’s applications include gassy environments
■ Hot-running applications
common to both thermal recovery and heavy oil applications, such as
● Low-production-rate wells

● Viscous applications with poorly


SAGD, steamflooding, and geothermal.
cooled motors Integrated motor
BENEFITS The Hotline Plus system features a prefilled, integrated, and sealed
■ Extends ESP run life motor. The all-weather-installed system also eliminates the need for
■ Reduces human error at wellsite oil well servicing, which substantially reduces risk, rig time, and cost.
The integrated motor unit with a full protector function includes the
■ Increases production and recovery
motor, redundant seals selection, thrust chamber, sand exclusion
■ Improves reservoir drainage and
filters, monitory gauges, and metal bellows for volume compensation
production in infill-drilled wells
at the bottom of the assembly.
■ Enables production in wells with
7-in [17.8-cm] casing The system’s architecture was optimized for best reliability during
■ Improves well cost of ownership with solids production and steam flushing.
■ faster workovers and reduced rig costs

● minimized maintenance costs


Integrated downhole monitoring
The Hotline Plus system integrates downhole fluid pressure and
FEATURES temperature gauges. Monitoring pressure and temperature at the
■ Bottomhole temperature rating of wellbore close to the pump intake helps operators continue producing
428 degF [220 degC] at the optimal temperature, reduce the steam/oil ratio, identify steam
■ Internal motor temperature rating of breakthrough, and improve overall pump efficiency. The ability to
550 degF [288 degC] monitor the motor’s internal temperature helps control the system’s
■ No onsite servicing required operating point and therefore extend the ESP system run life.
■ Single, prefilled, sealed motor with
integrated
● redundant shaft seals

● thrust chamber

● metal bellows for volume compensation

● sand exclusion filters

● motor internal temperature transducer

● fluid pressure and temperature gauges

● plug-in pothead design with dual

elastomeric seal
■ Thermally compensated compression pumps
and gas-handling devices
■ Bottom feeder intake
■ Surface monitoring interface card
REDA Hotline Plus system integrated
motor.

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ESP Systems | Technology 36
REDA Hotline Plus
REDA Hotline Plus ESP System Specifications Pressure and Temperature Gauge Specifications†
562 Series Parameter Rating Accuracy Resolution
Max. bottomhole temperature, 428 [220] Annulus pressure, psi [kPa] 5,000 [34,473] ±4 [27.57] 0.2 [1.38]
degF [degC] Annulus temperature, degF [degC] 500 [260] ±5.4 [3] 1.8 [1]
Max. motor internal temperature, 550 [288] Motor temperature, degF [degC] 752 [400] ±5.4 [3] 1.8 [1]
degF [degC] †This calibration is valid for temperatures ranging from 98–482 degF [35–250 degC].
Pump series A–L, in [mm] 3.38–7.25 [86–187]
Max. flow rate capability at 60 Hz, 54,000 [8,598]
bbl/d [m3/d]
Motor OD, in [mm] 5.62 [142.7]
Max. power at 50 Hz, hp 214 (single section motor)
Max. power at 60 Hz, hp 257 (single section motor)
Thrust bearing Enhanced keyway
Volumetric compensator Metal bellows
Motor oil Superior REDA* ESP systems #7
Power cable material Standard EPDM
Power cable rating, degF [degC] 450 [232]
Number of shaft seals 3
Integrated gauge Resistance temperature detector only or
full gauge
Gas/steam solution Vortex gas separator, bottom feeder
gas separator, bottom feeder charger,
AGH* advanced gas-handling device,
Poseidon multiphase gas-handling system
Metal composition CS, Ni-Resist™, INCONEL®, special alloy and
coating options

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ESP Systems | Technology 37
REDA Hotline XTend
Extended-capability high-temperature ESP system
APPLICATIONS The REDA* Hotline XTend* extended-capability high-temperature ESP
■ Oil thermal recovery system is designed to enhance reliability in wellbores not exceeding
● Steam-assisted gravity drainage (SAGD)
482 degF [250 degC]. The system is designed with an integrated
● Steamflooding
motor reengineered based on the latest generation of REDA Hotline*
● Cyclic steam injection (huff and puff)
high-temperature ESP systems, offering the best of combination
■ High-temperature (HT) applications horsepower and housing length.
● HT gradient oil wells

● Geothermal wells
The system’s temperature rating enables higher temperature steam
injection for optimum reservoir recovery while reducing downtime
■ Hot-running applications
and intervention cost. The Hotline XTend system is available in either
● Low-production-rate wells

● Viscous applications with poorly


SLIM size, for 7-in heavyweight casing, or 562 Series. The availability
cooled motors of the SLIM size increases recovery ratio by enabling completion in
infill wells, where smaller casing is used.
BENEFITS
■ Extends ESP run life The Hotline XTend system can be deployed in gassy environments
■ Reduces human error at wellsite common to both thermal recovery and heavy oil applications, such as
SAGD, steamflooding, and geothermal.
■ Increases production and recovery
■ Improves reservoir drainage and Integrated motor
production in infill-drilled wells The Hotline XTend system features a prefilled, integrated, and
■ Enables production in wells with sealed motor. Reengineered from the previous generation of Hotline
7-in [17.8-cm] casing systems, the system features materials that resist aging and enhance
■ Improves well cost of ownership with reliability when subjected to temperature cycling. The all-weather-
● faster workovers and reduced rig costs installed system also eliminates the need for oil well servicing, which
● minimized maintenance costs
substantially reduces risk, rig time, and cost. The integrated motor
unit with a full protector function includes the motor, redundant seals
FEATURES
selection, thrust chamber, sand exclusion filters, monitory gauges,
■ Bottomhole temperature rating of
and metal bellows for volume compensation at the bottom of the
482 degF [250 degC]
assembly. Both series of the Hotline XTend system use the same
■ Internal motor temperature rating of
motor lead extension.
572 degF [300 degC]
■ No onsite servicing required The system was enhanced for the best reliability when operating in
■ Single, prefilled, sealed motor with challenging conditions such as sands production and steam flushing.
integrated
● redundant shaft seals
Integrated downhole monitoring
● thrust chamber
The Hotline XTend system integrates downhole fluid pressure and
● metal bellows for volume compensation temperature gauges. Monitoring pressure and temperature at the
● sand exclusion filters wellbore close to the pump intake helps operators continue producing
● motor internal temperature transducer at the optimal temperature, reduce the steam/oil ratio, identify steam
● fluid pressure and temperature gauges breakthrough, and improve overall pump efficiency. The ability to
● plug-in pothead design with dual monitor the motor’s internal temperature helps control the system’s
elastomeric seal operating point and therefore extend the ESP system run life.
■ Thermally compensated compression pumps
and gas-handling devices
■ Bottom feeder intake
■ Surface monitoring interface card
REDA Hotline XTend system integrated
motor.

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ESP Systems | Technology 38
REDA Hotline XTend
REDA Hotline XTend ESP System Specifications
562 Series SLIM Series
Max. bottomhole temperature, 482 [250] 482 [250]
degF [degC]
Max. motor internal temperature, 572 [300] 572 [300]
degF [degC]
Pump series A–L, in [mm] 3.38–7.25 [86–187] 3.38–5.38 [86–136.65]
Flow rate range at 50 Hz, bbl/d [m3/d] 45,000 [7,156] 13,752 [2,186]
Max. flow rate capability at 60 Hz, 54,000 [8,598] 16,500 [2,623]
bbl/d [m3/d]
Motor OD, in [mm] 5.62 [142.7] 4.85 [123.2]
Max. power at 60 Hz, hp 257 (single section motor) 119
Thrust bearing Enhanced keyway Enhanced keyway
Volumetric compensator Metal bellows Metal bellows
Motor oil Superior REDA* ESP systems #7 Superior REDA systems #7
Power cable material Standard EPDM Standard EPDM
Power cable rating, degF [degC] 500 [260] 500 [260]
Number of shaft seals 3 or 4 4
Integrated gauge Resistance temperature detector (RTD) only RTD only or full gauge
or full gauge
Gas/steam solution Vortex gas separator, bottom feeder gas Vortex gas separator, bottom feeder gas
separator, bottom feeder charger, AGH* separator, bottom feeder charger, AGH
advanced gas-handling device, Poseidon device, Poseidon multiphase gas-handling
multiphase gas-handling system system
Metal composition CS, Ni-Resist™, Redalloy* high-nickel alloy, CS, Ni-Resist, Redalloy alloy, 5530,
5530, INCONEL®, special alloy and coating INCONEL, special alloy and coating options
options

Pressure and Temperature Gauge Specifications


Parameter Rating Accuracy Resolution
Annulus pressure, psi [kPa] 5,000 [34,473] ±4 [±27.57] 0.2 [1.38]
Annulus temperature, degF [degC] 500 [260] ±5.4 [±3] 1.8 [1]
Motor temperature, degF [degC] 752 [400] ±5.4 [±3] 1.8 [1]
‡This calibration is valid for temperatures ranging from 98–482 degF [35–250 degC].

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ESP Systems | Technology 39
Motors
For the REDA Hotline high-temperature ESP system
APPLICATIONS The motors for the REDA* Hotline* high-temperature ESP system are
■ Wells with high bottomhole designed for extreme conditions. They operate reliably in extremely high
temperatures including: temperatures found during steam-assisted gravity drainage and other
● steamflooding and thermal steamflooding applications. The motors have a three-phase squirrel cage,
recovery applications two-pole induction design similar to other standard ESP motors. Hotline
● geothermal applications system motors, however, are designed to handle the wide temperature
● poorly cooled motors in variations that result with cool surface temperatures and extremely hot
viscous applications downhole operating temperatures.
● wells with low flow rates

Design
■ Wells with abrasive fluids
The high-temperature design allows for increased starting torque and
■ Gassy wells greater efficiency. The steel stator laminations focus the magnetic forces
■ Wells with corrosive fluids, including on the rotors to reduce energy loss. The stator windings have added copper
H2S, CO2, and chemical treatments fill and a proprietary high-temperature insulation system.

BENEFITS Hotline system motors use a special motor pothead specifically designed
■ Extends ESP run life in severe applications to withstand thermal shock. The pothead has a highly reliable tape-in
■ Expands ESP operating range connection and metal-to-metal seals to act as a barrier to fluid entry.
The motors use special high-temperature dielectric oils and bearing
■ Increases production in thermal
systems to ensure that lubricity and load requirements are met in
recovery applications
high-temperature operating conditions. They also have a large oil reservoir
FEATURES in the motor base to allow the oil to expand and contract with wide thermal
■ Motor insulation system rated cycles and a filter to eliminate debris.
up to 550 degF [288 degC]
■ Capability of withstanding severe heating Motor Specifications
and cooling cycles Series 562
Motor OD, in [mm] 5.62 [142.75]
■ Nonelastomeric seal at pothead
Min. casing ID, in [mm] 7.0 [177.8]
■ Expanded oil reservoir for extra cooling Max. motor winding temperature, degF [degC] 550 [288] REDA Hotline system motor
capacity with integral oil filter Max. bottomhole temperature, degF [degC] 425 [218] with stator, windings, copper
Min. power at 60 Hz, hp 42.8 fill, and high-temperature
insulation.
Min. power at 50 Hz, hp 35.7
Max. power at 60 Hz,† hp 321
Max. power at 50 Hz,† hp 267
† Single section.

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ESP Systems | Technology 40
Advanced Motor Protectors
For the REDA Hotline high-temperature ESP system

APPLICATIONS Advanced motor protectors for REDA* Hotline* high-temperature ESP


■ Wells with high bottomhole temperatures systems are designed to operate reliably in extreme-temperature, highly
■ Steamflooding and thermal recovery abrasive, and corrosive environments common to thermal recovery heavy
applications oil production systems, such as steam-assisted gravity drainage and other
steamflooding applications. Their design features an INCONEL® metal
■ Geothermal applications
bellows that replaces the traditional high-temperature elastomeric bag.
■ Poorly cooled motors in viscous applications The metal bellows allows the temperature operating limit to be extended,
■ Wells with abrasive fluids and in gassy wells it prevents gas from migrating and displacing the motor
■ Gassy wells oil. The motor protectors are resistant to H2S and CO2 and impermeable to
gas. They are thus more suitable in wells that are highly corrosive or gassy
■ Wells with corrosive fluids, including H2S,
and in other harsh environments.
CO2, and chemical treatments
Advanced motor protectors have many special features that improve
BENEFITS
performance in wells producing sand or solids. One of these is a protector
■ Extends ESP run life in severe applications
head with dual elevated shaft seals and a sand diverter system. Its design
■ Expands ESP operating range allows any sand or solids falling from the intake to drop back into the
■ Increases production in thermal recovery wellbore through the drainholes. The sand shield also protects the top
applications shaft seal from excessive abrasives. The shaft bearings reduce abrasive
wear and improve shaft stability, reducing vibration in the system.
FEATURES
Advanced motor protectors have proven to be key in achieving long ESP
■ Availability with metal bellows, elastomeric
run life in harsh environments.
bag, or labyrinth fluid containment chamber
■ Metal bellows option that is resistant to
very high temperatures and eliminates gas
migration
■ Dual bearing system to reduce vibration and
eliminate bushing wear
■ Sand diverter system to protect mechanical
shaft seal Optional fluid containment chambers.
(From the left) Elastomer bag,
■ High-pressure check valve labyrinth, metal bellows.
Elastomer bag Labyrinth Bellows
■ Dual elevated shaft seals providing
redundancy Advanced Motor Protector Specifications
OD, in [mm] 5.130 [130.30]
Max. bottomhole temperature rating, 425 [218]
degF [degC]

Housing material Carbon steel or Redalloy*


high-nickel alloy
Chamber options Metal bellows, bag, and
labyrinth Advanced motor protector with
metal bellows option.
Shaft diameter, in [mm] 1.187 [30.15]
Deviation 0–90°

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ESP Systems | Technology 41
TECH REPORT
NISKU, CANADA

Temperature 401 degF [205 degC]


Pump setting depth
Casing size
1,565 ft [477 m]
95⁄8 in
REDA Hotline System Increases Run Life
Casing weight 36 lbm/ft by an Average of 149%
Motor OD 5.62 in [14.27 cm]
Pump OD 6.75 in [17.15 cm]
ESP system enhances production in high-temperature,
steam-assisted gravity drainage (SAGD) well
Background
Increased Run Life Using Hotline Systems Schlumberger installed the
An operator in Canada needed to perform
Hotline ESP system with a
a SAGD operation to produce from a well 1,200
high-temperature, non-weather-
with high fluid viscosity. However, the high dependent integrated motor
temperatures generated during the operation had with a downhole monitoring

REDA Hotline System Increases Run Life


caused other ESPs to fail earlier than expected. 1,000 gauge. The motor features a
With production dependent on high injection full protector and compensation
temperature, the operator asked Schlumberger for system configured for immediate
a high-reliability, high-temperature solution that 800 deployment in the well,

by More Than 149%


would effectively produce without compromising eliminating human error and
saving rig time during assembly.
Run life, days

run life.
The system was installed with a
Technologies 600 bottom-feeder gas separator along
■ REDA* Hotline* high-temperature electric with a high-temperature pump.
submersible pump systems The Hotline system increased
400 run life by an average of
■ Bottom-feeder gas separator
149% and is still running. This
■ High-temperature integrated gauge
improved the customer’s total
■ J12000N pump 200 cost of ownership by eliminating
unnecessary workovers and
deferred production.
0 ESP 1 ESP 2 ESP 3 Hotline system
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TECH REPORT
NISKU, CANADA

Temperature 392 degF [200 degC]


Pump setting depth
Casing size
1,163.22 ft [354.5 m]
7 in
REDA Hotline System Increases Run Life
Casing weight 23 lbm/ft by an Average of 445%
Motor OD 5.62 in [14.27 cm]
Pump OD 5.38 in [13.67 cm]
High-temperature ESP system improves recovery and reliability
in steam-assisted gravity drainage (SAGD) well
Background
Increased Run Life Using Hotline Systems Schlumberger installed the
To efficiently produce from a well, an operator
Hotline ESP system with a
in Canada needed to pump a high-temperature 1,200
high-temperature non-weather-
steam into the reservoir to decrease fluid viscosity dependent integrated motor with
enough to enable its movement toward the downhole monitoring gauge.

REDA Hotline System Increases Run Life


wellbore. However, the high temperatures that 1,000 The integrated motor features a
occur during SAGD operations can compromise full protector and compensation
ESP run life. With the reservoir recovery ratio system configured for immediate
dependent on the high injection temperature, the 800 deployment in the well, eliminating

by More Than 445%


operator asked Schlumberger for a high-reliability human error and saving rig time
during assembly. The system was
Run life, days

solution that would improve recovery without


installed with a bottom-feeder
compromising run life. 600 gas separator along with an
Technologies AGH device.
■ REDA* Hotline* high-temperature electric The Hotline system increased run
submersible pump systems 400 life by an average of 445% and
■ Bottom-feeder gas separator is still running. This improved
the customer’s total cost of
■ High-temperature integrated gauge ownership by eliminating
200
■ AGH* advanced gas-handling device unnecessary workovers and
deferred production.
0 ESP 1 ESP 2 ESP 3 ESP 4 Hotline system
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ESP Systems | Technology 42
D1050N
Low-flow-rate mixed-flow pump for REDA ESP systems
APPLICATIONS A component of REDA* ESP systems, the sand loop test, significantly increasing pump life
■ 5.5 in or larger casing D1050N pump is a unique mixed-flow-stage in sand-producing wells. Front seal wear is the
■ Flow rates from 300 bbl/d to 1,650 bbl/d solution for wells producing less than 1,000 bbl/d primary cause of increased internal recirculation
with high GOR of liquid. Wider vane openings and smoother and loss of hydraulic performance, necessitating
flow patterns provide better hydraulic efficiency pump replacement.
■ High abrasives production
and gas- and abrasives-handling capabilities
■ Uncertain or variable productivity compared with radial-flow stages, extending the Enhanced stability and strength
mixed-flow application envelope to as low as Different radial shaft-support options are available
BENEFITS for a variety of well conditions. The standard
■ Reduces operating costs through higher 300 bbl/d. As a result of extensive performance
optimization using CFD, the pump delivers enhanced stability (ES) configuration features
hydraulic efficiency, reliability, and longer life two ARZ* abrasion-resistant zirconium ceramic
higher head per stage and greater hydraulic
■ Eliminates need for costly replacements bearings located in the head and in the base of
efficiency than any other mixed-flow pump at
and production changes by having a wide the pump. The more advanced configurations
these production rates, reducing the power
operating range feature bearings with bushings and sleeves
consumption and the number of stages required.
■ Reduces risk of shaft failure through greater made of zirconia (ARZ-ZZ) or silicon carbide
torque transmission ability Increased reliability and pump life (ARZ-SS), evenly spaced throughout the pump
Compression construction and factory-shimmed at approximately 1-ft intervals. All the ceramic
FEATURES high-strength shafts increase the applicability and bushings are mounted within diffusers on two
■ Computational fluid dynamics (CFD)– reliability of the pump. In a compression-designed supporting Aflas® O-rings, using the REDA system’s
optimized design improves hydraulic REDA ESP system, the axial thrust developed by patented compliant bearing technology. This
efficiency and performance with free gas the stages is fully transferred to the high-load- feature allows the bushings to align better to the
and solids. capacity protector thrust bearing, ensuring that shaft and minimizes vibrations and the chance of
■ Advanced front seal design protects pump the impellers are ideally positioned relative to the damage to the bushing.
stage from abrasive wear and increases diffusers and completely eliminating downthrust
wear. Factory shimming allows the shafts to be set For applications with extremely high production of
pump life.
precisely at the factory and combined with REDA abrasives, the full bearing housing keyless sleeve
■ Compression, factory-shimmed construction (FBH-SS-KS) configuration is recommended, with
extends operating range, improves reliability, Maximus* ESP system factory-filled motors and
protectors. It reduces installation time by at least one silicon carbide bushing and a silicon carbide
and simplifies installation. keyless sleeve per stage. The keyless sleeve design
60%.
■ High-strength shafts transmit extra torque enables uniform stress distribution in the sleeve,
if required in emergencies such as a stuck A new front seal design minimizes sand trapping greatly reducing the possibility of cracking under
pump. and reduces abrasive wear by 50%, as seen in the load or from shock impact due to mishandling.
■ Availability of hard ceramic radial bearings
ensures ultimate shaft support and stability.
Mixed-flow geometry for
better efficiency and
gas and solids handling

New outboard front seal


design for superior protection
from abrasive wear

Proprietary REDA system-compliant


mounted radial bearings at locations
optimized depending on application.

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ESP Systems | Technology 43
D1050N
0.14
D1050N Pump Specifications
Series 387 and 400
0.12
Seal wear OD, in [mm] 3.87 [98.3]
Production loss
0.10 4.00 [101.6]

Production loss, %
Seal wear, in

0.08 80
Stage geometry Mixed flow
Flow range, bbl/d at 60 Hz [m3/d at 50 Hz] 300–1,650 [40–219]
0.06 60
Best efficiency point (BEP), bbl/d at 60 Hz 1,032 [137]
0.04 40 [m3/d at 50 Hz]
0.02 20
Efficiency at BEP, % 66.5
Head per stage at BEP, ft at 60 Hz [m at 50 Hz] 26.07 [5.52]
0.00 0
Max. free gas content, % by volume ~ 25
Traditional Design D1050N Design
Burst pressure, psi [kPa] 5,000 [34,474]
The D1050N seal showed 50% less wear from abrasives
than the seal of a traditional pump did after 400 hr in the Stage metallurgy Ni-Resist™, 5530 high-nickel, corrosion-resistant alloy
sand loop test well, with more than 1,350 lbm [612 kg] Housing metallurgy Carbon steel, Redalloy* high-nickel alloy (9 Cr:1 Mo)
of sand produced through the pump. This dramatically Shaft material High-strength MONEL®, INCONEL® 718
reduced rate of wear allowed the pump to produce more
fluid—that is, the production lost was only about half that Shaft diameter, in [mm] 0.68 [17.27]
lost with the traditional pump—and it prolonged pump life, Shaft rating, hp 154 (high-strength MONEL), 240 (INCONEL 718)
even in extremely abrasive well conditions.
Shaft radial support options ES, ARZ-ZZ, ARZ-SS, FBH-SS-KS
Radial bearing material ARZ zirconium, silicon carbide
Pump construction Compression, factory-shimmed, eliminating shaft setting at wellsite

REDA ESP Systems


Pump Performance Curve D1050N 60 Hz / 3,500 rpm
400 Series – 1 Stage(s) – sg 1.00

Optimum operating range 300 - 1650 bbl/d Shaft brake horsepower limit Standard 154 hp
Normal housing diameter 4.00 in High strength 240 hp
Shaft diameter 0.688 in Housing burst pressure limit Standard 5,000 psi
Shaft cross sectional area 0.371 in2 Buttress 6,000 psi
Minimum casing size 5.500 in Welded N/A psi Efficiency, %
Power,
BEP (hp)
Q = 1,032
30 H = 26.07 3.00
P = 0.30 60
Head E = 66.51
Efficiency
25 2.50 50

20 2.00 40
Head, ft

Operating range
15 1.50 30

10 1.00 20

5 0.05 10
Power

0
0 250 500 750 1,000 1,250 1,500 1,750 2,000
Capacity, bbl/d
The D1050N pump has a wide optimum operating range.

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ESP Systems | Technology 44
AGH
Advanced gas-handling device
APPLICATIONS The AGH* advanced gas-handling device is a highly modified, multistage,
■ High-GOR wells that are too gassy high-speed centrifugal pump designed specifically for the gassy ESP market,
for dynamic gas separators where wells have up to 45% gas volume fraction (GVF) at low intake pressures.
■ Subsea oil wells This device is normally installed in series below a center tandem multistage
submersible REDA* ESP systems pump. The AGH device functions by reducing
■ Gassy wells with deepset packers above
vapor bubble sizes and changing the gas-bubble distribution, homogenizing the
the pump
gas-liquid mixture so that it behaves like a single-phase fluid before entering the
■ Gas well dewatering pump. The AGH device can also be installed in series above rotary or vortex-type
■ Gas-lift-to-ESP conversion wells gas separators.

BENEFITS Production doubled


■ Increases production dramatically in wells In Kuwait, a well consistently gas locked after 60 to 70 min of operation using a
previously considered too gassy for ESPs REDA systems pump with a rotary gas separator. An AGH device was added to
■ Prevents degradation of pump the equipment string above the gas separator with no other equipment changes.
performance by conditioning gas Production increased to 2,100 from 900 bbl/d with no cycling because of gas lock.
liquid mixture New lift alternative
■ Extends equipment life by eliminating A well in Mexico was producing 4,774 bbl/d (258 ft3/bbl GOR at stock-tank
pump cycling because of gas lock conditions) with gas lift using 1 MMcf/d of gas. An ESP with an AGH device was
■ Provides superior reliability in sandy or installed below a packer with fluids having 29% GVF. Production increased
abrasive environments to 9,409 bbl/d of oil—at 363 ft3/bbl GOR at stock-tank conditions—with no gas
locking.
FEATURES
■ No surging and gas lock in wells with up
to 45% GVF and low bottomhole Without AGH device
pressure
Oil production

■ Abrasion-resistant construction Incremental oil produced by the


■ High-strength INCONEL® shafts installation of the AGH device

Economic limit

AGH advanced gas-handling


Time by increasing the drawdown and the
The AGH device can make a well more economical device.
amount of oil produced. This increases recoverable reserves and extends the
economic life of the field.

Before AGH device installation After AGH device installation


Case study showing the production results before and after installing AGH device.

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ESP Systems | Technology 45
AGH
AGH Advanced Gas-Handling Device Specifications
D5-21 D20-60 G20-40 G40-80 S70-100 H100-250 M190-350
Outside diameter, in [mm] 4.00 [101.60] 4.00 [101.60] 5.13 [130.30] 5.13 [130.30] 5.38 [136.65] 5.62 [142.75] 8.62 [218.9]
Length, ft [m] 6.3 [1.92] 6.3 [1.92] 6.3 [1.92] 6.3 [1.92] 6.3 [1.92] 5.7 [1.74] 6.5 [1.98]
Weight, lbm [kg] 135 [61.3] 135 [61.3] 272 [123.5] 272 [123.5] 284 [128.8] 229 [103.9] 1050 [476]
Power consumption with 1-sg fluid, 13 13 38 45 53 102 117
hp at 60 Hz
Shaft size, in [mm] 0.687 [17.45] 0.870 [22.10] 1.000 [25.40] 1.000 [25.40] ] 1.000 [25.40] 1.180 [29.97 1.37 [34.79]
Shaft power rating, hp at 60 Hz 200 410 600 600 600 637 1,280
Bearing systems ES†, ARZ* ES ES, ARZ zirconium ES, ARZ zirconium ES, ARZ zirconium ES, ARZ zirconium ES
abrasion-resistant
zirconium
Liquid flow rate, bbI/d at 60 Hz 500 to 2,100 2,000 to 6,000 2,000 to 4,000 4,000 to 8,000 7,000 to 10,000 10,000 to 25,000 19,000 to 35,000
† Enhanced stability

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ESP Systems | Technology 46
Poseidon
Multiphase gas-handling system
APPLICATIONS The Poseidon multiphase gas-handling system enables
■ Oil wells with excessive free gas volume for efficient handling of higher percentages of free gas. The
conventional gas-handling equipment system can be installed in conjunction with a gas separator
■ Oil wells with nonvented packers when gas can be vented into the casing, or it can be installed
with a standard intake if all the produced gas must go through
■ Subsea oil wells
the pump.
■ Conversions from gas lift to ESP
■ Shale oil applications The Poseidon system is designed to increase production and
extend the use of ESPs in oil wells with high gas cut in which
■ Gas well dewatering
production is limited by the centrifugal pump’s ability to
BENEFITS handle gas.
■ Increases production and recovery from
Laboratory tests and field trials have shown that the Poseidon
reservoirs with high GOR
system can successfully operate at lower intake pressures
■ Stabilizes pump operation and increases with gas volume fractions (GVF) in the pump up to 75%, far
drawdown at lower intake pressure exceeding the 40–45% GVF limitations of conventional gas-
■ Maximizes production with fewer gas- handling devices. The Poseidon system maintains high boost
locking production shutdowns pressure with increasing amounts of inlet gas fraction. It is
■ Improves ESP run life with stabilized motor designed to improve ESP operational stability in gassy wells,
current provide better slug handling in horizontal wells, and increase
the production rate and reserves recovery. The Poseidon
FEATURES system can also be used in subsea wells and wells with
■ Helicoaxial, multiphase stage design capable nonvented packers where separating the free gas into the
of handling extremely high gas volume annulus is not possible.
fractions (GVF)
Poseidon system pumps are available in various series to
■ Special hydraulic design to minimize liquid-
match the well conditions for combined gas and liquid
gas separation
downhole flow rates from 800–47,000 bbl/d [127–7,472 m3/d].
■ Abrasion-resistant construction suitable for Advanced metallurgy options for stages and housings are
sandy applications available for abrasive and corrosive environments. All Poseidon
■ Self-lubricating silicon carbide radial system pumps are built in full bearing housing configuration
bearings in every stage, capable of with a hard ceramic radial bearing at every stage to improve
handling 100% gas slugs abrasion resistance and ensure ultimate shaft stability during
operations with extremely high GVF.

Self-lubricating, graphitized silicon carbide radial bearings


enable continuous and reliable operation, even when the gas The Poseidon multiphase gas-handling
system increases production and improves
slug is passing through the pump with essentially no liquid ESP performance in oil wells with extremely
to lubricate the bearings. This allows the ESP system to “ride high gas cut.
through” the gas-locking situation and resume production
when the inflow conditions stabilize. Proper motor winding
temperature monitoring is critical to ensure the safe working
temperature limit is never breached during such periods.

Table of Contents Previous page Next page


ESP Systems | Technology 47
Poseidon
Poseidon Multiphase Gas-Handling System Specifications
400 Series (D8-42) 538 Series (S50-90) 862 Series (M90-470)
Outside diameter, in [mm] 4.00 [101.6] 5.38 [136.7] 8.62 [219]
Length, ft [m] 6.9 [2.1] 6.3 [1.9] 5 [1.5]
Weight, lbm [kg] 182 [82.6] 350 [159] 392 [178]
Power consumption, at 60 Hz and 16 50 200
1.0 g/cm3, hp
Housing material Carbon steel, Redalloy* high-nickel alloy Carbon steel, Redalloy alloy (9 Cr:1 Mo) Carbon steel, Redalloy alloy (9 Cr:1 Mo)
(9 Cr:1 Mo)
Stage metallurgy Ni-Resist™, 5530 corrosion- and Ni-Resist, 5530 corrosion- and abrasion- Ni-Resist, 5530 corrosion- and abrasion-
abrasion-resistant alloy resistant alloy resistant alloy
Radial bearing system Full bearing housing (FBH), 1 bearing per FBH, 1 bearing per every stage Full bearing housing keyless sleeve
every stage (FBH-KS), 1 bearing per every stage
Radial bearing material Self-lubricating, silicon carbide SICG SICG
graphitized (SICG)
Shaft material High-strength MONEL®, INCONEL® 718 High-strength MONEL, INCONEL 718 High-strength MONEL, INCONEL 718
Shaft diameter, in [mm] 0.87 [22.2] 1.00 [25.4] 1.37 [34.8]
Shaft power rating at 60 Hz, hp 316 (high-strength MONEL), 463 (high-strength MONEL), 988 (high-strength MONEL),
492 (INCONEL 718) 720 (INCONEL 718) 1,536 (INCONEL 718)
Liquid and gas rate at 60 Hz, bbl/d [m3/d] 800–4,200 [127–668] 5,000–9,000 [795–1,431] 9,000–47,000 [1,431–7,472]
GVF capability Up to 75% Up to 75% Up to 75%
Stage type Helicoaxial Helicoaxial Helicoaxial

100%
Poseidon system
Poseidon
to single-phase
performance
Head relative

system Conventional
gas-handling
Oil production

Conventional system
gas-handling
system

Gas fraction
Poseidon system technology enables ESP operation in wells with GVF up to 75%.

Time
The Poseidon multiphase system delivers incremental production and improved reserves
recovery compared with conventional equipment.

slb.com/poseidon

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Other company, product, and service names
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ESP Systems | Technology 48
Y-Tool & Bypass System
Intervention-enabling system below the ESP
APPLICATIONS The Y-tool and bypass system enables intervention or logging with
■ Wireline or coiled tubing logging wireline or coiled tubing below an ESP. It also provides a method to
■ Memory gauge deployment configure more than one ESP in a well to accomplish production goals.
■ Tubing-conveyed perforating gun The Y-tool is installed on the production tubing, providing two separate
deployment and detonation conduits. One conduit is concentric with the production tubing and Auto Y-Tool
■ Well stimulation through bypass or enables access to the reservoir below the ESP. The second conduit is
coiled tubing offset and used to support the ESP system. The bypass tubing is clamped
to the ESP for support. Wireline or coiled tubing plugs can be supplied
■ Wireline perforating
to seat in a nipple profile in the Y-tool to enable intervention or logging
■ Bottomhole sample collection operations without retrieval of the completion. If required, the ESP
■ Installing dual ESP systems can be run with these plugs in place to perform production logging or
■ Bridge plug setting for water shutoff other operations.
■ Well work without pulling the ESP The Y-tool is available as a standard system in which blanking plugs and
isolation sleeves are deployed, utilizing slickline services. This prevents ESP system
BENEFITS
recirculation of production fluids during normal operation. The Auto
■ Achieves accurate production logging in
Y-Tool* subsurface automatic diverter system option is also available. This
ESP wells
proprietary Y-tool offering uses flapper valve technology and is actuated
■ Reduces downtime by differential pressure. Thus, when the pump is operating, the flapper
■ Provides reservoir access below an ESP will seal the bypass tubing side and prevent recirculation.

FEATURES Diverter option


■ Concentric conduit from surface The Auto Y-Tool option is an addition to the ESP bypass product range.
to reservoir Consisting of a spring-loaded diverter valve that seals off the bypass
■ Manual or automatic switching tubing whenever the pump is running, the tool saves time in wireline and
Auto Y-Tool
coiled tubing operations, typically reducing the number of runs by two on
■ Logging and blanking plugs
any given well intervention.
■ Isolation sleeves
The tool is automatically closed by the flow produced by the downhole
pump. The diverter, which starts off the flow path of the pump, will hinge
over and seal off the bypass tubing. The pressure generated by the pump
will keep the diverter closed while the pump is running.

The diverter can be locked in the open position by landing a logging plug
into the nipple below, which extends up into the Y-tool and prevents the ESP system
diverter from closing. This allows logging to be performed while the pump
is running.

Additionally, no access to the wellbore is required to switch between the


upper and lower ESPs. Simply stopping one ESP and starting the other will
cause the diverter to switch positions, allowing production from which-
ever ESP is required while eliminating fluid recirculation.

Y-tool and bypass


system utilizing the
Auto Y-Tool
system option.

Artificial Lift

Table of Contents Previous page Next page


ESP Systems | Technology 49
Y-Tool and Bypass System
Bypass Tubing Selection Matrix
Maximum OD of ESP Assembly, in [cm]
3.750 [9.53] 4.000 [10.16] 4.562 [11.59] 5.130 [13.03] 5.400 [13.72] 5.400 [13.72] 5.625 [14.29]
Casing Size Bypass Tubing OD , in [cm]

6 5⁄8 in (20.0 lbm/ft) 2.125 [5.40] 1.500 [3.81] na ‡ na na na na


6 5⁄8 in (24.0–32.0 lbm/ft) 1.500 [3.81] 1.500 [3.81] na na na na na
7 in (23.0–26.0 lbm/ft) 2.375 [6.03] 2.125 [5.40] na na na na na
7 in (29.0–35.0 lbm/ft) 2.125 [5.40] 1.500 [3.81] na na na na na
7 5⁄8 in (26.4–33.7 lbm/ft) 2.875 [7.30] 2.375 [6.03] 2.125 [5.40] 1.500 [3.81] na na na
8 5⁄8 in (28.0 lbm/ft) 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.375 [6.03] 2.375 [6.03] 2.375 [6.03] 2.125 [5.40]
8 5⁄8 in (32.0 lbm/ft) 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.375 [6.03] 2.375 [6.03] 2.125 [5.40] 2.125 [5.40]
8 5⁄8 in (36.0 lbm/ft) 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.375 [6.03] 2.125 [5.40] 2.125 [5.40] 1.500 [3.81]
9 5⁄8 in (40.0–47.0 lbm/ft) 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.875 [7.30]
9 5⁄8 in (53.5 lbm/ft) 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.875 [7.30] 2.375 [6.03]
10 3⁄4 in (51.0–60.7 lbm/ft) ≥3.500 [8.89] ≥3.500 [8.89] ≥3.500 [8.89] ≥3.500 [8.89] ≥3.500 [8.89] ≥3.500 [8.89] ≥3.500 [8.89]
† See accompanying table
‡ na = not applicable

Standard Bypass Tubing Data

OD, in [cm] 3.500 [8.89] 2.875 [7.30] 2.750 [6.99] 2.375 [6.03] 2.125 [5.40] 1.500 [3.81]
ID, in [cm] 2.992 [7.60] 2.441 [6.20] 2.362 [6.00] 1.995 [5.07] 1.869 [4.75] 1.244 [3.16]
Drift, in [cm 2.875 [7.30] 2.347 [5.96] 2.268 [5.76] 1.901 [4.83] 1.775 [4.51] 1.150 [2.92]

slb.com/artificiallift

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ESP Systems | Technology 50
ESP Pod Systems
Multizone production and casing protection system
APPLICATIONS A pod system is a specially designed capsule that
■ High-horsepower applications encases and supports an ESP system in a sealed
■ Dual ESP systems in series environment. This system is used to isolate and
produce multiple zones independently or to
■ Highly corrosive fluids
configure two ESP systems in series (with the
■ High-pressure pumping systems option for an Auto Y-Tool* subsurface automatic Y-Tool
Deep, high-load ESP system deployment diverter system) and provide up to 2,000 hp in a

Pod system

■ Commingling fluids produced from single system.


multiple zones ESP
The pod system can also be used to isolate system
ADVANTAGES and protect casing in a harsh environment.
■ Produce greater volume of fluid from The pod system is installed, and the annulus is
deeper in the wellbore isolated with a packer or other sealing device. ESP
The annulus is then filled with a benign fluid system
■ Protect casing integrity from overpressure,
to prevent casing corrosion. The wellbore fluid
corrosion, and erosion
enters through the bottom of the pod system and
■ Sustain tubing load and protect is produced through the tubing without contact
ESP system with the annulus.
■ Allow natural flow bypass
Pod systems provide wellbore integrity and
higher flow rates from deeper in the well,

Pod system
bear the load of the tubing string, and enable
improved production in a sealed system.

Pod system
ESP
system
Sizing ESP
The correct pod casing size for a given application system
is based upon a number of variables:
■ casing size and weight
■ ESP series
■ external cables/control lines (dimensions)
■ pod system configuration
(e.g., single or dual ESP)
■ ESP motor cooling requirements
■ type of pod system casing
(coupled or flush joint).

Pod Casing Sizes


Well Pod System Maximum
Casing, in Casing Size, in ESP Series
7 51⁄2 456
7 5⁄8 51⁄2 456 Dual ESP systems configured with dual or single pod
systems for commingled or independent production.
8 5⁄8 7 562
9 5⁄8 75⁄8 562
10 3⁄4 85⁄8 675
13 3⁄8 95⁄8 675
slb.com/al

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ESP Systems | Technology 51
Bottom Intake Protector
For the REDA Coil coiled-tubing-deployed ESP system
APPLICATIONS The bottom intake protector fits below the motor and above the pump. The
■ Rigless ESPs motor oil communicates between the motor and the protector. When the
■ REDA* Coil* coiled-tubing-deployed motor is started and heats up, the oil expands. When the motor is shut down,
ESP system the oil contracts. The bottom intake protector is open to the well fluid to keep
pressure balanced inside the protector and motor.
BENEFITS
■ Isolates well fluids from the motor, In conventional ESP systems, the protector is located above the motor and
protecting it from mechanical damage below the pump and typically sees pump intake pressure and drawdown
only. In inverted ESP systems such as the REDA Coil ESP system, the bottom
■ Balances internal and external motor
intake protector initially sees pump intake pressure. When the pump is
pressure, maintaining efficient production
started, the pressure quickly changes to pump discharge pressure. The bottom
and extending system run life
intake protector, which is designed to accommodate the extreme shifts, can
■ Accommodates rapid pressure changes efficiently handle both rapid and large pressure changes.
between the intake and discharge pressures,
enhancing system reliability

FEATURES
■ Availability in a variety of materials
and elastomers
■ REDA* ESP system, 538 and
540 series pumps

Bottom
intake
protector

REDA Coil ESP system


string with bottom intake
protector.

slb.com/redacoil
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ESP Systems | Technology 52
Discharge Head
For the REDA Coil coiled-tubing-deployed ESP system
APPLICATIONS The discharge head for inverted ESP systems is situated above the pump. It
■ Rigless ESPs has an internal shaft to transmit torque from the motor above to the pump
■ REDA Coil* coiled-tubing-deployed below. The discharge head provides a path for the fluid to be discharged into
ESP system the annular area between the production tubing and the coiled tubing. From
the annular area, the fluid is produced to the surface.
BENEFITS
■ Creates annular discharge flow path for The annular flow path leads the fluid around the motor, cooling the motor
bottom intake (inverted) ESPs, allowing ESPs during ESP operations.
to be run in environments not suitable for
casing production

FEATURES
■ Annular discharge flow path
■ 1.18-in INCONEL® internal shaft
■ Availability in a variety of materials
and elastomers
■ REDA Maximus* ESP system 540/538,
540/540, and 540/562 series configurations

Discharge
head

REDA Coil ESP system


string with discharge head.

*Mark of Schlumberger
Other company, product, and service names

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ESP Systems | Technology 53
Lower Connector
For the REDA Coil coiled-tubing-deployed ESP system
APPLICATIONS The lower connector of the REDA Coil system provides the mechanical
■ REDA Coil* coiled-tubing-deployed connection between the coiled tubing and the ESP string. It also provides the
ESP system electrical connection between the ESP motor and the cable inside the coiled
tubing.
BENEFITS
■ Enables center tandem motor to be used in A flanged connection at the base of the lower connector is made up to the
inverted ESP string by providing an electrical motor or to a real-time downhole gauge at the top of the inverted ESP string.
and mechanical connection between the ESP An internal field-attachable connector is made up to the ESP power cable in
system and power cable the coil. The coiled tubing is terminated at the top of the connector using an Lower
■ Isolates the downhole electrical connection integral coiled tubing slip-type connector. connector
and ESP cable from well fluids, protecting
If required, additional control lines can be run in the coiled tubing alongside the
components from mechanical damage
ESP power cable. For well control, this configuration may include a chemical
FEATURES injection valve or a deepset safety valve in the tailpipe below the ESP.
■ Hydraulic shear release mechanism
The lower connector includes a hydraulic-release mechanism that can be used
■ Shear rating of 3,000 or 5,000 psi [20,684 to for troubleshooting when a completion is being retrieved. If hydraulic pressure
34,474 kPa] is applied internally to the coiled tubing, the connector will separate, allowing
■ 5-kV feedthrough connector the coiled tubing string to be retrieved. The ESP is then left in the well with a
■ Integral coiled tubing slip-type connector profile for fishing.
■ Optional control line outlets
■ Availability in a variety of materials
and elastomers
■ REDA Maximus* ESP system, 562 series
configuration

REDA Coil coiled-tubing-


deployed ESP system string
with lower connector.

*Mark of Schlumberger
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ESP Systems | Technology 54
Shrouded Intake and Thrust Chamber
For the REDA Coil coiled-tubing-deployed ESP system
APPLICATIONS In conventional ESP systems, the pump is located at the top of the string and
■ Rigless ESPs discharges directly into the production tubing string, isolating the discharge
■ Applications using REDA* Coil* coiled from the intake.
tubing-deployed ESP system
In inverted ESP systems, including the REDA Coil system, the pump is located
BENEFITS at the bottom of the ESP string. The pump discharges into the annular area
■ Enables standard center tandem pumps to between the production tubing and the coiled tubing, making it necessary
be used with REDA Coil system to isolate the intake at the bottom of the pump from the discharge above the
pump.
■ Isolates pump intake from discharge when
used in conjunction with seal assembly and Isolation is typically achieved by a sealbore packer or polished bore receptacle
sealbore, supporting an annular flow path installed above the producing perforations before the ESP is installed.
■ Accommodates the downward thrust
The ESP string includes a tailpipe string and seal assembly. The tailpipe is
generated by a pump in a shrouded
connected to the ESP by a shroud around the pump intake to isolate the pump
intake system, helping maintain efficient
intake from the discharge; the seal assembly fits into a sealbore packer or
production
polished bore receptacle.
FEATURES
A thrust chamber inside the shroud, fitted below the intake, has an internal
■ Compatibility with REDA Maximus*
bearing that accommodates the downward force generated by the pump
ESP system 540/400 or 562/400 series
during operations.
configuration
■ 400 series thrust chamber
■ Optional control line outlets, including a
port for the intake pressure line of the
Phoenix xt150* high-temperature ESP
monitoring system
■ Availability in a variety of sizes, materials,
and elastomers

Shrouded
intake and
thrust chamber

REDA Coil ESP system


string with shrouded intake
and thrust chamber.

slb.com/redacoil
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ESP Systems | Technology 55
Alternative Deployment

Increasing life cycle value


Alternative deployment systems provide a convenient, inexpensive way to
manage wellsite operations. ESPs are often selected as the optimum artificial
lift method but, when run on heavy jointed tubing, their finite run lives
require frequent rig or hoist interventions to replace failed systems. There are
also significant safety and environmental risks associated with heavy well
interventions. Schlumberger’s alternative deployment technologies enable
ESPs to be quickly replaced without a rig or hoist—minimizing operating
expenses and production deferment.

Table of Contents Previous page Next page 56


Compatible with standard Schlumberger ESPs, alternative deployment systems enable operators to avoid deferred production and minimize downtime.

Alternatively Deployed ESP Systems Overview


ESPs are often selected as the optimum artificial Rigless ESP replacement
lift method, but their finite run lives require Alternative deployment strategies enable ESPs
frequent rig or hoist interventions to replace to be replaced conveniently and inexpensively
failed systems. This incurs greater production without a rig or hoist, reducing operating
deferment, increased operating costs, and expenses, minimizing production deferment,
additional disruptions to operations. The safety eliminating disruptions to operations, and
and environmental risks associated with well ensuring rigs remain on the drilling sequence
interventions that use heavy jointed tubing where they belong. Alternatively deployed
can be minimized but never eliminated. These ESP technologies also present an opportunity
interventions also often keep rigs and hoists to replace systems before failure, optimize
from more profitable activities by delaying production as reservoir conditions change, and
drilling programs. adopt a preventive maintenance program that
increases system run life.
Faced with these complications, many operators
select gas lift as their artificial lift method. Alternative deployment technologies
Though typically incapable of matching the Schlumberger offers two alternatively deployed
drawdown and rates achievable with ESPs, gas ESP technologies: REDA Coil* coiled-tubing-
lift has significantly higher uptime and lower deployed ESP system is an inverted ESP system
operating cost. Unfortunately, this compromise conveyed on powered coiled tubing, and the
reduces both reserves and ultimate recovery. ZEiTECS Shuttle* rigless ESP replacement
system is a standard ESP system conveyed
on either wireline, rods, or coiled tubing and
electromechanically connected into a downhole
docking station.

Table of Contents Previous page Next page


Alternative Deployment | Technology 57
APPLICATIONS Both the REDA Coil and ZEiTECS Shuttle systems
■ Conventional and unconventional operations are complementary to the standard Schlumberger
■ Onshore and offshore (dry tree) ESP offerings; either may be configured to
accommodate the REDA* Maximus* ESP system,
■ Casing 7 in or larger
MaxFORTE* intervention-constrained high-reliability
■ Intervention-constrained markets ESP system, or REDA Continuum* unconventional
■ Applications where standard ESPs are the extended-life ESP.
preferred lift method
Schlumberger ESP systems
■ Substitution for gas lift, in some applications
Schlumberger ESP systems are designed to address
BENEFITS the fundamental vulnerabilities and challenges
■ Lowers operating expenses facing downhole equipment, including system run
life, robustness, efficiency, operating range, and
■ Minimizes production deferment
simplicity of installation. As a result, Schlumberger
■ Eliminates disruptions to operations ESPs have the longest run lives in the industry. In
■ Reduces HSE exposure and risk the event of failure in increasingly hostile wellbore
■ Facilitates preventative maintenance environments, Schlumberger high-reliability ESPs
and alternative deployment technologies work
■ Enables plug-and-play optimization
together to mitigate the impact of those failures.
ZEiTECS SHUTTLE SYSTEM FEATURES
■ Downhole docking station with female
electrical wet connectors
■ Retrievable motor connector with male
electrical wet connectors
■ Standard Schlumberger ESP components,
including motor, protector, and pump
■ Retrievable ESP gauge

REDA COIL SYSTEM FEATURES


■ Powered CT conveyance
■ CT connector with hydraulic shear release
■ Inverted Schlumberger ESP with motor on top
and pump on bottom
■ Shrouded intake and thrust chamber
■ Retrievable ESP gauge

slb.com/zeitecs

Alternative
*Mark Deployment | Technology 58
of Schlumberger Table of Contents Previous page Next page
Copyright © 2015 Schlumberger. All rights reserved. 15-AL-85412
ZEiTECS Shuttle
Rigless ESP replacement system
APPLICATIONS The ZEiTECS Shuttle* rigless ESP replacement motor connector is an ESP assembly, which
■ Standard ESP systems in casing 7 in system enables ESPs to be retrieved and consists of a standard, readily available pump,
or larger redeployed without a rig. This reduces total protector, motor, and optional gauges. At the
■ Well cleanup operations cost of ESP ownership and eliminates the top of the retrievable string is a seal assembly to
uncertainties of rig costs and rig availability. provide the necessary isolation between pump
■ Reservoir production optimization
operations A new method of ESP intervention
The plug-and-play design of the ZEiTECS Shuttle
BENEFITS
system allows any standard ESP assembly to
■ Lowers operating expenses
be retrieved and redeployed on wireline, coiled
■ Minimizes production deferment tubing, or sucker rods following initial installation
■ Eliminates disruptions to operations during a rig-supported workover.
■ Reduces HSE exposure and risk The ZEiTECS Shuttle system consists of a
■ Facilitates preventative maintenance downhole docking station and retrievable
ESP string.
■ Enables plug-and-play optimization
The downhole docking station is attached to the
FEATURES end of the production tubing. Inside the docking
■ Rigless ESP retrieval with wireline, coiled station are three electrical wet connectors and
tubing, or sucker rods landing shoulders that support the weight of
■ Plug-and-play design with patented motor the ESP and its reactive forces and prevent
connector and docking station the motor from counter-rotating on startup.
■ Retrievable gauge for reservoir Should mechanical reservoir access be required,
monitoring a throughbore below the docking station is
available.
■ Ability to accommodate multiple hydraulic
control lines The retrievable ESP string is made up of a motor
connector, a standard ESP assembly, a flexible
■ Throughbore access below the
seal assembly, and a bypass valve. The motor
docking station
connector contains female wet connectors and
has corresponding parts to orient and connect
the ESP to the docking station. Attached to the ZEiTECS Shuttle system 550 series motor connector.

ZEiTECS Shuttle System Specifications


450 Series 550 Series 700 Series
ESP size 338/375 series 400/450/456 series 513/538/540/562 series
Min. casing size, in [mm] 7 [177.8] 7 [177.8] 9 5/8 [244.5]
Max. casing weight, 35.0 [52.09] 26.0 [38.69] 53.5 [79.62]
lbm/ft [kg/m]†
Min. tubing OD, in [mm] 4.5 [114.3] 5.5 [139.7] 7 [177.8]
Max. tubing weight, 11.6 [17.26] 17.0 [25.30] 29.0 [43.16]
lbm/ft [kg/m]†
Throughbore, in [mm] 1.9 [48.26] 1.9 [48.26] 1.69 [42.926]
Max. OD
Docking station, in [mm] 5.875 [149.23] 5.875 [149.23] 8.390 [213.11]
Retrievable ESP string, 3.930 [99.82] 4.768 [121.11] 6.055 [153.80]
in [mm]
Flexible seal assembly, 4.120 [104.19] 5.010 [127.25] 6.330 [160.78]
in [mm]
† Only applicable at min. casing size

Table of Contents Previous page Next page


Alternative Deployment | Technology 59
ZEiTECS Shuttle
intake and discharge, as well as a bypass valve to allow fluid bypass on
system retrieval.

Shuttle installation procedure


The ZEiTECS Shuttle system is initially installed during a rig-supported
workover in three main phases:
■ The docking station is run to a shallow depth on jointed tubing with
cable banded or clamped to the outside, similar to a conventional
ESP installation
■ The retrievable ESP string with motor connector is assembled
■ The motor connector is lowered through the tubing into the docking
station at surface. The complete ZEiTECS Shuttle system (docking
station and ESP string with motor connector) is then lowered to pump
setting depth.

Ideally, a deep set packer is run below the docking station to extend the run
life of permanent components by keeping the annulus, and thus the power
and control lines, free of corrosive well fluid.

Rigless ESP retrieval and replacement


The retrievable ESP string is quickly unplugged from the docking station
and retrieved in a few hours. A GS tool is lowered on wireline, coiled
tubing, or sucker rod and latched to the retrievable ESP string, which
is then retrieved through the tubing. After service or replacement, the
retrievable ESP string is redeployed using the same means by which it was
pulled. Upon deployment, the motor connector automatically orientates and
connects to the docking station with specially designed alignment petals.

ESP system optimization


Rigless ESP deployment technologies increase the average production
profile and extend the economic cutoff for wells. Since there is no time
wasted waiting on a rig to move to location or hoist up, operators can
benefit from the following production optimizations:
■ A test system deployed to clean up the well or measure reservoir
productivity is upgraded to a system optimized for the well conditions
■ Quicker and more cost-effective responses to ESP failure
■ Options to develop a preventative maintenance program to eliminate
unplanned failures and further increase the average production profile
of the well.

Fig. 1 Fig. 2 Fig. 3

Figure 1: ZEiTECS Shuttle system semipermanent components. Figure 2: ZEiTECS Shuttle


system retrievable ESP string. Figure 3: ZEiTECS Shuttle system motor connector run into
docking station.

slb.com/zeitecs

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Alternative Deployment | Technology 60
TECH REPORT
ECUADOR

Temperature
Pump setting depth
246 degF [119 degC]
7,575 ft [2,309 m]
ZEiTECS Shuttle System Decreases
Casing size 9 5⁄8 in ESP Replacement Time by 87%
Casing weight 47 lbm/ft [69.9 kg/m]
Customer ESP riglessly retrieved in less than 2 days on coiled tubing
Motor OD 4.50 in [11.43 cm]
Pump OD 4.00 in [10.16 cm] 14
Well inclination 31.56°

Background
ZEiTECS Shuttle System Decreases
After experiencing multiple ESP failures, a customer
12

10

ESP Replacement Time by 87%


needed to reduce well downtime when replacing
the ESP. In Ecuador, it is typical for rigs and hoists
8 Time savings of 87%
Days

to take 7 to 10 days to respond to an ESP failure


and then an additional 4 days to replace an ESP on
jointed tubing. For this well, the inability to quickly 6
source a rig or rapidly retrieve ESPs would result
in deferred production of up to 9,000 bbl for each 4
heavy workover required.
Technologies 2
■ ZEiTECS Shuttle* rigless ESP replacement
system with motor connector, docking station,
0
and wet connectors Conventional ESP replacement Rigless ESP replacement with ZEiTECS Shuttle system
■ Standard 450 /400 series ESP
In response to this challenge, the 550 series ZEiTECS Shuttle system was installed
■ Retrievable ESP gauge in the well with a standard 450 /400 series ESP. The ESP ran for 72 days when it experienced
Standard completion equipment below an unexpected failure. After the initial response, the ZEiTECS Shuttle system was used to
slb.com/zeitecs

ZEiTECS Shuttle system docking station riglessly replace the ESP on coiled tubing in 1 day, 21 hours, and 15 minutes.
*Mark of Schlumberger
Copyright © 2015 Schlumberger. All rights reserved. 15-AL-41922

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Alternative Deployment | Technology 61
Coiled Tubing ESP Cable
For the REDA Coil coiled-tubing-deployed ESP system
APPLICATIONS The REDA Coil system’s coiled tubing ESP cable consists of a
■ REDA Coil* coiled-tubing-deployed length of coiled tubing in which an ESP power cable has been
ESP system preinstalled. The cable is supported inside the coiled tubing by
Coiled tubing
friction. A patented slack-management technique is used to ESP cable
BENEFITS install the cable.
■ Enables ESP system deployment using
standard coiled tubing equipment Preinstalling the power cable in the coiled tubing enables
■ Maintains isolation from well fluid the ESP system to be deployed with standard CT equipment,
chemical attacks and pressure cycles eliminates the need for cable protectors or bands on the tubing
string, and isolates the cable from well fluid chemical attacks
■ Eliminates use of cable protectors or
and pressure cycles.
bands on the tubing string
■ Enables control of completion accessories The power cable and coiled tubing are connected to the top
with option to include additional ¼-in or of the ESP string by the REDA Coil system’s lower connector.
3
⁄8-in capillary lines, hydraulic lines, or At the surface, the coiled tubing is made up to a coiled tubing
both, within the coiled tubing hanger that is landed in the wellhead. The ESP cable is
terminated to a wellhead penetrator for connection to a surface
FEATURES cable.
■ 23⁄8-in HS80 or HS90 coiled tubing
■ 0.175-in, 0.190-in, and 0.204-in coiled The coiled tubing commonly used with the #2 REDA MAX* ESP
tubing wall thickness selection electrical power cable is 23⁄8 in; other sizes of both the coiled
tubing and the ESP cable are possible.
■ Wide range of ESP cables with various
power requirements Additional hydraulic lines can be run with the ESP cable
inside the coiled tubing to control other downhole completion
equipment, including deepset safety valves and chemical
injection valves.

REDA Coil system string with coiled


tubing ESP cable.

slb.com/redacoil
*Mark of Schlumberger
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Alternative Deployment | Technology 62
Surface Electrical Equipment

Pump control for ESPs and surface pumping systems Variable speed drives
Schlumberger offers a complete line of surface electrical equipment specifically ■■ Enable pump performance across a wider operating range
tailored to applications involving ESPs and surface pumping systems. Field than typical by varying their speed; available in both low voltages
measurements and computer modeling are used to select and deliver products and medium voltages.
customized to your well.
Fixed speed drives
■■ Provide motor control, protection, and monitoring in low- to
medium-voltage switchboards.

Surface equipment controllers


■■ Eliminate the need for multiple surface components with all wellsite
control, surface, and downhole data acquisition functions in a
single interface.

Table of Contents Previous page Next page 63


SpeedStar 519 SWD
variable speed drive
18-pulse, low-voltage sine wave variable-speed
APPLICATIONS The SpeedStar 519 SWD* 18-pulse low-voltage sine wave VSD features the integral output sine wave filter
■ ESP operations technology for operating ESPs and surface pumps and meets IEEE 519 1992 guidelines. Many engineering
■ Surface pumping operations consulting firms consider this design to be the most effective and reliable because it virtually eliminates
harmonic distortion reflected back to the power system and provides clean power to the downstream device.
BENEFITS
■ Increases power efficiency
■ Reduces harmonic reflection on supply
power system
■ Prolongs run life of electrical systems
■ Lowers operating and installation costs
■ Reduces overall footprint
■ Protects against lightning strikes and
voltage surges
■ Simplifies installation with three-wire input
and three-wire output

FEATURES
■ No external phase shifting transformer
requirement; direct replacement for existing
6-pulse installations
■ TUV third-party-certified IP-56 enclosure
■ IEEE 519-compliant variable-speed drive
(VSD)
■ Integral phase-shifting auto transformer
■ Near unity power factor throughout all ESP
speed and load ranges
■ Output harmonic mitigation
■ Speed control to maintain constant load or
pressure
■ Smooth restart of a spinning motor
■ Rocking start for pumps stuck because of
sanding or scaling
■ Load-side, phase-to-phase, short-circuit
protection
The SpeedStar 519 SWD VSD combines integral output sine wave technology and meets IEEE 519 guidelines.
■ StarShield* transient voltage surge
suppressor for protection against lighting
strikes and voltage surges
■ Sine wave output filter

Table of Contents Previous page Next page


Surface Equipment | Technology 64
SpeedStar 519 SWD
Input harmonics SpeedStar 519 SWD VSD Specifications
The drive system is fitted with an innovative Control system Flux-vector PWM, V/Hz control
phase-shifting auto transformer that enables Input supply 380–480 V ±10%, 50/60 Hz ±2 Hz
■ reducing the harmonic distortion reflected Output voltage regulation Same as power supply
back to the power system within Frequency setting 0.01 to 90 Hz, 0.01-Hz resolution
IEEE 519 limits Non-SWD (PWM) 0.5 to 3.0 kHz (user adjustable) carrier frequency
■ improving electrical power Sine wave drive VSD 2.2-kHz carrier frequency fixed
system efficiency and utilization. Input configuration 18-pulse integral phase shifting transformer with diode front end
Inverter efficiency > 97% at full load
Typical low-voltage systems reflect back Power factor > 0.98 at full load
up to 25% current harmonic distortion. The Overload rating 120% for 60 s; 100% continuous
SpeedStar 519 SWD VSD effectively reduces Certification and standards UL-508
the amount of current harmonic distortion on
the power system typically by 80%, virtually
eliminating the harmonic reflection back to
the power system. The reduction in harmonic SpeedStar 519 SWD VSD Enclosure and Environmental Ratings
content dramatically improves the efficiency Enclosure rating NEMA 1 (indoor)† or NEMA 3R (outdoor) or IP-56 (optional)
and usability of the electrical power system. The Electronic section Sealed from outside air and cooled by heat exchanger
drive also features a third-party-certified IP-56 Transformer section Forced air cooled (automatic internal and external fans)
enclosure that meets strict standards for water Maximum altitude, ft [m] 4,921 [1,500] above sea level; output rating derated above
and dust ingress in harsh conditions. maximum altitude
Ambient operating temperature, degF [degC] –22 to 122 [–30 to 50]; output rating derated above
upper temperature
Ambient storage temperature, degF [degC] –40 to 140 [–40 to 60]
Relative humidity 20 to 95% maximum (noncondensing)
H2S protection Uses conformal coated circuit boards and tin-plated bus bars
Material 12-gauge carbon steel enclosure‡

Dimensions and specifications provided on request

Stainless steel provided on request

slb.com/speedstar

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Other company, product, and service names
are the properties of their respective owners.
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Surface Equipment | Technology 65
SpeedStar 2000 Plus & SpeedStar SWD
Variable speed drives
APPLICATIONS SpeedStar* variable-speed drives (VSDs) include
■ ESP operations many standard features to protect and control ESPs
■ Surface pumping operations and surface pumping systems for variable-speed
applications. Two configurations are available:
BENEFITS SpeedStar 2000 Plus* VSD and SpeedStar SWD*
■ Prolongs electrical system life VSD. The SpeedStar 2000 Plus drive is used
■ Reduces operating costs typically with surface pumping systems. The
■ Minimizes downtime SpeedStar SWD VSD, which has an integral output
sine wave filter, is typically used with ESPs. The
FEATURES output voltage wave form is similar to that of a true
■ Speed control to maintain constant load sine wave and thus results in less voltage stress
or pressure and a longer life for the motor, cable, and other
■ Ability to start an ESP while motor electrical components.
is spinning
The use of a VSD allows a pumping system to
■ Rocking start, used to start wells with perform across a wider operating range than is
stuck pumps possible using a fixed-speed drive (FSD) because
■ Programmable automatic load reduction of the VSD’s ability to vary the speed of the motor.
(soft-stall function) Optimum producing conditions can be preset and
■ StarShield* transient voltage surge maintained by automatically adjusting the speed to
suppressor for protection against lightning a preset drawdown pressure or load. Making this
strikes and voltage surges adjustment decreases the need to resize a pump
as operating conditions change. It thus reduces SpeedStar SWD VSD.
■ Load-side, phase-to-phase, downtime and operating costs.
short-circuit protection The modular, customizable controller provides
■ Sine wave output filter Enhanced operation and protection ■ a single point for all wellsite data

Standard features enhance downhole and surface gathering, including data from a
■ Hall-effect high-frequency response
operations. The rocking-start function switches the Phoenix* artificial lift downhole
current transformer for current sensing
motor direction back and forth to start units that monitoring system
are stuck, particularly in abrasive environments. ■ ability to start an ESP while motor is
The current-pressure mode allows pumps to be spinning
set to a target load or pressure and their speed
■ setting of alarms and parameters for
to be adjusted as operating conditions change.
auto restart
This flexibility in speed helps stabilize operations
in gassy and viscous environments, and it ■ programmable automatic load reduction
maximizes uptime. (soft-stall function)
■ user-adjustable long acceleration curve
SpeedStar VSDs use the Instruct* all-in-one
to prevent sand production.
acquisition and control unit as the single
user interface for all wellsite control and data SpeedStar VSDs are provided in NEMA 1–
acquisition requirements. The Instruct unit’s (indoor) and NEMA 3R–rated (indoor or outdoor)
expandable functionality optimizes data gathering, enclosures. For outdoor use, the NEMA 3R has all
remote monitoring, and controls related to its electronic components located inside a sealed
downhole and surface pumping operations. (NEMA 4) section of the drive enclosure with no
exchange of outside cooling air. It is suitable for
use in subzero and high-temperature submersible
pump climates, operating in temperatures ranging
from –30 degC to 50 degC [–22 degF to 122 degF].

Table of Contents Previous page Next page


Surface Equipment | Technology 66
SpeedStar 2000 Plus & SpeedStar SWD
SpeedStar 2000 Plus VSD and SpeedStar SWD VSD Specifications SpeedStar 2000 Plus VSD and SpeedStar SWD VSD Environmental Ratings
Control system Flux-vector PWM, V/Hz control Enclosure rating NEMA 1 (indoor) or NEMA 3R (outdoor)
Input supply 380 to 480 V ±10%, 50 or 60 Hz ±5% Cooling method Electronic section: sealed from outside air (NEMA 4 section) and
cooled by heat exchanger
Output voltage regulation Same as power supply Sine wave filter section: air–cooled
Frequency setting 0.01 to 120 Hz, 0.1-Hz resolution Max. altitude, ft [m] 3,280 [1,000] above sea level; output rating derated above upper
PWM carrier frequency SpeedStar 2000 Plus VSD: 0.5 to 3.0 kHz temperature
(user-adustable) SpeedStar SWD VSD: 2.2 kHz Ambient operating –22 to 122 [–30 to 50]; output rating derated above upper
Input configuration Diode, 6- or 12-pulse temperature, degF [degC] temperature
Efficiency >98% at full load Ambient storage temperature, –40 to 140 [–40 to 60]
degF [degC]
Power factor >0.97 at full load
Relative humidity 20% to 95% maximum (noncondensing)
Overload rating 120% for 60 s, 100% continuous
H2S protection Conformal-coated circuit boards and tin-plated bus bars
Certification and standards UL-508, CE (with addition of
compliance electromagnetic interference filter at Material 12-gauge carbon steel enclosure†
drive input) †
Stainless steel available on request

SpeedStar 2000 Plus VSD and SpeedStar SWD VSD 6- and 12-Pulse Specifications
Output Rating Ambient SpeedStar 2000 Plus VSD Dimensions SpeedStar SpeedStar SWD VSD Dimensions SpeedStar
Temperature (H × W × D), in [cm] 2000 Plus VSD (H × W × D), in [cm] SWD VSD
A kVA at kVA at Rating, NEMA 3R NEMA 1 Approximate NEMA 3R NEMA 1 Approximate
480 V 380 V degF [degC] Weight, lbm [kg] Weight, lbm [kg]
79 66 52 122 [50] 81.50 × 25.00 × 35.00 81.50 × 25.06 × 33.00 1,000 na† na na
[207 × 63.5 × 89] [207 × 63.7 × 83.4] [453.6]
100 83 66 122 [50] 81.50 × 25.00 × 35.00 81.50 × 25.06 × 33.00 1,000 na na na
[207 × 63.5 × 89] [207 × 63.7 × 83.4] [453.6]
132 110 87 122 [50] 81.50 × 25.00 × 35.00 81.50 × 25.06 × 33.00 1,000 99.50 × 25.00 × 35.00 99.50 × 25.06 × 33.00 1,500
[207 × 63.5 × 89] [207 × 63.7 × 83.4] [453.6] [252.7 × 63.5 × 89] [252.7 × 63.7 × 83.4] [680]
156 130 103 122 [50] 81.50 × 31.50 × 35.00 81.50 × 25.06 × 33.00 1,000 99.50 × 31.50 × 35.00 99.50 × 25.06 × 33.00 1,500
[207 × 80 × 89] [207 × 63.7 × 83.4] [453.6] [252.7 × 80 × 89] [252.7 × 63.7 × 83.4] [680]
196 163 129 122 [50] 81.50 × 31.50 × 35.00 81.50 × 25.06 × 33.00 1,000 99.50 × 31.50 × 35.00 99.50 × 25.06 × 33.00 1,500
[207 × 80 × 89] [207 × 63.7 × 83.4] [453.6] [252.7 × 80 × 89] [252.7 × 63.7 × 83.4] [680]
241 200 158 122 [50] 81.50 × 31.50 × 35.00 81.50 × 25.06 × 33.00 1,000 99.50 × 31.50 × 35.00 99.50 × 25.06 × 33.00 1,500
[207 × 80 × 89] [207 × 63.7 × 83.4] [453.6] [252.7 × 80 × 89] [252.7 × 63.7 × 83.4] [680]
313 260 206 122 [50] 81.50 × 46.00 × 42.00 81.50 × 37.06 × 40.00 1,200 99.50 × 46.00 × 42.00 99.50 × 37.06 × 40.00 2,000
[207 × 117 × 107] [207 × 94 × 101.6] [544] [252.7 × 117 × 107] [252.7 × 94 × 101.6] [907]
469 390 309 122 [50] 81.50 × 46.00 × 42.00 81.50 × 37.06 × 40.00 1,200 99.50 × 46.00 × 42.00 99.50 × 37.06 × 40.00 2,000
[207 × 117 × 107] [207 × 94 × 101.6] [544] [252.7 × 117 × 107] [252.7 × 94 × 101.6] [907]
546 454 359 122 [50] 81.50 × 46.00 × 42.00 81.50 × 37.06 × 40.00 1,200 99.50 × 46.00 × 42.00 99.50 × 37.06 × 40.00 2,000
[207 × 117 × 107] [207 × 94 × 101.6] [544] [252.7 × 117 × 107] [252.7 × 94 × 101.6] [907]
623 518 410 104 [40] 81.50 × 46.00 × 42.00 81.50 × 37.06 × 40.00 1,200 99.50 × 46.00 × 42.00 99.50 × 37.06 × 40.00 2,000
[207 × 117 × 107] [207 × 94 × 101.6] [544] [252.7 × 117 × 107] [252.7 × 94 × 101.6] [907]
623 518 410 122 [50] 81.50 × 90.00 × 48.00 81.50 × 72.00 × 46.00 2,000 99.50 × 90.00 × 48.00 99.50 × 72.00 × 46.00 3,100
[207 × 229 × 122] [207 × 183 × 117] [907] [252.7 × 229 × 122] [252.7 × 183 × 117] [1,406]
722 600 475 122 [50] 81.50 × 90.00 × 48.00 81.50 × 72.00 × 46.00 2,000 99.50 × 90.00 × 48.00 99.50 × 72.00 × 46.00 3,100
[207 × 229 × 122] [207 × 183 × 117] [907] [252.7 × 229 × 122] [252.7 × 183 × 117] [1,406]
842 700 554 122 [50] 81.50 × 90.00 × 48.00 81.50 × 72.00 × 46.00 2,000 99.50 × 90.00 × 48.00 99.50 × 72.00 × 46.00 3,100
[207 × 229 × 122] [207 × 183 × 117] [907] [252.7 × 229 × 122] [252.7 × 183 × 117] [1,406]
980 815 645 122 [50] 81.50 × 90.00 × 48.00 81.50 × 72.00 × 46.00 2,000 99.50 × 90.00 × 48.00 99.50 × 72.00 × 46.00 3,100
[207 × 229 × 122] [207 × 183 × 117] [907] [252.7 × 229 × 122] [252.7 × 183 × 117] [1,406]
1,121 932 738 122 [50] 81.50 × 90.00 × 48.00 81.50 × 72.00 × 46.00 2,000 99.50 × 90.00 × 48.00 99.50 × 72.00 × 46.00 5,000
[207 × 229 × 122] [207 × 183 × 117] [907] [252.7 × 229 × 122] [252.7 × 183 × 117] [2,268]
1,203 1,000 792 122 [50] 81.50 × 90.00 × 48.00 81.50 × 72.00 × 46.00 2,000 99.50 × 90.00 × 48.00 99.50 × 72.00 × 46.00 5,000
[207 × 229 × 122] [207 × 183 × 117] [907] [252.7 × 229 × 122] [252.7 × 183 × 117] [2,268]
1,443 1,200 950 122 [50] 81.50 × 110.00 × 48.00 81.50 × 84.00 × 46.00 3,500 99.50 × 110.00 × 48.00 99.50 × 84.00 × 46.00 5,000
[207 × 279 × 122] [207 × 213 × 117] [1,588] [252.7 × 279 × 122] [252.7 × 213 × 117] [2,268]
1,684 1,400 1,108 104 [40] 81.50 × 110.00 × 48.00 81.50 × 84.00 × 46.00 3,500 99.50 × 110.00 × 48.00 99.50 × 84.00 × 46.00 5,000
[207 × 279 × 122] [207 × 213 × 117] [1,588] [252.7 × 279 × 122] [252.7 × 213 × 117] [2,268]
1,804 1,500 1,188 104 [40] 81.50 × 110.00 × 48.00 81.50 × 84.00 × 46.00 3,500 99.50 × 110.00 × 48.00 99.50 × 84.00 × 46.00 5,000
[207 × 279 × 122] [207 × 213 × 117] [1,588] [252.7 × 279 × 122] [252.7 × 213 × 117] [2,268]

Not available.
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Other company, product, and service names
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Surface Equipment | Technology 67
SpeedStar MVD NEMA 1
Medium-voltage
Medium-voltagevariable
variablespeed
speeddrive—NEMA 1 for
drive—NEMA indoor
1 for applications
indoor applications
APPLICATIONS The SpeedStar MVD* medium-voltage variable
■ High-horsepower, variable-speed ESP and speed drive (VSD) is a NEMA 1 medium-voltage
surface electric motor applications, with drive (MVD) for the control of ESPs and surface
the drive installed in a climate-controlled electric motor-driven applications. It is the only
environment MVD in the industry available in multiple sizes. It
includes a fused disconnect switch, inbuilt copper
BENEFITS
isolation transformer with precharge circuitry to
■ Reduces operating costs
reduce inrush current and maintain transformer
■ Extends ESP system run life reliability on startups, and input vacuum contactors
■ Enhances operational safety with a 10-year mean time between failures—all
■ Optimizes space usage within an innovative footprint customized for tight
indoor spaces.
FEATURES
■ Plug-and-play sine wave output filter Design and operation
(for ESP applications) Unlike other designs, the control circuit topology
of the SpeedStar MVD VSD uses just three-phase
■ Multilevel pulse-width modulated (PWM)
output power cells and provides high performance,
inverter output with no neutral point shift,
which translates to low maintenance costs and
suitable for surface electric motors
simple troubleshooting and repair. The modular
■ Input power factor of 0.96 at all loads and vertical design of this VSD has the smallest
speeds The NEMA 1 version of the SpeedStar MVD VSD is
footprint in the industry, enabling quick power module intended for indoor use and can supply 500 to 2,500 hp.
■ Built-in, visible, fused disconnect switch interchangeability via rack-out power modules.
■ Built-in 24-pulse input transformer with
The main power circuit uses input diodes and insulated gate bipolar transistor (IGBT) technology at the
precharge circuitry
output, a highly reliable way to control speed in medium- and low-voltage drives. The reduction in overall
■ Ability to perform a smooth restart of a system energy consumption is as much as 6% compared with equivalent low-voltage systems.
spinning motor
■ Programmable automatic load reduction The drive provides precise motor control by using full-wave diode rectification, a constant-voltage DC bus, and
(soft-stall function) IGBT inversion. The inverter output is a multilevel PWM waveform with no neutral point shift. Coupled with a
patented integral output sine wave filter, it allows the drive to be used with standard ESP motors and cables
■ Speed control to maintain constant load or that typically have 5-kV–rated insulation, ensuring reliability and prolonging run life.
pressure
■ Rocking start for wells where the pumps The control system features a reduced chip count, which provides high performance and reliability, and
have stalled because of scale or sand both Volts-per-Hertz (V/Hz) and vector control capabilities. V/Hz is the preferred control method due to
its easy setup and flexibility during operation. In addition to target frequency, pressure or current control
■ Micro Series line available for even smaller
mode automatically adjusts the speed of the drive on the basis of predetermined set points.
footprints
■ Instruct* all-in-one acquisition and control
unit for control of the SpeedStar MVD VSD,
downhole tools, SCADA system, and
Liftwatcher* real-time surveillance service

Table of Contents Previous page Next page


Surface Equipment | Technology 68
SpeedStar MVD
SpeedStar MVD VSD Models and Dimensions NEMA 1 (3.3- to 6.6-kV input and up to 4.5-kV output‡)
Output rating, A 62 74 87 99 112 124 155 186 217 248
Output power at 4,160 V and 60Hz, 447 536 625 715 804 893 1,116 1,340 1,536 1,786
kVa [hp] [500] [600] [700] [800] [900] [1,000] [1,250] [1,500] [1,750] [2,000]
Standard MVD Dimensions 103.7 × 74 × 43.4 [263.4 × 188.0 × 110.3] 103.7 × 122 × 43.4 [263.4 × 309.9 × 110.3]
footprint with sine (H × W × D), in [cm]
wave filter Weight, 7,160 7,380 7,610 7,910 8,210 9,010 11,830 12,630 13,530 14,180
lbm [kg] [3,248] [3,348] [3,452] [3,588] [3,274] [4,087] [5,366] [5,729] [6,137] [6,432]
Micro Series MVD Dimensions 103.7 × 48 × 48 103.7 × 60 × 48 [263.4 × 152.4 × 121.9] 103.7 × 90 × 48 [263.4 × 228.6 × 121.9]
footprint without sine (H × W × D), in [cm] [263.4 × 121.9 × 121.9]
wave filter Weight, 6,000 6,200 7,000 7,200 7,400 7,600 10,400 10,600 10,800 12,000
lbm [kg] [2,722] [2,813] [3,175] [3,266] [3,357] [3,448] [4,718] [4,808] [4,899] [5,444]
Micro Series MVD Dimensions 103.7 × 48 × 48 103.7 × 60 × 48 [263.4 × 152.4 × 121.9] 103.7 × 112 × 48 [263.4 × 281.9 × 121.9]
footprint with sine (H × W × D), in [cm] [263.4 × 121.9 × 121.9]
wave filter Weight, 6,440 6,640 7,580 7,840 8,040 8,240 11,780 12,580 13,480 14,130
lbm [kg] [2,921] [3,012] [3,438] [3,556] [3,647] [3,738] [5,343] [5,706] [6,115] [6,409]

Power System Specifications


Control system Sinusoidal multilevel PWM control
Control precision ± 0.5% of maximum output frequency
Base control system V/Hz, sensorless vector control, variable torque, closed-loop vector control, constant torque
Efficiency 96.5% (total system), 98% (inverter)
Input power factor 0.96
Overload capacity 115% for 60 s, 100% continuous (in some models, overload capacity is 110% for 60 s)
Input voltage supply 2,400 to 13,800 V,† 50/60 Hz
Input tolerance Voltage: ±10%; Frequency: ±5%
Output Voltage: 0 to 4.5 kV; Frequency: 0 to 120 Hz
Main input power Three-phase input isolation transformer, 24-pulse design with visible input fused disconnect
and precharge circuitry
Control power supply Integral to main transformer: three-phase 480-V, 50/60-Hz, 20-kVA capacity via tertiary winding; 15 kVA
available for other uses
Internal protective functions Current limit, overcurrent, overcharge, overload, undervoltage, overvoltage, ground fault,
CPU error, abnormal cooling
PWM carrier frequency 2.048 kHz
Output transistor type IGBT
Applicable standards Electrical performance: NEC, ANSI
Components and others NEC, NEMA, UL, cUL, and CE

Requires addition of high-voltage circuit breaker at front end if higher than 6.6 kV

Construction Specifications
Panel construction Free-standing, front-maintenance type with channel base
Cooling Forced air cooled with optional redundant fan
Air filter Front-mounted, aluminum, washable, screened
Paint and color Gavlon 841, 2-mil minimum, UL1332 compliant, ANSI-61 gray

Enclosure and Environmental Ratings


Type NEMA 1–rated, IP20, IEC-529, gasketed, and filtered
Ambient temperature operating range, degF [degC] 14 to 104 [–10 to 40]; output rating derated above upper temperature
Ambient temperature storage range, degF [degC] –7 to 140 [–14 to 60]
Humidity 95% maximum (noncondensing)
Max. altitude, ft [m] 3,300 [1,000] above mean sea level
Vibration 0.5 gn or less at 10 to 50 Hz
Installation Indoor, no direct sunlight, protected against corrosive and explosive gases

In some models, the MVD must be derated beyond 4.16 kV

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Surface Equipment | Technology 69
SpeedStar MVD NEMA 3
Medium-voltage variable speed drive for outdoor applications
APPLICATIONS
■ Outdoor high-horsepower,
variable-speed ESP, and surface
electrical motor applications

BENEFITS
■ Reduces operating costs
■ Improves ESP system run life
■ Enhances operational safety

FEATURES
■ Plug-and-play design with integral output
sinewave filter (for ESP applications)
■ Multilevel pulse-width modulated (PWM)
inverter output with no neutral point shift
■ Input power factor of 0.96 at all loads and
speeds
■ Flexible input voltage design
■ Built-in, visible, fused isolation switch
■ 36-pulse input transformer with precharge
circuitry
■ Distribution-class lightning arrestors SpeedStar MVD VSD NEMA 3R for outdoor installations from 500 hp to 1,500 hp.
■ Ability to perform a smooth restart on or
catch a spinning motor The SpeedStar MVD* medium-voltage variable speed drive (VSD) is a NEMA 3R medium-voltage
■ Speed control to maintain constant load drive (MVD) suitable for outdoor installations. This drive is designed for the control of ESPs
or pressure and surface pumping systems. It provides a high-reliability, high-efficiency control solution for
high-horsepower, high-value applications in a single package. Energy consumption is reduced by
■ Rocking start for wells where the pumps
approximately 2% over a similar low-voltage VSD because a step-up transformer is not required. It is
have stalled because of scale or sand
the first MVD in the industry that does not require installation in a climate-controlled environment,
■ Available 500-hp configurations and above making it suitable for remote applications where building infrastructure is nonexistent. An optional
■ Instruct* all-in-one acquisition and control marine version is available for outdoor use in both nonhazardous and harsh environments typical with
unit platforms or offshore applications.

Design and operation


The outdoor SpeedStar MVD VSD features innovative safety and enclosure designs and power section
topology with no moving parts. For input voltages between 3.3 kV and 6.6 kV, the input transformer
section is dry-type convection cooled, with heat dissipated through passive vents at the top of the drive.
The dry-type input transformer is available in sizes up to 13.8 kV with additional high-voltage input
sections. For other voltages, an optional liquid-filled transformer suitable for outdoor installations can
be used for input voltages between 0.38 kV and 34.5 kV. This flexible alternative input voltage design
ensures there is never a need for an additional input transformer to minimize losses, improving system
efficiency.

The SpeedStar MVD VSD is the first MVD with a standard design featuring an integral main isolation
switch for lockout and tagout. The switch includes KIRK® key coordination and precharge circuitry, which
ensures an infinite number of MVD starts while maintaining transformer and overall equipment reliability.
The inverter section power modules are mounted on heat sinks on the back of the unit to dissipate heat to
the atmosphere.

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Surface Equipment | Technology 70
SpeedStar MVD
SpeedStar MVD VSD Models and Dimensions (with 3.3- to 6.6-kV input and up to 4.5-kV‡ output)
Output rating, A 62 124 186 248
Output power at 4.16 kV, kVa [hp] 447 [500] 893 [1,000] 1,340 [1,500] 1,786 [2,000]
107 × 168 × 63 107 × 168 × 63 107 × 168 × 63 107 × 222 × 72
Dimensions (H × W × D), in [cm]
[272 × 427 × 160] [272 × 427 × 160] [272 × 427 × 160] [271.8 × 563.9 × 182.8]
Weight, lbm [kg] 15,000 [6,804] 15,000 [6,804] 15,000 [6,804] 24,500 [11,113]
SpeedStar MVD VSD Models and Dimensions (with 34.5-kV† input and up to 4.5-kV‡ output)
Output rating, A 62 124 186
Output rating at 4,160 V, kVa [hp] 500 [447] 1,000 [893] 1,500 [1,340]
96 × 252 × 63 96 × 240 × 63 96 × 240 × 63
Dimensions (H × W × D),§ in [cm]
[244 × 640 × 160] [244 × 609 × 160] [244 × 609 × 160]
Weight,§ lbm [kg] 34,000 [15,422] 34,000 [15,422] 34,000 [15,422]
Power System Specifications
Control system Sinusoidal multilevel PWM control
Control precision ±0.5% of maximum output frequency
Base control system V/Hz, sensorless vector control, variable torque, closed-loop vector control, constant torque
Efficiency 96.5% overall
Input power factor 0.96
Overload capacity 115% for 60 s, 100% continuous
Input voltage supply 3.3 kV to 13.8 kV, 50/60 Hz (dry-type transformer) or 0.38 kV to 34.5 kV, 50/60 Hz user specified (liquid-filled transformer)
Input tolerance Voltage: ±10%; Frequency: ±5%
Output Voltage: 0 to 4,160/4,500 V; Frequency: 0 to 120 Hz
Main input power Three-phase input isolation transformer, 36-pulse design with visible input fused isolation switch (optional for liquid-filled transformer
>6.6 kV) and precharge circuitry
Control power supply 2-kVA control power transformer providing 110 V
Internal protective functions Current limit, overcurrent, overcharge, overload, undervoltage, overvoltage, ground fault, CPU error, internal RTDs for
temperature monitoring
PWM carrier frequency 2.048 kHz
Output transistor type Medium-voltage IGBT
Applicable standards Electrical performance: NEC, ANSI
Components and others NEC, NEMA, UL,†† cUL††
Construction Specifications
Panel construction Free-standing, front-maintenance type, back or bottom access for motor and input power cables
Two sections: input transformer section and inverter section
Cooling Dry-type transformer section, convection cooled; heat eliminated through passive vents at top of drive
Liquid-filled transformer section type, ONAN cooled
Inverter section: power modules mounted on heat sinks, forced air cooled and cooled using plate-type heat exchangers
Paint color Bright white
Environmental Ratings
Overall enclosure type NEMA 3R rated, gasketed††, or filtered outdoor MVD with liquid-filled transformer‡‡
Ambient temperature operating range, –13 to 122 [–25 to 50]‡‡
degF [degC]
Ambient temperature storage range, –22 to 140 [–30 to 60]‡‡
degF [degC]
Humidity 95% maximum (noncondensing)
Max. altitude, ft [m] 3,300 [1,000] above sea level or less
Vibration 0.5 g or less at 10–50 Hz
Installation Outdoor, nonhazardous, noncorrosive environment
†For other input voltages, dimensions and weights will be advised per project.
‡In some models, the MVD must be derated beyond 4.16 kV.
§All dimensions and weights are approximate.

†† Available with up to 6.6-kV input with dry-type transformers.


‡‡ For MVDs with liquid-filled transformers, temperature is variable, as specified on order. slb.com/speedstar

*Mark of Schlumberger
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Copyright © 2015 Schlumberger. All rights reserved. 15-AL-43886

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Surface Equipment | Technology 71
VariStar
Variable speed drive
APPLICATIONS The VariStar* variable-speed drive (VSD) is specifi-
■ Variable-speed ESP and surface cally tailored for controlling and protecting ESPs
pumping applications and surface pumps. Available in several models, the
VariStar VSD can be used with both surface pump-
BENEFITS ing systems and ESPs. The output voltage wave
■ Reduces downtime form is similar to that of a true sine wave and thus
■ Prolongs electrical system life results in less voltage stress and a longer life for
■ Minimizes operating costs the motor, cable, and other electrical components.
VSDs enable pumps to perform across a wider
FEATURES operating range by varying their speed. A unit’s op-
■ Plug-and-play system that eliminates the timum performance can be preset or automatically
need for wellsite adjustment adjusted to avoid no-flow and cycling conditions.
■ Expandable platform to accommodate addi- The VariStar VSD reduces the need to change out
tional protection and system requirements pump components as operating conditions change,
■ Pulse-width modulation (PWM) output thereby reducing downtime and operating costs
waveform or sine wave output waveform and contributing to
a longer system run life.
■ Load-side, phase-to-phase, short-circuit
protection Enhanced performance
■ Ability to start an ESP while motor is spinning The VariStar VSD provides state-of-the-art motor A 200-kVA [241-A] VariStar VSD with sine wave harmonic
■ Programmable automatic load reduction control incorporating advanced digital PWM flux output filter compartment at bottom of cabinet and optional
vector control that ensures constant speed and light receptacle package.
(soft-stall function)
torque. It also provides for higher torque per amp, Modularity and flexibility
■ Speed control to maintain constant load and less motor heating, and reduced torque pulsation.
pressure Optional modular components can be added to
Current sensing using a Hall-effect high-frequency- the VariStar VSD to enhance field operations and
■ Rocking start, used to start wells with stuck response current transformer ensures motor system protection. They include
pumps resulting from scale or sand problems stability. The VariStar VSD increases a system’s
■ space heater to prevent humidity buildup inside
■ Momentary power failure ride-through power factor substantially over one driven using
the drive and ensure long-term operation in
Air intake filter that prevents entry of a fixed-speed drive, and it decreases a system’s

high-humidity areas
blowing rain (at angles greater than 45°) electrical stress at startup to as low as 1.5 times
the operating motor current. Each size is heat-run- ■ StarShield* transient voltage surge suppressor
■ Hall-effect high-frequency-response current tested at full load and maximum ambient tempera- to protect the VariStar VSD and connected pump
transformer for current sensing ture to ensure proper operation at maximum rating. against lightning strikes and voltage surges
PROTECTION FEATURES ■ light and utility receptacles to enable the use of
Increased system run life additional electrical instruments in the field.
■ Main circuit overcurrent at startup For submersible motors used at extreme depths,
■ Heat-sink and enclosure overtemperature the VariStar VSD offers an automated plug-and- Enhanced operation and protection
play sine wave drive (SWD) with a harmonic output The VariStar VSD uses the UniConn* universal site
■ Open output phase
filter that eliminates problems related to reso- controller as a single user interface for all wellsite
■ Electronic thermal overload protection controller and data acquisition requirements. The
nance. The patented filter pushes the resonance
■ Soft stall: automatic load reduction during band of the downhole system below the drive’s modular, customizable controller provides for
overload with user-adjustable settings carrier frequency, eliminating excessive resonance ■ speed control in frequency, current, and
■ DC bus overvoltage/undervoltage and minimizing voltage overshoots, regardless of pressure modes
■ Regeneration power ride-through variations in cable length, motor type, and trans- ■ ability to start an ESP while motor is spinning
Momentary power failure ride-through former taps selected. The output voltage waveform
■ ■ setting of alarms and parameters for
is similar to a true sine wave and thus results
automatic restart
in less voltage stress and longer life for the motor,
cable, and other electrical components.
■ automatic speed reduction
■ remote wellsite data gathering, monitoring,
surveillance, and control.

Table of Contents Previous page Next page


Surface Equipment | Technology 72
VariStar
Standard features Optional features Monitored parameters Protection set points
■ Input circuit breaker disconnect ■ Three-phase current transformer ■ Current: drive, measured; motor, ■ Overload with time-response
with 100-kAIC–rated fuses for three-phase current calculated (three-phase mea- curve, underload, tracking
■ Diode front-end converter monitoring surement optional) underload, imbalance (optional)
■ Insulated-gate bipolar transistor ■ Potential transformers for three- ■ Input voltage: drive, calculated, ■ Overvoltage, undervoltage with
inverter phase voltage monitoring three-phase (optional) time-response curve, rotation
Output voltage: drive, calculated, (all optional)
■ Heat-sink–mounted power com- ■ Expansion cards ■

ponents with forced air cooling three-phase (optional) ■ High/low supply voltage with
■ Light and 110-/220-V utility
Supply voltage time-response curve
■ Hall-effect current transformer receptacle powered by a 1-kVA ■

sensing device potential transformer ■ Power: drive input and output, ■ Backspin, leg ground (optional)
■ UniConn universal site controller ■ Sine wave output harmonic filter running frequency
■ Weatherproof gasketed door with ■ Backspin frequency, leg ground
three-point padlockable latch (optional)
■ Lifting eyebolts

VariStar VSD PWM Output


Output rating, kVA at 480/380 V 200/158 390/309 518/410
Output rating, A 241 469 623
Ambient temperature, degF [degC] 14 to 122 [–10 to 50] 14 to 122 [–10 to 50] 14 to 104 [–10 to 40]
Dimensions, H × W × D, in [cm] 81.5 × 35.5 × 35 [207 × 90.2 × 89] 81.5 × 45.5 × 42 [207 × 115.6 × 106.7] 81.5 × 45.5 × 42 [207 × 115.6 × 106.7]
Approximate weight, lbm [kg] 1,000 [454] 1,200 [544] 1,200 [544]
VariStar VSD Sine Wave Output
Output rating, kVA at 480/380 V 200/158 390/309 518/410
Output rating, A 241 469 623
Ambient temperature, degF [degC] 14 to 122 [–10 to 50] 14 to 122 [–10 to 50] 14 to 104 [–10 to 40]
Dimensions, H × W × D, in [cm] 96 × 35.5 × 35 [243.8 × 90.2 × 89] 96 × 45.5 × 42 [243.8 × 115.6 × 107] 96 × 45.5 × 42 [243.8 × 115.6 × 106.7]
Approximate weight, lbm [kg] 1,500 [680] 2,000 [907] 2,000 [907]
VariStar VSD Principal Control Parameters
Control system PWM flux-vector, V/Hz control
Input power 380/480 V (± 10%), 50/60 Hz (± 5%)
Output voltage regulation Same as input power
Frequency setting 0.01–120 Hz, 0.01-Hz resolution
PWM carrier frequency User-adjustable: 0.5–3.0 kHz, sine wave fixed at 2.2 kHz
Input configuration 6-pulse diode only
Efficiency 98% at all loads and speeds
Power factor 96% at all loads and speeds
Overload rating 120% overcurrent for 60 s (100% continuous)
VariStar VSD Enclosure and Environmental Ratings
Type NEMA 3R-rated enclosure (outdoor); standard compliance with UL-508
Cooling method Forced air (internal and external fans)
Maximum altitude, ft [m] 3,300 [1,000] above sea level (derated above maximum altitude)
Relative humidity 20%–95% maximum (noncondensing)
H2S protection Coated circuit boards, heat sink
Material 12-gauge carbon steel enclosure

slb.com/al

*Mark of Schlumberger
Other company, product, and service names
are the properties of their respective owners.
Copyright © 2015 Schlumberger. All rights reserved. 15-AL-83443

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Surface Equipment | Technology 73
FixStar
Fixed speed drive
drives
APPLICATIONS FixStar* fixed speed drives provide electrical
■ Fixed-speed ESP installations system protection for downhole ESP systems
in fixed speed applications. It also provides an
BENEFITS
effective platform for analyzing well and pump
■ Increases safety for personnel
performance in real time. When the UniConn
■ Reduces maintenance costs controller’s expandable functionality and SCADA
enhancements are used, the FixStar drive gathers
FEATURES
data, monitors remotely, and controls ESP
■ Simplified data gathering and remote
operations.
monitoring and control of ESPs
■ Wide operating range for greater input The modular FixStar drive incorporates a fused
voltage flexibility main disconnect switch (circuit breaker) and a
■ Fault and equipment protection from vacuum (air-break) contactor that connects ESP
built-in safety features systems to the surface power supply. This design
provides maximum protection for the ESP system
■ Main disconnect that isolates personnel from
in case of major surface or downhole electrical
the high voltage
system faults. Built-in lightning arresters protect
■ Separate low- and high-voltage the ESP system from spikes in the power supply
compartments caused by lightning strikes. A control potential
■ Fused main disconnect switch (circuit transformer provides power for all instruments
breaker) with fuse and vacuum (air- housed in the FixStar drive enclosure.
break) contactor
The UniConn controller is located in a separate
■ Multitap control potential transformer low-voltage compartment isolated from the 3900-V FixStar drive low-voltage compartment equipped
■ UniConn* universal site controller high-voltage compartment that houses the drive with UniConn controller.
■ True root-mean-square (rms) three- components. The UniConn controller provides
phase current measurement extensive electrical system monitoring and
protection against both surface and downhole
■ Optional three-phase, direct-measured
electrical faults. The current transformer in
voltage monitoring
the UniConn controller, together with its
■ Backspin shunt and leg ground protection burden module, provides true rms three-phase
current monitoring. Three instrument-potential
transformers provide directly measured three-
phase voltages. The optional A095 backspin shunt
provides backspin and leg ground protection.

Some FixStar drive models have a factory-installed


Phoenix* artificial lift downhole monitoring
systems’ gauge surface choke housed in the high-
voltage compartment. This arrangement results
in a simple, compact unit with reduced footprint.
Optionally, a field-installed choke can be used.
All FixStar drive options, including a Bristol chart
recorder and pilot light set, can be preassembled
at the factory or assembled in the field. For most
applications, the FixStar drive is compatible with
the wellsite surface instruments required to
interface with the Phoenix system gauges and the
LiftWatcher* real-time surveillance service.

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Surface Equipment | Technology 74
FixStar
FixStar Fixed Speed Drive Specifications
Model 5000 3900 3300 1500
Voltage rating, V 5,000 3,900 3,300 1,500
Current rating, A 70; 130; 170; 200 70; 130; 170; 200 70; 130; 170; 200 70; 130; 170; 200
Frequency, Hz 50/60 50/60 50/60 50/60
Dimensions H × W × D, in [mm] 81 × 39 × 30.75 81 × 39 × 30.75 81 × 39 × 30.75 81 × 39 × 30.75
[2,060 × 995 × 785] [2,060 × 995 × 785] [2,060 × 995 × 785] [2,060 × 995 × 785]
Weight, lbm [kg] 1,100 [500] 1,100 [500] 1,100 [500] 1,100 [500]
Operating temperature, degF [degC] –40 to 122 [–40 to 50 ] –40 to 122 [–40 to 50 ] –40 to 122 [–40 to 50 ] –40 to 122 [–40 to 50 ]
Storage temperature, degF [degC] –58 to 158 [–50 to 70] –58 to 158 [–50 to 70] –58 to 158 [–50 to 70] –58 to 158 [–50 to 70]
Certification CE† CE CE CE
Power rating, kVA 606; 1,126; 1,472; 1,732 473; 878; 1,148; 1,351 400; 743; 972; 1,143 182; 338; 442; 520
†CE-89/336/EC (EMC Directive).

FixStar Drive Main Components


Main disconnect switch†
Power fuses‡
Vacuum contactor†,‡
Multitap control power transformer 1 kVA
Lightning arrestors
UniConn fixed speed controller†
Three current transformers (CTs) with CT burden module set
A095 backspin shunt
CSA-type 3R enclosure
Instrument potential transformers
† CSA certification.
‡ UL certification.

FixStar Optional Components


Phoenix system interface kit (UniConn controller Phoenix system card, three-phase choke and wiring)
LiftWatcher service interface kit (SCB, UniConn controller SCADA card, Phoenix system interface card (PIC) and wiring)
Bristol chart recorder kit
Pilot light kit
3900-V FixStar drive high-voltage compartment. †Available as field-installed kits.

3900-V FixStar drive low-voltage compartment.

slb.com/al

*Mark of Schlumberger
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Surface Equipment | Technology 75
SCB3
Sitecommunication
Site communicationbox
boxfor
foruse
usewith
withreal-time
real-timedata
datatransmission
transmission
APPLICATIONS The SCB3 site communication box provides simple, flexible, and secure access to real-time data from
■ Real-time data transmission and control remote wellsites located almost anywhere in the world while enabling automation and data buffering to
from remote wellsites worldwide overcome most communication outages without data loss. The SCB3 uses the high-speed BGAN satellite
network to enable remote data communication throughout most of the world.
BENEFITS
■ Saves time and costs with minimal Global communication, 24/7
maintenance requirements and small The network transmits data to Schlumberger servers, allowing web-based viewing or data extraction as
footprint required. Around-the-clock support, integrated with other Schlumberger network activities, is also available.
■ Reduces operating costs with remote
Fully assembled, standardized equipment
monitoring, equipment protection, and
The SCB3 is installed and commissioned in just hours by regular field crew and interfaces with standard
onsite automation
Schlumberger wellsite acquisition and control systems. Design and equipment standardization means
FEATURES simplicity, reduced risk, ease of maintenance, and cost efficiency at the wellsite and the location where
■ Embedded automation and production the data is received. The system is delivered fully assembled with a satellite modem, a powerful CPU
optimizaton workflows due to larger storage control board, a power supply with backup power for remote alerts, and field interface connectors inside
capacity and faster processors a small-footprint, corrosion-resistant, weatherproof enclosure.
■ Clearly labeled field connectors and Streamlined installation, customizable design
preconfigured hardware for easy installation Clearly labeled field connectors simplify installation and wiring. The hardware is preconfigured for
■ High-frequency (sub-minute) remote data standard Schlumberger acquisition and control systems. Schlumberger wellsite systems can also be
acquisition customized to integrate additional third-party equipment and sensors that can be critical for complete
■ One interface for multiple remote terminal system monitoring and analysis.
units (RTUs) The common Modbus® RTU protocol for data acquisition fully supports RS-232 and RS-485 (2-wire and
■ 24/7 support and power failure notification 4-wire) interfaces for device connection. Removable connector plugs speed installation and wiring.
system
■ Data transmission via high-speed satellite
network
■ Wide operating temperature range
■ Menu-based interface for easy
commissioning and troubleshooting

The SCB3 site communication box is assembled with a satellite modem, a CPU control board with memory buffer, a power
supply with backup, and field interface connectors inside a small-footprint weatherproof enclosure.

Table of Contents Previous page Next page


Surface Equipment | Technology 76
SCB3
SCB3 Site Communication Box Specifications
Wall Mount Enclosure
Height, in [cm] 15.75 [40]
Width, in [cm] 11.8 [30]
Depth, in [cm] 6.3 [16]
Satellite Antenna
Height, in [cm] 14.9 [38]
Width, in [cm] 14.9 [38]
Depth, in [cm] 1.1 [2.79]
Enclosure Construction
Material Blend of polybutylene terephthalate (PBT) and
polycarbonate (PC)
Finish Natural (off-white)
Ingress protection NEMA 3R
Maximum altitude 2,000 m above sea level
Temperature
Operating, degF [degC] –40 to 167 [–40 to 75]
Storage, degF [degC] –40 to 167 [–40 to 75]
Power
Input 100 to 240 V AC, 50 to 60 Hz
Output 14.7 V DC, 2.6 A
Ultracapacitor
Capacity 58 farad
Voltage 16.2 V, DC
Standards CSA C/US safety certification,
CE compliant, RoHS compliant

The SCB3 transmits real-time data via satellite from remote wellsites located almost
anywhere in the world.

slb.com/al

Other company, product, and service names


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Copyright © 2015 Schlumberger. All rights reserved. 15-AL-67271

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Surface Equipment | Technology 77
Instruct
All-in-one acquisition and control unit
APPLICATIONS The Instruct* all-in-one acquisition and control unit for artificially lifted wells provides a single
■ Variable-speed motor control and protection platform for protection, control, and data acquisition. The unit can monitor multiple wells, operating
■ Surface data acquisition for monitoring data points, electrical system data, information from external analog or digital devices, data measured
downhole gauges by the downhole monitoring system, and remote commands. Users can program alarm and trip settings
locally or remotely.
■ Wellsite interface for all artificially lifted
wells and remote monitoring with the In its basic configuration, the Instruct unit is a variable-speed motor controller and data acquisition device.
LiftWatcher* real-time surveillance service The unit has built-in RS232 and RS485 ports for communication connections that can be used in a variable
speed drive (VSD) application or for SCADA and LiftWatcher service connectivity.
BENEFITS
■ Provides centralized data gathering and The unit can be used as a stand-alone device to monitor up to four downhole tool systems. It can
storage for optimization, engineering accommodate four analog and six digital input channels and provide two analog and three digital output
analysis, and troubleshooting, eliminating channels, each individually configurable.
multiple surface components
Unit upgrades are typically performed at the wellsite by using a removable USB drive or laptop computer.
■ Installs directly in current UniConn*
For remote monitoring and control, the Instruct unit can be connected to a SCADA system or the
universal site controller installations
LiftWatcher service—or both in parallel, if required.
FEATURES
■ Remote access and control capability from
multiple SCADA systems and LiftWatcher
service in parallel
■ Plain-language, multilingual alarms and
prompts, at-a-glance wellsite assessment,
dedicated function keys, and color screen
■ 1 GB of internal memory with a removable
USB option (up to 32 GB), multiprocessor
architecture ensuring smooth performance
data logging and trending up to 32,000,000
data points
■ Modular design that increases expandability
and serviceability
■ PC-based StarView* wellsite display
software for device configuration, operation,
and troubleshooting
■ Acquisition system for Phoenix xt150* high-
temperature ESP monitoring system and
Phoenix CTS* cable-to-surface artificial lift
downhole monitoring system when paired
with system interface card
■ Acquisition system for REDA* Hotline* high-
temperature ESP systems and downhole
gauges when paired with high-temperature
interface card The Instruct all-in-one acquisition and control unit replaces the multiple surface components commonly needed for data
acquisition, monitoring, and control for VSDs and downhole gauges.

Table of Contents Previous page Next page


Surface Equipment | Technology 78
Instruct
Instruct All-in-One Acquisition and Control Unit Specifications†
Dimensions
Unit length, H × W × D, in [mm] 7.1 × 8.5 × 7.4 [180 × 216 × 187]
Unit weight, lbm [kg] 9.5 [4.3]
Faceplate length, H × W, in [mm] 7.64 × 10.59 [194 × 270]
Instruct unit option cards‡, mm 172 × 170 × 25
Standard option cards, mm 172 × 130 × 20
Power supply
Alternating current (AC) 100- to 240-V rms, 75 W, both 50 and 60 Hz
Direct current (DC) 24 V ± 2%, 75 W
Temperature rating
Operating range, degF [degC] –40 to 167 [–40 to 75]
Storage range, degF [degC] –76 to 185 [–60 to 85]
Expansion card rack
No. of slots Four
Cards available Modbus RS-232 or RS-485 communication card, PIC, EIC, and HTIC cards, Modbus TCP/IP card
Feature card rack
No. of slots Two
Input/Output
Digital output Three channels per card, 100- to 260-V AC rms, 10- to 28-V DC, 3 A maximum
Digital input Six channels per card, 24-V DC power internally supplied
Analog input Four insulated per card, double-wire channels; 0- to 10-V DC (0 to 20 mA)
Analog output Two individually configurable per card, 4- to 20-mA current loops
Maintenance port
Connection USB and standard serial port connector, DB9F, Modbus RS-232
Baud rate 300/600/1,200/2,400/4,800/9,600/19,200/38,400/57,600 bps
Serial communication Data bit: 8; stop bit: 1; parity: none
Remote communication interface
No. of channels One to six
Protocol Modbus RTU and Modbus TC/IP (with optional TCP/IP card)
Baud rate 300/600/1,200/2,400/4,800/9,600/19,200/38,400/57,600 bps
Serial communication Data bit: 7/8; stop bit: 1/2; parity: none/even/odd
Interface RS-232, RS-485, Modbus TCP/IP (one per communication card)
Gauge interface
Types of tools supported Phoenix xt150 system downhole gauge, Phoenix CTS system (all types), HTIC card
Interface PIC, EIC, or HTIC card
Data logging/trending
Logged events Starts, stops, alarms, trips, set point changes, system resets
Number of logged channels Up to 32 in parallel
Data storage capacity 32,000,000 data points
Sampling rate Individual per channel (up to one sample/s)‡
† CSA certified and CE compliant
‡ Options include sampling only when motor is running and exceeding user-set deviation limits.

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Other company, product, and service names
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Surface Equipment | Technology 79
Phoenix SoloConn
Data acquisition and control unit
APPLICATIONS The compact Phoenix SoloConn* data acquisi- it available in a user-friendly format at the PC or
■ Surface data acquisition for monitoring of tion and control unit provides power, alarming, desktop. In addition to pressure, temperature,
Phoenix CTS* cable-to-surface artificial and trending, enabling local and remote access vibration, current leakage, and other diagnostic
lift downhole monitoring system, Phoenix of wellsite data from the Phoenix CTS system data from Phoenix* artificial lift downhole moni-
xt150* high-temperature ESP monitoring gauges, Phoenix xt150 system, MultiSensor well toring systems, the digital output relay can be
system, MultiSensor* well monitoring unit monitoring unit, and Select downhole monitor- used for interfacing other external devices.
for submersible pump completions, ing gauges. It is designed for single gauge, well
and Select* artificial lift downhole application, or both. The Phoenix SoloConn unit is versatile and
monitoring gauges comes with the option of DC or AC surface power
This device interfaces with Modbus communica- supply and an indoor NEMA 1 enclosure.
■ Wellsite downhole gauge interface for
tion and control systems for wellsite monitoring.
monitoring of rod pumps, progressing
cavity pumps, gas lift systems, and ESPs The Phoenix SoloConn unit provides automated
alarms by set points and event logs, trends the
BENEFITS
data using a 8MB internal memory, and makes
■ Protects well or reservoir system
investment with enhanced control and
data management
■ Reduces equipment and training costs by
centralizing data access

FEATURES
■ AC- or DC-powered surface data
acquisition for alarming, trending,
and data storage
■ 8MB internal trend memory
■ StarView* wellsite display software
for device configuration, live data viewing,
and data download
■ Compatibility with SCADA systems using
Modbus® protocol and LiftWatcher* real-
time surveillance service The Phoenix SoloConn data acquisition and control unit is designed for single gauge, well application, or both.
■ Programmable trip and alarm relay
■ Data provision for production and
reservoir optimization

Artificial Lift

Table of Contents Previous page Next page


Surface Equipment | Technology 80
Phoenix SoloConn
Phoenix SoloConn Unit Specifications
Dimensions (H × W × L), in [mm] 2.6 × 4.1 × 10.75 [66 × 104 × 273] NEMA 1
Weight, lbm [kg] 3.3 [1.5] NEMA 1
Power supply 24-V DC ±5% 8W
110-V to 240-V AC, 50/60 Hz (optional)
Temperature, degF [degC] Operating range: –40 to 140 [–40 to 60] (DC input); –40 to 122 [–40 to 50] (AC input)
Storage range: –40 to 185 [–40 to 85]
Digital output 1 relay dry contact; 24-V DC 1 A, 125-V AC 0.3 A; 3-pin quick connect
Communication port 1 Modbus RS-485 port (4 or 2 wires); 2,400–57,600 bits per second; 6-pin quick connect
Configuration port 1 Modbus RS-232 DB9F port, 2,400–57,600 bits per second
Qualifications†‡ §†† CE, (c)UL, CSA, ROHS, and WEEE
Enclosure rating NEMA 1
Downhole Gauge Interface
No. of gauges Max. of 1
Gauges supported Phoenix CTS system gauges, Phoenix xt150 system gauges, MultiSensor well monitoring unit, Select downhole monitoring
gauge, and UltraLite* ESP monitoring systems
Max. output voltage/current 120 V, 34 mA
Software
Software StarView wellsite display software
Functionality Device configuration, including gauge coefficient upload
Live data viewing, capture, and trending
Internal trend memory data download to PC
† Conformité Européenne.
‡ Canadian Underwriters Laboratory.
§ Canadian Standards Association.
†† Restriction of certain hazardous substances.

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Surface Equipment | Technology 81
Phoenix ArConn
Rack-mountable data acquisition and control unit
APPLICATIONS The Phoenix ArConn* rack-mountable data The standard Phoenix ArConn unit is offered in
■ Surface data acquisition for monitoring of acquisition and control unit provides power, a rack-mountable NEMA 1 enclosure. It comes
Phoenix CTS* cable-to-surface artificial logging, and trending, and enables local and with the option of 24-V DC or 110-V to 240-V AC
lift downhole monitoring system, Phoenix remote access of data from up to 16 PIC V2 cards power supply.
xt150* high-temperature ESP monitoring connected to supported gauges. The rack is
system, MultiSensor* well monitoring expandable to accommodate up to 16 gauges via Device configuration and remote access
unit for submersible pump completions, individual gauge Phoenix* artificial lift downhole StarView wellsite display software enables
and Select* artificial lift downhole monitoring systems’ interface cards, extending the user to access the Phoenix ArConn unit
monitoring gauges the range of possible applications to fields with from a PC. Connection to a PC is made through
widespread monitoring needs. Each interface the serial port on the acquisition unit faceplate
■ Wellsite downhole gauge interface for
card slot is equipped with an LED that indicates using a standard DB-9 serial connector. The
monitoring of rod pumps, progressing
the communication status with connected StarView software is used to configure and
cavity pumps (PCPs), gas lift systems,
downhole gauges. locally download data from the device’s serial
and ESPs
port. All well commissioning and setup process
BENEFITS The Phoenix ArConn unit can be configured parameters can be preset in a controlled environ-
■ Protects well or reservoir system to trend data and log events using a 64MB ment, stored in the software, and uploaded at
investment with enhanced control and internal memory, and make data available in a the wellsite to simplify field operations.
data management user-friendly format. It acquires pressure,
temperature, vibration, current leakage, and For remote monitoring and control, the acquisition
■ Reduces equipment and training costs by unit can be connected to a land-based Modbus
other diagnostic data.
centralizing data access system through its remote communication port or,
The unit can be installed in the 19-in [48.26-cm] optionally, via the LiftWatcher service. A standard
FEATURES
rack typically found in control rooms on offshore Modbus protocol over a RS-485 communications
■ Compatibility with up to 16 Phoenix CTS
platforms or on a shelf. This device interfaces channel is used.
system surface gauges for local and
with SCADA and other remote communication
remote access of data
and control systems that gather data for wellsite
■ AC- or DC-powered surface data monitoring using standard Modbus protocol via
acquisition for alarming, trending, RS-485 or RS-232 communication links.
and data storage
■ 64MB internal trend memory
■ StarView* wellsite display software for
device configuration, live data viewing,
and data download
■ Compatibility with SCADA systems using
Modbus® protocol and LiftWatcher* real-
time surveillance service
■ Programmable trip and alarm relay
■ NEMA 1 enclosure option
■ Data provision for production and
reservoir optimization

The Phoenix ArConn rack-mountable data acquisition and control unit can connect to 16 gauges.

Artificial Lift

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Surface Equipment | Technology 82
Phoenix ArConn
Phoenix ArConn Unit Specifications
Dimensions (H × W × L), in [mm] 7 × 17.5 × 15.5 [178 × 445 × 394] (19-in [48.26-cm] rack mount)
Approximate shipping weight, lbm [kg] 30.0 [13.6]
Power supply 110-V to 240-V AC, 50/60 Hz (standard device only); 16-W;
full load: 16 PIC cards, 145-W (max. consumption); 24-V DC ± 5%, 150 W
Temperature, degF [degC] Operating range: –40 to 131 [–40 to 50]
Storage range: –40 to 167 [–40 to 75]
Configuration port 1 Modbus RS-232 DB9F port, 57,600 bits per second, on CPU card
Qualifications†‡§†† CE, (c)UL, CSA, and ROHS
Enclosure rating NEMA 1, IP10
Downhole Gauge Interface
No. of PIC V2 card slots 16
No. of gauges 1 per PIC V2 card (16 gauges)
Gauges supported Phoenix CTS system gauges, Phoenix xt150 system, and Select downhole monitoring gauges
Max. output current/power 30 mA, 3.6 W
Max. output voltage 120-V
Cable voltage status Short-circuit and open-line detection
Connection Through CPU card configuration port, using straight DB-9 serial cable
Software
PC software StarView wellsite display software
Functionality Device configuration, including gauge coefficient upload, live data viewing, capture, and trending; internal trend memory data
download to PC
Remote Communication
No. of channels 1 by default, up to 4
Protocol Modbus RS-232/485
Baud rate, bits per second 300; 600; 1,200; 2,400; 4,800; 9,600; 19,200; 38,400; 57,600
Port setting 8 data bits; 1 or 2 stop bits; none, even, or odd parity
Internal Data Storage
Event log Up to 1,500 events, first-in, first-out basis
Type of events logged Status change and configuration changes
Trend data Up to 64MB (4,874,240 data points) of available memory for trending; user-settable option to write over first data in,
or stop recording when memory is full
Trend data Temperature, pressure, vibration, and tool status
Sampling rate Up to 1 sample per second per PIC V2 card
† Conformité Européenne.
‡ Canadian Underwriters Laboratory.
§ Canadian Standards Association.
†† Restriction of certain hazardous substances. Qualifications are only valid with PIC V2 SLB PN 101095702.

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Surface Equipment | Technology 83
Gas Lift Systems

Reliable performance in both low-and high-productivity wells Side pocket mandrels


Our gas lift installations effectively manage abrasive materials, such as ■■ Minimize or eliminate costly workovers with an innovative and
sand, and can be used in low-productivity, high-GOR wells or deviated industry-original design.
wellbores.
Retrievable gas lift valves
Innovative gas lift systems ■■ Enhance well performance with one of the industry’s most
New gas lift systems are pressure barrier qualified and rated to a higher time-tested products.
pressure to provide reliable performance in deepwater and subsea wells,
deeper depths of gas injection, and enhanced wellbore integrity. Conventional gas lift systems
■■ Maximize production with conventional tubing-retrievable gas lift
equipment.

Table of Contents Previous page Next page 84


Barrier Series
Gas lift systems
APPLICATIONS Especially suited for high-pressure, deepwater, and subsea
■ High-pressure, deepwater installations, Barrier Series gas lift systems lower costs and
installations downtime by improving the pressure integrity of the entire
■ Subsea installations wellbore environment.
■ Safety-critical applications Complete gas lift wells and improve performance with the
with stringent pressure combined benefits of Barrier Series gas lift valves and the
integrity requirements MMRG-2V-B dual-pocket, side pocket mandrel. The MMRG-
■ Standard installations 2V-B dual-pocket, side pocket mandrel is based on the
existing, field-proven MMRG-2V dual-pocket, side pocket
BENEFITS configuration with a dual inline, redundant, leak-tight seal.
■ Reduces downtime by eliminating the
need for annulus fluid unloading following Enhanced capability and reliability
typical slickline operations A barrier-qualified check valve system that provides a positive
■ Lowers costs and downtime through metal-to-metal seal between the tubing and casing annulus is
improved pressure integrity of entire available in 11⁄2-in and 13⁄4-in injection-pressure-operated (IPO)
wellbore environment valves and orifice valves for multiple barrier valve options.

FEATURES The availability of dual bores and communication portals


■ Extended capability of existing gas in the barrier mandrel allows for two separate and distinct,
lift systems through a field-proven, retrievable, flow control check-valve devices that work
dual-pocket, side pocket configuration, independently to simultaneously serve both the flow control
with a dual-inline, redundant, and the pressure barrier requirements of the gas lift system.
leak-tight seal The barrier mandrel is a round-body, fully machined mandrel
■ Compatibility with existing field- with a one-piece, twin 11⁄2-in bore pocket design with a dual-tool
proven Camco* gas lift and subsurface discriminator containing a tubing-to-casing barrier valve
safety systems using orienting-type (TCBV). The TCBV prevents communication between the
slickline installation and pulling tools tubing and casing when the normal operating gas lift valve is
Barrier Series gas lift systems can
■ Industry-standard API 19G1, ISO 17078- removed from the primary pocket. be deployed in even high-pressure,
1, API 19G2, ISO 17078-2, and pressure deepwater, and subsea environments.
barrier qualifications
Valve, Mandrel, and Latch Compatibility
Barrier Series Gas Lift Valves Side Pocket Mandrels Latches
R-20-02-B injection pressure operated
O21R-B single-point-injection orifice M series side pocket mandrels
02-30R-B dual-check orifice MMRG-2V-B Barrier Series dual-pocket, R Series latches
S02-30R-B dual-check shear orifice side pocket mandrel
NOVA 15-B venturi orifice
High-Pressure Barrier Series Gas Lift Valves Side Pocket Mandrels Latches
XLI-B injection pressure operated
XLO-B high-pressure orifice XL series side pocket mandrels XL Series latches
XLO-R-B rupture-disk orifice

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Gas Lift Systems  |  Technology 85
Barrier Series
Designed to meet the challenges of demanding environments
Barrier Series gas lift valves are manufactured using state-of-the-art
technology and corrosion-resistant materials to meet the challenges of
demanding environments, accommodating a variety of critical operating
conditions and pressure ranges. The 13⁄4-in XLift* high-pressure gas lift
system’s IPO gas lift valve and the standard R-20-02 IPO valve enable well
unloading. Multiple models of the XLift system valve and traditional orifice
valves facilitate continuous-flow gas lift operations.

Strict quality, leak-rate, and performance criteria


The positive-sealing check valves are designed qualified to meet strict
quality, leak-rate, and performance criteria as defined by the Statoil TR2385
standard, API 19G2 and ISO 17078-2. With a test pressure rating of 10,000
psi [68,947 kPa], the check valve forms a metal-to-metal barrier between
the tubing and casing annulus that prevents undesired communication or
reverse flow, and mitigates the risks associated with typical gas lift valve
check systems.

Barrier Series gas lift systems extend the capabilities and range of existing gas lift
systems to even the most challenging environments.

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Gas Lift Systems  |  Technology 86
MMRG-2V-B
Barrier Series dual-pocket side pocket mandrel
APPLICATIONS The MMRG-2V-B Barrier Series dual-pocket side pocket mandrel enhances
■ High-pressure, deepwater installations the capability of existing gas lift systems. The MMRG-2V-B mandrel
■ Subsea installations uses a field-proven, dual-pocket side pocket configuration with a dual-
inline, redundant, leak-tight seal. This configuration of dual bores and
■ Safety-critical applications with stringent
communication portals allows for the use of two separate and distinct
pressure integrity requirements
retrievable flow control check valve devices that work independently
■ Standard installations to simultaneously serve both the flow control and pressure barrier
BENEFITS requirements of the gas lift system.
■ Reduces downtime by eliminating the need The barrier mandrel is a round-body, fully machined mandrel with a one-piece,
for annulus fluid unloading following typical twin 11⁄2-in bore pocket design with a dual-tool discriminator containing a
slickline operations TCBV. The TCBV prevents communication between the tubing and casing
■ Lowers costs and downtime through when the normal operating gas lift valve is removed from the primary
improved pressure integrity of entire well- pocket. The primary pocket accepts all standard and barrier version 11⁄2-in
bore environment OD gas lift type valves. Both TCBV and active gas lift valves are slickline
retrievable.
FEATURES
■ Field-proven, dual-pocket, side pocket The MMRG-2V-B SPM design incorporates dual, flush-mount, full-length
configuration, with a dual-inline, redundant, OD grooves to facilitate cable and control-line bypass. This reduces overall
leak-tight seal running OD while offering maximum line protection.
■ Compatibility with existing field-
proven Camco* gas lift and subsurface
safety systems’ orienting-type slickline
installation and pulling tools
■ Integral tubing-to-casing barrier valve
(TCBV) that prevents tubing-to-casing
communication when operating valve
is removed
■ Same barrier-qualified check valve
design found in barrier gas lift valves
■ Industry-standard ISO 17078-1 V1
qualification

MMRG-2V-B series side


pocket mandrels.

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Gas Lift Systems  |  Technology 87
MMRG-2V-B
MMRG-2V-B Barrier Series Mandrel Specifications
Tubing Size,† Type Material Type Major OD, Internal Drift, Test Pressure Test Pressure Latch Type Kickover Tool
in [mm] in [mm] in [mm] (Internal), psi [kPa] (External), psi [kPa]
4.500 [114.3] MMRG-2V-B 410-13Cr 7.580 [192.5] 3.833 [97.4] 8,500 [58,605] 8,000 [55,158] RK, RK-1, RKP OM-2V-B
5.500 [139.7] MMRG-2V-B 4130 8.285 [210.4] 4.653 [118.2] 8,000 [55,158] 7,000 [48,263] RK, RK-1, RKP OM-2V-B
5.500 [139.7] 410-13Cr 8.285 [210.4] 4.653 [118.2] 8,000 [55,158] 7,000 [48,263]
5.500 [139.7] INCOLOY® 925 8.285 [210.4] 4.653 [118.2] 11,000 [75,842] 9,630 [66,396]
†Additional design options for other tubing sizes and materials are available on request.

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Gas Lift Systems  |  Technology 88
TCBV
Tubing-to-casing barrier valve
APPLICATIONS The tubing-to-casing barrier valve (TCBV) is specifically designed for installation
■ Continuous-flow gas lift production into the barrier pocket of MMRG-2V-B Barrier Series side pocket mandrels. Used for
■ Safety-critical applications with stringent continuous-flow gas lift applications, the valve extends the capabilities of existing gas
pressure integrity requirements lift systems by providing dual-inline, redundant back-check seals. When the operating
valve is removed from the primary pocket, the TCBV prevents flow from tubing to
BENEFITS casing and thus maintains tubing integrity.
■ Enhances safety by ensuring wellbore integ-
rity during shut-in periods Based on field-proven Camco systems gas lift technology, these valves also contain a
Barrier-qualified, positive-sealing, integral reverse-flow check valve.
■ Extends capabilities of existing gas lift sys-
tems by using a dual-pocket, side pocket Operation
configuration with a dual-inline, redundant, Injection gas enters the TCBV through the external ports between the packing sets
leak-tight seal and travels down through the valve, past the reverse-flow barrier check valve, through
■ Saves costs and downtime by eliminating the pocket interstitial space, and into the inlet ports of the inline, primary, active gas
the need for annulus fluid unloading follow- lift valve.
ing typical slickline operations
TCBV Specifications
FEATURES OD (not including latch), in [mm] 1.500 [38.1]
■ Qualification to ISO 17078-2 V1 standard Length with latch, in [mm] 28.524 [724.510]
■ Corrosion-resistant nickel alloy con- Operating pressure (max. unloading differential), 10,000 [68,947.6]
struction psi [kPa]
Max. gas injection pressure in annulus na†
■ Barrier-qualified reverse-flow check valve (at valve location), psi [kPa]
system that provides positive seal between Max. differential pressures across check section, 10,000 [68,947.6]
tubing and casing annulus psi [kPa]
■ Compatibility with existing field-proven Max. temperature, degF [degC] 350 [177]
Camco* gas lift and subsurface safety Min. temperature, degF [degC] 50 [10]
systems’ orienting-type slickline installation Materials
and pulling tools Body parts MONEL® 400 and K-500
O-rings and seals Viton®
Seat MONEL K-500
Packing Modified Campac carbon
and moly-filled Teflon®
with PTFE/carbon fiber/
graphite filled PEEK®
backup and MONEL K-500
retainer ring
†Not applicable.

Tubing-to-casing barrier
valve (TCBV).

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Gas Lift Systems  |  Technology 89
R-20-02-B
Injection pressure–operated gas
Injection-pressure-operated gas lift
lift valve
valve
APPLICATIONS Schlumberger R-20-02-B Barrier Series injection pressure–operated (IPO)
■ Tubing or annular flow gas lift valves are used for continuous or intermittent gas lift production.
■ Continuous or intermittent production Based on field-proven Camco systems technology, these 1½-in-OD
retrievable valves feature a barrier-qualified, positive-sealing, integral
■ High-performance gas lift installations
reverse-flow check valve.
BENEFITS
Applications include tubing flow when they are installed in standard
■ Enhances safety because wellbore integrity
side pocket mandrels or annular flow when they are installed in side pocket
is ensured during shut-in periods
mandrels ported for annular flow. A nitrogen-charged, multi-ply MONEL®
■ Reduces downtime because of reliable bellows provides the force necessary to maintain the valves in a normally
performance closed position.
■ Lowers costs because of versatility and
efficiency Operation
The injection pressure necessary to compress the bellows of IPO gas lift valves
■ Increases production because of uniform
is controlled by precharged nitrogen pressure. Injection gas enters the valve
operation over a series of injection pressures
and acts on the effective bellows area. As the injection gas pressure overcomes
FEATURES the precharged pressure in the bellows, the bellows compresses and lifts
■ Field-proven design and operation the stem tip off the seat. Injection gas then flows through the seat, past the
reverse-flow check valve, and into the production conduit.
■ Qualification to ISO 17078-2 V1 standard
■ Corrosion resistance through stainless steel R-20-02-B Valve Specifications
or nickel alloy construction OD (not including latch), in 1.500
■ Guided valve stem that precisely aligns stem Length with latch, in [mm] 28.526 [724.560]
to seat during operation Max. operating pressure, psi [kPa] 5,000 [34,474]
■ Barrier-qualified reverse-flow check valve Max. differential pressure across check section, 10,000 [68,947.6]
psi [kPa]
system that provides positive seal between
Max. temperature, degF [degC] 350 [177]
tubing and casing annulus
Min. temperature, degF [degC] 50 [10]
■ Usable with Camco* gas lift and subsurface
Orifice size range, in 8/64 to 32/64
safety systems’ standard and select side
Materials
pocket mandrels
Body parts MONEL 400 and K-500
O-rings and seals Viton® with PEEK® backups
Seat Tungsten carbide
Packing Modified Campac carbon and
moly-filled Teflon® with PTFE/
carbon fiber/graphite-filled PEEK
backup and MONEL K-500 retainer
ring R-20-02-B injection
pressure–operated
Secondary accessories gas lift valve.
Latch RA, RK, and RK-1 latch, depending
on type of mandrel
Running tool JC-3 and RK-1
Pulling tool 2-in JDC and 15⁄8-in JDS
Kickover tool L, L2-D, OM series, and TPD
depending on type of mandrel
Mandrel series MMA, MMG, and MMRG

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Gas Lift Systems  |  Technology 90
O-O-221R-B
1R-B
Single-point-injection orifice
Single-point-injection orifice gas
gas lift
lift valve
valve

APPLICATIONS Schlumberger O-21R-B Barrier Series single-point-injection orifice gas lift


■ Continuous-flow gas lift production valves are used for continuous-flow gas lift applications. An integral choke
■ High-reliability wellbore integrity controls the flow of gas through this normally open valve into the production
conduit. The valves also have a floating choke. Based on field-proven Camco
BENEFITS systems technology, these valves also contain a barrier-qualified, positive-
■ Enhances safety because wellbore integrity sealing, integral reverse-flow check valve.
is ensured during shut-in periods
Operation
■ Lowers costs because a single valve
Injection gas enters the valve through the external ports between the valve
provides flexible operating ranges over
packing sets and then travels through the choke, past the reverse-flow barrier
a series of injection pressures
check valve, and into the production conduit.
■ Reduces downtime because of reliable
performance
O-21R-B Valve Specifications
FEATURES
■ 1 ⁄2-in OD
1 OD (not including latch), in 1.500
Length with latch, in [mm] 28.524 [724.510]
■ Qualification to ISO 17078-2 V1 standard
Operating pressure (max. unloading differential), 10,000 [68,947.6]
■ Field-proven design and operation psi [kPa]
■ Corrosion resistance through stainless steel Max differential pressure across check section, 10,000 [68,947.6]
psi [kPa]
or nickel alloy construction
Max. temperature, degF [degC] 350 [177]
■ Barrier-qualified reverse-flow check valve
Min. temperature, degF [degC] 50 [10]
system that provides positive seal between
Orifice size range, in 8
⁄64 to 44⁄64
tubing and casing annulus
Materials
■ Usable with Camco* gas lift and subsurface Body parts MONEL® 400 and K-500
safety systems’ standard and select side O-rings and seals Viton®
pocket mandrels Bellows Not applicable
Seat/venturi MONEL K-500
Packing Modified Campac carbon and moly-
filled Teflon® with PTFE/carbon fiber/
graphite filled PEEK® backup and
MONEL K-500 retainer ring
Secondary accessories
Latch RA, RK, and RK-1 latch, depending
on type of mandrel
Running tool JC-3 and RK-1
Pulling tool 2-in JDC and 15⁄8-in JDS
Kickover tool L, L2-D, OM series, and TPD, depending
on type of mandrel
Mandrel series MMA, MMG, and MMRG O-21R-B single-point-
injection orifice gas lift
valve.

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Gas Lift Systems  |  Technology 91
NOVA 15-B
Gas lift valves 15-B
APPLICATIONS NOVA* gas lift valves’ 15-B Barrier Series venturi orifice gas lift valves have
■ Continuous-flow gas lift production an exclusive dynamically tested flow profile to promote a constant-flow gas
■ High-reliability operations injection rate. This profile produces maximum gas passage with minimal
differential across the valve. The NOVA valve flow regime eliminates most
BENEFITS effects of tubing pressure on the gas injection rate and stabilizes the gas
■ Enhances safety because wellbore integrity injection pressure. Stable injection rates can result in more stable tubing
is ensured during shut-in periods pressure, increased production, and reduced operating expenses.
■ Increases production because of optimized
15-B valves replace traditional operating orifice valves where the injection
gas lift efficiency and well productivity
rate is inherently unstable because of the effect of tubing pressure. Even
■ Reduces downtime with more reliable slight variations in the tubing flow regime can lead to wide fluctuations
performance in tubing pressure and result in unsteady injection rates, instability, and
■ Lowers costs because of versatility slugging. Traditional square-edged orifice valves require a pressure drop of
and efficiency approximately 50% to achieve critical gas flow, and, in most cases, operating
with this much pressure loss is not practical.
FEATURES
■ Qualification to ISO 17078-2 V1 standard These valves achieve critical flow with a pressure drop as little as 10% or
■ Dynamically generated injection less. Within the critical flow regime, the injection rate is constant because
gas flow profile the tubing pressure does not affect the injection volume. Stabilizing the
injection pressure can lead to reduced maintenance costs and improved
■ Simple field-proven design that stabilizes
productivity and profit. This stabilization is achieved through innovative
injection pressure and production rate
engineering and a field-proven design.
■ Corrosion resistance through stainless steel
or nickel alloy construction Operation
■ Barrier-qualified, reverse-flow check valve The 15-B valve uses a nozzle venturi orifice and a positive-sealing, barrier-
that provides positive seal between tubing qualified check valve for continuous flow operations. It is installed in a side
and casing annulus pocket mandrel. Injection fluid or gas enters through the valve entry ports and
then flows through the nozzle venturi orifice. Injection pressure moves the
■ Usable with Camco* gas lift and subsurface
check valve off the seat, allowing gas to enter the production tubing. During
safety systems’ standard and select side
periods of no gas injection, the normally closed positive-sealing barrier check
pocket mandrels
valve prevents tubing fluids and pressure from flowing back into the casing.

NOVA gas lift valve 15-B.

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Gas Lift Systems  |  Technology 92
NOVA
NOVA Gas Lift Valve 15-B Specifications
OD (not including latch), in [mm] 1.500 [38.1]
Length with latch, in [mm] 28.524 [724.510]
Operating pressure (max. unloading differential), psi [kPa] 10,000 [68,947.6]
Max. differential across check section, psi [kPa] 10,000 [68,947.6]
Max. temperature, degF [degC] 350 [177]
Min. temperature, degF [degC] 50 [10]
Venturi orifice size range, in 8
⁄64 to 32⁄64
Materials
Body parts MONEL® 400 and K-500
O-rings and seals Viton®
Seat/venturi Tungsten carbide
Packing Modified Campac carbon and moly-filled Teflon® with PTFE/carbon fiber/graphite-filled
PEEK® backup and MONEL K-500 retainer ring
Secondary accessories
Latch RA, RK, and RK-1 latch, depending on type of mandrel
Running tool JC-3 and RK-1
Pulling tool 2-in JDC and 15⁄8-in JDS
Kickover tool L, L2-D, OM series, and TPD, depending on type of mandrel
Mandrel series MMA, MMG, and MMRG

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Gas Lift Systems  |  Technology 93
O2-30R-B
02-30R-B
Dual-check orifice
Dual-check orifice gas
gas lift
lift valve
valve
APPLICATIONS O2-30R-B Barrier Series dual-check orifice gas lift valves control the flow
■ Continuous-flow gas lift production of gas from the injection conduit to the production conduit at valve depth.
■ High-reliability operations Based on field-proven Camco systems technology, these 1½-in OD slickline-
retrievable, single-point valves are installed in an
■ H2S and CO2 wells
M series side-pocket mandrel by using an R series latch. They provide a
BENEFITS means of communication between the casing annulus and tubing.
■ Enhances safety because wellbore integrity
An integral choke controls the flow of gas through this normally open valve
is ensured during shut-in
into the production conduit. The valve includes a floating choke and contains
periods
a dual, integral, positive-sealing, barrier-qualified reverse-flow check valve
■ Reduces downtime with more reliable per- system.
formance
■ Lowers costs because of versatility and Operation
efficiency Injection gas enters the valve through the external ports between the valve
packing sets and travels through the choke, past the dual reverse-flow bar-
FEATURES rier check valves, and into the production conduit.
■ Barrier-qualified dual reverse-flow check
valve system to prevent backflow into tubing
annulus
O2-30R-B Valve Specifications
■ Usable with Camco* gas lift and subsurface OD (not including latch), in [cm] 1.500 [3.81]
safety systems’ standard and select side
Length with latch, in [mm] 28.689 [725.700]
pocket mandrels
Operating pressure (max. unloading 5,000 [34,474]
■ Qualification to ISO 17078-2 V1 standard differential), psi [kPa] (top check valve)
■ Field-proven design and operation Max. differential pressure across 10,000 [68,948]
check section, psi [kPa] (lower check valve)
■ Corrosion resistance through stainless steel Max. temperature, degF [degC] 350 [177]
or nickel alloy construction Min. temperature, degF [degC] 50 [10]
Venturi orifice size range, in 8
⁄64 to 40⁄64
Materials
Body parts MONEL® 400 and K-500
O-rings and seals Viton®
Bellows NA
Seat/venturi MONEL K-500
Packing Modified Campac carbon and moly-filled
Teflon® with PTFE/carbon fiber/graphite-
filled PEEK® backup and MONEL K-500
retainer ring
Secondary Accessories
Latch RA, RK, and RK-1 latch, depending on O2-30R-B dual-check
type of mandrel orifice gas lift valve.
Running tool JC-3 and RK-1
Pulling tool 2-in JDC and 15⁄8-in JDS
Kickover tool L, L2-D, OM series, and TPD depending
on type of mandrel
Mandrel series MMA, MMG, and MMRG

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Gas Lift Systems  |  Technology 94
SO2-30R-B
Dual-check shear orifice gas lift valve
APPLICATIONS SO2-30R-B Barrier Series dual-check shear orifice gas lift valves provide a selec-
■ Continuous-flow gas lift production tive means for communication between the casing and the tubing. Activated by
■ High-reliability operations differential pressure, the valve acts initially as a dummy valve. A piston seals off the
circulating ports in the valve and the side pocket mandrel. The piston is held in the
■ Completions in which flow through the ori-
closed position with a draw bar; the shear diameter of the draw bar determines the
fice valve is not immediately required
casing-to-tubing pressure differential required to open the valve. Based on field-
BENEFITS proven Camco* gas lift and subsurface safety systems, the valve includes a choke to
■ Enhances safety because wellbore integrity control flow and contains a dual, positive-sealing, barrier-qualified, integral reverse-
is ensured during shut-in flow check valve.
periods
Operation
■ Reduces costs and downtime because valve Annular pressure must be sufficiently increased to obtain the required differential
serves as a dummy valve until communica- pressure to shear the draw bar holding the valve piston closed. An increase in tubing
tion is required, thereby eliminating inter- pressure will not open the valve. When the draw bar shears and the piston locks
ruptions to production open, well fluids are free to flow, and an integral choke controls the flow of gas
■ Minimizes downtime with more reliable through this normally open valve into the production conduit.
performance
■ Lowers costs because of versatility and SO2-30R-B Valve Specifications
efficiency OD, not including latch, in [cm] 1.500 [3.81]
Length with latch, in [mm] 28.689 [725.700]
FEATURES Operating pressure (max. unloading differential), 5,000 [34,474] (top check valve)
■ Field-proven design and operation psi [kPa]
■ Barrier-qualified reverse-flow check valve Max. differential pressure across check section, 10,000 [68,947.6] (lower check valve)
psi [kPa]
system that provides positive seal between
Max. temperature, degF [degC] 350 [177]
tubing and casing annulus
Min. temperature, degF [degC] 50 [10]
■ Qualification to ISO 17078-2 V1 standard
Orifice size range, in 8
⁄64 to 40⁄64
■ Corrosion resistance through stainless steel Shear ratings, psi [kPa] Differential activation pressures on
or nickel alloy construction request
■ Activation by differential pressure Materials
Body parts MONEL® 400 and K-500
O-rings and seals Viton® with PEEK® backups
Bellows Not applicable
Seat/venturi MONEL K-50
Packing Modified Campac carbon and moly-
filled Teflon® with PTFE/carbon fiber/
graphite filled PEEK backup and
MONEL K-500 retainer ring
Secondary Accessories
Latch RKP latch SO2-30R-B dual-check shear
Running tool RK-1 orifice gas lift valve.
Pulling tool 15⁄8-in JDS
Kickover tool OM series or TPD, depending on type
of mandrel
Mandrel series MMG and MMRG

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Gas Lift Systems  |  Technology 95
RLC-4R-B
chemical injection
Barrier Series rupture-disc retrievable valve valve
APPLICATIONS The RLC-4R-B Barrier Series rupture-disc chemical injection valve is used
■ Continuous or intermittent to control subsurface corrosion or to eliminate paraffin, salt, and hydrate
chemical injection formation in the tubing string and flowlines. It enables precise control of
■ High-pressure, deepwater, and injection volumes and treatment of well fluid at the valve depth.
subsea installations
An INCONEL® spring provides the force necessary to maintain the valve in
■ Completions in which flow through the normally closed position. A wide selection of spring rates allows dif-
the valve is not immediately required ferential operating pressures up to 3,800 psi [26,200 kPa].
A tungsten carbide stem tip and valve seat provide a leakproof seal when
BENEFITS
the valve is closed.
■ Provides simple design with long operating
life A nonfragmenting rupture disc in the nose of the valve operates as a
■ Enables rapid, low-cost maintenance with positive pressure barrier, holding pressure in both directions and allowing
modular construction integrity checks to be carried out during the well completion and testing
■ Increases reliability and efficiency phases. The disc is opened, and the valve is activated by simply applying a
preset differential across the valve. No well intervention is required.
■ Enhances safety through ensured
wellbore integrity The barrier-qualified reverse-flow check valve system provides a positive
■ Lowers cost by eliminating seal between tubing and casing to ensure tubing integrity.
slickline intervention to remove
Operation
and replace dummy
Injection chemicals enter the valve from either the casing annulus or from
FEATURES a separate injection line attached to the appropriate side pocket mandrel.
■ MONEL® and high-nickel-alloy construction As injection pressure overcomes the preset spring force, plus the flowing
for corrosion resistance in the presence of tubing pressure at valve depth, the spring compresses and moves the
H2S and CO2 stem tip up and off the seat. Chemicals flow upward through the seat,
down through the crossover arrangement, past the reverse-flow check
■ Guided valve stem for precise alignment
valve, and into the production tubing.
with the seat during operation
■ Barrier-qualified reverse-flow check valve RLC-4R-B Chemical Injection Valve Specifications
that provides positive seal Valve size, in [cm] 1.500 [3.81]
■ Easy adjustment of operating pressure for Max. OD, in [cm] 1.546 [3.93]
precise control of injection volume, indepen- Overall length, in [cm] 21 [53.34]
dent of well temperature Check valve test pressure 10,000 [68,947]
■ Nonfragmenting pressure-barrier rupture (max. differential), psi [kPa]
disc to facilitate integrity checks during well Max. set pressure, psi [kPa] 3,800 [26,200]
completion and testing Max. temperature, 350 [177]
degF [degC]
■ Reliable, retrievable chemical injection valve Port size 3
⁄16 in
design using field-proven technology Burst disc ratings Available on request
Materials
Body parts MONEL
O-rings and seals Viton® with PEEK® backup RLC-4R-B Barrier Series
Seat Tungsten carbide rupture-disc chemical
Packing Modified CAM-PAC carbon and moly-filled Teflon® injection valve.

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Gas Lift Systems  |  Technology 96
KBMG Series Side Pocket Mandrels
Single-pocket mandrels that accept 1-in [25.4-mm] OD side pocket devices
APPLICATIONS Camco* gas lift and subsurface safety systems’ KBMG series side pocket mandrels
■ Normal and corrosive service are made as part of the tubing string when preparing a well for gas lift production,
■ Single- and dual-string completions chemical injection, waterflood, or other special applications. KBMG mandrels are
designed with an oval body construction and are available in a variety of tubing
■ Heavyweight casing
sizes and connection thread types. They incorporate all the standard design
BENEFITS features of Camco systems side pocket mandrels.
■ Enables precise alignment and insertion of
KBMG mandrels feature an integral, one-piece pocket and a tool discriminator
side pocket devices, minimizing the opportu-
that keeps larger slickline tools from entering the pocket area while guiding the
nity for hang-up during slickline operations
smaller side pocket devices into the pocket. An orienting sleeve helps ensure precise
■ Optimizes production with unique design alignment of positive kickover tools in highly deviated wells.
features to facilitate operations
Design variation
FEATURES The following mandrel designation indicates a design variation that tailors the
■ Positioning sleeve orientation system KBMG mandrels for specific production applications. Mandrels with this variation
■ Forged tool discriminator that deflects large are available in a wide range of sizes.
tools into the tubing bore ■ KBMG-LTS series
■ Integral forged pocket ● The mandrel has an integral connection for capillary tubing extending from
the surface wellhead.
■ Availability in a variety of materials
● The standard connection is a 1⁄8-in [3.2-mm] box that accepts a

1⁄4-in [6.4-mm] OD injection conduit.


● LTS mandrels are used when two or more fluids are being injected into

the well and must be kept separate until they are commingled in the flow
stream.
■ KBMG-2 series
● The mandrel has a slightly reduced OD and a fully open ID, allowing them
to be run in smaller ID casing. Most mandrels with this designation have a
reduced test pressure.
KBMG series mandrels are available in a range of fully traceable materials and can
be heat treated to comply with NACE specification MR0175 for stress-cracking
resistant metallic materials.

KBMG series
side pocket mandrel.

Table of Contents Previous page Next page


Gas Lift Systems  |  Technology 97
KBMG Series Side Pocket Mandrels
Engineering Data for KBMG Series Pocket Mandrels
Test Pressure (Internal), Test Pressure (External), psi
Tubing Size,† Major OD, in Minor OD, Internal Drift, psi [kPa]‡ [kPa]‡ Kickover
Type† Latch Type
in [mm] [mm] in [mm] in [mm] Corrosive Normal Corrosive Tool
Normal Service
Service Service Service
Integral, BK series,
2.375 [60.3] KBMG 4.236 [107.6] 2.906 [73.8] 1.906 [48.4] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] OK, TPM
BEK-2, BEK-3
KBMG- Integral, BK series,
2.375 [60.3] 4.531 [115.1] na§ 1.906 [48.4] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] OK, TPM
LTS BEK-2, BEK-3
Integral, BK series,
2.875 [73.0] KBMG 4.750 [120.7] 4.000 [101.6] 2.347 [59.6] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] OK, TPM
BEK-2, BEK-3
KBMG- Integral, BK series,
2.875 [73.0] 5.376 [136.6] na 2.347 [59.6] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] OK, TPM
LTS BEK-2, BEK-3
Integral, BK series,
3.500 [88.9] KBMG 5.390 [136.9] 4.155 [105.5] 2.867 [72.8] 7,000 [48,265] 6,000 [41,370] 5,500 [37,923] 4,500 [31,029] OK, TPM
BEK-2, BEK-3
KBMG- Integral, BK series,
3.500 [88.9] 5.843 [148.4] na 2.867 [72.8] 7,000 [48,265] 6,000 [41,370] 5,500 [37,923] 4,500 [31,029] OK, TPM
LTS BEK-2, BEK-3
Integral, BK series,
4.500 [114.3] KBMG 6.437 [163.9] 5.500 [139.7] 3.833 [97.4] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] OK, TPM
BEK-2, BEK-3
KBMG- Integral, BK series,
4.500 [114.3] 7.281 [184.9] na 3.833 [97.4] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] OK, TPM
LTS BEK-2, BEK-3
†Additional sizes and pressure ratings are available upon request.
‡Test pressures listed are all for low-alloy steel, heat treated for normal or corrosive conditions. These pressures may be reduced because of end connection limitations.
§Not applicable.

Guide to KBMG Series Side Pocket Accessories


Gas Lift Valve Equalizing Dummy Shear Circulating Chemical Waterflood Flow
Dummy Valves Valves Orifice Valves Valves Injection Valves Regulator Valves
BK EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na†
BK-1 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKT EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKT-1 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKF-12 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
OM-21R EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
NOVA-10 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKR-5 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
PK-1 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
DKO-2 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKO-3 EK, EK-1 E, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
†Not applicable.

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Gas Lift Systems  |  Technology 98
KBMM-R Series Side Pocket Mandrels
Single-pocket mandrels that accept 1-in [25.4-mm] OD side pocket devices
APPLICATIONS KBMM-R series side pocket mandrels from
■ Gas lift production Camco* gas lift and subsurface safety systems accept
■ Chemical injection, waterflood, or 1-in [25.4-mm] OD flow control devices and are made
circulation operations up as part of the tubing string when preparing a well
for gas lift production, chemical injection, waterflood,
■ Single-string completions
or other special applications. KBMM-R mandrels have
■ Sweet or sour service a round body, which provides a strong, robust design
BENEFITS with better, more uniform stress concentrations
■ Higher pressure ratings than comparable when compared to the traditional oval-body mandrel
oval side pocket mandrels designs. The KBMM-R mandrels are available in a
variety of tubing sizes and connection thread types.
■ Precise alignment and insertion of side
pocket devices, minimizing the opportunity The KBMM-R mandrel also incorporates a new body
for hang-up during slickline operations and pocket window design, which reduces overall
■ Field-proven reliability welding.

FEATURES Design
■ Positioning sleeve orientation system KBMM-R mandrels feature a one-piece pocket and a
tool discriminator that keep larger slickline tools from
■ Machined tool discriminator that deflects
entering the pocket area while guiding the smaller
large tools into the tubing bore
side pocket devices into the pocket. An orienting
■ Integral machined pocket sleeve located in the mandrels’s upper swage helps
■ Smooth internal and external shoulders ensure precise alignment and operation of positive
■ Availability in a variety of materials kickover tools in highly deviated wells.

Schlumberger standard side pocket mandrels are


manufactured from high-quality low-alloy steel,
the metallurgical properties of which are closely
controlled through rigid specifications. These
mandrels are heat-treated for both sweet and sour
(H2S) service, and the mandrels for H2S service
conform to NACE standard MR0175 for sulfide-stress-
cracking–resistant metallic materials.

KBMM-R mandrels have a round body, which provides a strong, KBMM-R series side pocket mandrel.
robust design with better, more uniform stress concentrations
when compared to the traditional oval-body mandrel designs.

Table of Contents Previous page Next page


Gas Lift Systems  |  Technology 99
KBMM-R Series Side Pocket Mandrel
Operation pocket of the mandrel. When the valve has high-pressure injection gas is injected down the
Valves are assembled to the appropriate Camco been installed into the mandrel pocket, the latch casing annulus. From the casing, gas enters the
systems BK series top latch and can be run locks under the latch lug, securing the valve mandrel, flows through the valve and into the
under pressure by slickline methods into the in the pocket. In regular gas lift operations, tubing, aiding fluid production.

KBMM-R Series Side Pocket Mandrel Specifications


Pressure Rating for Pressure Rating for
Sour Service† Standard Service†
Tubing Size, Min ID, Drift ID, Major OD, Drift OD, Internal, External, Internal, External, Latch type Kickover tool
in [cm] in [cm] in [cm] in [cm] in [cm] psi [kPa] psi [kPa] psi [kPa] psi [kPa]
2.375 1.924 1.901 4.236 4.369 6,000 6,000 7,500 7,000 Integral, BK-2 OK, TMP
[6.03] [4.89] [4.83] [10.76] [11.10] [41,369] [41,369] [51,711] [48,263] series
2.875 2.366 2.347 4.750 4.887 7,000 6,000 8,000 7,000 Integral, BK-2 OK, TMP
[7.30] [6.01] [5.96] [12.07] [12.41] [48,263] [41,369] [55,158] [48,263] series
3.500 2.915 2.867 5.390 5.550 7,000 5,100 8,300 6,000 Integral, BK-2 OK, TMP
[8.89] [7.40] [7.28] [13.69] [14.10] [48,263] [35,163] [57,226] [41,369] series
†Pressure ratings listed are all for low-alloy steel which has been heat-treated for sour service (80,000 psi [552 MPa] yield) or standard service (95,000 psi [655 MPa] yield). These pressures may be reduced due to

end connection limitations.

KBMM-R Series Side Pocket Mandrel Accessories


Gas Lift Valve Gas Lift Orifice Dummy Valve Equalizing Shear Orifice Circulating Chemical
Dummy Injection
BK DKO-2 E EK SO2M-14R BKFS CM-40R
BK-1 BKO-3 DK-1 EK-1 CSK-2 BKLK-2
BKF-12 OM-21R SCS-10 BKCI-2
BKR-5 NOVA-10
PK-1
WFM-14R

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Gas Lift Systems  |  Technology 100
KBG Series Side Pocket Mandrels
Single-pocket mandrels that accept 1-in [25.4-mm] OD side pocket devices
APPLICATIONS Camco* gas lift and subsurface safety systems’ KBG mandrels
■ Normal and corrosive service incorporate an integral, one-piece pocket and tool discriminator
■ Single-string completions and an orienting sleeve for positive kickover tool alignment in
highly deviated wells.
BENEFITS
■ Enables precise alignment and insertion of The tool discriminator excludes larger slickline tools from the
side pocket devices, minimizing pocket area. These mandrels are available in a variety of tubing
the opportunity for hang-up during connection sizes and incorporate all the standard design features
slickline operations of Camco systems side pocket mandrels.
■ Optimizes production with unique design KBG mandrels have round OD configurations similar to KBTG
features to facilitate operations series side pocket mandrels. The KBG has a discriminator and
pocket configuration similar to KBMG mandrels, and the round
FEATURES
design increases the mandrel’s pressure rating over the rating of
■ Positioning sleeve orientation system
the KBMG.
■ Integral machined discriminator
and pocket Design variations
■ Round body for higher pressure ratings and KBG mandrels have design variations tailored to specific
premium metallurgy applications production applications, and are available in a wide range of
sizes. KBG-2 series mandrel has a slightly reduced OD and a fully
■ Availability in a variety of materials
open ID designed for heavyweight tubing.
KBG series side pocket mandrels are available in a range of
fully traceable materials and can be heat treated to comply with
NACE specification MR0175 for stress-cracking resistant metallic
materials.

KBG series
side pocket mandrel.

Table of Contents Previous page Next page


Gas Lift Systems  |  Technology 101
KBG Series Side Pocket Mandrels
Engineering Data for KBG Series Pocket Mandrels
Test Pressure (Internal), Test Pressure (External),
Tubing Size,† Major OD, Internal Drift, psi [kPa]‡ psi [kPa]‡ Kickover
Type† Latch Type
in [mm] in [mm] in [mm] Normal Corrosive Normal Corrosive Tool
Service Service Service Service
BK series, BEK-2, BEK-3,
2.875 [73.0] KBG 4.875 [123.8] 2.229 [56.6] na§ 12,000 [82,737] na 12,500 [86,184] OK,TPM
Integral
BK series, BEK-2, BEK-3,
3.500 [88.9] KBG-2 5.369 [136.4] 2.867 [72.0] 13,000 [89,636] 11,000 [75,846] 12,400 [85,499] 10,400 [71,708] OK,TPM
Integral
BK series, BEK-2, BEK-3,
4.500 [114.3] KBG-2 5.984 [152.0] 3.600 [91.4] 6,616 [45,610] na 6,300 [43,439] na OK,TPM
Integral
†Additional sizes and pressure ratings are available upon request.
‡Test pressures listed are all for low-alloy steel, heat treated for normal or corrosive conditions. These pressures may be reduced because of end connection limitations.
§Not applicable

Guide to KBG Series Side Pocket Accessories


Equalizing Dummy Shear Circulating Chemical Waterflood Flow
Gas Lift Valve
Dummy Valves Valves Orifice Valves Valves Injection Valves Regulator Valves
BK EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na†
BK-1 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKT EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKT-1 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
NOVA-10 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKR-5 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
PK-1 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
DKO-2 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKO-3 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
BKO-5 EK, EK-1 EK, DK-1 SO2M-14R CSK-1, BKFS CM-40R, BKLK-2, BKCI-2 na
†Not applicable

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Gas Lift Systems  |  Technology 102
MMG Series Side Pocket Mandrels
11⁄2-in [38.1-mm] OD side pocket devices
Single-pocket mandrels that accept 1½-in
APPLICATIONS MMG series side pocket mandrels are available in a variety of tubing
■ Normal and corrosive service connection sizes and incorporate all the standard design features of standard
■ Single-string completions Camco* gas lift and subsurface safety systems’ side pocket mandrels.

BENEFITS Design variations


■ Enables precise alignment and insertion of The following mandrels have variations that configure them for specific
side pocket devices, minimizing production applications, and are available in a full range of sizes.
the opportunity for hang-up during
The MMG-2 series has a slightly reduced OD and a fully open ID. Most
slickline operations
mandrels with this designation have a reduced test pressure.
■ Optimizes production with unique design
features to facilitate operations MMG-LTS series has an integral connection extending from the surface
wellhead connection. This standard connection is a 1⁄8-in [3.2-mm] NPT box
FEATURES that accepts a 1⁄4-in [6.4-mm] OD injection conduit. LTS mandrels are used
■ Patented positioning sleeve when two or more fluids being injected into the well must be kept separate
orientation system until they are commingled in the flow stream. In this type of installation,
■ Forged tool discriminator that deflects large the LTS mandrel leaves the annulus free for other production uses.
tools into the tubing bore In chemical injection applications, injected chemicals enter the mandrel
■ Integral forged pocket pocket through the injection conduit and flow through the chemical
injection valve and into the tubing.

MMG series mandrels are available in a range of fully traceable materials


and can be heat-treated to comply with NACE specification MR0175 for
stress-cracking resistant metallic materials.

MMG series
side pocket mandrel.

Table of Contents Previous page Next page


Gas Lift Systems  |  Technology 103
MMG Series Side Pocket Mandrels
Engineering Data for MMG Series Pocket Mandrels
Test Pressure (Internal)‡ Test Pressure (External)‡
Tubing Size,† Major OD, Minor OD, Internal Drift, Kickover
Type† Normal Corrosive Normal Corrosive Latch Type
in [mm] in [mm] in [mm] in [mm] Tool§
Service Service Service Service
2.375 [60.3] MMG 4.673 [118.7] 4.000 [101.6] 1.901 [48.3] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] RK, RK-1, RKP OM, TP
2.875 [73.0] MMG 5.500 [139.7] 4.594 [116.7] 2.347 [59.6] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] RK, RK-1, RKP OM, TP
3.500 [88.9] MMG 5.968 [151.6] 5.000 [127.0] 2.867 [72.8] 8,000 [55,160] 7,000 [48,265] 6,500 [44,818] 5,500 [37,923] RK, RK-1, RKP OM, TP
3.500 [88.9] MMG-2 5.750 [146.1] 5.000 [127.0] 2.867 [72.8] 6,000 [41,370] 5,000 [34,475] 4,000 [27,580] 3,000 [27,580] RK, RK-1, RKP OM, TP
4.500 [114.3] MMG 7.031 [178.6] 5.625 [142.9] 3.833 [97.4] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] RK, RK-1, RKP OM, TP
4.500 [114.3] MMG-LTS 7.594 [192.9] na†† 3.833 [97.4] 7,500 [51,713] 6,000 [41,370] 6,000 [41,370] 5,000 [34,475] RK, RK-1, RKP OM, TP
5.000 [127.0] MMG 7.962 [202.2] 6.812 [173.0] 4.283 [108.8] na 6,500 [44,818] na 5,500 [37,923] RK, RK-1, RKP OM, TP
5.500 [139.7] MMG 7.962 [202.2] 6.812 [173.0] 4.653 [118.2] 8,500 [58,607] 6,500 [44,818] 7,000 [48,265] 5,500 [37,923] RK, RK-1, RKP OM, TP
†Additional sizes and pressure ratings are available upon request.
‡Test pressures listed are all for low-alloy steel, heat treated for normal or corrosive conditions. These pressures may be reduced because of end connection limitations.
§Use a spacer bar with the pulling tool and all OM series kickover tools.
††Not applicable

Guide to MMG Series Side Pocket Accessories


Gas Lift Valve Equalizing Dummy Shear Circulating Chemical Waterflood Flow
Dummy Valves Valves Orifice Valves Valves Injection Valves Regulator Valves
RGR-2, RKFS, RCS,
R-20-02 CEV RD SO2-30R C-31R, RCB RWF-B, RWFD
RG-1, RG-2
RGR-2, RKFS, RCS,
R-25P CEV RD SO2-30R C-31R, RCB RWF-B, RWFD
RG-1, RG-2
RGR-2, RKFS, RCS,
RP-6 CEV RD SO2-30R C-31R, RCB RWF-B, RWFD
RG-1, RG-2
RGR-2, RKFS, RCS,
RDO-20 CEV RD SO2-30R C-31R, RCB RWF-B, RWFD
RG-1, RG-2
RGR-2, RKFS, RCS,
O21-R CEV RD SO2-30R C-31R, RCB RWF-B, RWFD
RG-1, RG-2
RGR-2, RKFS, RCS,
O2-30R CEV RD SO2-30R C-31R, RCB RWF-B, RWFD
RG-1, RG-2
RGR-2, RKFS, RCS,
NOVA-15 CEV RD SO2-30R C-31R, RCB RWF-B, RWFD
RG-1, RG-2

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Gas Lift Systems  |  Technology 104
MMM-R Series Side Pocket Mandrels
Single-pocket mandrels that accept 1.5-in [38.1-mm] OD side pocket devices
APPLICATIONS MMM-R series side pocket mandrels from
■ Gas lift production Camco* gas lift and subsurface safety systems accept
■ Chemical injection, waterflood, or 1.5-in [38.1-mm] OD flow control devices and are
circulation operations made up as part of the tubing string when preparing
a well for gas lift production, chemical injection,
■ Single-string completions
waterflood, or other special applications. MMM-R
■ Sweet or sour service mandrels have a round body, which provides a
BENEFITS strong, robust design with better, more uniform stress
■ Higher pressure ratings than comparable concentrations when compared to the traditional
oval side pocket mandrels oval-body mandrel designs. The MMM-R mandrels
are available in a variety of tubing sizes and
■ Precise alignment and insertion of side
connection thread types.
pocket devices, minimizing the opportunity
for hang-up during slickline operations The MMM-R mandrel also incorporates a new body
■ Field-proven reliability and pocket window design, which reduces overall
welding.
FEATURES
■ Positioning sleeve orientation system Design
MMM-R mandrels feature a one-piece pocket and a
■ Machined tool discriminator that deflects
tool discriminator that keep larger slickline tools from
large tools into the tubing bore
entering the pocket area while guiding the smaller
■ Integral machined pocket side pocket devices into the pocket. An orienting
■ Smooth internal and external shoulders sleeve located in the mandrels’s upper swage helps
■ Availability in a variety of materials ensure precise alignment and operation of positive
kickover tools in highly deviated wells.

Schlumberger standard side pocket mandrels are


manufactured from high-quality low-alloy steel,
the metallurgical properties of which are closely
controlled through rigid specifications. These
mandrels are heat-treated for both sweet and sour
(H2S) service, and the mandrels for H2S service
conform to NACE standard MR0175 for sulfide-stress-
cracking–resistant metallic materials.

MMM-R mandrels have a round body, which provides a strong,


robust design with better, more uniform stress concentrations
when compared to the traditional oval-body mandrel designs. MMM-R series side pocket mandrel.

Table of Contents Previous page Next page


Gas Lift Systems  |  Technology 105
MMM-R Series Side Pocket Mandrels
Operation valve has been installed into the mandrel annulus. From the casing, gas enters the
Valves are assembled to the appropriate pocket, the latch locks under the latch mandrel, flows through the valve and into
Camco systems RK series top latch and can lug, securing the valve in the pocket. In the tubing, aiding fluid production.
be run under pressure by slickline methods regular gas lift operations, high-pressure
into the pocket of the mandrel. When the injection gas is injected down the casing

MMM-R Series Side Pocket Mandrel Specifications


Pressure Rating for Pressure Rating for
Sour Service† Standard Service†
Tubing Size, Min ID, Drift ID, Major OD, Drift OD, Internal, External, Internal, External, Latch type Kickover tool
in [cm] in [cm] in [cm] in [cm] in [cm] psi [kPa] psi [kPa] psi [kPa] psi [kPa]
2.375 1.935 1.901 4.673 4.767 7,000 6,000 8,000 7,000 RK Series OM, TP
[6.03] [4.91] [4.83] [11.87] [12.11] [48,263] [41,369] [55,158] [48,263]
2.875 2.366 2.347 5.500 5.666 6,500 5,500 8,000 6,500 RK Series OM, TP
[7.30] [6.01] [5.96] [13.97] [14.39] [44,816] [37,921] [55,158] [44,816]
3.500 2.915 2.867 5.968 6.059 7,000 6,000 8,000 7,000 RK Series OM, TP
[8.89] [7.40] [7.28] [15.16] [15.39] [48,263] [41,369] [55,158] [48,263]
†Pressure ratings listed are all for low-alloy steel which has been heat-treated for sour service (80,000 psi [552 MPa] yield) or standard service (95,000 psi [655 MPa] yield). These pressures may be

reduced due to end connection limitations.

MMM-R Series Side Pocket Mandrel Accessories


Gas Lift Valve Gas Lift Orifice Dummy Valve Equalizing Shear Orifice Circulating Chemical Water Flood
Dummy Injection
R20-02 RDO-20 RD CEV SO2-30R RKFS C-31R RWF-B
R-25P O-21R RKED RCS RCB-2 RWF-D
RP-6 O2-30R RGR-2
WF-14R NOVA-15 SCS-15

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Gas Lift Systems  |  Technology 106
MMRG Series Side Pocket Mandrels
Single-pocket mandrels that accept 11⁄2-in [38.1-mm] OD side pocket devices
APPLICATIONS Camco* gas lift and subsurface safety systems’ MMRG series side pocket
■ Normal and corrosive service mandrels are made as part of the tubing string when preparing a well for gas
■ Single-string completions lift production, chemical injection, waterflood, or other special applications.
MMRG mandrels are designed with a round body construction and are
BENEFITS available in a variety of tubing sizes and connection thread types. They
■ Enables precise alignment and insertion of incorporate all the standard design features of Camco systems side pocket
side pocket devices, minimizing mandrels.
the opportunity for hang-up during
slickline operations MMRG mandrels feature an integral, one-piece pocket and a tool discrimina-
tor that keeps larger slickline tools from entering the pocket area whilst guid-
■ Optimizes production with unique design
ing the smaller side pocket devices into the pocket. An orienting sleeve helps
features to facilitate operations
ensure precise alignment of positive kickover tools in highly deviated wells.
FEATURES
Design variations
■ Positioning sleeve orientation system
The following mandrels have variations that configure them for specific
■ Machined tool discriminator that deflects production applications and are available in a full range of sizes.
large tools into the tubing bore
■ Single-piece machined pocket
■ MMRG-4 series
●The ends of this mandrel are lengthened to accommodate the rema-
■ Superior design and construction, including chining of connecting threads.
no longitudinal welds
■ MMRG-5 series
■ Pressure and tensile rating near or equal to ●This mandrel has integral guard devices to protect chemical injection
that of the parent tubing conduits being run simultaneously with the mandrel.
MMRG-LTS series has an integral connection extending from the surface
wellhead connection. This standard connection is a 1⁄8-in [3.2-mm] box that
accepts a 1⁄4-in [6.4-mm] OD injection conduit. LTS mandrels are used when
two or more fluids being injected into the well must be kept separate until
they are commingled in the flow stream. In this type of installation, the
LTS mandrel leaves the annulus free for other production uses. In chemical
injection applications, injected chemicals enter the mandrel pocket through
the injection conduit and flow through the chemical injection valve and into
the tubing.

MMRG series mandrels are available in a range of fully traceable materials


and can be heat treated to comply with NACE specification MR0175 for
stress-cracking resistant metallic materials.

MMRG series side pocket


mandrel.

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Gas Lift Systems  |  Technology 107
MMRG Series Side Pocket Mandrels
Engineering Data for MMRG Series Pocket Mandrels
Tubing size,† in Type† Major OD, Minor OD, External Drift, Internal Drift, Test Pressure Test Pressure Latch Type Kickover Tool
[mm] in [mm] in [mm] in [mm] in [mm] (Internal), psi (External), psi
[kPa]‡ [kPa]‡
2.875 [73.0] MMRG 5.261 [133.6] 5.261 [133.6] 5.376 [136.5] 2.347 [59.6] 10,000 [68,948] 10,000 [68,948] RK, RK-1, RKP OM, TP
3.500 [88.9] MMRG 5.968 [151.6] 5.968 [151.6] 6.059 [153.9] 2.867 [72.8] 10,000 [68,948] 10,500 [72,395] RK, RK-1, RKP OM, TP
4.500 [114.3] MMRG 7.25 [184.15] 7.25 [184.15] 7.386 [187.6] 3.833 [97.4] 8,000 [55,158] 7,500 [51,711] RK, RK-1, RKP OM, TP
5.000 [127.0] MMRG 7.25 [184.15] 7.25 [184.15] 7.386 [187.6] 3.833 [97.4] 8,000 [55,158] 7,250 [49,987] RK, RK-1, RKP OM, TP
5.500 [139.7] MMRG 7.982 [202.7] 7.982 [202.7] 8.379 [212.8] 4.653 [118.2] 7,740 [53,365] 6,280 [43,299] RK, RK-1, RKP OM, TP
7.000 [177.8] MMRG 9.414 [239.1] 9.414 [239.1] 9.504 [241.4] 5.812 [147.6] 5,700 [39,300] 5,300 [36,542] RK, RK-1, RKP OM, TP
†Additional sizes and pressure ratings are available upon request.
‡Test pressures listed are all for low-alloy steel, heat treated for normal or corrosive conditions. These pressures may be reduced because of end connection limitations.
§Use a spacer bar with the pulling tool and all OM series kickover tools above.

Guide to MMRG Series Side Pocket Accessories


Gas Lift Valve Equalizing Dummy Shear Circulating Chemical Waterflood Flow
Dummy Valves Valves Orifice Valves Valves Injection Valves Regulator Valves
R-20-02 CEV RD SO2-30R RGR-2, RKFS, RCS, RG-1, RG-2 C-31R, RCB RWF-B, RWFD
R-25P CEV RD SO2-30R RGR-2, RKFS, RCS, RG-1, RG-2 C-31R, RCB RWF-B, RWFD
RP-6 CEV RD SO2-30R RGR-2, RKFS, RCS, RG-1, RG-2 C-31R, RCB RWF-B, RWFD
RDO-20 CEV RD SO2-30R RGR-2, RKFS, RCS, RG-1, RG-2 C-31R, RCB RWF-B, RWFD
O21-R CEV RD SO2-30R RGR-2, RKFS, RCS, RG-1, RG-2 C-31R, RCB RWF-B, RWFD
O2-30R CEV RD SO2-30R RGR-2, RKFS, RCS, RG-1, RG-2 C-31R, RCB RWF-B, RWFD
NOVA-15 CEV RD SO2-30R RGR-2, RKFS, RCS, RG-1, RG-2 C-31R, RCB RWF-B, RWFD

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Gas Lift Systems  |  Technology 108
Injection-Pressure-Operated Gas Lift Valves
Retrievablevalves
Retrievable valvesforfortubing
tubing
forfor annular
annular flowflow in continuous
in continuous or intermittent
or intermittent production
production
APPLICATIONS Camco* gas lift and subsurface safety systems’ injection-
■ Tubing or annular flow pressure-operated gas lift valves use nitrogen-charged,
■ Continuous or intermittent production multi-ply MONEL® bellows to provide the force necessary
to maintain the valves in the normally closed position. The
BENEFITS bellows assembly includes a hydraulic dampening system,
■ Enables uniform operation and extended which uses silicon fluid to reduce the movement of the
run life valve stem tip. This prevents destructive valve chatter and
■ Improves economics with operational prolongs run life.
versatility
1-in [25.4-mm] OD BK, BK-1, BKT, and BKT-1 valves and
■ Increases reliability and efficiency 11⁄2-in [38.1-mm] OD R-20-02 valves are available, featuring
FEATURES integral reverse-flow check valves.
■ Field-proven design These gas lift valves are installed in standard side pocket
■ Hydraulic forming process for the bellows mandrels for tubing flow and in specially ported side pocket
■ Premium materials that work in a variety of mandrels for annular flow.
applications
Port sizes
■ Floating seats ■ 1-in OD valves are available with port sizes for BK valves
■ Guided valve-stem for precise alignment in 1⁄16-in [1.6-mm] increments from 1⁄8 in to 5⁄16 in [3.2 mm to
with the seat during operation 7.9 mm], and port sizes for BK-1, BKT, and BKT-1 valves
■ Reverse-flow check valves to prevent back- in 1⁄16-in increments from 1⁄8 in to 3⁄8 in [3.2 mm to 9.5
flow into the tubing annulus mm].
■ 11⁄2-in [38.1-mm] OD valves are available with port sizes
for R-20-02 valves in 1⁄16-in increments from 1⁄8 in to 1⁄2 in
[3.2 mm to 12.7 mm].
Operation
The injection pressure necessary to compress the bellows
of these gas lift valves is determined by the precharged
nitrogen pressure in the bellows. Injection gas enters
the valve and acts on the effective bellows area. As the
injection gas pressure overcomes the precharged pressure,
the bellows compresses and lifts the stem tip off the seat.
Injection gas then flows through the seat, past the reverse-
flow check valve, and into the production tubing.

BK series gas lift valve (left) and R-20-02 series


gas lift valve (right).

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Gas Lift Systems  |  Technology 109
Injection-Pressure-Operated Gas Lift Valves
Engineering Data for Injection-Pressure-Operated Gas Lift Valves
Valve Type Nominal OD, in [mm] Latch Running Tool Pulling Tool Mandrel Series
BK 1.000 [25.4] BK series JK JDC KBM, KBMM, KBMG, KBG
BK-1 1.000 [25.4] Integral bottom GA-2 JDC† KBM, KBMM, KBMG, KBG
BKT 1.000 [25.4] BK series JK JDC KBM, KBMM, KBMG, KBG
BKT-1 1.000 [25.4] Integral bottom GA-2 JDC† KBM, KBMM, KBMG, KBG
R-20-02 1.500 [38.1] RA JC-3 JDC MMA
†Use core extension with this pulling tool for integral bottom latch valves.

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Gas Lift Systems  |  Technology 110
Production-Pressure-Operated
Gas Lift Valves
Production-Pressure-Operated Gas Lift Valves
Retrievable valves for continuous tubing flow production
APPLICATIONS Field-proven Camco* gas lift and subsurface safety systems’
■ Continuous tubing flow production-pressure-operated gas lift valves are available as
the 1-in [25.4-mm] OD BKR-5 and BKF-12 valves and the 11⁄2-in
BENEFITS
[38.1-mm] OD R-25P valves.
■ Enables uniform operation and extended
run life A multi-ply MONEL® bellows provides the force necessary to
■ Improves efficiency with free flow maintain the BKR-5 and R-25P valves in the normally closed
of injection gas to tubing position, while the BKF-12 valve uses an atmospheric-pressure-
charged, multi-ply MONEL bellows and an INCONEL® spring.
■ Increases reliability
All the valves contain integral reverse-flow check valves and
FEATURES
crossover seats. The 1-in valves also have floating seats.
■ Hydraulic forming process for the bellows
■ Large-area crossover seats Port sizes
■ Premium materials suitable for 1-in OD valves are available in 1⁄8-, 3⁄16-, and 1⁄4-in [3.2-, 4.8-, and
various environments 6.4-mm] port sizes. 11⁄2-in OD valves are available in 1⁄8-, 3⁄16-, 1⁄4-,
5
⁄16-, and 3⁄8-in [3.2-, 4.8-, 6.4-, 8.0, and 9.5-mm] port sizes.
■ Floating seats for versatile application
and economical replacement Operation
■ Guided valve stem for precise alignment Production fluid enters the gas lift valve and acts on the effective
with the seat during operation bellows area. The production pressure necessary to compress
■ Reverse-flow check valves to prevent the bellows of the BKR-5 and R-25P valves is determined by
backflow into the tubing annulus precharged nitrogen pressure. The force necessary to overcome
the INCONEL spring in the BKF-12 valve is provided by the
production and gas pressure times the effective bellows area.

As production pressure overcomes the precharged nitrogen


pressure in the bellows or the preset spring force, the bellows
compresses and lifts the stem tip off the seat. Injection gas
then flows through the seat, past the reverse-flow check valve,
and into the production conduit.

BKF-12 gas lift valve.

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Gas Lift Systems  |  Technology 111
Production-Pressure-Operated Gas Lift Valves
Engineering Data for Production-Pressure-Operated Gas Lift Valves
Valve Type Nominal OD, in [mm] Latch Running Tool Pulling Tool Mandrel Series
BKR-5 1.000 [25.4] Integral bottom GA-2 JDC† KBM, KBMM, KBMG, KBG
BKF-12 1.000 [25.4] BK series JK JDC KBM, KBMM, KBMG, KBG
R-25P 1.500 [38.1] RA JC-3 JDC MMA
R-25P 1.500 [38.1] RK RK-1 JDS MMM, MMG, MMRG
†Use core extension with this pulling tool for integral bottom latch valves.

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Gas Lift Systems  |  Technology 112
Pilot-Operated Gas Lift Valves
Slickline-retrievable valves for intermittent tubing flow production
APPLICATIONS Each Camco systems pilot-operated gas lift valve consists of a pilot section and
■ Intermittent tubing flow production a power section. A specially manufactured, nitrogen-charged, multi-ply MONEL®
bellows provides the force necessary to maintain the pilot section in the normally
BENEFITS
closed position, while the power section uses an INCONEL® spring for the purpose.
■ Increases efficiency
1-in [25.4-mm] OD PK-1 valves and 11⁄2-in [38.1-mm] OD RP-6 valves are available.
■ Enables uniform bellows operation The valves feature integral reverse-flow check valves and floating seats.
FEATURES Flow areas
■ Small spread between the opening and clos- The power section of the PK-1 valve has a flow area equivalent to a 3⁄8-in [9.5-mm]
ing casing pressures port. Port sizes for the pilot section are available in 1⁄16-in [1.6-mm] increments from
■ Large flow-area for high-volume gas injec- 1
⁄8 to 5⁄16 in [3.2 to 7.9 mm].
tion applications
The power section of the RP-6 valve has a flow area equivalent to a 9⁄16-in [14.3-mm]
■ Premium materials suitable for various envi- port. Port sizes for the pilot section are available in 1⁄16-in increments from
ronments 1
⁄4 to 1⁄2 in [6.4 to 12.7 mm].
■ Floating seats for versatile application and
economical replacement Operation
The power section of the valve is either fully open or fully closed, as determined by
■ Field-proven Camco* gas lift and subsurface
the pilot section. Injection gas enters the pilot section of the valve and acts on the
safety systems bellows in the
effective bellows area. As injection pressure overcomes the precharged nitrogen
pilot section
pressure in the bellows, the bellows is compressed and lifts the stem tip off the seat.
■ Reverse-flow check valves to prevent back-
flow into the tubing annulus Injection gas then flows down past the seat and eventually overcomes the preset
spring force of the power section. As the power section opens, a high volume of
injection gas flows through the valve, past the reverse-flow check valve into the
production tubing.

Engineering Data for Pilot-Operated Valves


Valve Nominal OD, Latch Running Pulling Mandrel Series
Type in [mm] Tool Tool
Integral KBM, KBMM,
PK-1 1.000 [25.4] GA-2 JDC†
bottom KBMG, KBG
RP-6 1.500 [38.1] RA JC-3 JDC MMA
RP-6 1.500 [38.1] RK RK-1 JDS MMM, MMG, MMRG
†Use core extension with this pulling tool for integral bottom latch valves.

PK-1 gas lift valve.

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Gas Lift Systems  |  Technology 113
Single-Point Injection Orifice Gas Lift Valves
Retrievable valves for continuous tubing flow production
APPLICATIONS An integral choke controls the flow of gas that passes through the nomally
■ Continuous tubing flow production open Camco* gas lift and subsurface safety systems’ single-point injection
orifice gas lift valve into the production tubing. This reliable line of valves
BENEFITS
comprises the 1-in [25.4-mm] OD DKO-2, BKO-3, and OM-21R valves and the
■ Operates reliably
11⁄2-in [38.1-mm] OD RDO-20, O-21R, and O2-30-R valves. O2-30-R valves have
■ Enables highly efficient and dual reverse-flow check valves. DKO-2 valves have nonfloating, replaceable
economical performance chokes, while the others have floating chokes. All the valves contain integral
reverse-flow check valves.
FEATURES
■ Field-proven design Port sizes
■ Integral reverse-flow check valves Port sizes for these valves are available in 1⁄16-in [1.6-mm] increments.
and replaceable floating and ■ 1-in OD valves:
nonfloating seats – DKO-2 valve ports are available from 1⁄8 to 3⁄8 in [3.2 to 9.5 mm]
– BKO-3 valve ports are available from 1⁄8 to 5⁄16 in [3.2 to 7.9 mm]
– OM-21R valve ports are available from 1⁄8 to 7⁄16 in [3.2 to 11.1 mm].
■ 11⁄2-in OD valves:
– RDO-20 valve ports are available from 1⁄8 to 1⁄2 in [3.2 to 12.7 mm].
– O-21R valve ports are available from 1⁄8 to 44⁄64 in [3.2 to 17.4 mm]
– 02-30R valve ports are available from 1⁄8 to 5⁄8 in [3.2 to 15.9 mm].

Operation
Injection gas enters the valve through the external ports between the valve
packing seats and travels through the choke, past the reverse- flow check
valve, and into the production tubing.

Engineering Data for Single-Point Injection Orifice Gas Lift Valves


Valve Type Nominal OD, Latch Running Pulling Mandrel Series
in [mm] Tool Tool
Integral KBM, KBMM,
DKO-2 1.000 [25.4] GA-2 JDC†
bottom KBMG, KBG
KBM, KBMM,
BKO-3 1.000 [25.4] BK series JK JDC
KBMG, KBG
KBM, KBMM,
OM-21R 1.000 [25.4] BK series JK JDC
KBMG, KBG
RDO-20 1.500 [38.1] RA JC-3 JDC MMA
MMM, MMG,
RDO-20 1.500 [38.1] RK RK-1 JDS
MMRG
O-21R 1.500 [38.1] RA JC-3 JDC MMA
MMM, MMG,
O-21R 1.500 [38.1] RK RK-1 JDS
MMRG
BKO-3 orifice valve.
02-30R 1.500 [38.1] RA JC-3 JDC MMA
MMM, MMG,
02-30R 1.500 [38.1] RK RK-1 JDS
MMRG
†Use core extension with this pulling tool for integral bottom latch valves.

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Gas Lift Systems  |  Technology 114
NOVA
Gas lift valves
APPLICATIONS NOVA* gas lift valves feature a computer-generated flow profile that enables
■ Continuous flow production maximum gas passage with minimal differential across the valve. The NOVA
valve flow regime virtually eliminates any effect of tubing pressure on the gas
BENEFITS
injection rate and stabilizes the gas injection pressure. Stable injection rates
■ Maximizes efficiency
can result in more stable tubing pressure, increased production, and reduced
■ Reduces costs operating expenses.
■ Improves productivity
The NOVA valve series replaces conventional orifice valves that have
FEATURES inherently unstable injection rates because of the effect of tubing pressure.
■ Computer-generated flow profile Even slight variations in the tubing flow regime can lead to wide fluctuations
■ Stabilized, lower injection pressure in the tubing pressure and result in unsteady injection rates, instability, and
slugging.
■ Simple, versatile, field-proven design
Conventional flat-faced orifice valves require an approximately 40% pressure
drop to achieve critical flow; in most cases, operating with such excessive
pressure loss is not practical. NOVA valves achieve critical flow with a pres-
sure drop of 10% or less. Injection rates are constant when operating in the
critical flow regime because the tubing pressure does not affect the injection
volume.

Higher productivity and lower costs are achieved with innovative engineering,
a field-proven design, and the same number of moving parts as a typical
flat-faced gas lift orifice valve. In addition, NOVA valves fit in any existing side
pocket mandrel.

Operation
The NOVA valve uses an orifice venturi check valve for continuous flow
operations. Injection fluid or gas enters through the entry ports and then
flows through the orifice venturi. Injection pressure moves the check valve
off the seat, allowing gas to enter the tubing. Reverse flow pushes the check
valve closed, preventing tubing fluids and pressure from flowing back into the
casing.

For injection of gas from the tubing to the casing annulus, the valve is installed
in a mandrel with a type EC pocket, which has tubing ports between the seal-
bores in the mandrel pocket. Injection gas flows out the bottom of the valve,
through the mandrel snorkel into the casing or tubing annulus.

NOVA orifice venturi

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Gas Lift Systems  |  Technology 115
NOVA
Engineering Data for Retrievable NOVA Gas Lift Valves
Valve Type Nominal OD, in [mm] Latch Running Tool Pulling Tool Mandrel Series
1.000 [25.4] BK series JK KBM, KBMM, KBMG,
10 JDC
KBG
15 1.500 [38.1] RA JC-3 JDC MMA
15 1.500 [38.1] RK RK-1 JDS MMM, MMG, MMRG

4,000
3,500 1,400 psi upstream
3,000
Improved orifice venturi valve
Flow rate, Mcf/d

2,500
2,000 900 psi upstream
1,500
Conventional orifice valve
1,000 400 psi upstream
500
0
0 200 400 600 800 1,000 1,20 1,400
Downstream pressure, psi

NOVA valves achieve critical flow with a pressure drop of 10% or less, while conventional orifice valves require an
approximately 40% pressure drop.

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Gas Lift Systems  |  Technology 116
Dummy Valves
For Camco gas lift and subsurface safety systems
APPLICATIONS Retrievable dummy valves for Camco* gas lift and subsurface safety
■ Mandrel strings without gas lift valves systems have two sets of packing that straddle and pack off the casing
or side-pocket accessories ports in the side-pocket mandrel. This line of valves comprises the 1-in
[25.4-mm] OD E and DK-1 valves and the 11⁄2-in [38.1-mm] OD RD valve.
BENEFITS
■ Operates reliably Operation
Communication between the tubing and the casing is positively sealed
FEATURES
off until the dummy valve is retrieved from the side pocket mandrel using
■ Premium materials
standard slickline methods.
■ Precision manufacturing
Engineering Data for Camco Dummy Valves
Valve Nominal OD, Latch Running Pulling Mandrel
Type in [mm] Tool Tool Series
KBM, KBMM,
E 1.000 [25.4] BK series JK JDC
KBMG, KBG
Integral KBM, KBMM,
DK-1 1.000 [25.4] GA-2 JDC†
bottom KBMG, KBG
RD 1.500 [38.1] RA JC-3 JDC MMA
MMM, MMG,
RD 1.500 [38.1] RK RK-1 JDS
MMRG
†Use core extension with this pulling tool for integral bottom latch valves.

DK-1 dummy valve. RD dummy valve.

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Gas Lift Systems  |  Technology 117
Conventional Reverse-Flow Check Valves
Velocity check valves used for gas lift services
APPLICATIONS Conventional reverse-flow check valves are velocity
■ Gas lift service check valves used with conventional Camco* gas lift
■ Used with conventional gas lift valves and subsurface safety systems that do not have integral
reverse-flow check valves. These check valves protect the
BENEFITS casing from backflow through valves that are below the
■ Protects casing from backflow with valves working valve and allow the application of pressure to
below the working valve the tubing for circulation or acidizing. Reverse-flow check
■ Prevents commingled production in dual gas valves also prevent the commingling of production fluids
lift installations in dual gas lift installations.

FEATURES This line of valves includes the 1-in [25.4-mm] OD BF


■ Rated to 10,000-psi [68,950-kpa] and B-1 valves and the 11⁄2-in [38.1-mm] OD CF and J-20
differential pressure valves. These valves each have an elastomeric soft seat
■ Ability to be converted from velocity check and a stainless steel hard seat. The initial seal is between BF and B-1 valves (left to right).
to positive-check valves the stainless steel check dart and the soft seat. These
check valves can withstand 10,000-psi differential pres-
sure and can be converted from velocity check valves to
positive check valves by adding a spring.

Flow area
The flow area for the 1-in OD BF and B-1 valves is equiva-
lent to a 5⁄16-in [7.9-mm] port.

The flow area for the 11⁄2-in OD valves is equivalent to a


1⁄2-in [12.7-mm] port for CF valves and a 9⁄16-in [14.3-mm]

port for J-20 valves.

Operation
Reverse-flow check valves require flow to close.
As the differential pressure across the check dart of the
valve increases, the dart contacts the soft seat and then
the hard seat to form a seal and close the check valve.
CF and J-20 valves (left to right).

Engineering Data for Conventional Reverse-Flow Check Valves


Type† OD, in [mm] Equivalent Port Size, in [mm] Connecting Thread, in - TPI
BF 1.000 [25.4] 0.313 [7.9] 0.500 - 14 NPT
BP-1 1.000 [25.4] 0.313 [7.9] 0.500 - 14 NPT
CF 1.500 [38.1] 0.500 [12.7] 0.500 - 14 NPT
J-20 1.500 [38.1] 0.563 [14.3] 0.500 - 14 NPT
†Optional spring is available.

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Gas Lift Systems  |  Technology 118
Conventional Injection-Pressure-Operated Valves
Gas lift valves for continuous or intermittent tubing flow
APPLICATIONS As part of Camco* gas lift and subsurface safety systems,
■ Gas lift service conventional injection-pressure-operated gas lift valves
■ Continuous or intermittent tubing flow are normally used for injection-pressure-operated gas lift
production with continuous or intermittent tubing flow. A
ADVANTAGES nitrogen-charged, multi-ply MONEL® bellows provides
■ Capable of operating with production or the force necessary to maintain these valves in a normally
injection pressure closed position.
■ Integral reverse-flow check valves or floating
This line of valves includes 5⁄8-in [15.9-mm] OD J-50 valves,
valve seat design
1-in [25.4-mm] OD J-40 valves, and 11⁄2-in [38.1-mm] OD J-20
valves. The J-50 valves have an integral reverse-flow check
valve while the J-40 and J-20 valves have floating valve seats.
The J-40 and J-20 valves operate with either production
or injection pressure. When used with the appropriate
conventional mandrel and reverse-flow check valve, the
J-40 and J-20 series valves can be used for either tubing or
annular flow.

Port sizes
The port sizes available for the 5⁄8-in OD J-50 valves are 1⁄8, 5⁄32, 13⁄64,
and 1⁄4 in [3.2, 3.9, 5.1, and 6.4 mm].

Port sizes are available for the 1-in OD J-40 valves in 1⁄16-in [1.6-
mm] increments from 1⁄8 to 3⁄8 in [3.2 to 9.5 mm].

Port sizes are available for the 11⁄2-in OD J-20 valves in 1⁄16-in
increments from 3⁄16 to 1⁄2 in [4.8 to 12.7 mm].

Operation
In injection-pressure-operated gas lift applications, injection
gas enters the valve and acts on the effective bellows area. As
injection pressure overcomes the precharged nitrogen pressure
in the bellows, the bellows is compressed and lifts the stem tip
off the seat. Injection gas then flows through the seat, past the
reverse-flow check valve, and into the production conduit.

J-40 valve.

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Gas Lift Systems  |  Technology 119
Conventional Injection-Pressure-Operated Valves
Engineering Data for Conventional Injection-Pressure-Operated Valves
Type OD, in [mm] Connecting Thread, in - TPI Reverse-Flow Check Valve Mandrel
J-50 0.625 [15.9] 0.250 - 18 NPT Integral †

J-40 1.000 [25.4] 0.500 - 14 NPT BF, B-1 B, B deflector lug, BR deflector lug
J-20 1.500 [38.1] 0.500 - 14 NPT CF, J-20 C Series
†Contact your Schlumberger representative.

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Gas Lift Systems  |  Technology 120
Conventional Production-Pressure-
Operated Valves
Gas lift valves for continuous or intermittent tubing flow production
APPLICATIONS Part of Camco* gas lift and subsurface safety systems, conventional
■ Gas lift service production-pressure-operated gas lift valves are normally used for
■ Continuous or intermittent tubing flow production-pressure-operated gas lift production in either continuous
or intermittent tubing flow applications. A nitrogen-charged, multi-ply
ADVANTAGES MONEL® bellows provides the force necessary to maintain the valves
■ Capable of operating with production in a normally closed position.
or injection pressure
This line of valves includes 5⁄8-in [15.9-mm] OD JR-50, 1-in [25.4-mm] OD
■ Integral reverse-flow check valves
JR-40, and 11⁄2-in [38.1-mm] OD JR-20 valves. The JR-50, JR-40, and JR-20
or floating valve seat design
valves have crossover seats that allow production pressure to act on the
bellows. JR-50 valves have an integral reverse-flow check valve. When
used with the appropriate conventional mandrel and reverse-flow check
valve, JR-40 and JR-20 valves can be operated by either production or
injection pressure and used for either tubing or annular flow.

Port sizes
The port size available for the 5⁄8-in OD JR-50 valves is 3⁄32 in [2.3 mm].

The port sizes available for the 1-in JR-40 OD valves are 1⁄8 and 3⁄16 in
[3.2 and 4.8 mm].

The port sizes available for the 11⁄2-in OD JR-20 valves are 1⁄8, 3⁄16,
and 1⁄4 in [3.2, 4.8, and 6.4 mm].

Operation
In production-pressure-operated gas lift applications, production fluid
enters the valve and acts on the effective bellows area. The production
pressure necessary to compress the bellows of JR-50, JR-40, and JR-20
valves is controlled by precharged nitrogen pressure. As production
pressure overcomes the precharged nitrogen pressure in the bellows or the
preset spring force, the bellows is compressed and lifts the stem tip off the
seat. Injection gas then flows through the seat, past the reverse-flow check
valve, and into the production conduit.

Engineering Data for Conventional Production-Pressure-Operated Valves JR-40 (left) and


Connecting Reverse-Flow JR-20 (right) valves.
Type OD, in [mm] Mandrel
Thread, in [mm] Check Valve
JR-50 0.625 [15.9] 0.250 - 18 NPT Integral †

B, B deflector lug,
JR-40 1.000 [25.4] 0.500 - 14 NPT BF, B-1
BR deflector lug
JR-20 1.500 [38.1] 0.500 - 14 NPT CF, J-20 C Series
†Contact your Schlumberger representative.

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Gas Lift Systems  |  Technology 121
Conventional Pilot-Operated Valves
Gas lift valves for intermittent tubing flow production
APPLICATIONS Camco* gas lift and subsurface safety systems include conventional pilot-operated
■ Gas lift service gas lift valves used for intermittent tubing flow production. Each pilot-operated
■ Intermittent tubing flow production valve consists of a pilot section and a power section.
A nitrogen-charged, multi-ply MONEL bellows provides the force necessary to
ADVANTAGES maintain the pilot section in a normally closed position, and an INCONEL spring
■ Nitrogen-charged, multi-ply provides the force necessary to maintain the power section in a normally closed
MONEL® bellows to maintain the position. This line of valves includes the 1-in [25.4-mm] OD BP-2 valves and the
pilot section 11⁄2-in [38.1-mm] OD CP-2 valves. Both of these valves have floating valve seats.
■ INCONEL® spring to maintain the
Flow areas and port sizes
power section
The power section of the 1-in OD BP-2 valves has a flow area equivalent to a
■ Floating valve seats 3⁄8-in [9.5-mm] port. The port sizes for the BP-2 pilot section are available in
1⁄16-in [1.6-mm] increments from 3⁄16 to 3⁄8 in [4.8 to 9.5 mm].

The power section of the 11⁄2-in OD CP-2 valves has a flow area equivalent to a
9⁄16-in [14.3-mm] port. The port sizes for the CP-2 pilot section are available in
1⁄16-in increments from 1⁄4 to 1⁄2 in [6.4 to 12.7 mm].

Operation
Injection gas enters the valve pilot section and acts on the effective bellows area.
As injection pressure overcomes the precharged nitrogen pressure in the bellows,
the bellows is compressed and lifts the stem tip off the seat to open the pilot
section. Injection gas then flows through the valve until it overcomes the
preset spring force of the power section. As the power section opens, injection
gas flows through the valve, past the reverse-flow check valve, and into the
production conduit.

Engineering Data for Conventional Pilot-Operated Valves


Type OD, in [mm] Connecting Thread, Reverse-Flow Mandrel
in - TPI Check Valve
BP-2 1.000 [25.4] 0.500 - 14 NPT B-1 B, B deflector lug
CP-2 1.500 [38.1] 0.500 - 14 NPT J-20 C, C deflector lug

CP-2 valve.

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Gas Lift Systems  |  Technology 122
PerfLift
Perforated-zone gas lift system
APPLICATIONS The PerfLift* perforated-zone gas lift system
■ Gas-lifting wells along the entire perforated is a cost-effective artificial lift system for
interval below a production packer low-rate gas-lifted oil and liquid-loaded gas
■ Liquid-loaded gas and coalbed wells. The system incorporates field-proven
methane wells Camco systems in an innovative completion
architecture that enables gas lift across long
■ Gas-lifted oil wells
completion intervals below a production packer.
BENEFITS
Reduce the cost and complexity of
■ Improves system efficiency compared with
liquid removal
traditional lifting methods
Most methods of liquid removal require costly
■ Lowers initial investment in new wells for intervention using a traditional workover rig or
accelerated payout and improved net pres- coiled tubing unit. The PerfLift system, however,
ent value is permanently installed when the completion is
■ Reduces operating costs run, so there is no need for a service rig to install
■ Increases production a system after the well is already producing.
The PerfLift gas lift system is ready for service
■ Enables chemical and fluid treatments
whenever it is needed, or in cases where liquid
across the perforations
loading is an ongoing problem, it can be used
FEATURES continuously to maximize production.
■ Field-proven Camco* gas
Optimize operations with a
lift and subsurface safety systems
simple system
■ Innovative completion design The PerfLift system employs a series of Camco
■ Reliable ported or dual-bore systems products in tubing strings above and
production packer below a ported or dual-bore production packer.
■ Real-time downhole monitoring with the Conventional or side pocket gas lift mandrels
Phoenix* artificial lift monitoring systems are installed in the upper tubing string. Internal-
gauge mount gas lift mandrels and valves are sized
and installed on the lower tubing string across
the perforated zone. During system operation,
gas is injected down the upper tubing-string
annulus and into the lower tubing string through
the packer to lift the fluid column across the
perforated zone. Liquids then travel to the
surface through the production string.

Monitor lift conditions in real time


The Phoenix system can be installed with the
PerfLift system to monitor liquid encroachment
and differential pressure in the wellbore at the
deepest point of gas injection. The gauge is
placed immediately above the lower-most gas lift
mandrel to provide real-time information that can
be used to optimize production.

The PerfLift system is the only gas lift system with


the proven capability to lift below the packer to the
perforated depth of the well.

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Gas Lift Systems  |  Technology 123
PerfLift
In the adjacent table are some early examples of Production Increases Using the PerfLift System
cost-effective production increases delivered by Well 1, Texas Well 2, Texas Well 3, Oklahoma Well 4, Wyoming
the PerfLift perforated-zone Gas, Mcf/d
gas lift system. Before 110 43 45 146
After 273 225 110 367
Oil, bbl/d
Before 0 0 2 0
After 0 1.5 40 0
Water, bbl/d
Before 60 40 15 79
After 159 74 20 159
Perforated interval, 2,373 [723.3] 964 [293.8] 2,255 [687.3] 1,002 305.4]
ft [m]
Casing, in 51⁄2 41⁄2 41⁄2 7
Upper tubing, in 23⁄8 23⁄8 23⁄8 27⁄8

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Gas Lift Systems  |  Technology 124
Sucker Rod Pumping

Advanced sucker rod pumping performance Pumping units


Our rod lift team offers expertise and equipment tailored for low-flow ■■ Maximize production with beam-balanced, low-profile, improved-
wells. Through technology, innovation, a system engineering approach, geometry, and conventional pumping units.
and leadership in automation, our rod lift team offers a range of equipment,
including pumping units, downhole and surface equipment, spare parts, Rods and downhole equipment
and reconditioned pumping units.
■■ Improve production reliability downhole with sucker rods, polished rods,
coiled tubing, downhole pumps, and gas separators.

Wellhead and surface equipment


■■ Reduce downtime with comprehensive lift packages that include all the
surface equipment used to hang the sucker rodstring and downhole
pump and to hook up the well to the flowline.

Concrete bases
■■ Stabilize equipment with portable concrete for various applications.

Prime movers
■■ Optimize energy consumption through a large selection of electric motor
and gas engine prime movers.

Table of Contents Previous page Next page 125


Shores Conventional Unit
Conventional geometry pumping unit
APPLICATIONS Shores conventional crank-balanced pumping units offer reliable, cost-effective performance at a
■ All wells that can deploy sucker competitive price. With more than 14,000 units currently pumping throughout North America, these
rod pumping units consistently exceed the expectations of producers.
■ Wells with deviations and high rod friction Manufactured to API standards, these units deliver high reliability and quiet operations. Shores
■ Unconventional shale reservoirs units have high-capacity saddle bearings, large self-centering drive bearings, and large lubrication
reservoirs, providing reliable performance for the long term. These conventional geometry units are
■ Conventional oil wells
stocked in API sizes 80 to 1280.
BENEFITS
■ Provides easy installation and maintenance Main Specifications
■ Offers long service life of over 25 years Specifications Basic Parameters Gear Reducer Balance
with proper maintenance Assembly
■ Lowers year over year operational cost Model Rated Stroke Rated Reducer Oil Storage Lubricant Weight of
Polished Rod Length, Torque, Gear Quantity, Crank, lbm
Capacity, lbm in in.lbf Ratio galUS
FEATURES
■ High-load, easily serviced center bearing C114D-173-64WL 17,300 64 114,000 28.395 25 1,655 × 2
based on proven railway bearing design C160D-173-100 17,300 100 160,000 28.593 39 2,022 × 2
ISO VG 150 winter
C160D-200-74WL 20,000 74 160,000 28.593 39 2,022 × 2
■ Dual-axis hinge pin style equalizer ISO VG 200 summer
C228D-246-86 24,600 86 228,000 28.91 43 3,106 × 2
bearing for long life and reduced stress
C228D-256-120 25,600 120 228,000 28.91 43 3,106 × 2
in assembly
C320D-305-100 30,500 100 320,000 29.46 75 3,106 × 2
■ High-capacity gear reducer designed far C320D-256-120 25,600 120 320,000 29.46 75 3,106 × 2
ISO VG 150 winter
beyond API requirements C320D-305-120 30,500 120 320,000 29.46 75 ISO VG 200 summer 3,106 × 2
■ Large low-speed shaft for long life and C320D-256-144 25,600 144 320,000 29.46 75 3,106 × 2
increased counterbalance support C456D-305-120 30,500 120 456,000 28.84 110 3,106 × 2
■ Field-serviceable gear reducer design with C456D-365-120 36,500 120 456,000 28.84 110 4,699 × 2
ISO VG 150 winter
bolt-on cranks C456D-305-144 30,500 144 456,000 28.84 110 4,699 × 2
ISO VG 200 summer
■ Fully enclosed horse head for C456D-365-144 36,500 144 456,000 28.84 110 4,699 × 2
maximum strength C456D-305-168 30,500 168 456,000 28.84 110 4,699 × 2
C640D-305-120 30,500 120 640,000 29.32 106 3,106 × 2
C640D-365-120 36,500 120 640,000 29.32 106 4,699 × 2
ISO VG 150 winter
C640D-305-144 30,500 144 640,000 29.32 106 4,699 × 2
ISO VG 200 summer
C640D-365-144 36,500 144 640,000 29.32 106 4,699 × 2
C640D-427-144 42,700 144 640,000 29.32 106 4,699 × 2
C640D-305-168 30,500 168 640,000 29.32 106 4,699 × 2
C640D-365-168 36,500 168 640,000 29.32 106 4,699 × 2
ISO VG 150 winter
C640D-365-192 30,500 192 640,000 29.32 106 4,699 × 2
ISO VG 200 summer
C912D-365-144 36,500 144 912,000 28.79 180 4,699 × 2
C912D-427-144 42,700 144 912,000 28.79 180 4,699 × 2
C912D-305-168 30,500 168 912,000 28.79 180 4,699 × 2
C912D-365-168 36,500 168 912,000 28.79 180 4,699 × 2
ISO VG 150 winter
C912D-427-168 42,700 168 912,000 28.79 180 4,699 × 2
ISO VG 200 summer
C912D-365-192 36,500 192 912,000 28.79 180 4,699 × 2
C912D-427-192 42,700 192 912,000 28.79 180 4,699 × 2
C1280D-365-192 36,500 192 1,280,000 28.672 185 4,699 × 2
C1280D-427-192 42,700 192 1,280,000 28.672 185 ISO VG 150 winter 4,699 × 2
C1280D-365-240 36,500 240 1,280,000 28.672 185 ISO VG 200 summer 5,971 × 2
C1280D-427-240 42,700 240 1,280,000 28.672 185 5,971 × 2

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Sucker Rod Pumping  |  Technology 126
Shores Conventional Unit
Dimensional Data, in
Model A B C E F H I J L M N R T W X AA BB
C114D-173-64WL 84.06 84.06 165.94 161.81 273.62 232.48 26.77 68.11 64.57 81.89 15.59 52.95 25.59 35.43 71.30 52.48 94.29
C160D-173-100 96.06 128.94 196.06 182.28 254.17 295.47 26.38 77.95 57.09 56.54 15.59 93.50 29.53 35.43 77.87 28.22 40.03
C160D-200-74WL 96.06 96.06 196.06 303.15 303.15 271.85 28.74 77.95 82.28 81.89 15.59 60.63 29.53 81.89 77.24 62.32 100.39
C228D-246-86 111.02 110.98 231.97 206.14 267.17 315.94 33.07 95.00 103.94 70.08 19.69 70.87 33.46 37.01 83.31 40.98 54.33
C228D-256-120 111.02 155.00 231.97 206.14 267.17 348.74 27.95 95.00 73.23 70.08 19.69 114.88 33.46 37.01 83.31 40.98 54.33
C320D-305-100 111.02 129.02 231.97 210.51 270.83 330.24 28.35 95.00 71.46 70.08 19.69 88.90 37.40 42.91 90.39 40.98 54.33
C320D-256-120 111.02 155.00 231.97 210.51 270.83 347.83 27.95 95.00 73.23 70.08 19.69 114.88 37.40 42.91 90.39 40.98 54.33
C320D-305-120 111.02 155.00 231.97 210.51 270.83 347.83 29.13 95.00 73.23 70.08 19.69 114.88 37.40 42.91 90.39 40.98 54.33
C320D-256-144 120.00 180.00 260.00 226.22 295.28 398.03 28.94 109.84 75.00 81.89 23.62 132.36 37.40 42.91 90.39 52.09 58.46
C456D-305-120 111.02 155.00 233.98 223.35 280.83 347.83 27.56 95.00 75.20 81.89 23.62 114.88 39.37 46.85 102.44 37.28 63.94
C456D-365-120 120.00 152.01 261.97 239.84 297.32 347.83 28.74 109.84 100.39 81.89 23.62 104.37 39.37 46.85 104.02 50.75 63.94
C456D-305-144 120.00 180.00 260.00 239.84 297.32 398.03 28.94 109.84 75.00 81.89 23.62 132.36 39.37 46.85 104.02 50.75 63.94
C456D-365-144 120.00 180.00 261.97 239.84 297.32 399.76 29.33 109.84 77.56 81.89 23.62 132.36 39.37 46.85 104.02 50.75 63.94
C456D-305-168 120.00 210.04 261.97 239.84 297.32 421.65 29.92 109.84 52.76 81.89 23.62 162.40 39.37 46.85 104.02 50.75 63.94
C640D-305-120 111.02 155.00 233.98 225.71 283.19 347.83 27.56 95.00 75.20 81.89 23.62 114.88 41.34 46.85 100.83 37.28 64.33
C640D-365-120 120.00 152.01 261.97 242.20 299.69 347.83 28.74 109.84 100.39 81.89 23.62 104.37 41.34 46.85 102.40 50.75 64.33
C640D-305-144 120.00 180.00 260.00 242.20 299.69 399.76 28.94 109.84 75.00 81.89 23.62 132.36 41.34 46.85 102.40 50.75 64.33
C640D-365-144 120.00 180.00 261.97 242.20 299.69 399.76 29.33 109.84 77.56 81.89 23.62 132.36 41.34 46.85 102.40 50.75 64.33
C640D-427-144 120.00 180.00 261.97 242.20 299.69 399.76 29.33 109.84 77.56 81.89 23.62 132.36 41.34 46.85 102.40 50.75 64.33
C640D-305-168 120.00 210.04 261.97 242.20 299.69 421.65 29.92 109.84 52.76 81.89 23.62 162.40 41.34 46.85 102.40 50.75 64.33
C640D-365-168 120.00 210.04 261.97 242.20 299.69 421.65 29.92 109.84 52.76 81.89 23.62 162.40 41.34 46.85 102.40 50.75 64.33
C640D-365-192 120.00 210.04 286.02 265.23 322.72 458.74 28.15 109.84 56.69 81.89 23.62 139.37 41.34 46.85 102.40 50.75 64.33
C912D-365-144 120.00 180.00 261.97 250.16 307.64 399.76 29.33 109.84 77.56 81.89 23.62 132.36 48.43 46.85 106.38 50.75 65.20
C912D-427-144 120.00 180.00 261.97 250.16 307.64 399.76 29.33 109.84 77.56 81.89 23.62 132.36 48.43 46.85 106.38 50.75 65.20
C912D-305-168 120.00 210.04 261.97 250.16 307.64 421.65 29.92 109.84 52.76 81.89 23.62 162.40 48.43 46.85 106.38 50.75 65.20
C912D-365-168 120.00 210.04 261.97 250.16 307.64 421.65 29.92 109.84 52.76 81.89 23.62 162.40 48.43 46.85 106.38 50.75 65.20
C912D-427-168 120.00 210.04 261.97 250.16 307.64 421.65 29.92 109.84 52.76 81.89 23.62 162.40 48.43 46.85 106.38 50.75 65.20
C912D-365-192 120.00 210.04 286.02 273.19 330.67 458.74 28.15 109.84 56.69 81.89 23.62 139.37 48.43 46.85 106.38 50.75 65.20
C912D-427-192 120.00 210.04 286.02 273.39 330.87 458.74 28.35 109.84 55.12 81.89 23.62 139.37 48.43 46.85 106.38 50.75 65.20
C1280D-365-192 120.00 210.04 286.02 279.88 337.36 458.74 28.35 109.84 55.12 86.61 23.62 139.17 56.69 50.00 119.29 63.43 50.75
C1280D-427-192 120.00 210.04 286.02 279.88 337.36 458.74 28.35 109.84 55.12 86.61 23.62 139.17 56.69 50.00 119.29 63.43 50.75
C1280D-365-240 127.56 228.35 331.89 287.44 344.92 533.86 29.33 118.11 55.70 86.61 23.62 157.48 56.69 50.00 119.29 59.02 63.43
C1280D-427-240 127.56 228.35 331.89 287.44 344.92 533.86 29.33 118.11 55.70 86.61 23.62 157.48 56.69 50.00 119.29 59.02 63.43

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Sucker Rod Pumping  |  Technology 127
Shores Conventional Unit
Counterbalance Data
Specifications
Model Structural Cranks Effective Counterbalance (ECB) Max. ECB, ft.lbf
Unbalance, lbm Cranks Only, ft.lbf
C114D-173-64WL 500 GRC170 4,104 13,780
C160D-173-100 –220 GRC110 2,945 10,485
C160D-200-74WL 700 GRC110 4,946 15,061
C228D-246-86 1,069 GRC130 8,262 26,617
C228D-256-120 50 GRC130 5,224 18,401
C320D-305-100 755 GRC130 6,972 22,802
C320D-256-120 –70 GRC130 5,104 18,281
C320D-305-120 120 GRC130 5,294 18,471
C456D-305-120 180 GRC130A 5,357 19,672
C640D-305-120
C456D-365-120 760 GRC120 9,526 32,130
C640D-365-120
C320D-256-144 –930 GRC120E 5,699 24,842
C456D-305-144 –285 GRC120 7,139 26,282
C640D-305-144
456-365-144 –365 GRC120 7,037 32,374
640-365-144
640-427-144
912-365-144
912-427-144
C456D-305-168 –1,400 GRC120 4,944 29,828
C640D-305-168
C640D-365-168
C912D-305-168
C912D-365-168
C912D-427-168 –1,255 GRC120B 5,093 29,976
C640D-365-192 –1,900 GRC120A 3,795 25,932
C912D-365-192
C912D-427-192 –2,070 GRC120C 3,629 25,766
C1280D-365-192 –2,070 GRC120D 3,629 29,457
C1280D-427-192
C1280D-365-240 –2,900 GRC140 3,430 26,852
C1280D-427-240 –3,400 GRC140 2,930 26,352

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Sucker Rod Pumping  |  Technology 128
TorqMax
Advanced-geometry
Advanced geometry pumping unit
APPLICATIONS The TorqMax* advanced-geometry pumping unit is an alternative to conventional pumping units. For
■ High-load wells that benefit from a fast certain rod pump applications, the TorqMax pumping unit can help reduce torque and lower prime
downstroke with a slower upstroke mover horsepower requirements, thus reducing lifting costs.
■ Enhanced oil recovery well designs
The primary differences between TorqMax pumping units and conventional units are:
such as steam fluids
■ The structure of the TorqMax pumping unit is shifted forward from the gear reducer toward the
■ Unconventional shale reservoirs
wellhead, whereas the center of the equalizer bearing shaft sits directly over the center of the
■ Oils wells with large variations slow-speed shaft of the gear reducer on conventional pumping units
in production and load ■ The crankpin holes are placed at an offset angle on the crank arm of the TorqMax pumping unit
■ Automation applications but run parallel to the crank arm on a conventional unit
■ Conventional oil wells ■ The TorqMax pumping unit must always rotate clockwise to maximize effects, while a conven-
tional unit can run in either direction of rotation.
BENEFITS
Delivers easy installation and maintenance
Main Specifications

■ Provides long service life of over 25 years


with proper maintenance Specifications Basic Parameters Gear Reducer
■ Lowers year-over-year operational cost Model Rated Stroke Rated Reducer Oil Storage Lubricant
Polished Rod Length, Torque, Gear Quantity,
■ Enables downsizing the unit and prime mover Capacity, lbm in in.lbf Ratio galUS
compared to conventional units, saving cost TM456D-365-120 36,500 120 456,000 28.84 110
initially and in day-to-day operations TM456D-305-144 30,500 144 456,000 28.84 110 ISO VG 150 winter
TM640-365-144TH 36,500 144 640,000 29.32 106 ISO VG 200 summer
FEATURES
TM640-427-144TH 42,700 144 640,000 29.32 106
■ Advanced geometry creating a larger
TM640D-365-168 36,500 168 640,000 29.32 106
allowable load range and more
efficient operation TM640-427-168TH 42,700 168 640,000 29.32 106 ISO VG 150 winter
TM912D-365-168 36,500 168 912,000 28.79 180 ISO VG 200 summer
■ Phased crank design with more
TM912-427-168TH 42,700 168 912,000 28.79 180
torque available for the upstroke
TM912-427-192TH 42,700 192 912,000 28.79 180 ISO VG 150 winter
■ High-load, easily serviced center bearing TM1280-427-192TH 42,700 192 1,280,000 28.672 185 ISO VG 200 summer
based on proven railway bearing design
■ Dual-axis hinge pin style equalizer
bearing for long life and reduced stress
in assembly
■ High-capacity gear reducer designed
far beyond API requirements
■ Large, low-speed shaft for long life
and increased counterbalance support
■ Field-serviceable gear reducer design
with bolt-on cranks
■ Fully enclosed horse head
for maximum strength

Table of Contents Previous page Next page


Sucker Rod Pumping  |  Technology 129
TorqMax
Counterbalance Data
Model
TM456D-365-120 TM456D-305-144 TM640D-365-144 TM640D-365-168 TM640D-427-168 TM912D-427-192 TM1280D-427-192
TM640D-427-144 TM912D-365-168 TM912D-427-168
Structural unbalance, lbm 590 –500 230 –900 –940 –2,610 –2,510
Cranks GRC150 GRC150 GRC160 GRC160 GRC160 GRC160 GRC160
Effective counterbalance 9,679 7,090 10,302 7,745 7,705 4,962 5,062
(ECB) cranks only, ft.lbf
Max. ECB, ft.lbf 30,020 24,076 35,702 29,544 29,504 24,056 24,516

Dimensional Data, in
Model A B C E F H I J L M N R T W X AA BB
TM456D-365-120 141.93 144.49 237.99 255.75 313.15 309.21 27.36 95.08 81.10 81.89 23.62 102.95 39.37 46.85 104.02 35.79 63.94
TM456D-305-144 141.93 173.03 237.99 255.75 313.15 321.46 26.77 95.08 57.87 81.89 23.62 131.50 39.37 46.85 104.02 35.79 63.94
TM640D-365-144 118.11 171.65 274.00 287.17 344.65 357.44 26.57 109.84 94.09 81.89 23.62 122.05 41.34 46.85 101.14 50.75 64.33
TM640D-427-144 118.11 171.65 274.00 287.17 344.65 357.44 26.57 109.84 94.09 81.89 23.62 122.05 41.34 46.85 101.14 50.75 64.33
TM640D-365-168 118.11 200.00 274.00 287.17 344.65 368.70 27.17 109.84 69.68 81.89 23.62 150.39 41.34 46.85 101.14 50.75 64.33
TM640D-427-168 118.11 200.00 274.00 287.17 344.65 368.70 27.17 109.84 69.68 81.89 23.62 150.39 41.34 46.85 101.14 50.75 64.33
TM912D-365-168 118.11 200.00 274.00 295.12 352.60 368.70 27.17 109.84 69.68 81.89 23.62 150.39 48.43 46.85 105.12 50.75 65.20
TM912D-427-168 118.11 200.00 274.00 295.12 352.60 368.70 27.17 109.84 69.68 81.89 23.62 150.39 48.43 46.85 105.12 50.75 65.20
8
TM912D-427-192 118.11
7
228.35 274.006 295.12 352.60 379.92
5
27.95 109.844 46.06 86.61 23.62
3
178.74 48.43 2 46.85 105.12 50.75
1
65.20
TM1280-427-192 118.11 228.35 274.00 301.61 352.60 379.92 27.95 109.84 46.06 86.61 23.62 178.74 56.69 46.85 119.29 59.02 63.43

A
H

B
D
I

BB T
C
AA

BOTTOM OF STROKE
C
J

L
N

E W

F R M
B
X

This drawing is the property of Shores Lift Solutions and is loaned to the recipient for his confidential use only. In
consideration of the loan of this drawing, the recipient promises and agrees that it shall not be used in any way
detrimental to the interest of Shores Lift Solutions, that it shall be returned upon request, and that it shall not be
reproduced, copied, loaned or otherwise disposed of, directly or indirectly without the express written consent of
Shores Lift Solutions.

Mark Group Division


Revision
Number
Signature Date
slb.com/rodlift
STM640-365-168TH
Designer Frank 1/21/2013 Standard
Stage
Weight
Scale A
(Kg)

N/A 1:40
STM dim
Reviewer

Approved
*Mark of Schlumberger Process
By

8 7 names
Other company, product, and service 6 5 4 3 2 1
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Sucker Rod Pumping  |  Technology 130
HG Pumping Unit
Curved walking beam pumping unit
APPLICATIONS The HG curved walking beam pumping unit With the HG pumping unit, the curved walking
■ High-load wells that benefit from variable is engineered with a combination of crank- beam places the beam weight at the furthest
counter balance and beam-based counterbalance weights distance from the samson post to provide
■ Wells that benefit from a faster to provide a dynamic structural imbalance. maximum leverage, helping the crank weight
downstroke and slower upstroke This superior combination of counterbalances and the motor to bring the horsehead back up.
results in a considerable reduction in operation
■ Enhanced oil recovery well designs At the end of the upstroke, when the
energy requirements and net torque curve.
such as steam fluids horsehead is up, the motor and conventional
■ Unconventional shale reservoirs The HG pumping unit uses two counterweights weight do the least amount of work. The weight
■ Oils wells with large variations instead of one: the conventional crank weight of the rodstring takes the horsehead back down.
in production and load and an adjustable beam weight positioned at Conventional pumping units use the weight of
the end of an engineered curved walking beam, the rodstring to pull the crank weight back up,
■ Conventional oil wells
which allows the counterweights to benefit the which usually results in negative torque on the
BENEFITS gearbox torque when it’s needed most. motor. With the HG pumping unit, the beam
■ Simplifies installation weight is at a minimum distance from the
At the beginning of the upstroke, when samson post, resulting in less leverage to resist
■ Reduces maintenance with long service the horsehead is down, the motor and the the horsehead’s fall.
life of over 25 years counterweight have to do most of the work
■ Minimizes year over year operational cost to bring the rod and fluid up.
■ Decreases initial cost and day-to-day Size Structure Stroke, Gear Set Structural Weight, Bottom Effective
operation costs with ability to downsize in Box Ratio Back, in Unbalance with No lbm of Stroke, Counterbalance,
the unit and prime mover Tail Weights, lbm in lbm
80 119 64 (54) (42) 30.12 52 375 17,070 52 7,000
FEATURES 114 143 74 (64) (54) 30.52 51.5 300 25,300 54 8,000
■ Advanced geometry creating a larger 160 173 86 (74) (64) 31.71 52 –225 30,800 54 10,300
allowable load range and more 228 173 100 (86) (74) 31.62 76 450 38,750 75 10,700
efficient operation 228 213 100 (86) (74) 31.62 75 450 42,000 55 11,500
■ Curved walking beam providing maximum 320 256 120 (100) (86) 30.87 74 200 49,700 48 14,300
counterbalance effect when it is needed 320 256 144 (120) (100) 32.47 98 200 52,600 52 14,300
and minimum when it is not needed 456 256 144 (120) (100) 31.5 98 200 52,600 52 14,300
■ High-capacity gear reducer designed 456 305 168 (144) (120) 31.5 121.5 211 67,100 68 15,300
far beyond API requirements 640 305 168 (144) (120) 31.3 121.5 211 71,000 74 16,400
■ Large, low-speed shaft for long life 640 365 192 (168) (144) 31.3 147 211 74,270 46 18,800
and increased counterbalance support 912 365 192 (168) (144) 31.05 147 579 81,800 46 18,000
■ Field-serviceable gear reducer design with 912 427 168 (144) (120) 31.05 121.5 211 81,000 57 23,100
bolt-on cranks 1,280 427 192 (168) (144) 30.47 147 410 90,000 52 23,100
1,280 427 216 (192) (168) 30.47 166 –516 92,000 52 23,100

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Sucker Rod Pumping  |  Technology 131
HG Pumping Units
C A

D
B
h

K
H

P R 1,2,3

HG Pumping Unit Geometry Dimensions


Straight Beam
Unit Type A, in C, in I, in P, in H, in G, in B, in D, in h, in E, in R1, in R2, in R3, in R, in
80-119-64 84 62 63 85 143 59 20 12.4 17.72 23.03 56
114-143-74 82 66 70 115 166 67 20 18.7 23.62 28.54 65
160-173-86 94 73 80 106 169 67 23 20.87 25.98 31.1 65
228-173-100 118 94.49 78 127 201 75 121 25 29 137 19.69 24.8 29.53 73
228-213-100 118 94.49 78 135 209 75 94 29 22 134 24.33 32.2 38.35 73
320-256-120 118 73 78 135 192 75 116 22 17 135 31.1 38.19 45.28 73
320-256-144 144 73 78 135 207 91 116 22 17 135 31.1 38.19 45.28 89
456-256-144 142 110 78 186 248 91 151 51 28 131 31.1 38.19 45.28 86
456-305-168 189 110 110 186 250 91 160 46 26 132 37.8 45.28 52.76 89
640-305-168 189 110 110 186 250 91 160 46 26 132 37.8 45.28 52.76 89
640-365-192 192 110 110 186 250 91 160 46 26 132 37.8 45.28 52.76 89
912-365-192 192 119 127 198 273 170 170 53 26 132 37.8 45.28 52.76 100

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Sucker Rod Pumping  |  Technology 132
Don-Nan Gas Separator
Packer-style
Packer style gas separator
APPLICATIONS The Don-Nan gas separator is a packer-style Operation
■ Wells with high gas and fluid levels separator that is most effective in wells with high The production fluid first flows through the ported
fluid levels. Its patented ported coupling improves coupling then up the annulus between the inner
BENEFITS
separation of entrained gas from production fluid and outer tube of the Don-Nan gas separator, and
■ Separates free and entrained gas from
and minimizes gas interference and gas breakout exits the slots at the top of the outer tube. The
production fluid
in the downhole rod pump. separated gas then travels up the annulus between
■ Improves pump efficiency the tubing and the casing, while the liquid falls and
The gas separator must be run above the perfora-
■ Reduces gas interference in pump accumulates on top of the packer.
tions in the well with a packer below it. The set
■ Decreases rod lift system wear packer directs the fluid through the separator by The separated production fluid is drawn into the
■ Increases daily run time with automation sealing off the annulus between the tubing and the inner tube of the Don-Nan gas separator through
casing. The Don-Nan gas separator improves pump the external intake port of the patented ported
FEATURES
efficiency, equipment life, and run time. coupling, and then travels up the inner tube to the
■ Patented ported coupling design
pump intake.
■ Repairable

Don-Nan gas separator

Gas Separator Specifications


Separator size, in [mm] 2.375 [60.325] 2.875 [73.025] 3.5 [88.9] 4 [101.6]
Casing OD, in [mm] 4.5 [114.3] 4.5 [114.3] 5.5 [139.7] 7.625 [193.675]
5.5 [139.7] 5.5 [139.7] 7 [177.8] 8.625 [219.075]
7 [177.8] 7.625 [193.675] 9.625 [244.475]
8.625 [219.075]
Max capacity, bbl/d [m3/d] 382 [60.7] 261 [41.5] 438 [69.6] 1,366 [217.2]
738 [117.3] 618 [98.25] 1,110 [176.4] 2,025 [321.9]
1,291 [205.25] 1,448 [230.2] 2,668 [424.1]
2,107 [334.9]
80% capacity, bbl/d [m3/d] 302 [48] 208 [33] 350 [55.6] 1,092 [173.6]
590 [93.8] 494 [78.5] 888 [141.1] 1,620 [257.5]
1,032 [164] 1,158 [184.1] 2,134 [339.2]
1,685 [267.9]

Inner Tube Specifications


ID, in [mm] 1 [25.4] 1.25 [31.75] 1.5 [38.1]
Capacity, bbl/d [m3/d] 630 [100.1] 1,350 [214.6] 1,930 [306.8]

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Sucker Rod Pumping  |  Technology 133
Slimhole Tubing Anchor
Anchor for flexible tubing placement
APPLICATIONS In contrast to a standard anchor, the slimhole This placement reduces wear caused by the tubing
■ Any well with production tubing anchor can be deployed at any point in the well in movement to the downhole assembly, tubing,
■ Anchors tubing during rod lift operation relation to the perforations. The improved design casing, and rods. In addition, tapered connections
also minimizes solids buildup in the anchor, and prevent anchor seizure by diverting solids that
■ Catches tubing in the event of a
the smaller cage OD improves gas flow past the might otherwise accumulate in the anchor.
tubing failure
anchor.
Alternatively, if the slimhole anchor is placed above
BENEFITS
Placement flexibility perforations, its design provides the benefit of
■ Improves pump efficiency
The ability to run the slimhole tubing anchor below increasing the width of the annulus between the
■ Reduces solids accumulation in the anchor perforations enables operators to pump from the OD of the anchor cage and the ID of the casing.
■ Enhances gas flow up the tubing or point in the well that maximizes oil production The smaller OD of the slimhole anchor cage
casing annulus and minimizes gas interference. The tubing can also increases gas flow past the anchor into the
be anchored at the deepest point in the string, casing or tubing annulus, thereby reducing gas
FEATURES
eliminating the need for tubing below the anchor. interference in the pump.
■ Ability to set anchor in or
below perforations
■ Smaller cage OD
■ Tapered connections
■ Adjustable shear rating
■ Slip protection drag blocks
■ Carbide and wicker slips available

The slimhole anchor has a smaller OD than the standard anchor, with large slips and slip protectors. Beveled couplings
prevent sand from getting inside the tool.

Slimhole vs. Standard Tubing Anchor Specifications


Casing OD, in [mm] 4.5 [114.3] 5.5 [139.7] 7 [117.8]
2.375 [60.325] 2.375 [60.325] 2.875 [73.025]
Tubing size, in [mm]
2.875 [73.025]
Standard 3.75 [95.25] 4.5 [114.3] 5.5 [139.7]
Max. tool OD, in [mm]
Slimhole 3.75 [95.25] 4.615 [117.221] 5.75 [146.05]
Standard 1.937 [49.199] 2.405 [61.087] 2.5 [63.5]
Tool ID, in [mm]
Slimhole 1 [25.4] 1.937 [49.199] 2.405 [61.087]
Standard 3.75 [95.25] 4.5 [114.3] 5.5 [139.7]
Cage OD, in [mm]
Slimhole 2.875 [73.025] 3.75 [95.25] 4.5 [114.3]
Standard 0.302 [7.6708] 0.392 [9.957] 0.866 [21.996]
Annular clearance†, in [mm]
Slimhole 1.177 [29.895] 1.142 [29.007] 1.866 [47.396]
Slimhole annulus increase, in [mm] 0.875 [22.225] 0.75 [19.05] 1 [25.4]
† Annular clearance calculated for the following casings: 4.5 in, 10 lbm/ft, 4.052-in ID; 5.5 in, 17 lbm/ft, 4.892-in ID; 7 in, 23 lbm/ft, 6.366-in ID

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Sucker Rod Pumping  |  Technology 134
Sand Diverter
Abrasion-combating plunger assembly
APPLICATIONS The sand diverter is a plunger assembly designed Abrasion and corrosion resistance
■ Wells with large volumes of sand to alleviate lost production and equipment failure The outer diameter of each component is
and solids caused by solids. The plunger assembly directs coated with spray metal, which protects against
the solids away from the pump barrel, maintains abrasion from solids. The plunger adapter is made
BENEFITS
the integrity of the downhole pump, and extends of strong, corrosion-resistant MONEL material and
■ Improves pump efficiency
run life. is designed for optimal fluid flow while maintaining
■ Prevents damage to plunger and barrel of component strength.
the pump Design
■ Extends run life
The sand diverter consists of a modified adapter Intermittent pumping
placed on top of the plunger and a positive seal The sand diverter protects the pump during
FEATURES seat plug on the bottom of the traveling valve. The intermittent pumping as well as regular operations.
■ Strong, corrosion-resistant MONEL® plunger adapter and positive seal seat plug have When solids settle in an automated pump when it
plunger adapter a precision fit of 0.002 in [0.05 mm] with beveled is turned off, a sand diverter directs solids to the
■ Precision clearance leading edges, which prevents sand and fines from plunger instead of between the plunger and barrel.
collecting between the plunger and barrel.
■ Beveled leading edges
■ Spray-metal coating

Sand diverters can be run with any hollow valve rod pump, insert pump, or tubing pump. Models designed to be
compatible with each of those pump types are shown above, from left to right.

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Sucker Rod Pumping  |  Technology 135
On-Off Tool
Downhole rod to pump release
APPLICATIONS The on-off tool connects to or disconnects from a Components
■ Any rod lift well sucker rodstring, at any point, based on the location The on-off tool comprises six different components:
of the tool in the rodstring. The tool is attached top bushing, body, locking pawl, balls, bottom latch,
BENEFITS
directly to the rodstring where the operator wishes and spring. Each component can be manufactured
■ Minimizes stripping job operations
to make the disconnection. The tool is then in different metallurgies as required by different
■ Enables retrieval of the rodstring in the disconnected by turning the rodstring and picking well conditions. This tool can be produced for both
event of a stuck pump up. The tool is connected by setting down weight right-hand as well as left-hand operation.
■ Permits the operator to fish broken rods on the bottom latch section and rotating the rod-
without unseating the pump string in the latch direction. Applications
In the event of a rod part above the on-off tool, the
FEATURES Elimination of stripping jobs operator can now fish and release the remaining
■ Ability to run an oversized tubing pump The on-off tool’s primary benefit is that it can rods from the pump, eliminating the need to unseat
■ Availability in a variety of high-strength virtually eliminate stripping jobs. A stripping job the pump. The on-off tool is also used when run-
materials including INCONEL® occurs when an operator must pull the tubing and ning an oversized tubing pump. An oversized tubing
rods simultaneously, usually as a result of inability pump gives the operator the ability to use a pump
■ Closed design
to unseat the downhole pump. Stripping jobs bore size larger than the tubing internal diameter,
■ Guide balls for proper latching add cost due to increased rig time and damaged displacing more fluid without replacing the entire
■ High-resistance springs to prevent equipment. The on-off tool enables the operator tubing string. The on-off tool is required with the
unintended release to release the rodstring from the pump, allowing oversized tubing pump to connect the rodstring to
■ Availability in both right-hand and retrieval of the rods and tubing separately. the plunger because the plunger outer diameter is
left-hand release larger than the internal diameter of the tubing.

Components of the on-off tool, from left to right: locking pawl with balls, top bushing, body, spring, and bottom latch.

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Sucker Rod Pumping  |  Technology 136
On-Off Tool
On-Off Tool Specifications
Model number 80 90 100 110 120 130
Tubing size, in [mm] 1.5 [38.1] 2.375 [60.325] 2.375 [60.325] 2.875 [73.025] 2.875 [73.025] 3.5 [88.9] and up
3.5 [88.9]
Tool OD, in [mm] 1.44 [36.576] 1.62 [41.148] 1.812 [46.0248] 2.15 [54.61] 2.312 [58.7248] 2.75 [69.85]
HDT = 1.94 [49.276] HDT = 2.44 [61.976]
Metallurgy† T/ST T/ST/AT/IT T/ST/AT/IT T/HDT/ST/AT/IT T/ST/AT/IT T/HDT/ST/AT/IT
Pin size, in [mm] 0.9375 [23.8125] 0.9375 [23.8125] 1.0625 [26.9875] 1.0625 [26.9875] 1.0625 [26.9875]‡ 1.1875 [30.1625]
1.0625 [26.9875] 1.0625 [26.9875] 1.1875 [30.1625] 1.1875 [30.1625] 1.1875 [30.1625] 1.375 [34.925]‡
1.375 [34.925]‡ 1.375 [34.925]‡
† T = Plain steel, HDT = 4130, ST = stainless steel, AT = 4140, IT = INCONEL
‡ Not available in HDT

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Sucker Rod Pumping  |  Technology 137
Carbide Insert Rod
ValveGuide
Rod Guide
Wear-resistant rod guide
APPLICATIONS A critical component of pump performance and Designed for flexibility and cost savings
■ Any insert pump efficiency, the valve rod connects the sucker A standard rod guide is manufactured in one piece,
rodstring and the plunger, which pulls the fluid out and therefore limited to a single metallurgy. The
BENEFITS
of the pump and to the surface. The carbide insert carbide insert rod guide features a three-piece
■ Minimizes wear on valve rod guide
valve rod guide protects the valve rod by stabilizing design composed of the clutch, carbide insert, and
■ Increases pump run life it during the pump stroke. body. This design allows operators to replace
individual components instead of the entire
FEATURES A standard valve rod guide incurs wear caused by
rod guide.
■ Three-piece assembly rod buckling and well deviation. The carbide insert
■ Nitronic® 50 clutch available valve rod guide has an ID that is appropriately sized The three-piece design also enables the operator
■ Several metallurgy options for the valve rod, minimizing wear on the valve to choose from multiple metallurgies to better
rod guide and the valve rod. The carbide insert accommodate downhole conditions and increase
■ Fluted or vertical discharge configurations
valve rod guide is especially helpful when sinker run life.
bars are used to assist the traveling assembly
down through compression, because the carbide
insert minimizes the wear caused by the additional
weight of the sinker bars on the valve rod guide.

The carbide insert rod guide comprises (from left to right) a clutch, carbide insert, and body.

Carbide Insert Rod Guide Specifications


Guide Type Tubing Size, in [mm] Valve Rod Size, in [mm]
Fluted vertical discharge 2 3⁄8 [60.325] 11⁄16 [17.4625]
2 7⁄8 [73.025] 7⁄8 [22.225]

Other company, product, and service names


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Sucker Rod Pumping  |  Technology 138
Rod Pump Controller
Pumpoff control and advanced modeling for sucker rod pump systems
APPLICATIONS
■ Automated control of sucker rod pump
starting and stopping

BENEFITS
■ Optimizes pump regulation to increase
production and prevent equipment damage
■ Improves efficiency and economics
of operation
■ Reduces travel to the wellsite through
remote monitoring

FEATURES
■ 115 or 230 V AC input supply
(460 V optional)
■ Rugged NEMA 4R polycarbonate enclosure
The RPC provides real-time surface and downhole dynamometer plots.
■ Backlit graphic display and keypad
■ Multiple analog and digital inputs and The rod pump controller (RPC) provides Comprehensive monitoring and
outputs, with four configurable I/O points economical pumpoff control of sucker rod reporting capabilities
■ Comprehensive monitoring and reporting pumping systems. Using sophisticated modeling The RPC provides real-time surface and
to facilitate troubleshooting and control software and a powerful digital downhole dynamometer plots, daily gauging,
signal processor, the RPC computes surface and fault and event logging, a user-configurable data
■ Polished rod load cell, beam position
downhole conditions to best regulate the starting sampler, and more.
inclinometer, optional tubing and casing
and stopping of the pump via a separate motor
pressure sensors Equipped with both web-based and smartphone
controller.
■ Automatic counterbalance check interfaces, the RPC can generate well reports
■ Oil, belt, and gearbox service reminders The RPC provides real-time surface and and dynacards from either interface. Wireless,
downhole dynamometer plots, daily gauging, radio, cellular, and satellite options allow
■ Wired local and remote serial ports, ANSI®
fault and event logging, a user-configurable monitoring at any distance. With optional web-
and Modbus® RTU protocols
data sampler, and more. Displayed data include based telemetry software, users can monitor
■ Bluetooth® interface option, gearbox torque; rod load, position, and velocity; multiple fields simultaneously from virtually
■ MaxStream™ wireless radio option, pump load, position, velocity, fill, and stroke; anywhere in the world. Key parameters can be
cellular and satellite options fluid level; daily fluid production; and pressures. remotely adjusted, eliminating the need for a trip
to the wellsite.

Other company, product, and service names

slb.com/rodlift
are the properties of their respective owners.
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Sucker Rod Pumping  |  Technology 139
UniStar
Downhole protection VSD system
APPLICATIONS The UniStar* downhole protection variable speed
■ Automated control of rod lift operation drive (VSD) system maximizes production and
equipment performance through sophisticated
BENEFITS modeling that makes use of all available parameters,
■ Optimizes production under with particular focus on protecting downhole
changing conditions equipment.
■ Protects gearbox and downhole equipment Multiple constraint optimization
■ Improves energy management At any instant during well operations, in particular
■ Reduces number of sensors within a pump cycle, there is a single constraint
that limits production, places equipment at risk, or
FEATURES both. Production can be maximized and equipment
■ Surface and pump dynacard generator protected by “automating” the system to operate UniStar downhole protection VSD system optimizes
at the particular limiting constraint at each instant production and maximizes efficiency and reliability.
■ Pump fill optimization
of time. Determining the applicable limits and load cell or internally computed without the need for
■ Pump speed control operating smoothly across them in real time is the external instrumentation (i.e., sensor-free).
■ Gas interference limiter key differentiator of the UniStar system.
■ Rod load control A rod load limiter automatically adjusts downstroke
Multiple-constraint optimization is particularly speed to eliminate rod float by maintaining minimum
■ Bridle separation control beneficial in applications with variable inflow rod load while maximizing production. Independent
■ Gearbox torque control conditions, such as those found in unconventional maximum and minimum rod load limits can be preset
and shale, high gas/oil ratio, thermally stimulated, to reduce rod stress. Rod load damping can be used
■ Motor current, torque, and thermal control
and coalbed methane wells. to suppress oscillations and improve pumping system
■ Power monitoring and control
Sophisticated modeling for precise control efficiency without the need for specific load limits.
■ User-friendly displays
The UniStar system’s models of all the system Gearbox protection
■ Data capture and communication
elements are run in real time by the controller to Gearbox torque is monitored and controlled to
■ Production monitors detect appropriate limits and enforce associated protect against damaging overload conditions. A
■ Automatic restart control strategies. Monitoring equipment contains crank position monitor provides a continuous reading
■ System modeling and simulation embedded mathematical models of drive, motor, of the angle of the crankshaft. The crank angle is
pump unit, rodstring, pump, flowline, tubing, referenced by a proximity switch, limit switch, or
casing, fluid, and reservoir that use component inclinometer. A belt slip monitor detects and reports
specifications and well completion information, along excessive drive belt slippage or breakage, while a
with field setup parameters. Identification routines starting-torque manager eliminates inrush currents
automatically determine installation-dependent and extends the life of the system by reducing the
system parameters. The models capture the thermal, violence associated with starting the pump.
mechanical, electrical, and hydraulic behavior of the
pumping system, enabling more precise control of The existing counterbalance effect is determined
the pumping process than ever before. by a counterbalance monitor, and an associated
counterbalance assistant makes it easy to adjust the
Downhole equipment protection counterweights to minimize gearbox stress.
Protecting downhole equipment begins with
rodstring design. A rodstring calculator establishes Efficient power usage
rod load and resonance parameters for continuous, Improving energy efficiency and protecting
coupled, straight, and tapered rod configurations. equipment are mutually aligned benefits delivered
Rod load is corrected for well deviation and rod by the UniStar system. The system uses detailed
friction is automatically identified. Rod and pump information on energy consumption, including
monitors continuously measure and display polished system input power, motor output power, polished
rod and downhole pump loads, velocities, and rod power, and pump lift power to optimize
positions. Rod force can be measured directly from a performance.

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Sucker Rod Pumping  |  Technology 140
UniStar
Peak and regenerative power limiters allow the maximum and regenerative power Production and fluid-level monitors
supplied by the drive to be conserved. Power flow control can be used to smooth A pump flow monitor provides a continuous estimate of flow without the need
power flow, reduce gearbox stress, and increase pumping efficiency without for additional instrumentation. Pumping speed and pump effective volume
specifying power limits. A power flow optimizer maximizes production for highly are used to estimate the production rate. Pump flow is totaled in a resettable
variable inflow conditions by operating the drive and motor at their maximum production accumulator. Estimated well production is displayed for the operator
thermal capacities. Special provisions optimize performance with generators and and is available for remote well monitoring through a serial communication port.
solar cells in alternative power systems.
A fluid-level monitor provides a continuous estimate based on pump load, fluid
An input power meter displays cumulative energy consumption, while a pumping properties, tubing pressure, and casing pressure. Tubing and casing pressures
efficiency monitor shows the effectiveness of input energy in producing useful can be entered as parameters for relatively fixed pressures or input from analog
lift work. sensors for significantly variable pressures.
Pump fill control to reduce stress and prevent sanding Automatic restart
The UniStar system accurately determines and regulates the percentage of pump The drive can automatically recover from fault conditions and intermittent power
fill without requiring separate sensors or control hardware. Instead of stopping a outages to ensure continuous operation with unattended wells. Start and stop
pump completely during a pumpoff condition, the system adjusts upstroke and events are automatically logged for subsequent retrieval.
downstroke speeds to maintain a target fill value and maximize production. This
allows the pump to automatically adapt to changing well inflow characteristics, Data capture and communication
eliminating fluid pound, reducing peak rod load, preventing standstill sand A data sampler captures real-time information for generating torque, velocity,
infiltration, eliminating stresses associated with start and stop cycling, and and position plots, as well as surface and downhole dynamometer cards. A
improving pumping efficiency by reducing viscous friction. data logger records time-stamped fault, warning, and event logs that can be
viewed through the keypad and display, uploaded to a personal computer or
The drive automatically slows down prior to fluid impact for a soft landing, tablet, or retrieved by a network server. Typical events include start, stop, mode
protecting the reservoir and subsurface formation. A pumpoff controller allows change, power-up, power loss, overvoltage, overcurrent, bridle separation, belt
the pump to dwell for a period in wells with low inflow. The off time is optimally slip, balance fault, low load, and high load. Pump fill and speed are periodically
selected by the control. A dwell period minimum pump speed can be used to logged for subsequent trend analysis.
prevent sanding in the well.

Sensor-free operation
The system uses a number of unique methods for precisely determining polished
rod and downhole pump position, velocity, and load without requiring external
rod position or load sensors. System variables can be observed through monitor
displays or recorded as time-based graphical plots of motor velocity, motor torque,
pump speed, pump velocity, gearbox torque, rod velocity, rod position, rod load,
pump position, and pump load, as well as dynamometer plots of surface and
downhole conditions.

Pump speed control Various key parameters and event logs can be displayed at the wellsite or accessed remotely.
The UniStar system provides a number of options for controlling pump
speed, including potentiometer adjustments, keypad presets, serial data
Several industry-standard serial protocols are available for communicating
communications, and internal optimization controllers. Single, dual, and triple
with popular programmable controllers, personal computers, or network
speed control options allow pump upstroke, downstroke, and cornering speeds
servers. These protocols include Modbus® RTU, Modbus Plus, ControlNet®, and
to be adjusted independently. The system automatically calculates braking
PROFIBUS®. Optional software is available for monitoring the pumping system
distances for the transition from straight to cornering speeds, as well as points for
using an iPhone® or iPad®. User-programmable reports can be generated using
accelerating out of the corners. In certain applications the motor can be operated
software that connects system parameters to Excel spreadsheets.
at up to twice the base speed at constant power. This allows the overall gear ratio
to be increased, thereby increasing low-speed torque while smoothing gearbox System simulation
torque at high pumping speeds. A pumping system simulator allows actual or hypothetical setup parameters to
be evaluated over a broad range of operating conditions. Simulations can be
Dynacard generation without a load cell run in the field using the UniStar system without powering the motor or on the
A motor torque monitor and pumping unit geometry can be used in place of a
desktop using a well monitor and emulator unit.
load cell to plot surface dynamometer graphs, using either a personal computer,
tablet, or smartphone. The system also estimates downhole pump stroke and
pump flow. Predicted surface and downhole dynamometer graphs are available slb.com/rodlift
for diagnosing well and pump issues on site.

*Mark of Schlumberger
Other company, product, and service names are the properties of their respective owners.
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Sucker Rod Pumping  |  Technology 141
KUDU HSU
Hydraulically powered rod-reciprocating system
APPLICATIONS The KUDU HSU hydraulically powered rod
■ Heavy, medium, and light oil wells reciprocating system uses long strokes to
■ Deep horizontal wells maximize production efficiency and minimize
downtime and workovers. Available in electric-
■ Shallow vertical wells
and gas-powered options, offered in several
■ Thermal wells different cylinder diameters and lengths, the
BENEFITS HSU system package provides flexibility to suit
■ Eliminates potential fluid leaks with no varying well conditions.
cylinder components exposed on the well Operation
■ Maximizes production efficiency caused by A hydraulic power unit consists of a hydraulic
rod stretch pump, a hydraulic tank, a cooling fan, controls,
■ Minimizes downtime and workovers and a prime mover (gas-powered engine or
electric motor), providing fluid to a cylinder
■ Increases the gas compression ratio to
which is directly attached to the wellhead. The
prevent gas locks
piston in the cylinder is attached to a polished
FEATURES rod which in turn connects to the sucker
■ Available in electric- or gas-powered options rodstring. As oil is pumped from the hydraulic
■ Various cylinder diameters and lengths power unit to the cylinder, the piston moves up
the cylinder, actuating the sucker rodstring and
■ Stroke length up to 336 in [8.53 m]
in turn the bottomhole pump.
■ No stuffing box required
Long stroke advantage
■ Ability to run up to two interdependent HSU and power unit installation.
The HSU system’s stroke with lengths of up to
wells with one power unit
336 in [8.53 m] reduces cyclic stress, minimizes Two cylinders and one power unit
rod stretch impact, improves gas compression The KUDU power unit is capable of operating
ratios, and enhances overall system efficiency. two cylinders at the same time. This option
Several different cylinder diameters and reduces capital cost compared to purchasing two
lengths provide design flexibility to suit any complete systems.
production requirements.
Easy installation and maintenance
Zero produced fluid leakage The HSU system’s quick and easy installation
The fully enclosed cylinders prevent leaks which significantly reduces the time required from
cause downtime related to environmental days to hours and does not require any special
exposure, equipment maintenance, and repair. site preparation. All system-setting adjustments
This design further protects against spillage with are viewable and can be changed either on site
a fully contained KUDU power unit enclosure. or remotely.

Artificial Lift

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Sucker Rod Pumping  |  Technology 142
KUDU HSU
50-hp HSU System Capabilities 75-hp HSU System Capabilities
10 10
Stroke Length Stroke Length
9 9
■ 80 in† ■ 80 in†
8 ■ 144 in 8 ■ 144 in
■ 240 in ■ 240 in
7 7 ■ 336 in
Strokes per minute

Strokes per minute


6 6
5 5
4 4
3 3
2 2
1 1
0 0
10 [4.5] 20 [9] 30 [13.5] 40 [18] 50 [22.5] 10 [4.5] 20 [9] 30 [13.5] 40 [18] 50 [22.5]
Peak polished rod load, lbm (thousands) [tons] Peak polished rod load, lbm (thousands) [tons]

†Thismodel is capable of higher SPM, however 10 strokes per minute is the highest
recommended speed for all HSUs.

100-hp HSU System Capabilities 150-hp HSU System Capabilities


10 10
Stroke Length Stroke Length
9 9
■ 144 in ■ 144 in
8 ■ 240 in 8 ■ 240 in
■ 336 in ■ 336 in
7 7
Strokes per minute

Strokes per minute

6 6
5 5
4 4
3 3
2 2
1 1
0 0
10 [4.5] 20 [9] 30 [13.5] 40 [18] 50 [22.5] 10 [4.5] 20 [9] 30 [13.5] 40 [18] 50 [22.5]
Peak polished rod load, lbm (thousands) [tons] Peak polished rod load, lbm (thousands) [tons]

The capabilities graphs are showing at 100% efficiency

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Sucker Rod Pumping  |  Technology 143
KUDU HSU
Level 1 HSU Models
As the entry-level offering, the Level 1 HSU system has the capacity to run
two wells with one power unit and gives operators the flexibility of many Peak Polished Rod Load, Cylinder Diameter, Stroke Length,
different cylinder diameters and lengths. With the Level 1 HSU system, lbm (thousands) [tons] in [mm] in [mm]
changing the speed is quick and simple. The system is designed around 30 [13.5] 3.5 [88.9] 80 [2,032]
specific production requirements, and in most instances, the Level 1 system 30 [13.5] 3.5 [88.9] 144 [3,658]
is able to retrofit to an existing power unit. 30 [13.5] 3.5 [88.9] 240 [6,096]
30 [13.5] 3.5 [88.9] 336 [8,534]
Level 2 40 [18] 4.0 [101.6] 80 [2,032]
KUDU’s Level 2 system offers all the functionalities of the Level 1 system, 40 [18] 4.0 [101.6] 144 [3,658]
but also gives operators the ability to monitor and change system 40 [18] 4.0 [101.6] 240 [6,096]
parameters either on site or remotely. The Level 2 system generates 40 [18] 4.0 [101.6] 336 [8,534]
a surface dynamometer card, which can be used to analyze the well.
50 [22.5] 4.5 [114.3] 80 [2,032]
It also provides a historical sampling of the entire system’s pertinent
50 [22.5] 4.5 [114.3] 144 [3,658]
data, including all alarm history, speed changes and set points.
50 [22.5] 4.5 [114.3] 240 [6,096]
50 [22.5] 4.5 [114.3] 336 [8,534]

kudupump.com

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Sucker Rod Pumping  |  Technology 144
PCP Systems

Advanced technical expertise KUDU PCP


KUDU PCPs incorporate unique designs to handle the demands of heavy, ■■ Produce with maximum efficiency and less power consumption
medium, or light oil, coalbed methane, and dewatering applications. in lower-flow-rate wells.
Engineered to deliver a consistent head capacity with superior handling of
solids and high-viscosity fluids, KUDU PCPs ensure maximum production Driveheads
performance even after the initial flow rate has dropped.
■■ Improve safety and reliability with durable driveheads ranging from
10 to 200 hp.
Applications for KUDU PCPs:
■■ Light to heavy sand laden crude oil Power units
■■ Prevent environmental spillage and provide noise control with open-skid
■■ Light crude oil with high aromatic content
and walk-in power unit designs.
■■ Dewatering gas wells
■■ Coalbed methane KUDU PCP Well Manager family of products
■■ Protect your oilfield equipment and ensure your well is always running
■■ High water cuts at optimum levels.
■■ Highly corrosive wells
■■ Thermal applications (SAGD,
and cyclic steam stimulation)
■■ Horizontal, slant, and directional wells

Table of Contents Previous page Next page 145


KUDU PCP
Positive displacement pump with a helical rotor spinning inside a fixed stator
APPLICATIONS KUDU PCP is a screw pump with a single helical
■ Heavy, medium, and light oil wells rotor, which rotates inside a double internal Drivehead

■ Dewatering coalbed methane and helical elastomer-lined stator. The stator is run
conventional gas wells into the well on the bottom of the production
tubing, while the rotor is connected to the end Power Unit
■ High-water-cut and sand-cut environments
of the rodstring. The rotor turns eccentrically in PCP Well Manager ™

■ Highly corrosive wells the stator, forming cavities from the intake at
■ Thermal applications the bottom of the pump to the discharge at Centralizer

■ Horizontal, slant, and directional wells the top of the pump.


Rod String
■ Water source wells The PCP delivers a constant flow that is
proportional to the size of the cavity and
BENEFITS
rotational speed of the rotor. Rotation of the PCP
■ Produces in high-viscosity and
rodstring at surface is powered by a hydraulic
high-sand-concentration fluids
or electric drive system, which causes the rotor Tag Sub

■ Tolerates high percentage of free gas to spin within the fixed stator, resulting in fluid Anchor

■ Resists abrasion production at surface.


■ Generates low levels of noise
KUDU also offers a high-temperature package,
■ Reduces lifting cost featuring an all-metal PCP capable of withstanding KUDU PCP system components.
■ Provides the highest overall efficiency the extreme downhole conditions of thermal
in all artificial lift methods recovery. EvenWall
EvenWall technology enables KUDU
FEATURES Elastomers to manufacture a PCP stator with
■ Smaller footprint than other forms of KUDU’s elastomers provide significant a uniform elastomer thickness. The
artificial lift systems improvements in bond strength, tear strength, advantage is maintaining a uniform
■ High-capacity and high-head lift pumps abrasion resistance, gas and water resistance, elastomer profile, particularly under
and temperature ratings. This has expanded swell conditions. Since the elastomer
■ Low internal shear rates to limit fluid
the use of PCPs in a variety of environments. swells evenly, it enables a more
emulsification through agitation
Elastomers are primarily made up of nitrile, consistent fit between the rotor and
■ No valves or reciprocating parts to clog, a copolymer of butadiene, and acrylonitrile. stator, ultimately improving pump
gas lock, or wear In addition, KUDU offers a fluorocarbon elastomer performance.
■ Elastomers resistant to most crudes for greater resistance to aromatics and H2S.
Various tag sub intakes Tough Coat
Rotors

KUDU’s Tough Coat is a spray metal coating
■ Wide range of geometries The rotor is the moving component of a PCP applied to PCP rotors. A Tough Coat rotor
■ Standard rotors with paddles to improve and is held from the surface by the drive string, provides greater resistance compared to
sand handling which is typically a conventional or continuous a typical chrome rotor, resulting in longer
sucker rod. The amount or degree of interference improved corrosion resistance compared to a
■ Standard EUE and NU stator connections
fit is critical to the efficiency and life expectancy typical chrome rotor, resulting in longer rotor
machined directly onto the stator tube
of the pump. Interference fit is changed by life, increased production efficiency, and lower
■ All-metal PCP utilizing special metallurgy choosing different rotor minor diameter.
to resist wear and maximize run life operating cost.
■ Proprietary Tough Coat™ technology with a ISO 15136-1 Elastomer Requirements† KUDU Compliant
spray metal coating applied to PCP rotors Material certification Yes
■ EvenWall™ technology to maintain uniform Elastomer hardness testing Yes
elastomer thickness of the PCP stator Elastomer bond testing Yes
Stator phasing aignment Yes
■ Easy to install and operate
Documentation Yes
■ Low maintenance required †ISO compliance ensures manufacturers adhere to a strict specification process to ensure products are of high

quality and meet requirements.

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PCP Systems | Technology 146
KUDU PCP
KUDU Elastomer Relative Specifications
Max.
KUDU Hardness Sand H2S CO2 Explosive
Elastomer† Temperature, Aromatics Hydrolosis
Reference Shore A Resistance Resistance Resistance Decompression
degF [degC]
High Nitrile Soft HNS 55 176 [80] 8 6 5 3 7 6
High Nitrile Hard HNH 68 194 [90] 6 7 7 7 5 8
Hydrogenated High Nitrile Hard HHNH 80 194 [90] 5 7 8 8 8 8
Fluorocarbon Hard FKMH 78 194 [90] 2 8 6 9 9 5
†Not all elastomers are available for every pump model. Check with a representative on elastomer and pump combinations to ensure the optimal elastomer selection. Elastomers are rated from 1 to 10, with 5 being average, 7

being good, and 10 being excellent.

Rotor Selection Guide


6 4 13 22 8 12 15 23 24 32 40 42 56 76 60 80 98† 100 120 122 160 m3/d at 100 rpm
34 25 83 136 50 75 94 145 151 201 244 264 352 478 377 503 616 630 755 767 1,006 bbl/d at 100 rpm

Rotor options
2 3⁄8 in 2 7⁄8 in 3 1⁄2 in 4 in 4 1⁄2 in 4 1⁄2 in Series
[60 mm] [73 mm] [89 mm] [102 mm] [144 mm] [144 mm]
EUE EUE EUE NU NU EUE
All technical specifications are deemed accurate, but situations may arise where additional information may be required. Please contact a KUDU representative for a technical consultation.
†Available in EvenWall.

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PCP Systems | Technology 147
KUDU PCP
Ability to Coil Past Rotor with 3/4-in Coiled Tubing
Tubing Size: 2.875 in [73 mm] Tubing Size: 3.5 in [88.9 mm] Tubing Size: 4.5 in [114.3 mm]
Crest to Crest
Series, in [m] Model Tubing Weight: 6.5 lbm/ft [9.67 kg/m] Tubing Weight: 9.3 lbm/ft [13.84 kg/m] Tubing Weight: 12.75 lbm/ft [18.97 kg/m]
Diameter, in [mm]
Drift ID: 2.35 in [59.61 mm] Drift ID: 2.99 in [72.82 mm] Drift ID: 3.96 in [97.36 mm]
3K 1.41 [35.92] Yes Yes Yes
2.375 [60] EUE 6 K 1.33 [33.78] Yes Yes Yes
16 K 1.46 [37.20] Yes Yes Yes
4K 1.73 [44.00] Yes Yes
13 K 1.78 [45.21] Yes Yes
2.875 [73] EUE
22 K 1.70 [43.18] Yes Yes
48 K 1.69 [43.03] Yes Yes
8K 1.99 [50.6] Yes Yes
12 K 1.99 [50.67] Yes Yes
15 K 1.86 [47.37] Yes Yes
24 K 2.01 [51.1] Yes Yes
3.5 [89] EUE
30 K 1.95 [49.58]
32 K 2.01 [51] Yes Yes
40 K 2.01 [51.08] Yes Yes
63 K 2.03 [51.44] Yes Yes
36 K 2.32 [58.90] Yes
45 K 2.29 [58.27] Yes
56 K 2.23 [56.52] Yes
4 [102] NU 60 K 2.29 [58.17] Yes
80 K 2.27 [57.66] Yes
100 K 2.31 [58.76] Yes
120 K 2.29 [58.29] Yes
4.5 [114] NU 122 K 2.45 [62.2] Yes
4.5 [114] EUE 160 K 2.67 [67.82] Yes
150 K 2.96 [75.21] Yes
5 [127] STC
200 K 2.96 [75.21] Yes

PCP Specifications
Pump Nominal Capacity at 100 rpm Pump Lift Stator Outside Stator
Series, in [m] Model
at Zero Head, bbl/d [m3/d] Rating, ft [m] Diameter, in [m] Length, ft [m]
2.375 [60] 3 K 600 19 [3] 1,968 [600] 2.795 [71] 2.94 [0.90]
EUE Pin 3 K 1200 19 [3] 3,936 [1,200] 2.795 [71] 5.91 [1.80]
3 K 2400 19 [3] 7,872 [2,400] 2.795 [71] 11.81 [3.60]
6 K 650 38 [6] 2,132 [650] 2.795 [71] 4.28 [1.31]
6 K 1300 38 [6] 4,264 [1,300] 2.795 [71] 8.56 [2.61]
6 K 2000 38 [6] 6,560 [2,000] 2.795 [71] 12.84 [3.92]
6 K 2600 38 [6] 8,528 [2,600] 2.795 [71] 17.13 [5.22]
6 K 3300 38 [6] 10,824 [3,300] 2.795 [71] 21.42 [6.53]
16 K 1200 101 [16] 3,936 [1,200] 2.795 [71] 17.73 [5.40]
16 K 1600 101 [16] 5,248 [1,600] 2.795 [71] 23.64 [7.21]
16 K 2000 101 [16] 6,560 [2,000] 2.795 [71] 29.53 [9.00]

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PCP Systems | Technology 148
KUDU PCP
Pump Nominal Capacity at 100 rpm Pump Lift Rating, Stator Outside Stator Length,
Series, in [m] Model
at Zero Head, bbl/d [m3/d] ft [m] Diameter, in [m] ft [m]
2.875 [73] 4 K 600 25 [4] 1,968 [600] 3.150 [80] 1.97 [0.60]
EUE Pin 4 K 1200 25 [4] 3,936 [1,200] 3.150 [80] 3.94 [1.20]
4 K 1800 25 [4] 5,904 [1,800] 3.150 [80] 5.91 [1.80]
4 K 2400 25 [4] 7,872 [2,400] 3.150 [80] 7.87 [2.40]
13 K 650 82 [13] 2,132 [650] 3.150 [80] 5.71 [1.74]
13 K 1300 82 [13] 4,264 [1,300] 3.150 [80] 11.42 [3.48]
13 K 1650 82 [13] 5,412 [1,650] 3.150 [80] 14.27 [4.35]
13 K 2000 82 [13] 6,560 [2,000] 3.150 [80] 17.13 [5.22]
13 K 2600 82 [13] 8,528 [2,600] 3.150 [80] 22.85 [6.97]
13 K 3300 82 [13] 10,824 [3,300] 3.150 [80] 28.54 [8.7]
22 K 600 138 [22] 1,968 [600] 3.390 [86] 8.56 [2.61]
22 K 1200 138 [22] 3,936 [1,200] 3.390 [86] 17.14 [5.22]
22 K 1400 138 [22] 4,592 [1,400] 3.390 [86] 19.68 [6.00]
22 K 1500 138 [22] 4,920 [1,500] 3.390 [86] 21.39 [6.52]
22 K 1800 138 [22] 5,904 [1,800] 3.390 [86] 25.69 [7.83]
48 K 600 302 [48] 1,968 [600] 3.390 [86] 17.13 [5.22]
48 K 900 302 [48] 2,952 [900] 3.390 [86] 25.69 [7.83]
3.5 [89] 8 K 600 INT† 50 [8] 1,968 [600] 3.780 [96] 2.57 [0.78]
EUE Pin 8 K 450 CAN† 50 [8] 1,476 [450] 3.780 [96] 2.57 [0.78]
8 K 900 INT 50 [8] 2,952 [900] 3.780 [96] 3.85 [1.18]
8 K 700 CAN 50 [8] 2,296 [700] 3.780 [96] 3.85 [1.18]
8 K 1200 INT 50 [8] 3,936 [1,200] 3.780 [96] 5.14 [1.57]
8 K 950 CAN 50 [8] 3,116 [950] 3.780 [96] 5.14 [1.57]
8 K 1800 INT 50 [8] 5,904 [1,800] 3.780 [96] 7.71 [2.35]
8 K 1400 CAN 50 [8] 4,592 [1,400] 3.780 [96] 7.71 [2.35]
8 K 2400 INT 50 [8] 7,872 [2,400] 3.780 [96] 10.27 [3.13]
8 K 1850 CAN 50 [8] 6,068 [1,850] 3.780 [96] 10.27 [3.13]
8 K 3,000 INT 50 [8] 9,840 [3,000] 3.780 [96] 12.85 [3.92]
8 K 2,350 CAN 50 [8] 7,708 [2,350] 3.780 [96] 12.85 [3.92]
8 K 3,600 INT 50 [8] 11,808 [3,600] 3.780 [96] 15.42 [4.70]
8 K 2,800 CAN 50 [8] 9,184 [2,800] 3.780 [96] 15.42 [4.70]
12 K 1,200 76 [12] 3,936 [1,200] 3.780 [96] 8.90 [2.71]
12 K 1,500 76 [12] 4,920 [1,500] 3.780 [96] 11.88 [3.62]
12 K 1,800 76 [12] 5,904 [1,800] 3.780 [96] 13.36 [4.07]
12 K 2,400 76 [12] 7,872 [2,400] 3.780 [96] 17.80 [5.43]
12 K 2,600 76 [12] 8,528 [2,600] 3.780 [96] 19.29 [5.88]
15 K 600 INT 94 [15] 1,968 [600] 3.780 [96] 4.37 [1.33]
15 K 450 CAN 94 [15] 1,476 [450] 3.780 [96] 4.37 [1.33]
15 K 900 INT 94 [15] 2,952 [900] 3.780 [96] 6.56 [2.00]
15 K 700 CAN 94 [15] 2,296 [700] 3.780 [96] 6.56 [2.00]
15 K 1,200 INT 94 [15] 3,936 [1,200] 3.780 [96] 8.75 [2.67]
15 K 950 CAN 94 [15] 3,116 [950] 3.780 [96] 8.75 [2.67]
15 K 1800 INT 94 [15] 5,904 [1,800] 3.780 [96] 13.12 [4.00]
15 K 1,400 CAN 94 [15] 4,592 [1,400] 3.780 [96] 13.12 [4.00]
15 K 2,400 INT 94 [15] 7,872 [2,400] 3.780 [96] 17.51 [5.34]
15 K 1,850 CAN 94 [15] 6,068 [1,850] 3.780 [96] 17.51 [5.34]
15 K 3,000 INT 94 [15] 9,840 [3,000] 3.780 [96] 21.85 [6.66]

Table of Contents Previous page Next page


PCP Systems | Technology 149
KUDU PCP
Pump Nominal Capacity at 100 rpm Pump Lift Stator Outside Stator
Series, in [m] Model
at Zero Head, bbl/d [m3/d] Rating, ft [m] Diameter, in [m] Length, ft [m]
15 K 2,350 CAN 94 [15] 7,708 [2,350] 3.780 [96] 21.85 [6.66]
15 K 3,600 INT 94 [15] 11,808 [3,600] 3.780 [96] 26.26 [8.00]
15 K 2800 CAN 94 [15] 9,184 [2,800] 3.780 [96] 26.26 [8.00]
24 K 1300 151 [14] 4,264 [1,300] 3.780 [96] 13.35 [4.07]
24 K 1500 151 [14] 4,920 [1,500] 3.780 [96] 15.55 [4.74]
24 K 2000 151 [14] 6,560 [2,000] 3.780 [96] 20.01 [6.10]
24 K 2600 151 [14] 8,528 [2,600] 3.780 [96] 26.71 [8.14]
24 K 3300 151 [14] 10,824 [3,300] 3.780 [96] 33.37 [10.17]
30 K 900 EW† 189 [30] 2,952 [900] 3.780 [96] 7.41 [2.26]
30 K 1800 EW 189 [30] 5,904 [1,800] 3.780 [96] 14.83 [4.52]
30 K 2700 EW 189 [30] 8,856 [2,700] 3.780 [96] 22.24 [6.78]
30 K 3600 EW 189 [30] 11,808 [3,600] 3.780 [96] 29.66 [9.04]
32 K 750 201 [32] 2,460 [750] 3.780 [96] 9.02 [2.75]
32 K 1,200 201 [32] 3,936 [1,200] 3.780 [96] 13.53 [4.13]
32 K 1,500 201 [32] 4,920 [1,500] 3.780 [96] 18.04 [5.50]
32 K 2,200 201 [32] 7,216 [2,200] 3.780 [96] 17.07 [8.25]
33 K 600 208 [33] 1,968 [600] 4.252 [108] 6.23 [1.90]
33 K 900 208 [33] 2,952 [900] 4.252 [108] 9.35 [2.85]
33 K 1,200 208 [33] 3,936 [1,200] 4.252 [108] 12.47 [3.80]
33 K 1500 208 [33] 4,920 [1,500] 4.252 [108] 15.58 [4.75]
33 K 1800 208 [33] 5,904 [1,800] 4.252 [108] 18.70 [5.70]
33 K 2400 208 [33] 7,872 [2,400] 4.252 [108] 24.93 [7.60]
33 K 3600 208 [33] 11,808 [3,600] 4.252 [108] 37.40 [11.40]
40 K 600 252 [40] 1,968 [600] 3.780 [96] 9.02 [2.75]
40 K 1200 252 [40] 3,936 [1,200] 3.780 [96] 18.04 [5.50]
40 K 1400 252 [40] 4,592 [1,400] 3.780 [96] 21.03 [6.41]
40 K 1500 252 [40] 4,920 [1,500] 3.780 [96] 22.56 [6.88]
40 K 1800 252 [40] 5,904 [1,800] 3.780 [96] 27.07 [8.25]
40 K 2400 252 [40] 7,872 [2,400] 3.780 [96] 36.09 [11.00]
63 K 400 396 [63] 1,312 [400] 3.780 [96] 9.02 [2.75]
63 K 800 396 [63] 2,696.16 [822] 3.780 [96] 18.04 [5.50]
63 K 1200 396 [63] 3,936 [1,200] 3.780 [96] 27.07 [8.25]
63 K 1600 396 [63] 5,248 [1,600] 3.780 [96] 36.09 [11.00]
3.5 [89] 23 K 600 145 [23] 1,968 [600] 4.252 [108] 4.49 [1.37]
EUE Box 23 K 900 145 [23] 2,952 [900] 4.252 [108] 6.77 [2.06]
23 K 1200 145 [23] 3,936 [1,200] 4.252 [108] 9.02 [2.75]
23 K 1500 145 [23] 4,920 [1,500] 4.252 [108] 11.28 [3.44]
23 K 1800 145 [23] 5,904 [1,800] 4.252 [108] 13.52 [4.12]
23 K 2400 145 [23] 7,872 [2,400] 4.252 [108] 18.04 [5.50]
23 K 3600 145 [23] 11,808 [3,600] 4.252 [108] 27.07 [8.25]
42 K 600 264 [42] 1,968 [600] 4.252 [108] 7.94 [2.42]
42 K 900 264 [42] 2,952 [900] 4.252 [108] 11.91 [3.63]
42 K 1200 264 [42] 3,936 [1,200] 4.252 [108] 15.91 [4.85]
42 K 1500 264 [42] 4,920 [1,500] 4.252 [108] 19.88 [6.06]
42 K 1800 264 [42] 5,904 [1,800] 4.252 [108] 23.85 [7.27]
42 K 2400 264 [42] 7,872 [2,400] 4.252 [108] 31.82 [9.70]
56 K 600 352 [56] 1,968 [600] 4.252 [108] 10.60 [3.23]

Table of Contents Previous page Next page


PCP Systems | Technology 150
KUDU PCP
Pump Nominal Capacity at 100 rpm Pump Lift Stator Outside Stator
Series, in [m] Model
at Zero Head, bbl/d [m3/d] Rating, ft [m] Diameter, in [m] Length, ft [m]
56 K 900 352 [56] 2,952 [900] 4.252 [108] 15.91 [4.85]
56 K 1200 352 [56] 3,936 [1,200] 4.252 [108] 21.19 [6.46]
56 K 1500 352 [56] 4,920 [1,500] 4.252 [108] 26.51 [8.08]
56 K 1800 352 [56] 5,904 [1,800] 4.252 [108] 31.82 [9.70]
56 K 1200 EW 352 [56] 3,936 [1,200] 4.252 [108] 13.78 [4.20]
56 K 2400 EW 352 [56] 7,872 [2,400] 4.252 [108] 27.56 [8.40]
76 K 600 478 [76] 1,968 [600] 4.252 [108] 14.44 [4.40]
76 K 900 478 [76] 2,952 [900] 4.252 [108] 21.65 [6.60]
76 K 1200 478 [76] 3,936 [1,200] 4.252 [108] 28.87 [8.80]
76 K 1500 478 [76] 4,920 [1,500] 4.252 [108] 36.09 [11.00]
4 [102] 36 K 1000 226 [36] 3,280 [1,000] 4.290 [109] 9.45 [2.88]
NU Pin 36 K 1500 226 [36] 4,920 [1,500] 4.290 [109] 14.17 [4.32]
36 K 2000 226 [36] 6,560 [2,000] 4.290 [109] 18.90 [5.76]
36 K 3000 226 [36] 9,840 [3,000] 4.290 [109] 28.35 [8.64]
45 K 1600 283 [45] 5,248 [1,600] 4.290 [109] 18.90 [5.76]
45 K 2000 283 [45] 6,560 [2,000] 4.290 [109] 23.62 [7.20]
45 K 2400 283 [45] 7,872 [2,400] 4.290 [109] 28.36 [8.64]
60 K 600 377 [60] 1,968 [600] 4.290 [109] 9.45 [2.88]
60 K 1200 377 [60] 3,936 [1,200] 4.290 [109] 18.90 [5.76]
60 K 1500 377 [60] 4,920 [1,500] 4.290 [109] 23.62 [7.20]
4 [102] 60 K 1800 377 [60] 5,904 [1,800] 4.290 [109] 28.35 [8.64]
NU Pin 60 K 2400 377 [60] 7,872 [2,400] 4.290 [109] 37.79 [11.52]
80 K 450 503 [80] 1,476 [450] 4.290 [109] 9.45 [2.88]
80 K 900 503 [80] 2,952 [900] 4.290 [109] 18.90 [5.76]
80 K 1150 503 [80] 3,772 [1,150] 4.290 [109] 23.62 [7.20]
80 K 1350 503 [80] 4,428 [1,350] 4.290 [109] 28.35 [8.64]
80 K 1800 503 [80] 5,904 [1,800] 4.290 [109] 37.79 [11.52]
98 K 600 EW 616 [98] 1,968 [600] 4.252 [108] 12.80 [3.90]
98 K1200 EW 616 [98] 3,936 [1,200] 4.252 [108] 25.59 [7.80]
98 K 1800 EW 616 [98] 5,904 [1,800] 4.252 [108] 38.39 [11.70]
100 K 400 629 [100] 1,312 [400] 4.290 [109] 9.45 [2.88]
100 K 800 629 [100] 2,624 [800] 4.290 [109] 18.90 [5.76]
100 K 1000 629 [100] 3,280 [1,000] 4.290 [109] 23.62 [7.20]
100 K 1200 629 [100] 3,936 [1,200] 4.290 [109] 28.35 [8.64]
100 K 1600 629 [100] 5,248 [1,600] 4.290 [109] 37.79 [11.52]
120 K 300 755 [120] 984 [300] 4.290 [109] 9.45 [2.88]
120 K 600 755 [120] 1,968 [600] 4.290 [109] 18.90 [5.76]
120 K 900 755 [120] 2,952 [900] 4.290 [109] 28.35 [8.64]
120 K 1200 755 [120] 3,936 [1,200] 4.290 [109] 37.79 [11.52]
120 K 1500 755 [120] 4,920 [1,500] 4.290 [109] 47.28 [14.41]
175 K 400 1,101 [175] 1,312 [400] 4.290 [109] 18.90 [5.76]
175 K 600 1,101 [175] 1,968 [600] 4.290 [109] 28.35 [8.64]
175 K 800 1,101 [175] 2,624 [800] 4.290 [109] 37.79 [11.52]
175 K 1000 1,101 [175] 3,280 [1,000] 4.290 [109] 47.24 [14.40]
4.5 [114] NU Pin 122 K 600 767 [122] 1,968 [600] 4.528 [115] 16.73 [5.10]
122 K 900 767 [122] 2,952 [900] 4.528 [115] 25.10 [7.65]
122 K 1200 767 [122] 3,936 [1,200] 4.528 [115] 33.46 [10.20]

Table of Contents Previous page Next page


PCP Systems | Technology 151
KUDU PCP
Pump Nominal Capacity at 100 rpm Pump Lift Stator Outside Stator
Series, in [m] Model
at Zero Head, bbl/d [m3/d] Rating, ft [m] Diameter, in [m] Length, ft [m]
122 K 1500 767 [122] 4,920 [1,500] 4.528 [115] 41.83 [12.75]
122 K 1800 767 [122] 5,904 [1,800] 4.528 [115] 50.20 [15.30]
4.5 [114] 160 K 600 1,006 [160] 1,968 [600] 5.000 [127] 19.03 [5.80]
EUE Pin 160 K 750 1,006 [160] 2,460 [750] 5.000 [127] 23.79 [7.25]
160 K 900 1,006 [160] 2,952 [900] 5.000 [127] 28.54 [8.70]
160 K 1,050 1,006 [160] 3,444 [1,050] 5.000 [127] 33.30 [10.15]
160 K 1,200 1,006 [160] 3,936 [1,200] 5.000 [127] 38.06 [11.60]
5 [127] 150 K 800 944 [150] 2,624 [800] 5.433 [138] 18.57 [5.66]
Casing Short Pin 150 K 1000 944 [150] 3,280 [1,000] 5.433 [138] 23.23 [7.08]
150 K 1200 944 [150] 3,936 [1,200] 5.433 [138] 27.85 [8.49]
150 K 1600 944 [150] 5,248 [1,600] 5.433 [138] 37.14 [11.32]
200 K 580 1,258 [200] 1,902.4 [580] 5.433 [138] 18.57 [5.66]
200 K 860 1,258 [200] 2,820.8 [860] 5.433 [138] 27.85 [8.49]
200 K 1150 1,258 [200] 3,772 [1,150] 5.433 [138] 37.14 [11.32]
†INT = international; CAN = Canada; EW = EvenWall

PCP models may vary depending on the location. Additional pump lengths and lifts are available upon request.
Please contact a KUDU representative for specific product offering in your region. Top Tag is available for all pump models. Tough Coat rotors are also available.

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PCP Systems | Technology 152
All-Metal PCP
Abrasion-resistant progressing cavity pump
APPLICATIONS A first for the Canadian market, the KUDU all- All-metal PCP options
■ Enhanced oil recovery methods, such as metal progressing cavity pump (PCP) consists HT Oryx seal
steam-assisted gravity drainage, cyclic of a metal stator and matching motor. With KUDU’s industry-proven HT Oryx seal is rated
steam stimulation, steam drive, solvent, special metallurgy to resist wear and maximize up to 500 degF [260 degC]. When using an early
electric heating, and infill wells run life, the pump is rated for temperatures up warning seal failure system, the HT Oryx seal
to 660 degF [350 degC], functions in low and increases operator safety while still delivering
BENEFITS high viscosities, and handles most solvents outstanding performance. It exceeds Alberta
■ Produces fluid at a wide range of or chemicals. Energy Regulator environmental standards.
pressures and flow rates
■ Operates at even low bottomhole Thermal recovery HT elastomer
pressures For production of highly viscous crude oil at KUDU HT elastomer pump creates even swelling
elevated temperatures, the all-metal PCP keeps to enable a consistent fit between the rotor
■ Eliminates rod failure problems
mid- to high-temperature applications pumping. and stator.
■ Lowers construction costs for pads when
compared with beam pump or gas lift KUDU’s thermal package consists of the Automation
following options: The KUDU PCP Well Manager™ is a suite of
FEATURES ■ All-metal PCP products created to protect oilfield equipment
■ High-temperature (HT) rating up to
KUDU drivehead (60–200 hp available) in thermal applications. KUDU’s automation
660 degF [350 degC] ■
package provides not only torque control
Fluid rates up to 2,830 bbl/d [450 m3/d] ■ HT Oryx seal

and protection for the rodstring and pump,
■ Internal tolerances to allow gas to ■ KUDU variable frequency drive but also easy connectivity to various SCADA
pass through the pump without ■ Optional 2-in segmented polished rod for and communication systems, gauge systems,
restriction unobstructed steaming through the pump and analog and digital input and output. The
■ Low internal shear without removal of the rodstring. advanced PCP pumpoff controller is also
■ Ability to steam through pump available with extended data logging capabilities
while downhole and a pump control algorithm.
■ Adjustable rpm to match reservoir
inflow rates
■ Small surface footprint
■ No gas lock
■ Zero emulsion

Pad slant installation of all-metal PCPs with driveheads in a SAGD well, Alberta, Canada.

Artificial Lift

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PCP Systems | Technology 153
All-Metal PCP
All-Metal PCP Specifications: 4-in Series 80MET1000 80MET1350 110MET750 110MET1000
Stator thread connection, in [mm] 4 [102] NUE 4 [102] NUE 4 [102] NUE 4 [102] NUE
Rotor thread connection, in [mm] 1.125 [28.5] 1.125 [28.5] 1.125 [28.5] 1.125 [28.5]
Capacity, bbl/d [m3/d] 5 [0.80] 0.80 [5] 1.10 [6.9] 1.10 [6.9]
Volume at 300 rpm and zero head, bbl/d [m3/d] 1,510 [240] 1,510 [240] 2,076 [330] 2,076 [330]
Pumphead capability, psi [bars] 1,450 [100] 1,959 [135] 1,088 [75] 1,450 [100]
Stator length, ft [m] 29.4 [8.96] 38.8 [11.84] 29.4 [8.96] 38.8 [11.84]
Stator outside diameter, in [mm] 4.5 [115] 4.5 [115] 4.5 [115] 4.5 [115]
Rotor length, ft [m] 30.4 [9.25] 39.4 [12] 30.4 [9.25] 39.4 [12]
Rotor head diameter, in [mm] 2.3 [57.5] 2.3 [57.5] 2.3 [57.5] 2.3 [57.5]
Crest-to-crest diameter, in [mm] 2.2 [56.7] 2.2 [56.7] 2.2 [56.7] 2.2 [56.7]

All-Metal PCP Specifications: 4.5-in Series 220MET750 220MET1000 300MET600 300MET800


Stator thread connection, in [mm] 4.5 [114.3] EUE 4.5 [114.3] EUE 4.5 [114.3] EUE 4.5 [114.3] EUE
Rotor thread connection, in [mm] 1.125 [28.5] MOD 1.125 [28.5] MOD 1.125 [28.5] MOD 1.125 [28.5] MOD
Capacity, bbl/d [m3/d] 13.8 [2.20] 13.8 [2.20] 18.9 [3.00] 18.9 [3.00]
Volume at 300 rpm and zero head, bbl/d [m3/d] 4,151 [660] 4,151 [660] 5,661 [900] 5,661 [900]
Pumphead capability, psi [bars] 1,088 [75] 1,450 [100] 900 [60] 1,200 [80]
Stator length, ft [m] 28.9 [8.80] 38 [11.59] 28.9 [8.80] 38 [11.59]
Stator outside diameter, in [mm] 5.3 [135] 5.3 [135] 5.3 [135] 5.3 [135]
Rotor length, ft [m] 29.6 [9.02] 39.4 [12] 29.6 [9.02] 39.4 [12]
Rotor head diameter, in [mm] 2.3 [57.5] 2.3 [57.5] 2.3 [57.5] 2.3 [57.5]
Crest-to-crest diameter, in [mm] 2.8 [72.2] 2.8 [72.2] 2.9 [73.5] 2.9 [73.5]

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PCP Systems | Technology 154
KUDU Rodless PCP
PCP with submersible electric motor
APPLICATIONS The most typical PCP failure occurs from sucker rod or tubing wear. The
■ Progressing cavity pump (PCP) wells severity of wear is determined by various factors such as DLS, water cut,
■ High dogleg severity (DLS) wells and sand cut. The wear is especially high for deviated and horizontal wells.
suitable for PCPs KUDU Rodless PCP™ eliminates all rod failures, resulting in a 30–50%
decrease in system failure rates, and allows for pump installations in a
■ Wells with rod restrictions, tubing wear,
high-DLS or horizontal section of the well.
or wax problems
■ Offshore heavy oil wells Rodless PCP components
The KUDU Rodless PCP features a low-speed downhole PMM drive and a
BENEFITS PCP, which work together without being limited by deviation profile. Every
■ Eliminates restrictions to running PCP in component of a KUDU Rodless PCP is selected based on well conditions
wellbores with high DLS and the customer’s operational parameters, such as production target
■ Reduces all PCP failures caused by rate. All other system components are selected dependent on this PCP and
rodstring and tubing wear motor combination.
■ Decreases torque and pressure PMM technology
losses in relation to high-viscosity fluid By adopting a low-speed PMM, the KUDU Rodless PCP provides constant
■ Reduces torque by 20–60% with the torque in the entire PCP speed zone, ranging from 50 rpm
elimination of rodstring to 500 rpm. Such system flexibility enables easy adjustment to a broad
■ Improves overall efficiency range of well production rates without replacing the pump.
■ Reduces power consumption The downhole assembly is effective in high temperatures of up to
300 degF [150 degC] and is corrosion resistant with special coating.
■ Increases safety without having rod A synchronous machine incorporating rare earth magnets in its rotor
backspin on the surface design, the PMM provides additional benefits, such as
■ Avoids leakage at surface without having ■ improved efficiency due to low power loss in the rotor
a stuffing box
■ increased power density with a shorter motor
■ Lowers wellsite maintenance cost
■ enhanced dynamic performance with a variable frequency drive (VFD)
■ Minimizes noise disturbance specifically designed for PMM.
FEATURES
Real-time downhole monitoring system
■ Permanent magnet motor (PMM) Applying downhole telemetry, KUDU Rodless PCP prevents pumpoff
downhole drive conditions, monitors equipment performance, and optimizes well
■ Broad range of PCP speeds from production. The system includes a multisensor downhole gauge package
50–500 rpm completed with a digital well monitoring system. The downhole sensors
■ Constant torque in the entire range are connected to the PMM base, and the surface interface box is mounted
of speed inside the control panel.
■ PMM applicable control panel in NEMA The unit also uses a power cable to receive signals from the downhole tool.
4 enclosure The signals are interpreted by a data acquisition system on the surface and
■ Completion and various components then sent to the VFD for monitoring, control, and recording. The system is
compatible with conventional ESP able to provide the following measurements:
■ Certified by Canadian standards ■ Intake pressure
association and underwriters laboratories ■ Intake temperature
FEATURES ■ Motor winding temperature
■ Downhole gauges to provide information ■ Vibration
for pumping intake pressure (PIP),
■ Pump discharge pressure (optional).

Rodless PCP
downhole assembly.

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PCP Systems | Technology 155
KUDU Rodless PCP
bottomhole temperature, motor Power cable
temperature, and vibration
■ Optional pump to discharge pressure Rotor
connection coupling
■ Control panels that offer
● variety of control algorithms including Flexible shaft
Motor
speed control, PIP control, fluid level lead extension Tubing drain
control, and torque control
Permanent
● connectivity to field data via a
magnet motor PCP
communication system Motor centralizer

● storage and management for


Pump intake
historical data
● ability to monitor field data remotely
Supporting unit

Motor protector

Permanent
downhole sensors

Rodless PCP downhole components.

PMM-specific control panel


KUDU Rodless PCP features a specially designed control panel that works with the downhole motor
as one unit without costly step-up transformers. The control panel has a built-in
NEMA 4 enclosure and offers a number of critical features, including
■ dynamic backspin brake
■ multiple speed controls
■ data logging and storage
■ programmable digital and analog inputs or outputs
■ remote communication options
■ data management software.

Rodless PCP Specifications


Production rate†, bbl/d [m3/d] 12–1,900 [2–300]
Maximum setting vertical depth, ft [m] 6,500 [2,000]
Maximum downhole temperature‡, degF [degC] 300 [150]
Operational speed range, rpm 50–500
Maximum power capacity, hp [kW] 60 [45]
Power supply requirements, V [Hz] Three-phase 380–480 [50–60]
Maximum pump axial load, lbm [kg] 13,200 [6,000]
Minimum casing size, in [mm] 5.5 [139.7]
†Based on pump model, fluid level, and pump setting depth.

‡ Maximum temperature for PMM.

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PCP Systems | Technology 156
Tough Coat
Spray metal coating applied to PCP rotors
APPLICATIONS
■ Progressing cavity pump (PCP) rotors
requiring an improved resistance to
corrosion and abrasion

BENEFITS
■ Eliminates peeling and problems caused
by peeling
■ Prolongs pump run life in corrosive or
abrasive well conditions
■ Maintains PCP efficiency over time
in corrosive environment compared
to chrome
■ Lowers operation costs
■ Provides more environmentally friendly
coating process than chroming

FEATURES
■ Coating material fused with
rotor-based material
Tough Coat PCP testing.
■ Nickel-based coating

Using advanced proprietary technology, KUDU’s Proven performance


Tough Coat is a spray metal coating applied Tough Coat has proven itself in light, medium,
to PCP rotors. In comparison to chrome rotors, and heavy oil applications. Extensive field
rotors with Tough Coat provide significantly analyses have shown significant rotor run life
improved resistance to corrosion and abrasion, improvement in all well conditions.
and pump more fluid over an extensive period
in highly corrosive environments. The result is The chart below shows three consecutive rotor
longer rotor life, increased production efficiency, runs in the same well at the same 195 rpm. The
and lower operating expenses. first two chrome rotors lasted 748 and 953 days
with pump efficiency dropping continuously.
Corrosive environments The Tough Coat pump was operating at 83%
A rotor with Tough Coat coating running at efficiency after more than 1,200 days. In 95% of
400 rpm in a highly corrosive, heavy oil field tests, Tough Coat has prolonged rotor life in
application is capable of maintaining the pump adverse conditions and continually achieved high
at high efficiency throughout its run life. Pumps production rates.
with Tough Coat rotors show no significant
weakening or wear, which is typical for chrome Relative Comparisons between
rotors in similar applications. Tough Coat and Chrome Rotors
Noncorrosive environments Chrome 1
The Tough Coat coating also works well in Chrome 2
environments where there are no corrosive or Tough Coat
abrasive characteristics. A pump with Tough 1,200+ days
748 days
Coat is able to produce at very high efficiency in 953 days
a light oil well. Run life and efficiency in a highly corrosive, medium-oil,
Cummings zone well.

Tough Coat is a trademark of KUDU Industries, Inc.


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PCP Systems | Technology 157
EvenWall
Uniform elastomer swell and thermal expansion in PCPs
APPLICATIONS In a conventional PCP, the heat accumulates where the elastomer
■ Progressing cavity pump (PCP) requiring is thicker, causing potential damage to the elastomer. EvenWallTM
a uniform elastomer profile due to high technology creates uniform elastomer thickness, resulting in an even
swelling conditions temperature distribution.

BENEFITS The constant elastomer profile works particularly well under swell
■ Uniforms elastomer swell conditions. As the elastomer swells evenly, it enables an accurate, more
and thermal expansion consistent fit between the rotor and stator, improving pump performance.
■ Reduces risk of swelling The reduction in swelling makes this technology suitable for high-API
applications or wherever the problem is presented.
■ Extends pump run life by decreasing
friction and built-up heat Steel tube.

FEATURES Elastomer.
■ Rated up to 194 degF [90 degC]
■ Lower drive power for the same delivery Pump slice. Transversal Longitudinal cross-section.
rate and pressure cross-section.

■ Shorter pump design due to more Steel tube.


pressure at each stage Elastomer.
■ Suitable for high-API applications
EvenWall elastomer creates more uniform wall thickness when compared with
a conventional elastomer’s nonuniform swell. KUDU EvenWall PCP.

KUDU PCP EvenWall Models


Series Model Pump Nominal Capacity Pump Lift Stator Outside Stator Length,
(Displacement Rate) at Rating, Diameter, ft [m]
100 rpm at Zero Head, ft [m] in [mm]
bbl/d [m3/d]
3 ½ in 30 K 900 EW 189 [30] 2,952 [900] 3.780 [96] 7.41 [2.26]
[88.9 mm] 30 K 1,800 EW 189 [30] 5,904 [1,800] 3.780 [96] 14.83 [4.52]
EUE Pin
30 K 2,700 EW 189 [30] 8,856 [2,700] 3.780 [96] 22.24 [6.78]
30 K 3,600 EW 189 [30] 11,808 [3,600] 3.780 [96] 29.66 [9.04]
3 ½ in 56 K 1,200 EW 352 [56] 3,936 [1,200] 4.252 [108] 13.78 [4.20]
[88.9 mm]
56 K 2,400 EW 352 [56] 7,872 [2,400] 4.252 [108] 27.56 [8.40]
EUE Box
4 in 98 K 600 EW 616 [98] 1,968 [600] 4.252 [108] 12.80 [3.90]
[101.6 mm] 98 K 1,200 EW 616 [98] 3,936 [1,200] 4.252 [108] 25.59 [7.80]
NU Pin
98 K 1,800 EW 616 [98] 5,904 [1,800] 4.252 [108] 38.39 [11.70]

EvenWall is a trademark of KUDU Industries, Inc.


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PCP Systems | Technology 158
KUDU Drivehead
Hydraulic or electric power system for PCP installations
APPLICATIONS KUDU hydraulic or electric driveheads are specifically designed for PCP installations in heavy to light
■ Progressing cavity pump (PCP) oil, gas dewatering, and thermal operations. These driveheads are either a vertical-shaft, bearing box
installations for type, or a right-angle drive gearbox type. Ranging up to 200 horsepower, KUDU driveheads are proven
● Heavy, medium, and light oil
performers and meet critical safety and environmental standards.
● Coal bed methane (CBM)

wells dewatering Oryx rotary seals


● Thermal wells
The patented rotary seal has a zero tolerance for leaks and requires
● Water source wells
little maintenance. Using an early-warning seal-failure system, it helps
to minimize environmental impact while still delivering outstanding
BENEFITS
performance. The oryx rotary seal is field serviceable and is offered for
■ Minimizes environmental impact by
all drivehead models except the VHGH. A high-temperature option is
eliminating wellsite contamination
KUDU oryx rotary seal. also available.
■ Ensures safety and reliability
VHGH-9.3T
■ Reduces operational cost
The most compact and high-capacity unit in KUDU’s driveheads offering, the
FEATURES hydraulic VHGH-9.3T drivehead is capable of transferring up to 1,600 ft.lbf
■ Electric- or hydraulic-powered options torque and is safe, reliable, and operator-friendly. KUDU’s patented integral
■ Balanced lift points for safer and seal, bearings, and gear set are kept separate from the hydraulic system,
easier installation which avoids contamination and costly repairs on hydraulic power units. Unit
installation is easy due to its compact, lightweight design and balanced lifting
■ Patented automatic antilock
KUDU VHGH-9.3T. points, making it ideal for slant well applications.
backspin control
■ Maximum speed of 500 rpm VH 60-hp 9.3T
This low-profile electric drivehead is also available in a hydraulic version.
■ Ability to isolate the drive unit from the
An internal pump assembly eliminates external brake lines, reducing the
borehole fluid
possibility of leaks and environmental contamination. The brake pads are
■ Low maintenance easily accessible, resulting in convenient servicing. The VH 60-hp 9.3T
■ Oryx seals features: is designed for rod string loads up to 9.3 tons [20,503 lbm], and is capable
● Patented design of handling up to 60 hp [45 kW]. It uses KUDU’s oryx rotary seal, which
KUDU VH 60-hp 9.3T.
● Zero tolerance for leaks prolongs the life of the seal assembly.
● Early warning seal failure system

● Field serviceable

● Available high-temperature option

KUDU VH 100-hp 13.7 or 22.8T. KUDU VH 200-hp 22.8T.

VH 100-hp 13.7 or 22.8T VH 200-hp 22.8T


KUDU’s first drivehead, the VH 100 is rated for The VH 200 is the most powerful drivehead of
both the 13.7-ton [30,200-lbm] and 22.8-ton KUDU’s product line. This high-capacity drive
[50,300-lbm] axial load capacity. It features a delivers up to 200 hp [145 kW] with 22.8 tons
simple design and delivers up to 100 hp [75 kW]. of axial load, allowing producers to run KUDU’s
highest volume PCP.

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PCP Systems | Technology 159
KUDU Drivehead
KUDU Drivehead Specifications
VHGH - 9.3T VH 60HP 9.3T VH 100HP 13.7/22.8T VH 200HP 22.8T
Drivehead speed ratio 4.1 : 1 1:1 1:1 1:1
Max. torque, ft.lbf [N.m] 1,600 [2,169] 1,250 [1,695] 1,772 [2,403] 3,544 [4,805]
Input shaft Vertical Vertical Vertical Vertical
Shaft type Hollow shaft Hollow shaft Hollow shaft Hollow shaft
Axial load capacity† 9.3T 9.3T 13.7 or 22.8T 22.8T
Maximum speed, rpm 500 500 500 500
Horsepower range, hp [kW] Up to 150 [Up to 110] 5–60 [4–45] 15–100 [11–75] 30–200 [22–145]
Polished rod diameter, in [mm] 1.25 [31.8] 1.25 [31.8] 1.25 [31.8] 1.25 [31.8]
1.5 [38.1] 1.5 [38.1] 1.5 [38.1]
2 [50.8] 2 [50.8]
Input shaft size, in [mm] n/a‡ 2.625 [66.7] 3.125 [79.4] 3.125 [79.4]
Backspin control Check valve with orifice Antilock disc brake Antilock disc brake Antilock disc brake
API wellhead connection (thread), in [mm] n/a 2.875 [73] n/a n/a
3.5 [88.9] EUE pin
API wellhead connection (flange), in [mm] 3.125 [79.4] 3.125 [79.4] 3.125 [79.4] 3.125 [79.4]
4.063 [103.2] 4.063 [103.2]
5.125 [130.2] 5.125 [130.2]
API wellhead connection (flange), psi [kPa] 3,000 [20,684] 3,000 [20,684] 3,000 [20,684] 3,000 [20,684]
2,000 [13,790] 2,000 [13,790] 2,000 [13,790]
Prime mover Hydraulic Electric or hydraulic Electric or hydraulic Electric or hydraulic
Driven sheave maximum diameter, in [cm] n/a 31.5 [80.1] 31.5 [80.1] 31.5 [80.1]
Minimum center distance, in [cm] n/a 21.6 [54.9] 20.6 [52.3] 24.2 [61.5]
Maximum center distance, in [cm] n/a 28.0 [71.1] 28.8 [73.2] 29.7 [75.4]
†KUDU Industries publishes the bearing rating according to the accepted standard using the ISO calculation for L10 life rating, based on 25,000 hours of operation at full rated load and maximum rated speed of 500 rpm. KUDU

uses a three-bearing system, which ensures the thrust bearing is isolated from the radial loads. KUDU's thrust bearing is self-aligning to provide uniform bearing load.
‡Not applicable.

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PCP Systems | Technology 160
KUDU Power Unit
Electric and hydraulic power source for PCPs
APPLICATIONS KUDU power units are electric- or hydraulic-powered and include open-skid and walk-in enclosures
■ Used for single or multiple, hydraulic or for individual or multiple-well production. The units can be specified to use diesel, propane, or natural
electric oil and gas wellsites gas to generate electricity or to provide hydraulic fluid power for progressing cavity pumps (PCPs).

BENEFITS With improved fluid containment, KUDU power units protect against environmental spillage, and the
■ Eliminates environmental spillage by optional sound attenuation package provides noise control.
containing fluid
Enclosed units
■ Reduces costly shutdowns caused
The enclosed units’ unique airflow design circulates
by overheating
clean, filtered air, eliminating overheating concerns
■ Provides ideal working temperature and costly shutdowns.
for the enclosures
The computerized climate control system monitors
■ Enables noise control
the enclosure’s temperature to ensure it remains
FEATURES optimal and makes adjustments if the temperature
■ Electric or hydraulic powered becomes lower or higher than specified levels.
■ Options for open-skid or enclosed units This feature works particularly well in severely
cold conditions.
■ One power unit able to support
multiple wellsites The enclosed design improves reliability and
■ Compliant with Alberta Energy Regulator delivers longer life by eliminating the environmental KUDU power unit in Sedgewick, SK, Canada
(AER) standards effects, such as snow and dirt, that can wear out
a power unit. The efficient layout provides room Genset configuration
■ Fuel shutoff valve KUDU power units are available for standby
to work inside and add additional components such
■ Tested and proven in temperatures as a gas scrubber or a variable frequency drive. electrical power or preservice power needs.
ranging from –40 degF [–40 degC] to
113 degF [45 degC] Additional options Tandem pump configuration
KUDU power units provide additional features, Each power unit can be fitted with multiple
■ Unique features for enclosed units:
including the following: hydraulic pumps to operate multiple wellhead
● efficient airflow design
drives and compressors.
● automatic climate-control system
Sound attenuation
■ Optional packages: The unit is constructed with sound-insulated walls Heat trace system
● sound attenuation
and a hospital-grade silencer. The KUDU sound The optional system package warms up the flow
● gas scrubber for fuel flexibility package surpasses the AER Noise Control Directive line to ensure better flow and conserves energy. It
● upgraded engine oil filtration for rural locations (35 dBA at 1,312.3 ft [400 m]). includes a centrifugal booster pump, valves, and
and capacity quick connectors.
● genset configuration
Fuel delivery
The unit is connected to supplied fuel hookups Safety features
● tandem pump configuration

for easy use with natural gas or propane. It can ■ Two full-access doors with panic bars comply
● heat trace system
also be fitted with an optional scrubber package with occupational health and safety standards
for fuel flexibility. for both Alberta and Saskatchewan, Canada.
■ 12V lighting provides excellent visibility.
Engine options
■ Each unit is equipped with a fuel shutoff valve
Several engine displacement options ensure
to meet the CSA B149.1 Natural Gas and
that each operation receives the right amount
Propane Installation Code requirements.
of horsepower. Unit engines are available in 4.3-L
GM™, 5.7-L GM, 5.9-L Cummins™, 8.3-L Cummins,
6.2-L Origin™, 8.0-L Origin, and 10.0-L Origin. US
Environmental Protection Agency certified engines
in the Origin line are available for the US market.

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PCP Systems | Technology 161
KUDU Power Unit
KUDU Power Unit Natural Gas and Propane Engine Specifications†
Manufacturer Displacement, L Engine Power, hp‡ Electrical Power, kW§
GM 4.3 56 33
GM 5.7 75 45
Cummins 5.9 84 50
Cummins 8.3 99 59
Origin 6.2 108 80
Origin 8.0 120 72
Origin 10.3 155 115
†Custom units are available upon request.
‡Allengines are rated under standard conditions at 1,800 rpm for continuous duty as per manufacturers’ ratings. hp refers to the amount of horsepower at
the flywheel.
§kW ratings are at 0.8 power factor correction.

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PCP Systems | Technology 162
Level 1 VFD
Entry-level variable frequency drive
APPLICATIONS
TM
As part of the PCP Well Manager suite,
■ Variable frequency drive (VFD) which the Level 1 VFD uses proprietary motor control
controls speed and torque of a progressing algorithms to achieve optimal reaction times
cavity pump (PCP) system with full scalability to match well application
requirements. This VFD model has an average
BENEFITS
mean time between failures of 250,000 hours
■ Protects the rodstring by
or 28.54 years, as per IEC 62380 standards.
limiting rod torque
■ Reduces cost and downtime Simple-to-use interface
to optimize well production The Level 1 VFD is easy to use and program
with simple startup procedures and very few
FEATURES parameters requiring adjustments. It offers an
■ Upgradable platform to grow increased level of equipment protection including
and adapt to well needs a soft start to decrease shock on pump components,
■ User-friendly keypad controls as well as torque protection.
■ Low initial investment in
Upgradable platform for comprehensive
PCP well automation
well automation
■ High- and low-torque protection Equipped with the capability to upgrade the
■ Drive-in NEMA 3R (IP 14) enclosure automation platform to troubleshoot well KUDU Level 1 VFD mounted unit.
■ 20–150 hp at 480 V activities, the Level 1 VFD provides the
■ UL, cUL, IEC, and GOST foundation for more comprehensive data
certifications available analysis. The user-friendly Altivar 71 keypad
displays speed, torque, alarms, and well status
■ Transient voltage surge suppression to inform the operator of the well’s condition.
■ Options: These key parameters can all be easily adjusted
● passive filters for optimal well automation.
● communications port

● arctic package

Altivar 71 keypad on KUDU Level 1 VFD.

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PCP Systems | Technology 163
Level 2 VFD
Well automation
Well automation unit
unit with
with advanced
advanced HMI
HMI and
and on-board
on-board data
data logger
logger
APPLICATIONS The second tier of the PCP Well Manager™
■ Progressing cavity pump (PCP) systems family of products, the Level 2 VFD features an
requiring an embedded human machine integrated variable frequency drive (VFD) panel
interface (HMI) and advanced data logging with basic control capabilities to handle PCP
data logging functionality and pump software
BENEFITS interface.
■ Protects the rodstring by limiting
rod torque Human machine interface (HMI)
■ Manages power fluctuations with KUDU’s Level 2 VFD provides a simple-to-
optional microcut power-loss ride-through navigate menu structure, easily accessible data
protection logging information, and real-time response. Level 2 PCP Well Manager.
FEATURES It is able to seamlessly retrieve data via a
■ Seamlessly upgradable platform USB port and analyze the results through
specialized software.
■ High- and low-torque protection
■ Long start and stuck pump handling Simple and intuitive display navigation
■ Data logging functionality for simple, easy allows the operator to fully access well data
data transfer via USB for comprehensive analysis. Understanding
■ Easy-to-use operator software to download the activity and production of the well enables
and share logs troubleshooting of potential issues that are easily
■ Drive-in NEMA 3R enclosure solved before turning into costly workovers.
■ 20–300 hp at 480 V The Level 2 VFD menu structure allows operators
■ Service entrance rated to navigate various screens and gather in-depth,
■ UL, cUL, IEC, and GOST instant feedback on pump performance. Through Advanced controller common status screen gives
various screens such as common system status, operators an overview of well operation data.
certifications available
VFD status, or protection and alarms, all well
■ Advanced HMI with 6-in color
data is easily accessible, readable, and managed.
touchscreen
■ PCP application firmware included
■ Data logger installed with 8 GB SD card
■ Options:
● passive filters
● communications connectivity

● arctic package

The VFD status screen of the advanced controller displays


the simple single-touch navigation, which presents the
operator with full well data analysis.

PCP Well Manager is a trademark of KUDU Industries, Inc.


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PCP Systems | Technology 164
Level 3 VFD
Embedded advanced control and optimization system
APPLICATIONS The Level 3 VFD provides an integrated embedded
■ New and existing progressing control with either surface or downhole instruments.
cavity pumps (PCP) for advanced This allows for extended data logging, advanced
production optimization control software, and remote control capabilities.

BENEFITS Maximize well production with


■ Enhance energy efficiency and control algorithms
fluid management With patented optimization algorithms, the Level
■ Improve reservoir performance with 3 VFD provides pumping system configuration,
accurate real-time data monitoring and diagnostics, statistics logging,
and trending through an HMI. Using this
■ Optimize gas recovery while reducing
information, the Level 3 VFD reduces well
water production with the gas
interventions, production losses, and pump
optimization algorithm
failures; enhances liquid recovery; and monitors
■ Optimize liquids recovery with bottomhole pump wear using the surface flowmeter-based
pressure (BHP) control, dynamic liquid control algorithms.
level (DLL) control, or inflow detection
(flowmeter) algorithms Prevent costly workovers
Using the wellhead instrumentation of a flow-
FEATURES meter, the inflow control method determines an
■ Drive-in NEMA 3R enclosure adjusted pump model and the maximum liquid
■ 20–300 hp at 480 V inflow to the well. The inflow control method
■ Service entrance rated precisely calculates the pump speed to match
outflow with well inflow. Operator-friendly HMI panel with the Level 3 VFD.
■ UL, cUL, IEC, and GOST certifications
available With its easy-to-use configuration, the Level 3 VFD controller enables operators to program various
■ Advanced human machine interface (HMI) pump operation parameters, including initial pump speed, inflow test duration, flow dead band, and
with 6-in color touchscreen inflow test interval. These parameters are used in the control algorithm to match the pump speed with
■ PCP application firmware included the optimum production rate.
■ Data logger installed with 8 GB SD card A wide array of available protections guard the pumping system, including pump efficiency, pump
■ Incorporated variable frequency drive cavity fillage, flow rate, speed difference, torque limiting, and high- or low-torque shutdown. Flow
(VFD) with advanced control capabilities to rate from the meter is also used as the input to a proportional-integral-derivative control block that
operate and optimize PCP wells varies the speed of the pump to maintain target flow rate. A high-rpm protection allows the pump
to be shut down if the speed is too high, such as in the event of flow dropping and speed increasing
■ Five separate control methods:
to maintain the flow setpoint.
● production optimization
● target production Slippage Test Well Inflow Test
● BHP

● DLL
Pump Operation Parameters

Pump Operation Parameters

● speed
(speed and flow)

(speed and flow)

■ Stuck pump routine


■ Connectivity to any fieldbus systems
■ USB port and Ethernet
■ Options:
● heater for cold environments
● backspin control and protection 0 5 10 15 20 20 30 40
with and without power Time, min Time, min
● power loss ride-through protection Production optimization algorithm.

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PCP Systems | Technology 165
Level 3 VFD
■ Seamlessly upgradable platform Understand well activity
■ High- and low-torque protection Level 3 VFD provides a simple-to-navigate menu structure, easily accessible data logging information,
and real-time response. It is able to seamlessly retrieve data via a USB port and analyze the results
■ Rod torque limitation to protect the rodstring
using specialized software.
■ Long start and stuck pump handling
Simple, intuitive display navigation allows the operator to easily access well data for comprehensive
■ Optional microcut power loss ride through
analysis. By improving understanding of well activity and production, operators can perform trouble-
protection to manage power fluctuations
shooting to avoid potential issues before they necessitate a costly workover.
■ Data logging functionality for simple, easy
data transfer via USB Achieve gas optimization
■ Easy-to-use operator software to download Wellhead instrumentation offers gas flowmeter with gas optimization production or a water
and share logs flowmeter. The advanced HMI provides data login and memory key download capabilities,
as well as a user-friendly and remotely accessible configuration.

Understand conditions
The Level 3 VFD is the first controller to offer the ability to understand well inflow,
model pumps and systems, calculate pump cavity fillage, and track pump swell and wear.

Level 3 VFD architecture


Three-phase power

Rotation sensor
Electric drive

Drivehead

Speed
Modbus (pulses)
RS485
Flow (4 to 20 mA)

Pump
Flowmeter
Hardwired HMI

Ethernet to host
HMI and
data logging

Level 3 VFD architecture.

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PCP Systems | Technology 166
Advanced Controller
Stand-alonecontrol
Stand-alone controlsystem
systemwith
with a surface
a surface flowmeter
flowmeter or downhole
or downhole instruments
instruments
APPLICATIONS The advanced controller provides an integrated
■ New and existing progressing cavity solution with either surface or downhole
pumps (PCP), variable frequency instruments and allows for extended data
drives (VFD), or PCP hydraulic units for logging, advanced control software, and remote
advanced production optimization control capabilities.

BENEFITS Maximize well production with


■ Optimizes gas recovery while reducing control algorithms
water production with the gas The advanced controller reduces well
optimization algorithm interventions, production losses, and pump
■ Enhances energy efficiency and failures. It is able to operate multiple brands of
fluid management VFD and power units, as well as KUDU hydraulic
driveheads. The controller also supports generic
■ Improves reservoir performance with
drives through an analog input or output.
accurate real-time data
■ Optimizes liquids recovery with KUDU’s advanced controller enhances liquid
bottomhole pressure (BHP) control, recovery and monitors pump wear using the
dynamic liquid level (DLL) control, or surface flowmeter-based control algorithms.
inflow detection (flowmeter) algorithms The advanced controller provides a pumping
system configuration and remote monitoring and
FEATURES diagnostics, statistics logging, and trending via a
■ Ability to retrofit pumpoff controller human machine interface (HMI).
(POC) to any VFD or hydraulic units as
input or output control device
■ Incorporated panel with advanced
control capabilities to operate and
Inflow control method KUDU’s advanced controller.
optimize PCP wells
■ Ability to control combined system with
flowmeter or downhole instruments
Pump Operation Parameters

■ Five separate control methods:


(speed and flow)

● production optimization
● target production Slippage test
Well inflow test
● BHP

● DLL

● speed

■ Stuck pump routine


■ Connectivity to any field bus systems
0 5 10 15 20 25 30 35 40
■ USB port and Ethernet
Time, min
■ Optional heater for cold environments
Production optimization algorithm.

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PCP Systems | Technology 167
Advanced Controller
Prevent costly workovers with patent- Advanced controller architecture
pending inflow control method
Using the wellhead instrumentation of
a flowmeter, the inflow control method
determines an adjusted pump model and the
OR OR
maximum liquid inflow to the well. The inflow
Serial Satellite GSM / GPRS Modem F/O
control method precisely calculates the pump Radio Modem Switch
speed to match outflow with well inflow.
Lightning Protection
With its easy-to-use configuration, the
POC
controller enables the operator to program
various pump operation parameters, including
POC HMI
initial pump speed, inflow test duration, flow Battery Wireless Base

dead band, and inflow test interval. These


parameters are used in the control algorithm
to match the pump speed with the optimum
production rate.

A wide array of available protections guard the


pumping system, including pump efficiency,
pump cavity fillage, flow rate, speed difference,
torque limiting, and high- or low-torque
shutdown. Flow rate from the meter is also used
as the input to a proportional-integral-derivative
control block that varies the speed of the BRINGING SOLUTIONS TO SURFACE

pump to maintain target flow rate. A high-rpm


protection allows the pump to be shut down if
the speed is too high, such as in the event of
flow dropping and speed increasing to maintain Production optimization Wellhead Separators and tanks
Pump motor control Security
the flow setpoint. instrumentation instrumentation instrumentation

Achieve gas optimization Data collected from the KUDU advanced controller.
Wellhead instrumentation offers gas flowmeter
with gas optimization production or a water
flowmeter. The advanced HMI provides data
login and memory key download capabilities,
as well as a user-friendly and remotely
accessible configuration.

Understand conditions with


smart field concept
The advanced controller is the first controller to
offer the ability to understand well inflow, model
pumps and systems, calculate pump cavity
fillage, and track pump swell and wear.

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PCP Systems | Technology 168
Top Tag
Rotor tagging system without a tag sub
APPLICATIONS KUDU’s patented Top Tag™ system is a rotor tagging solution in PCPs. This system is the first
■ Progressing cavity pump (PCP) engineered PCP tool enabling operators to locate the rotor inside the stator without using a tag sub.
installations where high viscosity and With the Top Tag system, the paddled rotor directly agitates the fluid within the casing rather than
the presence of sand can cause intake being limited to the fluid entering the tag sub. Since the rotor continuously clears the stator intake,
restriction and plugging the Top Tag system reduces burnt pumps due to plugged pump intake and reduces rotor breakage, as
SAM

the rotor is never run in compression on the tag sub.


BENEFITS
■ Eliminates intake restriction and Engineered for maximum benefits Drivehead
intake plugging An exposed rotor in the annulus increases wellbore agitation and gas breakout. This improves the
■ Reduces loading, flushing, and coiling pump’s run life as there is more mixing of sand and oil. By eliminating plugged pump intakes, Top Tag
system simplifies troubleshooting, reduces cost compared to spring loaded tag subs, and can be easily
■ Provides easy access to coil into the
rethreaded
Rod String or removed and installed on a replacement stator.
annulus and cleanout sump
Power Unit
■ Decreases number of burnt pumps Since 2007, more than 3,200 installations of the Top Tag system have been performed, proving the
PCP Well Manager

■ Increases fluid agitation with an exposed system’s high reliability Sucker


and ability to
Rod Coupling
produce from high-viscosity and high-sand-cut wells.
rotor paddle in the annulus Rotor Head
■ Extends pump run life Rotor
Centralizer
■ Increases pump fillage and intake access Top Tag Collar
■ Minimizes components at the bottom
of pump Stator
Rod String

■ Uses the same space-out procedure as a


tag sub Rotor Landing
on Top Tag
FEATURES PCP

■ Exposed rotor in the annulus


■ Ability to easily repair and reuse Saw Tooth
Collar
■ Reduced cost compared to spring-loaded Paddled Rotor
Tag Bar

tag sub Extension


Anchor
■ Easy to remove and install on a
replacement stator
KUDU Top Tag system installation. Typical PCP installation.
■ Ability to replace the Top Tag system plate
instead of the entire collar
■ Rethreadable

Top Tag is a trademark of KUDU Industries, Inc.


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PCP Systems | Technology 169
Antivibration Sub
Provides cushion between the tubing string and casing inside diameter (ID)
APPLICATIONS The KUDU antivibration sub reduces wear on
■ Progressing cavity pumps (PCPs) requiring pumps, tubing, rodstrings, and anchors. It uses
vibration dampening or harmonic spring-loaded blocks to lessen tubing movement,
resonance reduction dampen vibration, and reduce harmonic
resonance. Designed to work with PCPs, the
BENEFITS
sub provides a resilient cushion between the
■ Protects tubing string connection
tubing string and casing ID. Configured to be
from unthreading
similar to other KUDU downhole tools, the sub
■ Reduces wear on pumps, tubing, features some drag and spring components
rodstrings, and anchors that are interchangeable with other KUDU PCP
■ Provides a resilient cushion between the anchor products.
tubing string and casing
■ Connects interchangeably on the pump
intake and or discharge
■ Installs easily

FEATURES
■ Availability in 2.875-in [73.02 mm] EUE,
3.5-in [88.9 mm] EUE, and 4-in [101.6mm]
NU thread connections
■ Ability to be reused
■ Anticorrosion coating on body
■ Replaceable drag blocks
KUDU antivibration sub.
■ Various sizes for casing ID ranging from
5.5 in [139.7 mm] to 8.625 in [219.1 mm]
KUDU Antivibration Sub Specifications
with maximum outside diameter (OD) up
to 5.5 in [139.7 mm] Connection, Casing Size, Maximum OD, Length, Standard ID,
in [mm] in [mm] in [mm] in [mm] in [mm]
2.875 [73.02] EUE 5.500 [139.7] 4.35 [110.49] 15.25 [387.4] 2.50 [63.5]
2.875 [73.02] EUE 5.750 [146.1] 4.35 [110.49] 15.25 [387.4] 2.50 [63.5]
2.875 [73.02] EUE 6.625 [168.3] 4.35 [110.49] 15.25 [387.4] 2.50 [63.5]
2.875 [73.02] EUE 7.000 [177.8] 4.35 [110.49] 15.25 [387.4] 2.50 [63.5]
2.875 [73.02] EUE 177.8 [7.000] 5.50 [139.7] 17.00 [431.8] 2.50 [63.5]
2.875 [73.02] EUE 7.625 [193.7] 5.50 [139.7] 17.00 [431.8] 2.50 [63.5]
2.875 [73.02] EUE 8.625 [219.1] 5.50 [139.7] 17.00 [431.8] 2.50 [63.5]
3.5 [88.9] EUE 7.000 [177.8] 5.50 [139.7] 17.00 [431.8] 3.00 [76.2]
3.5 [88.9] EUE 7.625 [193.7] 5.50 [139.7] 17.00 [431.8] 3.00 [76.2]
3.5 [88.9] EUE 8.625 [219.1] 5.50 [139.7] 17.00 [431.8] 3.00 [76.2]
4 [101.6] NU 8.625 [219.1] 5.50 [139.7] 17.00 [431.8] 3.00 [76.2]

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PCP Systems | Technology 170
Cam-Loc
Progressing cavity pump anchor
APPLICATIONS KUDU’s patented Cam-Loc progressing cavity pump (PCP) anchors
■ Applications where prevention of pump contain the proven locking action of a cam with an improved separate slip
assembly rotation is required activating mechanism. Extra bypasses allow for additional flow area and
prevent sand bridging around the tool. Specialized coatings are available
BENEFITS
for preventing corrosion or scale and reducing erosion.
■ Offers greater cross-sectional area of
each component with separate slip and Operation
drag blocks Cam-Loc anchors use separate slip and drag blocks to eliminate premature
■ Experiences less wear on the slips, drag slip wear during installations. An INCONEL® X 750 spring retracts the slips
blocks, and casing ID into the body while it is running in the hole. The drag blocks centralize the
tool and provide the frictional interference to deploy the slips when torque
■ Avoids sand bridging around the tool with
is applied.
additional flow area
■ Prevents corrosion, scale, and erosion with As the torque is applied, the cam profile moves underneath the slips and
special coatings forces them outward. The cam then drives the slips into contact with
■ Uses frictional interference to deploy slips the casing ID. Large, vertical teeth securely grip the casing, preventing
when torque is applied a clockwise rotation while still enabling vertical movement as the tubing
expands or contracts.
■ Installs easily
Using separate slip and drag blocks offers each component a greater
FEATURES
cross-sectional area, which translates into more area for load distribution
■ Available in
applied to each part. The result is less wear on the slips, drag blocks, and
2.375-in [60.3-mm] EUE,
casing ID, which improves the service life.
2.875-in [73.0-mm] EUE,
3.5-in [88.9-mm] EUE,
and 4.5-in [114.3-mm] EUE
thread connections
■ Clockwise rotation of pump to lock
■ Replaceable slips and drag blocks
KUDU Cam-Loc anchors.
■ Reusable and repairable
■ Various anchor sizes cover casing
ID range from 4.5 in [144.3 mm]
to 10.75 in [273.1 mm]

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PCP Systems | Technology 171
Sucker Rod Centralizers
Centralizer
Nonrotating sleeve design that eliminates
to eliminate rodrod coupling
coupling wear
wear
APPLICATIONS KUDU’s sucker rod centralizers eliminate rod
■ Progressing cavity pump (PCP) coupling wear and feature a nonrotating sleeve
installations when paired with design that is tapered for rod tripping. The
the rodstring centralizers reduce torque in deviated wells and
lower workover frequency, and they reduce or
BENEFITS
eliminate rotational rubbing and rod wear.
■ Reduces torque in deviated wells and
lowers workover frequency In abrasive conditions, KUDU recommends
■ Minimizes rotational rubbing and rod wear centralizing the sucker rodstring wherever
the coupling or tubing loading exceeds
■ Prevents eccentric motion of the rotor
25 lbm [11 kg]. In nonabrasive conditions,
from being transmitted to the rodstring
KUDU recommends centralizing wherever
■ Eliminates wobble in the rodstring from the loading exceeds 50 lbm [23 kg].
being transmitted to the polished rod The centralizers should be installed
FEATURES to keep the loading below 100 lbm [45 kg]
■ Nonrotating sleeve design that is tapered on each centralizer.
for easy installations
KUDU also suggests the use of a minimum of
■ Conventional spindle and API coupling for five nonrotating centralizers on vertical wells
regular applications (e.g., low sand) to prevent
● Spindle made of 4140 hardened,

tempered, stress-relieved tool steel, ■ eccentric motion of the rotor from being
KUDU sucker rod centralizers.
which resists abrasion transmitted to the rodstring, which can be
■ Chromed rod couplings for severe rectified by placing
● one centralizer 12 ft [3.66 m] above
conditions (e.g., high sand)
the rotor head
■ Kevlar-Nylon copolymer-made sleeve ● one centralizer on top of each of the
to resist sand embedment
two full sucker rods.
■ Imperviousness to aromatics and H2S
■ wobble in the rodstring from being
with a temperature rating
transmitted to the polished rod, which
of 212 degF [100 degC]
reduces the life of the seal or stuffing
■ Tubing sizes from 27⁄8 in [73 mm] box and can be solved by placing
to 41⁄2 in [114 mm] ● one centralizer at the bottom

■ Sucker rod sizes from 7⁄8 in [22 mm] of the polished rod
● one centralizer at the bottom
to 11⁄8 in [29 mm]
of the adjacent sucker rod.

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PCP Systems | Technology 172
Production Lifting
Services

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Production Lifting Services

Innovative solutions from start to finish Alternate deployment conceptual and detailed designs
■■ The engineered solutions group is made up of a multidisciplinary team ■■ Designs review possible alternate deployed systems for CT systems,
of petroleum, mechanical, and electrical engineers with extensive ZEiTECS Shuttle rigless ESP deployment system, or wireline.
experience in artificial lift applications and solutions. These technical
experts provide innovative solutions from concept to design and testing. System integrated test
■■ The test ensures proper installation and testing of mechanical integrity,
Feasibility, concept, and front-end engineering design studies operational procedures, and field personnel training.
■■ Superior workflows and software packages enable the selection of the
most viable and economic lift method for a field or well, deployment Engineered completions architecture solution
options, and completions design. ■■ Experts customize specific items to suit any application as required.

Advanced and complex artificial lift designs and optimization Electrical power optimization studies
■■ Operators can create advanced and complex designs for a variety of ■■ Electrical and electronics engineers ensure units have the necessary
applications including subsea, dual ESPs, multizone, viscous fluid power supply for any application and provide guidance in surface
production, multiphase flow simulation, ESP with POD, dual bypass, equipment selection, assessment, integration, and packaging.
dual concentric, multizone commingling, and HPHT wells.
Project management
Completions design and stress analysis ■■ Risk analysis, documentation control, and changes are
■■ Tubular stress analysis verifies the integrity of the completion under the properly managed.
combined tension, compression, burst, and collapse stresses throughout
the life cycle of the well.

Table of Contents Previous page Next page 174


Engineered Solutions Group
Expert services to provide viable, fit-for-purpose artificial lift solutions
APPLICATIONS
■ Feasibility, concept, and front-end
engineering design (FEED) studies
■ Artificial lift well and field
production optimization
■ Advanced and complex artificial
lift applications:
● Subsea

● Dual ESPs

● Multizone

● Heavy oil or viscous fluid production

● Multiphase flow simulation

● Complex ESP completions

● Multizone comingling simulation

● HPHT

■ Completion design and tubing


stress analysis
■ Alternate deployment systems
■ Factory acceptance test and system
integrated test The Schlumberger artificial lift engineered Advanced and complex artificial lift
■ Electrical power optimization studies solutions group is a team of technical experts designs & optimization
in artificial lift application technology. The The group provides advanced and complex
■ Project management
multidisciplinary team comprises petroleum, artificial lift design for challenging applications,
ADVANTAGES mechanical, and electrical engineers and project including subsea wells, dual ESPs, heavy oil or
■ Provides comprehensive artificial management practitioners with extensive viscous fluid, gassy applications, encapsulated
lift solutions experience in providing complete artificial ESP systems, dual bypass, dual-ESP boost
■ Lowers total cost of ownership lift solutions. The engineered solutions group systems, dual concentric, and HPHT applications.
provides artificial lift concepts, application
■ Achieves viable, fit-for-purpose solutions Completion design and tubular
engineering, completion engineering, alternative
for your asset stress analysis
deployment techniques, surface power system
■ Improves production and asset worth evaluations, and project management. An ESP creates pressure and temperature
■ Extends run life changes that exert forces on the completion
The team collaborates with manufacturing, string. Tubular stress analysis verifies the
■ Achieves optimal production and engineering, and operations teams to deliver mechanical integrity of the completion string
enhanced ultimate recovery holistic, customized, fit-for-purpose solutions.
■ Optimizes systems integrity and reliability
FEED studies
Selecting the most viable and economic artificial
lift method for a field or well requires careful
consideration. Feasibility, concept, and FEED
studies use advanced workflows, expertise,
and software packages to design, optimize, and
recommend the most comprehensive solution.

Artificial Lift

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Production Lifting Services  |  Services 175
Engineered Solutions Group
Engineered completions architecture solution
The group is able to design and engineer specific completion components
to suit the most challenging applications as required.

Electrical power optimization studies


For ESP applications, power supply to the unit is crucial to the success
of the run life of the unit. Our engineers ensure the selected units have
the necessary power supply for the application and provide guidance in
surface equipment selection, assessment, integration, and packaging. In
addition, the group works with third-party companies to provide analysis
of load flow, short circuit, harmonic, protective device coordination, and
arc flash.

Project management
Project management is a critical element to ensure on-time, on-scope
service and product delivery. Tools and methodologies are put in place to
ensure that project milestones and desired results are achieved, the most
under different static and dynamic operating conditions. The engineered
efficient resources are utilized, and stakeholder expectations are surpassed.
solutions group uses a TDAS* tubing design and analysis software system
to perform tubular stress analysis of the artificial lift system and its auxiliary Artificial lift well and field production optimization
components to ensure that the ESP completion can be installed, operated, It is an imperative to get the most out of assets in a safe manner to
and retrieved while remaining within the required safety factors. increase overall net worth. Well optimization looks at the system from a
nodal perspective, ensuring each part of the production system, including
Alternate deployment systems
the near-wellbore reservoir, is analyzed and all aspects of the completions
The group reviews various alternative or rigless deployment systems,
are reviewed so the system operates as anticipated.
including coiled tubing, wireline, or the ZEiTECS Shuttle* rigless ESP
replacement system. Proprietary software tools assess the suitability of the
different methods.

System integration test


In the event of a new completion design or new completion equipment, a
system integration test is recommended to test the mechanical integrity,
validate the installation and operational procedures, and ensure training of
the field personnel involved in the installation process. Our team of experts
ensures these tests follow the proper quality plan and processes.

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Production Lifting Services  |  Services 176
ESP Well Testing
Using TCP or DST to improve reservoir understanding and maximize well potential
APPLICATIONS With an established track record of ESP system
■ Exploration wells or newly drilled wells success, the artificial lift team offers operators REDA MAX*
■ Heavy oil or subsea wells an early understanding of reservoir mechanisms, ESP electrical power cable
determination of essential reservoir properties
BENEFITS and pressures, and capturing of samples for PVT
■ Ensures optimal production and analysis. A powerful combination of multiple
enhances recovery technologies including ESPs, tubing-conveyed
SenTREE 3*
■ Improves understanding of the perforating (TCP), and drillstem testing (DST)
subsea test tree
reservoir mechanisms enable operators to evaluate exploratory wells
■ Provides comprehensive artificial lift when the reservoir pressure is not sufficient for
solutions the fluids to reach the surface by natural flow.
■ Reduces potential workover cost Well testing methodology
Methodologies can vary from well to well and
FEATURES
are customized to meet specific exploratory or
■ Design of artificial lift equipment
development objectives, such as critical inflow
and completion
performance relationships. Based on the chosen
■ Project management methodology, the team provides accurate,
■ Reservoir analysis and interpretation high-quality well test results to ensure the right Encapsulated REDA*
■ Real-time acquisition system decisions are made for the life of the well and Maximus* ESP system
and interpretation the reservoir.
■ Modular variable speed cabins to power Integration of multiple technologies
and control the ESP This integration of multiple technologies delivers
■ reduced operating time required for IRDV* intelligent
job execution remote dual valve
■ decreased wellsite operation time to minimize
deferred production SCAR* inline independent
■ reliable reservoir information after perforating, reservoir fluid sampling
especially in wells that will be completed
using an artificial lift method
■ lower workover cost by accomplishing some Hydraulic packer
acid treatments without pulling the ESP.

Right sizing of the ESP configuration


To effectively lift reservoir crude to surface, an
ESP needs to be properly sized to cover the entire Screens
range of expected flow rates. The artificial lift team
has the expertise to properly select the right pump eFire* electronic
to meet requirements, such as accommodating a firing head
wide operating range by combining compression
pump stages with a powerful medium-voltage
HSD* high shot density
variable speed drive (MVD).
perforating gun system

Heavy oil test string integrating


a REDA ESP system and TCP
gun system

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Production Lifting Services  |  Services 177
Real-time collaboration process
Real-time ESP monitoring and well testing services use workflow and communication protocols
to perform well test interpretation and optimize test duration. Using the latest communication tools,
all the team members can communicate, share ideas, and provide recommendations to support field
operations in real time.

Reservoir analysis
During the well test, different drawdowns could be imposed via an MVD to create the required
pressure transients and meet test objectives, and the artificial lift team has the expertise to obtain
valuable reservoir parameters from any ESP DST and/or TCP test. Every pump shutdown and startup
is an opportunity to evaluate well productivity and obtain reservoir parameters.

Surface well test spread


Our testing division provides an optimized package to effectively handle production fluid at surface,
including applications with constrained deck space. The packages often include a steam generator, steam
exchanger, heating coils in knockout separator, diesel and surge tanks, and other pipework.

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ART Center
ESP maintenance services
APPLICATIONS Maintenance, repair, and testing is vital for the performance and longevity of ESP systems.
■ ESP assembly, testing, and maintenance The goal of each assembly, repair, and test (ART) center is to extend run life, ensure maximum
■ Mechanical and electrical repairs reservoir production, and reduce the total cost of ownership of Schlumberger ESP systems
for operators.
■ Fit-for-application ESP system
■ Dismantle, inspection, and failure analysis Global ESP maintenance network
As part of our commitment to provide world-class service, Schlumberger operates a global network
ADVANTAGES of ART centers to keep ESP systems running at peak levels. Each ART center follows a quality control
■ Extends life cycle of ESP system plan developed by Schlumberger engineers to ensure zero artificial lift product defects.
■ Lowers total cost of ownership
From diagnosis through remanufacturing
■ Follows best-in-class QA/QC processes
Expert manufacturing engineers and ESP technicians have decades of experience in the repair and
■ Determines cause of run life failure remanufacturing of ESP components. Each rebuild or refurbishment of a Schlumberger ESP system
■ Reduces downtime with quick turnaround is supported with standardized diagnostic techniques, original Schlumberger parts, and the highest
standards of workmanship. No matter the downhole conditions, ART center technicians can help
optimize production and extend ESP run life throughout the life of the reservoir.

Quick turnaround
Production is critical for operators, and Schlumberger is committed to delivering reliable artificial
lift equipment safely and on-time. Each ART center and regional distribution center maintains the
inventory and equipment needed to minimize production downtime for operators while their ESP
systems are being repaired.

Dismantle, inspection, and failure analysis


ESP systems fail for many reasons, and it is critical to understand and address the root causes
of failure to consistently meet and exceed run life and production targets. Expert product failure
analysis is an integral part of the Schlumberger ART center’s continuous improvement philosophy,
and Schlumberger engineers and technicians use sophisticated processes and state-of-the-art
equipment to determine why an ESP component fails and to implement the most effective
mitigation and preventative measures. ART center failure analysis investigations are thorough
and provide specific, practical recommendations to operators.

Best-in-class ESP testing, quality assurance, and quality control


In an effort to eliminate potential costly delays during installation and ensure maximum run life,
Schlumberger maintains a global fleet of calibrated horizontal pumping test systems to hydraulically
test individual components—such as main cable systems, motors, pumps, and sensors—and confirm
that design specifications are met. Schlumberger conducts comprehensive factory acceptance tests
for ESP subsystems and offers additional full system integration testing when recommended.

Schlumberger ESP system integration testing is available at ART center locations in Singapore;
Bartlesville, US; and Inverurie, UK. Each system integration test involves assembling the ESP system
within a fully instrumented test well and running the ESP under rigorous test conditions to validate
component functionality and operation.

Highly trained and experienced ART center technicians


Schlumberger makes substantial investments in employee training to guarantee we have the best
technical staff in the industry. Our technical competency assurance program and standardized
tools, processes, and procedures enable us to deliver high-quality ESP systems that run longer and
maximize production.

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Production Lifting Services  |  Services 179
Power Systems Analysis
Complete system optimization
APPLICATIONS Schlumberger power systems analysis uses field
■ Electrical power systems measurements and computer modeling to analyze
■ Oil and gas mining, petrochemical, power systems, make recommendations, and
industrial, and utility sectors deliver custom products such as filters and power
factor correction capacitor banks, enabling the
■ Power system optimization
efficient and economic use of electric power.
BENEFITS Projects have been performed in petroleum,
■ Improves safety for personnel and mining, petrochemical, industrial, and utility
equipment sectors throughout the world.
■ Enables efficient, economic use of power The power systems analysis database serves
■ Reduces losses and operating costs as the basis for improving system performance
■ Mitigates penalty charges due to poor and power quality, reducing operating costs,
power factors and harmonics and providing a reliable supply of power during
system operation. Using the latest software tools,
FEATURES Schlumberger engineers can deliver complete
■ Load flow studies system optimization.
■ Short circuit analysis
Final reports detail the voltage, current, and power
■ Harmonic analysis factor at various locations in the system. Typically,
■ Evaluation of system expansion on this type of study is used to optimize transformer,
existing network switchgear, and cable loadings. A mathematical
■ Protective device coordination model o