Abrasion Resistant Pump

Technology

REDA

Mechanical Failure Modes

The mechanical failures of an ESP can
generally be classified as:
•Radial Instability
•Downthrust
•Erosion/Corrosion
•Vibration

Abrasives will accelerate these conditions

1
The Effects of Radial Wear

• Tight clearances begin to open up

• A loss of hydraulic efficiency
• Eccentric rotation causes higher
bearing loads
• Excessive vibration leads to other
problems

Common Problem Areas in a

Radial Flow Stage
Impeller Diffuser

Flowpath

Erosion Erosion/Wear Wear

2
 Common Problem Areas in a
Mixed Flow Stage
Impeller Diffuser

Flowpath

Erosion Wear/Erosion Wear

Journal Bearing Materials

Standard Pump Configuration

Shaft/Sleeve Impeller Shaft/Sleeve

Journal Hub/Diffuser Journal
Bearing Bore Bearing
Journal
Bearing

3
 Journal Bearing Materials
Material Hardness
10
Boron Carbide
Silicon Carbide
Alumina
9
Tungsten Carbide
Mohs

Garnet
8
Zirconia
7
Silicon Dioxide
6
Nickel
5

0 1000 2000 3000 4000 5000 6000 7000

Knoop
(Kg/mm^2)

Journal Bearing Design

Bearing-Mounting
O-Ring Journal
Retaining
Ring Compliant
Bearing

4
 Journal Bearing Design
Bearing-Mounting
Retaining
Ring

O-Ring

Compliant
Bearing

Journal

Journal Bearing Materials

ARZ Configuration

Abrasion Abrasion Abrasion

Resistant Resistant Resistant
Bearing Bearing Bearing
Impeller Impeller
Hub/Diffuser Hub/Diffuser
Bore Bore
Bearing Bearing

5
 CONTROLLED SAND TEST
for Full Sized Units
SAND WITH TYPICAL
OIL WELL SIZE CLEAR WATER
DISTRIBUTION
DIRECTIONAL
VALVE

SAND SEPARATOR

ORIFICE
PRESSURE SANDY WATER AND
SAMPLE GAUGE
ANALYSIS USED SAND
MAKE UP
WATER

CLEAR WATER

TEST SAND
PUMP SAND

SETTLING TANK

Journal Bearing Application

Accelerated Sand Loop Testing
562-Series Pump
0
-1
Percent Pressure

-2
-3
Loss

-4
-5
-6
-7
1/4T 1/2T 3/4T T
Time (hrs)
Zirc onia Bearing/Zirc onia Journal Zirc onia Bearing/Silic on Carbide Journal

6
 ARZ Application
Case History
Standard Zirconia
Bearing Bearing
Installations Applications
Average equipment life 221 days 670 days
Pulls / year 5 1
Equipment replacements / year 5 1
Customer’s Annualized
Expenses (K$)
Initial Purchase $135 $150
Replacement Equipment $202 $ 75
Pull/Install Cost $ 90 $ 18
Lost Production $210 $ 42
Customer’s Total Cost $637 $285

Types of Stage Construction

Floater
• Each Stage Carries Its Own Load
• Shaft has Free Axial Movement
• Easier Installation

7
Floater Stage Construction

Force
Downthrust
is absorbed
here

Types of Stage Construction

Floater
• Each Stage Carries Its Own Load
• Shaft has Free Axial Movement
• Easier Installation

Compression
• Stage Load Carried by Shaft
• Downthrust Controlled by Protector
Thrust Bearing
• Shaft Must be Matched at Installation

8
 Types of Stage Construction

Each Pump
Pump
Stage Each
Carries Stage
Its Own Load is
Thrust Transfer-
red to
Shaft
Shaft Load
Protector
is Carried Protector
on Thrust Shaft
Bearing Load is
Carried
Motor on
Motor
Thrust
Bearing

Floater Compression

Stage Metallurgy
Standard Alloy: Type 1 Ni-Resist
–Austinetic Cast Iron
•Cast Iron Structure
•Corrosion Resistance Similar to 302/304 SS

–Composition
•Nickel 15%
•Copper 6%
•Chromium 2%
•Silicon 2%

–Hardness
•120-160 Brinell

9
 Stage Metallurgy
Alternate Alloy: REDA 5530
–Modified Type D-4 Ni-Resist
•Castable by Conventional Methods
•Corrosion Resistance Similar to 316 SS

–Composition
•Nickel 30%
•Chromium 5%
•Silicon 5%
•Molybdenum 2%

–Hardness
•180-220 Brinell

10