Lex – Solution for ESP power saving up to 50% in complicated wells operation

Solution for ESP power saving up to 50% in complicated wells operation

The complicating factors drive down the efficiency of submersible equipment, so most of the wells worldwide need to optimize power consumption. Our solution saves power due to the use of the Lex Ultra-High-Speed ESP (UHS ESP™), steadily operating in harsh environments and reducing workover costs.

Solution for ESP power saving up to 50% in complicated wells operation

The artificial lift is the most energy-intensive process in oil production. Fluid production and maintenance of reservoir pressure consume more than 70% of overall oil output power. 

Quite often, there are complicating factors in the well (solids, salts, flooding, gas issues, variable inflows, etc.) that affect the overall production efficiency. Given the standard equipment design, the traditional rated speed, and outdated configurations, the overall efficiency of the entire system can rarely achieve more than 25-50%.

The main contributors to low efficiency are the pump which efficiency falls dramatically beyond the operation range and in harsh environments, and the motor, which is mostly the Asynchronous Motor with its low nameplate and operation efficiency.

This low efficiency raises power operation costs and results in a loss in the reliability of equipment.

A standard solution would be replacing equipment with schedule size and changing the Asynchronous Motor with the Permanent Magnet Motor, whose efficiency is higher. However, the limited adjustment range prevents them from adapting to the variable conditions and steadily maintaining high efficiency.

We have created a new power-saving solution, replacing the standard ESP with the unique Ultra-High-Speed ESP – Lex UHS ESPТМ, capable of reaching the operating speed of 12,000 rpm. 

Our engineers thoroughly collect and analyze the candidate wells data and produce accurate calculations to tailor up our selection of equipment package for maximum ROI.

Based on aerospace technologies, our Ultra-High-Speed submersible permanent magnet motors have the efficiency up to 92%, which produces:

Such an approach results in power saving to 25-50% and avoiding maintenance and replacement cost thanks to optimization of equipment standard size.

All solutions

Related products

Ultra-High-Speed ESP (UHS ESP™)

Ultra-High-Speed ESP (UHS ESP™)

Lex Ultra-High-Speed ESP (UHS ESP™), driven by a permanent magnet motor (PMM) and having an operating speed range from 1,000 to 12,000 rpm, is unrivaled worldwide. Due to its high nameplate operating speed of 10,000 rpm, the length of the UHS ESP™ is 2–3 times shorter than any conventional ESP. The efficiency of the Permanent Magnet Motor exceeds 91%, the use of hard-alloy materials gives our modular pump the abrasion resistance up to 2,000 ppm (2,000 mg/l).

Universal Permanent Magnet Motors

Universal Permanent Magnet Motors

We develop and continually improve Lex Universal Permanent Magnet Motor (Universal PMM) technology, an alternative way to provide rotational energy for electrical submersible, screw or sucker rod pumps. Lex features a product range of Lex UPMM from 85 to 12,000 rpm operating speeds, high efficiency up to 95%, operational flexibility, lower motor heating rise, stable operation at any frequencies, and high-temperature environments up to 392 °F (200 °C).

Related case studies

+20% production gain, -40% energy saving at a group of fields in Western Siberia, Russia

+20% production gain, -40% energy saving at a group of fields in Western Siberia, Russia

Salym Petroleum

Group of fields in Western Siberia (Russia)

-30% power saving, the operation of the complicated wells is stabled at fields in Romania, Eastern Europe