Lex – Solution to extend runlife of artificial lift equipment by 60% in gassy wells

Solution to extend runlife of artificial lift equipment by 60% in gassy wells

An increase in the volume of free gas at the pump intake significantly reduces its efficiency, leading to failures at pump delivery and in the artificial lift system. We have developed our Jet ESP technology to prevent shutdowns and reduce equipment fault risks. Based on our Lex Ultra-High-Speed ESP by Lex for gassy wells, this technology ensures the trouble-free operation of submersible equipment.

Solution to extend runlife of artificial lift equipment by 60% in gassy wells

70% of wells in the world are complicated by free gas, caused by a gas cap or a high saturation of liquid with gas. This results in gas appearing when the reservoir or bottom hole pressure drops below the saturation point pressure.

The resulting issues include operational instability, premature failure of the submersible equipment, gas blocks, intermittent operation, local pump heating after a gas intrusion, cavitation, a decrease in daily production, additional maintenance costs and overall higher power consumption.

Usually, to solve the problem, the booster equipment is used to either separate the oil-well gas or break gas bubbles To solve these problems, booster equipment is usually used to either separate the oil-well gas or break gas bubbles to a quasi-homogenous state to prevent the formation of gas blocks inside the pump. Neither of these methods is reliably effective, as when the volume of free gas reaches more than 50%, the standard devices are no longer able to effectively operate. Another option is to configure the Variable Speed Drive to respond in specific settings, but whilst this approach protects the equipment by shutting down in an emergency, it means more downtime and potential production losses.

Our solution makes use of the Ultra-High-Speed pumps by Lex. 

The UHS ESPTM by Lex comprises a high-efficiency gas separator with an operating speed of up to 12,000 rpm. High frequencies steady the running of equipment when the intake of free gas reaches up to 75%, avoiding voluntary stops and subsequent production losses.

The Jet ESP artificial lift system operates in gassy wells, remote fields with high line pressure, and in wells with inoperative (missing, frequently freezing, blocked, etc.) check valves. The technology comprises a UHS ESPTM with a high-efficiency gas separator and a jet pump mounted on one string. This technology returns separated gas into tubing from the annulus, including from under the packer, reducing volume and preventing the harmful effect of gas on the ESP.

The above solutions provide oil companies with up to 45% reduction in gas-related shutdowns and an increase in equipment run-life of more than 60%.

All solutions

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ESP with Jet Pump (Jet ESP)

ESP with Jet Pump (Jet ESP)

To improve production gain from gassy wells, we designed the ESP with a jet pump (Jet ESP). The Jet ESP stabilizes the pump operation and increases the drawdown by reducing the bottom hole pressure. A jet pump and UHS ESP™ are being installed in a single completion string and are very effective in wells with high GOR, installed packer or in case of surface check valve failure.

Ultra-High-Speed ESP (UHS ESP™)

Ultra-High-Speed ESP (UHS ESP™)

We’ve developed our innovative PMM-driven Ultra-High-Speed ESP (UHS ESP™) with an operating speed between 1,000 and 12,000 rpm. UHS ESP™ provides effective operation in harsh well conditions, with limited power supply, and below perforation range.

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We develop and continually improve Lex Universal Permanent Magnet Motor (UPMM) technology - an alternative way to provide rotational energy for electrical submersible 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).