Multiple onshore oilfields across several regions
The Cases below are based on the operating history of Lex Ultra-High-Speed ESP (UHS ESP™) in various fields with the highest recorded solids content of all wells equipped with our ESPs. The project was targeted to overcome frequent ESP failures due to the high solids content in the produced fluid.
We proved the high tolerance of Ultra-High-Speed ESP (UHS ESPTM) to solids in the produced fluid over 2,000 ppm (2,000 mg/l)
Ramp-up time was reduced in most of the field cases by average 30% vs. standard equipment
Zero wear-related failures of Gen4 Ultra-High-Speed ESP from 300+ installations have been found since 2016
| Static Pressure | 140–160 bar |
| Bubble Point Pressure | 69 bar |
| Solution GOR | 178 scf/stb (32 m³/m³) |
| Oil Density | API 30.4 (874 kg/m³) |
| Oil Viscosity | 21 cP |
| Reservoir Depth | 7,100–7,200 ft TVD (2,162–2,195 m TVD) |
| ESP Setting Depth | 8,700 ft MD (2,651 m MD) |
| Production | 35–55 cmpd |
| WC | 43–49% |
| FBHP | 40 bar |
| Start-up Date | 15 March 2015 |
| Status | Pulled |
| Runlife | 1,280+ days |
| Max Sand Production | 2,080 ppm (2,080 mg/l) |
| Running cycles | 15 000+ |
| Operating duty | Periodic |
| Static Pressure | 140–160 bar |
| Bubble Point Pressure | 69 bar |
| Solution GOR | 178 scf/stb (32 m³/m³) |
| Oil Density | API 30.4 (874 kg/m³) |
| Oil Viscosity | 21 cP |
| Reservoir Depth | 7100–7200 ft TVD (2,162–2,195 m TVD) |
| ESP Setting Depth | 9,586 ft MD (2,922 m MD) |
| Production | 40–45 cmpd |
| WC | 41–45% |
| FBHP | 40 bar |
| Start-up Date | 10 July 2017 |
| Status | Pulled |
| Runlife | 364 days |
| Max. Sand Production | 2,448 ppm (2,448 mg/l) |
| Static Pressure | 215–235 bar |
| Bubble Point Pressure | 72 bar |
| Solution GOR | 147 scf/stb (26,3 m³/m³) |
| Oil Density | API 30.4 (874 kg/m³) |
| Oil Viscosity | 21 cP |
| Reservoir Depth | 7,160 ft TVD (2,182 m TVD) |
| ESP Setting Depth | 8,600 ft MD (2,623 m MD) |
| Production | 90–100 cmpd |
| WC | 10–14% |
| FBHP | 40 bar |
| Start-up Date | 02 January 2017 |
| Status | Stopped |
| Runlife | 1,242+ days |
| Max. Sand Production | 2,390 ppm (2,390 mg/l) |
| Operating duty | Constant |
| Static Pressure | 179–225 bar |
| Bubble Point Pressure | 72 bar |
| Solution GOR | 163 scf/stb (29 m³/m³) |
| Oil Density | API 30.4 (874 kg/m³) |
| Oil Viscosity | 21 cP |
| Reservoir Depth | 6,804–7,000 ft TVD (2,074–2,131 m TVD) |
| ESP Setting Depth | 7,310 ft MD (2,227 m MD) |
| Production | 14–35 cmpd |
| WC | 15–20% |
| FBHP | 40 bar |
| Start-up Date | 23 September 2015 |
| Status | Pulled |
| Runlife | 514 days (runlife of previously installed ESP was 94 days) |
| Max. Sand Production | 1,226 ppm (1,226 mg/l) |
| Operating duty | Constant |
| Static Pressure | 179–225 bar |
| Bubble Point Pressure | 72 bar |
| Solution GOR | 163 scf/stb (29 m³/m³) |
| Oil Density | API 30.4 (874 kg/m³) |
| Oil Viscosity | 21 cP |
| Reservoir Depth | 6,804–7,000 ft TVD (2,074–2,131 m TVD) |
| ESP Setting Depth | 7,310 ft MD (2,227 m MD) |
| Production | 15–35 cmpd |
| WC | 15–20% |
| FBHP | 40 bar |
| Start-up Date | 05 March 2017 |
| Status | Pulled (leakage problem) |
| Runlife | 463 days |
| Max. Sand Production | 1,794 ppm (1,794 mg/l) |
| Operating duty | Constant, followed by periodic mode |
| Static Pressure | 180–220 bar |
| Bubble Point Pressure | 72 bar |
| Solution GOR | 163 scf/stb (29 m³/m³) |
| Oil Density | API 30.4 (874 kg/m³) |
| Oil Viscosity | 21 cP |
| Reservoir Depth | 6,800–6,970 ft TVD (2,075–2,125 m TVD) |
| ESP Setting Depth | 8,583 ft MD (2,616 m MD) |
| Production | 8–21 cmpd |
| WC | 21–29% |
| FBHP | 40 bar |
| Start-up Date | 27 September 2015 |
| Status | Pulled (insulation failure) |
| Runlife | 420 days (runlife of previously installed ESPs was 25 and 65 days) |
| Max. Sand Production | 3,250 ppm (3,250 mg/l) |
These reservoirs are found at 6,900–8,200 ft TVD (2,100-2,500 m TVD). Oil wells are drilled from well pads, ESP friendly deviated along 8,860-11,800 ft MD (2,700-3,500 m MD) and completed with 7″ (177,8 mm) and 6,61″ (168 mm) API Casing. Downhole temperatures are ranging between 176 and 212 °F (80-120 °C).
The complicating factors:
The Client contacted us to address rapid wear and frequent ESP failures due to high sand content in the produced fluid.
We have developed an innovative wear-resistant modular UHS ESP™. Also, we created new methods of testing the heat resistance of the UHS ESP™ bearings. Also, we tested the reliability of bearings and components of the system in high sand content conditions on specially designed testing benches.
After passing extreme sand content tests, we manufactured and installed in client’s wells the following UHS ESPs:
It is considered that a higher rotational speed hurts the wear resistance of ESP components, particularly when exposed to abrasive fluids. However, advanced design features and material selection enlarged the tolerance of UHS ESP™ to solids content more than 2,000 ppm (2,000 mg/l), which outweighs the traditional standard-speed ESP 2-4 times and improved other performance properties due to a high operating speed of 12,000 rpm.
We design, manufacture, market, and operate equipment in compliance with recognized industry API, ISO and CE standards. Lex is an active member of API ESP Recommended Practice review committee
Trusted by world-class brands
Our engineers have carried out over 500 ESP systems installations at our clients’ oil fields in Europe, Siberia, Middle Africa, Southeast Asia, and North America.
