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Artificial Lift Techbook 2016

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ARTIFICIAL LIFT TECHBOOK: TECHNOLOGY 24 | May 2016 | "We take a two-pronged approach to addressing abrasives the pump–erosive and abrasive resistant enhancements. The frst step, however, is to perform what we call a sand analysis, where the abrasive is characterized with fve different metrics, and based upon that, we can then recommend the best solu- tion," said Lawrence Burleigh, technical support director, artifcial lift systems for Baker Hughes. "From the erosive perspective, different geome- tries in the pump can minimize the effective veloc- ity of the sand and the impact of the sand on the vane surfaces. When designing the FLEXPump series pump line, the hydraulics and vane geome- tries were optimized to minimize erosive wear. The sand will pass through the pump more easily due to wider vane openings and more direct hydrau- lic path. Coating the stages also minimizes erosive wear. As far as the abrasive wear, various carbide bearings that have a hardness greater than quartz can be selected," he said. Another product tackling the challenge of frack sand fowback is Borets' new ESP system that uses a unique material and process to produce a new stage that resists abrasive wear in most wells by the geometry of the stage, the materials and the manufacturing process. The Wide Range Resis- tant (WR2) ESP system is suited for harsh well conditions and has the ability to handle a wide range of production, abrasives and gas, according to the company. The WR2 stage material is stronger and harder than traditional ESP stage materials on the micro level which allows it to resist erosion from sand and proppant. The WR2 stage material has a hardness rating near that of ceramic bearings and a hardness close to quartz, according to the company. The spe- cial construction allows for unique vane geometry that helps prevent gas locking and provides eff- cient operation at high RPM. The future of lift With Big Data playing a much greater role in day- to-day operations, artifcial lift systems have and will continue to adapt and evolve to bring greater effciencies and production at lower costs. "In terms of artifcial lift overall, what we're see- ing is just the envelope being stretched. There are currently no dramatically new types of artifcial lift. However, we're seeing lift systems produce fuids from deeper, or produce at higher rates or in higher temperatures," Lane said. As Richard Spears noted in his market overview, proximity to urban living centers and the technical need for long-stroke rod lift systems are driving operators to new technologies. The high-performance FLEXPump series pumps are specifcally designed to maximize production and ultimate reserve recovery from unconven- tional resource plays in which the production index declines rapidly. (Image courtesy of Baker Hughes) Components for the WR2 ESP system are manufactured through metal-injection molding, allowing engineers to use geometries in design that cannot be economically produced in a foundry. (Image courtesy of Borets)

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