Development of Low Density Rigid Gels/Composites for ESP Packer Penetrator Protection
- Weishu Zhao (Saudi Aramco) | Jin Huang (Saudi Aramco) | Ghanem H. Zoraia (Saudi Aramco) | Jinjiang Xiao (Saudi Aramco)
- Document ID
- Society of Petroleum Engineers
- SPE Kingdom of Saudi Arabia Annual Technical Symposium and Exhibition, 23-26 April, Dammam, Saudi Arabia
- Publication Date
- Document Type
- Conference Paper
- 2018. Society of Petroleum Engineers
- 2 in the last 30 days
- 62 since 2007
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Electric Submersible Pumps (ESP) are commonly used artificial lift equipment in production wells. The ESP packer penetrator system is designed to carry the electric power cable that connects the electric motor in ESP to the surface control panel. Various chemicals downhole make up highly corrosive and hostile environments to the metal wires and their insulation materials for electric connectors. Many ESP failures could be attributed to packer penetrator failure due to corrosion of the electric connector beneath the ESP packer.
A method is developed to generate a low density gel system that isolates the electric connector from downhole chemicals in order to provide prolonged protections of electric connectors against corrosive atmospheres and chemical attacks. Mixture of low-density materials/composites are prepared on the surface and then pumped into targeted place through the bypass tubing. The mixture has low density so that it travels upwards in the wellbore and floats on the top of downhole fluids. Under a given well temperature, a rigid gel/composite system forms between the electric connector and the downhole fluids, isolating the electric connector from the hostile chemicals thus providing a better protection. We have developed the low density settable material and demonstrated its performance in the lab scale. It is also scaled up to a mocked up physical simulator to observe the flow dynamics and chemical reaction in realistic geometry.
Electric Submersible Pump (ESP) is an important artificial lift technology for boosting well production (Tacks 2009). Its main advantage over other artificial lift methods include high rate and the ability to produce wells to abonnement. An ESP system mainly consists of a centrifugal pump, a protector, power delivery cable, and a motor. The pump is used to lift well fluids to the surface. The motor provides the mechanical power required to drive the pump via the shaft. The power delivery cable provides a means of supplying the motor with the needed electrical power from the surface. The protector absorbs the thrust load from the pump, transmits power from the motor to the pump, equalizes pressure, provides/receives additional motor oil as temperature changes and prevents well-fluid from entering the motor. The pump consists of stages, which are made up of impellers and diffusers. The impeller, which is rotating, adds energy to the fluid to provide head, whereas the diffuser, which is stationary, converts the fluid kinetic energy from the impeller into head. The pump stages are typically stacked in series to form a multi-stage system that is contained within a pump housing. The sum of head generated by each individual stage is summative; hence, the total head developed by the multi-stage system increases linearly from the first to the last stage.
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