Electric Submersible Pump Systems
APC’s multi-stage centrifugal pumps, whether of a radial or a mixed flow configuration, are designed to efficiently lift a full range of volumes of oil, water or brine over the life of a well with minimal maintenance or downtime.
Corrosion resistant K-Monel shafts are standard component on all APC pumps. Optional high- strength Inconel shafts are also available for high torsional load applications. Corrosion resistant coatings and ferritic steel construction are available for protection in well-bores containing Hydrogen Sulfide, Carbon Dioxide or other similar corrosive environments.
For wells containing abrasives or where extended run life is demanded, APC provides a full range of performance enhancing options. APC manufactures both radially stabilized floater and compression pump stage designs. These designs incorporate hardened materials such as tungsten carbide in the bearing surface areas. Additional radial support is provided by stage bearings which are situated strategically throughout the pump section to provide optimal shaft stability and enhanced run life.
APC® Intakes and Gas Handling Equipment
Typically, fluid enters the submersible pump through a standard screen intake or a gas separator. APC offers a variety of intakes and gas handling equipment serving a broad range of well conditions. APC intakes and gas handling equipment are designed to operate efficiently for long periods of time under both abrasive and corrosive pumping conditions. The abrasive resistant material, Tungsten Carbide, is utilized in the bearings and sleeves of all APC intakes and gas handling equipment.
For corrosive wells, APC offers intakes and gas separators constructed of ferritic steel.
In order to maximize run life, APC offers gas handling equipment in both a two bearing and a three bearing configuration. These handling equipment, when used in conjunction with ferritic steel construction, greatly enhance the overall equipment performance in abrasive and corrosive well-bore environments.
APC also offers the Pro Max Gas Processing Unit (GPU) for gassy wells, having up to 45% gas volume factor (GVF) at low intake pressures. The APC Pro-Max GPU is designed to be installed directly below a center tandem multi-stage APC pump, where it effectively reduces the size of the gas vapor bubbles and compresses them back into solution facilitating production through the electrical submersible pump (ESP) without gas locking. It can also be installed above one or two APC rotary gas separators to facilitate the production in extremely gassy wells.
APC® ProSeals
The APC ProSeal prevents well fluids from entering the ESP motor, yet allows for the motor oil’s expansion and contraction, which equalizes internal motor pressure with the well-bore pressure, as well as absorbs pump axial shaft thrust.
The proven technologies of both the labyrinth and positive seal elastomer bag are featured in APC ProSeals. ProSeals contain multiple redundant separation chambers in either a labyrinth, bag or a modular design to maximize the overall ESP system’s run life.
The APC bag-type ProSeals utilizes the bag as an elastomer barrier which physically isolates the motor from the well fluid. This type of ProSeal is ideal for deviated wells or in the presence of very light well fluids.
APC ProSeals come with a variety of performance enhancing options. High load bearings and high strength shafts are available for high horsepower and high head applications. APC has various selections of elastomers to meet any given downhole conditions. Further corrosion protection is provided by added flame spray coating or the ferritic steel construction.
Typically, the three phase, two pole induction motor connects to the bottom of the seal section. The ESP motor may be a single motor or may be made up of two or more motors bolted together in tandem, depending on the total horsepower (HP) required to obtain the necessary lift. All ESP motors are filled with refined mineral based oil or synthetic oil that withstands high temperatures, while providing dielectric strength and lubrication for the bearings through thermal conductivity.
Motors are hand-wound by skilled APC technicians with the latest industry techniques. Primary insulation in APC’s standard motors is provided by Kapton insulated magnet wire which is suitable for temperatures up to 325o F/162o C. Proprietary insulation materials are also used for applications where higher operating temperature ratings are required. Resistance to exterior corrosion is provided by flame spray coatings or ferritic steel construction.
APC® Universal Motor Base and/or Downhole Monitor
The bottom of the motor may have a bolt on universal motor base or a downhole sensing device/monitor. The APC Downhole Monitor (DHM) bolts directly to the bottom of an upper or center tandem motor, with telemetry obtained through the motor’s power cable. No additional special connections or signal wires are required. The APC DHM consists of robust choke components with built-in ground fault protection. Installation of a DHM ensures maximum run-life while enabling the operator to optimize production through automatic or remote control. It safeguards the ESP system with built-in alarms and trips, protecting the ESP system, as well as the well itself against deadheading or shut-in, high or low flow rates, excessive well draw down, motor heating and resonant vibration frequencies.
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