How to use ISO and API Standards for Artificial Lift Systems SPE ALCE-NA Training Course, October 5...

How to use ISO and API Standards for Artificial Lift Systems

SPE ALCE-NA Training Course, October 5th, 2014

What responses to AL bid tenders seem like:

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Endusers: need to be able to compare “apples to apples” for optimal equipment / vendor

selection

Manufacturer’s need to know that their system is being compared fairly / correctly against others

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Why are artificial lift standards developed?

• Standards help optimize operations and therefore improve the bottom line.

• Lack of standardized performance ratings and function tests makes comparisons across manufacturers difficult.

• Assurance that the equipment performs as it is marketed to do so and supported with sound engineering practices.

• Need to establish a common nomenclature and definitions so that everyone is talking the same language.

Value of standards references:1.http://www.api.org/publications-standards-and-statistics/standards/~/media/Files/Publi

cations/FAQ/valueofstandards.ashx2.http://www.iso.org/iso/home/standards/benefitsofstandards.htm

4

http://www.api.org/publications-standards-and-statistics/standards/~/media/Files/Publications/FAQ/valueofstandards.ashx

http://www.api.org/publications-standards-and-statistics/standards/~/media/Files/Publications/FAQ/valueofstandards.ashx

http://www.iso.org/iso/home/standards/benefitsofstandards.htm

Enduser Potential Benefits

• Provides a way to communicate requirements in a standardized format to the manufacturers and then to receive a response in a consistent manner

• these communication requirements indicate whether the enduser is looking for a lower-end system (ie low cost), or is expecting a more premium product

• “apples to apples” comparison

• Way to ensure that manufacturers are meeting the same minimum baseline criteria in terms of design validation, and various testing procedures.

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Manufacturer Potential Benefits

• Standards can be used to segment the market into those who cannot even meet the baseline through to those manufacturers who can provide the higher quality and design validation grades.

• Endusers may specify one unit at high levels to ensure supplier has capability and then order the rest at lower levels to minimize cost. This can actually help the large manufacturers compete with companies who don’t have the cost burden of quality assurance programs and R&D.

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What a standards is NOT:

• It is not a contract with the manufacturer.

• It does not guarantee or become an issue of equipment warranty.

• For ISO standards and API standards that adopted an ISO standard, manufacturers are not required to comply unless required by an enduser (ie. enduser has to invoke use of the standard in purchase / bid tender documents).

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ISO vs API: Differences and similarities

•Committees required to have global representation from both manufacturers and endusers

•Approval process is a democratic vote by member country – 2 rounds

•ISO members are the national standards bodies of 165 countries

•Process from new draft to published standard can take 18 months – several years.

•Only publishes standards, no recommended practices.

•Has requirements for both endusers and manufacturers

• Committees do not have to be global, but need to have both manufacturers / endusers.

• Approval process is by API member company with some companies having stronger voting privileges.

• API members are corporations, ranging from producers to service and supply companies

• Published both RPs and standards (majority of 11C documents are RPs)

• Process to published standard or recommended practice can happen in

less than one year.

• Monogramming program8

Structure of an ISO document

• Clauses 1-9: Requirements

• Normative Annexes: Additional details for requirements in Clauses.

• Informative Annexes: Related Guidelines

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ISO document structure - 3 main components

FunctionalSpecifications•Operation conditions

•Well•Fluids•Operational parameters

•Q/C & documentation requirements

•Other requirements

TechnicalSpecifications•Equipment characteristics•Design criteria•Validation procedures

SupplierRequirements•Documentation and data control

•Product identification•Q/C procedures•Design verification

What the user needs

Manufacturers response to user’s

request

How we ensure this happens

Clause 5

Clause 6

Clause 7

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ELECTRIC SUBMERSIBLE PUMPS

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What’s available for ESPs?

• Standards

– ISO 15551-1(pending final round approval)

• RPs

– API RP11S (r2013)

– API RP11S1 (r2013)

– API RP11S2 (r2013)

– API RP11S3 (r2013)

– API RP 11S4 (r2013)

– API RP11S5 (r2013)

– API RP11S6 (r2013)

– API RP 11S8 (r2013)

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Refresher: API Recommended Practices (RPs)

• 11S: Operation, Maintenance & Troubleshooting of ESP Installations

• 11S1: ESP Teardown Report

• 11S2: ESP Testing

• 11S3: ESP Installations

• 11S4: Sizing & Selection of ESP Installations

• 11S5: Application & ESP Cable Systems

• 11S6: Testing of ESP Cable Systems

• 11S7: Application & Testing of ESP Seal Chamber Sections

• 11S8: ESP System Vibrations13

The first ESP industry standard kick off meeting, Nov 2009

Manufacturers:

Schlumberger, Baker Hughes, Woodgroup ESP and Borets-Weatherford

Endusers:

ConocoPhillips, ExxonMobil, Nexen, Oxy, Statoil, Shell, Chevron, Petrobras, Total

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What ESP components are covered?

• centrifugal pumps including gas handling devices,

• discharge heads,

• seal chamber sections,

• Bolt-on intake systems,

• mechanical gas separators,

• induction motors,

• MLE, potheads and power cables.

• Assembled ESP systems

ISO 15551-1

But after the 2013 peer review, had to exclude

previously used subcomponents. For ISO equipment to be supplied,

every single subcomponent that makes up a component

has to be new.

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ISO 15551-1

ISO specification for downhole oilfield ESP components that defines requirements for:

• Design verification & validation,

• Manufacturing,

• Performance ratings,

• Functional evaluation,

• Handling, storage, inspection and repair API RPs

cover some of

these

Engineering design of the component, not the application

design for a specific well.

ISO 15551-1

Removed after 2013 peer review16

Enduser Requirements (Clause 5)

Clause 5, the Functional Specification, is where the use of the ISO document really begins.

The user/purchaser shall prepare a functional specification when ordering components which conform to this part of ISO 15551 and specify the requirements and operating conditions as appropriate. This information is used by the supplier/manufacturer to recommend the components for the application…….

If the user/purchaser (Enduser) does not provide the functional requirements as indicated in Clause 5, the supplier/manufacturer cannot be held to any part of this ISO standard.

ISO 15551-1

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The specific functional requirements indicated provide a list of data that shall be specified and also data that should be provided (if available) for the following:

1.Well information

2.Completion information

3.Operating and production information

4.Environmental Compatibility

5.Compatibility with related well equipment and services

ISO 15551-1

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As part of the functional specification, the user/purchaser also needs to specify the desired grades for:

6.Design Validation

7.Component Functional Evaluation

8.Quality

….more on the definition of these grades to follow.

ISO 15551-1

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Grades for flexibilityISO 15551-1

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How can this process be used in a bid situation?

1.Single well / single system

In this scenario the user/purchaser would provide the data as per Clause 5 (and the form in Annex G) for the supplier/manufacturer to respond to.

BENEFIT: By providing the information as specified in Clause 5 to all bidders the user/purchaser is more likely to receive responses that are applicable to the desired requirements to allow for an “apples to apples” comparison.

ISO 15551-1

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How can this process be used in a bid situation?

2.Multi-well / multi-system

In this scenario the user/purchaser would provide the data as per Clause 5 (and the form in Annex G) for each unique requirement “type” (i.e. unique well type) for the supplier/manufacturer to respond to. Although not specified in the ISO document, it would likely be of benefit that the user/purchaser would also indicate the anticipated purchasing volume of each requirement “type” as relative to the overall bid requirement.

BENEFIT: Same as single well / single system (allow for “apples to apples”)

ISO 15551-1

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Refresher on ISO document structure…

FunctionalSpecifications•Operation conditions

•Well•Fluids•Operational parameters

•Q/C & documentation requirements

•Other requirements

TechnicalSpecifications•Equipment characteristics•Design criteria•Validation procedures

SupplierRequirements•Documentation and data control

•Product identification•Q/C procedures•Design verification

What the user needs

Manufacturers response to user’s

request

How we ensure this happens

Clause 5

Clause 6

Clause 7

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Technical Specification – Clause 6

The two key sections in this clause are going to create a significant amount of effort and change among the suppliers / manufacturers, if they want to supply ESP components that comply with this standard.

– provide material specification details– provide performance ratings as per the criteria in Annex

A for components and as per Annex B for assembled systems.

ISO 15551-1

Note: The content of this clause was the hardest task by the committee to write. The philosophy was not to capture the current state of the industry, but rather what it should be to “raise the bar” and open the doors of communication between all parties.

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Supplier Requirements – Clause 7

• documentation to demonstrate that each product manufactured meets the functional and technical specifications

• defines documentation in design file, what must be supplied at time of delivery, minimum information in operators manual

• defines requirements for certificate of compliance (COC)

• defines requirements for product identification

• defines quality grades and associated inspections and documentation - requirements vary depending on grade

ISO 15551-1

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ESP Performance Ratings

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Performance Ratings – Shaft and Shaft Couplings

• Shaft power rating:

– Physical testing (pull and torsion) to be completed and rating is calculated and reported at the reference speed and reference temperature and the maximum rating operating temperature.

• Shaft coupling rating:

– Torsion testing to be completed and rating is calculated and reported at the reference temperature and the maximum rating operating temperature.

Note: For both ratings, the supplier / manufacturer may elect to apply additional de-rating correction factors to the calculation, however this will be defined in the design validation documentation.

ISO 15551-1

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Performance Ratings – BOD and BOI

• Bolt on discharge – pressure rating (ΔP from inside to outside).

• Bolt on discharge and bolt on intake - flow capacity rating.

– Reported as both rate and velocity.

– The manufacturer must have a documented process for this rating.

ISO 15551-1

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Performance Ratings: Pump and Gas Handler

• Design performance curve

• GVF rating

• Pump stage thrust rating

• Housing pressure rating

ISO 15551-1

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Pumps and GH: GVF rating

Data Example

ISO 15551-1

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Example of a Design Performance CurveISO 15551-1

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Performance Ratings: Mechanical Gas Separator

• Design performance curves shall be provided showing mechanical gas separator efficiency and horsepower as a function of intake free gas percentage at a constant intake flow rate.

Remember: These ratings are not meant to provide the entire performance envelope of a

component. They are meant to provide a data point or single curve to allow an enduser to fairly compare between different models or

even between vendors.

ISO 15551-1

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Mechanical Gas Separator: Performance Curve

This is an example that Lyle Wilson gave at the 2013 training to show the about of data collection required to generate this performance rating.

ISO 15551-1

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Performance Ratings: Seal Chamber Sections

• Volume contraction capacity

• Operation deviation limits

• Thrust load bearing capacity

• Minimum operating speed

• Number and severity of pressure cycles

• Horsepower requirement

ISO 15551-1

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Performance Ratings: Motors

• Motor performance parameters

• Motor voltage for minimum current

• Motor winding temperature rise

• Motor operating internal temperature limits

• Locked rotor current, torque and power factor

ISO 15551-1

Over 15 years ago, a group of industry motor experts tried to create a ESP motor standard through API that ended up disbanding due to lack of

progress tackling a large scope.While there are many motor specifications and ratings that can be

considered, the ISO ESP committee focused on providing requirements that all agreed were essential and obtainable to allow product

comparison.35

Performance Ratings: Power cable and MLE

• Voltage and temperature rating

• Ampacity coefficients

• Conductor size

• Acceptable minimum bending radius rating

ISO 15551-1

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Performance Ratings: Pothead

• Voltage and temperature rating

• Ampacity coefficients

• Differential pressure performance

• Thermal cycling performance

ISO 15551-1

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Assembled System Performance Ratings

• Axial compressive and tensile strength

– Validated by calculation

• Surface temperature rating

– Min/Max surface temperature rating during installation

– Validated by documented historical record or testing

• Amperage rating

– Limited by motor or cable or MLE

– Determined by calculation

ISO 15551-1

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• Dog leg severity limits

– Checked by calculation

– Through installation path, and at setting depth

• Deviation limits

– By calculation (typically seal section limit)

– Considering installation path, and at setting depth

• Min, max and differential operating environment temperature rating

– By calculation

– Limiting components to be specified

ISO 15551-1

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• Maximum pressurization and depressurization rates


– Limiting components to be identified

• Power requirements (KVA and kW)

– Determined by calculation at the input end of the cable

• Motor fluid % Utilization of each seal chamber contraction capacity


– From maximum ESP internal temperature to min static BHT

• Minimum and maximum operating speed

– Supplier to have a documented process for determining these values

ISO 15551-1

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Functional Evaluation (Annex C)

• Important definition # 1:

“In conformance with supplier/manufacturer specifications and acceptance criteria”

Where used within the functional evaluation tables, this statement means that any specifications and acceptance criteria the supplier/manufacturer has for the item are acceptable (even if this does not include physical testing).

ISO 15551-1

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Functional Evaluation (Annex C)

• Important definition #2:

“Supplier/manufacturer shall perform testing in conformance with supplier/manufacturer specifications and acceptance criteria”

Where used within the functional evaluation tables, this statement means that the supplier/manufacturer must perform a test to functionally evaluate the component, however the specifications and acceptance criteria of the test are entirely determined by the supplier/manufacturer.

ISO 15551-1

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Functional Evaluations: Pump and Gas Handlers

More test pointsMore test points

and tighter acceptance criteria

ISO 15551-1

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Functional Evaluations: Mechanical Gas Separators

F2 F1

Mechanical – Shaft rotation In conformance with supplier/manufacturer specifications and acceptance criteria

Per F2

Mechanical - Shaft extension, shaft end play and shaft side play

In conformance with supplier/manufacturer specifications and acceptance criteria

Per F2

Mechanical – Shaft Total Indicator Run-out


Per C.10

Mechanical – Rotor In conformance with supplier/manufacturer specifications and acceptance criteria

Rotor sub-components to be dynamically balanced per supplier/manufacturer specifications and acceptance criteria.

Vibration In conformance with supplier/manufacturer specifications and acceptance criteria

Per 11S8, but for component outer diameter <15.24 cm (6 in): maximum velocity amplitude for vertical test is 0.508 cm/sec (0.200 in/sec) [0.137 G rms], for horizontal testing is 0.396 cm/sec (0.156 in/sec) [0.107 G rms]For component outer diameter ≥ 15.24 cm (6 in); maximum velocity amplitude for vertical and horizontal testing is 0.635 cm/sec (0.250 in/sec) [0.172 G rms]. All vibration spectrums shall be taken over a frequency range of 0 – 600 Hz.Supplier/manufacturer shall have a documented procedure to ensure that shaft radial support bearings are adequately lubricated during vibration testing.

ISO 15551-1

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Functional Evaluations: Seal Chamber Section

F3 F2 F1

Hydrostatic evaluation – bag/bladder/bellows, relief valves, mechanical seals, housing joints

Per 11S7 Per F3 Per F3 and including a pressure bleed off test during the air test using a pressure gauge to ensure pressure holds for a minimum of 5 minutes.

Mechanical – power loss, shaft extension, shaft end play and shaft side play

Per 11S7 Per F3 Per F3 and loaded power loss per supplier/manufacturer specifications and acceptance criteria

Mechanical – Shaft Total Indicator Run-out


Per F3 Per C.10

Seal fluid - dielectric In conformance with supplier/manufacturer specifications and acceptance criteria

Supplier/manufacturer shall perform testing in conformance with supplier/manufacturer specifications and acceptance criteria

Per F2


Per 11S8, but for component outer diameter <15.24 cm (6 in): maximum velocity amplitude for vertical test is 0.508 cm/sec (0.200 in/sec) [0.137 G rms], for horizontal testing is 0.396 cm/sec (0.156 in/sec) [0.107 G rms]For component outer diameter ≥ 15.24 cm (6 in); maximum velocity amplitude for vertical and horizontal testing is 0.635 cm/sec (0.250 in/sec) [0.172 G rms]. All vibration spectrums shall be taken over a frequency range of 0 – 600 Hz.

Per F2

ISO 15551-1

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Functional Evaluations: Motors

F3 F2 F1

Hydrostatic evaluation – pressure test for leaks (vacuum or pressure)



Per F2

Mechanical – standard idle/coast, kW In conformance with supplier/manufacturer specifications and acceptance criteria


Per F2

Mechanical – load test No requirement No requirement Per A.3.7.3.1

Electrical functional testing – insulation testing, dielectric oil breakdown, phase imbalance

Per C.8.2 Per F3 Per F3

Mechanical – shaft extension, shaft end play and shaft side play (if applicable)



Per F2


Per 11S8, but for component outer diameter <15.24 cm (6 in): maximum velocity amplitude for vertical test is 0.508 cm/sec (0.200 in/sec) [0.137 G rms], for horizontal testing is 0.396 cm/sec (0.156 in/sec) [0.107 G rms]For component outer diameter ≥ 15.24 cm (6 in); maximum velocity amplitude for vertical and horizontal testing is 0.635 cm/sec (0.250 in/sec) [0.172 G rms]. All vibration spectrums shall be taken over a frequency range of 0 – 600 Hz.

Per F2

ISO 15551-1

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Functional Evaluations: Cable and MLEISO 15551-1

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Informative Annexes

• Functional evaluation guideline – assembled ESP systems

• Establishing recommended operating range (ROR) of ESP systems

• Example user / purchaser ESP functional specification form

• Considerations for use of 3-phase low and medium voltage adjustable speed drives for ESP applications

• Analysis after ESP use (Note: Based on ESP-RIFTs nomenclature)

• Downhole monitoring of ESP assembly

• Information on permanent magnet motors for ESP applications

ISO 15551-1

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How to use ISO and API Standards for Artificial Lift Systems SPE ALCE-NA Training Course, October 5...

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