Lifting Expectations: Protecting ESP Systems in Harsh Environments

With almost 1 million oil-producing wells in the United States alone, most require the use of an artificial lift system. There are various methods of artificial lift which are utilized to increase pressure within the reservoir to push oil to the surface. This allows operators to enhance production and extend well life. 

One of the most efficient and reliable methods of artificial lift for moderate to high volumes of fluids from well bores is through the use of Electrical Submersible pumps (ESP). It is important for ESP systems that every component stands up to the rigors of high pressures, high temperatures, and direct contact with the well fluids and contaminates common in oilfield environments.

One type of critical component is the electrical thermal insulators that mate with electrical connectors and feedthroughs downhole. Electrical thermal insulators are designed to protect sensitive electrical connectors and feedthroughs transmitting critical data in extreme temperatures and pressure environments. Without an effective insulator, connectors are at risk of not being able to transmit a continuous signal and power to vital surface equipment. This could have serious consequences, such as unscheduled and costly oil well downtime.

Finding an insulation material that can deliver the required electrical performance and reliability while also withstanding the harsh HPHT downhole environmental conditions is critical, but finding the right material is not easy.

To address these downhole needs, Greene Tweed has developed a patented cross-linked PEEK thermoplastic, Arlon 3000XT. This innovative material platform can withstand temperatures ranging from 260 to 300°C (500 to 572°F), environments with high pressure in excess of 35,000 PSI, and harsh media such as hydrogen sulfide, methanol, drilling fluids, and well products.

Arlon 3000XT is already being rapidly adopted by global oilfield companies. Let’s see why: Engineers put Arlon 3000XT through a rigorous test in extreme oil & gas applications. It demonstrated superior performance at high temperatures ranging from 260 to 300°C—the typical temperature range in oil wells. Compared to competitive materials (polyimides, other polyketones), Arlon 3000XT performed consistently even when exposed to fluids at temperatures ranging from 260 to 300°C for 112 days. It delivered superior mechanical property retention and outperformed standard grades of PEEK in tensile strength and Young’s Modulus, showing no statistically significant difference after aging at 300°C compared to baseline data(unaged samples).

Both surface and volume resistivity were above standard insulative requirements at high temperatures, tested up to 250°C. In addition, any exposure even to minimal amounts of water or moisture may irreversibly attack polyimides; while Arlon 3000XT is able to withstand not only moisture but has even withstood the harsh chemical exposure conditions required to successfully attain Norsok certification.