PCP System

Elastomer Brochure “Draft Version”

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Application Guideline of Elastomer to PCP Stators

Baker Hughes Centrilift Leading Elastomers Technology

Lifteq stators combine leading technologies in elastomer compounding, processing and

testing to provide high strength materials with outstanding resistance to well conditions.
Each elastomer compound is formulated for specific well conditions to provide long
service life and superior downhole performance.

Baker Hughes Centrilift counts on high tech proprietary manufacturing capabilities as

well as a specialized in house lab equipment to produce advanced PCP stators suitable for
a broad variety of applications. State of the art research in elastomer performance
provides the basis to determine design specifications to develop new materials to meet
the most demanding market needs.

General Lifteq stator elastomer attributes include:

™ Variety of compound ™ Outstanding resistance to

available for multi H2S environments
parameter applications
™ Long service life in crude ™ Successful performance in
oil extraction and well temperature over 250° F
dewatering application
™ Superior resistance to well ™ High mechanical strength to
fluids including maximize service life
hydrocarbons, water and
gases
™ Excellent bonding ™ Maximum abrasion
characteristics to assure long resistance for sandy
run life. applications

Lifteq elastomers differentiate from main competitors in the following characteristics:

™ Superior water resistance

™ Low compression set
™ Low hysterisis
™ High abrasion resistance
™ Reduced hydrocarbon swelling in a wide range of API gravities (specific
elastomer series)
™ Superior H2S resistance (specific elastomer series)
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Product Portfolio

Baker Hughes Centrilift offers the following choices in elastomer materials for PCP
stators:

LT 2000 is a standard nitrile rubber (NBR) used in the majority of applications.

This material exhibits good oil resistance, good mechanical properties and
abrasion resistance. It also offers superior resistance to gas environments and
explosive decompression. Service temperature limit is rated up to 180 °F.

LT 2001 is a nitrile rubber (NBR) with a superior chemical resistance, especially

designed for light oil applications with low water cuts. It also has outstanding
mechanical properties and resistant to gas environments. With a superior wear
resistance, this elastomer is ideal for applications where the solid volume fraction
is high. The service temperature is rated up to 180 °F.

(This product has not been released as part of the Lifteq PCP elastomers portfolio
yet. LT 2001 is still under lab testing and field trial validation.)

LT 3000 is considered a saturated high nitrile (HNBR) elastomer suitable for light
oil applications, high temperature environments or when H2S is present. The
product is conceived for use in applications not suitable for LT2000 series mainly
due to the level of aromatic fluids or temperature. It has superior resistant to
aromatic well fluids, water and H2S with a service temperature up to 250 °F. It
also has good physical properties. Not applicable to gassy wells.

LT 3001: is similar to LT 3000 with a higher temperature rating due to an

enhanced bond systems. Service temperature limit is 300 °F. Not applicable to
gassy wells

Specific attributes of each elastomer compound are presented in Table 1.

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Table 1. Lifteq elastomers main characteristics

Scope of Application

Lifteq PCP elastomers are specifically designed for down hole applications, including
crude oil production and gas well dewatering. They are capable of handling a wide range
of fluids from water and light crude to highly abrasive heavy oil. Typical applications
encompass:

™ Heavy crude oil and bitumen with high content of sand

™ Medium crude oil with limits on H2S and CO2
™ Light crude oil (up to 42 ° API) with limits on aromatic content, H2S or
CO2
™ High water cut wells
™ Dewatering gas wells for coalbed methane exploitation
™ All type of well geometries: Horizontal, directional or vertical wells
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Lifteq Elastomer Application Guidelines

The heart of the PCP is the stator elastomer itself. This is why is so critical to select the
right elastomer for a desired application.

The selection of an elastomer for Progressing Cavity Pumps depends on 1) oil

composition (specific gravity, aromatics, CO2, H2S contents, water cut), 2) temperature of
crude at pump level, 3) abrasiveness and 4) nature of chemical treatment eventually
applied to oil wells. Figure 1 shows general application guidelines for Lifteq elastomers.

300
• LT 3000 series:
LT 3001 • ≤ 50 stb/stb GLR
• ≤ 1.0 % molar for H2S
Well Temp(˚F)

250
• ≤ 2.0 % molar for CO2
LT 3000
• Gassy wells (loose fit)

180

• LT 2000 series:
LT 2000 LT 2001 • No limits in GLR provided
( on trial) (GIP) ≤ 40 %
• ≤ 0.03 % molar for H2S
• ≤ 15 % molar for CO2

°API 25 35 42

Figure 1. Lifteq elastomer general application guidelines

LT 2000

The application guideline for LT 2000 is as follow –

™ ≤ 25°API Gravity
™ ≤ 180 °F
™ ≤ 40 % free gas at pump intake
™ ≤ 300 ppm for H2S concentration
™ ≤ 150.000 ppm for CO2 concentration

ƒ Results from lab tests indicate that LT 2000 experiences limited resistances in
high aromatics concentration fluids. That is why this elastomer is not
recommended for light oil applications with API gravity exceeding 25˚.

ƒ Even though nitrile elastomers are rated for 212 ˚ F (based on thermal stability),
service temperature is limited to 180 ˚F due to restriction imposed by dynamic
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mechanical work during operation. In general, elastomers tend to loose

mechanical properties when temperature is increased.

ƒ LT 2000 is permitted in gassy applications as long as free gas at the pump intake
does not restrict the amount of liquid available to provide sufficient lubrication
and cooling. As a rule of thumb, the free gas at the pump intake should not exceed
40 %. However, this limit is influenced by the total flow rate, speed, application
temperature etc. Over this limit, there is a risk of burning the elastomer.

ƒ In environments with high CO2 concentrations, nitrile elastomers experience

swelling and softening; on the other hand; high H2S levels cause brittleness and
hardening due to chemical over cross linking. CO2 and H2S theoretical limits, as
defined above, will be used until separate validation tests have been completed.

ƒ LT 2000 exhibits outstanding water resistances, so the elastomer is suitable for

applications where high water cuts are expected. In these cases, the influence of
the minority oil phase could determine the expected swelling degree over
prolonged periods of times (lab validation in progress).

LT 2001

The application guidelines for LT 2001 elastomer is as follows –

™ ≤ 42°API Gravity
™ ≤ 180 °F (82°F)
™ ≤ 40 % free gas at pump intake
™ ≤ 300 ppm for H2S concentration
™ ≤ 150.000 ppm for CO2 concentration
™ Low water cut wells

ƒ Results from lab tests indicate that LT 2001 experiences very low swelling in
different oil compositions. Also, LT 2001 swelling does not vary much with crude oil
API gravity meaning that application guidelines can cover a wider range of viscosities.

ƒ Degree of swelling might be affected by generic type of crude oil. Certain species in
the oil are required to interact with this elastomer to compensate swelling. The best
way to ensure proper application is to provide a crude oil sample for lab compatibility
testing.

ƒ In high water cut applications, LT 2001 behaves very similar to LT 2000 elastomer.
Both elastomers experience similar degree of swelling in water.

ƒ Other application guidelines are similar to LT 2000 since both elastomers belong to
the same series.
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ƒ LT 2001 has not been released yet. It is still on field trial and lab validation.
Elastomer is only available for specific applications supervised by PCP Engineering
group

LT 3000 series

The application guidelines for LT 3000 and LT 3001 elastomers are as follows –

™ ≤ 35°API Gravity
™ ≤ 250 °F (121 °F) for LT-3000
™ ≤ 300 °F (135 °C) for LT-3001
™ ≤ 50 scf/stb
™ ≤ 10.000 ppm for H2S concentration
™ ≤ 20.000 ppm for CO2 concentration

ƒ Results from lab tests indicate that LT 3000 experiences very low swelling in
different oil compositions. Also, LT 3000 swelling does not vary much with crude oil
API gravity meaning that application guidelines can cover a wider range of viscosities.

ƒ Service temperature limits are based on general knowledge about thermal resistance
of HNBRs under dynamic conditions and also temperature limitations associated to
glue systems. Previous studies have shown that LT 3001 exhibits a higher
temperature rating than LT 3000 in terms of thermal bond strength, being 300 °F for
the former and 250 °F for the later.

ƒ LT 3000 is not recommended for most applications with significant gas production.
Additional testing is being conducted in order to redefine this parameter. In the mean
time, applications with GOR ≤ 50 scf/stb are considered within the “safe zone” for
the deployment of this product.

ƒ LT 3000 exhibits outstanding resistance to H2S and sour environments compared to

competitor elastomers. CO2 and H2S theoretical limits, as defined above, will be used
until validation tests have been completed.

ƒ LT 3000 exhibits remarkable water resistance, so this elastomer is suitable for

applications where high water cuts are expected.

For well parameters beyond the scope of these application guidelines, please contact PCP
Application Engineering for further assistance.
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Elastomer Comparison Charts

The following figures are intended to present comparative guidelines for Liftteq
elastomers selection under the influence of different well parameters. These charts should
be used as a reference only. The elastomer performance might vary in multiparameter
environments where several of these factors are simultaneously present. For specific
applications please contact PCP application Engineering.

Chemical Resistance Temperature Rating

Water Resistance
45 6 300
40
5 250
35
30 4 200
LT 2000 LT 2000 LT 2000
25
LT 2001 3 LT 2001 150 LT 2001
20
LT 3000 LT 3000 LT 3000
15 LT 3001 2 100
LT 3001 LT 3001
10
5 1 50
0 0 0
API Gravity Ranking Degree °F

Mechanical Properties H2S Resistance Gas resistance (CO2/CH4) (b)

5
5 5

4
4 4

3 LT 2000 LT 2000 LT 2000

3 3
LT 2001 LT 2001 LT 2001
2 LT 3000 2 LT 3000 2 LT 3000
LT 3001 LT 3001 LT 3001
1 1 1

0 0 0
Ranking Ranking Ranking

Wear Resistance
5
Ranking:
4
5. Excellent
3 LT 2000 4. Very good
LT 2001 3. Good
2 LT 3000 2. Fair
LT 3001 1. Poor
1

0
Ranking

Selections guidelines are base on laboratory testing, field performance and Baker Hughes
Inteq studies. Validation in process
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Spider Chart

Next plot summarizes application window based on previous ranking

Chemical Resistance
5
4.5
4
3.5
3
2.5
2
Temperature Resistance 1.5 Gas Resistance
1
LT 2000
0.5
LT 2001
0
LT 3000
LT 3001

Abrasion Resistance Mechanical Porperties

Rotor elastomer interference (Fit):

Besides the elastomer selection itself, the rotor stator fit is critical to prolong PCPs run
life. A very tight rotor usually results in high level of stresses over the elastomer which
ultimately could cause bond problems and material tear. On the other hand, a very loose
fit causes a decrease in volumetric efficiency and also a reduction in fluid heat transfer
capacity. An optimum fit is required to assure sufficient run life and it is very application
dependant. Fit optimization should consider the expected thermal expansion and swelling
under downhole conditions.

For Lifteq PC pumps, each combination of rotor/stator is intended to be matched to

downhole conditions to provide highly efficient operation and optimum production
enhancement. Resulting compression fit between rotor /stator is designed to minimize
fluid slip, reduces internal friction and maximize volumetric efficiency without
compromising pump run life.

Each application requires an estimation of the expected degree of swelling and thermal
expansion so stator thickness variations could be compensated by choosing the proper
rotor size. As a general rule of thumb, a test bench volumetric efficiency should be
designed to target an extrapolated volumetric efficiency of about 80 %@300 rpm, at
bottom hole conditions and rated pressure.

Wear and compression set could also take place in a different time scale during the pump
run life. Wear is the consequence of solid or abrasive particles (sand) acting over the
elastomer material and compression set is the result of dynamic mechanical fatigue
causing a permanent deformation. Both factors tend to reduce rotor/stator interference
with a consequent decrease in efficiency.
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General considerations about fit:

ƒ It has been observed that a looser rotor fit is advised to maximize performance
from LT-2000 and LT 3000 series. The selection of rotor size is very application
dependant and special attention should be given to those applications where high
swelling is expected due to either upper aromatics or CO2 limits.

ƒ A tighter rotor fit is advisable in light API fluids if elastomer experiences low
degree of swelling. This statement does not apply to gas environments since the
elastomer may experience significant swelling due to high CO2 concentrations.

ƒ For heavy oils applications, a looser fit can be selected since the oil viscosity help
creating a hydrodynamic seal that reduces slip.

OIL, GAS, SAND

ROTOR

CAVITIES ROTOR
STATOR

STATOR SAND

OIL, GAS, SAND

Figure 2. Rotor interference fit concept

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Bond

PCP stators require good initial bond and also bond retention under downhole conditions
to assure optimum service run life.

Elastomer is bonded to the metal housing by using a special adhesive system and a
proprietary process. Elastomer-metal bond is critical for PCP performance since
mechanical stresses are transmitted to the bond interface during operation. In all cases,
elastomer adhesive force should exceed elastomer cohesive force. In other words the
elastomer should tear apart before debonding.

A piston test has been designed to determine bond characteristic in PCP stators. In this
particular test, a stator ring is pushed with a piston as shown in figure 3. After testing, the
stator internal surface is inspected to identify the percentage of debonded area. A good
bond means that the elastomer is torn apart before debonding occurs.

Aging test under diverse environments are also conducted to analyze bond retention as a
function of down hole conditions (ex. hot water aging). Same test procedure as well as
tolerance limits apply in these cases.

Figure 3. Bond test assembly

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TIPS FOR SELECTING PCP ELASTOMERS

The PCP elastomer selection methodology should consider the following fundamental
parameters:

Chemical Environment

Crude Oil Specific Gravity: Light oils are usually more aggressive than heavy oils since
they are generally constituted by low molecular weight aromatics which are highly
compatibility with nitrile elastomers causing swelling. However, API gravity by itself can
not be used as an absolute guideline since some heavy crude oils might contain a high
conc. of aromatic species and in contrast, some paraffinic light oils may possess small
amounts.

Typically. crude oils with API gravity lower than 24° can be handled by conventional
nitriles such as LT 2000. Higher API gravity oils require a more resistant elastomer such
as LT 3000.

Crude Oil Aromatic Content: Characterization of type and concentration of aromatic

species in the crude oil is critical for elastomer selection since these species are
responsible for nitrile rubbers swelling.

Light aromatics , the most aggressive species, are typically constituted by compound with
6 to 11 carbon atoms such as benzene, toluene, xylene, short chain alkyl aromatics and
non substituted diaromatics (ex. naphthalene). These species possess a high swelling
power since they are highly compatible with nitrile rubbers and also capable of diffusing
within the elastomer matrix. Light aromatics are typically found in oils at absolute
concentration varying from 0 to 5 %.

Aromatic species typically found in heavy oil are mixtures of higher molecular weight
mono, di and poly aromatics highly substituted with long alkyl chains. These species tend
to have a lower swelling power (less compatible with nitrile rubbers and slower diffusion
rates) but their effect can not be underestimated since they are usually present in high
concentrations (up to 50 %). Among heavy aromatic, monoaromatic, diaromatic and
thiophenes possess the highest swelling power.

Regarding a selection guideline, crude oils with light aromatics concentration lower than
3 % can be handled by conventional nitriles such as LT 2000. For concentrations between
3 and 6 % a most resistant elastomer such as LT 3000 must be selected. Concentrations
above 6 % usually require special consideration.

For critical applications, an elastomer compatibility test is advised to estimate the

swelling degree under simulated down hole conditions. Measured swelling values allow
designing rotor-stator fit more precisely.
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Water cut: Lifteq elastomers exhibit outstanding resistance to formation water. Water
only causes limited swelling since it is more polar than nitrile rubbers. Typical Lifteq
elastomers experience low swelling values in water, being particularly low for LT 3000.

In a sense, we may think that water might act as diluents of the most aggressive aromatics
species present in the oil fractions limiting the swelling power of the water/oil mixture.
However, over prolonged periods of time the oil fraction effect could dominate causing
some swelling problems. In other word, water just may delay the time required to observe
the oil phase equilibrium swelling. This phenomenon has been observed in the lab by
means of aging oven tests in brine/oil mixtures at different concentrations.

H2S and CO2 content: H2S causes rigidization of nitrile elastomer due to a chemical
reaction with the rubber structure. This gas causes progressive cross linking of elastomer
chains resulting in hardening, shrinkage and ultimately material cracking. To handle H2S
at concentrations above 300 ppm an HNBR such as LT 3000 must be used.

CO2 causes an opposite effect, while H2S hardens the elastomer, CO2 diffuses into the
elastomer matrix causing swelling and softening due to a physical interaction.

CO2 concentrations below 20.000 ppm are considered low and they can be handled by the
majority of elastomers. Concentrations above this limit usually require more resistant
elastomers such as LT 2000 series. Base on field trials, LT 2000 series appears to be best
at handling application with large amount of CO2. Again, as with aromatics, CO2 swelling
must be compensated with the appropriate rotor size.

Gases in the well are capable of causing an additional effect. When a pump is operated in
an environment with free gas, the elastomer absorbs gas up to a saturation value. If a
decompression process occurs and the gas is liberated too rapidly, then the elastomer
suffers internal blistering, tearing or cracking due to the abrupt gas expansion. This
phenomenon is commonly known as explosive decompression and occurs frequently in
high concentration CO2 environments. Elastomer permeability, degree of cross linking as
well as mechanical properties defines material resistance to explosive decompression.
Also slow decompression rates as well as low elastomer thickness help preventing this
phenomenon.

Service Temperature: Elastomers, being organic compounds exhibit limited temperature

reistance. Typical service limits for PCP elastomers are 180 °F for conventional nitile
elastomers (NBR) and 300° F for hydrogenated nitriles (HNBR). It is also important that
the elastomers retain mechanical properties at the operational temperature during the
service life.

Sand content : Sand laden oil lift requires high resilient PCP elastomers with elastic
recovery capability which allows the pass of sand particles across the seal line without
causing elastomer tearing. This is typically accomplished with elastomers having high
elongation to break and good abrasion resistance.
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Sand content and particle size have also an influence on elastomer wear. Usually sand
content under 1 % by weight is considered low, values between 1 and 3 % are considered
medium and above 4 % by weight are considered high.

In general, Lifteq elastomers exhibit outstanding wear resistance so they are capable of
handling different level of sand content well. Among them LT 2001 exhibits remarkable
performace.

GOR: PCP stators allow handling well bore fluids with high free gas content. However,
PC pumps can not run dry since the excessive friction and heat burn the elastomeric
material. PCP operation requires a minimum fluid amount to provide lubrication and
cooling capacity. Lifting fluids with high gas/oil ratios usually require high displacements
pumps with low differential pressure per stage. A loose fit also helps to decrease the heat
generation due to friction. This is why it is so critical to control fit in those types of
applications.

It has not been establish an absolute quantitative criterion about how much gas a PCP can
efficiently handled. A general rule of thumb indicates that the amount of free gas at the
pump intake should not exceed 40 %. This general guideline may vary depending on how
much flow passes through the pump.

In a multi-parameter environment, conditions have to be carefully evaluated to prevent

premature failure due to adverse exposure. It is possible that some well variables have
either synergistic or opposite effect over elastomer performance. An understanding of the
effect of those variables combined together is critical for proper elastomer and fit
selection.
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Important Definitions

• NBR (Nitrile Elastomer) is an elastomer manufactured by copolymerization of

butadiene and acrylonitrile (ACN). The incorporation of acrylonitrile in the elastomer
structure imparts resistance to hydrocarbons and oils. Butadiene imparts flexibility
and rubber like behavior in the copolymer.

• HNBR (hydrogenated nitrile elastomer) is a nitrile that has been processed to increase
the degree saturation of the polymer. This process reduces the total amount of double
bonds which are susceptible to degradation resulting in a polymer more resistance to
environment, temperature and chemical degradation.

The content of acrylonitrile in the copolymer, primarily determine the resistance of

the rubber to hydrocarbons. The higher the ACN content the more resistant the
elastomer will be. However, other important properties may also be affected in a
negative way. Lifteq elastomers are carefully designed with the right balance of ACN
content and other ingredients to maximize performance in multi parameter
environments. Focusing in ACN content alone may not yield the proper material for
the specific downhole environment.

• General requirements for a PCP elastomers:

Elastomer compounds used in manufacturing PCP stators must fulfill the following
basic attributes and characteristics:

¾ Good chemical resistance to well fluid

¾ High thermal resistance
¾ High wear and abrasion resistance.
¾ Elastic recovery capability
¾ Outstanding mechanical properties in particular fatigue resistance
¾ Low compression set

• Swelling

Swelling is a thermodynamic phenomenon that occurs when certain elastomers are

exposed to a fluid which is chemically compatible. In general, non polar solvents
attack non polar elastomers and vice versa. In a presence of chemical affinity between
the fluid and the elastomer, the solvent-elastomer interaction forces (solubility forces)
overcome elastomer-elastomer interaction forces and swelling occurs. Swelling
means that the elastomer is capable of absorbing certain amount of fluid which causes
an increase in volume.
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In fact elastomer dissolution (like sugar with water) does not occur because the
material is crosslinked. Crosslinking opposes the dissolution process limiting the
amount of fluid the elastomer can absorb

The degree of swelling depends on the solubility power of the solvent species. The
material swells up to a point where the solubility forces are equalized by the elastic
force exerted in the crosslinking bridges. Four fundamental factors are important in
determining the equilibrium swelling value: chemical nature of elastomer, chemical
nature of swelling species, elastomer degree of crosslinking and temperature.

The higher the chemical compatibility between the elastomer and the solvent the
higher the expected swelling will be. On the other hand, a higher crosslink density
wills result in a lower swelling degree. An increase in temperature will result in
higher swelling degree since temperature favors polymer solvent interactions.
Pressure also plays a role by increasing the expected swelling value, but is not as
critical as the other factors.

Within the crude oil composition, aromatics species are the most aggressive ones
since they are very compatible with nitrile rubbers in terms of chemical affinity.

Fluid

Temp

Figure 4. Elastomer swelling representation