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Electric Submersible Pumps Mohamed Dewidar 2013

Chapter 4

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Protector (Seal)
Table of Content
Section Content Page
1 Seal section functions 2
2 Seal section basic type 3
2.1 Labyrinth seal
2.2 Positive seal
3 Mechanical face seal 11
4 Axial thrust bearings 13
5 Modular protector 17
6 Seal operation cycle 20
7 Application 25










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Protector (Seal)
What is Protector?
Protector is located between the intake/GS above, and the
motor below. It serves as a vital link in the entire ESP
system.
It has several functions and each of them has to be
considered carefully for overall system design.
4.1. Seal Section Functions
4.1.1. Equalize pressure
It equalizes the pressure inside and outside of the
system and at the same time provides room for motor oil
thermal expansion.
The Protector needs to balance the pressure inside the
system and the pressure outside.
How does it do this??
o By maintaining a fluid interface between the motor oil
and the well fluid of different specific gravity
(labyrinth protector), if the well fluid specific gravity
is greater than 0.85, or
o Maintain separation of the two fluids through an elastomer
bag (bag protector), if the well fluid specific gravity is
lower than 0.85.
o Protector is open to the well-bore, allowing the motor
pressure to remain the same as that in the well annulus
around it.
o The labyrinth design uses the difference in specific
gravity of the well fluid and the motor oil to keep them
apart even though they are in direct contact.
4.1.2. Absorb thrust
Another function of the Protector is to absorb the
thrust generated by the pump. It can either be upthrust or
downthrust, depending on the pumping conditions.
The seal sections position is driven by the need to support
the pump shaft thrust load, so that none of the thrust is
transferred to the motor thrust bearing. The seal section
has room for a large thrust bearing with more capacity than
is possible in the motor head (where the motor thrust
bearing is located). Also, the seal section does not have to
support the motor rotor weight, allowing more capacity for
pump thrust support.
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The thrust bearing works on hydrodynamic lubrication
principle. The runner carrying the thrust forces is riding
on a hydrodynamic oil film created by the relative motion
between the runner and the bearing. There are three types of
bearing (Reda).


Fig (4.1) Thrust Bearing

Standard bearing Babbitt (lead based)
HL Bronze bearing - (9000 LBS 540 series, 60 HZ)
HL bearing Polymer coated tilting pad bearing
(12000 LBS 540 series, 60 HZ)
4.1.3. Isolate motor oil
It isolates the clean dielectric motor oil from well
bore fluid. Preventing well fluid entry is critical for
bearing lubrication and electric isolation strength. For
this reason multiple redundant isolation chambers have
become standard.
4.1.4. Transmit torque
One other function which the Protector carries out is
transmission of the motor torque to the pump since it is
physically located between the two.
Although this may seem a little trivial, in the selection
process we need to be certain that the Protector shaft is
capable of delivering the full torque required without
exceeding its yield strength which could result in a broken
shaft.
4.2. Seal Section Basic Types
4.2.1. Labyrinth Type
Fig (4.2) shows a typical labyrinth type isolation chamber in
the lower chamber. The labyrinth design uses the difference in
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specific gravity of the well fluid and the motor oil to keep
them apart even though they are in direct contact.
The heavier gravity well fluid is separated by gravity.
A U-tube design keeps the heavy well fluid going lower
into the unit keeping the thrust bearing and motor full of
clean oil. With this design, the motor oil and well fluid
are in contact.
The labyrinth chamber is isolated from the shaft rotation by
the shaft tube so that no mixing will occur by unit turning.
The well fluid is generally immiscible with motor oil so,
even though there is a direct contact; there is no tendency
to contaminate the motor oil.

Fig (4.2) typical labyrinth type

Fig (4.3) shows motor oil expansion and contraction in the
labyrinth type (Top of unit is in contact with well fluid via
the pump intake and bottom of unit is in direct contact with
motor head)
A schematic layout is shown in fig (4.4). It is referred to as
"labyrinth" or "U tube" style chamber.
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Typically, there is a mechanical seal located at the top of
this chamber and mounted on the shaft. Its function is to
prevent the well fluid from traveling directly down the shaft
and through the chamber. The mechanical seal will be discussed
in detail in a later section.

Fig (4.4)
For pressure equalization to the well annulus, a passageway is
provided in the seal head connecting the area just above the
mechanical face seal to the outside annular section of the
labyrinth chamber.
The complete fluid flow path through the chamber is shown in
fig (4.5).
As the temperature of the unit increases, the dielectric oil
expands up the inner annular section formed by the shaft and
the shaft support tube. At the top of this annulus, the
dielectric oil migrates over to the middle annular section
formed by the shaft support tube and middle tube. It then
travels down this section and up the outer annular section
formed by middle tube and the outer housing. The dielectric
oil then travels through the passageway connecting the area
above the mechanical face seal. Upon the contraction, the
dielectric oil follows the reverse path through the chamber.
During expansion mode, motor oil (dielectric oil) is being
vented through the chamber to the well bore. As the unit cools
down and the motor oil inside the unit contracts, fluid
outside the chamber (well fluid) is pulled back along the flow
path into the outer annulus of the chamber. As well fluid
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usually has a higher specific gravity than the motor oil, it
will settle to the bottom of that annular section.
Therefore, as the unit goes through further thermal cycling,
the well fluid in this chamber will U-tube back and forth
between the middle and outer annular sections. If there is a
several expansion cycle, then the well fluid can be U-tubed
out of the middle annulus and additional motor oil can be
displaced by well fluid. If there is a sever contraction, well
fluid could be pulled high enough into the middle annulus to
flow over into the inner annulus and down into the cavity
below the chamber.
One weakness of this style is the fact that the two fluids
have a common interface. With time, the motor oil will see a
degradation of dielectric strength because of water saturation
or wetting from the well fluid.

Fig (4.5) flow diagram
There are conditions when it is not convenient to use this
type of protector:
Well fluid,
The heavier gravity well fluid is separated by gravity.
A "U-tube" design keeps the heavy well fluid from going
lower into the unit keeping the thrust bearing and motor
full of clean motor oil.
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With this design, the motor oil and well fluid are in direct
contact. The labyrinth chamber is isolated from the shaft
rotation by the shaft tube so that no mixing will occur by the
unit turning.
The well fluid is generally immiscible with the motor oil so,
even though there is direct contact; there is no tendency to
contaminate the motor oil.
When the well fluid is lighter gravity than the motor oil
(i.e. about 0.85). The motor oil will go to the bottom of the
chamber rather than the top causing the motor fluid to be
replaced by well fluid pretty quickly.

Fig (4.6) The well fluid is lighter than the dielectric oil
Horizontal or Highly Deviated Wells.
Labyrinth Protectors also will not work in horizontal or
highly deviated wells. The gravity separation design requires
the unit to be mostly upright. This Protector can operate in
some amount of deviation but the expansion volume is somewhat
reduced.
Deviation from vertical at the setting depth has a significant
effect on the expansion / contraction capacity of all
labyrinth type chambers. In the extreme situation case the up-
down-up labyrinth path becomes left-right-left. Needless to
say, the usefulness of density separation in this extreme
situation is eliminated.
Fig (4.7) shows labyrinth chamber in 90
O
deviation and its
remaining capacity. The capacity of the chamber is reduced in
direct proportion to the deviation angle.
It is important to make sure that the labyrinth type chambers
have enough expansion capacity for the application at the
installed deviation angle. If the a chamber does not have
enough capacity, well fluid can pass the chamber in one
thermal cycle. The amount of oil expansion / contraction at
each isolation chamber depends upon three variables:
1. The amount of oil below each chamber.
2. The oils coefficient of thermal expansion.
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3. The operating thermal cycles of all oil volumes below the
chamber.


Fig (4.7) Labyrinth Type in Horizontal Position
4.2.2. Positive Type
Often referred to as a "bag" or "bladder" style
chamber, this design incorporates a positive barrier between
the well fluid and motor oil. The middle tube of the labyrinth
style chamber is replaced with flexible membrane which seals
around the chamber shaft support tube.
An illustration of this chamber is shown in fig (4.8)

Fig (4.8) positive seal
The positive seal is applied where the well fluid and motor
oil gravities are similar or where a well is highly deviated.
The positive barrier style chamber has a mechanical face seal
located on the shaft above the chamber. Its function it to
protect the shaft radial support bushing and to prevent well
fluid from migrating directly down the shaft and through the
chamber. It is important to protect the shaft pushing to
preserve the proper functioning of the mechanical face seal.
Pressure equalization to the well annulus is provided for by a
flow passageway communicating from the interior section of the
membrane, to the outer section, then through the head to the
well bore.
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A flow diagram is shown in fig (4.9).
On expansion, the dielectric oil travels from the area below
this chamber, up through a communicating passageway to the
inner annular section. At the top of this section, it flows
into the interior section of the membrane through a set of
communication holes located near the top the shaft support
tube.
After the membrane interior section is equalized or filled,
the fluid will continue up the inner annular section to the
communication passageway at the top of the chamber. There it
will pass through two, low pressure check valves set in
series, to the outer section of the chamber.
The use of multiple check valves will enhance their functional
reliability in case of one of them fails to seal. The fluid
will then flow through another communication passageway to
area above the mechanical seal.
On contraction, the check valves remain seated and the
flexible membrane will compensate for the volume reduction by
collapsing inward. The pressure in the outer section is
equalized by the flow of the well fluid back into this section
of the chamber from the area above the face seal.
The higher specific gravity well fluid will settle to the
bottom of this section away from direct contact with the check
valves.
Upon further thermal cycling, the flexible membrane will
expand as the fluid heats up and contract as fluid cools down.
Unless the maximum temperature of the initial thermal cycle is
exceeded, there should be no further expansion of motor oil
out of the membrane interior section.

Figure (4.9) flow diagram
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Fig (4.10) Typical Bag Type
The bag is made of a high temperature / high performance
elastomer which can withstand the harsh downhole environments
typically encountered. The bag keeps the well fluid and the
clean motor oil completely separate from each other on either
side of the elastomer that the bag is made of.
When the motor oil expands or contracts, the bag simply
expands or contracts to accommodate the necessary volume
change.


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Fig (4.7)
Bag Type in inflated and deflated position
Positive Seal Protectors Limitations
The positive seal Protector offers a great deal of
flexibility and is useful in a wide variety of applications.
One area where care needs to be taken with this type of
Protector is with harsh well chemicals as may be experienced
with a treatment program. As with any oil field elastomer,
care must be taken to ensure that the rubber will not be
damaged by anything it will encounter in the well (See table
4.1)

Table (4.1)
* Temperature Limit above indicates maximum operating temperature for the
pecific REDA compound. An elastomeric component will operate at a
temperature higher than the well ambient temperature depending on its
location in the equipment. Contact REDA for specific application assistance.
1 = Excellent long term resistance (very low swell/maintains very high
physical properties)
2 = Good long term resistance (moderate swell/maintains high physical
properties)
3 = Fair - depends upon exposure time and temperature (good short term
resistance)
4 = Poor - no resistance even in short term
Table (4.1) Ealstomer Selection
4.3. Mechanical Face Seals
Each independent isolation chamber has its own mechanical
face seal, usually located at top of each chamber. The
mechanical seal is a dynamic seal that prevents well fluid
migration down the shaft. It has rotating assembly that fixed
to the shaft and a stationary component called a seat or
primary ring. Fig (4.11) shows a mechanical seal and all four
of its critical seal location.
Each mechanical face seal includes three static seals. The
first is the o-ring between the stationary seat and the bore
in which it is inserted. The third static seat is between the
rubber bellows and the shaft.
Each of static seals uses rubber materials which are
compressed against hard surfaces with an appropriate finish.
The rubber materials must be selected for compatibility with
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the well fluid and any chemical treatments. A leak at any of
the three static seals location will cause well fluid to fill
the chamber which the mechanical face seal protects.



Fig (4.11) Mechanical Face Seal
The dynamic seal location is between the rotating face and
stationary seat. The rotating face and stationary seat must be
extremely flat on the surface in contact with the other. Any
surface defects can cause dynamic seal to leak. It is also
important that the rotating face must be moving in a very
circular path. The dynamic seal is a wet seal with motor oil
extending partially across the face from one side, and well
fluid extending in from the other. Significant eccentricity in
the rotation well cause the motor oil and well fluid to
intermingle and result in a pumping affect across the seal
face, usually outward. Sand and scale can damage the dynamic
seal faces and cause leaks. In wells with significant amount
of scale and/or sand, ceramics or tungsten carbide are good
selections for the faces in the uppermost mechanical face
seals.
Proper filling of the motor and seal section is critical
to the mechanical health of the bearings in both components.
However, even under ideal conditions, a small amount of air
may remain in the system after filling. Any air remaining in
the motor or seal section will tend to rise up and form pocket
under mechanical seals. The motor, having more oil volume and
laminated construction, is the most likely source of residual
air. An air pocket will reduce the dynamic seal face
lubrication and provide insulation. Reduce lubrication causes
more heat generation and insulation raises the seal face
temperature, further reducing lubricity. A graphite seal face
will tolerate loss of lubrication much better than other
materials, due to its self lubricating nature.
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Therefore, a graphite rotating mechanical seal face is
frequently used in lower position(s), where air is most likely
to form pockets.
The metal components of the mechanical face seal are
commonly available in either stainless steel or monel. The
spring is most often attacked first due to it being in pre-
stressed condition. Monel should be specified for the
uppermost mechanical seal spring(s), when H
2
S acid or other
chemistry is present that could lead to corrosion or hydrogen
stress cracking in stainless steel. When the spring is
upgraded to monel, the rest of the mechanical seals metal
component are also often upgraded.
4.4. Axial thrust Bearings
ESP system predominately use tilting pad type plane
thrust bearing. This type of bearing generates much less heat,
tolerates more contamination and support more thrust under
3600 rpm operating condition, compared to rolling element
bearings. A variety of thrust bearing designs are available in
the industry and the ESP manufacturer guidelines for thrust
capacity should be adhered to when selecting the thrust
bearing design.
Several factors affect the thrust capacity of the bearing and
thrust exerted on it by the pump.
The first factor is the pump stage type. Different pump sages
produce different thrust characteristics, even through the
stages may appear quite similar.
The second factor is how each stage transmits its thrust onto
its support. Floater type stages transmit their thrust
directly onto the mating diffuser below. Floater pumps produce
shaft downthrust equal to the differential pressure generated,
multiplied by the area of the shafts cross section. Stages
fixed to the shaft transmit their thrust entirely onto the
shaft. Fixed stage pumps typically generate more shaft thrust
than floater pumps and the thrust level is characteristic of
the stage hydraulics.
Third factor is speed. The seal thrust bearing capacity varies
approximately in direct proportion to the speed for a limit
range above and below 3600 rpm. Meanwhile, the pump thrust
tends to change in relation to the square of the rotating
speed. The net result is that you can carry few stages at
higher speed and more stages at lower speed.
The forth factor is the viscosity index of the oil type being
used in the seal. More viscous oils will carry higher loads
under the same condition. However, more viscosity also causes
the radial bearings with fixed clearances to generate more
heat and this can cause problems, practically in the motor
rotor bearings. A good rule of thumb is to use the same oil in
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the seal as that recommended by ESP manufacturer for proper
performance of the motor radial bearings, under the expected
operation conditions. This will result in an appropriate
viscosity index selection.
The fifth factor is the temperature of the seal section thrust
bearing lubricating oil. As temperature increases, viscosity
decreases, thereby reducing the thrust capacity.
In one set of circumstances, the pump down thrust can actually
increase of the life of the system. Mixed flow pump stages are
often hydraulically balanced by a seal ring on the top of each
impeller. If this seal balance ring becomes worn by erosion
and/or corrosion, the resulting flow over the top of the stage
can cause the pressure on the top of the stage to rise. The
pressure increase can cause doubling of the pump stage
downthrust, and sometimes more. This is only a factor for the
seal section if the impellers are fixed to the shaft so that
they transmit their thrust onto the seal section. So, if you
have hydraulic balance (mixed flow) stages, fixed to the pump
shaft and operating in an erosion or corrosion condition, then
the thrust exerted on the seal section can increase
significantly over the life of the system.
Proper thrust bearing design and selection is critical to seal
assembly. Applications requiring high pump TDH (Total Dynamic
Head) outputs coupled with the inherent diametric restrictions
of ESP equipment have demanded rigorous service from these
bearings.
The basic operating principles of hydrodynamic thrust bearing
designs utilized in ESP's are very similar.
The stationary bearing surface is divided into a number of
separated pads, with each pad allowed to pivot under operating
conditions.
The bearing is submerged in lubricating oil, which adheres to
the moving and stationary surfaces and is thus carried into
spaces between the thrust runner and the bearing pads.
Tapered lands are machined on the pad edges to aid this
process.
Fluid pressure builds along the entrance side of the pads,
causing the pads to tilt. This tilting action allows the
formation of a wedge-shaped oil film, generating sufficient
pressure to completely separate the runner and thrust pads.
This separation minimizes friction and wear to the bearing
surfaces insuring long bearing life.
Fig (4.12) depicts the hydrodynamic thrust bearing operation
mode.
A common bearing design employed in ESP's is the pedestal or
solid shoe type, illustrated in fig (4.13). the individual
bearing pads are mounted on pedestals located at the center of
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each pad. The pedestals are designed to deflect slightly in
operation, allowing the pads to tilt and form the necessary
oil; film.
For applications requiring higher loading capacity, a self-
equalizing tilting pad thrust bearing is available, shown in
fig (4.14). These bearings use a series of leveling link to
control individual pad heights so that the load is shared
equally by all pads.
The individual pads are supported by balls or spherical faced
links, allowing them to pivot freely. This freedom of motion
coupled with a self aligning feature, typically permits
allowable bearing loads of 400-500 psi, twice the capability
of solid shoe bearing.

Fig (4.12) hydrodynamic thrust bearing operation

Fig (4.13) Solid shoe thrust bearin
A more recent development in thrust bearing design is swing-
pad bearing, shown in fig (4.15). the individual pads are
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round in shape, consist of spherical segments of bonded
alternate metal elastomer layers. Instead of tilting on a
centerline, the pads swing in the direction of the curvature
thus allowing the film wedge to form.

Fig (4.14) modified Kingsbury thrust bearing

Fig (4.15) swing pad thrust bearing
This bearing has been successfully applied in ESP's at face
loading pressures to 800 psi and has been laboratory tested
under ESP loading conditions to 1000 psi without failure.
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4.5. The Modular Protector
The modular protector system consists of a single
infrastructure upon which all protector types are built. Since
all chamber types (such as labyrinth or bag) have been
designed with common interfaces, they can be placed in almost
any order and, theoretically, in any quantity. There are
practical limits to the number of chambers, however, imposed
by maximum available shaft length, power consumption, and
cost. The system is shown schematically in fig (4.16).
Initially, protectors with two or three chambers are planned,
though this will be subjected to change once the protectors
are in production. The new system can be used to make a
version without any chambers as well. This would essentially
be a bearing section which could be added between the main
protector and motor to provide a back up thrust bearing.
If a back up bearing is desired, a bearing only section could
be added between the motor and protector which would provide
additional protection in the case of wear debris cause
failure.
4.4.1. Reda Designation of Protector Types (See fig(4.17)
Due to the enormous number of types of protectors which
can be made using this system, a standardized system of
designating the configuration has been arrived at. The first
part of the designation will consists of letters designating
the chambers and their interconnection, beginning with the top
chamber and using the following configurations:
L = Labyrinth B = bag S = Series
P = Parallel
For example, the designation [LSBPB] indicates that there is a
labyrinth chamber on the top in series with a bag chamber
which in parallel with another bag chamber. The designation
[LSL] describes a chamber model similar to 66L protector.
MP = Modular Protector
HL = High Load (bearing)
HS = High Tensile Strength (Shaft)
FS = Ferritic Steel (Material of base, head and housing)
It is important to note that there are several restrictions in
the specification of chambers:
o Parallel labyrinth chambers are not currently supported.
Labyrinth chambers in parallel with bag are not available.
o It is not generally accepted to put a single bag chamber in
series with parallel bag chamber.
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Fig (4.16) Modular Protector System

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Fig (4.17) Reda Designation
4.4.2. Centrilift Designation of Seal Types (See table(4.2)
and fig (4.18))

Table (4.2) Centrilift designation

Fig (4.18)
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4.6. Seal Operation Cycle.
o All modular Protectors come "pre-filled.
o During field assembly, the FST (Field Service
Technician) will "top up" the protector to replace any
oil lost during the assembly process.
o Vent plugs are replaced at intervals.

Fig (4.19) servicing the protector prior to installation.
This is an view of an LSB protector. The red arrows indicate
the oil flow path during filling. The vent plugs are replaced
at intervals to ensure all air is removed from the unit.
Since the protector is serviced at surface, the motor oil
temperature will be the current Outside Ambient Temperature
(OAT), fig (4.20)


Fig (4.20) Protector holds 100% oil
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System landing at setting depth, oil expands, fig (4.21).
Given that the system can only hold 100% volume, the system
will dump the 9% overboard. This oil will never be
recovered.

Fig (4.21) system landing at setting depth, oil expands.
Motor Operates, oil expands more, fig (4.22).
When the system is started for the first time, the internal
heating of the motor will increase its temperature until the
motor reaches its operating temperature (MOT). This will
cause an additional expansion of oil, typically another 2-
4%.

Fig (4.22) motor Operates, oil expands more.
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Motor Operates, oil expands more, fig (4.23).
But again, the system can only hold 100% volume. The 2-4%
oil expanded will again be lost to the well bore.


Fig (4.23) motor Operates, oil expands more.
Motor stops, oil contracts, fig (4.24).
Now the system is only 96 - 98% full of motor oil so the
protector will then have a small amount of well fluid in the
first chamber making up the balance of the volume.


Fig (4.24) motor Stops,, oil contracts
Bag contracts
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Motor operating cycles-on, oil expands, fig (4.25).
As the unit cycles, the system can loose additional motor
oil due to several reasons: Motor Temp, Specific Gravity,
Gas in Motor Oil, Emulsions, etc.


Fig (4.25) motor Operates, oil expands.

Motor operating cycles-off, oil contracts fig (4.26).

Fig (4.26) motor Operating ,cycle off, oil contacts.
Pulling the unit to surface, oil contracts, fig (4.27).
Bag expands
Bag contracts
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When the unit is pulled, the motor oil will cool once again
to surface temperature (OAT). Most bag damage is caused
during system removal from the well and not during down hole
operation.

Fig (4.27) pulling the unit to surface, oil contracts


Fig (4.28) seal operation cycles

Bag contracts
more
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4.7. Application
One of the primary reason for the existence of the
Modular Protector system is its ability to supply a protector
configured for specific set of well conditions. The
information given below is to aid in specifying a system
appropriate to the application:
High GOR or Low Specific Gravity Fluid
In wells with low specific gravity fluids a labyrinth
chamber serves very little function. Since the well fluid
floats on top of the motor oil, it accumulates at top of the
chamber where it is easily drawn in when the oil cools and
contracts at shutdown.
If there is a high gas concentration, especially free gas
with saturated oil, the gas can come out of solution in the
protector chamber as the pump pulls the fluid level down and
reduces the down hole pressure. As the gas comes out of
solution, it rises to the top of the chamber and could
actually push the fluid out of the protector chamber.
This may not a big problem until fluid os pushed from the
next labyrinth chamber below and falls below the gas cap
when the unit restarts. Depending upon the type of cycling
the unit is subjected to, gas can then be pulled off the top
of the upper chamber into the next chamber down, thus
displacing oil, and could eventually pump a large amount of
oil out of the protector.
The recommendation in these cases would be to have a
positive (bag) seal chamber on the top of the protector to
provide a solid barrier to gas or low SG fluid entry.
Low Angle Operation
A labyrinth decreases in effectiveness as the equipment is
operated closer to horizontal. In general, it is best to use
bag chambers if low angle operation is anticipated.
High Water Cut
This typically the best use of a labyrinth chamber, where
gravity separation is most effective. Of course a bag
chamber is also effective in these cases. All things being
equal, a labyrinth on top and bag below can be one of the
most effective combinations for this basic application.
Fluid which Degrades Bag Material
In these cases, it is necessary to run either an all
labyrinth chamber protector or labyrinth protector over the
bag chambers. In general, the fluids which are causing the
bags problems are probably also effecting the seal bellows
and o-rings as well, so one should know as much as they can
about these fluids before designing a protector for
them.(See table 4.1 for elastomer selection).

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