How to use ISO and API Standards for

How to use ISO and API Standards for Artificial Lift Systems SPE ALCE-NA Training Course, October 5 th, 2014

What responses to AL bid tenders seem like: 2

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 3

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-andstatistics/standards/~/media/Files/Publications/FAQ/valueofstandards. ashx 2. http: //www. iso. org/iso/home/standards/benefitsofstandards. htm 4

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. 5

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. 6

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). 7

ISO vs API: Differences and similarities • Committees required to have global representation from both manufacturers and endusers • Committees do not have to be global, but need to have both manufacturers / endusers. • Approval process is a democratic vote by member country – 2 rounds • Approval process is by API member company with some companies having stronger voting privileges. • 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 • API members are corporations, ranging from producers to service and supply companies • Published both RPs and standards (majority of 11 C documents are RPs) • Process to published standard or recommended practice can happen in less than one year. • Monogramming program 8

Structure of an ISO document • Clauses 1 -9: Requirements • Normative Annexes: Additional details for requirements in Clauses. • Informative Annexes: Related Guidelines 9

ISO document structure - 3 main components Clause 5 Clause 6 Functional Specifications • Operation conditions • Well • Fluids • Operational parameters • Q/C & documentation requirements • Other requirements What the user needs Technical Specifications Clause 7 Supplier • Equipment characteristics Requirements • Design criteria • Validation procedures Manufacturers response to user’s request • Documentation and data control • Product identification • Q/C procedures • Design verification How we ensure this happens 10

ELECTRIC SUBMERSIBLE PUMPS 11

What’s available for ESPs? • Standards – ISO 15551 -1(pending final round approval) • RPs – API RP 11 S (r 2013) – API RP 11 S 1 (r 2013) – API RP 11 S 2 (r 2013) – API RP 11 S 3 (r 2013) – API RP 11 S 4 (r 2013) – API RP 11 S 5 (r 2013) – API RP 11 S 6 (r 2013) – API RP 11 S 8 (r 2013) 12

Refresher: API Recommended Practices (RPs) • 11 S: Operation, Maintenance & Troubleshooting of ESP Installations • 11 S 1: ESP Teardown Report • 11 S 2: ESP Testing • 11 S 3: ESP Installations • 11 S 4: Sizing & Selection of ESP Installations • 11 S 5: Application & ESP Cable Systems • 11 S 6: Testing of ESP Cable Systems • 11 S 7: Application & Testing of ESP Seal Chamber Sections • 11 S 8: ESP System Vibrations 13

The first ESP industry standard kick off meeting, Nov 2009 Manufacturers: Schlumberger, Baker Hughes, Woodgroup ESP and Borets-Weatherford Endusers: Conoco. Phillips, Exxon. Mobil, Nexen, Oxy, Statoil, Shell, Chevron, Petrobras, Total 14

What ESP components are covered? ISO 15551 -1 • centrifugal pumps including gas handling devices, • discharge heads, • seal chamber sections, • Bolt-on intake systems, • mechanical gas separators, 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. • induction motors, • MLE, potheads and power cables. • Assembled ESP systems 15

ISO 15551 -1 ISO specification for downhole oilfield ESP components that defines requirements for: • Design verification & validation, • Manufacturing, • Performance ratings, Engineering design of the component, not the application design for a specific well. • Functional evaluation, • Handling, storage, inspection and repair Removed after 2013 peer review API RPs cover some of these 16

Enduser Requirements (Clause 5) ISO 15551 -1 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. 17

Enduser Requirements (Clause 5) ISO 15551 -1 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 18

Enduser Requirements (Clause 5) ISO 15551 -1 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. 19

Grades for flexibility ISO 15551 -1 20

Enduser Requirements (Clause 5) ISO 15551 -1 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. 21

Enduser Requirements (Clause 5) ISO 15551 -1 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”) 22

Refresher on ISO document structure… Clause 5 Clause 6 Functional Specifications • Operation conditions • Well • Fluids • Operational parameters • Q/C & documentation requirements • Other requirements What the user needs Technical Specifications Clause 7 Supplier • Equipment characteristics Requirements • Design criteria • Validation procedures Manufacturers response to user’s request • Documentation and data control • Product identification • Q/C procedures • Design verification How we ensure this happens 23

Technical Specification – Clause 6 ISO 15551 -1 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. 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. 24

Supplier Requirements – Clause 7 ISO 15551 -1 • 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 25

ESP Performance Ratings 26

Performance Ratings – Shaft and Shaft Couplings ISO 15551 -1 • 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. 27

Performance Ratings – BOD and BOI ISO 15551 -1 • 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. 28

Performance Ratings: Pump and Gas Handler • Design performance curve • GVF rating ISO 15551 -1 • Pump stage thrust rating • Housing pressure rating 29

Pumps and GH: GVF rating ISO 15551 -1 Data Example 30

Example of a Design Performance Curve ISO 15551 -1 31

Performance Ratings: Mechanical Gas Separator ISO 15551 -1 • 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. 32

Mechanical Gas Separator: Performance Curve ISO 15551 -1 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. 33

Performance Ratings: Seal Chamber Sections ISO 15551 -1 • Volume contraction capacity • Operation deviation limits • Thrust load bearing capacity • Minimum operating speed • Number and severity of pressure cycles • Horsepower requirement 34

Performance Ratings: Motors ISO 15551 -1 • Motor performance parameters • Motor voltage for minimum current • Motor winding temperature rise • Motor operating internal temperature limits • Locked rotor current, torque and power factor 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 ISO 15551 -1 • Voltage and temperature rating • Ampacity coefficients • Conductor size • Acceptable minimum bending radius rating 36

Performance Ratings: Pothead ISO 15551 -1 • Voltage and temperature rating • Ampacity coefficients • Differential pressure performance • Thermal cycling performance 37

Assembled System Performance Ratings ISO 15551 -1 • 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 38

Assembled System Performance Ratings ISO 15551 -1 • 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 39

Assembled System Performance Ratings ISO 15551 -1 • Maximum pressurization and depressurization rates – Determined by calculation – Limiting components to be identified • Power requirements (KVA and k. W) – Determined by calculation at the input end of the cable • Motor fluid % Utilization of each seal chamber contraction capacity – Determined by calculation – From maximum ESP internal temperature to min static BHT • Minimum and maximum operating speed – Supplier to have a documented process for determining these values 40

Functional Evaluation (Annex C) ISO 15551 -1 • 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). 41

Functional Evaluation (Annex C) ISO 15551 -1 • 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. 42

Functional Evaluations: Pump and Gas Handlers More test points ISO 15551 -1 More test points and tighter acceptance criteria 43

Functional Evaluations: Mechanical Gas Separators F 2 ISO 15551 -1 F 1 Mechanical – Shaft rotation In conformance with supplier/manufacturer specifications and acceptance criteria Per F 2 Mechanical - Shaft extension, shaft end play and shaft side play In conformance with supplier/manufacturer specifications and acceptance criteria Per F 2 Mechanical – Shaft Total Indicator Run-out In conformance with supplier/manufacturer specifications and acceptance criteria 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 11 S 8, 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. 44

Functional Evaluations: Seal Chamber Section ISO 15551 -1 F 3 F 2 F 1 Hydrostatic evaluation – bag/bladder/bellows, relief valves, mechanical seals, housing joints Per 11 S 7 Per F 3 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 11 S 7 Per F 3 and loaded power loss per supplier/manufacturer specifications and acceptance criteria Mechanical – Shaft Indicator Run-out In conformance with supplier/manufacturer specifications and acceptance criteria Per F 3 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 F 2 Vibration In conformance with supplier/manufacturer specifications and acceptance criteria Per 11 S 8, 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 F 2 Total 45

Functional Evaluations: Motors ISO 15551 -1 F 3 F 2 F 1 Hydrostatic evaluation – pressure test for leaks (vacuum or pressure) In conformance with supplier/manufacturer specifications and acceptance criteria Supplier/manufacturer shall perform testing in conformance with supplier/manufacturer specifications and acceptance criteria Per F 2 Mechanical – standard idle/coast, k. W In conformance with supplier/manufacturer specifications and acceptance criteria Supplier/manufacturer shall perform testing in conformance with supplier/manufacturer specifications and acceptance criteria Per F 2 Mechanical – load test No requirement Per A. 3. 7. 3. 1 Electrical functional testing – insulation testing, dielectric oil breakdown, phase imbalance Per C. 8. 2 Per F 3 Mechanical – shaft extension, shaft end play and shaft side play (if applicable) In conformance with supplier/manufacturer specifications and acceptance criteria Supplier/manufacturer shall perform testing in conformance with supplier/manufacturer specifications and acceptance criteria Per F 2 Vibration In conformance with supplier/manufacturer specifications and acceptance criteria Per 11 S 8, 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 F 2 46

Functional Evaluations: Cable and MLE ISO 15551 -1 47

Informative Annexes ISO 15551 -1 • 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 48