OTC 24266

Development of Downhole Magnetic Drive Systems for Rigless Artificial Lift

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Applications
Jamie Cochran, Allan Denholm, Iain Maclean; Zi-Lift Ltd

Copyright 2013, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 6–9 May 2013.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract mus t contain conspicuous acknowledgment of OTC copyright.

Abstract
This paper describes innovative small diameter electrical pump systems which can be installed through tubing or casing using
cable deployment or coil tubing deployment, eliminating the need for a rig during pump installation and retrieval operations in
the field. The capability is being developed for 10 bbl/day to 10,000 bbl/day pumping systems.

The underlying, new technology which enables small, high force dense pumping systems is permanent magnet technology,
including novel permanent magnet motors and permanent magnet transmissions. This technology, which has been under
development for the last 3 years, exists for pumps so small they can be retrofitted though 2 3/8” production tubing (low
volume pumping) and larger diameter for high volume pumping. Integrated downhole sensors provide valuable data for
production management and condition monitoring of the downhole pumping system. Systems utilizing these technologies are
currently undergoing qualification testing in preparation for field trials late 2012/ 2013.

Numerous rigless intervention opportunities can be realised in most oilfield environments as the technology enables a key
industry transition from a workover activity to an intervention activity for installation and retrieval of pumping systems.
Conveyance of pumping systems is decoupled from jointed pipe rigs, offering significant opportunities for operational cost
savings and production uptime. For example, pumps can be installed and maintained from a riserless light well intervention
vessel in a subsea well, or in a well on a normally unmanned offshore installation, or installed in a remote land location
without a using rig.

Background
Artificial lift plays a major role in the production of hydrocarbon resources around the world. Today it is estimated that there
are around 1 million producing oil wells worldwide approximately 85-90% of them on artificial lift. In addition, more and
more natural gas wells are requiring artificial lift systems for deliquification in order to assist depletion of maturing gas
reservoirs. For world-wide oil and gas well applications, the number of artificially lifted wells is approaching 1 million
installations, however, this industry started from more humble beginnings.

Edwin L. Drake is, credited with discovering America’s first commercial oil well. In 1859 he used a common water well hand
pump in order to assist lifting the hydrocarbon from a depth of 69.5 feet and can thus be considered the first pioneer of
pumped artificial lift.

Powered Oklahoma-type Pumping Jacks driving sucker rod pumps became was popular in many oilfields. They were operated
by a central power source to which they were connected via rod lines. E.D. Yates obtained a patent in 1880 for a push-pull
central power unit and via a series of inventions, his system evolved to the 1896 patented gear-driven model. Oilmen later
adopted the 1913 “Simplex Pumping Jack” which allowed a single power source to drive multiple pump units as the preferred
method of production.

Over time development of the Pumping Jack (which became affectionately known under many names such as nodding donkey,
horse heads etc.) has continued through the use of electrical drive systems, localised power generation and efficiencies in
pump and sealing technologies. However the basic principle extends back to before the turn of the 20th century.
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In the 1920’s Russian born Armais Arutunoff patented what was to become the next major advancement in mechanical, down
hole artificial lift systems with his development of the Electrical Submersible Pump (ESP). His machine utilised 3 phase 2
pole induction motors to drive a multi stage centrifugal pump at diameters of 5 3/8” and above1.

Also in the 1920’s, Frenchman René Moineau invented the Progressing Cavity Pump (PCP), however it was not until the
1970’s that PCPs were deployed within the downhole environment for the purposes of artificial lift. Such systems were driven
from surface using rods somewhat akin to the Jack Pump arrangement however using a rotary as opposed to reciprocating
motion.

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Many alternative means of artificial lift have been developed in the interim, including hydraulic pumping, gas lift and foaming
techniques, however the primary methods used for mechanical artificial lift have not changed significantly over the history of
the oilfield. For example, since the start of the 20 th century, pump jacks have been used to operate rod pumps. Although this
method has undoubtedly evolved and improved, the basic underlying principle is still the same. The prime mover for these
machines has evolved from steam to gas engine to electric induction motor, driving incremental improvements in efficiency.

Since the introduction of the electric submersible pump by Arutunoff in 1926, the use of induction motors at a fixed speed /
frequency was employed for over half a century. It was not until the introduction of commercially viable Variable Speed
Drives (VSD) in the 1970’s that ESP technology took its first major step forwards in utilisation. Interestingly, it can be
observed that the overwhelming majority of ESP systems still operate with a frequency similar to that during the first 50 years
of ESP operations, despite the introduction of VSD.

Traditionally the oilfield business has a history of being slow to adopt new technologies, and the artificial lift sector of the
industry in no exception. Often times this reticence can be identified as due to risk aversion and the “if it ain’t broke – don’t
fix it” attitude. Where new technologies have been adopted their utilisation has in many cases proven to be “game changing”
– witness the success of direction drilling, coiled tubing applications and so forth. However this path is also littered with many
technical successes, but commercial failures along the way. It is worth noting that the only artificial lift methods to be
consistently used in offshore environments is ESP and gas lift systems, both are tubing deployed and both requiring tubing rigs
to install and workover. The remainder of this paper will discuss how one emerging technology may prove to be the next game
changing technology within the artificial lift sector through the use of modern downhole drive systems which enable the use of
alternative deployment techniques.

Figure 1 shows a brief approximate history timeline compiled from various sources.
 OTC 24266

1932
Progressing Cavity Pump Invention
Moineau et al

1846 1957
Compressed Air
WL retrievable gas lift valve
to lift oil well

1856 1880s
Central Steam 1925 1950
Hand Pump Used
Engine Powered Counterbalanced Use of Mechanical 1977
to Lift Oil Well
Pumps Pump Jack Seal ESP Protectors Variable Speed Drives

1940
1846 1900 2013
Bellows charged gas lift (King) valve
1913
Simplex Pump Jack 1970 1992
Gas Powered ESP Rotary Gas Separators Coiled Tubing Deployed ESP

Figure 1 A brief history timeline of Artificial Lift Technology Introduction

1926
US Patent 1,610,726
Arutunoff ESP Principle
3

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Permanent Magnet Materials – a rapidly evolving resource

The first permanent magnet material to be discovered was termed Lodestone and was thought to have been created during
lightning strikes. After that, Carbon Steel magnets were developed in the eighteenth century, however were proven to have
limitations particularly due to thermal stability. Iron alloy based “Alnico” magnets developed in the 1930s were the first
modern permanent magnets offering considerable improvement in magnetic durability over the magnetic steels previously
available and due to their high Curie temperature, ~850°C, they are still used for certain applications today. Cobalt Platinum
Magnets were developed in the 1950s, however, due to their high cost they did not gain widespread use. Hard Ferrite Magnets
have been some of the most important commercial magnets for the last few decades and still remain the most common
magnetic material in bulk, low energy applications.

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It was not until the commercial exploitation of the lanthanide chemical group (along with scandium and yttrium), collectively
known as the “Rare Earth” (RE) family of chemicals became viable that magnetic technology was to take its next leap
forward. Samarium Cobalt developed in the late 1960s exhibits high energy hard magnetic behavior and have good thermal
stability, making them ideal for high temperature oil and gas applications. Neodymium Iron Boron Magnets were first
produced in 1984 and combine a high saturation magnetisation with good resistance to demagnetization and are used
increasingly in applications where miniaturisation is an important design criterion. Beyond the current state of the art,
development of Samarium Iron Nitride alloys is still ongoing offering a promising new candidate for permanent magnet
applications with even better performance.

Maximum Energy Product is a measure of the volume of material which is required to produce a given magnetic flux level and
is given the symbol BHmax. With the development of permanent magnets in the 20th Century BHmax has improved
exponentially, doubling every 12 years. This revolution in permanent magnetic materials commenced with the introduction of
the samarium-cobalt family of hard magnetic materials with magnetic energy densities hitherto undreamed of. This revolution
accelerated recently with the discovery of a new generation of rare-earth magnets based on neodymium, iron and boron with
even higher magnetic energy densities than samarium-cobalt (SmCo) 2.

Neodymium-iron-boron magnets were discovered almost simultaneously late in 1983 by Sumitomo Special Metals Company
and General Motors and this new magnetic material was found to be stronger than previous generations. Production of rare
earth oxide elements used in the manufacture of permanent magents has grown considerably over the past twenty five years, as
demonstrated in figure 3, and shows a significant increase. The demand for RE magnetics has grown rapidly, and an advanced
supply chain has emerged equally rapidly over the past decade to service the same.

The progress advancement of permanent magnetic materials can be viewed as progressing in a series of steps with each
material being developed and improved before being supplanted by a new one. This trend is shown in figure 2 which details
the development of permanent magnet materials throughout the 20th century. The graph shows the improvement BHmax over
time. The benefit of increased magnet strength is demonstrated by the reduction in size of magnets and is illustrated vividly in
figure 6.

Figure 2 Evolution of Magnet material influence on Maximul Energy Product BHmax 2

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Figure 3 Worldwide Mining Output of Rare Earth Oxide Materials 3

Rare earth ores used for the manufacture of permanent magnet materials have been mined and made commercially available
for over half a century with one of the primary sources having been Molycorp’s Mt. Pass mine in California. Between 1998
and 2001, Molycorp greatly reduced its processing output due to low market prices and environmental issues at the mine.
China now supplies 97%+ of the rare earth materials in the global market, however a resurgence of the Molycorp production
and the addition of suppliers in Australia, Canada and South Africa 3. With the recent price fluctuations of rare earth elements,
numerous mining activities have started. Figure 4 shows deposit locations and those named have promising short or mid-term
performance expectations.

Figure 4 Worldwide Rare Earth Deposit Locations

The recent and rapidly growing application of permanent magnet material to optimise machines based on power density is
evident from figure 5. Many of these applications demonstrate early adoption of this technology in distruptive and game
changing ways. Of the many applications for rare earth permanent magnets, hard disk drives (HDD), CD’s and DVD’s
continue to represent the largest segment. Motors are the second largest and will grow as conversion from induction to PM
motors takes place for efficiency gains. The two newest growth categories are hybrid (and EV) automobile drive systems and
wind power generation.
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Figure 5 Industrial Applications for Rare Earth Permanent Magnets

Interestingly, oil and gas applications for permanent magnet machines are not yet common place. The oilfield cannot be
considered an early adopter of this new technology; however other industries have enabled significant technology development
and a corresponding supply chain to be established already. This could provide the artificial lift sector with a significant
opportunity to reap the benefits of this fast developing technical advancement.

Permanent Magnet Machines – an emerging opportunity

The use of newer rare earth permanent magnet materials offers a significant advantage over previously available magnet
materials. The ability of rare earth magnets to do work per unit volume of material is significantly higher as shown in figure 6
below. When applied to artificial lift, this enables smaller and smaller machines to be developed to perform the same function
as larger traditional machines, for example, induction motor systems.

Figure 6 Relative magnet size and shape comparison (N48 and SmCo represent more recent rare earth magnets)
OTC 24266 7

Several key uses of Permanent Magnet Technology are specifically applicable to oil and gas artificial lift.

Firstly, the use of AC synchronous Permanent Magnet Motors (PMM) to replace traditional induction motors enables a
reduction in motor length and diameter for the same power output is now a real opportunity, made possibile by the recent huge
increases in permanent magnet flux density. Due to the efficient nature of a sychronous PMM, the cost of ownership of the
artifical lift system can be reduced, whilst enabling a reduction of size and, most importantly for deployment, a reduction in
power conduit size. A promising trend can be seen from early results of the PMM development programme and is shown in
figure 7.

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Figure 7 Power density comparison from early development results

Secondly, combination of PMM technology with Variable Frequency Drive (VSD) systems enables smaller motors to provide
higher work output AND can easily be adapted to run much faster than the commonly used 50 or 60 Hz 2 pole ESP motor.
Running at higher speeds (typically 7,500 rpm and above) enables a significantly increased pump performance curve (head
and flow) for a given size of multi stage centrifugal pump system. Effectively, this contributes to higher performance in a
smaller machine envelop.

The Third opportunity of note is the use of Permanent Magnet Transmission Systems to eliminate the use of meshing
mechanical gears for low speed, high torque applications. When this emerging torque converstion technology is combined
with PMM and VSD technology, a highly efficient, power dense machine can result. Magnetic gears offer significant potential
advantages compared with mechanical gears, such as reduced maintenance and improved reliability, inherent overload
protection, and physical isolation between the input and output shafts4.

Smaller machines with high efficiency enable easier deployment and more importantly deployment through tubing rather than
on tubing.

Artificial Lift and Alternative Deployment

Several key industry dynamics are now at play that make conventional tubing deployed artificial lift systems less attractive
while favoring the application of an alternately deployed (such as thru-tubing or rigless conveyed) bottom hole driven artificial
lift system. These dynamics include the following:

 The growing number of installed artificial lift systems is requiring between 600,000 to 1 million well workovers
annually.
 The significant expansion of deviated and horizontal wells limits the application of surface rod driven (reciprocating
and rotating) systems especially as the artificial lift installation is required below the tangent section.
 Well workovers using tubing pulling units are a major industry cost and can result in significant non-productive time
(NPT) that impacts producer cash flow. This is particularly significant offshore, when mobile rigs are required to pull
tubing on unmanned platform wells or subsea wells.
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 Increasing environmental and safety regulations are making artificial lift systems with large surface footprints and
moving surface assemblies less desirable.

Given the above dynamics, there is a keen interest by producers in the potential of deploying artificial lift systems without
tubing rigs which could reduce workover time, costs, and lost production while reducing surface footprints and exposure to
environment and safety issues. Combining these considerations with the fact that a bottomhole driven artificial lift system can
usually be deployed to full horizontal can create significant capabilities for well drawdown and optimizing total produced
fluids and reservoir depletion.

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Alternately Deployed Thru-Tubing Artificial Lift System Challenges
Although alternately deployed artificial lift (ADAL) systems have been of interest for some time, few systems are currently
commercialized and available for broad application. Several key challenges have deterred the development of viable systems.
Some of the key challenges are:

 Achieving high prime mover power densities in small diameters that can fit inside tubing yet deliver adequate pump
head and flow requirements for a broad range of wells and changing operating conditions
 Commercial availability of alternate deployment means such as coiled tubing or electric wire line components which
are designed specifically for artificial lift systems
 Availability of capable and efficient coil tubing and electric wire line service units that can be used with ADAL
systems.
 General risk aversion and slow technology uptake nature of the oil and gas industry

Although each of the mentioned key challenges are important, the most difficult initial challenge has been the technical
development of small diameter prime movers with high power densities for bottomhole drive deployment. Over the last
several years, the development of permanent magnet motors (PMM) has begun to produce promising results. Using high
power density PMM technology, ZiLift Limited has been developing prime mover systems that produce significantly more
power density than conventional downhole motors.

With the development of high power density downhole prime mover technology, the next step was to apply this technology to
the major pump types being commonly deployed in the oil and gas industry. The task also included integrating a complete
system including the components necessary for running into the well and suspending the ADAL system in the well bore.

Two systems that are in various stages of testing and commercialization are described in the following sections.

Alternately Deployed Thru Tubing Centrifugal Pump System

A thru-tubing Electric Submersible Pump (ESP) is being developed to be run through 3 ½ inch and larger tubing. This system
has been designed in an inverted configuration compared to a conventional ESP with a high speed PMM above the pump.
Included in the assembly is a pressure equalization (seal) section which carries pump thrust, balances pressure across the
motor, and provides for motor fluid expansion. Also integrated into this system is a real time monitoring system for tracking
well parameters such as pressure and temperature while also providing vital information on the operation of the pumping
system.

This speed drive for a multi stage centrifugal pump has been designed for electric wire line cable deployment. As the wire line
is used for both power transmission as well as for deployment (installation and retrieval) suspension, reduction in size and
weight is a critical success factor in the development. Using a highly efficient machine is a key enabling in ensuring that the
cable size is optimally small.

Tubing deployment requires exceptionally small diameter pump assemblies (e.g. 2 5/8” inch outside diameter for 3 ½ inch
tubing) and is made possible by the high power density of the PMM and high speed operation. However, the flow and head
ranges for this system have limitations based upon a number of key factors such as tubing erosion and the maximum practical
motor length for handling.
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Alternately Rigless Deployed PCP System

A downhole torque drive system to be coupled to a progressive cavity pump (PCP) system is also being developed and utilizes
a PMM working through a contactless torque transmission to provide rotary power to a conventional PCP. Since the PCP is
driven downhole there is no requirement for a rod string or gearbox / drivehead at the surface. This feature allows for
installation in highly deviated or horizontal wells while also substantially reducing the required surface footprint and
eliminating moving surface mechanical assemblies such as the PCP drivehead.

The system was originally designed for installation in 4 ½ inch tubing and is therefore small (3”OD) and is being scaled down
to fit into 2 3/8 inch tubing for gas well dewatering applications. The system was developed for coil tubing deployment but

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can also be conveyed on electric wire line or conventional tubing if desired depending on the application. Using coil tubing or
wire line conveyance does not require a conventional workover rig and can be installed and pulled in much less time than the
conventional tubing design. The small size of this equipment and the flexibility of deployment methods lends the system to
application in offshore environments where tubing deployment is not always cost effective.

The PMM motor is combined with the torque converter transmission to optimize the efficiency and power density of a high
speed PMM with the lower optimized speed of a PCP. Although traditional rod driven PCP’s have their speed limited by the
RPM capabilities of the rotating rods, the system speed can be substantially increased if desired for certain applications. This
of course allows greater production rates than a conventional system and also enables a wider range of operating points with a
single system.

The contactless magnetic transmission provides speed reduction to drive the PCP at their normally applied speeds of 300 to at
least 600 RPM if required, while amplifying the torque delivered from the motor. Because of its unique design, it is
contactless which eliminates mechanical gear wear which can reduce life and cause failure in other types of bottom drive PCP
systems. A novel feature of this torque converter is its ability to act as a mechanical fuse in the event of over-torque
conditions, for example created by a blocked or stuck pump. In the event of an over torque condition, the transmission slips
until the output torque requirement is reduced (i.e. blockage cleared), thereby preventing mechanical damage to the equipment
and allowing remedial actions to take place before catastrophic equipment failure.

The magnetic transmission comprises an outer permanent magnet array that is fixed to a stationary housing. A high speed
input shaft with permanent magnets bonded to it (linked to the PMM) rotates within a low speed (high torque) output shaft that
is made from a composite nonmagnetic material with ferrous pole piece laminations inserted into it.

The ADAL PCP surface equipment consists of a specially adapted Variable Speed Drive tuned to operate the PMM. This
controller is compact therefor requiring minimal surface footprint and has no moving parts. In addition, the system does not
require a rotary rod stuffing box at the surface, therefore reducing the potential of environmental or well integrity issues of a
dynamic hydrocarbon seal. It is worth noting that the use of dynamic hydrocarbon seals in a marine based production
environment has always been a severe limitation PCP systems. The arrival of this permanent magnet based downhole torque
drive technology could be a key enabler to using PCPs in an offshore environment.

The system has been prototyped and assembled with full factory testing completed. The first field test unit has been
assembled and shipped to a producer in the western United States and is scheduled for installation at the time of this writing.
The application for the field test is a thermal recovery project for heavy oil and will provide valuable information on the
performance of the system.

The general arrangement of this torque driven PCP system is shown in Figures 8 and 9 for different conveyance options which
also have potential to be suitable for offshore operations.
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Well Casing
Cable Suspension Produced
Fluids Production Tubing
Tubing Hanger

Casing Hanger

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Pump Discharge

Pump

Pump Intake

Producing Interval

Figure 8 Wireline deployed PCP configuration

Coil Tubing
Cable Suspension Produced
Fluids Well Casing

Coil Tubing Hang Off

Produced
Gas
Casing Hanger

Flow Shroud

Pump Discharge

PCP

Pump Inlet

Producing Interval

Figure 9 Coiled Tubing deployed PCP configuration

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Conclusion
The artificial Lift sector within the oilfield has a long established history of technical development, however, significant step
changes to production methods have been rare and infrequent, particularly in the past thirty years. In contrast, Permanent
Magnet Motor and Transmission technology has made significant advances in the past twenty years, driven predominantly by
disruptive increases in magnet material performance.

A significant opportunity to introduce changes in artificial lift machines that benefit from these technological advancements
has been identified and two system developments were introduced as examples. The principle benefit from both developments
is an increase in power density, enabling smaller machines to be effectively applied through tubing or conveyed on coiled

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tubing or wireline. Additionally, improvements in efficiency have been realised which provide an opportunity to lower the
production cost per barrel.

ADAL systems offer significant operational advantages when applied to offshore applications, and have specific potential to
be a key enabler for rigless deployment and intervention. This has the potential to move artificial lift completion and
workover operations from the domain of mobile drilling rigs to lower cost intervention vessels with considerable cost saving
benefits.

The need for ADAL systems has never been greater as the industry focuses on managing a significant number of artificial lift
system workovers on an annual basis while also focusing on optimizing well production and reservoir recovery through new
well completions that involve deviated and horizontal technologies. In addition, the industry continues to look for equipment
solutions that maximise personal safety and minimise environmental exposure. The benefits of ADAL systems such as
described in this paper directly address the needs of the producer in adapting to the current and future oil and gas operating
environment.

The evolution of high density power obtained from permanent magnet motor prime movers and transmissions can lead to
viable small diameter artificial lift systems. Currently ADAL system products are in various stages of testing and
commercialization. Early prototype testing is encouraging and field testing is beginning. The oil service industry greatly
benefits from the efforts of producers who are early technology adopters and especially their sponsorship of new technology
development and field trials. Ongoing feedback from producers to developers of novel production systems is to be encouraged
and can provide substantial benefits to timely and effective commercialization of new technology.

References
[1] Electrical Submersible Pumps Manual: Design, Operations, and Maintenance By Gabor Takacs

[2] Information condensed from The University of Birmingham web page

http://www.birmingham.ac.uk/research/activity/metallurgy-materials/magnets/background/magnetic-materials-history.aspx

[3] Data collected and tabulated by USGS, via Arnold Magnetics

[4] Design, analysis and realisation of a high-performance magnetic gear Atallah, K. Calverley, S.D. ; Howe, D Dept. of
Electron. & Electr. Eng., Univ. of Sheffield, UK. Electric Power Applications, IEE Proceedings - Mar 2004Volume: 151,
Issue: 2 Page(s): 135- 143