Reverse ESP - Point Water Injection into the Reservoir

To increase oil recovery in reservoirs with declining pressure, a pressure maintenance method is employed, where liquid is injected into one well to create pressure, pushing hydrocarbons towards another production well. Deep water injection, including wastewater and produced water, can be facilitated by highly efficient reverse-type ESP.

Novomet can manufacture a reverse-type installation based on any serial pump. Thanks to its wide range of standard and energy-efficient pumps, the reverse-type ESP offers a broad nomenclature and can be produced in any configuration depending on operating conditions. This type of standardization significantly reduces manufacturing time and equipment costs, as well as enhances maintainability— all necessary parts are always on hand.

The company ensures the performance of reverse-type installations in the range of 15 to 12,000 m³ with a high level of system efficiency. Efficient motors and pump stages reduce energy costs. "Reverses" can be used with high inlet pressures of up to 400 atm.

Today, Novomet offers equipment configurations to address a wide range of technological tasks. This includes water injection into the reservoir from the surface, inter-well pumping from the upper layer to the lower one, from the lower to the upper, and from the upper layer to the lower with partial water injection to the surface. The range of sizes for reverse-type ESPs includes dimensions from 5 to 16. The average operational performance is significant—typically around 500-600 m³/day, with maximum figures reaching up to 1800.

Additionally, if necessary, a telemetry system can be connected to measure pressure, temperature, vibration at the intake, and flow at the pump discharge, along with a submersible flow meter for determining flow rate and viscosity (Novomet has its own patented device).

Moreover, it is possible to connect the Novomet Track software-hardware complex, which provides remote access to the control station and allows users to view and adjust parameters from anywhere in the world.

— The reverse-type ESP for point water injection into the reservoir is a sought-after and high-performance product, - summarizes Novomet’s chief designer Konstantin Saveliev. – Its wide range of serial installations, the ability to manufacture a "reverse" in an energy-efficient configuration, high operational performance, additional options, as well as a flexible approach and comprehensive selection by the company’s specialists make it so.

Injection pumps can also be used in disposal wells. This allows for solving the problem of wastewater accumulation in the most economical way and transitioning a well from operational to injection status after its profitable lifespan while reusing the control station.

Y-tool – Well Research Without Equipment Retrieval

Novomet presents a technology for conducting geophysical surveys while the ESP (Electric Submersible Pump) is operational – bypass systems (Y-Tool).

This technology addresses tasks such as investigating wells with multiple production zones while the ESP is in operation, studying objects under different operating modes of the ESP, examining horizontal sections of the reservoir (lowering instruments on continuous coiled tubing or using a well tractor), processing the near-wellbore zone through the bypass line, and deploying special tools for work with packer equipment.

The Y-Tool is deployed on tubing and consists of two pipelines. One pipeline is designed to displace the submersible centrifugal pump installation within the well, while the other runs parallel to the ESP and provides a direct path for the geophysical instrument or other device to access the zone below the submersible centrifugal pump installation without the need for its retrieval.

Thus, bypass systems enable research in vertical, inclined, and horizontal wellbores, capturing parameters such as pressure, flow rate of the lifting fluid, and temperature in real-time.

Novomet's Y-Tool product line consists of three products: a bypass system, a load-bearing bypass system designed for offshore production and unique in the Russian market, and an automatic bypass system currently undergoing final testing.

The load-bearing bypass system expands the application possibilities of the Y-Tool. One of its advantages is the ability to install additional equipment below the bypass system, including the installation of a backup ESP – a second (backup) unit can be launched to enhance total run time without retrieving all equipment.

In summary, the main advantages of this technology include access to the zone below the ESP without equipment retrieval, conducting geophysical surveys during the operation of the installation with the possibility of mode changes, protection of the installation during free-flowing or pressurized injection modes, and deployment in wells with production casing diameters starting from 146 mm.

“When developing bypass systems, we rely on our vast experience in oil machinery manufacturing and our achievements in applying advanced technologies,” explains Novomet's lead design engineer Evgeny Kozlov. “This makes our bypass systems reliable equipment that allows for conducting any geophysical surveys, which involve multiple stages and require an experienced approach, without compromising well operations.”

Smart Checkup – First-Class Analysis

In the operation of equipment, the quality of the manufactured product is of paramount importance. The final and one of the most critical stages of quality assurance is the testing of installation components at service bases before they begin operation in a well. Each Novomet pumping unit undergoes a complete set of acceptance tests before shipment.

Testing stands are used for this purpose. Their main function is to confirm the suitability of products and their characteristics (electrical, hydraulic, mechanical) in accordance with the technical requirements of the customer. Typically, this is the last stage of equipment verification.

Novomet manufactures stands for both acceptance testing and periodic testing. In the first case, it involves checking serially produced equipment. Such stands are located at production sites in each assembly shop and in every separate division of the company. In the second case, the stand equipment is designed by Novomet specialists according to the individual requirements of the customer, after which it is manufactured and delivered to the production area for assembly, calibration, and commissioning.

"We can conduct extended tests with the measurement of additional parameters based on a specialized technical assignment," explains Mikhail Politov, head of non-standard equipment production at Novomet. "The main advantage of our stands is the ability to meet individual customer requirements under specific conditions. The company has separate teams of developers for automated control systems, software, mechanics, hydraulics, and pneumatics, who are ready and capable of addressing various requirements."

Each stand is designed for testing a specific type of equipment. The main types of stand equipment at Novomet include:

• Acceptance testing stand in idle mode
• Acceptance and periodic testing stand under load
• Hydrodynamic protection testing stand
• Horizontal stand for testing pump sections
• Horizontal stand for testing and preserving pump sections
• Stand for determining leakage current in cable extensions and cable lines
• Stand for testing stages of submersible centrifugal electric pumps
• Stand for testing submersible telemetry blocks

The stands are equipped with modern software that allows tests to be conducted in automatic mode with control over specified parameters. Following the tests, a report is generated in the form of a convenient document ready for printing.

"This results in low errors in measured parameters, implemented with first-class accuracy, allowing for a more precise determination of equipment characteristics," adds Mikhail Politov. "The uniqueness lies precisely in the selection of such precise equipment and, most importantly, in the ability to work with it, measure parameters, convert them into software, and ultimately produce an automatic test protocol."

Moreover, Novomet's testing stands represent a fully proprietary assembly production, offering a wide range capable of testing the entire spectrum of submersible and surface equipment from measurement engine blocks to control stations, as well as associated technological equipment for assembly productions and service centers designed to ensure service and operation of submersible and surface equipment.

IT Optimization in Action: How to Make Well Operations Most Efficient

Novomet offers a comprehensive system of software solutions for production management.

“Today, the entire oil industry is focused on optimization,” notes Alexander Sorokin, Project Manager of PumpSite at Novomet. “It is essential to evaluate and plan how to make the extraction process more efficient and cost-effective not only from the equipment perspective but also regarding IT products right from the exploration stage. During development, geologists learn about the current well conditions. Based on this data, it is possible to select equipment and forecast how it will perform under the given conditions.”

One of Novomet's promising programs is PumpSite. This equipment selection program can serve as an excellent alternative to long-established software that has set industry standards. Unlike those, PumpSite is a modern web application that is rapidly evolving and open to new developments. Today, it helps over 200 users in Russia and abroad quickly, effectively, and conveniently select the appropriate equipment.

The program allows users to select the main components of ESP (pump, motor, hydraulic protection, cable) and surface equipment (control stations), consider devices for gas handling (gas separator, gas stabilizer, multiphase pump), and determine the parameters of the gas-liquid mixture in the well. Users have access to a vast array of parameters and a large database of equipment based on both Russian and international standards, with the option to input any custom equipment.

The application is accessible from anywhere in the world with internet access. Calculations occur instantly. The server is protected by the latest security technologies, ensuring high confidentiality of data. PumpSite features a modern interface with flexible settings tailored to user needs, including calculation configurations. There is operational user support (issues are resolved promptly) and a unified information space for data exchange within the company, available to all participants in the process without the need for file transfers.

Among other software solutions is the Novomet Track hardware-software complex, which provides complete remote access to the ESP control station from anywhere in the world via a secure internet connection. The system allows monitoring of installation operating parameters and changing its operating mode as if the operator were directly in front of the control station. This includes not only remote control of pump operation but also maintaining a history of changes in operating parameters and visualizing these changes in graphical and tabular formats.

Stat Pro is a reliability assessment program for submersible equipment. The software utilizes extensive modeling capabilities to predict the operational lifespan of ESP based on well parameters and reservoir characteristics. Accurate forecasting enables proactive planning to reduce downtime and production losses. Additionally, results from Stat Pro can be used to select ESP without being tied to a specific well or to tailor them to the conditions of a particular well.

Impala - a reliable solution for a wide range of flow rates

To achieve maximum production in conventional and challenging wells with unstable or rapidly changing inflow, Novomet offers flexible and high-performance Impala ESP systems.

Novomet's ImpalaESP consists of electric submersible pump (ESP) installations that include a specialized line of pumps with an extended operating range. This allows the use of a single installation instead of having to replace the ESP when production levels change. The system is ideally suited for wells with rapidly declining inflow and sharp fluctuations, complex shale oil fields, late-stage development fields, and reservoirs with low permeability.

The wide range of the Impala ESP is achieved due to low axial force and improvements in pump design. The design of the Impala pump stages features special unloading systems that include a combination of slot seals, vortex blades, and unloading ports, which reduce axial force, thereby decreasing wear on the thrust bearings and extending the service life of the installation.

"It is also very important that we use a more wear-resistant material for the production of ImpalaESP," says Novomet's chief designer Konstantin Saveliev. "We carefully studied the operational experience of corrosion-resistant pumps in shale oil fields and concluded that, in addition to changing hydraulic parameters and stage design, it is necessary to replace the material of the working components. This led us to use steel, which was previously only used in the aviation industry. This material has excellent mechanical properties and high wear resistance. For example, its yield strength and tensile strength are four times superior to those of the previous material, and its abrasion wear resistance is 40-60% higher. The transition to this steel has enabled operation under more severe conditions."

Novomet's ImpalaESP is available in three modifications – a basic model with a mechanical impurity content limit of up to 500 mg/l, a wear-resistant model up to 1 g/l, and a model for ultra-heavy operating conditions up to 3 g/l. The company's specialists have developed a unique range of wide-range pumps – together they can replace 20 sizes of serial analogs. This simplifies the selection of ESPs for wells and increases the profitability of service projects by reducing the inventory of pumps of various sizes.

Additionally, ImpalaESP features high efficiency maintained over a wide range of flow rates. The operational life of these pumps exceeds 700 days, with some long-lasting models achieving nearly 1800 days.

Wide-range ESPs can be equipped with either a valve or an asynchronous electric motor, allowing them to work with existing control stations, as well as pre-installed devices for gas handling if necessary.

As a result, Novomet's ImpalaESP offers a broad operating range, increased wear resistance, high efficiency, and reliability in harsh conditions. All these factors contribute to improved profitability in equipment operation and service maintenance.

Reliable Power Supply for ESP on Land and Under Water

A crucial component of any submersible pump installation is the cable, through which electricity is supplied to the well. Novomet has its own cable manufacturing facility, launched in 2021. This leads to a reduction in the cost of a complete installation, shorter production times, and guarantees timely product delivery.

"The cable was the last major product we were purchasing from outside, but after launching our own production, we ensured 100% manufacturing of all key components of complete installations," says Yuri Vinogradov, head of cable production at Novomet. "Today, we fully supply our branches both in Russia and abroad with cables. We use the most modern materials and maintain a high level of quality control. The reduced insulation layer significantly lightens the weight of the product, which is one of our competitive advantages in the market."

The submersible cable from Novomet is designed for powering submersible motors with a maximum operating voltage of up to 5000V AC and a frequency range from 50 to 400 Hz. Its applications include mechanized oil extraction, water injection into reservoirs, and intra-well pumping, as well as the operation of offshore fields, water intake wells, and geothermal wells.

The cable can be used both as part of an extension cord and for the main cable line in deep wells with complex characteristics—high temperatures of the surrounding working fluid, high water content, acids, salts, and other aggressive substances, increased intra-well hydrostatic pressure, and high gas factors. A wide range of sizes for cable extensions allows their use in any ESP from size 2A to size 9.

The special durability of the cable is achieved through a protective armor for various operating conditions, which reduces the number of failures when lowering installations into horizontal boreholes. The cable is resistant to temperatures ranging from -60 to +232°C. It can be manufactured according to individual parameters depending on the working environment conditions—corrosion-resistant designs, increased corrosion resistance, and resistance to stress corrosion cracking, particularly in especially challenging wells.

Higher reliability is ensured through the use of new heat-resistant electrical insulating materials, as well as through continuous improvement of the technological processes in their manufacturing.

Today, Novomet's production capacity is designed to produce 180 km of finished high-temperature submersible oil cables per month. The production lines are capable of manufacturing all sizes of submersible oil cables used for mechanized extraction. In the future, plans are in place to double the cable production capacity.

Universal downhole dosing unit – a universal assistant in the fight against salts and corrosion

Damage to submersible pump installations due to salt deposits and the carryover of insoluble solid particles from the reservoir remains one of the main factors complicating oil production. Novomet offers a comprehensive solution to this problem – the use of salt deposition inhibitors, filters (previously discussed here/link), and separators, as well as various design implementations.

"The formation of salts in the well occurs due to the supersaturation of water with poorly soluble salts when there are changes in temperature, pressure, pH levels, gas release, or mixing incompatible liquids. Salt is dangerous because it precipitates on equipment, mainly on pumps," explains Novomet process engineer Dmitry Savakov. "To protect against this, oil workers have several methods – physical, chemical, and technological. Today, the most effective method is chemical technology – the use of salt deposition inhibitors. They are introduced into the reservoir fluid and suppress the growth of salt and corrosion crystals. The best way to deliver them to the well is through containers installed beneath the submersible electric motor. Their advantages lie in the simplicity and convenience of installation and low operating costs."

The universal downhole dosing unit consists of a cylindrical body containing the inhibitor and a dispenser that controls the uniform flow of the mixture for at least a year. The technology operates without additional equipment and without human control, which enhances the efficiency of servicing wells in hard-to-reach areas. The location of the container at the bottom of the installation protects not only the pump but also all equipment, including safeguarding the motor from overheating.

A fundamental feature and advantage of the universal downhole dosing unit design is the placement of the dispenser on the container lid. This allows it to be used in simultaneous-separate operation when, due to the presence of a packer, it is not possible to dose the inhibitor from the surface.

The container is called universal because it can work with both solid and liquid fillings, as well as with chemistry against salt deposition and corrosion. Inhibitors in capsule form have become particularly widespread since their active base dissolves gradually rather than immediately. The design of the container for encapsulated inhibitors was proposed to reduce reagent consumption at the initial stage and to ensure a long-term stable supply of inhibitor into the reservoir fluid. This technology has undergone pilot industrial testing and has proven successful in operation with submersible electric pumps (ESP) at fields, with operational durations reaching up to 600 days or more. It can also be used in horizontal wells.

Thus, dosing units are installed in a single operation with the ESP, making them one of the most effective and economical solutions for preventing salt deposition and ensuring longer operation in the well.

ESP downhole disc filter – Reliable Protection for Long-Term Operation of Submersible Pumps

More than 60% of problems with submersible pumps arise due to the presence of solid mechanical impurities in reservoir fluids. They damage equipment, reduce production volumes, and incur additional maintenance and repair costs. The most common method of combating mechanical impurities has been the use of wedge filters; however, these devices are prone to rapid clogging and do not guarantee reliable protection for the installation.

Specialists from Novomet have developed a new volumetric device - ESP downhole disc filter. The design consists of a set of mesh rings mounted on a perforated shaft, which are manufactured using stamping. The size of the cells is chosen based on the required filtration fineness - 100, 200, 300, or 500 microns. The filtering element is made from corrosion-resistant material. The design of the filter is protected by a patent.

- The main advantage of the downhole disc filter is that filtration occurs not only on the surface but also inside the filter itself – in the mesh cells. In wedge filters, particles are retained only on the surface, allowing smaller clay particles to freely enter the pump and clog it, leading to faster blockage, - explains Yuri Korotkov, head of the design bureau for submersible pumps at Novomet. – At the same time, the downhole disc filter, providing high protection against mechanical impurities and extending the service life of the installation, wins in dimensions. Its length is 3-4 times shorter while maintaining the same necessary flow rates. Reducing metal consumption decreases weight and increases the overall resource of the submersible pump.

As a result of bench tests comparing clogging in wedge and disk filters of equal length with solid particle sizes of 0-200 microns, it was found that the throughput of the disk filter is 6-8 times higher. This is explained by the high specific area of open cells. The disk filter increases the service life of the submersible pump by 2-3 times, and in some cases even more.

The downhole disc filter easily performs its function in curved wells and in wells complicated by the carryover of mechanical impurities with an average particle diameter greater than 100 microns. It can be part of both compact submersible pumps of sizes 2A and 3 as well as the most common installations of sizes 5 and 5A. The downhole disc filter is mounted on a sealed casing or on the motor base (or Downhole ESP sensors) through a sealing unit.

To extend the service life of the submersible pump and ensure uninterrupted operation in the well, the filter can be equipped with a safety valve if necessary. This helps eliminate the risk of motor overheating during clogging of mesh disks. Additionally, one of the important advantages of the downhole disc filter is regeneration and multiple reuse. During scheduled maintenance or other instances when the installation is lifted to the surface, the filter can be cleaned and reused.

Overall, Novomet's downhole disc filter is currently the most successful and effective solution for protecting well pumps from mechanical impurities while maintaining reduced dimensional length and low hydraulic losses.

Rotary displacement cylindrical pumps - New Solutions for Extracting Heavy Viscous Liquids

Recent studies show that nearly half of the world's oil reserves consist of viscous and bituminous liquid deposits, with recovery rates ranging from 5% to 30%. Various technologies have been employed for its extraction, including cold production with mechanical admixtures, steam-assisted gravity drainage, open-pit development, and others. However, all of them are inefficient and create additional problems that reduce profitability.

Novomet has developed a solution unique to the market – a rotary displacement cylindrical pumps for extracting high-viscosity oil. This volumetric machine has become an excellent alternative to screw and rod pumping units, which significantly underperform in conditions of high mechanical impurities, gas content, and declining pressure. Additionally, the Rotary displacement pumps can replace electric submersible pumps (ESP) when operating at low flow rates (intermittent mode).

The configuration of the Rotary displacement pumps is similar to classic electric submersible pump systems, but compared to them, the Rotary displacement pumps eliminates operational interruptions caused by low inflow and high gas factors without additional pre-installed devices. It differs from screw pumps in that it uses components in its design that are resistant to aggressive environments, reducing wear and the likelihood of breakdowns. Advantages over rod pumps include a smaller footprint and dimensions, the ability to operate at depths of up to 3000 meters, no need for regular maintenance, and reduced risk of damage to sucker rods. Installation is standardized and does not require additional qualifications.

The volumetric rotary pump is designed for pumping liquids with a viscosity range from 20 to 5000 cSt. It is produced in sizes 5 and 5A. Its areas of application include wells with high-viscosity oil, low-flow wells, and wells complicated by mechanical impurities. It works excellently in wells with low inflow rates of 5-50 m³/day at temperatures up to 170°C. Moreover, the higher the viscosity of the oil, the better its efficiency, which increases extraction effectiveness without the need for complex and costly technologies.

"Today we are working on enhancing the uniqueness of our equipment and increasing the liquid pressure generated by each stage of the pump; we are conducting additional experimental tests," says Andrey Orlov, head of the design bureau for volumetric pumps and filtration systems at Novomet. "Increasing the pressure will reduce the number of stages and, consequently, the length of the pump, decrease material consumption and the risk of premature failure, as well as reduce power consumption per stage, which in turn will lower energy consumption."

Thus, the Rotary displacement pumps by Novomet is an entirely new pump design that provides excellent performance indicators such as output, efficiency, long service life under low flow conditions and heavy oil extraction, despite complications from mechanical impurities and high gas content.

Novomet is excited to participate in the SPE Middle East Artificial Lift Conference and Exhibition

On October 29-30, the 6th SPE Middle East Artificial Lift Conference and Exhibition will take place at the Gulf Hotel in Manama, Bahrain. This annual key event is essential for clients, manufacturers, and providers of artificial lift technologies for staying informed about technological advancements, networking with industry leaders, and gaining insights tailored to the Middle Eastern market.

The theme of the 2024 conference will be "Towards a Sustainable, Efficient, and Reliable Artificial Lift," highlighting the critical role of the oil and gas industry in ensuring global energy security. As the world progresses towards energy transition, Artificial Lift technologies remain essential in supporting the supply of both conventional and emerging energy sources. By enhancing the effectiveness and efficiency of Artificial Lift applications, the companies can contribute to global efforts to reduce greenhouse gas emissions and support energy security.

The event participants will discuss the topic of exploration cutting-edge innovations and addressing challenges in Artificial Lift, with a focus on advancing a sustainable future. An extensive technical program is planned.

This year, Novomet is proud to feature presentations by esteemed speakers: Sergei Nesterov will present "Ultra Slim ESP - Extending ESP Application," and Evgenii Zamesin will discuss "Variable Speed Drive In-Field Upgrade to Operate PMM."

We warmly invite you to visit us at booth #11. Join us to discover the latest developments at Novomet and share your requirements with our team. We look forward to meeting you!

Novomet at ADIPEC 2024 – We invite you to visit our booth

From November 4 to 7, the largest international event in the oil, gas, and petrochemical industry, the ADIPEC 2024 Exhibition & Conference, will take place in Abu Dhabi at the Abu Dhabi National Exhibition Center (ADNEC).

ADIPEC brings together communities, countries, and industries from around the world, fostering collaborative actions in the industry towards providing affordable, safe, and sustainable energy for all. The success of the exhibition is supported by strong partnerships with governments and national and international oil companies.

The 2024 exhibition will focus on exploring energy opportunities in accelerating transformations across the entire economy that benefit people and the planet as a whole. Over four days, ADIPEC will facilitate important dialogue and collaboration across various sectors – from energy, technology, and finance to maritime transport, logistics, manufacturing, and transportation – which are essential for advancing the energy transition and accelerating climate action.

This year, over 70 leaders in the oil and gas industry will be exhibitors at ADIPEC, with an exhibition area exceeding 100,000 m².

Novomet will be represented at booth No. 13195. We invite you to visit our booth, where our specialists will be happy to share information about the company's capabilities and products and answer any questions you may have.

SlimLine – the smallest installations for the most challenging wells

For cases where well operation involves lowering equipment into a «narrow» casing or navigating complex sections, such as transitioning from a larger diameter casing to a smaller one or lowering a pump into a lateral bore, Novomet offers a solution – the SlimLineESP equipment line in sizes 2A and 3.

SlimLineESP allows operation in lateral bores and production casings of 102 and 114 mm. These are small-sized electric submersible pumps (ESPs) with cross-sectional dimensions of 82 mm and 95 mm, respectively. Due to their compact size, they easily navigate complex curved sections, ensuring safe equipment lowering into the calculated suspension zone and trouble-free operation during the warranty period. SlimLineESP equipment can also be used as part of bypass systems like Y-tools in casings from 146 mm, where geophysical studies are required, and in dual systems for simultaneous-separate operation of multiple reservoirs.

The small-sized ESPs are powered by a high-speed valve motor of 81 mm on permanent magnets, which, combined with special algorithms from the control station, reduces energy losses. Novomet offers a wide range of valve motors, both single-section and two-section, with rated power from 20 to 200 kW. Additional equipment is used for protection against mechanical impurities – slotted and disc filters; to combat salt deposition – containers with inhibitors; and to manage gas – pre-installed devices (multiphase pumps, gas separators, gas stabilizers). Novomet specialists have developed a broad range of energy-efficient pre-installed devices for sizes 2A and 3, allowing reliable operation at speeds up to 8000 rpm.

Additionally, the company has developed a unique design of a volumetric action filter, which is more efficient than standard slotted filters. Its distinctive feature is that filtration from mechanical impurities occurs both on the surface of the filter itself and directly inside between the discs. As a result, it is shorter and, due to its unique design, more repairable. The filter is produced in size 81 – specifically for ESPs of sizes 2A and 3.

Overall, Novomet's SlimLineESP line is the most extensive on the market – with five sizes in 2A and six sizes in 3. The pump rotation speed ranges from 3000 to 6000 rpm. The average operational life is over 500 days, with more than 1,500 implementations for each size. Operational practice shows that this is a proven and reliable serial equipment today.

- A new improved model of the installation is currently under development with a motor rotation speed of 7200-8000 rpm, - reports Novomet's chief designer Konstantin Saveliev. - This will significantly reduce the length of the installation, making it possible to master wells with more curved sections.

Thus, Novomet's small-sized ESPs represent a new installation design with the widest range of pumps, valve motors, and pre-installed devices that ensure operation in challenging conditions with confirmed high reliability.

Geyser - Earth's Heat for Future Technologies

Geothermal energy is a highly promising field based on the use of hot water from the Earth's depths to generate energy, and it is considered the most stable among alternative energy sources. Currently, the majority of geothermal deposits consist of flowing wells, but reservoir pressure is rapidly declining, prompting consumers to seek solutions for mechanized extraction. Most submersible pumps either fail under high-temperature conditions or consume significant amounts of electricity.

To address the challenge of cost-effective operation of geothermal fields, specialists at Novomet have applied their extensive experience in the development and production of submersible electric centrifugal pumps, which has been proven reliable and effective in oil well operations. Now, this enhanced technology is applicable to even harsher, extreme conditions of geothermal water extraction, says Sergey Stolbov, Deputy Director of the Department of Innovative Developments at Novomet.

The Geyser systems for geothermal waters are equipped with heat-resistant components and filled with high-temperature motor oils. Additionally, they feature tandem hydraulic protection and two independent thrust bearings for increased reliability. The equipment can withstand temperatures up to 230 degrees Celsius, is resistant to aggressive environments, and can operate at depths of 1400 meters or more. The performance reaches up to 12,000 m³/day, with a service life exceeding a thousand days.

Renewable energy obtained from geothermal deposits is used for generating electricity at geothermal power plants or directly for heating and hot water supply, including greenhouse heating.

The Geyser technology not only ensures reliability but also significantly reduces energy consumption—resulting in a 25% savings in electricity. Consequently, this increases the service life and maintenance intervals while enhancing operational efficiency. Practical experience shows that the use of Geyser systems with a valve motor reduces specific energy consumption by up to two times for clients. Furthermore, the technology contributes to a decrease in CO2 emissions into the atmosphere.

In summary, high-performance geothermal pumping systems from Novomet provide reliable delivery of high-temperature formation fluids, feature a wide range of flow rates designed for operation under extreme temperatures, and ensure substantial energy savings, ultimately increasing the efficiency of electricity generation on the surface.

PowerSaveESP – A Complex Technology for Reducing Production Costs

Up to 61% of the energy consumed by a standard ESP system is lost to heating the fluid and equipment, with only 39% of the power used directly for hydrocarbon extraction. This is typical across the industry, and oil companies have long been working to reduce specific energy consumption. Various methods are employed, such as using high-voltage motors in the ESP systems, pumps with higher efficiency, changing equipment selection criteria, and others.

Novomet has taken a step further by creating the PowerSaveESP technology – energy- efficient installations. Its uniqueness lies in a complex approach that enables maximum reduction of oil extraction costs.

Firstly, it involves the proper selection in specialized software and operating equipment at maximum efficiency, which is ensured through special control station algorithms. Specialized software can define precise parameters for conditions and select an installation that will operate at the point of maximum efficiency.

Secondly, operation at high speeds (over 3000 RPM) has been researched at the company to determine the impact of rotational frequency on ESP efficiency. Tests confirmed that higher pump speeds lead to increased efficiency and head, allowing for a reduction in ESP length by up to 60%. An effective design simplifies installation, placement in wells, and replacement.

Thirdly, the installation incorporates pumps of a new design and valve electric motors. Energy-efficient pumps feature more complex, optimized geometries that reduce losses and increase stage efficiency by 10-15 points. A reinforced construction is used for operation at elevated rotational frequencies, ensuring necessary reliability. The advantages of valve motors are well-known – a wide range of regulation, lower losses, reduced heat generation, and consequently, higher efficiency.

Additionally, as part of the comprehensive approach to combat gas issues, solutions such as additional energy-efficient pre-installed devices – gas stabilizers and gas separators – are utilized. These devices are characterized by increased wear resistance and reduced energy consumption. The claimed specifications are confirmed by full resource testing and real-world operating conditions with clients.

All these solutions in total can reduce the energy consumption of ESP systems by 25- 30%, and in some cases, up to 35%. Furthermore, the pumps and motors included in the PowerSaveESP system manufactured by Novomet have a high energy efficiency class specified in their documentation and may qualify for various tax incentives. Novomet’s PowerSaveESP installations offer a very wide range, produced in sizes from 2A to 8 with flow rates ranging from 15 m³/day to 4000 m³/day.

- Thus, switching to energy-efficient ESP systems will reliably save up to 25% of electricity when lifting fluids from wells, - summarizes Novomet's Chief Designer Konstantin Saveliev. - It will enhance the reliability of submerged equipment, especially in challenging conditions, allow for stable operation at maximum efficiency or maximum extraction rates, and ultimately increase production volumes through effective selection.

FOR NOVOMET-CANADA, 2023 MARKS THEIR 10-YEAR ANNIVERSARY!

Starting from zero in a small shop in Devon, Alberta was no easy task. Over the years, the Canadian operation tripled the shop space and doubled the staff size. In 2017, Novomet-Canada started in-house VSD assembly. In 2019, a new Novomet service center was opened in Weyburn, Saskatchewan to better serve our Saskatchewan clients.

Small but very experienced team, the company’s commitment to learn, grow, execute, and lead the way to sustainable positive changes helped strengthen the team, empower a growth culture, and create long-term value for both the employees and the company.

The Novomet PowerSave technology reduces energy consumption by up to 30% which significantly reduces CO2 emissions and electrical operating expenses. Over the years, the demand in Canada for sustainable and power-save technology continued to increase. Building a strong local presence and ESP well count in Alberta and Saskatchewan, Novomet PowerSave ESP’s are experiencing above average run-life cycles and quickly becoming a very desirable option for O&G companies due to economic challenges such as higher electricity prices, lower oil prices and inflation.

We would like to express our gratitude to our customers who were pioneers and early-adopters in the implementation of the Novomet SlimLine and PowerSave ESP. We also want to thank the entire Novomet-Canada team for their high professionalism and excellent results. We are proud of you! Congratulations to the whole team and our local partners for this amazing milestone. The best is yet to come!

Novomet-Egypt celebrates its 10th anniversary

Novomet-Egypt is a young, but rapidly growing company.

Its history began in 2012 with the first installation of slimline ESP of 319 series equipped with permanent magnet motor for sidetrack operation, which was performed in the MENA region specially for Eshpetco Company. This equipment had reached almost 1200 days of run-life. The article SPE-184195-MS covered these developments was released in 2016 at the conference in Bahrain.

Nowadays, more than 100 ESP systems are in operation, which is about 12% of Egyptian market share and it's only the beginning. Novomet products are in high demand thanks to the quality of equipment and provided services as well asthanks to the unique technologies in its portfolio: Power-Save equipment with permanent magnet motors (50% of Egyptian wells stock , energy saving is about 25-30% compared to peers), slimline equipment (272, 319 series), solutions for wells with high gas-oil ratio (gas separators, multiphase pumps, advanced gas handlers), solutions for solids management (filters) and scale management (solid/liquid inhibitors), ESP systems with extended operating range (Impala ESP).

Company’s office is located in Cairo and assembly facilities, which are one of the most modern workshops to assemble ESP systems in the country and throughout the African continent, are located in Alexandria. Moreover, in Alexandria Novomet has a Test Center dedicated to testing of VSDs by of different brands to check compatibility with permanent magnet motors by Novomet origin. As well Novomet has a Training Center, where both Customers and Novomet employees are trained to operate ESP systems, courses are available in English and Arabic and for various levels of competency.

We are proud of Novomet-Egypt! We would like to express our gratitude for a major contribution to Novomet-Egypt growth and achievement to our esteemed Customers and Partners, to the whole team and especially to
Wael Sayed (Country Manager), Ossama Abu-Hozifa (Sales and FS Manager), Nikolai Kurlykin (BD & Application Engineer) and Hany Elsayed (Assembly Base Manager).

ColibriESP on the Malaysian offshore.

News about the implementation of ColibriESP technology on the offshore.
We recently talked about the installation of Novomet systems on a platform in Qatar.
Today news from Malaysia is on the agenda.
On the offshore platform of Petronas, located near the city of Miri in the Tukau field, three 272 cable-deployed rigless ESP systems were run into gas lift wells (ColibriESP technology by Novomet).

The installation was carried out using advanced technologies in the field of downhole and surface equipment. The shut-off and flange fittings are equipped with automatic remote control subsurface safety valves.
The peculiarity is that the procedure was preceded by the dismantling of the previous equipment, accompanied by well killing. This is the first time this has been done at offshore fields. The new equipment has been put into operation. The customer is completely satisfied with the quality and reliability and is ready for further implementation in their fields.

2021 ESP Symposium

Natalia Lykova, Deputy Vice President for Alternative Energy delivered a presentation to the Society of Petroleum Engineers.

The presentation included lessons learned through our experience running permanent magnet motors and ESPs in geothermal wells. It generated many questions and interest from engineers in attendance.

Permanent magnet motors were a major focus at the SPE Gulf Coast Section Electric Submersible Pumps Symposium that took place in The Woodlands, Texas in October. Lykova shared with attendees the steps Novomet has taken to modify our PMMs and develop downhole pumping systems that stand up to the harsh conditions of geothermal wells.

Natalia Lykova : "It was so exciting to see all the biggest companies in one place. We saw a huge interest to geothermal project. I believe participation in SPE will bring us a new implementation of geothermal submersible pumps in USA market. I'm proud of being part of the Novomet and it was honored for me to do a presentation in SPE conference".

Learn more about Novomet geothermal pumping systems here /products-services/renewable-energy-solutions/geothermal-pumps/

Wil Faubel Named President of Novomet USA

Novomet announced today that Wil Faubel has joined the company as President of Novomet USA. In this newly created role, Wil will be responsible for guiding company strategy in the US to impact growth. He has more than 40 years of leadership experience in oil and gas with positions at Hughes Christensen, Centrilift, Baker Atlas, Baker Hughes Corporate and Borets among others.

“We are pleased to welcome Wil Faubel to the Novomet family as President of our US operations. As a highly respected executive in oilfield services and artificial lift, Wil is a transformational leader with a strong track record of delivering significant growth,” said Polina Plotnikova, Vice President International, Novomet. “His leadership and industry experience, client relationships and organizational development expertise will be an invaluable resource for our US team as we continue to grow in North America.”

Wil joins Novomet from Borets, where he spent the last four years as Senior Vice President and President. Before joining Borets, he was Chief Commercial Officer and Senior Vice President of Global Business Development for MHWirth, formerly Aker Solutions Drilling Technologies. Wil holds a Bachelor of Science degree in Mechanical Engineering from Southern Methodist University.

Novomet presents innovative technologies for oil production and energy at EGYPT PETROLEUM SHOW "EGYPS 2020".

International exhibition and conference takes place on February 11-13, 2020 at the Egypt International Exhibition Center in Cairo.
We invite you to visit the Novomet Group stand!

Geyser High-Flow, High-Temp ESPs Deployed in Geothermal Wells in Turkey, Cut Electrical Usage by 28%

Geothermal power plants use water naturally heated by the earth to generate electricity. Geothermal energy is clean, renewable, and helps reduce carbon emissions related to power generation. But harsh conditions in geothermal wells cause many downhole pumps to fail prematurely. Typical geothermal well environments feature:

• Reservoir temperatures up to 200°С (392°F)
• Conditions prone to active scale accumulation

In 2018 and 2019, Novomet engineers used decades of knowledge and experience gained through deploying electrical submersible pumping (ESP) systems in harsh oil and gas wells to begin developing a cost-effective geothermal pumping system. This newly adapted geothermal ESP system featured heat-resistant, corrosion-resistant pumps and permanent magnet motors, which consume less electricity and produce less heat than downhole induction motors. Geothermal fields in Turkey provided the challenging conditions needed for Novomet to pilot its geothermal pumping systems. After initial development and lab simulations, Novomet engineers began installing and testing geothermal ESPs in wells across Turkey.

Novomet geothermal ESP systems performed well despite the harsh conditions. After seeing how successful the first systems were, Novomet began standardizing the design so it could be offered as a new line of pumps. Because of the massive volume of water required in geothermal operations, Novomet made additional design improvements, including high-volume, high-performance pumps and high-power permanent magnet motors. The result is the high-temperature, high-flow Geyser geothermal ESP.

In November 2019, three more Geyser geothermal ESPs were installed in Turkey. These systems have the ability to produce fluid at the rate of 10,000 m³/day (2.6 million gal/day) and they are powered by highly efficient 660-kW permanent magnet motors. These three systems are still running perfectly and bring the total count of Geyser ESP systems in operation in Turkey to 21. Despite geothermal fluid temperatures ranging from 155–195°C (311–383°F) Geyser systems have now been in operation for more than 380 days.

Because Novomet ESP designs are more efficient than competing systems, Geyser ESPs have also reduced the electricity required to pump a cubic meter of water in geothermal operations. The closest competing geothermal pump in Turkey uses 1.25 kWh per cubic meter of produced water, while Novomet Geyser systems consume only 0.9 kWh to lift the same volume of water. This reduces ongoing power consumption and costs by 28%, further supporting the goal of reducing carbon emissions.

Finding cost-effective, alternative energy sources remains a high priority for countries and companies alike in a joint effort to curb the increase in global average annual temperatures. Geyser ESP systems not only support sustainable geothermal energy initiatives to reduce greenhouse gas emissions, but they also reduce energy consumption by lowering the power required to produce geothermal fluids. Novomet is an active supporter of the Paris Agreement and is proud to join other technology-forward companies in the hunt for alternative, green energy solutions.