We started our operations in 2015 and our mission was to increase the Reliability and Run life of Electrical Submersible pump systems used in oil production and in particular Off-shore, Arctic, Desert and thermal applications such as Geothermal and Steam Assisted Gravity Drainage (SAGD).
From day one we charted a course for the company to innovate in design and equipment qualification processes using disciplines and methodologies from sectors other than the oil and gas sector.
With a background in aerospace and energy sectors, where aspects of reliability, availability, and survivability are critical elements in the design, build and qualification processes, we were confident that we will achieve our aims of improving these aspects in the oil and gas equipment too.
As a company, we have used a bottom-up approach by systematically understanding the root causes of the failure modes of ESP systems and come up with effective technical solutions to eliminate these root causes or reduce their impact on the run-life of ESP systems. In particular, we focused on the three key components of an ESP system namely the motor, the protector and cable, and cable termination.
Our team includes some seasoned Oil and Gas equipment design specialists but we have also attracted other disciplines to complement the team’s broad experience.
The aim of our business is to develop the next generation Permanent Magnet motor system that pushes the boundaries of motor technology to improve the rate of recovery while increasing the run life to above and beyond where the existing systems are today.
COREteQ is based in a new purpose-built workshop in Frimley, West London and has a test well and equipment qualification facility in Great Yarmouth.
The company is developing the technology building blocks that will cover the full spectrum of applications with the aim of maximising run life enabling operators to maximise production and return from their assets.
COREteQ Systems’ mission is to MAXIMISE RUN LIFE of the electrical motors used for submersible pumping in the oil and gas. This mission is driven by existing Electrical Submersible Pumps (ESPs) having failures that limit their run life, which impacts the business case for using them in high-value assets such as subsea.
COREteQ Systems has reviewed the available data and engineered solutions that eliminate the failure modes and extend the use of ESP to much harsher and more lucrative segments of oil and gas pumping applications.
Due to the harsh conditions and the extremely high cost of downtime and repairs in downhole applications, an electrical downhole pump system must have a robust construction and high reliability. Compared to traditional induction motor based submersible electric motors, Permanent Magnet Motors (PMMs) have a number of characteristics that make their application more attractive. PMMs which have started to occupy a leading position in a number of industrial sectors, they have better performance characteristics than induction motors.
COREteQ's innovations address the vast majority of failures and focus on the three key components of ESP’s namely; Motor, Protector, Cable and Cable terminations. COREteQ's innovative approach will ensure that the key objectives of enhanced reliability sought by operators are achieved.
Existing Electrical Submersible Pumps (ESPs) typical failure rates of the key components are as follows;
Induction motor 30%
Cable and Terminations 15%
COREteQ addresses the weaknesses of the ESP components in the following way;
The motor employs permanent magnet technology, making the motor shorter and lighter for the equivalent power of an induction machine (3-4x shorter and lighter).
This enables the stator to be “canned”, that is the stator is never exposed to rotor cavity fluids, eliminating this major weakness.
In addition, the stator has a unique motor winding arrangement, where each motor conductor is segregated from every other motor conductor, both through the stator and at the end turns, eliminating another significant weakness.
Insulation rating both temperature and voltage far exceeds best available in class. Specifically, the motor maximum temperature is 400C vs. 280C, similarly, the motor insulation is rated to 13.8KV vs. 5KV.
100% quality testing of every motor at full temperature and rated voltage before shipment, this eliminates infant mortalities.
The power cable is “canned” so both mechanically and chemically isolates the insulation from wellbore fluids. The cable design enables metal to metal terminations at the pot head and any packer or wellhead penetration, ensuring maximum reliability for this part of the system.
The Guardian protects the protector top seal against the harsh environment and extends its life.
OUR VALUE PROPOSITION
Short ESP run life is good for a business model of service companies but is very costly for operators. Major service companies will not drive radical innovations to increase run-life. Oil operators continue to push service companies to enhance their equipment run life with only incremental changes rolled out.
COREteQ Systems’ mission is to MAXIMISE RUN LIFE of critical electrical motors used for submersible pumping in the oil and gas.
By addressing the major failure modes associated with current electrical motors, the end user will see significant increase in run life (estimated at better than 3x life over the best available technology)
The impact of COREteQ’s Innovations to oil production operations are as follows;
More uptime, increasing total production, and cash flow. Average run life is 2-3years. COREteQ target is 3x this. Each day a well can produce 1,000 to 10,000 barrels of fluid, at $50/bbl this represents $50,000-500,000/day revenue.
Reduced Capital Expenditure (CAPEX) Each system is between $250-1,000K replaced every 2-3 years
Operating Expenditure (OPEX) Each workover requires a rig, on land this can be as little as $25K/day, subsea this can be $1,000,000/day. The business case for the subsea use of ESPs with current technology cannot be justified.
Small and agile companies such as COREteQ are better able to provide radical solutions to the run-life challenges.