Case Study

Non-Metallic Materials Selection Review and Failure Analysis for Progressive Cavity Pumps

Client

ConocoPhillips

Location

North Sea, UKCS

Background

ConocoPhillips is a multinational energy company with operations in the exploration and production of oil and gas. The company operates in several locations around the world, including the North Sea, UKCS.
The J-Block, one of ConocoPhillips' key production sites, was facing a significant challenge as their production was being impacted by closed drain system outages. The closed drain system stopped functioning due to systematic failures in the pumps, which were attributed to the swelling of the stator material around the rotor. This caused damage to the stator material, pump mechanical seal and gearbox failure, increased production loss, and increased maintenance frequency.
ConocoPhillips needed a solution to reduce the loss of production related to stator failures, and they turned to OGC Energy for help. With expertise in non-metallic materials, OGC Energy was well-equipped to tackle the challenge faced by ConocoPhillips at their J-Block.

Challenge

ConocoPhillips' J-Block was facing a critical challenge as their production was being impacted by closed drain system outages. The closed drain system stopped functioning due to systematic failures in the pumps, which were attributed to the swelling of the stator material around the rotor. This led to damage of the stator material, pump mechanical seal and gearbox failure, increased production loss, and increased maintenance frequency. ConocoPhillips needed a materials team with expertise in non-metallics to reduce the loss of production related to stator failures.

How OGC Energy Helped ConocoPhillips

OGC Energy's non-metallic specialists stepped in to help ConocoPhillips. They carried out a review of the non-metallic materials selection and failure analysis of several failed stators. The team also completed an in-depth compatibility analysis to confirm the materials selection was adequate and demonstrated through a detailed failure analysis that the damage was not due to chemical incompatibility but due to mechanical damage. These results allowed ConocoPhillips to focus on reviewing the process control strategy in the closed drain system and implementing changes that eliminated blockages in the system and prevented damage to the progressive cavity pumps.
The collaboration between OGC Energy and Optimus (Aberdeen) Ltd resulted in the elimination of outages in the closed drain system and an increase in production of hydrocarbons at ConocoPhillips' J-Block.
OGC Energy's expertise in non-metallic materials was critical in resolving the challenges faced by ConocoPhillips. The team's solution reduced production loss and increased efficiency, demonstrating the effectiveness of their approach.

How we help you

Are you an oil and gas operator of ageing assets struggling with production loss due to closed drain system outages? Let OGC Energy help you with their expertise in non-metallic materials and eliminate the loss of production related to stator failures. Contact us today to learn more about our services and how we can help you improve the efficiency of your operations."

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