Breaking Barriers: 350°C Rated Permanent Magnet Motor Design for Electric Submersible Pumps in SAGD wells

Mansir, Hassan (COREteQ Systems Limited) | Rimmer, Michael (COREteQ Systems Limited) | Waldner, Leon (CNOOC International) | Graham, John (Suncor Energy) | Hong, Claire (Cenovus Energy) | Wycislik, Kerry (Cenovus Energy) | Duong, Bruce (Alberta Innovates)

OnePetro 

The development of a High-Temperature Permanent Magnet Motor (PMM) was initiated with the main objective to bring forth a technical solution to significantly increase temperature capability and run life of ESPs in Steam Assisted Gravity Drainage (SAGD) beyond current technology. This is in response to operators needs for improved safety margins and increased production rates. Existing ESP motor technologies are limited to approximately 300 C internal motor winding temperatures, driven by the available motor electrical insulation systems. The use of PMMs in SAGD was also prohibited by the availability of magnet materials capable of operating in such temperatures, without partial or full demagnetization. The project's aim is to break this barrier and extend internal temperatures to 350 C and beyond, allowing well ambient temperatures to be pushed beyond the 260 C downhole environment. In addition, for assurance of motor reliability, rigorous and methodical design validation and qualification testing of basic materials, components, sub-assemblies were undertaken.