A leading global oilfield services provider faced significant reliability issues when stators, electrical connectors, and sealing systems within their ESPs were failing. Their existing material solution—machined from polyimides—presented multiple problems.
- Thermal Degradation: The material’s electrical insulation properties declined at elevated temperatures.
- Water Ingress: Even minor exposure to moisture led to performance failures.
- Manufacturing Limitations: The incumbent polyimides were only available in rod stock form, requiring extensive machining, leading to longer lead times and higher costs.
With ESPs' reliability on the line and operational expenses rising, the oilfield services company sought a superior material solution that could withstand these conditions while enhancing long-term performance and cost efficiency.
A Breakthrough in ESP Insulation: Arlon 3000XT®
Recognizing the urgent need for a more durable, high-performance insulating material, Greene Tweed (GT) initiated an extensive root-cause analysis in 2023.
Their goal: To find a solution that would address the application constraints while delivering superior thermal, mechanical, and electrical insulation properties.
After a multiphase material testing program, Arlon 3000XT, a patented crosslinked PEEK (polyetheretherketone) thermoplastic, emerged as the optimal choice.
Unlike traditional materials, Arlon 3000XT is engineered to thrive in extreme oilfield conditions—offering exceptional electrical insulation, high-temperature resistance, and enhanced durability in high-pressure, high-moisture environments.
The Science Behind the Solution
The validation and qualification process for Arlon 3000XT was rigorous, ensuring that the material not only met but exceeded industry expectations. Key testing phases included:
1. Coupon Testing for Material Qualification
The first step in validating Arlon 3000XT was coupon testing, assessing its thermal stability, electrical insulation properties, and moisture resistance. The results confirmed its ability to withstand temperatures ranging from 260°C to 300°C ( 500°F to 572°F), while maintaining mechanical and electrical integrity.
2. Machined Prototype Verification
Once the baseline properties were validated, GT engineers produced machined prototypes for further testing. This phase was critical in ensuring that real-world ESP conditions would not compromise the material’s form, fit, and function.
3. Injection Molding for Production Efficiency
Unlike polyimides, which required time-intensive machining, Arlon 3000XT enabled the production of injection-molded components.
This breakthrough in manufacturing led to:
- Greater design flexibility—allowing for custom-molded shapes that optimized ESP insulation and sealing performance.
- Faster production cycles—reducing lead times.
- Lower material waste—resulting in cost efficiencies.
The Real-World Impact: Enhanced ESP Performance and Lower Costs
The final validation phase demonstrated Arlon 3000XT’s real-world advantages in ESP applications. Upon integrating the material into their downhole electrical components, the oilfield services company recorded immediate and long-term benefits.
- Improved ESP Reliability—Enhanced electrical resistance at extreme temperatures minimized system failures.
- Waterproof Insulation—Custom-molded designs eliminated water ingress, solving a major performance risk.
- Reduced Total Cost of Ownership—The combination of superior performance and efficient manufacturing cut overall operational costs.
- Shorter Lead Times—Injection molding streamlined production, allowing for quicker deployment and maintenance.
With these demonstrated improvements, the oilfield service company made a full transition to Arlon 3000XT for all ESP insulation components—ensuring more reliable artificial lift operations while achieving significant cost savings.
Why Arlon 3000XT Stands Out in Artificial Lift Applications
Not all high-performance polymers are created equal. Compared to competitors, Arlon 3000XT delivers unmatched benefits in artificial lift applications:
- Patented Crosslinked PEEK—Specifically formulated for high-temperature, high-pressure oilfield environments.
- Proven Long-Term Durability—Withstood 300°C conditions and 112 days of fluid aging (ASTM D638 testing).
- Exceptional Electrical and Mechanical Properties—Maintains integrity in the presence of harsh chemicals, moisture, and extreme thermal cycles.
- Optimized for Injection Molding—Enabling custom designs that enhance ESP performance and longevity.
Future of Artificial Lift Technology: Smarter Materials, Better Performance
The success of Arlon 3000XT in ESP applications underscores the critical role of advanced materials in optimizing artificial lift performance. As oilfield operations continue to push the limits of temperature, pressure, and production efficiency, innovative solutions like Arlon 3000XT® will shape the future of downhole technology.
For operators looking to enhance reliability, efficiency, and cost-effectiveness in ESPs, the question is no longer if material upgrades are necessary—but how soon they can be implemented.
🔗 To learn more about how Arlon 3000XT® can transform your ESP operations, contact our engineering team today.
