12/9/2014

Webinar 5. Electrical Submersible Pumping

(ESP)
Cesar Gomez
Dec 16, 2014

Webinar Series
1. Introduction to Artificial Lift Aug 27 ’14
2. Reciprocating Rod Lift (RRL) Sep 23 ’14
3. Gas-Lift Oct 21 ’14
4. Progressing Cavity Pumping (PCP) Nov 19 ’14
5. Electrical Submersible Pumping (ESP) Dec 16 ’14
6. Hydraulic Lift: Jet Pump & Piston Pump Jan 13 ’15
7. Plunger Lift and Capillary Deliquification Feb 10 ’15
8. Production Optimization for Artificial Lift Mar 10 ‘15

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Presentation Outline
• Electrical Submersible Pumping System
• Advantages, Limitations
• Components
• Pump Curve Reading Example
• Preventing Pump Failures
• ESP Surveillance, Optimization
• Typical Applications

Lift Technologies by Energy Source

Plunger Foam Rod Hydraulic
Gas-Lift PCP ESP Lift
Lift Lift Lift

Leverage Well Energy Add Lifting Energy

© 2014 Weatherford. All rights reserved. 5

Lift Technology by Lift Capacity

Plunger Foam Rod Hydraulic
PCP ESP Gas-Lift
Lift Lift Lift Lift

200 500 5000 6000 35000 60000 75000

Low Medium High

© 2014 Weatherford. All rights reserved. 6

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Poll Question
In which lift technology is the
most money invested?

Poll Question
In which lift technology is the
most money invested?
1. Reciprocating rod pump
2. Gas Lift
3. Progressing cavity pump (PCP)
4. Electric submersible pump (ESP)
5. Plunger lift
6. Hydraulic lift
7. Other

Market Share Amongst Artificial Lift Types

Source: Oilfield Market Report, 2005-

2014, Spears & Associates, Inc.

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Poll Question
Which 2 lift technologies produce the most oil?

Poll Question
Which 2 lift technologies produce the most oil?

1. Reciprocating rod pump

2. Gas-lift
3. Hydraulic lift
4. Electric submersible pump (ESP)
5. Progressing cavity pump (PCP)
6. Plunger lift
7. Other

Electric Submersible Pump

• A High Volume production tool that can operate in deep
wells

• ESP’s are typically packaged systems which are designed by

the supplier and commissioned by the suppliers field
engineers.

• Requires minimal surface space and can operate in very

highly deviated wells

• Requires minimal maintenance during its life cycle.

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Operating Range vs. Casing Size for Typical Oil well

Systems
5000
16000

4500
14000
400 Series
4000

12000
3500

10000
513 Series
3000
Head [m]

Head [ft]

2500 8000
5.50" Casing

2000
538 Series
6000

1500 6.625" Casing

4000

1000

2000
500 7.00" Casing

2000 4000 6000 8000 10000 12000 14000 16000 18000

Flow [BpD]

500 1000 1500 2000 2500

Flow [Cubic metres per day]

Surface Power & Control Equipment

Typical Range Maximum*
Operating
Power
Depth Cable1,000’ - 10,000’ TVD 15,000’ TVD
Operating
Volume 200 - 20,000 BPD 60,000 BPD
Operating
Temperature 100° - 275° F 450° F
Bolt-on Discharge Well
Head bore up to 15°/30m 0 - 89° Pump
Deviation Placement -
<3°/30m Build
Motor Lead Extension Angle
Corrosion Handling Good
Pump
Gas Handling Good
Solids Handling Fair
IntakeFluid Gravity >10° API
Servicing Workover or Pulling Rig
Prime Mover Type
Motor Seal
Electric Motor

Motor Offshore Application Excellent

System Efficiency 35%-60%
Downhole Sensor

Advantages
• High Volume and Depth
Capability
• High Efficiency Over 1,000 BPD
• Strong drawdown
• Minimal Maintenance
• Minimal Surface Equipment
Needs
• Good in Deviated Wells
• Applicable for ≥ 4-1/2” casing
• Ideal for Well Testing / step rates

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Limitations
• Availability of electric power
• High volumes of free gas
• Sand, heavy scale, paraffin, and
particulate matter
• Highly corrosive well fluids
• High fluid viscosity
• Extreme BHT
• Discharge pressures ≤ 6,000 psig

ESP System Application Considerations

Typical Range Maximum
Depth 1,000’ - 10,000’ 15,000’
Volume (BPD) 200 - 20,000 60,000
Temperature 100° - 275° F 450° F
Deviation <10° Build Angle
Corrosion Good
Gas Handling Good
Solids Handling Limited
Fluid Gravity >10° API
Servicing Workover or Pulling Rig
Prime Mover Electric Motor
Offshore Excellent
Efficiency 35%-60%
*Requires special analysis

ESP Animation

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Centrifugal Pump

The term “centrifugal pump” has been used to describe a wide

variety of pumping applications and designs through the years.

Definition: A centrifugal pump is a machine that moves fluids

by rotating them with a rotating impeller within a diffuser that
has a central inlet and a tangential exit. The fluid path is a
spiral that increases from the entrance to the center to the
tangent to the diffuser exit. The impeller transmits kinetic
energy to the fluid. In the diffuser, part of the kinetic energy is
transformed into potential energy (height) by an increased
flow area.

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Centrifugal Pump

A centrifugal pump creates pressure through a series

of rotating blades on an impeller.
The rotational movement forms a partial vacuum
at the impeller suction.
The function of the impeller is to transfer power to
rotating the fluid passing through it, thus raising the
kinetic energy.

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Centrifugal Pump

The diffuser then converts this energy into

potential energy by raising the discharge
pressure.
External forces, such as atmospheric pressure,
push fluid into the impeller eye toward the
periphery of the impeller.

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Centrifugal Pump Dynamics

Hence, the rotating

impeller at high speed,
launches the fluid within
the diffuser.

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Centrifugal Pump
Each stage consists of an impeller and diffuser.

Diffuser
1 Stage

Impeller (rotor)

Diffuser

Centrifugal Pump
Once again, the impeller takes the
fluid and kinetic energy is imparted.
The diffuser converts the kinetic
energy into potential energy
(height).

In summary, the main function of a

centrifugal pump is:

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Electric Submersible Pump

An ESP is a multi-stage centrifugal

pump, containing a selected number
of stages (depending on the
application) equipped with impellers
and diffusers, within their respective
nozzles, arranged in series on a shaft
which is driven by an electric motor .

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ESP Name Nomenclature

• The pump stages are "named" according to:
– "best efficiency point" (BEP) – flow rate at 60 Hz
– Pump Housing Diameter

• For example, a pump stage type 400-1800

describes a pump that:
– The 400 in the name designates an OD of 4 inches
• (other companies use letters such as A, D, G, H, J, K, L, M,
N & P)
– The 1800 designates that the pump is most efficient
at about 1800 BPD when operating on 60 Hz power.

ESP Materials
• Stages
– Standard - Ni-Resist Type 1
– For special applications, such as highly corrosive
environments, handling abrasives, asphaltenes or
scale problems, special coatings and alloys for stages
are available.
• Journal Bearing
– Head and Base – Tungsten Carbide
– Standard Pump – Ni-Resist Type 1
– Abrasion Resistant Pumps – Tungsten Carbide
– Low Lubricity Fluids – Graphalloy

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The Electrical Submersible Pump

System components – The Pump Stage Type

• There are two styles of stages for the range of flow rates in which
ESP’s operate.
1. The first is a radial stage: Its geometry has the flow
2. The secondthe
entering is aimpeller
mixed-flow stage: Itsparallel
or diffuser geometry tohas
thethe
axisflow
of
o
exiting the impeller
the shaft at an
and exiting angle less thanto90the
perpendicular toshaft
the shaft.
or in a
Generally this angle changes
“radial” direction. They arefrom near perpendicular
sometimes referred totoasnear
axial, as the design
“pancake” flow rate ofstages,
or “mushroom” the stage increases
because for a
of the
particular
impellers’diameter-unit.
flat shape and the diffusers mushroom-
shaped down-thrust pedestal.

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The Two Types of ESP Stages

Radial Flow
• High lift
• Short stage length

Mixed Flow
• More gas tolerant
• Long stage length

TOTAL DYNAMIC HEAD (TDH)

• Total Dynamic Head is the

amount of energy a volume of
fluid needs to overcome to
reach the surface.

• Electrical Submersible Pump

imparts energy to the volume of
fluid to produce it to the
surface.

TDH (FT)= WHH ( FT)+ NVL (FT)+H fric. Loss ( FT)

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Pump Performance Curve

Pump Recommended Operating Range

Pump Curve Reading Example

• If the Total Dynamic Head (TDH) required for
an application is 3550 ft, when producing a
flow rate of 9000 BPD.
– How many stages of a 538-8500 pump would we
require? (Operating frequency = 60Hz)
– What would be the pump efficiency?
– How many horsepower would we require,
assuming a fluid with specific gravity of 1.00?

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Pump Curve Reading Example

9000

Pump Curve Reading Example

36

9000

Pump Curve Reading Example

TDH
No. stages = -------------- = # stages required
Lift per stage
3550 ft
No. stages = -------------- = 99 stages
36ft/stg

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Pump Curve Reading Example

73

9000

Pump Curve Reading Example

3.2

9000

BHP Total = 100 stages * 3.2 = 320 HP

Lift Per Stage

Multiple pump stages are used to increase total
dynamic head (lift) capacity.
1 Stage = 29.5 ft of lift
at a given rate

How many pump stages will be

required to lift liquids from 2950 ft?

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Lift Per Stage

Multiple pump stages are used to increase total
dynamic head (lift) capacity.
1 Stage = 29.5 ft of lift
at a given rate

How many pump stages will be

required to lift liquids from 2950 ft?
1. 1
2. 100
3. 50
4. 1000

Centrifugal Pump

Head Bearing Pump Head

Impeller

Diffuser Stage Bearing

(Abrasion Resistant Pumps)
Housing
Shaft

Pump Base Base Bearing

Pump Intake
• The intake section functions as
a suction manifold feeding fluid
to the pump.
• Depending on the fluid
gradient, it can be a “standard”
intake adapter with inlet holes
or a gas separator.
• The use of a gas separator
mitigates potential problems
inherent in wells where
excessive free gas at the intake
pressure may cause the pump
to “gradient lock” and create
thrust problems.

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Pump Intake/Gas Separator/Gas Handler

• The standard intake is used in wells that
produce with a very low free gas or vapor to
liquid ratio (VLR). The amount of free gas by
volume at pump intake conditions should be
no more than 10%-15% for a radial flow stage
and 20%-25% for a mixed flow stage.

• The rotary gas separator will separate free

gas with an efficiency of up to 90% under
some conditions. The rotary gas separator
should be used where the free gas available
at the intake exceeds 10% with a radial flow
stage and 20%-25% with a mixed flow stage.

Multiphase Pumps
• Compresses fluid to reduce gas bubble
size.
• Creates a more homogeneous flow
regime.
• Fluid behaves similar to a single-phase
fluid.
• Installed above Rotary or Vortex gas
separators.
• Improves ESP efficiency and reliability for
gassy fluids

Gas Separator
• Separates free gas from entering
pump
• Rotory or vortex fluid separation
– Heavier liquids move to housing wall
– Lighter gases remain around the
shaft
• The gas and liquid “cross-over”.
– Gas vent to the annulus.
– Liquids enter the pump.

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Motor Seals
• Transfer power from motor to pump
To Intake
• Absorb thermal expansion and pump
Shaft
• Isolate motor from well fluids
• Absorb thrust of fluid column
Bag
Chambers
Shaft
Seals

Labyrinth
Chamber

Thrust
Bearing

To
Motor

Motor Seals
Bag Seal Labyrinth Seal
• Positive elastomeric • Dependent on difference
barrier made of: in specific gravity of the
– Nitrile
well fluid and motor oil to
– Aflas
function
• Benefits
– Positive barrier to well
• Benefits
fluid – Simple
• Limitations – Larger oil volume
– Temperature ≤ 350 °F • Limitations
(170°C) – Setting at angles > 40°
– Aggressive well treatment
– Miscible well fluids
fluids
– Produced fluid sg < .85

Electric Motor
• 2 pole 3 phase Thrust Thrust Runner
induction Bearing
Motor Head

– 3450 rpm @ 60 Hz End Coil

Motor Leads

– 45 to 75 Hz range
• Permanent magnet Rotor

motors Rotor Bearing

Laminations
• Dielectric oil filled
– Lubrication Shaft

– Heat transfer

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Power Cable
• Solid & stranded configurations
– #1 thru #6 AWG sizes
– 3 kv, 4 kV and 5 kV ratings
• Round & flat profiles
• Galvanized, stainless steel or
MONEL armor

Motor Lead Extension

• Connects the power cable to the motor
– Pothead isolates the motor from well fluids
– Spliced to the power cable
– Smaller gauge cable along the ESP length

Important Downhole Options

Depending on the field operations and well conditions the
following options are often included in an ESP installation
• Downhole Monitoring System
– Installed at the motor base and transmits downhole conditions up the
power cable
• Gas separator and/or gas handler
– Replaces Intake when excessive free gas is present
• Check or standing valve
– Prevents back flow through pump which can delay restarts when
power is lost to the system
• Cable protectors & centralizers
– Increased protection for cable during installation
• By pass tools
– Allows wireline or coil tubing intervention below the ESP
• Chemical injection systems, etc.
– Well treatment to enhance production or prevent scale

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Downhole Monitoring
• Real-time status
• Typical measured parameters:
– Intake Pressure & Temperature
– Motor Winding Temperature
– Two-Axis Vibration
– Current Leakage
– Pump Discharge Pressure

More Complex Configurations

• Shrouded Below Perforations
• Production to Injection
• Redundant / Parallel Systems
• Dual-Boost Completion
• Multi-Zone Completion
• Coiled Tubing Deployed
• ESP / Gas-lift Dual Completion
• Packer with Annular Production

Surface Equipment
• Motor controller
– Switchboard
– Variable speed controller
(VSD)
• Step-up transformer
• Vented junction box
• Wellhead

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ESP Wellheads

Feed-through connector
for higher pressures

Seal on cable for

low pressure
(150 psi)

Preventing Pump Failures

Preventing Pump Failures

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Challenges in ESP Optimization

ESP Surveillance
All the data in one place !

Typical ESP Applications

• High volume high value wells for medium & light oil
– Deviated, vertical, multilateral

• Offshore
– Minimal surface equipment conserves deck space
– No rods to compromise SSSV (safety valves)
– No gas-lift infrastructure required

• Medium & light oil with volumes over 5,000 BPD

• Steam Assist Gravity Drainage (SAGD) heavy oil wells
– Special high temperature systems to 260°C/500°F

• Low volume shallow dewatering of CBM/CSG wells

• Mining and water wells

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Rajan.Chokshi@Weatherford.com
William.Lane@Weatherford.com

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