ESP Completion Guide

SAUDI ARAMCO WORKOVER MANUAL
Drilling Technical Department September 2013
CHAPTER 4 COMPLETION PRACTICES

SECTION I ESP COMPLETIONS
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ESP COMPLETIONS
1.0 ELECTRICAL SUBMERSIBLE PUMP (ESP) DEFINITION Back
1.1 Impeller
1.1.1 Mixed Flow Impeller
1.1.2 Radial Flow Impeller
1.2 The Diffuser
1.3 ESP Stages
1.4 Pump Thrust & Recommended Operating Range (ROR)
1.5 Total Dynamic Head (TDH)
2.0 ESP DOWNHOLE EQUIPMENT
2.1 The Pressure Gauge

2.2 ESP Motor
2.3 Motor Lead Extension (MLE)
2.4 Seal Sections/Protectors/Equalizers
2.5 Intake
2.5.1 Gas Separator Intake
2.5.2 Gas Handling
2.6 Bolt-on Discharge
2.7 Auto-flow Sub
2.8 ESP Cables
2.9 ESP Penetrator
3.0 TYPES OF ESP PUMPS
3.1 Pump Construction

3.3.1 Compression Pumps
3.3.2 Floater Pumps
4.0 SURFACE EQUIPMENTS
4.1 Variable Speed Drives (VSD)

4.2 Fixed Speed Drives (FSD)
4.3 Transformers
4.4 Junction Box
5.0 ADVANCE LIFTING SYSTEM
5.1 Bypass System Completion Schematic

5.2 Dual ESP Completion
5.3 Parallel ESP Completion
5.4 POD Completion

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6.0 DOWNHOLE PACKER
6.1 Quantum Packer

6.1.1 Setting Mechanism of Quantum Packer
6.2 Isolation Valve
6.2.1 MFIV Setting Procedure
6.2.2 MFIV/Quantum Packer Completion Table
6.2.3 Running MFIV Shifting Tool
6.3 ESP Production Packer
7.0 ESP RUN-IN-HOLE PROCEDURE
7.1 Typical ESP Completion Table

7.2 Typical ESP Completion Schematic

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ESP COMPLETION
1.0 ELECTRICAL SUBMERSIBLE PUMP (ESP) DEFINITION
The ESP pump is a centrifugal pump

that moves fluid by spinning it with a HEAD
rotating impeller in a diffuser that has
a central inlet and a tangential outlet. PUMP
The pressure (head) develops against
the inside wall of the diffuser because
the curved wall forces fluid to move in PUMP
a circular path converting velocity to
(pressure) head or, more generally,
SCREENED INTAKE
kinetic energy to potential energy. The OR
basic ESP is unit consists of GAS SEPARATOR
centrifugal pump, seal section, intake
and motor although other accessories
SEAL
may be included in the system. The Assembled
Length
standard ESP is suspended in the well
MOTOR LEAD CABLE
by the production tubing with the total
weight being supported by the
wellhead tubing hanger. The power MOTOR
cable is banded or clamped to the
outside of the tubing to help protect
the cable as well as transfer the
weight of the cable to the tubing. MOTOR
DOWNHOLE
DATA
ACQUISITION
INSTRUMENT
Fig 1: ESP Basic Downhole Equipment
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The centrifugal pump is a

multistage pump containing a PUMP, STD FLOATER RADIAL FLOW
selected number (application
dependent) of impellers equipped Head
with vanes, inside a closely fitted
Bearing Support
diffuser, located in series on axial O-Ring
shaft, driven by the electrical
motor. The number of stages is
dictated by many parameters Bushing
including but not limited to desired
flow rate, pump setting depth,
reservoir pressure, well KeyStop
productivity, water cut, GOR,
tubing size and length and
required wellhead pressure. Diffuser
Impeller
Shaft
Housing
Bearing Support
Bushing
Base
Coupling
Fig 2: Typical configuration
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1.1 Impeller
A centrifugal pump creates pressure by the rotation of a series of vanes
in an impeller. The number of vanes might vary from one stage size to
another and generally come in odd numbers. The pump manufacturer
has to find the right balance when developing the impeller design.
Fig 3: Impeller cutaway
The impeller is keyed or fixed to the rotating shaft and adds kinetic
energy to the fluid as it moves from the inlet (or eye) to the outlet. The
larger the impeller diameter and the faster it rotates both increase the
kinetic energy imparted to the fluid. There are two basic types of
impellers used in ESP systems (axial flow impellers & radial flow
impellers). Specific speed is a function of shaft RPM, flow rate at best
efficiency point (BEP) and head. Radial flow stages will likely have a
specific speed in the range of 500 to 4000 while mixed flow stages are
typically anywhere from 2000 to 8000. The ESP vendor always works to
achieve optimum performance from the stage which is maximum head
and efficiency for a given flow rate.
1.1.1 Mixed Flow Impeller:

Mixed flow impellers get their name because, as the fluid moves
through the impeller, it is moving in both the X-axis (radially
outward) and the Y-axis (axially upward). These tend to be used in
higher flow rate pumps and/or larger diameter pumps but, again,
this is simply a necessity dictated by the specific speed. One
advantage of mixed flow stages is that they have less tendency to
gas lock because gravity separation will help gas move through the
pump. These stages should also have a slightly higher reliability
(less wear) when pumping abrasive fluids due to the smother flow
transition through the stage.
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Fig 4: Mix flow impeller
1.1.2 Radial Flow Impeller:

A radial flow (pancake) impeller gets its name from the fact that
virtually all the fluid movement in the impeller is directed radially
outward with very little axial component. While it would be
desirable to use mixed flow pumps in most cases, at very low flow
rate, it simply isn’t practical because the resulting pump efficiency
would be too low. The radial design allows the impeller to impart
the maximum amount of kinetic energy to the fluid permitted by the
impeller diameter and speed (RPM).
Fig 2-10: Radial flow impeller
Fig 5: Radial flow impeller

1.2 The Diffuser
The diffuser section then converts this kinetic energy to potential energy,
raising the fluid pressure. Unlike the impellers, the diffusers do not rotate.
Diffusers will always have a different number of vanes than their
corresponding impeller. This is to prevent pressure pulsations (vibration).
They are rigidly fixed inside the pump in some manner. For very large
vertical turbine pumps, the impellers are actually bolted together.
In the case of the ESP, there is not enough metal available to fix with screws
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or pins so the entire diffuser stack is held in place by compression set during
manufacture. The compression is held by the pump head and base. If this
compression is ever lost – which is a possibility – some of the diffusers will
spin inside the housing. This is one mode of ESP failure. In the short term,
the result is loss of flow/head. In the long term, a spinning diffuser can
potentially cut the pump housing in two which will drop the majority of the
ESP in the hole which means fishing.
Fig 6: The Diffuser
The diffuser works in the opposite way from the impeller. The diffuser moves
the fluid from the outside back in toward the shaft and into the eye of the
next impeller or, for the last diffuser, to the pump’s discharge.
1.3 ESP Stages

The stage is simply the combination of one impeller and one diffuser. The
pump will have one more diffuser than impellers. That’s because it needs an
entrance diffuser. The entrance diffuser does no actual work – it is there to
provide physical contact between the first stage diffuser and the pump intake
in order to maintain the required compression. Flow is not additive. If one
stage will produce 5,000 BPD then 73 stages will also produce 5,000 BPD.
Head (pressure) is additive. If one stage produces 36 feet of head then 10
stages will produce 360 feet of head. So the flow rate determines the type of
stage and the application determines the number of stages required.
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Fig 7: The Stage
1.4 Pump Thrust and Recommended Operating Range (ROR)
The recommended operating range of the pump is determined by several

factors. Some are practical and some are physical. When vendors had many
pumps with overlapping flow ranges, they intentionally limited the ROR in
order to help these operators select the right pump.
Fig 8: Recommended Operating Range
Note that, outside the ROR, the efficiency is very low. It is likely the vendor
will have another stage that is much more efficient at those flow rates. In the
figure below, typical efficiencies can be seen for different pump families.
Each color represents a certain diameter of pump housing.
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Fig 9: Typical Pump Family Efficiencies
The only real constraint on the ROR is the thrust handling capability of the
stage and/or seal section. The total thrust is the vector sum of four individual
components.
PUMP THRUST - AXIAL

Total thrust of a impeller has four contributors:
1. The pressure acting upon the upper shroud minus the

pressure acting upon the lower shroud. (acts downward) F1
2. The change in axial fluid m omentum (acts upward) F2
3. The weight of the impeller in fluid (acts downward) F3
4. Pump discharge pressure acting on the end of the pump shaft (acts downward) F4
NET PRESSURE X AREA CHANGE IN SHAFT END LOAD

lbs . MOMENTUM lbs.
lbs .
ILLUSTRATION OF AXIAL THRUST

NE T HYDRAULIC THRUST T = F1 + F3 - F2
TOTAL THRUST T (TOTAL ) = F1 + F3 + F4 - F2
Axial thrust is one of th e most important factors to be considered to establish
"OPERATING RANGE " for Multistage Centrifugal Pumps.
Fig 10: Components of Pump Thrust
Although the term “floating impeller” is commonly used in the industry, it is a

misnomer. All pumps should have at least a small amount of downthrust. If an
impeller actually did float (and this is possible), it would be a very unstable
operating condition and could lead to failure. Operating in downthrust
improves reliability and can add 3 to 5% on efficiency since recirculation is
mitigated.
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Fig 11: Recirculation Path in Upthrust
The key is to limit the downthrust to a level that the downthrust washers can
manage (or go to a compression style pump). The best run life will be
achieved operating slightly to the right of the best efficiency point (BEP).
Fig 12: Typical Thrust Curve
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1.5 Total Dynamic Head (TDH)
ESP pump curves are generally plotted as head versus flow with head being
some distance unit such as feet or meters. This is convenient because the
centrifugal pump, over a wide range of conditions, produces constant head. If
the pump will lift oil 5,000 feet, it will lift water 5,000 feet. The pressure the
pump develops, however, depends on the specific gravity of the fluid inside
the pump. The amount of head the pump must produce is the Total Dynamic
Head (TDH) required by the system (reservoir, tubing, wellhead).
TDH is the sum of three basic components:

Net Vertical Lift (NVL) = is the net distance over which the fluid must be lifted.
Tubing Friction loss (FL) = based on total tubing length and the rate being
pumped
Tubing Head Pressure (THP) = Pressure which the unit must pump against
(back pressure caused by choking on well head or surface facilities
pressure).
Fig 13: Total Dynamic Head
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2.0 ESP Downhole Equipment
2.1 The Pressure Gauge
One optional accessory for the ESP is a downhole pressure gauge. Simpler
models offer only two channels (pressure and temperature) while more
expensive models can measure annulus pressure, pump discharge
pressure, intake temperature, motor oil (or winding) temperature and
vibration. Some gauges offer current leakage as well but this is usually a
parameter calculated in the surface unit rather than an actual measurement.
The ESP gauge is connected to the three phase motor winding with the
gauge’s adapter providing the Y-block. Historically ESP gauges used an i-
wire to transmit their signal back to the surface. At the moment, the industry
is using the system ground to transmit the signal to the surface readout.
MEASUREMENT RANGE ACCURACY
Pressure 690 bar (10,000 psi) 0.1%
Temperature 150 C (3 02 F) 1%
Flow rate 4 700 m 3/d 5%
Vibration 12g 1%
Current Leakage 25 m A 0 .0 5%
Because the gauge uses the system ground for data transmission, if the
system is partially (or completely) grounded, the gauge becomes useless
although the ESP may still be operational. With regard to motor temperature,
it is preferred to measure motor winding temperature rather than motor oil
temperature. The difference might prevent a failure. When a motor gets “hot”
from an overcurrent condition, the winding heats instantaneously. Capturing
this event in the gauge and acting upon this condition in the motor controller
trip settings will prevent any permanent damage to the motor.
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Fig 14: Pressure Gauge Assembly
2.2 ESP Motor

The typical Submersible motor is a three phase, two pole, squirrel cage
induction design and has changed little since its invention in the 1920’s.
Significant advances have been made in insulation materials, bearing design,
lamination design, efficiency and reliability. Motors have rotors fixed to the
shaft which rotate inside the stator. Rotors are about 1-1/2 to 2 feet in length
and the vendor determines how much horsepower (Hp) the rotor is designed
for. Rotor strike usually results in immediate failure of the motor. In a 60 Hz
system, a two pole stator field rotates at 3600 RPM. Because the motor is an
induction design, the rotor/shaft assembly will run at a slightly slower speed
(3450 – 3500 RPM). The difference in speed is called “slip” and is a
requirement in an induction design. In order to get more Hp than one rotor
can provide, additional rotors are used with radial bearings placed between
them to provide radial stability to the rotor/shaft system. Most ESP motors will
not be longer than 30 feet but some vendors offer a 35 foot motor for high Hp
systems.
If more Hp is required than can be provided by one motor, motors can be

connected in tandem electrically in series. ESP motors are achieving 1,500
Hp or more although the reliability of ESP systems is generally inversely
proportional to Hp. In other words, lower Hp lasts longer. The ESP motor, at
full voltage, will come up to full speed (3500 RPM) in about 12 cycles (1/4 of
a second).
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When pulling an ESP, if the motor/MLE checks electrically bad, the pothead
should never be removed from the motor. There is no benefit to breaking this
connection to see whether the problem is in the motor or the MLE. By
removing the pothead, valuable evidence as to cause of failure may be
destroyed. Always cut the MLE at least 1 foot above the pothead, band it to
the motor head and ship it back intact.
Fig 15: Typical Motor Components
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Fig 16: Rotor and Stator Laminations and Winding
The induction motor has no electrical connection to its rotor. The currents
that flow in the rotor are "induced" there by the stator's magnetic field cutting
the copper bars in the rotor's squirrel cage. This current produces a magnetic
field, which repels the stator's magnetic field and causes the rotor to turn. If
the rotor ever reached synchronous speed, then there would be no current
induced. The lines of flux represent the strength of the magnetic field. The
area with the most flux lines circling around it has the highest intensity that
corresponds to the slots with the highest current.
Fig 17: Typical Flux Pattern in ESP Motor
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2.3 Motor Lead Extension (MLE)

The motor lead extension comes with the pothead already attached. The
motor lead can conceivably be any length but should be at least long enough
to pass the entire length of the ESP system above the motor head up to
about 15 feet above the pump discharge where it would be spliced to the
main power cable. If a production packer is to be run above the ESP, the
MLE should be long enough to reach the packer without the need of an
additional splice. Typically this would be about 200 feet. The MLE often will
be smaller conductor than the main power cable. This is done to minimize its
size because there is often very little space between the motor/seal/pump
and the casing and the motor pothead cavity is quite small as well and larger
conductors simply won’t fit through the hole.
An MLE should never be reused. If, during an ESP installation, the unit has to
be pulled out of the hole for any reason, the MLE should be replaced with a
new one prior to running back in. It is too fragile to take the risk.
2.4 Seal Sections/Protectors/Equalizers
The seal section has four vital functions to the successful operation of the
ESP: 1) transmits the torque developed by the motor to the pump shaft, 2)
absorbs any upthrust and/or downthrust developed by the pump, 3) equalizes
the pressure between the inside of the motor and the puressure in the TCA
around the motor and 4) isolates the well fluid from getting into the motor. If
the seal section fails in any one of these aspects, the system will fail requiring
a rig intervention.
a) The seal section shaft couples the torque output of the motor to the intake
of the pump. Seal shaft breakage is a mode of failure. When the seal
shaft does break, it usually occurs at the thrust bearing.
b) Regardless of the type of pump construction, the seal section will have to
absorb any downthrust or upthrust developed by the pump. Although all
pumps are intended to run in some downthrust, some stage types will
momentarily jump into upthrust on startup. The downthrust may be only a
few hundred pounds to upwards of 20,000 lbs depending on the stage
type and number of stages. If the downthrust bearing fails, this will cause
other system problems which will eventually fail the ESP.
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TYPICAL
SEAL THRUST BEARING
UP-THRUST
BEARING
T hrust Runner
Direction of THRUST
movement RUNNER
Fluid
Wedge Thrust
Bearing
Pad
DOWN-THRUST
BEARING
Anti-Rotation Pin
Fig 18: Upthrust & Downthrust Bearings and Thrust Runner
c) The motor and seal section are filled with some type of oil. The exact oil
is selected based on the anticipated operating temperature. The ESP can
undergo thermal cycles easily in the range of 80F or more. As the oil gets
hotter, it expands. As it cools, it contracts. The seal section has to provide
some mechanism for this volumetric change. If the volume change were
not compensated for, the motor internal pressure would split the motor
housing, blow out the pothead or fail at some other weak point.
d) The two most common forms of seals are an elastomer bag and a
labyrinth seal. The main difference between the two is that the elastomer
bag provides a positive barrier between the motor oil and well fluid while
the labyrinth provides a contact point for the two fluids. In some cases,
the labyrinth can be enhanced with a high viscosity agent such as
Beaverlube. This is often used in Coiled Tubing Deployed ESPs.
2.5 Intake
Some pumps come with an intake integral to the pump itself. This is
especially true of very high volume pumps. More commonly the ESP pump
will come with a base flange and use a bolt-on intake installed in the field.
Integral intakes are generally more reliable (one less connection, one less
coupling, etc.) and they create less friction loss than a bolt-on intake. The
intake is required to get the fluid from the annulus into the pump itself. If
intake is not installed but rather bolted the pump directly to the seal section,
the ESP will pump all the oil out of the seal section and motor. This vacuum
will pull well fluid into the motor and fail the ESP within a few seconds.
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Intake Body
Shedder
Bushing, Intake Upper
“O”Ring
Shaft
Screen
Bushing, Intake Lower
STANDARD INTAKE
Fig 19: Simple Bolt-on Intake
The intake may have a suction screen or it may not. The purpose of the
screen is to prevent very large particles from getting into the pump where
they can cause damage to the impellers. If the screen is used and it gets
plugged such that no fluid can enter the pump, the ESP will fail almost
instantaneously.
Bolt-on intakes, while commonly used, are a potential source of failure. For
any piece of the ESP pulled from the well, the coupling at the flange should
always be left in place and the flange protected with a shipping cap. The
coupling will be inspected during failure analysis for concentricity and run-out.
Bad couplings can easily cause failures so it is important that they be
included in the analysis.
2.5.1 Gas Separator Intake
Another type of intake is a vortex gas separator. These are not

currently used in Saudi Aramco because the pump intake pressure is
always maintained above bubble point pressure and all ESPs are
currently run with a production packer (except in Central Arabia).
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When using a gas separator, the intake separates gas from the
pumped fluid and sends the separated gas to the surface through the
TCA by natural gravity. The TCA gas is then tied back into the flow-
line at the wellhead.
Fig 20: Dynamic gas separator

2.5.2 Gas Handling
If free gas is present at the pump intake and it can’t be separated

(packer above), the other option is to handle the gas. The ESP pump
itself can handle some free gas – maybe 10% to 15% by volume but
certainly no more than that reliably. The purpose of the gas handler is
to redistribute the bubble size into much smaller bubbles that the ESP
pump can more easily manage. Even with a gas handler, any
installation intending to produce with the ESP intake below bubble
point pressure should have the entire completion scrutinized very
closely. The goal is to have every last bubble of gas go into the pump
with no opportunity for accumulation (through natural separation)
above the pump. If a gas pocket is allowed to form above the pump,
frequent gaslocking of the pump will result in less than satisfactory
operation.
2.6 Bolt-on Discharge
The ESP pump requires a bolt-on discharge head to adapter to the
production tubing or flow sub it is connected to. More likely this will be a
combination of pressure sub and discharge. The pressure sub communicates
to the downhole sensor below the motor via capillary tube running alongside
the ESP string.
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2.7 Auto-Flow Sub
In some cases, an ESP may be installed in a well that will flow naturally. If
the production is required before the commissioning date of the ESP or
during downtime after an ESP has failed, an autoflow sub may be used to
divert fluid around the pump so it doesn’t have to pass through the ESP. If
the completion includes a Y-tool, an autoflow sub isn’t required because
production can flow up the bypass tube if the blanking plug is removed. Flow
can go through the pump itself but it is not desirable. If the well flows
naturally through the pump, the impeller/shaft assembly will spin unless the
pump is locked up with scale. When the ESP is started, the high discharge
pressure of the pump will automatically close the sub to the TCA.
Another potential benefit of the autoflow sub is that, when the pump is
stopped, the sub can open allowing the fluid in the tubing to drain back to the
TCA rather than through the pump. Some designs require that the tubing
drain almost completely through the pump before they can open & this flow
back through the pump can be harmful.
2.8 ESP Cables

ESP Cables deliver the voltage and current from the surface to the motor and
come in several combinations of insulations and voltage ratings. Most cables
used in Saudi Aramco are rated for 4 kV. If required (for very high
horsepower applications), 5 kV cable is available. The only difference
between 4 kV and 5 kV cable is the thickness of insulation (and the overall
diameter). Except for very low temperature applications, the primary
insulation is generally some form of ethylene-propylene diene monomer
(EPDM). EPDM is a good insulation rated at very high temperature and is
very resistant to H2S. Saudi Aramco requires that all copper conductors be
coated with a lead-tin coating prior to applying the insulation. H2S can easily
migrate through the EPDM material and, if allowed, will attack the copper in
the conductors. The lead-tin coating is designed to prevent the H2S from
being able to reach the copper.
After the insulation, some type of protective jacket is applied. This jacket is
provided to help protect the cable from damage during installation and
pulling. Aside from the jacket, some cables include a fluoropolymer tape such
as polyvinyl fluoride tightly wrapped over the insulation and they may even be
braided over the tape. The PVF tape is designed to protect the EPDM
insulation from the hydrocarbons that would cause it to swell.
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Braiding is often used when lead is extruded over the insulation. The braid is
typically a low temperature material designed to dissolve in water. The
braid’s only function is to protect the insulated cable (or lead jacket) from
damage by the cable armor during manufacture. The armor has sharp edges
and can easily cut into the soft lead. This is especially true if a very hard
material such as Monel is used for the armor material.
In the parallel cable shown in Figure below, the cable has EPDM insulation
covered by a lead extrusion and then braid. While lead cable does offer some
protection from H2S, if the lead is not replaced at splices, its benefits are
diminished. On the other hand, replacing the lead at the splice is also a
potential failure source if the technician doing the splice is not highly skilled at
the process.
Power cables come in both round and parallel configurations. Round cable is
always preferred. Parallel cable is only used where space in the TCA won’t
accommodate round cable.
Fig 21: Parallel and Round ESP Cable
Round cable has a much thicker protective jacket which can also absorb
compression during running in hole.
The parallel cable creates phase imbalance in the motor/cable system.

Round cable is completely symmetric so has no ability to create phase
imbalance. For the parallel cable, the centre conductor runs hotter than the
two lateral conductors. This additional heat increases the resistance of that
conductor which, in turn, creates more voltage drop. Even if the voltage is
balanced at the surface, it will be unbalanced by the time it gets to the motor.
This makes the ESP motor run hotter than it would with parallel cable and
temperature degrades insulation life.
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Factors to be considered when selecting cable:

• Downhole temperature
• Type of fluid the cable will operate in
• Electrical Properties
• Physical Dimensions
• Environmental Resistance
• Mechanical Strength
• Conductor operating temperature
• Handling considerations
2.9 ESP Penetrator
The penetrator is a connection system that allows the power cable to

penetrate a pressure barrier while the barrier is still sealing. There are two
common penetrator systems in ESP completions. The first one is the
Wellhead Penetrator which allows the power to be transmitted from the
surface to the ESP cable through the tubing hanger and bonnet. The cable
will be spliced to the wellhead penetrator which is installed in the tubing
hanger before it’s landed. There are several companies that manufacture
wellhead penetrator including QCI and BIW. QCI offers two types of
penetrators: P-5000 and P-3000 which are corresponding to 5,000 psi and
3,000 psi pressure ratings. Clearance considerations have to be also taken
when selecting the proper wellhead penetrator. For example, P-3000 cannot
be usually run in 11” X 11” Tubing Spools installed over 7” Casing while P-
5000 can.
The second type of penetrators is the Packer Penetrator which has the same
function as the wellhead penetrator but through the ESP packer. The packer
penetrator works as a connection between the round cable in the isolated
TCA and the flat cable (MLE) below the packer. Penetrator systems come in
different pressure ratings, configurations and installation procedures. Splicing
the cable to the packer/wellhead penetrator is a critical step in ESP
installation and plays a major rule in prolonging the ESP run life while poor
splicing jobs can cause an immature failure of the ESP.
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Fig 22: ESP Wellhead Penetrator
3.0 Types of ESP Pumps
Electric motors can be connected in tandem configuration to create the desired

Horsepower required for each application assuming that the total voltage does not
exceed the system limits. Although internally to the motor, the stator winding/rotor
system is essentially the same; motors can come in several configurations such as:
• Single
• Upper Tandem
• Center Tandem
• Lower Tandem
The differences in these motors are in the heads and bases. A single motor is, by
definition, complete. It cannot have another motor connected to it to increase the
Hp because the motor winding three phase wye connection is internal to the motor.
In principle, a single motor is more efficient than any of the other configurations.
This is because the single motor can place the wye connection in the motor head.
In any type of tandem motor, one half wrap of each phase winding is “lost” because
each phase has to terminate in the top of the motor.
All motors must eventually be terminated with a wye connection or wye block. An
upper tandem motor can have one or more center tandem motors placed below it
electrically in series to increase the available horsepower. The wye block
eventually completes the circuit by bolting on either a universal motor base or a
downhole pressure gauge. Both of these contain a wye block for this purpose.
Some vendors offer a universal motor head which can be used on top of a tandem
motor to complete it. The primary driver for this is that it allows the vendor to
reduce inventory costs and stock only center tandem motors. This additional
connection adds unreliability to the system.
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When putting more than one motor together in a tandem combination, it is best to
match the two (or more) sections with the same HP and voltage. For example, A
200 HP motor should be made up of two 100 HP motors rather than something like
a 75 HP motor in tandem with a 125 HP motor. In addition, when two motors are
added together, it is critical that they have the same amperage rating. A 100 Hp
1018V 62A motor cannot be placed in tandem with a 1368V 46A motor. The result
would likely be a broken shaft between the motors. It is possible to connect motors
of different horsepowers if the amperage of each section is the same. For example,
connecting a 75 Hp 1026V 46A motor to a 125 Hp 1710V 46A motor is probably
okay. The resulting motor would be 200 Hp 2736V 46A.
3.1 Pump construction

ESP pumps are of two types. 1) Compression Pump & 2) Floater
construction pump.
3.1.1 Compression Pumps

In a compression pump, all the impellers are rigidly fixed to the shaft
so that if an impeller wants to move up or down, it will take the shaft
with it. All the impellers are "compressed" together to make one rigid
body.
.
Fig 23: Compression Pump
Use of compression pumps

• In very gassy wells, the flow volume changes so drastically within
the pump that parts of a floater pump could be in very severe
thrust while others are not so a compression pump could be one
alternative.
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• Since all the down thrust is handled in the protector, as long as

the protector has a great enough capacity, the pump operating
range can be extended over a much wider area without any
increased wear or reduced life.
3.1.2 Floater construction pump
Since a floating impeller is free to move up and down the shaft, the
only thing to stop it is either the upper or lower diffuser. "Thrust
washers" are provided at all mating surfaces between the impeller
and diffuser to absorb any thrust generated. Each impeller is free to
move up and down so it is said to "float" on the shaft.
Fig 24: Floater pump
Use of floater pumps

• Since each stage handles its own thrust, a very large number
of stages can be put in a pump without having to worry about
protector bearing capacity.
• Floaters are also very good with mild abrasives since they
prevent material from getting into the radial bearing area.
4.0 Surface Equipment

All ESPs will require a motor controller on the surface. These controllers may either
be fixed speed (60 Hz) or variable speed. Fixed speed controllers are simpler,
cheaper and more reliable. Variable Speed Drives are more problematic but offer
much more flexibility with the operation of the pump.
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VSDs are especially useful in new wells were the reservoir parameters are not well
defined. The motor controller is a combination motor starter, overload/underload
protection device and recording instrument. It provides lightning, surge, and fault
current protection for the cable and motor.
4.1 Variable Speed Drives (VSD)
The variable speed drive functions not only as a motor controller but also as
a speed changer. A Variable Speed Drive (VSD) is an electronic device
which synthesizes a three phase variable voltage, variable frequency power
supply for induction motors. As oil well characteristics change, the VSD is
used to change SPS pump head and flow optimizing the well output. The
VSD may be either a six step or pulse width modulated (PWM) output. An
ESP system may be grounded downhole but still be operable. If this is the
case, and it is running on a VSD, minimize the number of trips for this well.
While an ESP may operate on a VSD while grounded, it may be impossible
to restart on a VSD.
4.2 Fixed Speed Drives (FSD)
The FSD (or switchboard) is used as starting switch for the downhole
equipment. It also provides protections and control. The FSD runs the
downhole equipment on line frequency (i.e. 50 Hz or 60 Hz). The speed of
the ESP cannot be controlled. It is only on or off. FSDs are available in either
mechanical or solid state models. Even when using a VSD, if space permits,
a FSD may be place in parallel to the VSD with a bypass switch to allow the
ESP to continue operation if the VSD fails for some reason.
Fig 25: Internals of a FSD
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4.3 Transformers
The transformer is used to convert the incoming voltage at the location to the
correct voltage for the submersible motor. In most cases the voltage
delivered to the location will be a common distribution voltage such as 34,500
volts. Transformer selection is based on the power rating in KVA (Kilo Volt
Amperes), primary voltage, secondary voltage, and tap arrangement.
KVA = 0.00173 x (E x I)
Where:
E = voltage (volts)
I = current (amps)
A transformer consists of two coils connected by a magnetic path (iron core).

These transformers are generally an isolation type having no electrical
connection between its two coils. The input coil (primary) is designed for the
desired input voltage, such as 13.8Kv or 34.5 Kv. The KVA rating of the
transformer must be designed to provide the power required by the downhole
ESP motor under any operating condition as well as account for losses in the
power cable and any harmonic content in the motor/cable system.
Three Phase Step-Up or Step-Down Transformer

Isolation Type OISC
PR ESSU RE R ELIEF VAL VE
SE COND ARY BUSH ING PRI MARY BUS HING OIL LEVEL GAU GE
TEMPE RATU RE GAU GE
PADLO CKAB LE H INDGED COVER F ILTER VALV E
LIFTING LUG S NAM EPL ATE COO LING PROV ISION S(1 4 GA. PLATE)
LIQU ID LE VEL PLUG
TAP
CH A NGERS
COND UIT HU B (4") C OND UIT HU B (2 ")
GRO UND IN G PR OVIS IONS

DR A IN VA LVE
"H" (LOAD) TERMINAL CONNEC TIONS FOR DELTA ( ) OR WYE (Y) C ONNECTIONS
DELTA C ONNECTION WYE CONNECTION

H6 H1 H4 H5 H6 H6 H1
H1 H4 H2 H5 H3 H6
H4 H2 H4 H2
H5 H3 H5 H3
H1 H2 H3
Fig 26: Typical Three Phase Step-down Transformer
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4.4 Junction Box
The junction box is used for connecting the power cable and venting gas (in
case gas has migrated up the power cable) between the well and
switchboard. It provides a connection point for the surface cable from the
motor control panel to the power cable in the wellbore.
18 IN 10 IN
VENT
Is olate
In strument
18 IN Wire Whe n
Not Used -
Do Not Ground
BOX VENT
GROUND WIRE
Vented Junction B ox Control Panel

50 ft Minimum
Tubing Head 15 ft Minimum 35 ft Minimum

G round Wire Cable may be
Buri ed
Steel Casing
CAUTION: D OWNH OLE CAB LE MU ST BE VEN TED AS SH OWN BETWEEN

WELLHEA D AND CONTRO L P ANEL.
CON TROL PANEL & JUNCTION BOX SH OULD BE GROU NDED - PREFERA BLY TO WELLHEAD .
J UNCTION BOX SHO ULD N EVER BE US ED INSID E OF A BUI LDIN G.
Fig 27: Typical Junction Box
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5.0 Advance Lifting System
Many Saudi Aramco ESPs are run with a by-pass system. The Y-tool is used for
single connection to production string. The by-pass tubing below allows the
passage of logging tools to the well. The offset portion of the Y-tool attaches to the
ESP. The Y-tool and the bypass clamps on the ESP below the Y-tool have slots to
accommodate the MLE, discharge pressure capillary, other capillaries or control
lines as required by the completion. The internal profile is design to ensure a
smooth flow path from ESP to production tubing. The Y-Tool needs a blanking plug
(provided with the Y-tool) to provide a seal while ESP is running. Other plugs are
also provided by the vendor for coiled tubing or wireline or slickline work. These
plugs are normally specified in the ESP contract. If other plugs are needed beyond
the scope of the contract, these would be buy-out items.
Fig 28: Typical Y-tool
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5.1 By-Pass System Completion Schematic:
5.2 Dual ESP Completion
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Dual ESP lift systems enable cost-effective production in applications where

rig availability may be at a premium and where the cost of workover impacts
the overall profitability of the well. Dual ESP systems can be used in series to
double the horsepower in a well, or they can be used in parallel to produce
independent zones. The systems can also function as an in-well backup
system to reduce downtime and lost or deferred production while mobilizing
workover equipment. Saudi Aramco ran the 1st the dual ESP in ABSF-17.
Dual ESP has the applications in the following areas:

• Subsea or deep water application.
• High cost workover areas.
• High volume ESP production.
• High horsepower ESP production.
• Dual zone production in isolation.
Fig 29: Dual zone application
5.3 Parallel ESP Completion
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The parallel ESP system may used in hi PI (productivity Index) wells to

increase production rate where one ESP cannot provide enough horsepower
or may be used to pump from two different zones proving there is isolation
between the zones. In this case, both ESPs would operate concurrently. This
completion may also be used to provide a redundant (or back-up) system in
the well. If the first ESP fails, the second one may be operated by changing
the nipples in the Y-tools. This system requires two power cables and two
wellhead and packer feedthrus.
Fig 30: Dual zone application
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5.4 Pod Completion
The Pod Completion is used to in conjunction with SmartWell completions

operated by a wet connect. The latching/delatching forces required by the wet
connect could damage a conventional ESP system. With the ESP installed
inside a POD, all axial tension and compression forces are transferred to the
POD housing leaving the ESP protected.
Fig 31: POD Completion
6.0 Downhole Packer Below ESP
Running the ESP in Saudi Aramco is usually incorporated with a packer to isolate
the casing - annulus between the pump and the isolation valve below the pump,
and the packer is also used to hang the mechanical isolation valve (MFIV). This
packer can be set on wireline or hydraulically utilizing the service tool (tubing
deployment). At present only Quantum packer from Schlumberger is being used
31 of 38

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6.1 Quantum Packer

The Quantum packer is specifically designed to increase reliability and
improve all aspects of sand control operations. The Quantum packer is the
core component of the Quantum gravel pack completion system, which is
specifically designed for single-trip production gravel packing in deep,
deviated, and horizontal wells. The Quantum packer is available in standard
and large-bore configurations, allowing seal assembly IDs to match
production tubing IDs. The large-bore design facilitates multiple completions
in which the lower production tubing must pass through an upper packer
assembly without damaging the sealbores. All operations are completed with
pressure and vertical movement and do not require rotation. Quantum
packers are designed to be retrieved with straight pull or to be milled if
necessary. These packers can be set on wireline and retrieved using an
internal retrieving tool. These packers feature one-piece, self-energizing
packing elements and one-piece, bidirectional slips that reduce the risk of
loss when retrieving or milling. The slips are located below the packing
element for maximum protection from debris fouling.
Fig. 32: Quantum Packer
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6.1.1 Setting Mechanism of Quantum Packer:
When the packer reaches the setting depth, a non-magnetic setting

ball (primary) is dropped down the work string to provide a seal in ball
seat. As the pressure in the tubing is increased (relative to the
pressure in the annulus/wellbore), the setting pistons are energized
and slips engage the casing wall. This process applies a compressive
load on the rubber elements pressed the rubber elements against the
casing wall. To confirm the integrity, tensile and compressive loads
are applied to the work string and pressure is applied to the annulus
above the packer to make sure packer is sealing.
6.2 Isolation Valve
The Mechanical Isolation Valve (MFIV) is a monobore completion valve that

normally runs below the packer to avoid any losses during workover. This
valve uses a non-translating ball to seal the pressure above and below to
control the well and to protect the formation. The valve is opened and closed
using the mechanical shifting tool. The MFIV protects formations from
damage resulting from fluid loss during completions and workover
operations. The MFIV can be actuated to open and close mechanically via
the shifting tool. In high-pressure, high-temperature (HPHT) environments,
the MFIV serves as a barrier to isolate reservoir fluids in the lower completion
providing increased wellbore safety. Isolating the formation from damaging
fluids, the MFIV enhances production and simplifies completion operations.
By isolating the formation from the wellbore, it provides increased wellbore
safety. The MFIV serve as a downhole lubricator valve for safe removal of
long perforating strings. Other applications include well suspension,
temporary abandonment of a well, and fluid-loss prevention in high-
differential pressure applications. The reliability of MFIV technology has
extended its use to remedial workover operations, in which the tool is used to
isolate the formation during removal and reinstallation of an electrical
submersible pump or production tubing.
6.2.1 Procedure to Set MFIV & Setting Procedure
a) RIH Quantum packer assembly w/MFIV on DP to setting depth.

Record pick up and slack off weight. Break circulation, record
rates and pressures. Drop 1-3/8” brass setting ball. Pressure test
lines to 4000 psi. Open valve to work string and pressure up string
to +/-1600 psi gradually to set the Quantum packer. Close hydrill
and pressure test annulus to 1000 psi. Hold for 10 minutes. Bleed
off annulus and open hydrill.
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b) Pull up 10-20 k-lbs over the string weight. Set 10 k-lbs weight
down over string weight, pressure string to 2400-psi (2700 psi
maximum pressure). Bleed off pressure and then pick up. The
Quantum service tool is free (If it is unable to release the tool
hydraulically, turn to right & release the tool mechanically).
c) Pick up slowly 10’ above packer. Pressure the work string to 3200
psi, shear ball seat to provide a circulation path. Pick up slowly to
un-sting from the packer and close MFIV. (MFIV closed when
service tool is out of the packer). Close the BOP rams and
pressure test MFIV to 1000 psi. Bleed off to zero. POH & LD tool.
d) Pick up the following assembly from the bottom up:
6.2.2 MFIV & Quantum Packer Completion Table:

OD ID Length
Item DESCRIPTION
(in) (in) (ft)
1 4-1/2" 11.6# New Vam wire line entry guide. 4.862 4.000 ± 0.50
2 4-1/2" 11.6# J-55 New Vam tubing joint box x pin 4.862 4.000 ± 40.0
3 4-1/2" 11.6# J-55 New Vam pup joint box x pin 4.862 4.000 ± 6.00
4 Mechanical formation isolation valve MFIV 5.5" X 2.94" 5.500 2.940 ± 9.35
7 Extension seal bore for 7" x 4", quantum packer, 10 ft 5.530 4.000 ± 10.00
long 4.937" 6 stub acme pin x 4-1/2” 11.6# New Vam pin
a) Pick up and RIH the following inner string liner:
OD ID Length
Item DESCRIPTION
(in) (in) (ft)
A 2.94" STC-C MFIV shifting tool w/ 2-3/8" Hy 511 box up 2.940 1.500 ± 5.73
B 2-3/8" Wash pipe W/ 2-3/8” 4.6# Hyd 511 box x pin (with
10 foot perforated on the bottom) 2.375 1.995 ± 30.0
b) Continue MU the lower completion assembly detailed as follows:
OD ID Length
Item DESCRIPTION
(in) (in) (ft)
8 Extension mill out for 26-29# quantum packer 2 ft long, 5.530 4.000 ± 2.00
4130/4140 w/ 4.937" stub acme, box x box. (This will be
connected to item “9”)
9 7" X 4" 23-26# quantum packer w/ 4.937" 6 stub acme 6.110 4.000 ± 5.60
pin down
10 7” x 4” quantum type III setting tool, w/ 3-1/2” IF box up 5.800 1.375 ± 12.00
x 2-3/8” 4.7# CS hydril pin down
11 Crossover 3-1/2” IF pin X 4” XT39 box 4.000 2.560 ± 1.50
12 4" XT39 drill pipe 4.000 2.560 To surface
34 of 38

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6.2.3 Running MFIV Shifting Tool Table:
OD ID Length
Item DESCRIPTION
(in) (in) (ft)
1 2.94” STC MFIV shifting tool w/ 2-3/8” Hyd 511 box 2.940 1.500 ± 5.73
up
2 2-3/8” Wash pipe W/ 2-3/8” 4.6# Hyd 511 box x pin (with 2.357 1.995 ± 30.00
10 foot perforated on the bottom)
X-Over, 3.625-8 stub acme box x 2-3/8” 4.6 # hydril 511 3.992 1.995 ± 0.8
pin
3 7” x 4” locator seal assembly w 3.625-8sa box x pin 3.992 3.000 ± 15.0
4 7” x 4” locator seal assembly w 3.625-8sa box x pin 3.992 3.000 ± 2.0
5 7” x 4” no-go top sub w/3-1/2” 9.3# EUE box up 4.2 3.000 ± 0.50
6 3-1/ 2” perforated joint w/ 3-1/2”, 9.3# EUE box x pin 3.500 2.992 ± 10.06
7 3-1/2” pup joint w/3-1/2”, 9.3# , EUE box x pin 3.500 2.992 16.00
8 3-1/2” tubing joint w/3-1/2”, 9.3#, EUE box x pin 3.500 2.992 30.00
9 X-Over 2-3/8” 4.7# EUE pin x 3-1/2” 9.3# EUE pin 3.740 1.995 ± 0.71
6.3 ESP Production Packer
The Weatherford Hydro-II dual bore is an ideal submersible pump packer. It’s
a dual-string, hydraulic set, double grip retrievable production packer. The
Hydro-II dual bore packer is available with additional bores for ESP cable,
chemical injection lines, control lines & well monitoring devices. The Hydro-II
packer has a patented sequential upper-slip releasing system that is
designed to release each slip individually to reduce the pull required to
release the packer. The angles on the slips, cone & upper-slip body results in
increase forces that allow the penetration of the slips to be released smoothly
from the casing. When running an ESP set between two packers, it is critical
that there be some method to allow the ESP to thermally grow. If the MFIV,
for example, locks into the Quantum packer, then a telescoping joint must be
run between the ESP and the MFIV. The ESP only needs a fraction of an
inch available for growth but, if this is not available, the ESP will build
compressive forces on the order of 20,000 lbs.
7.0 ESP Run-in-Hole Procedure
• Perform a pre-job Safety Meeting to review the completion plan and handling
procedures of the ESP equipment.
• A dedicated cleanout trip and junk sub will be run in hole prior to running ESP.
• Rig up the cable spooler and sheave.
• Pick up the motor with the multi-sensor assembled. A crane should be used in
conjunction with the winch line on the rig to safely hoist the equipment to a
point where the chain assembly on the motor clamp can be secured into the
hook assembly in the elevators.
35 of 38

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• Lower the unit into the well.

• Place the coupling and rotate the shaft coupling to ensure the shaft is free.
• Follow Motor Oil Filling Procedure as per service company standard procedure.
• Attach lifting clamp to the top of the protector .Pick up and position over motor.
Protectors are lifted using the same methods used to lift motor.
• Engage the motor and protector with the motor coupling.
• Lower the unit down in hole.
• Connect the intake and pump. If pump is compression, then follow vendor
standard procedure on shimming. Raise the unit to the motor head.
• Perform the Pothead connection as per vendor standard procedure.
• Lower the unit down in hole but still with access to the oil filling port in the head
of the motor.
• Follow Protector Oil Filling Procedure as per vendor standard procedure.
• Fit Motor Lead Extension Protectolizers on the equipment flanges.
• RIH as per completion Program. Run tubing as per completion Program.
• Attach the Cross Coupling Cable protector as required.
• Pick up the “XN” nipple, Adjustable sub and packer sub assembly and connect
to the tubing.
• Fit the QCI/BIW penetrator to the packer and perform MLE space out. Perform
Cable splice above the packer.
• Run in hole with tubing as per completion Program. Maintain a uniform running
speed to allow the spooler to provide minimum cable tension.
• Perform seal assembly space out to have the packer at required setting depth.
• Reverse circulate through Phoenix auto flow sub to displace TCA and tubing to
packer fluid (saturated brine inhibited with 1% coat B-1400, 1 lb/bbl of Caustic
Soda to have a PH-11 and 0.5 lb/bbl Sodium Sulfite (oxygen scavenger).
• Make up tubing hanger (prepared for QCI Penetrator + CL). Install QCI & CL
through the hanger. Confirm electrical system integrity from above tubing
hanger penetrator.
• Sting into Quantum packer and shift the MFIV open. Slack off and land tubing
hanger slowly with extreme caution not to damage the penetrator. The tubing
hanger should be landed with the cable facing in the same direction as it was
pulled. This will provide a much easier task of pipe fitting the wellhead.
• RIH and set “PXN” plug at “XN” Nipple. PT tubing. Pressure up tubing & set
Hydro II dual bore packer.
• Fill TCA with saturated NaCl inhibited brine if needed. Pressure test TCA with
and tubing separately.
• ND BOPE. Check the pump electrical integrity. NU existing tubing bonnets
prepared for QCI Penetrator + CL. NU existing offshore tree. Splice ESP cable
to QCI penetrator. Exit 1/4” control line out of the tubing bonnet.
• Retrieve “PXN” plug from “XN” Nipple. Set FV in SSSV and close same.
• Function test ESP pump as per and flow the well for clean up.
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7.1 Typical ESP Completion Table
Depth
Item DESCRIPTION OD (in) ID (in)
(ft)
1 EA Phoenix multi sensor assy 4.500 n.a.
1 EA Phoenix motor base crossover 5.375 n.a.
1 EA Reda Motor 540 series 1800 HP, 60 HZ 5.620 n.a.
1 EA Reda ESP protector BPBSL, 540/540 NTB/HL 5.400 n.a.
1 EA Reda pump intake 5.130 n.a. xx±
1 EA Reda ESP pump 540 series, GN7000 59 STG 5. 380 n.a.
1 EA Reda ESP discharge head 5.380 n.a.
1 EA Pup joint 3-1/2" , 9.3# J-55, EUE 3.500 2.992
1 EA Phoenix auto flow sub 5.595 2.992
1 EA Phoenix discharge sub 5.135 2.615
4 Jts Tubing 3-1/2" , 9.3# J-55, EUE 3.500 2.992
1 EA X-Over 2-7/8", EUE box X 3-1/2" EUE pin 3.500 2.441
1 EA Pup joint 2-7/8" , 6.5# L80, EUE 2.875 2.441
1 EA 2-7/8" EUE , XN-nipple ( no go ID 2.205" ) 2.875 2.205
1 EA Pup joint 2-7/8" , 6.5# L-80, EUE 2.875 2.441
1 EA Weatherford adjustable sub 3.693 2.485
1 EA Pup joint 2-7/8", 6.5# , EUE 2.875 2.441
1 EA Weatherford 7" hydrow II dual bore packer 6.000 2.375 xx±
1 EA Pup joint 2-7/8", 6.5 # L80, EUE 2.875 2.441
1 EA X-Over 3-1/2” EUE box x 2-7/8”EUE pin 3.500 2.441
1 EA Pup joint 3-1/2", 9.5 # J-55, EUE 3.500 2.441
As req. Tubing 3-1/2" EUE , 9.3# J-55 3.500 2.992
1 EA Pup joint 3-1/2", 9.3# J-55 EUE 3.500 2.992
1EA Schlumberger 3½” WL Ret SSSV 4.375 2.812 xx±
1 EA Pup joint 3-1/2", 9.3# J-55 EUE 3.500 2.992
6 Jts Tubing 3-1/2", 9.3# J-55 EUE 3.500 2.992
1 EA Pup joint 3-1/2" , 9.3# J-55 EUE 3.500 2.992
1 EA 3-1/2" Extended neck tbg hanger prep. for QCI
penetrator & CL w/ 3-1/2" BPV prof.
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7.2 Typical ESP Completion Schematic
38 of 38

ESP Completion Guide

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SAUDI ARAMCO WORKOVER MANUAL

Drilling Technical Department September 2013

CHAPTER 4 COMPLETION PRACTICES

2.0 ESP DOWNHOLE EQUIPMENT

2.1 The Pressure Gauge

3.0 TYPES OF ESP PUMPS

3.1 Pump Construction

4.0 SURFACE EQUIPMENTS

4.1 Variable Speed Drives (VSD)

5.0 ADVANCE LIFTING SYSTEM

5.1 Bypass System Completion Schematic

CHAPTER 4 COMPLETION PRACTICES

6.0 DOWNHOLE PACKER

6.1 Quantum Packer

7.0 ESP RUN-IN-HOLE PROCEDURE

7.1 Typical ESP Completion Table

CHAPTER 4 COMPLETION PRACTICES

1.0 ELECTRICAL SUBMERSIBLE PUMP (ESP) DEFINITION

The ESP pump is a centrifugal pump

Fig 1: ESP Basic Downhole Equipment

CHAPTER 4 COMPLETION PRACTICES

The centrifugal pump is a

Fig 2: Typical configuration

CHAPTER 4 COMPLETION PRACTICES

Fig 3: Impeller cutaway

1.1.1 Mixed Flow Impeller:

CHAPTER 4 COMPLETION PRACTICES

Fig 4: Mix flow impeller

1.1.2 Radial Flow Impeller:

Fig 2-10: Radial flow impeller

Fig 5: Radial flow impeller

CHAPTER 4 COMPLETION PRACTICES

Fig 6: The Diffuser

1.3 ESP Stages

CHAPTER 4 COMPLETION PRACTICES

Fig 7: The Stage

1.4 Pump Thrust and Recommended Operating Range (ROR)

The recommended operating range of the pump is determined by several

Fig 8: Recommended Operating Range

CHAPTER 4 COMPLETION PRACTICES

Fig 9: Typical Pump Family Efficiencies

PUMP THRUST - AXIAL

1. The pressure acting upon the upper shroud minus the

NET PRESSURE X AREA CHANGE IN SHAFT END LOAD

ILLUSTRATION OF AXIAL THRUST

Fig 10: Components of Pump Thrust

Although the term “floating impeller” is commonly used in the industry, it is a

CHAPTER 4 COMPLETION PRACTICES

Fig 11: Recirculation Path in Upthrust

Fig 12: Typical Thrust Curve

CHAPTER 4 COMPLETION PRACTICES

1.5 Total Dynamic Head (TDH)

TDH is the sum of three basic components:

Fig 13: Total Dynamic Head

CHAPTER 4 COMPLETION PRACTICES

2.0 ESP Downhole Equipment

2.1 The Pressure Gauge

MEASUREMENT RANGE ACCURACY

Pressure 690 bar (10,000 psi) 0.1%

Flow rate 4 700 m 3/d 5%

CHAPTER 4 COMPLETION PRACTICES

Fig 14: Pressure Gauge Assembly