Artificial Lift Electric Submersible Pumps (ESP) May 2010 (Compatibility Mode)

Artificial Lift – Electric Submersible
Pumps (ESP)
Mohammad Khalifa
Sub Surface Manager – FC14
Agenda
20th May 2010
2 Electric Submersible Pumps /

Mohammad Khalifa
Agenda
21st May
2010

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FUNDAMENTALS - SYSTEM PERFORMANCE
RESERVOIR
INFLOW PERFORMANCE
SIBHP
Vogel ?
BHP (psi)
Productivity
PI (bpd/psi)
Q (bpd)

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RESERVOIR
INFLOW PERFORMANCE
SIBHP
BHP (psi)
Productivity
PI (bpd/psi)
Q (bpd)

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RESERVOIR
INFLOW PERFORMANCE
SIBHP
BHP (psi)
Productivity
PI (bpd/psi)
Q
Q (bpd)

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RESERVOIR
INFLOW PERFORMANCE
SIBHP
BHP (psi)
Productivity
PI (bpd/psi)
Q
Q (bpd)

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WELL SYSTEM
OUTFLOW PERFORMANCE
Hagedorn & Brown ?

Duns & Ross ?
Beggs & Brill ?
BHP (psi)
etc.,etc….
f ( fluid, T, conduit, process)
Q (bpd)

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WELL SYSTEM
OUTFLOW PERFORMANCE
BHP (psi)
Q (bpd)

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WELL SYSTEM
OUTFLOW PERFORMANCE
BHP (psi)
Q
Q (bpd)

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WELL SYSTEM
OUTFLOW PERFORMANCE
BHP (psi)
Q
Q (bpd)

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RESERVOIR WELL SYSTEM

INFLOW PERFORMANCE OUTFLOW PERFORMANCE
BHP (psi)
BHP (psi)
Productivity
PI (bpd/psi)
Q (bpd) Q (bpd)

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RESERVOIR WELL
INFLOW PERFORMANCE OUTFLOW PERFORMANCE
SIBHP
BHP (psi)
SYSTEM PERFORMANCE
BHP (psi)
PI (bpd/psi)
Q (bpd) Q (bpd)
BHP (psi)
Q
Q (bpd)

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BHP (psi) SYSTEM PERFORMANCE
Q
Q (bpd)
NATURALLY FLOWING WELL

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BHP (psi) SYSTEM PERFORMANCE
Q BHP (psi)
Q (bpd) Q (bpd)
NATURALLY FLOWING WELL DEAD WELL

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DEAD WELL
BHP (psi)
Q (bpd)

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REQUIRED ‘LIFT’
DEAD WELL
BHP (psi)
BHP DEFICIT
Q (bpd)

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REQUIRED ‘LIFT’
REQ. LIFT (psi)

BHP (psi)
BHP DEFICIT SYSTEM CURVE

(REQUIRED LIFT)
Q (bpd) Q (bpd)

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Electric Submersible Pumps (ESP)
FLP Pressure
Natural Flow
Fluid Gradient
Depth
SBHP

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FLP Pressure
Natural Flow
Fluid Gradient
Depth
SBHP

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FLP Pressure
Dead Well / No
Flow At Surface
Fluid Gradient
Depth
SBHP

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FLP Pressure
ESP Assisted
Depth
Total Dynamic Head
PIP PDP
SBHP

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FLP Pressure
ESP Assisted
Fluid Gradient
Depth
Total Dynamic Head
PIP PDP
SBHP

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Artificial Lift Systems Comparison
► Progressive Cavity Pump (PCP)
► Sucker Rod Pump (Beam Pump)
► Gas Lift
► Electric Submersible Pump (ESP)

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Artificial Lift Systems
Hydraulic BY WELLS / SYSTEMS
Electro Sub. Pumping Others % WW Wells WW
Reciprocati
Pumps ng Pumps Rod Pumps (reciprocating) 40% 308,160
PCP's Gas Lift 34% 261,936
PCP's 5% 38,520
Electro Submersible Pumps 18% 138,672
Hydraulic Pumping 1% 7,704
Gas Lift Others 2% 15,408
Lifting Systems by Type WW 100% 770,400
Worldwide, there are approximately 800,000 oil wells in production, 94% of them have
associated an artificial lift system.
The most popular artificial lift system is reciprocating pump (40%) of total population, then gas
lift (34%), electro submersible pumps (5%), progressive cavity pump at 6%.

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Why Electric Submersible Pumps (ESP)
► High Flow rate.
► Deep installation.
► Long run life (Based on the application)
► High Temperature wells.
► Reservoir access (With Y-tool)

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Advantages
The main advantage of the electrical submergible pump is the

flexibility of the system.
► Flexible flow rate with VSD.

►Can be used at low bottom hole pressures.
► Can operate reliably in deviated in wells.
► Can be used effectively for offshore applications.
► Operate under extreme conditions such as higher bottom hole

temperate applications with the use of alternative materials.
► Can be utilized in a corrosive and scale conditions

with alternative materials.
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Disadvantages
► High Capital cost compared to PCP and Sucker Rod Pumps.

► Higher power requirements (High OPEX)
►Reliable power source is required.
► Solids can cause wear in the pump causing premature
failure.
► Once operating below bubble point pressure, gas lock can
be an issue.

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Typical ESP String
MLE Cable
Submergible
Pump
Intake
Protector
Motor

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ESP String

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Centrifugal Pumps
Each Centrifugal pump consist of number of
stages.
Impeller Diffuser

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Centrifugal Pumps
The rotation of the high-speed impeller

throws the liquid into the diffuser. The
impeller takes the fluid and imparts
kinetic energy to it. The diffuser
converts this kinetic energy into
potential energy (head).
Diffuser
Impeller
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Pump Curve
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Pump Intake
► Integral.
► Bolt-on.
► Intake
► Gas Separator+Intake.

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The Protector
The protector is the
piece of equipment
that is typically
placed between the
motor and the intake

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Functions for the Protector
The primary functions of the protector are:
To couple the motor to the pump, to transmit the torque to rotate

through the shaft
To act as a reservoir chamber for fluctuations in cycling the

equipment for oil expansion
Provides the thrust bearing to carry the thrust load of the pump
To act as a seal chamber to prevent the migration of well fluids from

entering the motor
To equalizes pressures between the motor and the wellbore

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Labyrinth Protector
Well Fluid slowly

enter the Once the Well
Labyrinth on fluid enter the
every motor. The
temperature system fail.
change

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Bag Protector
Well Fluid is
totally isolated The seal is the
from the lower elastomer ..
part

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Modular Protector

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Submersible
Electric Motor
The motor is a three

phase, squirrel cage,
two pole induction
design.

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Motor Components
► Stator
► Rotor
► Shaft
► Thrust bearing.
• Depending on how many rotors
installed, we measure the capacity by
HP.
Is there a limit ??

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Downhole Configuration
Coupling
These Sections Are All Connected by
Couplings to Join Each Shaft Section.
Coupling
Coupling
Shaft
Coupling
Coupling

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MultiSensor (DMT)
Important tool for diagnostics and proper
operation for the ESP.
Typical measurements:
Intake pressure
Intake / Motor Temperature.
Vibration.
Discharge Pressure.
Current leakages in the system.

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MultiSensor (DMT)
VSD / SB
Important tool for diagnostics and proper Readout
operation for the ESP.
Choke
Typical measurements: Transformer
Intake pressure
Intake / Motor Temperature. Cable
Vibration.
Discharge Pressure.
Current leakages in the system. Motor
DMT

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Cable – Motor Connection
Tape-In Design
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Cable Configuration
ETBO
ROUND
- Electrical Properties
- Mechanical Properties
FLAT
- Clearance ELB

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The main components of the
power cable include:
The conductor - electrical properties

Insulation material - protects and covers the conductor
wire
Barrier Jacket - protects and covers the insulation.
Jacket Material - rubber compound designed for
temperature, chemical, and gas considerations.
The exterior armor - the outer shield that holds it all
together

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Cable Components
CONDUCTOR
INSULATION
BARRIER
JACKET
ARMOR
INJECTION TUBE (optional)

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Cable Termination
Cable is connected to the MLE with a SPLICE.
Splice can be made on well site or in the shop.
Pre-spliced mandrel would save time (higher cost).
Splicing is required between MLE and main cable,
and at the wellhead.

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Surface Equipment

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Junction Box
• Provides a connection point for the
surface cable from the motor control
panel to the power cable in the
wellbore.
• Allows for any gas to vent that may
have migrated through to the power
cable.
• Provides easy accessible test point
for electrically checking downhole
equipment.

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Switchboard
The controller is a device that can be used
as a soft-start for the motor with overload
and underload protection capabilities.
The controller can provide the capability to

monitor the ESP system with the use of a
recording instrument.

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Variable Speed Drive (VSD)
The variable speed controller

allows for flexibility of the downhole
system for flow control capabilities.
It provides a constant ratio of
between voltage and frequency
for proper operation.

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Transformers
► Step Down Transformer:
To reduce the incoming power to the
motor operating voltage.
OR
To reduce the incoming power to the
VSD operating voltage.
► Step Up Transformer:
►Used with the VSD to convert the
output voltage to the motor
operating voltage.

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Total Dynamic Head

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Total Dynamic Head (TDH)

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VSD Applications
If we know the pump performance at 60 Hz (i.e. we

have a pump curve), we can easily calculate it at
any other frequency.
HZ
Flow HZ = Flow 60 ×
60
2
HZ
Head HZ = Head 60 ×
60
3
HZ
BHP HZ = BHP60 ×
60
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TDH is the sum of three basic components:
1) The Net Vertical Lift or net distance which the fluid must be
lifted.
2) The friction loss in the tubing string
3) The wellhead pressure which the unit must pump against.

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Components of the TDH
Wellhead
Wellhead Pressure
3
Ground Level Flow
1
2 Net Vertical Lift
Total Friction Loss
Producing Fluid Level
Pump Set Depth
Flow Flow
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Total Dynamic Head (psi) =
Net Vertical Lift (psi) + WHP (psi) + Friction Loss (psi)

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Net Lift Net Lift
PFL
Regardless of
where the pump is
set, or the angle,
the vertical lift will
not change.

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Net Vertical Lift
Wellhead
Ground Level
Note that even

though the pump is
Net Vertical Lift
much lower, the net lift
does not change.
Producing Fluid Level

Pump Set Depth
Pump Set Depth
Flow Flow
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Casing Annulus Tubing Discharge
or
or Tubing Head Pressure
Casing Head Pressure

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No
Worrie
s
Excuse me
Sorry
Certainly

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Example:
Well Number: 123 - Campina
Perforation: 980-1000m
Pump Depth: 936m
Static Level: 500m
Oil API: 21
Water cut : 80%
PI: 10 bbl/psi
Desired Well Head Pressure: 10 Bar

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Selecting The ESP System
Pump
►Flow rate (400 Series , 540 Series , 562 Series .. Etc.)
►Number of stages ( Total Dynamic Head )
Breaking Horse Power Required
►Motor Selection (HP)

►Other components (Protector, Intake, Cable, Packer .. Etc.)

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Total Dynamic Head - Wellhead Pressure
This is the equation to convert from psi to feet but we still need to
know the specific gravity.
Wellhead Pressure*2.31
Wellhead "Feet" = ----------------------------------
sp.gr.

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Break?

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Minimum Maximum Limit
The limit with the lowest value is the
controlling limit.
The common denominator is the
stage count. Calculate the
maximum number of stages for
each limit.
The lowest number will be the
maximum that can be used in this
installation.

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Sample Problems
The discussion has been on
technique to this point.
Here are some sample problems to
further illustrate these limits.

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Physical Limitations
This is because we should understand the reasons so we can

anticipate problem areas in the actual design process. Let's look at
one brief example here illustrate how we arrive at a maximum number
of stages.
Casing = 7" Pump Type= GN3200

Sp. Gr. = 1.08 Temperature=225°F

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Do we have everything we need?

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It might be helpful to know the power frequency. Let's assume 60 Hz

in this case. We will also assume pump intake pressure is close to
zero.
Since we are in 7" casing, we know that the largest protector we can
use is a 540 series. Let's look at the thrust ratings for both a standard
and hi-load bearing protector.

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We need to find 225F on the X-axis and then read
the maximum allowable load from the curve.
15,000
12,500 Hi Ex Bearing
Load (LBf)
10,000 Bronze
Bearing
7,500
5,000
0 50 100 150 200 250 300
Bottom Hole Temp (°F)

60 Hz and Above 50 Hz
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From these curves, we can see the maximum load for the bronze
bearing is 9,500 lbs while the Hi Ex bearing will take up to 12,000 lbs.

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Our pump, at shut-in, will produce about 57 feet of
head per stage. Converting this to pressure with a
sp.gr. of 1.08 gives us 26.65 psi / stage.
Reda Single Stage Pump Performance Curve
GN3200 540 Series Pump - 3500 RPM HP
Head Pump
Feet Motor Only
Load EFF
60
50
40
30 75
20 2.00 50
10 1.00 25
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
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Capacity - Barrels per Day
Since this is a floater pump, all we have to worry about is shaft thrust.
We can calculate the maximum number of stages as follows:
psi 2
# of Stages × × Area(in ) = Thrust(lbs)
stage
For a bronze bearing :

2
9500(lbs) in
# of Stages = × × = 593 Stages
26.65(lbs) 0.6013(in 2)
For a Hi Ex bearing :
2
12000(lbs) in
# of Stages = × × = 749 Stages
26.65(lbs) 0.6013(in )2
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In terms of thrust, the maximum allowable number of stages is 749.
The maximum horsepower (60 Hz) allowable with the pump shaft is
410 on a high strength shaft.
GN3200 60 HZ / 3500 RPM Pump Performance Curve 540 Series - 1 Stage

Optimum Operating Range 2,200 4,100 bpd Shaft Brake Horsepower Limit: Standard 256 Hp
Nominal Housing Diameter 5.13 inches High Strength 410 Hp
Shaft Diameter 0.875 inches Housing Burst Pressure Limit: Standard 5000 psi
Shaft Cross Sectional Area 0.601 sq. inches Buttress 6000 psi
MInimum Casing Size 6.625 inches Welded 6000 psi

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From the pump curve, the maximum horsepower required by the
pump is about 1.42 BHP / stage. Do not forget to multiply by the
specific gravity. This will give us a BHP of 1.53 per stage.
GN3200 540 Series Pump - 3500 RPM

Head HP Pump
Feet Motor Only
Load EFF
60
50
40
30 75
20 2.00 50
1.4
10 21.00 25
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
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410 HP
----------------- = 268 stages.
1.53 Hp/stage
So the maximum number of stages we are allowed by horsepower

limitations is 268.

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The maximum horsepower available in a motor for 7" casing is

somewhat subjective depending on the application. Let's just pick a
number of 750 Hp.

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750 HP
----------------- = 490 stages.
1.53 Hp/stage
So the maximum number of stages we are allowed by motor

availability is 490.

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What about pressure? According to the catalog, the maximum

allowable pressure for this pump housing is 6000 psi. We know that,
at worst case, our pump will put out 26.65 psi / stage.
6000 psi
------------------ = 225 stages.
26.65 psi/stage

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Parameter Maximum Stages

Protector Thrust 749
Shaft Horsepower 268
Motor availability 490
Housing pressure 225
The minimum of these four maximums is 225 stages so this is the

maximum we could put in the pump.

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What about any other limitations?
Is there anything else we really should consider?

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How about making sure the unit we size will actually fit in the well?
For example, consider that we are using a 456 motor and 400 series
pump and protector which are 4.562" O.D. and 4.000" O.D.
respectively.

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What size casing will this unit fit in to?

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In principle this unit is designed for 5.5" casing but not all casing is the
same.
5.5" casing is nominally 5.5" O.D. but, depending on the "weight" of

the casing, the I.D. can vary considerably.

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Some common 5.5" casings are:
14 pounds per foot ------------- 4.887" Drift diameter

15.5 ppf ------------- 4.825"
17 ppf ------------- 4.767"
20 ppf ------------- 4.653"
23 ppf ------------- 4.545"

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Note that even though the nominal I.D. of 17 ppf casing is 4.892", we
are using, instead, the drift diameter of 4.767" for our calculations.
Why do this and what is drift diameter anyway?

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Casing is manufactured to a tolerance just like everything else and due

to manufacturing tolerances, the diameter can be as much as 1/8"
smaller than the nominal number and still be acceptable.

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Even though this is a "worst case" diameter, more often than not the
casing will really be this diameter at some place in the tube. This is
especially common at both ends where the casing tends to neck down
just a little.
Because of this, the drift diameter is a much better number to use for
calculations of clearance.

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Now that we know the diameter, it should be a simple matter to see if

the unit will fit or not.
5.5" casing drift diameter:

15.5 ppf ------------- 4.825"
17 ppf ------------- 4.767"
20 ppf ------------- 4.653"
23 ppf ------------- 4.545"

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Since the motor is only 4.562" O.D. and the pump and protector are
smaller, we can see that the unit will fit in anything up to 20 ppf
casing, right?
5.5" casing drift diameter:

15.5 ppf ------------- 4.825"
17 ppf ------------- 4.767"
20 ppf ------------- 4.653"
23 ppf ------------- 4.545"
< 4.562" Motor

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Actually not.
It turns out that the problem is slightly more complicated

than this.
For one thing the motor will usually have lock plates
welded to the housing and head which will increase the
effective diameter. We also need to consider that we have Lockplate
to get electricity to the motor somehow (i.e. we have a
power cable to worry about).

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In addition to the cable, we may or may not use cable guards which
would, if used, increase the effective diameter and we also have to
"attach" the cable to the unit with or without guards so cable band
thickness must be considered as well.

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An easy way to look at the problem is by looking at the unit from the
end.

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Assembly Dimensions: 456 Motor 400 Protector 400
Pump
0.602" 0.750"
arc arc
#6 Cable Guard ** One Design Lockplate on Motor
0.125 + 0.031 x 3.125 wide
0.028" thick Clamp
4.926 min. casing w/ guard

#6, 456 series
Flat Cable 4.828 min. casing w/o guard
.125 4.805 min. casing w/o

guard or clamp
4.790 min. casing w/o guard,
clamp or lockplate
4.562" dia. Motor
4.500" dia. Protector base
Protector & Pump lockplate

0.125" + 0.031" clearance
103
End View
Electric Submersible Pumps /
** May beMohammad
omitted by Special Order
Khalifa 4.000" dia. Protector housing & Pump
With a drawing like this, all possibilities are considered for the
downhole equipment. Almost every possible configuration of
equipment has been laid out in an end-view drawing already and
these are readily available in InTouch.
It is much easier to refer to the drawing than to try to calculate this by

hand.

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Another area to consider is the power cable.
This is typically much larger than the motor lead extension and it must
fit in the annular space between the tubing coupling and the casing.

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Another consideration in running an ESP in a well is the problem of

deviations.
Directional drilling has been around for a while but horizontal

completions are becoming more popular all the time.
Even in older directional wells, it is necessary to set the ESP deeper as

reservoir pressures decline.

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It may therefore be necessary to run the ESP through a dogleg to reach

a straight section lower in the hole.
As long as the Reda ESP is landed in a straight section, it can operate at

any angle up to horizontal as long as certain factors such as protector
selection have been considered.
The problem is getting it through the dogleg without permanent

damage.

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- Always install in a straight section
- Avoid inclinations higher than 40 deg.
- Maximum inclination 85 deg.
- Never install past or on horizontal section
- Never install in a bend (dog leg)

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Since the ESP is smaller than the casing, it can pass some deviation
without any deflection at all.
Greater deviations will cause deflection (bending) of the Reda ESP unit.
Since it is not a rigid piece, it can handle some amount of deflection
without permanent damage and will straighten back out after it passes
the dogleg.

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Maximum bending stresses occur at the joints in the smaller

diameter or "necked down region". If the stress exceeds the
material's yield strength, permanent damage will occur.
Casing ESP Deflection

Deflection
Clearance

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Normally doglegs less than 3° per 100 feet present no problems for
the Reda ESP unit. Deviations greater than this need to be reviewed
on a case-by-case basis with Reda engineering.
If an operator is drilling a new well, recommend a "long radius" rather

than a "short" one and larger casing is always better.

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Troubleshooting

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SWITCH BOARD

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Switchboard & Surface Equipment

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SWITCH BOARD

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Troubleshooting
5 6 AM 7 8
4 60 9
Here is a typical amp chart. We 3
50
10
40
know that the downhole unit is 30
20
operating correctly and pulling
11
10
nameplate amps (we checked it
NOON
1
with our amprobe at the junction
MIDNIGHT
box).
2 1
11
3
10
4
9 5
8
7 6 PM

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Here is an example of what is 5 6 AM 7 8
mostly a "normal" chart with the 4

60 9
50
exception of periodic and seemingly 3
10
40
30
random "spikes". 20
11
10
NOON
1
MIDNIGHT
2 1
11
3
10
4
9 5
8
7 6 PM

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With the ESP, the amperage varies
inversely to the voltage for a constant
Spikes
load. If the primary supply voltage 5 6 AM 7 8
decreases, the ESP current will increase to 4 60

50
9
3
compensate. The most common cause for
10
40
30
these spikes is periodic heavy loading on 20
11
10
the power system as could be caused by Primary
NOON
1
startup of high horsepower equipment Power
MIDNIGHT
elsewhere on the system. Fluctuation
1
Could also be caused by lightning strikes "Spikes"
2
somewhere on the power system.
11
3
10
4
9
5
8
7 6 PM

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Here is a chart which shows startup
followed by a gradual decrease in Gradual decrease
amperage until about 7:30 AM
where the line becomes very 4
5 6 AM 7 8
9
Amperage
60
ragged. At about 8:30 AM, the 3

50 becomes
10
40
amperage takes a drastic drop and

30
20 erratic
11
10
becomes very smooth.
NOON
1
MIDNIGHT
2 1
11
3
10
4
9 5
8
7 6 PM

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When the unit is first started, the fluid level is high
Pump has
so production and current are slightly high. As
the fluid level is reduced, the current decreases gas locked
until the level is so low that gas begins to form at 5 6 AM 7 8
the intake. The wide variation is specific gravity 4 60

50
9
3
cause the erratic amperage. Eventually enough
10
40
30
gas forms so that the pump "gas locks". When 20
11
10
the pump is gas locked, it is not producing any
NOON
1
fluid. Note that, even though the pump is not Gas
MIDNIGHT
producing fluid, the motor is continuing to run Locking
1
(amperage is not zero). This will cause the motor
2
11
to eventually burn since there is no fluid
3
movement to cool it.
10
4
9 5
8
7 6 PM

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In this case, we need to raise the
underload setting so that the unit shuts Pump has
off if it gas locks. Shutting the unit down gas locked
6 AM 8
may clear the gas lock although if a check 4
5
60
7
9
valve is installed, it may prevent it from 3

50
10
40
clearing. If possible, choke back the 30
20
11
10
production to raise the annular fluid
NOON
1
level. It may be necessary to lower the Gas
MIDNIGHT
pump if there is room in the well to gain Locking
1
additional submergence. It might also be
2
wise to resize to a smaller unit.
11
3
If a VSD is being used, reduce the
10
4
frequency. 9 5
8
7 6 PM

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This chart shows high current after
startup which eventually drops 5 6 AM 7 8
down to a "normal" value. If the 4 60 9

50
overload were set at 46 amps, this 3
10
40
30
unit could not continue to run. The 20
11
10
overload must be set higher than 60
NOON
1
amps (or it is not working).
MIDNIGHT
2 1
11
3
10
4
9 5
8
7 6 PM

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5 6 AM 7 8
One possible cause is that the pump is 4 60 9
50
unloading the well of heavy kill fluid. The high 3
10
40
30
gravity fluid causes an increase in current until 20
11
it is all pumped out of the well -- then the 10
NOON
current drops to a normal value. If this Unloading
1
condition is to be expected, it may be Heavy
MIDNIGHT
1
necessary to temporarily raise the overload Kill Fluid
setting until the kill fluid is gone and then set it
2
11
to the normal 115% value. If this condition is
3
expected to last for more than a few minutes, it
10
may be necessary to use a larger motor than
4
9
normal so that the overload does not cause
5
8
high internal temperatures which may reduce 7 6 PM
the operational life. Note: If a VSD is being used, try

lowering the hertz to reduce the
load until the kill fluid is gone.

Mohammad Khalifa
This chart shows a unit which starts 5 6 AM 7 8
and runs for 2 hours with gradually 4 60 9
50
decreasing current until it becomes 3
10
40
30
very erratic. The unit stops for 3 20
11
hours and repeats the cycle. It 10
NOON
restarts just after noon and runs
1
longer but eventually stops.
MIDNIGHT
21
11
3
10
4
9 5
8
7 6 PM

Mohammad Khalifa
This is a case where the pump is producing
more fluid than the well can deliver. The 5 6 AM 7 8
pump is lowering the fluid level, hence the 4 60 9

50
amperage, until free gas begins to form at the 3
10
40
30
intake. The low gravity gas mixed with the 20
11
10
high gravity fluid causes wide swings in
NOON
1
current. The unit eventually shuts off on U/L
and automatically restarts after three hours. Pump Off
MIDNIGHT
1
Possible solutions are to choke back on with Gas
production, lower the pump further in the Interference
2
11
hole, or resize to a smaller unit.
3
With a VSD, try lowering the frequency.
10
4
9 5
8
7 6 PM

Mohammad Khalifa
This chart is similar to the previous
5 6 AM 7 8
one except that the amperage is 4 60 9
fairly steady prior to shut-down. 3
50
10
40
30
20
11
10
NOON
1
MIDNIGHT
21
11
3
10
4
9 5
8
7 6 PM

Mohammad Khalifa
This is also a case of "pump-off" 5 6 AM 7 8
except that there is not much gas 4 60 9

50
in the reservoir to cause 3
10
40
30
interference in the pump. 20
11
10
Corrective measures are the same
NOON
as before. If this conditions
1
Pump Off
develops after several months (or
MIDNIGHT
(no Gas
1
years) of normal operation, it may
Interference)
be that skin damage is reducing
2
11
the well productivity. Stimulation
3
may restore the productivity to the
10
original level (or better).
4
9
5
8
7 6 PM

Mohammad Khalifa
This chart is similar to the pump-off 5 6 AM 7 8
chart except that there are some 4 60 9

50
additional spikes at 7:00 AM, 1:00 3
10
40
30
PM and 7:00 PM. 20
11
10
NOON
1
MIDNIGHT
2 1
11
3
10
4
9
5
8
7 6 PM

Mohammad Khalifa
The additional spikes are due to
failed restart attempts. The restart
Failed Restart
6 AM
timer is set too low and the pump is 4
5 7 8
9
60
trying to restart while there is 3
50
40
10
insufficient fluid in the wellbore and 30
20
2
it trips due to underload. Immediate
11
10
action is to increase the automatic
NOON
Pump Off
1
restart time. Long-term, the unit w/ False
MIDNIGHT
1
needs to be resized. Restarts
2
11
3
10
4
9
5
8
7 6 PM

Mohammad Khalifa
This chart shows a unit operating
near the correct level but the chart is 5 6 AM 7 8
4 60 9
very "fuzzy". 50
3
10
40
30
20
11
10
NOON
1
MIDNIGHT
21
11
3
10
4
9 5
8
7 6 PM

Mohammad Khalifa
This chart is almost invariably caused
6 AM
by free gas being ingested into the 4
5 7 8
60 9
pump although it is possible that 3
50
10
emulsion production could also cause 40
30
it. It may be possible to smooth out the 20
11
10
line by choking back or lowering the
NOON
1
pump. Producing free gas will usually
Free Gas
MIDNIGHT
reduce the stock tank production rate so
in Pump
1
it is beneficial to reduce the effect.
Many pumps are operated with this
2
11
kind of chart. As long as the underload
3
is set properly, there should be no
major problems. 10
4
9
5
8
7 6 PM

Mohammad Khalifa
This chart shows a normal start-up
at 4:00 AM followed by a gradual 5 6 AM 7 8
4 60 9
reduction in current where it 50
3
steadies out at about 20 amps until
10
40
30
midnight when the unit shuts down 20
11
10
on overload.
NOON
1
MIDNIGHT
21
11
3
10
4
9 5
8
7 6 PM

Mohammad Khalifa
This is a case where the unit
pumped the well off to the point 5 6 AM 7 8
Idle Amps
that there was no fluid being 4 60 9
50
produced so the unit was running at 3
10
40
30
idle load until enough heat built up 20
11
10
to cause the motor to burn which is
NOON
U/L
1
when it tripped on overload. This is
set below
MIDNIGHT
a case where the underload was set
1
"No Load"
to low. Underloads need to be
2
11
raised and unit should be resized.
3
10
4
9
5
8
7 6 PM
Unit trips on O/L (burns)

Mohammad Khalifa
This is a chart for a unit which is
being controlled by a tank level 5 6 AM 7 8
4 60 9
switch. A common application for 50
3
ESP's is to produce into a holding
10
40
30
tank. This tank will have a level 20
11
10
controller which will shut the unit
NOON
1
off when it is full and allow it to
restart when the level drops to a
MIDNIGHT
1
certain point.
2
11
3
10
4
9 5
8
7 6 PM

Mohammad Khalifa
The problem here is that the automatic restart
time is set too short. When the pump stops, Downtime too
the fluid in the tubing column will tend to fall 5 6 AM 7 8 Short
back down through the pump causing it to 3
4 60
50
9
"turbine" or backspin. While this is not a
10
40
30
20
problem in itself, if the unit is restarted while
11
10
this is occurring, a broken shaft could result.
NOON
1
Tank Level
While a check valve may help guard against
MIDNIGHT
Controller
1
this, they can leak and should not be relied
2
upon. To give complete protection, a
11
backspin relay should be used in the motor
3
10
control circuit. Otherwise, set the restart 9
4
timer to a minimum of 30 minutes.

5
8
7 6 PM

Mohammad Khalifa
This chart shows a normal startup Normal
followed by a period of near normal
current. At 7:00 AM the current
Amps
O/L
begins to increase until the unit 6 AM
finally trips on overload and stays 4

5
60
7 8
9
Trip
50
off. There is no automatic restart on 3
10
40
30
an overload trip. 20
11
10
NOON
1
MIDNIGHT
2 1
11
3
10
4
9
5
8
7 6 PM

Mohammad Khalifa
Until the cause of the O/L is cleared, 5 6 AM 7 8
restart should not be attempted. 4 60 9
Common causes of this problem are: 3
50
40
10
► Increased fluid gravity 30
20
11
► Sand production 10
NOON
► Viscosity increases (emulsion
1
formation)
MIDNIGHT
Overload
1
► Mechanical or electrical
problems downhole
2
11
► Electrical power supply
3
problems, etc. The complete
10
installation should be checked 4
out thoroughly.
9
5
8
7 6 PM

Mohammad Khalifa
This chart shows a normal start
followed by a period of erratic 5 6 AM 7 8
4 60 9
current which smoothes out to a 50
3
normal curve.
10
40
30
20
11
10
NOON
1
MIDNIGHT
2 1
11
3
10
4
9
5
8
7 6 PM

Mohammad Khalifa
5 6 AM 7 8
This is often caused by debris being pulled into 4 60 9
the pump such as scale, sand, muds, LCM, etc. 3
50
40
10
While this is not uncommon, it is not desirable 30
20
2
as these materials may adversely affect pump
11
10
wear. In cases like this, the well should always
NOON
1
Pump
be bailed prior to running the pump to remove
MIDNIGHT
the foreign material. If this is caused by
Handling
1
unconsolidated sand, it may be wise to Solids
2
partially choke the well on start up and slowly
11
3
increase production -- especially on wells
10
newly converted from rods which produced a 4
lower flow rate. The reduced rate should still

9
5
provide adequate cooling for the motor

8
7 6 PM
however.

Mohammad Khalifa
This chart shows a normal startup
6 AM
followed by a periodic gradual 5 7 8
4 60 9
increase in production followed by a 50
3
sudden drop to normal current. The 40
10
30
chart shows this occurs over a fairly 20
11
10
predictable time interval.
NOON
1
MIDNIGHT
1
2
11
3
10
4
9
5
8
7 6 PM

Mohammad Khalifa
One possible cause is emulsion formation in
5 6 AM 7 8
the pump which periodically clears. If this is 4 60 9
the case, an emulsion breaker should be 3

50
10
40
considered. 30
20
11
This can also be caused by decreasing 10
NOON
surface voltage due to other heavy
1
Emulsion?
equipment on the line which is cycling on
MIDNIGHT
Surface Load?
1
and off. Try to reduce demand on the Generator?
system.
2
11
This may even be caused by a unit which is
3
on a generator if the regulator is faulty
10
4
causing fluctuation in voltage or speed 9 5
changes resulting in changing power 8
6 PM
frequency. Repair the generator.
7

Mohammad Khalifa
Mohammad Khalifa
Mohammad Khalifa
Troubleshooting
► Pi + Pd Increasing
► WHP Increasing
► Motor Temperature Increasing (no flow to cool the
motor)
► Current (Running Amps) Decreasing (No load)

Mohammad Khalifa
Wellhead
Ground Level Flow
Flow Flow
Mohammad Khalifa
Mohammad Khalifa
Troubleshooting
► Pi + Pd Increasing
► WHP Decreasing
► Motor Temperature Increasing (no flow to cool the
motor)
► Current (Running Amps) Decreasing (No load)
► No flow at Surface ..

Mohammad Khalifa
Wellhead
Ground Level Flow
Flow Flow
Mohammad Khalifa
Mohammad Khalifa
Troubleshooting
► Pi + Pd decreasing
► WHP Decreasing
► Current (Running Amps) Up & Down

Mohammad Khalifa
Wellhead
Ground Level Flow
Flow Flow
Mohammad Khalifa
Mohammad Khalifa
Troubleshooting
► Pd – Pi decreasing
► WHP Decreasing
► Current (Running Amps) Decreasing Slightly
► Flow Rate Decreasing

Mohammad Khalifa
Wellhead
Ground Level Flow
Pump Worn Out
Flow Flow
Mohammad Khalifa
Mohammad Khalifa
ESP Field Assembly Procedure

Mohammad Khalifa
Other ESP Applications
Y-tool ESP System / By-pass ESP System

Mohammad Khalifa
Dual ESP System

Mohammad Khalifa
Coiled Tubing ESP

Mohammad Khalifa
Mohammad Khalifa
Horizontal
Wellhead
Wellhead
Extension
CT Hanger

Mohammad Khalifa
END

Mohammad Khalifa

Artificial Lift Electric Submersible Pumps (ESP) May 2010 (Compatibility Mode)

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Artificial Lift Electric Submersible Pumps (ESP) May 2010 (Compatibility Mode)

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Artificial Lift – Electric Submersible

20th May 2010

2 Electric Submersible Pumps /

3 Electric Submersible Pumps /

4 Electric Submersible Pumps /

5 Electric Submersible Pumps /

6 Electric Submersible Pumps /

7 Electric Submersible Pumps /

Hagedorn & Brown ?

f ( fluid, T, conduit, process)

8 Electric Submersible Pumps /

9 Electric Submersible Pumps /

10 Electric Submersible Pumps /

11 Electric Submersible Pumps /

RESERVOIR WELL SYSTEM

12 Electric Submersible Pumps /

13 Electric Submersible Pumps /

NATURALLY FLOWING WELL

14 Electric Submersible Pumps /

NATURALLY FLOWING WELL DEAD WELL

15 Electric Submersible Pumps /

16 Electric Submersible Pumps /

17 Electric Submersible Pumps /

REQ. LIFT (psi)

BHP DEFICIT SYSTEM CURVE

18 Electric Submersible Pumps /

19 Electric Submersible Pumps /

20 Electric Submersible Pumps /

21 Electric Submersible Pumps /

Total Dynamic Head

22 Electric Submersible Pumps /

Total Dynamic Head

23 Electric Submersible Pumps /

24 Electric Submersible Pumps /

25 Electric Submersible Pumps /

26 Electric Submersible Pumps /

The main advantage of the electrical submergible pump is the

► Flexible flow rate with VSD.

► Can operate reliably in deviated in wells.

► Can be used effectively for offshore applications.

► Operate under extreme conditions such as higher bottom hole

► Can be utilized in a corrosive and scale conditions

► High Capital cost compared to PCP and Sucker Rod Pumps.

28 Electric Submersible Pumps /

29 Electric Submersible Pumps /

30 Electric Submersible Pumps /

31 Electric Submersible Pumps /

The rotation of the high-speed impeller

34 Electric Submersible Pumps /

35 Electric Submersible Pumps /

To couple the motor to the pump, to transmit the torque to rotate

To act as a reservoir chamber for fluctuations in cycling the

To act as a seal chamber to prevent the migration of well fluids from

To equalizes pressures between the motor and the wellbore

36 Electric Submersible Pumps /

Well Fluid slowly

37 Electric Submersible Pumps /

38 Electric Submersible Pumps /

39 Electric Submersible Pumps /

The motor is a three

40 Electric Submersible Pumps /

41 Electric Submersible Pumps /

42 Electric Submersible Pumps /