Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Electrical Submersible Pump/REDA Course
By: Panca S Widiantoro
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Class Schedule
Instructor: Panca S Widiantoro
Phone: 0821 38 578 625
E-mail: pancasuciwidiantoro@gmail.com
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Course Outline
1. Introduction to Electrical Submersible Pump/REDA
2. History and evolution of ESPs
3. Principle of ESP
4. ESP Component
Subsurface component
Surface component
5. Nodal Analysis
6. Total Dynamic Head
7. ESP Design
Manual Calculation (using Ms.Excel)
Software Calculation (using Prosper Software)
8. New ESP Innovation
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP (concept of Artificial Lift)
Natural flow
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP (concept of Artificial Lift)
How to lift the fluid ?
- Decrease the fluid
Psep Pwh
gradient in the tubing
- Add some extra
energy to push fluid
well from bottom hole No - Flow Well
Gradient
?
to the surface
Solution :
Energy
Use the artificial lift ?
Pwf
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP (concept of Artificial Lift)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP (Artificial Lift Method)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP (Artificial Lift Method)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Comparison of Lift Methods
Typical Artificial Lift Application Range
Ft./Lift
12,000
11,000
10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 20,000 30,000 40,000 50,000 BPD
Rod PC Pumps Hydraulic Lift Submersible Pump Gas Lift
Pumps
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Electrical Submersible Pumping
• Second most commonly used method worldwide (+100,000 wells)
• Used massively in Russia and in significant number of wells in US
• Responsible for the highest amount of total fluids produced (oil and water) by
any artificial lift method and an ideal method for high water cut wells
• Problems with sand production, high gas liquid ratio and high bottom hole
temperatures
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
ESP video
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
The system’s surface equipment includes transformers, a switchboard, junction
box and surface power cables. Power passes through a cable running from the
transformer to the switchboard and junction box, then to the wellhead
The ESP downhole assembly is located in the well at the bottom of the tubing.
The motor, seal, intake and pump assembly, along with the power cable, goes in
the well as the tubing is run.
Below the pump is an intake that allows fluid to enter the pump. Below the intake
is a gas separator and a protector or seal, which equalizes internal and external
pressures and protects the motor from well fluids. At the bottom is a motor that
drives the pump. The assembly is positioned in the well above the perforations;
this allows fluid entering the intake to flow past the motor and cool it.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Benefits of ESPs
They can be economically designed for both oil and water wells, at production
rates ranging from 200 to 60,000 B/D and at depths of .up to 15,000 feet.
They can be used in crooked or deviated wells. DLS < 9 degrees/100ft
They have a relatively small “surface footprint,” and so are appropriate for use in
offshore, urban or other confined locations. They are relatively simple to operate.
They generally provide low lifting costs for high fluid volumes.
They make it easy to apply corrosion and scale treatments.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Limitations of ESPs
They are generally limited to single-zone completions
They requires a source of high-voltage electric power
The presence of a power cable alongside the tubing string can make it more
difficult to run or pull tubing.
They are not particularly good at handling gas and solids production.
Analyzing the system performance can be a challenge.
Power cables may deteriorate in high temperature conditions—400 degrees
Fahrenheit (about 200 degrees Celsius) is their general upper limit with respect
to operating temperature.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
History and Evolution of ESP
REDA: Russian Electric Dynamo of Arutunoff estalished
in 1930 in Bartlesville, OK
Armais Arutunoff
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
History and Evolution of ESP
Armais Arutunof
Develop ESP for Purchased by
dewatering mines and Schlumberger
Got US Patent
ship
Rotary Gas Separator
Introduced
Test ESP in horizontal
position
1910 1916 1926 1950 1970 1977 1998
Found Seal with mechanical
seals Introduced VSD
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
History and Evolution of ESP
ESP providers nowadays:
1. Schlumberger-REDA (Bartlesville, OK)
2. Centrilift – Baker Hughes (Claremore, OK)
3. Weatherford
4. Wood Group ESP - GE (Oklahoma city, OK)
5. ALNAS (Russia)
6. Novomet
7. EJP (Local Indonesia)
8. Etc..
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Principle of ESP
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Components
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
−Subsurface components
• Cable
• Motor
• Seal Section/Protector
• Gas Separator (Optional)
• Pump
• Sensor (Optional)
• Drain Valve
• Check Valve
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Electric Cable
A power cable runs from the junction box then through the wellhead and all the
way to the bottom to supply power to the pump motor.
Cable is available in round and flat styles
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Subsurface Components – Cable Amperage
The first consideration in selecting cables is amperage. The limits on amperage
for cables containing copper conductors are as follows:
Note that the cable with the smaller number has the larger diameter. Thus, a
Number 1 cable can carry a maximum of 115 amps.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Subsurface Components – Voltage Drop
The second selection consideration is the voltage drop that will occur between
the wellhead and the pump. Normally, the maximum voltage drop for an
electrical cable is about 30V per 1000 feet.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Motor
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Seal/Protector
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Gas Separator
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Subsurface Components – Gas Separator
Separates the free gas in order to reduce the quantity of gas that flows into the
pump.
There are two types: static and rotary gas separator.
Static: No applying any additional mechanical force. They provide a tortuous
path that turns the fluid stream and moves it down toward the inlet ports. Some
of the free gas accompanies the liquid to the intake and a portion is separated.
Dynamic gas separators, on the other hand, actually impart energy to the fluid
to separate the vapor from the fluid.
http://www.woodgroup-esp.com/products/Pages/GasSeparators.aspx
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Subsurface Components – Gas Separator
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Gas Separator
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Gas Separator (AGH)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Gas Separator (Poseidon)
Can handle free gas content up to 75%
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Pump
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
ESP Classification
ESPs can be classified into two main categories: Radial flow and Mixed flow
Radial Flow Pump
Mixed Flow Pump
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Pump
Each stage consists of an impeller and a diffuser
The rotating impeller takes the fluids and imparts kinetic energy from the
rotating shaft to the fluids
The stationary diffuser converts the kinetic energy of the fluids into pressure
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Pump
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Pump
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Pump
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Pump
https://www.scribd.com/doc/135870869/Schlumberger-ESP-Catalog-pdf
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
ESP Classifications
The performance characteristics of stages at the best efficiency point is a function
of a dimensionless number called specific speed
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
ESP Classifications
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Subsurface ESP Components
Subsurface Components – Check Valve
A check valve is installed about two to three
joints above the ESP pump to maintain a full
liquid column in the tubing string during
equipment shut down periods. It prevent leaking
of the fluid from the tubing down through the
pump when the pump is not running.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Surface ESP Components
Surface Components – Check Valve
Surface components
• Transformers (Primary and Secondary)
• Switchboard or Variable Speed Drive or Soft Start
• Junction Box
• Wellhead
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Surface ESP Components
Surface Components - Transformer
transformer system is used to step-up
or step-down the voltage from the
primary line to the motor of the
submersible pump. Because a range
of operating voltages may be used for
submersible pump motors, the
transformer must be compatible with
the selection of the motor voltage.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Surface ESP Components
Surface Components - Switchboard
The switchboard controls the pump motor
and provides overload and underload
protection.
Protection against overload is needed to
keep the motor windings from burning.
Protection during underload is needed
because low fluid flow rates will prevent
adequate cooling of the motor.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Surface ESP Components
Surface Components – Junction Box/ vent Box
The junction box connects the power cable from the switchboard to the power
cable from the well. It provides an explosion-free vent to the atmosphere for
any gas that might migrate up the power cable from the wellbore.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Surface ESP Components
Surface Components – VSD
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Surface ESP Components
Surface Components – Wellhead
Must provide means for installing the cable with adequate seal
May include adjustable chokes, bleeding valves
Onshore wellheads have a rubber seal and offshore have a electric mandrel
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
Surface Components – Wellhead
The Safe-T-Lok is supplied with factory molded cable on both the top and the
bottom. The lower cable will be spliced to the ESP cable, and the top cable
will connected to the junction box.
The Safe-T-Lok is installed in the wellhead by feeding through the tubing
hanger from below
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Introduction to ESP
ESP Operating Principles
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
If you guys understood everything about
“ESP”
Let us have a coffee and smoking
break!!!
aram
aram Gudang G
aram Gudang G
Gudang G
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Nodal Analysis
1 Phase IPR
2 Phase IPR
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Nodal Analysis
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Nodal Analysis
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Nodal Analysis
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Nodal Analysis
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Nodal Analysis
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Nodal Analysis
Natural Flow With Pump
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Total Dynamic Head (TDH)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Total Dynamic Head (TDH)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Total Dynamic Head (TDH)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Total Dynamic Head (TDH)
4000 ft
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Total Dynamic Head (TDH)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Total Dynamic Head (TDH)
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
For 2 7/8 “, friction = 200*6.5 = 1300 ft of loss 2
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
Total Dynamic Head (TDH)
Total Dynamic Head = Fluid level + Tubing friction + Back pressure
Wellbore
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016 ESP Pressure Gradient
Wellhead pressure
Liquid Level
Total Dynamic Head Discharge Pressure
Suction Pressure
Bottomhole pressure
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Design
1. Using MS Excel
2. Using Software
API 11S4
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Innovation
Coil Tuibing Deployed ESP System
Cable suspended and coil tubing
ESPs can also be used. They can
also be used to kick-off wells,
clean wells after a frac job and test
wells
Figure on the side is the coil tubing
deployed ESP system.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Innovation
Coil Tuibing Deployed ESP System - Offshore
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Innovation
Coil Tuibing Deployed ESP System - Offshore
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Innovation
Cable Suspended ESP System
Cable Suspended ESP:
• The unit is lowered in the well without using a tubing. It is
suspended from a cable and the power cable is banded to it.
• A special seating element supports the pump and
provides locking to avoid excessive torque on the cable.
• Differently from the conventional installations, the motor
is located above the pump.
• The system produces through the annular.
• It main advantage is the reduction in al costs associated
with tubing pulling job, specially offshore
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Innovation
Combination between ESP and Gas Lift (Hybrid system)
Some installations combine ESP
with other artificial lift methods
• ESP and Gas lift
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Innovation
Subsurface Components –ESP Bypass System
Wireline or coiled tubing plugs can be supplied to seat in a nipple
profile in the Y-tool to enable intervention or logging operations
without retrieval of the completion
Can be also used for installing two parallel ESPs in the well.
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
ESP Innovation
Shuttle ESP
Advantages:
1. Low installation and WO
cost
2. Using minimal crew when
installation process
3. Suitable for low oil price
condition
Electrical Submersible Pump
Training and Talk “ESP” AKAMIGAS Balongan
Indramayu, Oct 2016
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Electrical Submersible Pump
