THE
ELECTRIC SUBMERSIBLE PUMP
(ESP)
Advanced Thinking – Down to Earth Service
THE ELECTRIC SUBMERSIBLE PUMP
INTRODUCTION
TO
ELECTRIC SUBMERSIBLE PUMPS (ESP)
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THE ELECTRIC SUBMERSIBLE PUMP
Benefits of ESPs
• Wide performance range and versatility
• Better production and well control
• Can operate in high angle and horizontal wells
• Most efficient and economical lift method on a cost-per-
barrel basis
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Typical ESP Installation
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Total Dynamic Head (TDH)
TDH is the sum of three basic components
• The vertical distance the fluid must be lifted, which is
calculated from fluid level
• The friction loss in the tubing string
• The wellhead pressure which the unit must pump against
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Total Dynamic Head (TDH) – Vertical Lift
Is vertical lift different then where the pump is landed at?
YES
If you turn the pump off, the fluid level will be at the same
level in the tubing as in the annulus.
The fluid level above the pump is providing pressure at the
intake, so the pump does not have to supply this energy to
lift the fluid.
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Total Dynamic Head (TDH) – Friction Loss
Friction loss is the amount of energy the moving fluid
losses while flowing through the tubing.
In most cases, the bigger the tubing the less the loss, but
when deciding the size of tubing there are a few other
factors to consider.
We actually measure friction loss as pressure which is then
converted to head feet.
See chart on next page.
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Total Dynamic Head (TDH) – Friction Loss
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Total Dynamic Head (TDH) – Wellhead Pressure
Wellhead pressure can be called by many names; surface
pressure, back pressure, tubing discharge pressure, or
even flowline pressure, but the most common is tubing
discharge pressure.
The most accurate is back pressure, because this is the
pressure the pump must work against.
Flowline pressure can actually be much lower, depending if
a surface choke is being used to restrict flow from the well.
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Total Dynamic Head (TDH) – Wellhead Pressure
The back pressure can be converted to head feet for easier
use when deciding the lift required for the ESP.
𝑊𝐸𝐿𝐿 𝐻𝐸𝐴𝐷 𝑃𝑅𝐸𝑆𝑆𝑈𝑅𝐸 ∗ 2.31
WELLHEAD FEET =
𝑆𝑝 𝐺𝑟
Or if you have API
141.5
Sp. Gr. =
131.5 + 𝐴𝑃𝐼
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Total Dynamic Head (TDH)
All three of these factors are added together to help
determine the amount of lift the ESP will require to properly
produce fluid to surface
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THE ELECTRIC SUBMERSIBLE PUMP
The Electric Submersible Pump consists of two major parts
• The first part is the down-hole equipment.
• The second part is the surface equipment.
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The Down-hole Equipment consists of several different
components
• Pump
• Intake (Gas Separator)
• Protector
• Motor
• Sensor
• Motor-lead Extension and Main Power Cable
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The Pump
The Intake (RGS)
The Protector
The Motor
The Sensor
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The Pump
BOD (bolt on discharge)
PUMP
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The Pump
A centrifugal pump is a machine that moves fluid by
spinning it within a rotating impeller that has a central inlet
and a tangential outlet inside a stationery diffuser
The path of the fluid is an increasing spiral from the inlet to
the outlet of the impeller from where it passes to the
diffuser.
The fluid pressure (head) develops against the inside wall
of the diffuser as the curved impeller vane forces the fluid
to move in a circular path. The velocity “head” of the fluid is
converted to potential energy in the fluid.
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The Pump
The pump is positioned at the top of the ESP assembly.
More than one pump of the same type can be connected to
create more lift (head).
The pump is made up of stages.
The stages are stack in series on the pump shaft, the
number of stages is determined by the head (lift) needed.
The type of stage is determined by the required application.
Each stage consists of
• Impeller
• Diffuser
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The Pump - Stage
Impeller
Diffuser
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The Pump - Stage
Diffuser
Impeller
Notice the path of the fluid, as it travels through the stages
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The Pump
Each pump design has a required operating range that is
determined by the pump type and stage type.
This range can be found on the Pump Curve.
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The Pump - Curve
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The Pump - Curve
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The Pump - Curve
The pump curve can provide other valuable information to
ensure a long running life of your ESP system.
• Proper operating ranges to prevent down thrust or up
thrust, which either can damage the pump
• Required horsepower
• Estimated lift (head)
• Estimated production
• Rough fluid levels
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The Intake (Rotary Gas Separator)
Body
Inlet screen
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The Intake (Rotary Gas Separator)
The intake is positioned between the pump and protector.
There two types of intakes for ESPs
• Rotary gas separator
• Standard intake
Both provide the pump with the fluid to be lifted to surface.
The gas separator, separates some free gases back into
the annulus before the fluid enters the pump
Where as the standard intake well allow gas and fluid to
enter pump
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The Protector
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The Protector
Protector is positioned between intake and motor. It serves
as a critical link in the entire ESP system.
It has several functions and each of them has to be
considered carefully for overall system design and
application.
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The Protector
It equalizes the pressure inside and outside of the system
and at the same time provides room for thermal expansion
of oil in the motor.
It also separates the well fluid from the motor oil through
preconfigured chambers; such as DB (double bag) or
Labyrinth.
The HL protector also carries the up thrust and down thrust
created by the pump.
It also transmits the torque developed by the motor to turn
the pump.
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The Motor
Motor head – MLE
connection
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The Motor
The motor is positioned between the protector and sensor.
It is the driving force of the electric submersible pump.
It’s speed is practically constant, regardless of its load.
It is classified as a 3 phase, squirrel cage, 2 pole, high
voltage induction motor.
All vital information can be found on the motor’s nameplate,
such as rated Voltage, Horsepower, Amps, and Frequency
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The Motor
The motor horsepower needed for the application can also
be determined by the Pump Curve.
More the one motor of the same nameplate rating can be
connected for increased horsepower.
The motors horsepower and voltage is linear to its
operating frequency.
The greater the frequency, the greater available
horsepower, the more voltage needed.
The lower the frequency, the lower the available
horsepower, the less voltage needed.
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The Motor
The motor’s nameplate amperage is a constant. If a motor
is rated for a maximum of 30 amps, this rating is applied to
any operating frequency.
The motor is cooled by the movement of well fluid over the
its surface.
The movement of fluid is created by the suction of the
pump.
For proper cooling of the motor, the fluid must travel at a
minimum velocity of 1.3 ft./s over the surface of the motor.
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The Sensor
Motor Base
Multisensor
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The Sensor
With the multisensor, the client can observe various
different data to help optimize and prolong the ESPs life.
• Intake pressure
• Discharge pressure
• Motor winding temperature
• Intake temperature
• Vibration
• Current leakage
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The Sensor
All the data acquired from the sensor are transmitted to the
surface via the ESP power cable.
At surface the high voltage is filtered out through the High
Voltage Choke and the signal is sent to the Surface Panel.
Once there it is interrupted by the Surface Panel and the
values are displayed on the screen and sent to the VFD via
a Modbus connection. (see VFD manual)
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The MLE and Main Power Cable
Main
MLE
Reels of main cable
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The MLE and Main Power Cable
In each ESP installation, both types of cables are used.
Both cables have three conductors covered with an
insulation, lead sheathed, and finally wrapped in armour.
The armour is their made of galvanized or monel material,
this is dependent on the application.
The size of the cables is determined by amperage, voltage
drop, temperature, and space between the tubing collar
and the casing.
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The MLE
The first is the Motor Lead Extension (MLE), which is
thinner in size; allowing it to be ran along side of the ESP
assembly.
There are various different MLE cable types, these are
determined by the needed application.
The MLE is connected to the motor through a tape-in type
connection at the pothead.
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The MLE - Pothead
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The MLE - Pothead
The tape-in pothead is the most reliable and has the
highest breakdown strength in the ESP industry.
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The Main Cable
The main cable is connected to the MLE through a tape
splice, this is usually 10 meters above the top of the ESP
assembly.
The selection of the main cable, like the MLE, is
determined by the application.
The two most critical data values are well temperature and
fluid composition.
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The Surface Equipment consists of several different
components.
• Power supply (generator or utility)
• Variable Frequency Drive (see CAI VFD manual)
• Step-up Transformer
• High Voltage Choke
• Surface Panel
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Surface Equipment Connection Diagram
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Power Supply
• The ESP can be supplied by either generator or by the
utility company.
• Most remote locations are supplied by generators.
• The supply is usually rated as KVA (kilo volt amps).
• Voltage varies from 380 volts to 5000 volts. The selected
surface equipment will determine the actual voltage
needed for the supply source.
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Power Supply – The Generator
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The Generator
• The generator generates AC electrical power.
• There are 2 generators connected to the auto transfer
switch. If one generator fails or needs to be serviced, the
auto transfer switch will start the alternate generator and
switch the load. THE ESP WILL SHUT DOWN AND
MUST BE MANUALLY RESTARTED!
• The auto transfer switch distributes the voltage to the
VFD.
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The Variable Frequency Drive (VFD)
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The Variable Frequency Drive (VFD)
SEE VFD MANUAL
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The Step-up Transformer
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The Step-up Transformer
• The step-up transformer takes the supplied voltage from
the VFD and increases it to a level the ESP can use.
• See VFD manual for more detail
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Surface Panel
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High Voltage Choke
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Surface Panel – High Voltage Choke
• The surface panel is the processing center for the
sensor.
• It sends a 120 VDC signal to the sensor via the high
voltage choke and transformer
• The transformer allows the signal to travel down-hole
through the high voltage cable.
• When the signal returns, the high voltage choke filters
out the high voltage and allows the signal to travel to the
surface panel for analysis
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Surface Panel – High Voltage Choke
• The surface panel then interprets the signal and displays
the values on the display.
• It also transmits the values to the HMI via a Modbus
connection, allow for the exact values to be displayed on
the HMI. (see VFD manual)
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Thank you for your attention
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