3/15/2019

Baker Hughes ESP Overview

© 2012 BAKER HUGHES INCORPORATED. ALL RIGHTS RESERVED. TERMS AND CONDITIONS OF USE: BY ACCEPTING THIS DOCUMENT, THE RECIPIENT AGREES THAT THE DOCUMENT TOGETHER WITH ALL INFORMATION
INCLUDED THEREIN IS THE CONFIDENTIAL AND PROPRIETARY PROPERTY OF BAKER HUGHES INCORPORATED AND INCLUDES VALUABLE TRADE SECRETS AND/OR PROPRIETARY INFORMATION OF BAKER HUGHES
(COLLECTIVELY "INFORMATION"). BAKER HUGHES RETAINS ALL RIGHTS UNDER COPYRIGHT LAWS AND TRADE SECRET LAWS OF THE UNITED STATES OF AMERICA AND OTHER COUNTRIES. THE RECIPIENT FURTHER
AGREES THAT THE DOCUMENT MAY NOT BE DISTRIBUTED, TRANSMITTED, COPIED OR REPRODUCED IN WHOLE OR IN PART BY ANY MEANS, ELECTRONIC, MECHANICAL, OR OTHERWISE, WITHOUT THE EXPRESS PRIOR
WRITTEN CONSENT OF BAKER HUGHES, AND MAY NOT BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO BAKER HUGHES’ INTEREST.

Basic ESP System

VSD
Step-Up Transformer
Junction Box
Transformer

Power Ride Through Cable

(optional)
Pump

Seal

Motor

Sensor

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The ESP System

• Its purpose is to deliver the required lift at the

desired flow rate
• Should be set above the perforations of the well for
unit cooling
• Must be sized to specific well data
• Should be monitored for changes in well and/or
unit performance

3 © 2012 Baker Hughes Incorporated. All Rights Reserved.

The Pump

• Hangs from the production tubing

• Lifts the fluid through the tubing to the
surface
• Is a multistage centrifugal type
• Is constructed from impellers and
diffusers (stages)
• Must be sized to match the well
production
• Has an intake that either bolts on or is
threaded into the pump housing

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Pump Stage

• Consists of an impeller and diffuser

• The impellers rotate with the shaft and spin
at the RPM of the motor
• The diffusers turn the fluid into the next
impeller and do not rotate
• A stage will produce a given amount of flow
and lift (head) at the motor RPM

5 © 2012 Baker Hughes Incorporated. All Rights Reserved.

Impeller and Diffuser

Diffuser redirects the fluid up into

the next impeller and turns fluid
energy into “head”

Impeller spins and gives energy

to fluid which exits around the
outside

Diffuser directs fluid into the eye

of the impeller

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Pump Stage

Pump Stage – Impeller and Diffuser Cutaway of a Pump Stage

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Rotary Gas Separator

• Used as the pump intake

• Rotating chamber (rotor) or induced vortex
imparts centrifugal force on the fluid
• Heavier fluids are forced to the outside while
free gas migrates to the center
• Liquid is ported internally to the pump inlet
while the gas is vented to the casing annulus

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Seal Section Functions

• Transfers the motor torque to the pump shaft

• Equalizes the internal unit and wellbore pressure
• Provides for motor oil expansion volume
• Isolates the well fluid from the clean motor oil
• Absorbs the pump shaft thrust load
• Labyrinth or bag chamber options allow for use in
vertical or deviated wells

9 © 2012 Baker Hughes Incorporated. All Rights Reserved.

Seal Section Components

Major components are ...

• Mechanical Seals - prevent fluid migration down
the seal shaft
• Bag(s) or Bladder(s) - provides expansion
volume and isolation for clean motor oil
• Labyrinth Chamber(s) - provides expansion and
isolation volume in vertical or near vertical wells
• Thrust Bearing - carries the thrust load of the
pump shaft and stages (fixed impeller type only)

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The Electric Motor

• Drives the downhole pump and seal section
• Is rated for a specific horsepower, voltage, and
current
• Is a two pole, three phase, AC induction type
design
• Rotates at approximately 3500 RPM at 60 Hertz
(equivalent to 2917 RPM at 50 Hertz)
• Is constructed of rotors and bearings stacked on
the shaft and loaded in a wound stator
• Contains synthetic oil for lubrication
• Relies on fluid flow past the housing OD for
cooling
• Can be deployed with or without a downhole
sensor

11 © 2012 Baker Hughes Incorporated. All Rights Reserved.

Motor Construction

Housing

Stator
Laminations
Epoxy Winding
Rotor Encapsulation

Rotor Bearing Insulated Magnet

Wire

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Motor Product Range

725 Motor

562 Motor

450 Motor

375 Motor

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The Power Cable Components

• Power to the motor
• Two down-hole sections
– Power Cable
– MLE
• Fastened to tubing
– Metal bands
– Cast clamps

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The Power Cable Components

• Conductor (copper)
• Insulation (Polypropylene or EPDM rubber)
• Jacket (Nitrile or EPDM rubber or Lead Sheath)
• Armor (galvanized steel, stainless, or Monel†)
†Registered Trademark of the Special Metals Corp.

15 © 2012 Baker Hughes Incorporated. All Rights Reserved.

Motor Lead Extension with Pothead

Motor Lead Extension
• Lowest section of power cable
string
• Lower profile than standard flat
cable to run the length of pump
and seal section
Pothead
• Terminal end of motor flat cable
• Allows entry of electric power
into the motor
• Seals the connection from well
fluids

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Downhole Sensors and Monitoring

• Downhole sensors send data to the surface
to help monitor the condition and
performance of the ESP system
• Various downhole sensors can be attached
to the bottom of the motor and/or deployed
separately in the wellbore
• Signals are sent to the surface by
– Impressed DC signal on the power cable
(“comms on”)
– A separate instrument wire
– Fiber optics
• Monitoring important parameters improves
run life and enhances the decision-making
process during ESP operation

17 © 2012 Baker Hughes Incorporated. All Rights Reserved.

ESP Surface Controls

Electrostart Switchboard
• Fixed speed, limited flexibility
• Full voltage / current starting
• Suitable for stable well
conditions where on-off cycling
is not a primary concern

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ESP Surface Controls

Electrospeed Advantage Variable
Speed Drive (VSD)
– Changes motor speed / pump
flow rate by changing
operating frequency
– “Soft starts” unit by ramping
frequency over time to final
operating point
– Available in outdoor and
indoor enclosures
– Allows customer to maximize
production & limit down time
– Suitable for unstable well
conditions or where,
maximizing efficiency or
production is a primary
concern

19 © 2012 Baker Hughes Incorporated. All Rights Reserved.

Production Optimization

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