ESP 06 - Virtual Session 1 PDF

Electrical Submersible Pumps Fundamentals
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Electrical Submersible Pumps

Fundamentals
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Virtual Session 1
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Basic ESP Components
 Transformer
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 Switch Board
Surface
 Vent Box
 Wellhead Feed-thru connections
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 Round cable
 Pump
 Intake / Separator Downhole
 Seal Section
 Flat Cable
 Motor
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© PetroSkills, LLC., 2016. All rights reserved. 1
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ESP Downhole Components
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Functions of Main Components
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The Pump
 The function of the pump is to reduce the

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bottom-hole flowing pressure to gain more

production
 An ESP is a centrifugal pump and comprises a
series of stages; so named because head
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added to fluid is largely due to centrifugal

effects
 Characterized by:
• Small diameter
• Large quantity of stages
• High design loads
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2 © PetroSkills, LLC., 2016. All rights reserved.
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The Pump
 Normally driven by a two-pole

submersible motor at an operating
speed of 3,500 rpm (60 Hz power
supply)
 Performance:
• Head = ƒ ( µ , glr )
– Viscosity and gas reduce head
• Flow = ƒ ( µ )
– Flow is reduced by viscosity
• Power = ƒ ( sg , µ )
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– Power required by the pump
increases with density and
viscosity
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The Pump
Impeller
 The motor causes a shaft to rotate
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 The impellers (keyed to the shaft)

turn with the shaft
 Each rotating impeller adds kinetic
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energy to the fluid

 The stationary diffuser slows down
the fluid and converts kinetic
energy to potential energy
 The potential energy of the pump is
measured in feet (or meter) of
head or as a pressure differential
across the pump
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ESP Pump Curve
Head Capacity
Pump
Efficiency
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BHP
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H-27
ES P
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ESP PUMP Cu rve Fo r 5-1/2” Well Casing Pump
Curve
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Impeller Shape and Performance

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Radial flow
More head, less flowrate
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Mixed flow
Axial flow
Less head, more flowrate
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Radial Flow Impeller
 Also called ‘pancake’ type

 Vane angle close to 90 degrees
 Usually for low flow rate
 Low cost pump stages
 Each stage compact
• Pumps sections much shorter
than a pump section with same
number of mixed flow stages
 More prone to issues with gas,
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scale, solids and viscosity
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Mixed Flow Impeller
 Has vane angle close to 45

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degrees
 Usually for higher rates >1800
bfpd
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 Requires a lot more metal / stage

 More tolerant of:
• Solids
• Scale
• Gas
• Viscosity
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Multiple Stages to Achieve Head
 Single stage
• Each stage comprises of an
impeller and a diffuser
 Multiple stages
• Multiple stages in series
• Each stage adds some
head to the fluid
• When length of the stacked
stages gets too large, the
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stages are grouped into
multiple housings
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Pump Performance Curve
 Published by manufacturers
for each pump type, showing:
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• Head vs. flowrate

• Hydraulic HP requirement
• Efficiency vs. flowrate
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• Recommended operating
range for pump
• Best Efficiency Point (BEP)
• Usually produced for one
stage with fluid SG=1.0
• Head curve is not affected
by the specific gravity of the
fluid it is pumping
• More stages increase pump
head; flowrate stays the
same
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Typical Pump Performance Curve
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Typical Pump Performance Curve: SI Units

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C
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The Pump
 Two construction methods for pumps:

• Floater (original)
• Compression
 Floater
• The impeller is free to “float” or move up and down relative to the
pump shaft
• Does not transfer impeller hydraulic thrust to the seal thrust bearing
 Compression
• Built such that the impeller hubs stack together and transfer all thrust
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to the seal thrust bearing instead of to the diffuser
• This pump is a good choice for wells that pump experience downthrust
wear due to low flowrates
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• May have advantages for gas, abrasives, low fluid levels or
combinations of these problems
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Floater / Compression Pumps
Floater Compression
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Standard bearing High load bearing

Longer pump sections possible Maximum 80-100 stages per
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housing
Lower cost Higher cost
Only for smaller pumps Available in all pump sizes
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Impeller Terminology
Upthrust Washer Impeller Hub
Top Shroud
Impeller
Vane
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Bottom Shroud
Downthrust Washer
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Impeller Skirt
Impeller Eye
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Pump Thrust
 Under normal operating conditions,

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fluid recirculation on the top and

bottom side of the impeller cause
forces to be applied on the upper and
lower impeller shrouds
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 When the recirculation forces are

greater on the upper shroud, the
impeller is moved down-Downthrust
(head is too high)
 When the recirculation forces are
greater on the lower shroud, the
impeller is moved up – Upthrust
(flowrate is too high)
Operating with excessive Downthrust or Upthrust will cause inefficient

operation and may induce vibration; leading to pump failure
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The Pump
 Approximate thrust profile of a pump
Downthrust
+ (positive)
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0
Upthrust
-
(negative)
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Shut In BEP Wide Open
Operating Range
IG STAGE FLOW RATE

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The Pump: Performance Tolerances
 API performance curve test tolerances

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• Pumps (new or re-run) should conform to published curves (within

certain ranges) as per the following
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Calculation of ESP Pump Stages Quiz
 Well parameters (vertical)

• Fluid = 35°API Oil
• Water cut (%) = 0
• Pump depth: 6500 ft. (1981.2 m)
• Mid Perf: 6750 ft. (2057.4 m)
• Casing pressure: 0 psig
• THP: 150 psig (1034.214 kPa)
• Friction loss in tubing: 150 ft. (45.72 m) Produced Fluid
• Fluid over the pump: 1200 ft. (365.76 m)
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 Calculate:
1. Pwf, PIP and PDP
2. The number of pump stages required,
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if each stage develops a head of 58
ft/stage (17.68 m/stage)
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Calculation of ESP Pump Stages Quiz

Solution
 Calculate:
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1. Pwf, PIP and PDP

2. The number of pump stages THP = 150 psi
required if each stage develops a CHP = 0 psi
head of 58 ft/stage
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Gradient = 0.433*0.85 = 0.368 psi/ft (8.32 kPa/m)

Pwf = (1200 + 250)* 0.368 = 534 psi (3681.8 kPa)
Produced Fluid
PIP = 1200*0.368 = 442 psi (3047.483 kPa)
PDP = 2598 psi
TDH = (6500-1200) +150 +408 = 5858 ft (1785.51 m) PIP = 442 psi
∆P = 5858*0.368 = 2156 psi (14865.1 kPa)

PDP = 2156+442 = 2598 psi (17912.58 kPa)
Pwf = 534 psi
Number of stages = 5858/58 = 101 Stages
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ESP Variable Speed Drive
 A variable speed drive (VSD) provides flexibility to the otherwise

fairly inflexible ESP system at a price
 The Variable Speed Drive (also known as Variable Frequency
Drive (VFD), Variable speed controller or Variable frequency
controller) can change the rotational speed of the motor by
changing the frequency of the AC power before sending it down
hole to the ESP
 Frequencies achievable with a VSD are from 20 Hz - 100 Hz
60 Hz
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IN 80 Hz
OUT
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 By changing the rotational speed of the pump, the operating

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range expands
 An increase in Hertz
• Increases RPM
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• Increases pump head

• Increases the HP requirement
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Pump / Motor Speed Variation Laws
 Pump affinity laws**

• May be driven at other speeds either due to power
source or intentionally to modify performance
– Flow = ƒ (rpm) = ƒ (frequency)
– Head = ƒ (rpm2) = ƒ (frequency2)
– Power = ƒ (rpm3) = ƒ (frequency3)
 Motor: The rotational speeds and the horse

power (HP) produced by motor are proportional
to Hz to the first power:
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• A 250 HP motor spinning at 3500 rpm with 60 Hz
supply
– Increase frequency from 60 to 66 Hz
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– Speed will increase to 3850 rpm, and
– Will produce 275 HP
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** Note: These are pump laws and not motor laws
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The Pump
 Pump affinity laws for ESP (at BEP)

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N2
Q2  Q1 ( )
N1
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N2 2
H 2  H1 ( )
N1
N2 3
bhp2  bhp1 ( )
N1
 Motor performance (HP developed)
Hz2
N 2  N1 ( )
Hz1
N2
HP2  HP1 ( )
N1
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The Pump
 The Tornado plot shows the pump performance and range at

different Hz
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 The motor horsepower output is a function of frequency, varying

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in a straight line slope

 Motor : HP2 = HP1 * (Hz2 / Hz1)
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200
150
HP 100
50
0
0 20 40 60 80 100
Frequency (Hz)
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 The pump horsepower required is a function of rotational speed

(frequency) cubed
 Pump : HP2 = HP1 * (Hz2 / Hz1 )3
200
150
HP 100
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50
0
0 20 40 60 80 100
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Frequency (Hz)
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 This gives an upper limit to the range of frequency allowed to a

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given ESP system

 Up to a certain frequency, the motor is underloaded, and, beyond
that frequency, the ESP cannot be operated because the motor is
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overloaded
Underloaded Overloaded
200
150
HP 100
50
0
0 20 40 60 80 100
Frequency (Hz)
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Examples of Max Shaft BHP/Housing DP
 Centrilift shaft/housing ranges
Pump Series Shaft (Max bhp) Housing (DP)

338 110/240 4,310
400 110/240/550 5,020
513 550 4,970
562 1017 3,510
675 1017 2,680
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875 1017 4,315
1025 1500 3,054
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Shaft rating is based on 60 Hz operation
On VSD operation, shaft rating varies with (Hz/60) ratio
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How Rates May Vary Within Pump Series
 Centrilift capacity ranges

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Pump Series Diameter Flow Range (bpd)

338 3.375” 550 – 3,100
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400 4.000” 150 – 6,800

513 5.125” 750 – 12,000
562 5.625” 9,500 – 24,000
675 6.750” 4,500 – 44,500
875 8.750” 10,300 – 32,200
1025 10.250” 19,200 – 58,900
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Pump Curve Quiz
 For the pump GC 4100 Wood Group, find:

• The head per stage, horse power requirement and the
efficiency while pumping 4500 BFPD
• Is the pump on Upthrust or Downthrust under these
conditions? Is this acceptable?
• What is the fluid rate corresponding to the BEP?
• What will happen to the power requirement of the pump if the
SG of the fluid increases by 8%
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Pump Curve Quiz

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C
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Pump Curve Quiz

Solution
BEP
65%
40.5 ft 2.05HP
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IG 4500
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Pump Curve Quiz

Solution
 For the pump GC 4100 Wood Group, find:
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• The head per stage, horse power requirement and the efficiency
while pumping 4500 BFPD
40.5 ft/stage (12.34 m/stage)
2.05 HP/stage (1.5287 kW/stage)
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65% Efficiency
• Is the pump on Upthrust or Downthrust under these conditions? Is
this acceptable?
Mild Upthrust, acceptable
• What is the fluid rate corresponding to the BEP?
4100 BPD (651.85 m3/day)
• What will happen to the power requirement of the pump if the SG of
the fluid increases by 8%
The HP demand will increase by 8%
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Gas Handling
 Excessive gas at pump intake can:

• Create gas lock
• Reduce bearing life
• Decrease flow, head, efficiency
• Reduce the cooling of the ESP system
 Three basic methods to minimize gas entry into pump:
• Avoidance
• Separation
• Handling
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 Gas avoidance:
• Bottom feed intake systems
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• Shrouded systems
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Gas Separator
 Gas separator
• Used in applications where free gas
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causes interference with pump

performance
• Units separate some of free gas from
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fluid stream entering pump to improve

pump’s performance
 Rotary gas separator
• Specially designed rotating chamber
acts as centrifuge
• Forces the heavier fluid outside and
allows free gas to migrate to the
center of the chamber
• At the top, two streams are physically
separated
• Liquid rich stream is ported internally
to the pump inlet
• Gas rich stream is vented to the
casing annulus
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Gas Separator
 Use gas separators when …

• Free gas % is more than 10% with radial flow
stages
• Free gas % is more than 15% with mixed flow
stages
– Approximate rotary separator efficiency could be
50-90%
• Vortex gas separator may be used where
production of abrasives/solids through the pump
is a possibility
 Notes:
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• After separation, free gas going into the first
stage should be less than the above
percentages
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• Very gassy wells may require a tandem
separator or advanced gas handler
• Sandy wells requiring a rotary gas separator
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should utilize specially design abrasion resistant
units or another form of gas handling technology
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Gas Separator: Has Rate Limitations
 Rotary gas separator ranges (note, flowrate expressed as BPD)

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Series Intake Flowrate, BPD (Max)

338 2,700
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400 4,400
513 13,000
675 25,000
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Advanced Gas Handlers
 Homogenize the gas and liquid before it enters the pump, reducing
the tendency of gas locking
• Able to handle 45% of gas volume fraction under normal conditions
• Use in tandem with gas separators to increase the gas handling
capability
• The Poseidon gas handling system (helicoaxial multiphase pump)
primes the main production pump and pushes the gas-liquid flow stream
into the stages, reducing gas volume by compression (can handle up to
75% GVF)
GAS HANDLING CAPABILITY
Device Gas Volume Fraction [V/(V+L)] %
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Radial Flow Stage
Mixed Flow Stage
Single Vortex Gas Separator
Single Rotary Gas Separator
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Advanced Gas Handler
Tandem Vortex Gas Separator
Tandem Rotary Gas Separator
Tandem Vortex Gas Separator

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+ Advanced Gas Handler
0 10 20 30 40 50 60 70 80 90 100
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Seal / Protector
 Located between pump and motor

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 Function
• Balances pressure between motor
and wellbore
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• Transmits force from motor to pump

• Protects motor from contamination
by well fluid
• Absorbs thrust from pump
 Nomenclature
• Seal = Centrilift
• Protector = Reda / WG
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Seal / Protector
 Steps in the operation cycle of a

protector:
• Servicing the protector prior to
installation
• System landing at setting depth, oil
expands
• Motor operates, oil expands more
• Motor stops, oil contracts
• Motor operating cycles
• Pulling the unit to surface, oil contracts
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 The motor should remain filled with the
special blend oil that lubricates and
electrically insulates the components
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• The equalizer should permit expansion /
contraction of the motor oil
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Protector Types
Positive Seal Protector Labyrinth Seal Type

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Well fluids
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Flexible bag
Motor fluid
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Protector Types
 Flexible Bag type  Labyrinth Seal Type

• Flexible bag to handle the • Better in vertical wells
variation in motor fluid volume • Works on the principle of U-Tube
• Elastomer selection critical • Depends on separation of fluids -
• Provides complete isolation significant difference in specific
gravities between motor and well fluid
required
• Not recommended for horizontal wells
 Protector Construction
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• Series / parallel
• Multiple chambers
• Thrust bearings in base of assembly
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Seal / Protector
 Mechanical seals
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• Usually John Crane

• Allow slight leakage for lubrication of
shaft
• Prevent passage wellbore
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 Thrust bearing
• Thrust runner fixed to shaft Upthrust
• Rides on Upthrust or Downthust bearing
bearings
• Shimming critical in compression Thrust
pumps Runner
Downthrust
bearing
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Motor
 Motor is oil filled (dielectric)

 It is a two-pole, three phase, 3,600 RPM
design (60 Hz)
 Some motor components are designed to
withstand up to 500oF temperatures
 Motor cooling is achieved by:
• Internal oil circulation
• Flow of well fluid along outside skin (min
velocity of fluid past motor 1ft/s)
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 A shroud is used if:
• ESP is set below perforations
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• Or, to improve the fluid velocity past the
motor (by reducing the clearance area
between the motor and the casing)
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Motor
 Motor components
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C
Housing
Stator Laminations
Epoxy
Encapsulation
Kapton-Wrapped
Bearing with T-ring Magnet Wire
Rotor
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Motor
 Name plate on motor
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Motor
 Motor component parts

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C
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Motor
 Function of the motor

• 3-phase alternating current creates
revolving magnetic fields in stator
• Magnetic fields cause rotor and shaft
inside stator to spin
• Each rotor is then capable of
producing X number of horsepower
with given voltage
 Voltages, on surface, may be changed
to adjust horsepower capabilities and
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performance of motor (within limit)
• Motor speed = f (frequency)
• Horsepower = f (frequency)
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Motor Speed
 The induction motor synchronous speed can be calculated when

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the number of poles (2 in this case) and frequency of supply is

known:
Hz x 120
RPM =
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Number of Poles
 Due to losses due to slip, friction and windage, the motors run at
lower speeds:
Supply Frequency Synchronous Speed Actual Speed
60 Hz 3600 RPM 3450 RPM
50 Hz 3000 RPM 2915 RPM
 Large HP requirements may be met by bolting more than one

motors together as tandem motors
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Motor
 Motor performance curve
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Motor Performance Curves: Reda 562 Series 60 Hz

3600 87
Speed RPM 86 % Power Factor

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3550
85
84
3500
83
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3450 82
81
3400
90 100
89 Voltage
80
88
87
60
86 Amperage
85 % Efficiency
40
84
83
20
82
40% 50% 60% 70% 80% 90% 100% 40% 50% 60% 70% 80% 90%
Percent of Nameplate Load Percent of Nameplate Load
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Motor
 Total motor load =

Pump load (Brake HP) +
Intake load (Brake HP) +
Seal section load (Brake HP)
 Motor selection
• For one HP rating there are
usually several NPV, NPA
possibilities
• However most choose the
highest voltage to minimize
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losses in the cable
• Check motor rotation using a
phase rotation meter before
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running in hole
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Motor
 Amp chart - motor amps with

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time
• Amps to motor can be
diagnostic to pumping
condition
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• Computer may just record

linear trace instead of using
amp chart
HP
 no of stages  s.g. of fluid
stage
Amps 
Volts  Efficiency  Power Factor
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Motor
 Motor sizes
Motor Series Diameter HP Range

375 3.750” 19 – 195
450 4.500” 15 – 306
544 5.438” 18 – 75
562 5.625” 38 – 920
725 7.250” 175 - 750
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HP range is based on 60 Hz operation
On VSD operation, motor hp varies with (Hz/60) ratio
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ESP Design Resource Material

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 Refer to the Engineering

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Training resource material

from Centrilift to assist
understanding of
performance characteristics
of various ESP components
and their limitations
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Electrical Submersible Pumps Fundamentals

Electrical Submersible Pumps

Basic ESP Components

ESP Downhole Components

 The function of the pump is to reduce the

bottom-hole flowing pressure to gain more

added to fluid is largely due to centrifugal

 Normally driven by a two-pole

 The impellers (keyed to the shaft)

energy to the fluid

ESP Pump Curve

Impeller Shape and Performance

Radial Flow Impeller

 Also called ‘pancake’ type

Mixed Flow Impeller

 Has vane angle close to 45

 Requires a lot more metal / stage

Multiple Stages to Achieve Head

Pump Performance Curve

• Head vs. flowrate

Typical Pump Performance Curve

Typical Pump Performance Curve: SI Units

 Two construction methods for pumps:

Floater / Compression Pumps

Standard bearing High load bearing

Lower cost Higher cost

Only for smaller pumps Available in all pump sizes

Upthrust Washer Impeller Hub

 Under normal operating conditions,

fluid recirculation on the top and

 When the recirculation forces are

Operating with excessive Downthrust or Upthrust will cause inefficient

 Approximate thrust profile of a pump

IG STAGE FLOW RATE

The Pump: Performance Tolerances

 API performance curve test tolerances

• Pumps (new or re-run) should conform to published curves (within

Calculation of ESP Pump Stages Quiz

 Well parameters (vertical)

Calculation of ESP Pump Stages Quiz

1. Pwf, PIP and PDP

Gradient = 0.433*0.85 = 0.368 psi/ft (8.32 kPa/m)

∆P = 5858*0.368 = 2156 psi (14865.1 kPa)

ESP Variable Speed Drive

 A variable speed drive (VSD) provides flexibility to the otherwise

ESP Variable Speed Drive

 By changing the rotational speed of the pump, the operating

• Increases pump head

Pump / Motor Speed Variation Laws

 Pump affinity laws**

 Motor: The rotational speeds and the horse

 Pump affinity laws for ESP (at BEP)

 The Tornado plot shows the pump performance and range at

ESP Variable Speed Drive

 The motor horsepower output is a function of frequency, varying

in a straight line slope

ESP Variable Speed Drive

 The pump horsepower required is a function of rotational speed