ESP Design 2018

Field Production Phases
Artificial Lift Overview
ESP Design
ESP Components
1-PRIMARY Recovery:
The reservoir energy is the only one used to produce hydrocarbons
2- SECONDARY Recovery:
Energy used to produce the reservoir is external, such as water or gas injection
3-TERTIARY Recovery “EOR”

Complex methods such as miscible fluid injections, thermal methods,
chemical methods ...
ESP Design
ESP Components
➢ Any system that adds energy to the fluid column in a wellbore with the objective of initiating
and improving production from the well.
➢ That is means of overcoming bottomhole pressure so that a well can produce at some desired
rate, either by injecting gas into the producing fluid column to reduce its hydrostatic pressure,
or using a downhole pump to provide additional lift pressure downhole.
➢ Reduce the weight of the hydrostatic column on the reservoir, by reducing the density of the
fluid column, thereby reducing the loss pressure in the drawdown on the reservoir (Pi - Pwf),
so the formation can give up the desired reservoir fluid
➢ Add energy to the reservoir fluid for lifting, this also achieves the aim above.
Note that this is different from gas injection for pressure maintenance
• Injection of gas or water into reservoir to maintain reservoir pressure
• Improve recovery
When the hydrostatic

• When reservoir pressure gradient of the liquid column
drops and cannot support the prevents gas from coming
weight of column and losses into the well in low rate gas
in the line and condensate reservoirs.
Preservoir < Pline+ Phydrostatic
Preservoir < Phydrostatic
• When economic production

rates cannot be achieved by
natural drive and energy of
the reservoir.
An artificial-lift pumping system using a surface

power source to drive a downhole pump
assembly.
A beam and crank assembly (pumping unit)
creates reciprocating motion in a sucker–rod
string that connects to the downhole pump
assembly.
The pump contains a plunger and valve
assembly to convert the reciprocating motion to
vertical fluid movement.
➢ Pumping capacity, within the limits, can easily be changed to adjust for changes in the well
inflow performance. Intermittent operation is also feasible.
➢ Rod pumps account for approximately 80% of onshore artificial lift completions
➢ Industry accepted, economic in the correct application
➢ Not gas dependent
➢ Under average conditions, it can be used until the end of a well’s life, up to abandonment.
➢ Limited efficiency, maintenance intensive and require vertical wellbores

➢ Well depth and deviation limitations
➢ Sand and gas sensitive
➢ Surface pumping unit requires a big space; it is heavy and obtrusive
➢ Wireline access not possible
➢ Production tubing
An artificial–lift method in which gas is

injected into the production tubing to reduce
the hydrostatic
pressure of the fluid column. The resulting
reduction in bottom hole pressure allows the
reservoir liquids to enter the wellbore at a
higher flow rate. The injection gas is typically
conveyed down the tubing–casing annulus and
enters the production train through a series of
gas–lift valves. The gas–lift valve position,
operating pressures and gas injection rate are
determined by specific well conditions.
➢ Initial downhole equipment costs lower
➢ Low operational and maintenance cost
➢ Simplified well completions
➢ Production rate can be controlled at the surface
➢ Flexibility – can handle rates from 10 to 80000 bpd
➢ Can best handle sand / gas / well deviation
➢ Intervention relatively less expensive

➢ Must have a source of gas
➢ Imported from other fields
➢ Produced gas - may result in start up problems
➢ Possible high installation cost
➢ Top sides modifications to existing platforms
➢ Compressor installation
➢ Casing at high pressure
➢ Limited by available reservoir pressure and bottom hole flowing

pressure
An artificial-lift system that operates using a

downhole
pump (piston or jet pump). A surface hydraulic pump
pressurizes crude oil called power oil, which drives
the bottom pump. When a single production string is
used,
the power oil is pumped down the tubing and a
mixture
of the formation crude oil and power oil are produced
through the casing-tubing annulus
– Tubing and downhole components are kept clean

– Water can be used as power fluid
– Treatments for corrosion, scale and emulsion are easy to apply
– Inefficient lift method

– Large volumes of high pressure fluid are required
– Systems using oil as a power fluid present a hazard
– Dual fluid conduits may be required
A type of gas-lift method that uses a plunger that

goes up and down inside the tubing. The plunger
provides an interface between the liquid phase and
the lift gas, minimizing liquid fallback. The plunger
has a bypass valve that opens at the top of the
tubing and closes when it reaches the bottom.
Plunger-lift methods are used to remove water and
condensate from a well, but they can handle only a
limited
column of liquid. Typically, these methods are
applied on gas wells with high gas liquid ratio
(GLR) to operate only with formation gas.
– Components can be retrieved without pulling completion

– Low cost
– Systems has no moving parts
– Can be used in deviated holes
– System may not be capable of producing well to depletion

– Low rate wells
– Requires supervision
– Plunger sticking and problems associated with sand production
– Surging flow may hamper the effectiveness of the surface
equipment assembly
PCP systems typically consist of a surface

drive and a down hole progressing cavity
pump with a single helical shaped rotor that
turns inside a double helical elastomer–
lined stator.
The stator is attached to the bottom of a
production tubing string and, in most cases,
the rotor is attached to a rod string
suspended and rotated by the surface drive.
– Can pump up to 5000 bpd

– Easy to install and simple to operate
– Easy to transfer location - only pick up truck required
– Require small 'foot print' and ground space
– Reported system
– Sand is handled efficiently
– Easy to vary the rates as a speed range can be adjusted
without any change of the downhole equipment
– Low capital cost (25% – 50% less than SRP)
– Energy saving from 60% to 70 % efficiency between 60% to 70%
– Excellent for viscous fluids
– Elastomer affected by temperature ( > 250 degree F)

– Tubing need to be retrieved for stator repairs
– Short run life in stator
– Not accessible for downhole pressure survey
– Sensitive to time cycle and pump off, thus shutdown
especially in high viscosity or sand producer must be
avoided
An artificial–lift system that utilizes a down

hole pumping
system that is electrically driven. The pump
typically comprises several staged centrifugal
pump sections that
can be specifically configured to suit the
production and wellbore characteristics of a
given application. Electrical submersible pump
systems are a common artificial–lift method,
providing flexibility over a range of sizes and
output flow capacities.
➢ High fluid volume capability
➢ Can be fitted with downhole pressure sensor (data

transmission via power cable)
➢ Compatible with crooked or deviated wellbores
➢ Corrosion and scale treatments are relatively easy to perform
➢ Available in a range of sizes and capacities
➢ Lifting cost for high volumes ($/bbl) typically very low

➢ Cable insulation deteriorates in high temperatures
➢ System is depth limited (+10,000 ft) due to cable cost and inability to
provide sufficient power
➢ Entire system is downhole, therefore, problems and maintenance require

the unit to be retrieved from the wellbore
➢ Large casing/liners are required

ESP Design
ESP Components
ESP DESIGN
ESP DESIGN
▪ Reservoir Pressure (Pr) ▪ Oil API

▪ Test Flowrate (Qt) ▪ Water SG
▪ Well Flowing ▪ Watercut
▪ Pressure (Pwf) Bubble Point (Pb) ▪ FVF_Oil
▪ FVF_Water
▪ Production Casing OD
▪ Production Casing ID ▪ Wellhead Pressure (WHP)
▪ Perf Depth ▪ Production Target (Q)
▪ Tubing OD ▪ Electric Power Frequency
▪ Tubing ID
▪ Pump Depth
ESP DESIGN
ESP DESIGN
 Hydrostatic losses- Due to the density of the fluid

column
 Frictional losses- Due to fluid movement through

the tubing, wellhead and surface equipment
 Kinetic losses- Due to diameter restrictions, pipe

bends or elevation changes.
ESP DESIGN
Inflow=IPR
Outflow=VLP
ESP DESIGN
VLP “ESP”
VLP “N”
IPR
ESP DESIGN
ESP DESIGN
Pump Discharge Pressure (PDP)

= WHP + FG_mix x Pump Depth + Friction Losses
Pump Intake Pressure (PIP)

(from the Well Performance Chart)
(ΔPpump) = PDP– PIP
TDH = ΔPpump /FG_mix
ESP DESIGN
Head/Stage (From the Pump Performance Curve)
Number of Stages = TDH / (Head/Stage)

ESP DESIGN
From the Pump Performance Curve:

Pump Horse Power per Stage
Pump HP = 1.5 * Number of Stages
Correction for Mixture SG = 0.92
Corrected Pump HP = Pump HP * 0.92
Motor HP = Pump HP * 1.2

ESP DESIGN
SUBSURFACE COMPONENT
PUMP
Schlumberger POMPA PUMP PERFORMANCE CURVE

REDA Producti on Systems
PUMP PERFORMANCE CURVE
EFF % BHP
RECOMMENDED CAPACITY RANGE
STATIC HEAD DEVE
LO PE
HEAD
• Vertical axis shows pump discharge
head in Feet
HEAD (FEET)
CY
EN
• Horizontal axis, shows production rate

CI
FI
EF
HORSE POWER
measure in BPD, GPM etc.
0 Q max
FLOW (BPD)
Iws/ Basic ESP- 2001
• Discharge head measured feet, with different fluid SG results in different pressure.
• Measuring head in feet is important rather than measuring head in psi.

ESP DESIGN
PUMP PERFORMANCE CURVE
EFF % BHP
RECOMMENDED CAPACITY RANGE
STATIC
HEAD
HORSE POWER
0 Q max
FLOW (BPD)
ESP DESIGN
ESP Design
ESP Components
ESP DESIGN
▪ Cable • Transformers
▪ Cable Clamps • Motor controller Switchboard of Variable
▪ Pumps Speed Drive (VSD) or Soft Start
▪ Gas Separator • Junction Box
▪ Seal Section • Wellhead
▪ Motor
▪ Sensor- Data Acquisition
Instrumentation
▪ Intake
▪ Discharge
ESP DESIGN
ESP DESIGN
• Transformers
• Provides required voltage for down
hole motor
• Works by transforming the voltage
through induction magnetic field
In general, 3 types of transformer :

✓ Single phase transformer
✓ Three phases transformer
✓ Auto transformer
ESP DESIGN
• Switchboard of Variable Speed Drive (VSD)

➢ Control panel for electric motor
➢ Equipped with motor controller
▪ Monitors overload / under load problems

▪ Can be set to auto restart in the case of intermittent well
▪ Detects voltage unbalance
➢ Equipped with Amp chart to record motor

performance
What Does The VSD Do For Us?

➢ Provides constant torque through the entire speed range
➢ Can be used manually to set the V/Hz ratio for specific applications (Base Speed)
➢ Provides reduced starting capabilities (Soft Start)
➢ Optimizes the output of the well
ESP DESIGN
• Junction Box
FUNCTION:
• Ventilation for gas that possibly comes up to surface through the cable
• Connection terminals, easier to reverse motor rotation and to take initial readings
ESP DESIGN
• Wellhead
The Wellhead is the equipment that is
installed at the surface of the well bore.
It’s purpose is: to suspend the tubing
string in the well, and to monitor and
control high pressures conditions often
present within the well.
ESP DESIGN
PUMP
 Multistage Centrifugal pump
 Head capacity correlated to number of stages
 A stage is a combination of one impeller and one

diffuser
 Impellers are keyed to the shaft
 Diffusers are compressed within the housing and

are stationary
ESP DESIGN
Pump Stage
• Fluid enters impeller through ‘eye’ near shaft
and exits impeller on outer diameter (OD)
• Diffuser (in blue) redirects fluid into next
impeller
Pump Impeller Pump Impeller

ESP DESIGN
• STANDARD INTAKE
o Functional as a fluid inlet.

o Does not separate gas
o Installed in low GLR wells
o Gas content less than 10% of total
producing fluid
ESP DESIGN
• GAS SEPARATOR
➢ Used in applications where free gas causes

interference with pump performance
➢ Units separate some of free gas from fluid

stream entering pump to improve pump's
performance
ESP DESIGN
• Seal Section
➢ Protects motor from contamination by well fluid
➢ Absorbs thrust from pump

➢ Equalizes pressure between wellbore and motor
ESP DESIGN
•Submersible Motor
➢ Motor is filled with oil
➢ It is a two-pole, three phase,3,600 rpm (revolutions per
minute) design
➢ Motor components are designed to withstand up to 500oF
temperatures
 Sensor can also be added to the pump below the motor to

acquire data like downhole pressure, temperature, and
vibration, these supply pump monitoring data.
ESP DESIGN
Electric Power Cable

There are different types of cables available in the industry. These include;
• Round Cables
• Flat Cables
• Number of conductors also varies from 1,2,4 etc…depending on company
Cables also vary depending on the type of insulation based on the working
environment, there are special cable insulation for corrosive fluids and severe
environments.
ESP DESIGN
Design and
Specification
Design or
Procedure Manufacture
Mode
Teardown
ESP Life Cycle
and analysis Installation
Pulling Start-Up
Operation

ESP Design 2018

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Field Production Phases

Artificial Lift Overview

3-TERTIARY Recovery “EOR”

Artificial Lift Overview

When the hydrostatic

• When economic production

An artificial-lift pumping system using a surface

➢ Limited efficiency, maintenance intensive and require vertical wellbores

An artificial–lift method in which gas is

➢ Initial downhole equipment costs lower

➢ Low operational and maintenance cost

➢ Simplified well completions

➢ Production rate can be controlled at the surface

➢ Flexibility – can handle rates from 10 to 80000 bpd

➢ Can best handle sand / gas / well deviation

➢ Intervention relatively less expensive

➢ Must have a source of gas

➢ Imported from other fields

➢ Produced gas - may result in start up problems

➢ Possible high installation cost

➢ Top sides modifications to existing platforms

➢ Casing at high pressure

➢ Limited by available reservoir pressure and bottom hole flowing

An artificial-lift system that operates using a

– Tubing and downhole components are kept clean

– Inefficient lift method

A type of gas-lift method that uses a plunger that

– Components can be retrieved without pulling completion

– System may not be capable of producing well to depletion

PCP systems typically consist of a surface

– Can pump up to 5000 bpd

– Elastomer affected by temperature ( > 250 degree F)

An artificial–lift system that utilizes a down

➢ High fluid volume capability

➢ Can be fitted with downhole pressure sensor (data

➢ Compatible with crooked or deviated wellbores

➢ Corrosion and scale treatments are relatively easy to perform

➢ Available in a range of sizes and capacities

➢ Lifting cost for high volumes ($/bbl) typically very low

➢ Cable insulation deteriorates in high temperatures

➢ Entire system is downhole, therefore, problems and maintenance require

➢ Large casing/liners are required

Artificial Lift Overview

▪ Reservoir Pressure (Pr) ▪ Oil API

 Hydrostatic losses- Due to the density of the fluid

 Frictional losses- Due to fluid movement through

 Kinetic losses- Due to diameter restrictions, pipe

Pump Discharge Pressure (PDP)

Pump Intake Pressure (PIP)

Head/Stage (From the Pump Performance Curve)

Number of Stages = TDH / (Head/Stage)

From the Pump Performance Curve:

Pump HP = 1.5 * Number of Stages

Correction for Mixture SG = 0.92

Corrected Pump HP = Pump HP * 0.92

Motor HP = Pump HP * 1.2

Schlumberger POMPA PUMP PERFORMANCE CURVE

• Horizontal axis, shows production rate

• Measuring head in feet is important rather than measuring head in psi.

PUMP PERFORMANCE CURVE

Artificial Lift Overview

In general, 3 types of transformer :

• Switchboard of Variable Speed Drive (VSD)

▪ Monitors overload / under load problems