ESP SYSTEM OVERVIEW

The major components of an Electrical Submersible Pump (ESP) system are shown in (Figure 1).

Figure 1

The systems 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. The
well power cable is spliced to a motor cable that is connected to the outside of the downhole
assembly. Power from the surface facilities connects to the ESP at the junction box. The ESP itself
 is a centrifugal pump located at the top of the downhole assembly (Figure 2: ESP systempump
diagram. Courtesy of Schlumberger).

Figure 2

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.

ESP Benefits and Limitations

ESP systems offer several advantages over other types of artificial lift:
They can be economically designed for both oil and water wells, at production rates ranging
from 200 to 40,000 B/D and at depths of .up to 15,000 feet.
They can be used in crooked or deviated wells.
They have a relatively small surface footprint, and so are appropriate for use in offshore,
urban or other confined locations.
Once in place, 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.
 Where justified economically (e.g., offshore locations where well intervention would require a
platform drilling rig or mobile offshore drilling unit), dual ESPs can be run in a single well; the
second ESP serves as a backup in case the first one fails (Duffy et. al, 2005)

Disadvantages of ESP systems include the following:

They are generally limited to single-zone completions
They requires a source of high-voltage electric power
Changes in well productivity may require expensive changes in downhole equipment.
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 conditions400 degrees Fahrenheit (about
200 degrees Celsius) is their general upper limit with respect to operating temperature.

ESP POWER COMPONENTS

This section describes the major components that supply power from the surface down to the
submersible pump.

Transformer
The first component of the ESP system is the transformer system, which is used to step-up or
step-down the voltage from the primary line to the motor of the submersible pump. The system is
usually arranged in banks of three single-phase transformers, a three-phase standard transformer,
or a three-phase autotransformer. 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.
For example, a primary voltage of 12,500 volts (V) may need to be stepped down to 2,400V by a
transformer. On the other hand, the primary voltage delivered to a well may be 440V, so a
transformer would be needed to step up that voltage to 880V. In general, the manufacturers of
electrical submersible pumps also build and sell the necessary transformers. An example of
transformer specifications, adapted from one page of a manufacturers catalog, is given in Table 1.

Table 1: Transformer SpecificationsSingle-Phase, OISC 60 Hertz

55 Degrees Centigrade Rise
(after TRW)

Size, Height, Width, Depth, Weight, Delta Delta

kVA in. in. in. lbs. Primary Secondar
Volts y Volts

25 40 22.5 24.8 460 12500 480 / 960

25 47.5 22.5 28.8 500 24950 480 / 960

50 51.5 29 33 915 12500 650 / 1300

50 52.5 29 33 935 24950 650 / 1300

75 53.5 29 33 1095 12500 650 / 1300

75 59.5 29 33 1100 24950 650 / 1300

100 56.5 29 33 1325 12500 650 / 1300

 100 62.5 29 33 1350 24950 650 / 1300

Switchboard
The electrical cable from the transformer goes to the switchboard (Figure 1: Switchboard for ESP
system. Courtesy Weatherford International Ltd).

Figure 1

Switchboards sold by the ESP manufacturer are available in a range of sizes and models to
accommodate the electrical submersible pump system (Table 2)

Table 2: SwitchboardsGeneral Data

(After TRW)

Clas Typ Siz Max HP Max Heigh Width Depth Weight

s e e . . t, , , , lbs.
Volt Full inche inche inche
s Loa s s s
d
Am
ps

DFH- 72 2 600 25 50 36.5 22.0 8.3 130

2

3 600 50 100 46.5 23.0 8.3 180

4 600 100 150 56.5 25.0 8.9 262

5 600 200 270 71.5 30.0 13.0 600

 MFH 76 2 100 70 45 37.0 34.0 12.0 175
0

3 100 160 120 68.0 26.3 20.3 530

0

MDF 76 3 150 150 100 68.0 26.3 20.3 530

H 0

4 150 250 150 68.0 26.3 20.3 530

0

RPR- 275 700 140 58.0 34.0 35.0 1100

2M 0

RPR- 275 700 165 58.0 34.0 35.0 1100

2S 0

390 125 165 58.0 34.0 35.0 1100

0 0

490 125 165 58.0 34.0 35.0 1100

0 0

1512 76 240 700 140 68.6 39.0 38.6 1095

0

275 700 165 68.6 39.0 38.6 1095

0

390 125 165 68.6 39.0 38.6 1095

0 0

490 125 165 68.6 39.0 38.6 1095

0 0

The switchboard controls the pump motor and provides overload and underload protection.
Protection against overload (a condition where excessive amperage flows through the motor) is
needed to keep the motor windings from burning. Protection during underload (a condition where
the pump is not displacing its design volumes) is needed because low fluid flow rates will prevent
adequate cooling of the motor.
In addition to these functions, the switchboard may be used to record amperage on a continuous
basis, using a 24-hour chart. This chart is a good diagnostic tool for measuring pump
performance. The switchboard can also be used as an adjustable time-automatic restart control. In
this case, a pump that shuts down because the well is pumped off would depend on a switchboard
control to begin pumping again after a fixed time period. This protection is needed because the
pump should not be restarted until the previously pumped fluid has stopped backflowing through
the pump. Such backflow causes the motor impeller to reverse circulate. Placing a standing valve
in the tubing will normally eliminate this problem.
The switchboard may include additional features such as signal lights and automatic remote
control. Switchboards are available in ranges from 240 to 4800V.

Junction Box
The next component of the ESP system is the junction box, which connects the power cable from
the switchboard to the power cable from the well. As such, it should provide an explosion-free vent
to the atmosphere for any gas that might migrate up the power cable from the wellbore. The
 junction box should be located at least 15 feet from the wellhead, and should be securely locked
at all times to protect against vandalism.

Wellhead and Power Cable

A power cable, made up of three insulated conductors, runs from the junction box to the wellhead
(Figure 2: ESP power cable components. Courtesy of Schlumberger.)

Figure 2

A special wellhead is used to pack off the power cable so that it can enter the wellbore without
leaks . Cable is available in round and flat styles (Figure 3: Round ESP cable; Figure 4: Flat ESP
cable). The conductors are available in different sizes and are usually made of copper or
aluminum.
Figure 3
 Figure 4

The proper selection of the cable and the conductors depends on:
The expected amperage that will flow through the cable to the motor
The calculated voltage drop in the line from the surface to the pump.
The space that exists between the tubing collar and the casing (even though the cable is
banded to the tubing at selected points, there must be enough space to install and pull the
pump without damaging the cable or hanging it in the well).
The equipment operating environment - such as the operating pressure and temperature at
pump depth.
CABLE AMPERAGE
The first consideration in selecting cables is amperage. The limits on amperage for cables
containing copper conductors are as follows:

Cable No. Maximum Amperage

1 115

2 95

4 70

6 55

Note that the cable with the smaller number has the larger diameter. Thus, a Number 1 cable can
carry a maximum of 115 amps.

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.
(Figure 5) is a graph of amperage versus voltage drop per thousand feet of cable length for
various conductors.

Figure 5
 For example, if a 60-amp current is flowing through a 1000-foot cable, then the voltage drop in a
No.1 copper conductor will be about 16 V. In a No.4 copper conductor, it will be about 31V; while a
No. 6 copper conductor produces a voltage drop of about 45V. Clearly, the larger conductor with
the lower voltage drop is more desirable, especially in deep wells. A counter-argument to this is
that the larger cable costs more, and might not fit within accepted tolerances between the tubing
collars and the casing. These factors must be anticipated and balanced when designing a system.

ESP OPERATING PRINCIPLES

In most cases, submersible pumps are installed on tubing, although some are suspended at the
end of the power cable so that they can be retrieved without having to pull the tubing. In this
section, we will limit our discussion will to downhole pumps installed at the bottom of the tubing.
Electrical submersible pumps are multi-staged centrifugal pumps Each stage consists of a rotating
impeller and a stationary diffuser (Figure 1: Single stage of a centrifugal pump, showing impeller
and diffuser).
 Figure 1

As the shaft of the pump moves in response to the force of the motor, the impeller turns, causing a
rotating motion in the fluid. The diffuser changes the direction and velocity of flow and directs fluid
from the impeller of one stage to the impeller of the next stage. The type of stage determines the
volume of fluid to be produced. The number of stages contained in a pump determines the total
pressure, or head, generated. The horsepower required by the motor is determined by both the
volume displaced and the head generated. Pumps are manufactured in a range of capacities to
satisfy almost all well conditions.
A pumps impellers are designed to operate efficiently over a specific capacity range (Figure 2:
Optimal ESP operating range). Operating the pump below its design capacity causes the impeller
to downthrust against the diffuser, resulting in wear on the bearings and washers. Conversely, if
the pump operates above its design capacity, the impeller upthrusts against the upper part of the
diffuser, causing similar wear. Ideally, the impeller should float freely, and will do so throughout its
recommended operating range. This recommended operating range will allow the pump to run at
highest efficiency.

Figure 2

Pump length and diameter are constrained by manufacturing and wellbore conditions. Assembly
and handling difficulties usually limit the length of a single pump section to about 20 to 25 feet.
However, it is possible to join pump sections together, adding successive stages to develop the
required head. Pump diameters are limited by the size of casing in which they are to be run. Table
3 lists the suggested pump diameters for various casing sizes; for example, a 3 3/8-inch OD pump
will fit within 4 1/2-inch OD casing. If the casing diameter is 8 5/8 inches or greater, then larger
pumps could be used.

Table 3: Recommended ESP diameters for various casing sizes

(after Brown, 1980)

O.D. of Casing Motor O.D. Pump O.D.

casing weight

4.50 inch 11.5 lb/ft 3.75 inch 3.375 inch

 9.5 lb/ft

5 inch All weights 3.75 inch 3.375 inch

5.5 inch 20 lb/ft 4.5 inch 4.0 inch

17 lb/ft

15.5 lb/ft

7 inch 28 lb/ft 4.5 inch 4.0 inch

26 lb/ft 5.5 inch 5.375 inch

24 lb/ft

20 lb/ft

8.625 inch or All weights 4.5 inch 4.0 inch

greater
5.5 inch 5.125 inch
7.375 inch 6.75 inch

The number of stages that can be added to a pump are limited by three variables:
Horsepower rating of the shaft that turns the pump
Pressure rating of the pump housing
Capacity of the thrust bearing

The pump manufacturer takes each of these variables into account when a customer specifies the
capacity range for a pump.

ESP SYSTEM DESIGN

This section examines the considerations and design procedures involved in selecting a pump and
motor for an ESP system, and the steps needed to determine the surface voltage requirements.

Pump Performance Curves

In selecting a pump for a particular application, we must look carefully at its performance or test
curves, which typically chart three different aspects of performance: head versus pump capacity,
motor horsepower versus capacity and pump efficiency versus capacity (Figure 1: ESP
performance curve. Courtesy Schlumberger-Reda.)
 Figure 1

These curves are published by pump manufacturers for each of their individual pump typesthe
ones shown in (Figure 1), for example, are for a 100 stage, Schlumberger-Reda D1350 pump .
They are obtained by running a pump in water at a constant speed, while varying its throughput by
throttling the discharge side of the pump. During the test, the pressure difference across the pump,
the brake horsepower, and the pump efficiency are measured at different pump throughput rates.
The resulting pressure increase is then converted to its equivalent head. With this data,
performance curves are drawn showing head, pump efficiency, and brake horsepower for a
specified number of pump stages, as a function of pump throughput rate.
Although these curves are generated using fresh water (with a specific gravity of 1.0), the same
values of head are usually used when selecting a pump for a fluid with a different specific gravity
provided the viscosity of the fluid is similar to the viscosity of water. Brake horsepower, on the
other hand, does require a specific gravity correction.
Pump performance curves are normally published for either a single pump stage or, as was done
in Figure 1, for 100 pump stages.
Pump Horsepower Requirements
Using the pump performance curve shown in (Figure 1) above, we may determine the horsepower
requirements for a pump under a given set of operating conditionsfor example, a flow rate of
1250 B/D and a required pump pressure of 1725 psi.
First, we note the following values corresponding to a capacity of 1250 B/D:
Head generated for 100 stages = 2280 ft, or 22.8 ft per stage
Brake horsepower required = 32.5 hp, or 0.325 hp per stage
Pump efficiency = 64 percent.

The number of stages required is:

(1)

The total head is equal to the required pump pressure divided by the pressure gradient of fresh
water (the fluid upon which the pump curve is based), or 0.433 psi/ft. Therefore,

To calculate the required brake horsepower (hp), we multiply the horsepower per stage by the
number of stages and by the specific gravity of the fluid being pumped (in this case, the fluid is
fresh water, and so the specific gravity is 1.0):
hp = (hp per stage) x (stages) x (specific gravity) (2)
= (0.325) x (l75) x (1.0) = 56.9 hp
In summary, this procedure requires specifying the pump operating conditions (required capacity,
in B/D, and the required fluid head). The required capacity of the pump is based on an estimate of
the wells inflow performance. The performance curves are actual test curves. If we assume that
very little gas will be pumped, we do not need to apply a pump efficiency factor. We should select
the pump to provide the desired capacity based on continuous operation.
In evaluating the capabilities of various pumps, we may have a number of options from which to
choose. It is important to study the performance curves supplied by the manufacturer to select a
pump that, at the required capacity, will operate in its optimal capacity range at the highest pump
efficiency. Remember that pump capacity depends on the design of the impeller and not on the
number of stages. With the selected performance curve and pump capacity, look up or calculate
the head/stage and horsepower/stage. Once we know the required head, we can calculate the
total number of stages needed and the horsepower required for the motor.

Total Dynamic Head

Along with specifying the required capacity of a pump, we need to determine how much total
dynamic head (TDH) it must provide. The TDH is the total head required when pumping at the
desired rate. It is the difference between the head at the pump discharge and the head at the
pump intake.
Assuming the produced fluid has no free gas, and that all pressures are converted to head (in
feet) using the specific gravity of the produced fluid, TDH is equal to:
the head caused by backpressure in the tubing,
minus the frictional losses generated by flow in the tubing,
 plus the head contributed by the liquid column in the tubing,
minus the head caused by the operating liquid column in the annulus,
minus any head caused by a backpressure imposed on the annulus.
Generally, the annulus backpressure is negligible and so the liquid columns may be netted out to
give a single term for the net lift. As a rule of thumb, a pump should have at least 500 feet of fluid
above it when in the operating mode.
As an example, consider a well producing under the following conditions:
Tubing backpressure is 75 psi.
Pump depth is 8500 ft; operating fluid load depth is 700 ft above the pump.
Tubing size is 2 7/8-inch OD; casing size is 7-inch OD.
Desired pump rate is 1400 B/D.
Fluid being pumped is 25-degree API oil (specific gravity = 0.904; gradient = 0.392 psi/ft).
Assume that there is no packer in the hole

Because there is no backpressure on the annulus, the TDH, expressed in feet, can be estimated
using the following equation:
TDH = head due to tubing backpressure + frictional losses + net lift (3)

Tubing backpressure head =

The frictional losses during flow in the tubing are obtained using viscosity correlations provided by
the pump manufacturer, and are found to be approximately 9 psi per 1000 feet of tubing. This
converts to

The net lift, with no packer in the hole, is simply the depth to the pump, minus the height of the
fluid level above the pump:
Net Lift = 8500 - 700 = 7800 ft
When all values are substituted, the total dynamic head is:
TDH = 191.3 + 195 + 7800 = 8186.3 ft
This is the value of TDH to use when selecting a pump.

Motor Selection
Once we determine a pumps required capacity and TDH, the next step in the design is to review
performance curves from different manufacturers. The goal is to (1) select the pump that best
meets the capacity needs, (2) calculate the number of stages required, and (3) specify the
required motor horsepower.
To illustrate, assume the same well conditions that were given in the Total Dynamic Head
calculation above, and use the resulting TDH value of 8186 feet. Assume also that after reviewing
the performance curves, the pump from (Figure 1) was selected . This pump has an OD of 4
inches and will easily fit within the 7-inch casing.
The performance curves for this pump show that at a throughput rate of 1400 B/D and a TDH of
8186 ft:
head = 2100 ft / l00 stages
hp = 34 hp/100 stages
The number of stages and motor horsepower required are as follows:
stages = 8186 ft divided by 21 ft/stage = approximately 390 stages
hp = (hp / stage) x (stages) x (spec. grav.) = (0.34) (390) (0.904) = approximately 120 hp
If the bottomhole temperature is higher than 180 F, the horsepower required should be increased
by as much as 20%. In the example well, high temperature is not a limiting factor, so we can go
with 120 hp in our design.
Next, we need to select a 120 hp motor that will fit into a 7-inch OD casing. In this case, we can go
to our manufacturers catalog and see a listing of 120 HP Series 456 motors with the
specifications shown in Table 1.

Table 1: 456 Series Motors (4.56-inch OD)60 Hz

HP Volts Amps

120 1000 77

120 1170 66

120 1350 57

120 2300 34

The Series 456 has an OD of 4.56 inches, which easily fits inside the 7-inch casing. Each of the
120 HP motors listed above has a different required voltage; note that the higher voltage motors
require lower current.
Now we must select one motor for the application. In general, the choice of motor voltage is a
function of line voltage losses, capital costs, and the electric power cost.
The required surface voltage is the voltage required by the motor, plus voltage losses between the
motor and the surface, including losses in the cable, other system components, and the
transformer. The cable losses are the most significant. As an upper limit, cable losses should be
less than 30V/1000 ft.
If, for example, we select the 1000V, 77-amp motor from Table 1, we can then go to (Figure 2)
(Amperage per voltage drop per 1000 feet of cable, various conductors).
 Figure 2

We note that an ideal conductor is the No. 2 copper conductor, which at this amperage has a
voltage drop of 25V per l000 feet of cable.
Another option would be the 2300V, 34-amp motor. This would allow us to use a smaller No. 6
copper conductor and have the same voltage drop along the cable. Because the No. 6 copper
conductor is smaller than the No. 2, going with this higher-voltage option would result in a lower
capital cost for the cable. However, a higher voltage switchboard will be more expensive than a
lower voltage switchboard.
We could also consider using a larger conductor cable (for instance the No. 2 copper cable) with
the 2300V motor. The voltage loss in the cable will drop from 25V to 11V per 1000 ft. The larger
conductor cable will require a higher capital cost, but lower operating costs. Within limits, then, a
larger, more expensive cable will allow for lower line losses and thus lower operating costs.
 In summary, motor selection requires an economic analysis of voltage and cable alternatives;
however, the following recommendations should serve as a guide:
For low horsepower motors and shallow depths, use a 440V system.
For less than 70 hp at intermediate depths, use an 830V system.
For 70 to 200 hp in deep wells, use a 1500V system.
For motors of 200 volts and greater, use a1500V or 2400V system. The choice of voltages will
depend on economics.

Surface Voltage Requirements

Before we can select a switchboard and transformer for our ESP system, we must determine the
required surface voltage, Vs:
V s = V m + V c + V com + V t (4)
Where:
V s = required surface voltage, volts
V m = motor voltage, volts
V c = cable voltage losses, volts
V com = system component losses, volts
V t = transformer voltage losses, volts
Consider the 2300V motor for analysis. With the this motor, the No. 1 copper conductor, and a
pump depth of 8500 ft, the voltage loss in the cable, V c, is 76.5 volts. Assume the surface
component losses, V com, are negligible. The transformer losses, V t, are usually estimated to be
2.5 percent of the required voltage. In this case the required surface voltagewithout significant
electrical component voltage losses and using the No. 1 copper conductorwould be:
V s = 2300 + 76.5 + 0 + 0.025(2376.5) = 2436 V
Operating voltage is variable within a 50V range; thus, a standard 2400V transformer system
would meet this systems voltage requirements. In most cases, it is better to have a required
surface voltage below 2400V. For this reason, we should analyze the other motor and cable
options to find one that will provide a surface operating voltage somewhat below that of the
transformer system. Further analysis of this specific pump system shows that the 1170V motor
with a No. 4 copper conductor cable will require a surface voltage of 1495V. With this pump and
cable, we may specify a system voltage of 1500V.
The switchboard would have a maximum voltage rating of 1500V and a maximum amp load of at
least 66 amps.
The transformer size is expressed in kilovolt-amps, kVA, and is given by the expression:
kVA = 0.00173 V s A m (5)
Where:
kVA = transformer size, kV-amps
V s = system voltage, V
A m = motor amperage, amp
For this example, V s is equal to 1495 volts and A m is equal to 66 amps. So the transformer size
is:
kVA = 0.00l73(l495)(66) = 171 KVA
If we use three single-phase transformers, each will require one-third of this value, or about 57
kVA. Other specifications of the transformer would be determined in consultation with the
manufacturer and would include consideration of the primary line voltage available in the operating
area (Table 2 ).
 Table 2: Transformer SpecificationsSingle Phase OISC 60 Hz, 55 deg C Rise
(After TRW)
Size, Height, Width, Depth, Weight, Delta Primary Delta Secondary
kVA inches inches inches lbs. Volts Volts
25 40 22.5 24.8 460 12500 480 / 960
25 47.5 22.5 28.8 500 24950 480 / 960
50 51.5 29 33 915 12500 650 / 1300
50 52.5 29 33 935 24950 650 / 1300
75 53.5 29 33 1085 12500 650 / 1300
75 59.5 29 33 1100 24950 650 / 1300
100 56.5 29 33 1325 12500 650 / 1300
100 62.5 29 33 1350 24950 650 / 1300

Presence of Excessive Free Gas

The TDH calculation outlined in this section is accurate if significant volumes of gas are not being
pumped, and if no gas is coming out of solution as fluid is produced up the tubing. If gas is
present, then additional considerations come into play.
Normally the pump is installed on the tubing without a packer. This means that free gas is
easily vented up the annulus. (Many ESP well installations--especially offshore--do include
packers.)
It is not feasible to vent annulus gas to the atmosphere so it must travel through surface flow
lines. However, the annulus backpressure and any surface venting must be controlled so
that the pump is below an acceptable level or fluid submergence. If not, the pump may
become gas-locked.
Manufacturers provide downhole gas separators to assist in preventing gas from entering the
pump.
If the pump is set at a depth at which the pressure is below the bubble point, any free gas that
is not separated will be pumped. The pump will perform normally if the volume of free gas is
below 10%.
If significant gas volumes are present in the fluid, a higher capacity pump will be needed. An
offsetting factor is that the presence of gas in the tubing will reduce the TDH and thus
reduce the required motor horsepower.

All other considerations equal, it is more difficult to size pumps for wells that pump gas, because it
becomes necessary to estimate the pressure-volume effects that occur between the pump intake
and discharge pressures. This is illustrated in (Figure 3) (Effect of gas compression on ESP
throughput) .
Note that the initial pump stages perform a substantial amount of gas compression. Between an
intake pressure of 500 psi and a discharge pressure of 1215 psi, the fluid volume is reduced
almost by half.
 Figure 3

Handling gas effects in the ESP design generally involves the following steps:
1. Estimate the pump intake pressure from inflow data
2. Estimate the pump discharge pressure from multiphase flow correlations
3. Divide the range of pressure between the inlet and discharge valves into discrete increments
and then calculate the pressure-volume changes that occur between increments
4. Calculate the average volume throughput and average fluid gradient, from the pump intake to
discharge points, and, with this data, select a pump and then specify the number of stages
required using the pumps performance curves.

The appropriate calculations are typically incorporated into company and manufacturer ESP
design software. You should check on the individual program that you are using to ensure that gas
effects are taken into account where appropriate.
ESP SYSTEM OPERATION
One disadvantage of ESP systems is that the tubing string normally has to be pulled in order to
replace the pump or other subsurface equipment (unlike, for example, a free hydraulic pump, a
rod pump or a wireline-retrievable gas lift valve). This requires a workover rig, which adds to the
cost of well maintenance and repair.
Replacement of downhole equipment may become necessary because of failures at the motor,
pump or cable (Table 1), or because the pump needs to be re-sized due to changes in the wells
inflow performance.

Table 1: Common ESP Failures

Type of Possible causes

failure

Motor Excessive motor overload

Leak in the protector caused by worn or defective seals
Insufficient fluid movement to cool the motor
Motor housing corrosion
Faulty installation
Switchboard problems
Lightning

Unbalanced electrical system

Pump Downthrust or upthrust wear on the pump bearings
section Wear caused internally by the pumping abrasives
Plugged or obstructed stages caused by deposition or corrosion

Twisted shaft caused by starting a pump while the fluids are still moving
downward in the pump after shut-down
Cable Mechanical damage caused during running or pulling operations
Deterioration caused by the downhole environment

High temperatures caused by amperage loads

If the wells inflow has been increasing, the cost of bringing in a workover rig is relatively easy to
justify, because the newly installed pump will pay for itself with the higher production rate. But if
the inflow is decreasing, the expense is harder to bear, and the temptation might be to just cycle
the pump daily instead of replacing it.
The problem with cycling an ESP is that large current surges occur when starting up a high
voltage, high horsepower induction motor that is separated from its starter at the surface by five or
ten thousand feet of cable. These surges are often five to eight times the normal operating current
(in Figure 1, a normal 32-amp current surged to 141 amps at start-upNeely, 1982). This type of
starting is referred to as across-the-line starting. Starting and stopping the motor also causes
amperage and voltage spikes that can damage or burn out the motor. Normally, only a limited
number of stops and starts are possible, so most operators are reluctant to stop and start a
submersible pump unless it is absolutely necessary.
 Figure 1

Optimizing Pump Performance

There are several ways to optimize pump performance as the well inflow performance changes.

CHANGES TO THE MOTOR AND PUMP

If well inflow performance is decreasing and the pump is oversized and continuously running,
pump performance can be improved by:
Changing the pump. This requires pulling the tubing, losing some production, and buying and
installing a new pump. Try to avoid this option.
Increasing the backpressure at the wellhead. This will reduce the capacity of the pump. This is
also undesirable because of the energy waste and the potential for thrust problems in the
pump.
The remaining alternatives require modifying the electrical submersible pump system.
Cycle the pump and motor. This method eliminates the current surges during start and stop
operations. This is similar to what is done with the motor of a rod pumping system.
Reduce the motor speed and, thus, the speed of the pump. This is the preferred method of
changing the pump capacity.

SOFT START/SOFT STOP

The surges in current during start and stop operations may be limited by using silicone-controlled
rectifiers at the surface starter to provide controlled levels of power at the pump. With these
rectifiers, the voltage and amperage are allowed to ramp up or ramp down at acceptable rates
over a specified period of time. This type of start and stop control, which provides smooth power
flow to and from the motor during stop/start operations, is referred to as soft start and soft stop
(Figure 2). Soft-start controllers have been used under field conditions and have demonstrated
that pumps may be cycled numerous times without damage (Neely, 1982).
 Figure 2

VARIABLE FREQUENCY DRIVE

Another option for changing the capacity of an electric submersible pump is to install a surface
device that can change the voltage frequency supplied to the motor. This device is referred to as
a variable frequency generator (VFG), variable frequency drive (VFD) or variable-speed drive
(VSD). It is used instead of the standard 50- or 60-Hz motor controller at the surface.
As an example, a VFG may be rated at 300 KVA with a frequency range of 36 to 90 Hz. Because
the motor speed is proportional to frequency, and the pump speed is equal to the motor speed, a
variable speed generator allows the pump to operate at a speed above or below its rated capacity
at 60 or 50 Hz. There is an upper limit, though, on pump speed variability. This limit is at the
amperage overload condition of the downhole motor. Subject to this limit, a variable frequency
generator can be used to increase or decrease pump rates by as much as 20% to 30%, to satisfy
changing inflow performance. If greater changes are required, a resizing of the pump will be
necessary.
 Variable frequency generators and variable-speed drives can also provide soft-start protection.
Using a VSD to control a pump motor can reduce the strain on the pump shaft and reduce pump
damage by slowly ramping-up the motor speed. A number of operating procedures have been
developed to make the electrical submersible pump more versatile in its application to a specific
well or field. However, the best approach is to carefully design and select a pump for each well
based on its own characteristics and assume that the pump will operate continuously.

ESP System Monitoring and Control

ESP systems are complex and require specific operating conditions with respect to the power, fluid
level, fluid content, and gas-liquid ratios. Without proper ESP monitoring, operators cannot tell
what is happening downhole, and this lack of monitoring may lead to low efficiency, high lifting
costs and frequent repair and replacement. Poor ESP performance can also result from improperly
designed pump assemblies. Monitoring and performance analysis can extend the life of ESP
pump installations by reducing system down time and the cost of repair and replacement of the
pumps. Reducing down time also results in higher production from the well, improved ESP
performance and increased profitability.
Analysis of ESP performance collected from the wellsite data gives the operator real-time
information, historical data, and the ability to optimize the wells from a remote location. Monitoring
and comparing changes in ESP performance over time can help identify potential problems and
correct them before the ESP fails.
Typical components include:
Downhole pressure, temperature, and electrical sensors
Surface System using well sensor data
Remote Terminal Unit (RTU) and communications system
Interpretation and Analysis Software

DOWNHOLE PRESSURE, TEMPERATURE, AND ELECTRICAL SENSORS

A well controller gathers data from downhole sensors that provide measurements of ESP
performance. The sensors can also measure data such as pump intake pressure, wellhead
pressure, and flow rate. Data of this kind can help identify problems before they become more
serious. Pump wear, paraffin or scale buildup, sand production, pump off, and blocked perforations
can also be identified by making downhole measurements of changes in current and voltage,
power factors, and pump intake pressure.

SURFACE SYSTEMS USING WELL SENSOR DATA

An ESP surface controller may be connected to the downhole sensors and surface instruments to
measure conditions and control the operation of the ESP pump in each well. The operator may
want to monitor surface performance parameters such as wellhead pressure, net oil, flow volume,
and flowline temperature, among others.
The controller can be programmed to automatically adjust pump operations using data from the
well sensors. The controller regulates the cycling operations of well so that startup of the well is
smooth, reducing stress on the motor and pump, improving pump efficiency, and extending the run
life of the system. The controllers can also be programmed to send data from the downhole
sensors, motor controller to the remote locations using the RTU.

REMOTE TERMINAL UNIT (RTU) AND COMMUNICATIONS SYSTEM

The sensor data must be communicated from the well to the operator. A typical ESP monitoring
system has a remote terminal unit that sends the sensor data to the operator. The RTU may use
radio or telephone modem to transmit wellsite data to the operators office.
 INTERPRETATION AND ANALYSIS SOFTWARE
The software, running on a desktop platform, allows the operator to monitor and set the ESP
controller on each well in a field.
The ESP monitoring and analysis software allows the operator to control, monitor, track, and
report on ESP wells. It provides a means of reporting production parameters, tracking lifting costs
and detecting operating problems. Proper monitoring of ESP performance can increase pump life,
reduce operating and repair costs and improve profitability.
With the analysis of pump performance data, the operator can model reservoir inflow and pump
performance so that the pump can run at its highest efficiency. The operator can also simulate the
performance of several combinations of pump size, setting depth and production rates. This allows
the operator to avoid designs that cause stress on the pump, motor, or cable.

ESP System Design Using Field Data

Observations of ESP performance over a long time are used to design the best pump
configuration by modeling various combinations of pumping system equipment. The operator can
experiment with parameters such as pump setting depth, production rate, and fluid level to
determine how these changes affect well performance.