Electric Submersible Pumping, Ifp Trainning, 80 PGS, 2x1

~
iiii1f1ANIJ.ii
- - - - -- - - - -- - - - - -1
ELECTRIC SUBMERSIBLE
PUMPING
I To Summary I
I
Electric submersible pumping:

General configuration & principle
I To Summary I
General electric submersible pumping:
General configuration & principle CONTENTS
- GENERAL CONFIGURATION of the installation

- PRINCIPLE
PR001329 - Elecbic submersible ~
-,::... General electric submersible pumping:

.,,-!~~GENERAL CONFIGURATION of the installation (1/4)
~~5 Tn111sfonna
]LlJltfi!lllbOl.
(ti,,t1 ~111)
- DOWNHOLE AND
SURFACE EQUIPMENT:
S,,!,u i - -----1-u
n - , -- Tubi111
t1Hu'til• D.0:. ••11H - - •
- -1'~,
I i i - - ,.....
~ General configuration of the installation (2/4)
m'r=
- DOWNHOLE
PUMPING UNIT:
'I
L.-
1ri
LlJ-.. ~
1~-1\,..............,,.. .
.~ ·- ill j

,,!~ General configuration of the installation (3/4)
j,~~~
- EFFLUENT PATH:
•
ij
The effluent produced by the well is used
to cool the electric motor
'1•t11u~ ~
i
,1.a.u .... I
Pt•do:icli1>t1.c-Mnl 8
I;
/Lina-
.... ..,,,.J j
~ General configuration of the installation (4/4)
1~7iii«i
- A PUMP STAGE (impeller & diffuser):
Each pump stage consists of a rotating

impeller drived by a shaft, and a fixed
(stationary) diffuser
Cross section
of a stage Couniud de dirTunur (diffu.urp11d)

General configuration & principle CONTENTS
- GENERAL CONFIGURATION of the installation

- PRINCIPLE
~ _ _ __ _ _P_R_IN
_C_ I_P_L_E_____,(1_
__ /3-"-
) _ _ _ __
;,.,....,.,., - PRINCIPLE of energy transmission to the fluid (1/2):
• The ESP pump is a centrifugal pump which transmits
mechanical energy to a fluid _passing through it. This
energy is provided by its electric drive motor in the form
of kinetic energy i.e. speed
• This is obtained by the rotation of a wheel called the
impeller inside the pump body
tll
VI
t
.,,,
·3 1 Path of a fluid particle
"."'
:l\ in the impeller
I
I
A.~1'111ut11111
PR001329- Eleclric submersible J»IJINlill
General electric submersible pumping: Principle (2/3)

- Principle of the transmission of energy to the fluid
(2/2):
• The kinetic energy is then converted into potential
energy in the diffuser
• The diffuser has stationary vanes which slow down the
effluent:
- as the speed falls the pressure increases
- the effluent is thus pumped up
Fixed vane diffuser
A~plndio11
~ General electric submersible pumping: Principle (3/3)
~Aiiiiil1i
DYNAMIC HEAD:
• The dynamic head generated by an ESP pump depends
on the fluid velocity at the impeller outlet
• Using Bernoulli's equation (expressed in "energy per uni!
mass") gH + P/p + v2/2 = est:
H = v 2/2g [or, in terms of pressure: P = pv2!2]
where: g = gravitational acceleration in m/s 2
H = dynamic head in m of liquid
P = pressure increase provided by the pump in Pa
p = density of the fluid in kg/m 3
v = velocity at the impeller outlet in m/s
• Hence:
- H is independent of the density, thus the dynamic head generated
by an ESP pump is independent of the density of the fluid pumped
In other words the dynamic head expressed in meters will be the
same whether the fluid pumped is water (d = 1), crude (d = 0.00) or salt
water (d >1)
- However the pump delivery pressure depends on the density of the
fluid pumped
PR001329- Electric submersible~
, { ~ _ _ _ _ _ _ _D_e_ n_s_it_y_a_n_d_d
_y_ n_a_m_i_c_ h_e_a_d_ _ _ _ _ _ _ _ __
1i',"O'ilAJ"iN:i
IJ.
w
I .
,: The dynamic head
~ I= developed by a pump is
the same whether the fluid
pumped is water (d = 1),
salt water (d = 1.30) or oil (d
= 0.80)
It is independent of the
density of the fluid
pumped
However, the delivery
pressures of this same
pump (same diameter, same
frequency) are different
Spec. grav. = 1.0 Spec. grav = 0.80 Spec. giav. = 1.35
TDH = the dynamic head which must be supplied by the pump [Total Dynamic Head]
PR001329- Electric u ll,mlfllltl4 Ctl1'1111119

~~-------------------
~
Characteristic curves
of an ESP pump
I To Summary I
PA001329- Eleclrlc submarsi~e P J ~
Characteristic curves of an ESP pump

~ _ _ _ _ _ _C_O_N_T_E_N_T_S_ _ _ _ __
...~iiiiici
- CHARACTERISTIC CURVES: GENERAL

- EFFECT OF PUMP ROTATIONAL SPEED ON THE
CHARACTERISTIC CURVES
- EFFECT OF PUMP DIAMETER ON THE
~ CHARACTERISTIC CURVES: GENERAL (1/4)
- RELATIONSHIP BETWEEN FLOW RATE AND
DYNAMIC HEAD:
• For a pump rotating at constant speed, the theoretical
relationship between the flow rate and the differential
head is a straight line
• In reality, different losses must be taken into account
(mechanical and hydraulic) and we finally obtain the
characteristic curve for the given pump
B • Reminder: ::
Mcchnnicnl and hydmullc lo~scs
- the dynamic head is independent
of the density of the fluid pumped
Theoretical straight line
- However, the pump delivery
pressures depend on the density
of the fluid pumped
__... True 1.: hHrnct.cri~tii: i.:urw!
u Q
~ . ___C_h_a
_ ra_c_ te_r_i_s_t _
i c_ c_u_rv
_ e_s_:_G
_e_ n_e_r_a_l _ (_2_14_)_ _
1r,.-j6J11i.NQ
- HYDRAULIC POWER OF AN ESP PUMP:
P[kWJ = O[m31hJ x AP[barJ I 36 T)

where 11: pump hydraulic efficiency
Other formulas:
P[kWJ # Q[m'lhJ X HTM[mJ X d / 367 'IJ
PfcvJ # O[m'lhJ x !:i.Pfkg!cm2J I 27 'IJ # Q[m'lhJ x HTMfmJ x d / 270 'IJ
note: 1 cv # 0.736 kW
P[hpJ # O[m'lhJ X AP[barJ / 26.8 'IJ # Q[m'!hJ X HlMfmJ X d / 274 'IJ
note: 1 hp# 0.746 kW
Example:
Q = 240 m3/day
t:i.P = 40 bar
11 = 0.65
p = ?
, J ~ ___C_h_a_ra_c_t_e_r_is_t_i_c_c_u_rv
_e_s_:_ G_e_n_e_r_a_l_(_
31_4_) _ _
.-,.-;-fi!Ailffii!i
- CHARACTERISTIC CURVES:
• To define an ESP pump's operation, we must know its "flow
rate - head capacity" characteristic curve:
it is an experimental curve given by the manufacturer
H • The manufacturer also

E Head Capacity adds to this curve:
p
- a power consumption
,, ,,
,, - - ' .... .,..,,,- Ettlclency
curve:
- an efficiency curve
,, ''
,, ,,
(deduced from the previous
'
. ~" _ • _ . _ .. Power input 2 curves): - .- .- .-
,I , ford= 1 we see that there Is a
I •,.... •
' \
maximum hydraulic
efficiency point
•i
. -,!-. - . - .
,I -·-
\ we must thus try to operate
the pump around this value i
I
I
I
I
I
I
f
0 Maximum
efficiency zone
fl ow
rate
I
J
~ Pump operating range

/cnspm - - - -- - - - - -- - -- -- - - - -- - - - - - - -- - -- -
~~=-~
I k ,i,I in fr~t
l I I Eff. J)lll11p
---
-- Optl111111n IIJh>mti ny mntc· only
i--. ~
- llrakc
''~"<I c~t
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I ...... I',..
II P
~II
-- >--- - ' - i;>tl'tj .

....... 70
4~ ~
.10
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uu
--
t,\I
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/" I
llr"l:c h Of&e )OWCI l ,iHl Sil
/ ,_- ._::::,
20
L--- V - .8(1
, 6()
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.,u
10
r/ - -, -
\
,\- ,-
20
~() 20
JO
0
ii
V ~ j
IOOO 2000 3000 .JOI)()
I
[),u·rds p~r da) (42 U.S. gallons)
o,1 10,Vi5gb
i
I
10 60 80
Gallons 1.:r Ill in utc
JUO 120 l;
J
~ Pump typical performance curve showing the tolerance
~~ _ _ _ _ _ _r_a_n~g_e_s_r_e_c_o_m_m_e_n_d_e_d_b~y_A_P_I_R_P_1_1_5_2_ _ _ _ __
i1Ti"iiAiiiii
015)!1'10
-
Rec mnmnded
. 4-
operarmg rn11ge
All11>,,-,1blt f1c:~d,now 111,

pcd1.1nu21.1c.c 1J m1d
.,.,
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ir>',et....6'"
.,---- /
-t,<f:.f_,." tfr.,l,ney limil
,,
.I'
_..,//
.,
______
.I'
Brake_
1,~!P~~r - .. - - -
-.
- f
-- --
Allowable DIJP-flow rate
o/ p.nfonn;u1cc band
0 B~rrels per day

All multistage pumps manufactured are factory-tested by the manufacturer before delivery.
If the tolerance ranges are not met, the pumps are rejected
iP- Floating impeller ESP pump: impeller positions for different pump
~nse2' ________________o~p_e_r_a_t_i_n~g~p_o_i_n_t_s________________
.,, ..~
1
Down1luu,11
?~0 au,i: 1·,
WO
160 -
;I 120
~
llfl
10
0
0 8 10 12 JG
RateinGPM
PR001329 - Electric: submersible~

~ Example of REDA pump performance curve
1111• TI.Altllll(I
Retla Pump Performance Curve IH•J011 $

100 Stage • GN2500 • &OHz
Reda Pump Division 540 Series - 3500 RPM
U• ~ CU"'1 11l:•G 5l8 IN ODC~.tc• Cll~1;n.n
I I Rc(omn,cndcd
capac-il~nms1
1100 1000
4000
For Q = 2700 bpd:
H =?
1,oc • p =?
JOOO 7l
ZOO lU
IIVIJ j()() 1000 1100 2000 BOO JOOO J/00 4000

111;\lay 200 -100 GOO
G?~l - llPD1) I J
Capacity
~~ ___C_h_a_r_a_c_t_e_r_is_t_i_c_c_ u
_ rv_e_s_:_ G_e_n_e_r_a_l_(_
41_4_) _ _
t~-~_.,-..-..
1t, .. f li'iM11•0
- PRACTICAL CONCLUSIONS:
After examining the characteristic curves we can
make the following comments:
• An ESP pump follows its characteristic curve when
providing all the flow rates from zero to a maximum value
(for H = 0)
• Each flow rate has a corresponding determined head
capacity
• The flow rate-head capacity curve depends on the
rotational speed, the diameter and the shape of the
impeller:
- if the pump rotates faster, the flow rate increases
- similarly, a larger diameter impeller delivers higher flow rates
• The type of fluid pumped will affect the different pump
characteristics:
- density: only the power Input curve is affected
- viscosity:
it affects all the characteristics
the flow rate, height and efficiency fall with a simultaneous increase in
power input
~ _ _ _ _ _ _C_O_N_T_E_N_T_S_ _ _ _ __
ffii"Olli~illii
- CHARACTERISTIC CURVES: GENERAL

EFFECT OF PUMP ROTATIONAL SPEED on

~
~eb~---- - the characteristic curves (1/3)
------------_,_--~----- -
lboia..-. 11.-111
• When an ESP pump's rotational speed is changed its

performance is modified and these modifications are
predictable
• The laws governing an ESP pump's performance when
the speed changes are known as the "affinity laws"
• These laws state that:
- the flow rate varies proportionally to the speed:
flow rate .. a RPM
- the dynamic head varies with the square of the speed:
H .. a(RPM) 2
- the hydraulic power varies with the cube of the speed:
P "'a(RPM) 3
Effect of pump rotational speed on the
~ _ _ _ _ _ _c_h_a_r_a_c_t_e_r_is_t_i_c_c_u_rv_e_s_(~2_/_3~)_ _ ____ 1
1ni·, l~Jll"iiNQ
• Using these proportionalities we can construct the

characteristic curve for each speed
• From points on the standard curve (60 hz), it is possible to
obtain equivalent points at the new speed for
aproximately equivalent hydraulic conditions (type of fluid
flow, thrust on the impellers, hydraulic efficiency)
• The equations to be used are:
0 2 = 0 1 x (N 2/N 1)
H2 = H1 x (N 2/N 1)2
P 2 = P 1 x (Nz'N 1)3
where: Q = flow rate
H = dynamic head
P = power to be supplied on the pump shaft
N = speed or frequency
~ Construction of the 70 Hz characteristic curve from the

~~~ __
6_0_H_z_ c_u_rv
_ e________________________
1,i•,1'ii:mfoi0
Hz 60 70 60 : 70 60 i 70 60 70 60 70
a 0
! 300 500
l 758 817
H (fl) H 30 25 20 i 13,6 0
40
: I ; : ; ; : ;
1---,-----,-----,-----,,---,----,--_ _ _ _~~--~~~~--~~~
: :: : . : i .
__ J .______ J ... i..... -··- i.... L_. i.... i ........ i__ ._.i _... L...L ...... :_. __ i ... _i._..1. ... .
!: !I Ii i: !I i: i: iI .I !: i: i: i: i: !: !:
········r····i····r···· ···· 1 ··:::r.: ::;::::r::: ::::r::::r::::r::::r::: :::.1::::l::::i::::l::::
i : . i i i i ! i i
. ---:----l--:---i---i---+.-""c,:--l--:---+--+--+---J--:--+--:,---1
20 1---:---:.-i-
' i i ' ' . ' i . . ' . . . :
.... : .... : .... ! .... :_____ .... : _____ : . · -· : .. __ j ____ ..... :____ : .... : .... :__ ....•. :_ ... .: ..• :-- ·. :__ .. .
1
--·+-+-+--+-·- -- ·+---I---+--- - -i-·-r-··:····I····· ···+·+·+···i·····
··-- !·· ···: .. ··!·---:----· -· --~ ·---·:· ·.. !.. · ·:- .... ---- ~-----:--- ·!·- -1--·.. ····i···· ·;·--:-.. ·~-·...
! : : : : : : : : : : l : : I :
I : : ; ; : : : : : I : : :
o ~~~~-~~~~---~~---o-~~--~~~-
o 500 1000 0 (bpd)
Characteristic curves of a pump for different frequencies
1 according to the manufacturer"s catalogue
/ens pm - - - - - - - - - - - - -- - -
~~
CENTRlllFT PUIIP FOR lollNll,IUl.l 1%' 0.0. W£U CASING
..II" IT . ·r, · , . , · · · · :-
i-'2~ ,.. ;I; /I: .,.
-JJ.. ·,'· -~:,; .. . [JI! Q
u1,1; . . ,l'Jt_rt_,,,.,..~1'1--:n:r._., .;i . ~ l lll
,_
l~J'Pl~Yl•JU.&.GA4."~
- r;-
"'
0
0
0
ij
i
From the min. (12,000 BPD) and max. (•26,000 BPD) points in the 60 Hz recommended operating range
f
it is possible to define the recommended operating ranges for all frequencies (30 to 90 Hz in the present
case)
I
The pumps overall recommended operating range is funnel-shaped
PR001329- Bll(.)(c:.a,ulilNOliUloPJJll,Clr,_g
i
Effect of pump rotational speed

~~ _____o_n_t_h_e_c_ h_a_ra---'-c-'-te_r_i-'-s_ti_c_ c_u_rv---"--e-'-s_(._3'--'/.-- 3-#,
. C. . )_ _ __
1r.,.-,lliiii.i11-N'2
- RECOMMENDED CASES FOR USING A VARIABLE

SPEED PUMP:
• If we wish to produce a high flow rate with a small-
diameter pump this forces us to operate at a frequency
greater than the electricity network frequency (USA: so Hz,
Europe & Africa: 50 Hz), hence using a variable frequency
drive
• To pump viscous effluents or those containing sand it is
preferable to operate at a low frequency to extend the
lifetime of the units
• If gas is present in the pump, the pump rotational speed
should be increased
Note:
We shall see that to vary the pump rotational speed we shall adjust
the current frequency and the supply voltage of the electric drive
motor
~ ______C_O_N_T_EN_T
_ S_ _ __ _ _ ,
1-nio"Tiiiiiiiici
- CHARACTERISTIC CURVES: GENERAL -

CHARACTERISTIC CORVES
EFFECT OF PU MP DIAMETER ON THE

~ - --__,;C::;..:H
:--=-=A
'-=R
=--=A
:;.. :aC
-=---=--
T=E=R.::;_;:IS::.. . .:T:;.. :al-=C__,;C::.. . :.:cU. . R
:=-=-V
-=.. .;E
=-S
= ------
jf~-·,1..•,•o
Diameter change: Speed change: Diameter & speed

change:
02 /01 =(D2 I D1) 02 I01 =(N2 / N1) 0 2 /01 = (D2 / D1) x (N 2 / N1)
H2 /H 1 =(D 2 / D1)2 H2 IH1 =(N2 / N1) 2 H2 /H 1 =(D2 / D1) 2 x (N2 / N1)2

P 2 /P 1 =(D2 / D1)3 P2 IP1 =(N2 / N1)3 P 2 /P 1 =(D 2 / D1) 3 x (N 2 / N1) 3
a, : initial flow rate

H, : initial dynamic head "il
P, : initial power to be supplied on the pump shaft
0 1 : initial pump diameter
N, : initial speed
i
0 2, H2 , P2, D2, N2 : new values r
A pump with a larger diameter can produce a higher flow rate and deliver a higher head f~
I
I .
~ ~ - - - - - - - - - - - - - - - - - - - -•
1,-,,,w11111Q

Equipment
I To Summary I

~------E-" ip_m_e_n_t__C
q_u--=- _ O_N_T_E
_ N_T_S_ _ __
ii'TiiaiiliTl«i
- WELL COMPLETION
- DESCRIPTION OF THE DOWNHOLE PUMPING
UNIT
- ELECTRICAL EQUIPMENT
Electric submersible pumping: Equipment
~ ____W_E_L_L_C_O_M_P_L_E_T_I_O_N------'-(1_/4--'-)_ _ __
~
PUMP SUSPENDED
TO THE TUBING: ._ MOTOA COHT'RO~LEA

,-!~. Well completion (2/4)
u, .••-.••
- ~ '!!"l -:- •
·.:,:.10 '11,
- PUMP WITH PACKER S:tfoty \'alv,:: - - ,- "

for well safety
concerns:
4 1: 2 ¼mlUbings - r-
~~;
i;-
u\:ul'11fn~ \.t.h·~
"t::: ~ 0
~ 1---l f) ,lu,ulic duublc l

. . ViK:~\ft I
,:
Cu-=lwi,,g v:tl\'c
- - ( 111,1d,. \tl lVC I
Pump
J
~sl s~1ion ~
PA00 10:2'il • Elomfc•~PJtt"*!f

Motor
- I
~ _ _ _ _ __W_e_l_l _c_o_m---=-
p_ l e_t_io_n_ (.,_3_/4--'-)_ _ _ __
1rP1TR,UIIIN6
- COMPLETION WITH A "Y"

"Y"tool--
TOOL for downhole
interventions:
Cable clamp - -
By-pass tubing - -
PR001329- Electric submersible f]Wt.dJl',I

,{~ _ _ __ _W
_ e_ll_ c_ o
_m--=--p_le
_t_io
_n----=-(4_/----'
4),____ _ __
l,jj,;-rJ,.. .,
- PUMP POSITIONED
UNDER THE
PERFORATIONS:
Note the presence of a shroud

around tfle motor to force the
effluent to flow around it to
cool it
~-----E~q~u~ip_m_e_n_t_ _C_O_N_T
_ E_N_T_S
_ __ __
~,._~.
- WELL COMPLETION
- DESCRIPTION OF THE DOWNHOLE PUMPING
UNIT
- ELECTRICAL EQUIPMENT

~ DESCRIPTION of the downhole pumping unit (1/9)
m,·~o
- DOWNHOLE PUMPING
UNIT:
~ __D_e_s_c_r_i-=-p_t_io_n_ o_f_t_h_e_ d_o_w_n_h_o_ le~ p_u_m~p~i_n~g~u_n_it~(2_/_9~)_
ifi,;TIWIIJNG
- DIAMETERS OF THE PROPOSED EQUIPMENT (for

oil wells):
• Pump 3.38 11 / motor 3.75 II ~ casing 4 1/2 11 (< 11 lb/ft)
• Pump 4 II
/ motor 41/2 II ~ casing 5 1/2 11
• Pump 5.13 11 / motor 5.44 II ~ casing 7 11
5.38 II 5.62 11
5.62 II
• Pump 6.75 11 / motor 5.62 II ~ casing 9 5/8 11
7.25 II
Note:
- The different elements of the pump are transported in special metal
boxes
- The maximum length of the elements is 10 m approx.
Different manufacturers:
- American: Reda
Centrilift/OD1
ESP
- Russian: RAMCO / ALNAS
- Chinese: COSCO

~~ _ _D_e_s_c_r_i~p_ti_o_n_o_f _th
_e_ d_o_w_ n_h_o_le~ p_u_m~p
~i_n~g~u
_ n_
i t_(~J_/9
~)'-------1
i,h~t u.a•.NIII
- ELECTRIC MOTOR (1/3):

• 2-pole squirrel-cage rotor asynchronous 3-phase motor:
- the stator is powered by AC
- the rotor is short circuited
- the magnetic field generated by the stator rotates the rotor and thus
the shaft
- the rotational speed is proportional to the supply current frequency
(,. 2900 rpm if 50 llz)
- the motor's copper windings are immersed in a mineral or synthetic
dielectric oil for lubrication and heat distribution
- the standard motor insulation is class H (max. recommended operating
temperature= 140°C)
PA001329- El!iK:trie i.ubl!Cf:rtl.1 ~,nolni;I

~ __D_e_s_c_r----'ip,_t_i_o_n_ o_f _th_e_d_o_w_n_ h_o_le---=-p_u_m--=p'--i_n-=g'--u_n_i_t----'('--4_/9--=)-
~
- Electric motor {2/3):

• LID = 5 to 50 to enter oil wells, there are several rotors on
the shaft (series of small motors)
• To prevent vibrations there is a bearing every 1.3 ft;
these bearings are non-magnetic
• To support the "shaft + motor" there is a thrust bearing
which is lubricated by the motor's dielectric oil
• Starting current {I) = 5 to 7 times the motor nominal
current
• Electric motor cooled by the well fluid (speed between motor
and casing ID > 0.30 m/s)
• Motor heating under load= 20°c approx.
• The cost of the motor is high
PR001329-Eloctric~•WI~

~ __D_e_s_c_r_i~p_t_io_n_ o_f_t_h_e_ d_o_w_n_h_o_ le---=-p_u_m----'p'-i_n-=g'----u_n_it------=-(5_/_9"""")_
1N'eJ,\A,Lii111'1'i
- Electric motor {3/3):

Recommendations:
• It is recommended to use the motor within the half load
to full load operating range, otherwise it will overheat
• The supply voltage must be guaranteed to ± 5%
otherwise problems may arise
• If the motor is correctly cooled then it will operate
problem-free
• In cold wells the motors may be overloaded
• The motor operating temperature greatly affects its
service life (the same is true for frequent shutdowns-and restarts)
• The installation's undercurrent relay must be set to a
value greater than the motor's off-load current
PR001329- EJecbic •ubme<slbh1 ~

~ __D_e_s_c_r_i~p_t_io_n_ o_f_t_h_e_d_o_w_n_h_o_l_e_p_u_m_p_i_n_g_u_n_it~(6_/_9~) _
l~iili«i
- ROLE OF THE PROTECTOR OR SEAL SECTION

(part located between the motor and the pump):
• Connects the pump and the motor (connection of the 2 shafts)
• Seals the top of the motor with respect to the annulus
fluid and thus protects the motor's dielectric oil from all
external contamination
• Equalises the pressure between the motor oil and the
annulus fluid
• Absorbs the axial thrust generated on the motor shaft at
the level of the pump stages by means of an axial thrust
bearing located at its base
• Provides additional cooling for the motor dielectric oil
(additional contact area with the pumped effluent) since its lower
part is partially filled with motor dielectric oil
The following types of protectors / seal sections may be
used:
- labyrinth
- bag
- mixed

~ __D_e_s_c_r_i~p_t_io_n_ o_f_t_h_e_ d_o_w_n_h_o_l_e_ p_u_m_p_i_n_g_ u_n_it~(7_/_9~)_
r~'?".~~-~
lrfl' O T~MIII>!~
- PUMP SIZE (different flow rates possible) (1/2):
Rate best Operating range

Series Type efficiclency
60 Hz 50 Hz 60 Hz 50 Hz
(BPD) (m 3/d) (BPD) {m'/d)
338 DC800 800 106 550 950 73 126
DC1000 1000 132 700 1300 93 172
DC1250 1250 166 950 1600 126 212
400 FV320 320 42 180 460 24 61
B11W 380 50 180 460 24 61
FS400 400 53 180 490 24 65
FC650 650 86 400 850 53 . 113
FC925 925 123 650 1100 86 146
FC1200 1200 159 950 1550 126 205
FC1600 1600 212 1200 2100 159 278
FC2200 2200 291 1700 2700 225 358
FC2700 2700 358 2100 3100 278 411
FC4300 4300 570 3000 5200 397 689
FC6000 5600 742 3600 6800 477 901
During the design stage, the choice of pump is based on lhe flow rate to be produced
PR001329 - Eleclrlc submersible plltllC'ing

~~ frlioTAAININQ
Description of the downhole pumping unit (8/9)
- PUMP SIZE (different flow rates possible) (2/2):
Rate best Operating range
Serles Type efliciciencv
60 Hz 50Hz 60 Hz 50 Hz
(BPD) (m'id) (BPD) (m 3/ d)
513 GC1200 1200 159 800 1600 106 212
GC1600 1600 212 1000 2000 132 265
GC2200 2200 291 1500 3000 199 397
GC3000 3000 397 2200 3600 291 477
GC3500 3500 464 2200 4700 291 623
GC4100 4100 543 2500 5600 331 742
GC6100 6100 808 3650 8100 484 1073
GC8200 8200 1086 4400 10300 583 1365
562 KC12000 12000 1590 9500 14500 1259 1921
KC15000 15000 1987 11250 18750 1490 2484
675 HC7000 7000 927 4500 9000 596 1192
HC9000 9000 1192 6000 11500 795 1524
HC12000 12000 1590 7500 15000 994 1987 •
i
HC19000 19000 2517 12000 24500 1590 3246
875 1A600 21000 2782 10300 27500 1365 3643 i
C
1025
18700
JA1100
JB1300
24500
36500
43000
3246
4836
12700
19200
19900
32200
45900
58900
1683
2544
2636
4266
6081 i
5697 7803
f
During the design stage, the choice of pump Is based on the flow rate to be produced ~
PA001329- Eledrlc ~ubmersiblo ~ Q I

I

,-!~ __
D_e_s_c_r_i~p_t _io_n_ o_f_t_h_e_ d_o_w_n_h_o
_l_e--=--
p_u_m-'p'--i_n--=g'---
u_n_it_c._
(9_/_9~) _
·--
u-r.fMiaiMlli
- Metallurgy & Elastomer:

• Housing= carbon steel(+ monel and epoxy coating if requested)
or
ferritic material (little used)
• Impeller/ diffuser = Ni resist (castings)
• Shaft = K monel
• Bearing, thrust bearing pads = bronze
• Normally used elastomer = nitrile
Note: if H2 S present, bronze not used for the pump body

and elastomer = AFLAS
PR001329 - Electric SUbmefsi bl e p,a~

~ _ __ _ _E__,q,____u-=ip_m_e_n_t_ _
C_O_N_T_E_N_T_S_ __ _ _ 1
ITT.i"Tuiiii!i
- WELL COMPLETION
DESCRIPTION OF THE DOWNHOLE PUMPING
UNIT
ELECTRICAL EQUIPMENT
PR001329- Electiic submersible pill~
J:lectric submersible pumping: Equipment

~~ _ _ _E_L_E_
C_T _R_IC_A
_L_ E_Q_U_IP
_M_ E_N_T---'-
(1_/1_2.. ):. . _ _
w,--;;1t,t1•u•di
The electric power cable is

a weak link in the process:
there is a risk of damaging
it when running it into the
well and it is expensive
(price depends on insulation
quality}
•ii
The electric power cable
i
along the pump is thin and
flat f
I.
'
PR001329 - Electric submersible ,aimp"tig
I
~ _____E_le_c_tr_i_c_a_l_e~q~u~ip~m_e_n_t~(2_/_1_2~
) ____ 1
irii"irWIIIH
- ROUND ELECTRIC POWER CABLE:

J25j0-415QO Elastomer jacket
Insulation
Galvanized armor
.
~
Copper conductor
7 stranded for downhole measurement i
copper condur.:tors transmission if
.
'
j

~ _____E_le_ c_t_r_ic_a_l_e_q_,,__u_,,_ip_m_e_n_t --=-(3_/_1---'
2):....___ __
lfP•Tli"'1"1"1i
- FLAT ELECTRIC POWER CABLE :

2 3 4 5
\
1 - Armor: Galvanized Steel
2 - Tape/Braid: High Temperature Barrier
3 - Jacket: High Modulus, Breathable EPDM Rubber
4 - Insulation: High Dielectric, Low Swell EPDM Rubber
5 - Conductor
~ _ ____E_l_e_c_t _ri_c_a_l _e_q.,._u_i-=-p_m_e_n_t__,_(4_/_12___,)'------
ifjl,"-;--fjii(ilii,i"ij
- DIMENSIONS OF THE ELECTRIC CABLES

PROPOSED:
• Cables with copper conductors - 3 KV/ 5 kV -120/130 A
Type Size Weight Diameter
(lbs/ft) (in}
Round N°1 1.75 1.343
armoured N"2 1.65 1.265
N°4 1.17 1.140
N'6 0.88 0.970
Flat armoured N°1 1.42 0.69 X 1.83
N"2 1.40 0.65 X 1.70
N°4 1.39 0.59 X 1.51
Size no.1 = largest cross section for copper conductors
Size no.6 = smallest cross section for copper conductors
The cable is transported wound on wood or metal spools which protect ii against
impacts
PA001329 - Electric subme<sibl11 riwr.olnQ

~ _ ____E_l_e_c_t_ri_c_a_l_e_q.,._u_i-=-p_m_e_n_ t-----'-(5_/_12_,)' - - - - - -•
1f,.TR.1Jtt11iQ
- SPLICES (1/2):
.f)]JJ))~:2 [) ~-~
Jnckcl ---
-----~ _j t---5 I~
19~----J
-+--
- -
7 T"-1
Row1djacketed cable
Pfa.tlic im·1if"li011
~ Bnud fil l~ d
+]))))]))J1r:h
aui.ous I I
.
2 7
19
i
..j s . =-1
s . R11bber i11s11/atio11
Flat or round unjacketed cable

~ _____E_l_e_c_t_ri_c_a_l_e_q-=-u_i-=-p_m_e_n_t__,_(6_/_12___,)'-------
ITTotiiiliiici
- Splices (2/2):
. <,_\\\\\\\\\)
'C llllJJ111 ~i'i""'"'~~f'j• l'l'"lllljjl'llj++IURi!A'~
hltt!!'i':@:SZ,DI rnlff!l1Jiiiiiffiiw,illj)
Ir.lier The splices are hand made
FIiier ,1,tnl/ (average time per splice
= 3 to 4 hours)
Is-i..,~ , • .i.
Am,ord~lnil
V,i~u l'Mllllil 1tdm1;r
!ku-1d1il)GJ
½........ _____E_l_e_c_t_r_ic_a_l_e~q_u___,ip~m_e_n_t----=--(7_/1_2_,)_ _ __
.,,.
- GRAPH FOR CHOOSING THE ELECTRIC POWER

CABLE:
cl
~
0
8
..,
~
§
§
0
0
!il
~~r--i---if-f"trt-r.r--;..--t-7'-,j;,-"'--t--,:lr""-t-:::...-"::),-"''--t-~ g
~ ~
I
~ 0
~ il
~ J
;:J
0
"' f
'"w
cl
I
;
AMPERES
IDD 1:io
"'0 I
I-
~~ _ _ _ _ _
E_le_c_t_ri_c_a_l_e_q~u'--ip~m_e_n_t___,('--
8/_1_2.,_
) _ _ __
""'• tl-:U.~
- WELLHEAD ELECTRICAL
PENETRATOR:
Swfooepowe,
~ n n e c l Q I - -~
Downhole power
connector - - - - , - - t i -I

~
._.,ri-.. _____E_l_e_c_tr_i_c_a_l _e_q~u_i~p_m_e_n_t~ (9_/_12----")~ - - -
111P11 .... 1i11!i
:i .. r....,.,...
1(·1.{t'
Ul(III
- WELLHEAD AND PACKER ~,_......!!?ln-1inwtl
ELECTRICAL PENETRATORS
r
~
ti rl11Jmtd.~J1
... ,~ffal1""11 llfJ
DliaH1,_
11M4l-111J,,,\.,'ll,l,
mQor,q.,,.ll.a-.1
........~ ~
)l1i11111~Mn1f~liM
,.~"" ,..,. ·-«...-

- ""'•'1"• •• 11!'•~d
'S'tii""'ltt-""ffltJi1h1
i C-.t.s.
·-~- 'f
~ _____
E_le_c_t_r_ic_a_l_ e
~ q_
u~ip~m_e_n_t~<~1_01_1_2~)_ _ __
1,-, ,t,i,.,11111,Ui
ELECTRICAL CONTROL PANEL (switchboard):
• Functions:
- startup I shutdown
- records the motor's current consumption
- overcurrent relay for electrical protection
- undercurrent relay for electrical protection
- timeout for restarting
• Relay adjustment:
- overcurrent = motor lnomlnal + 5 to 7 %
- undercurrent = motor lnomlnal • 10 to 20 %
- It is preferable that the relay should trip before the flow rate
reaches zero
(possible overheating of electric motor)
• During operation, if I > lnomina, of the motor in place,

problems may arise
Electrical control panel (switchboard)
Rca1 ofnr11m.:1ci
compartment
PA001329- Electric submersible ~

~ -_____
E_le_c_t_r_ic_a_l_ ~
e q_u-ip~m
_ e_n_t~<~1_1_
/1_2~)____ 1
i'ifiri;i:iiii"iia
- VARIABLE SPEED CONTROL:

• A Variable Speed Controller (VSC) is used to vary the
frequency of the electric motor's supply current and
supply voltage
• Since it is an induction motor, its rotational speed is
proportional to the frequency:
N # 120 F / P
where: N = rotational speed rpm
F = stator excitation current frequency
P = number of stator poles
• By varying the pump's rotational speed we can change 0
~
the flow rate, the dynamic head or both at the same time
without modifying the downhole unit i
rf
.
i
~ Variable speed controller

enspm - - - - - - - -- - - -- - - - - - - - - - - - - - - - - ,
i~7.~ij
0}l_,C:H1
~ _____
E_le_c_t_r_ic
_a_l_e__,,q_u_,,ip'--m
_ e_n_t___:(,__1_2_
/1_2_,_)____ 1
11ii"'i'liAiii"i,ii!i
- VARIABLE SPEED CONTROLLER OPERATION:

• No choke is required to start the unit
• When a variable speed controller is used no check valve
is required, however a special transformer must be used
• It also acts as an electrical control cabinet (switchboard)
• In addition it can contain safety devices: max. frequency,
min. frequency
~ - - - - - - - - - - - - - - - - - - - - - - - - -1
IN'•fAA1N1N'lii

Installation design
•
il
j
! ! f
To Summary
l
~
j
~_ ___l_n_s_ta_l_la_t_io_n_ d_e_s--=ig=--n_ _ C_O_N_T_E_N_T_S_ __
f~;i:
- REQUIRED LIFTING HEAD AND ESP PUMP

OPERATING POINT
- PUMPING INSTALLATION CALCULATION
.
1
REQUIRED LIFTING HEAD AND ESP

~ _ _ __ P_U_M_P_O
_P_E_RA
_ T_I_N_G_P_O
_I_N_T~('--
1 /_4 __,_
) _ _ __
fri,"rii:Uiffili:i
- WHAT HAPPENS AT THE LEVEL OF THE WELL TO BE

LIFTED:
H
(m) • For a given flow rate the
required lifting head is
the sum of 3 variables:
- the distance between
dynamic level/ wellhead
Tubing hcnd prcssuro - the pressure drops In the
tubing
- the pressure required at
the wellhead
() Q
(Ill /j} • A curve of the lifting •
head required by the well i
according to the flow j
111 1
rate can be drawn:
- H on the y-axis
r
- Q on the x-axis J
~
I
Variation of the required lifting head
1 for different flow rates
--1,nspm _ _ _ _ _ _ _ _ _..:....;:;.;;....;;;;.:;;:.:..;:;.;;_;:;..:.;:..;:_;:.;;..;:;..:.;:.....;.=.;;=.:=-------- -- ---
_,,._
.,,. ~ .1i
H
Q= 0 Q ~ 200 Q ~,100
m) Tubing losses
~ ~ Tuhing hca<l pressure
Stmlc lifi
0 200 -100 Q
(m 1/j)
When the flow rate increases, the dynamic level in the well is deepened
and the required lifting head increases
~ Curve for the "Lifting head required by the well according to

~~~~ --=f:..::l-=oc..:w:..::..._=-ra=t-=e=--"---- - - - -- -- - -- - - - -- - - - - - - - - - -
lr••ru.011NC1
C ..s1•ra
II
(m)
Tubing los...:s
0)1mni lin
S1or;c Jill
fub111g hc:111 1w.c, urc
0 200 400 600 Q

(111J/j)
~ Example of the lifting head required for a well to be lifted
,,-!!~
~~
-------------------------
Head Ft.
~l.:... fi f!lo
10000
9000
8000
,./
7000
./
vv
6000
V
V
5000
vv
-
I/
4000
v"""
3000 0
...-- !
2000
I
1000
I
0
PR001329-Eleclric 'l~"'1!1,pir,,g
500 lOOO 1500
QBPD
'
ii
f
Required lifting head and ESP

~~ _ _ _ ___,p,_u_m___p_o......p_e_r_a_t_in__.g_____p_o_i_n_t__.__(2_/_4-S--)_ _ __
ifr''i"ri iuiWiii
- What happens in the WELL at PUMP location:

(FIXED FREQUENCY PUMP)
Ilead Ft :' o~~~~t~ng ':
]0000 I I '"-'"'
I
I
9000 t-------1--+--+--+-t---t-~+-1---1-1--1--1---1--1--1---1-1
: PJmJ ch roe crl, tic unc
1
8000 1-<--+--+--+o--+--1-T-t---t----t--+-·l--+--o---<--+--+--+--I
60 J,lz
7000 !=1=1''-1---lct=:::l_-lj_
-4-,. _,,,.v v
6000 1--1-+-+-+--+-t , -......_ _..... - - l 1f til ll.1..,e.=-
a >'--lt-------1
·,---" 1
·) C
,
nqu re, .'?l
t )e l~st Ila for
- We wish to produce
5000 900 BPD
- We select an approP.riate
4000 pump with a suitable
I/
...-- \ number of stages
3000 - We produce 900 BPD
V
2000
1000 i\
' I\
0 500 1000 1500
900 QBPD
PR001329- Elecbic J.ijttr.,,tlo ~l'I~
Required lifting head a nd ESP
~ _ _ _ ___,p"'-u~
m.=.p
.c=.. -o--ac
-= pc._ec.c . .r=- a=--=
-=- t=in=g........._p---'o'---'i_n=t--"-(3=/--"4.). . _ _ __
ffi'fif~
- USING A CHOKE TO CONTROL THE FLOW RATE:
(fixed frequency pump}
:• O~nratlng 11
Hea d Ft. 1
ange :
1
10000 ~ - ~ ~ ~ ~....· ~~~~+- -~~~....,.;c°';~'
.;;~'"
9000 1--l--l----ll----l---l--+.L
,...j.-...j.---l----l-----l-----l----l----1----11----1---I-I
, : Pumi ch rac ort Uc ~un e
8000 1-----1-----l----lf----1+1----J--+r--+--+--+-+-+--+---l----lf----lf----l-i
60 Hz t v
1~ol= -_,4~+,4~--+--+-+-~-h'~ ++++-j
_F_=F'_~_~_~_d,_
H
sooo 1--1---,1---,f--1-_--1-
__ -+_v
1
60o'o 1-~f--..ll--rl,-.II--I-.;.-~
- - _c_~~i ':g_ ---+~r ~~~
' ~---... ......I--J...<!::';.:k::~~L~1ft!!!i1110
- ~,...<F-l--"l----1--+-<r-+-+--f--1--+--1
1
a~ea~~~--1
l~it~1?~1or
• 0 = Oma1 . possible with the
pump m place for the
considered well data
(in this case O = 900 BPD)
,1000 1--11--t-l---+">"Fl/
--t--t--+-_+r\.
~-I-+--+---+-+---,
i.....-v-- r\. - If we wish to produce the
flow rate a, < a we must I
0
3000 1-
~--b--F---l-lf--+-t--t--t-+-f------l---'IJ-~}-:-1-lf--+-t---+--,
choke at the wellhead
2000 1--1----11----1---1---1--+--+--+~~--I--H., -1---1----1----1------J-i ij
1000 1--1----11----1---1---1--+--+--+~--t----i--l-''-l--
l\,._
, 1----11----1---1-1
r--
- If we wish to produce the
flow rate 0 2 > a, we must i
0 500
01 o=
1000 1500
change the pump
f~
02 Q BPD
PA001329 - El!M:lriC submersible pw~1i;i

900
I
Required lifting head and ESP

~~
f«._.,.....,,..
- - -- ~P~U~m=--=--=-p_o=--,p""'"e~ ra=t=i=n"-g_ p_o_in
----"'-
t ...L..(4-=/-"4.£....
) _____ 1
111 ... 1- W
- What happens in thet WELL at PUMP location:
(VARIABLE frequency pump}
• Using a variable speed

with:
- the previous pump
- the previous well
• Reminder: for a frequency of 0
60 Hz we can produce a flow !

rate Q = 900 BPD ii
I\ • By varying the frequency 1·
\ from 50 to 71.6 Hz we can
produce from 600 to ii
500 1000 1500 1200 BPD ~
0
O,= 0= 02= QBPD ~
PA001329- Eleclric submersible~

600 900 1200
l
~ _ _ ___ln_s_t_a_ll_a_ti_o_n_d_e_s_i=g n_ _C_O
_ N_T_E
_ N_T_S
_ _ __ 1
iffofiAiiiirel
- REQUIRED LIFTING HEAD AND ESP PUMP-- "'

OPERATING POINT
- PUMPING INSTALLATION CALCULATION
PR001329-Electricsubrn01siblop,1"1PMI

PUMPING INSTALLATION CALCULATION (1/2)
- BASIC PRINCIPLE:
• The type of pump determines the flow rate which can be
produced (each stage produces the same flow rate)
• The number of stages determines the dynamic head
generated and the power required
•
!
j
f
I;
I
~ - ----D_e_s_i_g_n_o_f_a_n_E_S_P_p_u_m
_ p_in_g_ i_n_s_ta
_ ll_a_t_io_n_ _ _ _ _ _ __
1,,,.,.-rr
l Well, depth and casing diameter data
Fluid data
l
Use of the IPR curve if necessary
1
Choice of flow rate~ flowing bottom hole pressure
1
Effluent suction flow rate calculation
Gas separation estimation
! Choice of tubing diameter ~
...
I
Choice of pump type & series Calculation of the pump delivery I
pressure I
Use of a variable speed controller or not I Calculation of the pressure drop
I
I
l due to friction
I
I
I
Calculation of the number of stages & power required I 0
l Choice of the type of electric cable :!

Choice of the motor series - HP, voltage & current I-> and size ~ -' I
rating Calculation of the voltage drop
Choice of electrical switchboard, control panel and f
transformer
l
I
-1
Calculation of the electrical power consumption (kW)
J

~ __
P_u_m_p
_ in~g_ in
_s_ t_a_l_la
_ t_i_o_n_c_a_lc_u
_ la_t_io
_n~ (_2/_2~) _ _
~;;~-;;~t;1
- CALCULATION EXAMPLE (using the manufacturer Reda's
catalogue, fixed frequency design):
• Data:
- reservoir depth: 1000 m
- flow rate: 300 m 3/d of anhydrous oil (watercut= o %)
- FVF (Bo) = 1.15 at Pintake and Tdownhole
- d 011 = 0.80 (at downhole conditions)
- GOR = 40 m3/m 3
- Pbubble = 20 bar at downhole temperature
- Pstatlc at 1000 m = 78 bar
- IP= 10 m 3/d/bar
- dynamic annulus level corresponding to
the flow rate 300 m 3/d = 400 m/sol
- p required at wellhead = 8 bar
- Tdownhale = 50 "C
- limestone reservoir
- 7" casing
- pump delivery column= 3 112" tubing (prior choice)
- electric current frequency = 50 Hz
- oil viscosity: low(< 10 cP)
~ Calculation example: diagram corresponding to the data
iR'"i"ir'Mimia
Tubing head
0
pn:ssure Pb
Sb
Tubing
3' Ir.!.,,
111 ,100111
0~1~1mic lcl'cl
h - 800m
l'11mp
i-:1..;;;;
00c.::O..;.;
m' - - - - " "--- _ _..\_
;:;;._ I'___;::....._ _ _ Rcser,oir <lepth
,, "~
Lm ~8 h 78 h
~ - - - - - - - - - - - - -- -- - - - - - - - - - - - - - -
ifi.iiiMiiiiii

Use of a variable speed controller
•
ii
i
f
I
1
I
~ _ U_ S_ E_O_F_A_V_A_R_I_A_B_L_E_S_P_E_E_D_ C_O_N_T_R_O_L_L_E_R~ (_1_/3~) _
m,.r1iiilfiiii:l
- INTRODUCTION:
• The existing electric power cable is used to directly
control the rotational speed of the multistage ESP pump
and the energy transmitted to the motor
• We could adjust the current, the voltage, or the frequency
• In our case we will modify the last two parameters to:
- change the pump's rotational speed and modify its hydraulic
characteristics to increase its operating range
- maintain a constant voltage / frequency ratio on the motor to allow
it to provide sufficient torque to drive the pump independently of
the speed
• These operations are performed by the variable speed
controller (frequency) which thus supplies the 3-phase
electric current to the downhole motor via the electric
cable clamped along the tubing

~ _ _U_s_e_ o_f_a_ v_a_r_ia_b_ le_ s~p_e_e_d_ c_o_n_t_r_o_l_le_r~ <~2_/3~>-
fr,--,riiA"'iH,H-li
- DESCRIPTION:
• It converts a 3-phase AC supply with fixed voltage and
frequency to an AC supply with controlled variable
voltage and frequency by passing through a continuous
intermediate stage
\'oltrigc incr..:-a~c • Remarks:
- a control circuit manages the
different switching
operations performed using
power semiconductors
- the high voltage variable
speed controllers are now
too expensive and too large,
hence the variable speed
controllers used for the ~
submersible pumping are l
installed on the low voltage
side rI
I~
I
~ __s_c_h_ e_m_a_t_ic_ d_i_a_g_r_a_m
__o_f_t_h_e_ v_a_r_i_a_b_l_e_s_p_e_e_d
_ c_o
_ n_t_ro_ll_e_r_____
ifr.'iiliAiiiiil-ci
A.C. D.C. Six Step

Waveform
'VVV\.
3 Phose Input
I Inverter
D.C. Volt
Feedback
Output
Frequency
Control Signals
Speed Ref.
®---~
- The variable speed controller performs a double current
conversion:
AC=> DC=> AC
- Recommended operating frequency range: 35 to 75 Hz
~ , ___
E_n_g_i_n_e_ t_o_r_q_u
_ e_a_n_d_ w_ e_l_l_r_e_s_i_s_t_i_
n_g_ t_o_r_q_u_e_ c_u
_ rv
_ e_s______
fr,--.TP.Tiiwic
I
M\l'C.t-.-,fll.'-'1.I.Hin:111~
\\! r "ltt;
ra,.::111 ~~i:y
1110 1/
,SO II, MI it. 1011,
JI~
100
:.? 3 rr1nir·1
RPMx 103
- The pump starts up smoothly from 12 hz to the displayed frequency in a few

minutes (starting law)
- The frequency ramp is modifiable
!'P-!I Electric and hydraulic power variations according to
~_f_r_e~q~u_e_n_c_y_._M_a_x_im_u_m
__o~p_e_r_a_t_in_g_f_r_e~q~u_e_n_c_y__________
lflll0 nlJll:HG
300 Point al which lo

I
l'nm p -~h~fl
calculate kva requirement hp dt111 11ml
200
opcraling
100 frequency
~--~ :1 Ovoduad >

0 10 20 30 50 60 70 80 90 100
Frequency, Hz
- The electric motor power varies proportionally to the speed (Hz)
- The hydraulic power required by the ESP pump varies with the cube of the
speed (Hz 3)

~ _ _U_s_e_ o_f_a_ v_a_r_i_a_b_le_s_.p..__e_e_d_c_o_n_tr_o_l_le_r. .(3_/_3
. . ......) _
17~----.·-rn-,.i11liiii
- INSTALLING A VARIABLE SPEED CONTROLLER:

-Allows the design to be adapted to the rroduction start,
particularly when the well data is not wel known
- Increases downhole pumping equipment lifetime by
modulating the load, particularly during starting
- Improves the overall efficiency hence saves energy
-Allows the operation of the pumping unit to be controlled
by a control system
'
Important: When a variable speed controller is used, a
special transformer with a larger ferrous volume must be
used to prevent the saturation phenomenon
~ - - - - - - - - - - - - - -- - - - - -
~

Special cases
•
11
I To Summary I 'If

~ p_e _c i_a_l _c_a _s e_s_ _C_O_N_T_E_N_T_S_ _ __
- - - - -5-=--
,,,.,,u.1..-iiO
- INTRODUCTION
- PUMPING VISCOUS CRUDES
- PUMPING GASSY CRUDES
- PUMPING WITH SANDY EFFLUENT
- PUMPING IN DEVIATED WELLS
PR001329- Eloclricsubmersibla ~~
!!F.!s Electric submersible pumping: Special cases
~J~ ______IN_T_R_O_D_U_C_TI_O_N_ _ _ _ _ _ ,
ifii'o1'mNTi«i
• With electric submersible pumping, we must take into

account the conditions present on the suction side of the
pump:
- flow rate
- pump intake pressure
- type of effluent pumped:
• viscosity
• density
• % free gas
• possible presence of solids
• We will examine the effect of the following on the
operation of the pumps:
- effluent viscosity
- percentage of free gas in the effluent
- presence of solids in the effluent
• We will also consider the case of deviated wells
•
I
!!h Illustration of the effect of viscosity & of the % of free gas on

~ _a_n_ E_S
_P_p
_ u_m_p_'s~ p_e_rf
_o_rm_a_n
_ c_e_________________
i.r.'~:t:1
Qmax
Rate
decrease
j ~
oP.
,. ~
(> (;
"-'S.,~'\.
More viscous
I cP More gas
0% Free gas
When µ or free gas % increase, the pumped flow rate decreases
~ _ s_ _C_O_N_T_E_N_T_S
- - - - -S---=p'-e_c_i_a _l _c _a _s e _ _ _ __
w~:,.-,-ii'ci
- INTRODUCTION
PA001329- Eleclric Wb'tl.<:11:1.itl.l ~
Electric submersible pumping: Special cases

{~ _ _ _P_U_M_P_I_N_G_ V
_ I S_C_O
_U_S
_ C_R_U_D_E_S___,_(_
1/____,
,,,•. ~~
2)' ---_
• If viscous crudes are pumped, this affects the performance
of the electric submersible pumps:
- reduces: dynamic head
flow rate
efficiency
- increases the power required to drive the pump
• The effluent viscosity at the pump intake must thus be taken
into account for the installation calculation
Otherwise, the pump will be undersized and will not produce
the desired flow rate
• In practice:
- ifµ< 10 centipoises: no correction
- ifµ> 10 centipoises: correction
• If the crude is very viscous it is preferable to carry out a test
on site to ensure that pumping is feasible
• The manufacturers have carried out tests to evaluate the
viscosity effects on the characteristics of their pumps and
define the correction factors
• For each pump in the catalogue, the manufacturer has a set
of characteristic curves according to the given viscosities
PA001329 - Eloctric &ll tfflcnll:q p,rrtfflD
Example of correction table for pumping
~ ini'"iTThNliici
viscous crudes (Centrilift ~um~ J61 - series 400}
Viscosity Flow Dynamic Efficiency Power

(SSU) capacity head
50 100 100 98.7 101.3d
80 99.3 100 96.3 103.1 d
100 98.8 99.7 95.0 103.7d
150 97.3 98.6 91.5 104.9d
200 96.2 97.8 88.0 106.9d
300 94.0 96.5 81.8 110.9d
400 91.8 95.5 76.5 114.6 d
500 90.0 94.6 71.7 118.7d
600 88.5 93.7 67.5 122.9d
700 86.7 92.8 64.0 125.7d
800 85.2 92.0 61.0 128.5 d
900 84.0 91.0 58.6 130.4d
1 000
1 500
2000
82.6
77.0
73.0
90.6
86.3
83.2
56.4
47.7
41.0
132.7d
139.3 d
148.1 d
.l!
2 500
3000
69.6
66.7
81.8
80.5
36.3
32.2
156.8 d
166.8 d
i
4000
5 000
PA001329 - Eleclric si1 ~11lt41 J.'Qr,;m.g

d = density
61.3
57.1
78.6
78.2
25.2
19.0
191.2 d
235.0 d
Perfonnance in % of the performance with water at the optimum efficiency point

' l:-
1
l
Hydraulics Institute correlations: practical graph when no pump

I correction factors are available (for a 60 % pump efficiency with water)
'1,n~~
,r,:-r;~ ... - - - -- - - - - - - - - - - - - - - - - - - - - - - -- - -
Corrections to be applied to obtain: - the corrected dynamic head
- the corrected flow rate
- the corrected power
1111
Notes:
the viscosity to be considered
E!" t:~
.,. ~
is at the pump intake
temperature
le § the presence of free gas
"'C
Ii
·=[;l ~o downhole is not taken into
account
:i:: 5'-'
1,/1 1,1
SIi 1.2 a
c t:
ii ~
~ 40
§
0::
so 70 l 00 150 200 JOO -IOO 500

SSU vicosity 0>11am,,
PA001329 - Electric .ubMlliti'D ~ 1 1

~ Electric submersible pumping: Special cases
~~ ____P_u_m___p_in~g__v_i_s_c_o_u_s_c_r_u_d_e_s_~<2_/_2~)_ _ _ ,
lfP • T~.o.lfl111i:i
- RESTARTING THE PUMP:

• After a long shutdown period the viscosity at the pump
intake may be high because the temperature has fallen
• Two possible cases:
- if waxy crudes ~ risk of blocking the tubing
- if crudes with asphaltenes ~ restart at low flow rates to slowly
increase well temperature and reduce the viscosity
• Possible solutions:
- descend the pump deeper down in the well to obtain a higher
temperature (11 !)
- heat the delivery column
- start at low flow rates (using a variable speed controller)
- circulate a light effluent in the delivery column after the unit has
been shut down
PR001329-Eleclricsubmer'l..lla~IQ

~ ~ - - - - -S---'p'--e_c_i_a _l _c _a_s e_s_ _C
_O_ N_T_E_N_T_S
_ _ _ __
lr,.,u.1PIINii
- INTRODUCTION
PR001329- Electric sutxnersible ~

~~ __P_U
_M_ P_IN
_ G_G
_A
_ S_S_Y_C
_R_ U_D_E_S_(_P=su=cU=on_<_ Pb~u~b·~J~<~1_/8~)_ _
ITT-.r1iii;iiilri6
- PROBLEM & BASIC SOLUTIONS:

• In principle, ESP pumps are designed to pump single-phase
fluids
• However, they are often used in conditions where free gas is
present in their intake orifices
• To limit the free gas passing through the pump, the
producers can use gas separators. These are basically of 2
types:
- static or reserve flow
- dynamic (centrifugal separator)
• In addition, part of the free gas arriving at the pumping unit
does not enter the separator but is directly evacuated via the
casing-tubing annulus
=> Basic solutions:
- Using a static separator
- Using a centrifugal separator
- Pump positioned under the perforations
Note: It is better to vent the gas via the annulus than to produce ii
PR001329 - Electric sutniersible Pl""*"P
~ Conventional electric submersible

!!~ pumping application
~~~~ . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
111r;i1Uilll.•i
0 0
t 0
0 t The gas is vented via the
annulus
Pump w~h ccr11rifugnl
sas scp.ir.tt()r
The pump is positioned

above the perfora tions
PR001329- Elecbioa.lltirnGt1lU1tp,i'®nQ
~ ---C_h_a_n_g_e
_ i_n_p_e_r_
c_e_n_t_a_g_e_ o_f_f_r_e_e_g_a_s_in_ t_h_e_e_ff_l_u_e_n_t_____
~
-$- Gas at the 1st stage of the pu

the residual% of gas arriving at the
1st stage of the pump is:
[G (1-a) (1-b)] I [G (1-a) (1-b) + L]
* Gas escaping into the annulus:

by natural flow, a¾ of the gas
* Gas extracted by the separator:
the separator extracts b¾ of the gas
present in the initial effluent from the gas bearing effluent which
escapes between the tubing and the enters via its intake orifices
casing
Scparalor inrakc
• Gas at the separator intake: ----+t.tm""'
the % of gas in the effluent which
enters the separator is:
[G (1-a)] I [G (1-a) + L]
* Initial effluent (G and L):-------1+1

if G is the quantity of free gas and L
the quantity of saturated single-
phase liquid, the % of free gas in the
initial efluent is: .
G/[G + L]
PR001329- Eleclric submeisible ~
I
!!h Electric submersible pumping: Special cases

,,.!!!::'UMPING
ensprn
GASSY CRUDES (Psuction < pbubble) (2/8)
~~rm:;:
- PROBLEMS for calculating a pumping installation

with gas present of the suction side:
• To correctly calculate an ESP pumping installation in a 2-
phase environment, there are 3 problems:
problem 1:
find the percentage of gas which escapes directly via the annulus
considering the well geometry (pump 0, separator 0, casing ID, well
inclination) and the speed of the effluents passing in front of the
separator intake orifices
problem 2:
for the type of separator used, find the percentage of gas which it
extracts from the effluent it receives
problem 3:
find the effect of the residual gas present in the effluent which
arrives at the first stage of the pump on the characteristics of this
pump
• The answers to these three problems are not easy and are
widely debated
~~ __P_U_M_P_ I_N_G_ G_A_S_S_Y_ C_R_U
_D_ E_
S_,_(.....
P s=uc=tl=o"'--<_P--=b=ub=ble=-)_,_(_3 /_8_,_)_ _
~iiiiiii
- PROBLEM 1: for a determined geometry {well - pump -

motor, etc), what is the percentage of free gas present
in the initial effluent which directly escapes mto the
annulus?
• A well can be assimilated to a large separator, the
degassing which takes place there is excellent
• There is no graph since each well is a special case
0
I
i
f
f
;
PA001329 - Ehictric submersi~e IJ.llnDlriQ
I
!!h Effect of casing diameter

,JJ~ _______.{_r-'-e"""su'---1-'-ts"--'-o""f-'-te'""'s'""'t-'-s_o_n_v_e_rt-'-i-'-c_a _l w_ e_ll-'-s._)_ _ _ _ _ _ __ __
iniofUl""i'LiiQ
% of free gas in the annulus at the side of the pump

before the motor trips due to undercurrent
' ' IJ:.lllf;
0 fi~~ing
0 CL'W11.c
9" 1.ttf Q < 200 to 300 m 3/d
Psuction < 10 bar
500 series pum.P. equipped
0 0 with a centrifugal gas
separator
%gas= %gas=
SO to 60 % BO to 90 %
11111 As the pump is equipped with a

centrifugal gas separator, there
11 • lOb a is the simultaneous action of the 0
natural degassing in the well and ~
of the centrifugal separation
0
I
0
I
§ f~
PHQ01UQ - E),1Qi:1,LbnfN'~JM!ITlpl'lg
f
~~~ __P_U_M_P_IN_G_G_A_S_S_Y_C_R_U_D_E_S_(_P_su_ct_ion_<_P_b_ub_bl_e)_(_4_
/8_)_ _
irri"f~Tliiio
- PROBLEM 2: What is the % of gas present in the

effluent entering the separator which is eliminated
by the separator?
• Use of a static separator:
- the percentage of gas it is capable of extracting from the total fluid
it absorbs is low:
• approximately 10 % at the maximum
- the use of such a separator does little to improve the pumping
conditions
• Use of a centrifugal separator:
- it is more efficient than a static separator
- this depends on:
the flow rate
the pump suction pressure
• the type of effluent
PR001329- Eleclric submersible~
~ Static separator Centrifugal separator

,~ ("a-~,,
?enspm
ur-.JJl'l:.--.ail,
-----------------------------
lti... l • H
Cia;;v1:rud•1;11_..,..._..,,_.., .
t.llJd wi ~- fr.-"1-e-"\VdJlllm1lu
pump111l:\:.e
•
'St.uw•11lni.n
l
1•
lllt~ka::
r
f
~

I
~ _ _P_ U
_ M_P_I_N_G_ G_A_S_S_Y_ C_R_U_D_E_S_(_P=su=ctl=on~<~Pb=ub=b=le)_(~S_/8_)~_
ini.Tii~irniQ
- PROBLEM 3: How the pump characteristic curves,

particularly the head versus flow rate curve, are
affected by the % of free gas which arrives at the
1st stage of the pump ?
• There are two thresholds:

- the first set to 6 % of the free gas at the 1st stage, below which the
operation of the pumps is guaranteed
- the second, set at 10 % of the free gas at the 1st stage, above which
problems arise
• In the zone between 6 and 10 % the pump characteristics
deteriorate
• The fall in the characteristics can be compensated (in the
stable domain) by adding stages and by increasing the
motor power
PA001329 - Electric 1.~1.blil ~
~ Variations in the characteristic curve according to the % of gas on

.~ _t_h_e_s_u_ c_ t_i_o_n_s_i_d_e_o_f_ t_h_e~p_u_m_p~(_C_en_t_ri_lif_t_s_er_ie_s_5_1_3-p_u_m-p_-_la_b_o_ra_t_o~ry~t_e_st~)_ _ _ ,
1r,.r11..iuil1NO
- The values given must be sllglltly

modified according to the
geometry of the pump Impellers
tne purely centrifugal type {radial
impeller) is no doubt less well-
adapted than the "diagonal" type
(mixed flow Impeller)
- The pump diameter must also be
taken into account
When it increases, the accel)lable
percentage of free gas is higher:
series 400 pump: 4 to 5 %
series 500 pump: 7 to B %
series 675 pump: 10 to 12 %
I
~:~ __P
_ U_M_P
_I_N_G_G_A_S_S_Y_C_R_U_D
_E bu_bb_le_)_(6_/_8_)__
_ S_(_P_su_ct_lon_<_ P_
1FPoTTu""iiiia
- INTERFERENCE & GAS LOCK:

• Depending on the quantity of free gas entering the pump,
there may be a slight interference or a gas lock
phenomenon
• The presence of gas in the pump is indicated on the
surface ammeter by rapid motor load variations
• Gas locks arise when the pump absorbs too much gas
and stops pumping because it loses its dynamic head
• The motor is no longer on-load and stops due to an
undercurrent
~~ _ _C_ h_a_r_a_c_t_e_r_is_t_ic_ c_u_rv

_ e_,_i_n_t_e_rf_e_r_e_n_c_e_ a_n_d_ g_a_s_ lo_c_ k
_ _ _ _ __
frj'OJ',::;;1Ni111i
~·
M"IOf
lood
Gas
Interference lO
,o 0,20 20
d Capacity - Barrels per Day

I) f!;,,N t5
~ Effect of the presence of free gas on the motor"s current
~ _c_o_n_s_u_m~p~t_i_o_n_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
rfl'otlUINING

~~~ __P_U_M
_P_ IN_G
_ G_A_S_S_Y_C_R_U_D_E_S_(_Ps_u_cti_on_<_P_b_ub_bl_e>_(7_/_8_)_ _ •
1,,.. ..... 111":i
- FEASIBILITY CURVE FOR ELECTRIC

SUBMERSIBLE PUMPING ON GASSY WELLS:
• The gravity separation due to the well geometry,

combined with the centrifugal separator efficiency, allow
the pumping of a mixture where a high % of the total
volume is gas in the annulus at the pump depth
• See graph on next page as an example:
- on 'this graph, it is not possible to quantify the efficiency of each of
the two types of separation (gravity or centrifugal)
!&!I Feasibility curve for
~---------"e""'l-"-e--"c--'t"'-r"-ic"---"s'-'u""'b"-m_e_rs_i_b-'--l~e_._p_u_m~p_i_n~g..__________
r.r.a
Vo ,,.,
r-i
VIIIJH+ Vol liquid

~
- - --
r-,-r ·1 I
KGV !!llS separator
,- ,~ - Cl\-1UU-
100 - - ODI 70 , .,.,., (.1 00)
~'
~,
',I
\'~
''
't;~:: ......
".. -:___,..--._- - -
', -
,,
20
,,
-- ---- -,
r--
~ --
::-:- r:::-::-- 10¼
~ Gl:
~ Oh tkl" J1Utn,
0 2000 4000 6000 8000

Flow-BPD
Serles 500 pump equipped with a centrifugal gas separator run Into a 7" casing, vertical well
PR001329- Eledl1c subm8faJblB pumpwlg
~ - -- - -P_u_m_p_s_e_t_ b_e_l_o_w_ th_e_ p_erf_o_ra_t_io_n_s_ _ _ _ __ __ 1
i1r."'fuiiiii1.i
PR001329- Electric submersible ~ Q

~-----5--=p_e_c_i_a_l _
ca _ e_s_ _C
_s _O_ N_T_E
_ N_T_S
_ _ _ __
r-- ... ~
,r,, •...""'"'
- INTRODUCTION
- { ~ __
P_U_M_P_I N
_ _G_W
_ IT_H_ S_A_N_D_Y_ E_F_F_L_U_E_N_T
~ <~1/_5~)_
ITT'"'aT~'Aiiiiic
- BASIC SOLUTIONS FOR SANDY EFFLUENT:

• The presence of abrasive elements in the pumped effluent
reduces the lifetime of the rotating equipment
• There are three main methods to prevent that:
- 1: sand control + standard pump
- 2: no sand control + special antiwear pump
- 3: no sand control + standard pump
• Solution No. 1 gives the longest lifetime
• The difference in lifetime between solutions 2 and 3 is
less clear: however, solution 2 has a slight advantage over solution 3

. ~ . ___P
_ u_m~p_i_n~g_w
_ it_h_ sa
_ n_
d~y _e_f_fl_u_e_n_t~
(2_/5~)_ __
If;, fi.<J•11111ii
- LIFETIME & TYPE OF WEAR WITH SANDY

EFFLUENT:
• Everyone agrees that the presence of sand in the effluent
greatly reduces pump lifetime and that the wear arises in
three ways:
- radial abrasion of the bearing between the pump shaft and the
impellers
- abrasion of the surfaces on which is exerted the axial thrust
generated by the pressure difference between the suction and
delivery sides of the pump
- erosion of the surfaces over which the effluent flows in the
impellers and diffusers
• The radial abrasion wear is generally the most rapid
• It is followed by the axial abrasion wear, then by the
wearing of the surfaces over which the effluent flows
~ _ _ _P_u_m
---=-
p_in___,g=--
w_i_th
_ s_a_n_d~y_e_f_f_lu_e_n_t~ <J_/5~)___ 1
ir,-.-miiwic
- THE RATE OF PUMP WEAR DEPENDS ON:
• The characteristics of the abrasive material:

- the abrasive material can be characterised by:
• its product volume (percentage of the fluid flow rate)
• the size, shape and hardness of its grains
- the grain size affects the method of wear as follows:
• a small size tends to generate wear by axial abrasion
• a large size tends to generate wear by radial abrasion
• The pump design: see below
PR001329- Elec!iic mtmlnitl• i ; u ~

/~ _ _ _P_u_m
-----=--p_i_
n=g_w
_ it_h_s_
a_n_d=y_e_f_f_
lu_e_n_t~(4_/5~)_ __
i,-;.-.yk,YMIHCi
- PUMP DESIGN (1/2):

• Given the methods of wear, the suppliers are turning
towards the following design principles:
- improving the bearing resistance by using hard materials (alloy,
ceramic) or materials which are less sensitive to abrasion such as
elastomers (rubber bearing)
- reducing the contact between the bearing and the effluent
- smoothing the direction changes of the fluid path in the impellers
and the diffusers and using materials more resistant to erosion
- reducing the axial thrust forces by altering the hydraulic balance in
the impellers
• All these measures tend to greatly reduce pump wear,
but they result in higher purchase price
PROCl1329 - Eleclrlo 11ul:ati:lo/"8 l)UlUlln,J

~
,,,,,,,,_ _ _ _P_u_m~p_in___,g=----w
_i_t h
_ _s_a_n_d--=y'---
e_f f_lu_e_n
_t__,_
(5_/5_,)_ __
171.1ii;1111•I
- Pump design (2/2):

• Another important parameter: good pump sizing to
correctly control the axial forces
• The concept of thrust direction on the impellers (upthrust -
downthrust) according to the pump's operating point is
important, particularly where abrasive fluids are present
(sand, etc.)
• ODI has developed a "modular" design for this type of
application by including "intermediate bearings" with
ceramic inserts (every 30 to 40 stages) in the pump, this
system limits the sand abrasion phenomena
PA001329- Electric•~ p,iriiu,g
~ ODI pump including "intermediate bearings"

,,.!!~ with ceramic inserts
enEpm
..........
,-..,.,.,-
., - - - - - - - - - - " " " " ' - - - - ' - - ' - - - - - - ' - - - - - -- - - - - -- -
D1ivc.r
n-il~lwY'1bv. Liil
""'!!""itl,iiitl,0111"°""'\t>
lh1,n-,iclltt•s11-..<n
lb,~~N"anritr6le(Ve
,,.,...iti,m., .. a,.odul"""'"''
Cc.ra:mi,;ih:it;IJ.noa-.:rs
l'r<mdomo!™<I""'-"'~
,•,rlo:,Jl)>i,•.,.,.,, .. .,,,,_rl
Rulilx:1bt-mi11t;\
P,a_,,i.,,.,..;..,.,,..._.
rwial"'W"f,1
~~-= Spac;::r;;l<).;\',::,.
t:....-..,.upa""dl .... ib,,1, ..,.,f
11\"dl-..lion.-.-'
""""'='-'-- C1mvc1du~l.ll lhm;L wil>11c"1~

c..,-t.l,,ft-o-4,,•.to.ulil lll1.t.ii:•,
IA"'l\m~•"""'h-llln•••l\"C!i
, ... pkl<l~,1.1,.,. ,o::1-~•u,l.,,,l,i
~ _ s_e_s_ _C_O_N_T_E_N_T_S
- - - --S---=p'--e_c_i_a _l _c a _____ 1
ini.fi~
- INTRODUCTION
'- PUMPING VISCOUS CRUDES
•
l
i
f
I;
I

~ _ _P_U_M_P_I_N_G_I_N_ D
_E_V
_ I_A_T_E_D_W
_ E_L_L S
_ (~1/_6.a-._
) __ ,
1rloTR11.11111,i::,
• Well deviation is theoretically a dual cause of possible

problems for electric submersible pumps:
- due to the mechanical stresses:
the pump shaft bends in alternate directions which, combined with the
normal tortional stress, reduces Its lifetime
in addition, the axial thrust brearlngs do not recei ve a normal reaction
Pump bending
- when positioning the pump:

the friction when descending the pump and thus the risk of cable
deterioration increase with the we/l's inclination
~ _ _ __P_u_m_.p
__in__,g,""---
in_ d_e_v_ia
_ t_e_d_ w_e_l_ls
_ _,_
(2_/6____,) '-----
~~
- RUNNING ESP PUMPS INTO WELLS, PASSING

THROUGH DOG LEGS:
• During the running in operation, the pumping unit may have
to pass through zones with a low curve radius either in the
precurved pipe conductors, or in the well
• The stresses which the pumping unit would be subjected to
when passing through the well's max. dog leg can be
evaluated taking into account:
- the inclination
- the production casing diameter
- the length & diameter of the considered pumping unit
• The stresses compatible with the standard pumping •
equipment are acceptable up to 28,000 psi ~
ij
• Manufacturer's recommendations:
- max. pump bending in static mode: 3 ° /100 ft during running in f
- max. bending of pumps in dynamic mode at the pump depth: 1 °/100 ft
I
PR001329- Electric submersible fi'IJffl!CIV

~~ ____P_u_m____,p,__i_n-=g,__i_n_d_e _v _ia_t_e_d_w
_ e_ll_s_(.,_3_/6--=-)_ __
lfl'o'n..:i111HQ
- ESP TYPE VERSUS CURVE RADIUS:

• Well with long radius: standard ESP
• Well with medium radius: special ESP (pump with reinforced
flanges)
• Well with short radius: ESP positioned in the vertical part
of the well
C!l,'H1~
Long radius well: dog leg 2 to 7° / 100 ft

dog leg 0.70 to 2.3 ° / 10 m
Medium radius well: dog leg 10 to 20° / 100 ft
dog leg 3.3 to 6.6° / 10 m
Short radius well: dog leg 60 to 200° / 100 ft
dog leg 20 to 66° / 10 m
Long rndi us (2° to 7° / I 00 ft)
Medium radius (I 0° to 20° I I 00 ll)
Short rndius
(60° lo 200° ,' I 00 ll)
PR001329- Eleclric submersible pumpiog
, ) ~ ____P_u_m~p_in~g~in_d_e_v_i_a_te
_d_ w_ e_ll_s~(,__
4_/6__,_)_ _ _ 1
ii'Poffi:iiiii'6
- ESP pumping IN HORIZONTAL WELLS WITH

2-PHASE EFFLUENT at reservoir level (1/3):
• To be able to get a horizontal well to produce by ESP
pumping with a maximum production, it 1s recommended
to (1/2):
- drill the well as wide as possible :
the increased clearance between the pump and the production casing ID
reduces the unit's bending when passing through the restrictive dog legs
and offers the possibility to provfde good protection for the electric ca6le
and to centre the motor In the well If necessary
• in addition, a large diameter production casing improves gravity
degassing in the well, which Increases production
- reduce the number and size of the dog legs as far as possible and
thus have a regular well profile of the long radius type:
• see following diagram
PA001329- Elachic SUIJTIOfsiblu SIii'~
~ Long radius well profile (vertical cross section)

eneprn - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - -
~~=
0
Cl'2-I'' ~fod line
100
Casing 19" 5/8
300 · Casing 13" 3/8
400
Centrifugal pump (85°)
500 ·
600
- ............... --·----~........... ···
700
(m) .___.__ __.__ _.____._ _.__....__.___.__ __.__.......____.'-----___,._-_.__..___,
600 I000 I500 m
01:port
PR001329- Eleclric ~t.lb~PJffiP'IQ

~ ____P_u_m____._p_in_,g=--i_n_d_e_v_i_a_te_d_w_ e_ll_s_,(,_5_/6_,_)_ __
~IIAiliiN?i
- ESP pumping in horizontal wells with

2-phase effluent at reservoir level (2/3):
• To be able to get a horizontal well to produce by ESP
pumping with a maximum production, it 1s recommended
to (2/2)
- maintain a permanent inclination, in the so called horizontal part of
the well, down to bottomhole with a deviation lower than 90°:
• a slight inclination allows the free gas to be vented more easily via the
annulus and reduces gas locks in the pump
the return flow of the gas rejected by the centrifugal separator to the
pump is also reduced
• however, an inclination greater than 90 ° results in a gas build up
downhole
this may produce slugs which are very bad for the pump
- create a 20m-long straight part on either side of the planned pump
setting depth so that the pump can operate in the best possible
conditions without bending
- where necessary, provide a reduced diameter for the production
column just below the pump and down to bottomhole:
to increase the effluent flow speed, since an increased speed reduces the
possibility of slugs
PA001329-ElectricsubrnerslblePJf~

,1~ ____P_u_m____._p_in_,g=--i_n_d_e_v_i_a_t e_ _d_w_ e_ll_s_,(,_6_/6_,_)_ __
/j'ji.fii"'.olJJiiiii5
- ESP pumping in horizontal wells with

2-phase effluent at reservoir level (3/3):
• In conclusion, to construct horizontal wells, we should
use regular wells with long radius profiles and dog legs
of 5 ° / 100 ft (1.60° 110 m) maximum, m order to be able to
set the pump deep in the well, the production casing at
pump depth being at the minimum 7 5/8" - 26.4 lb/ft
• The pumping unit must be equipped with bag seal
sections mounted in tandem
,.
I
~ - -- - - - - - - - - - - - - - - - - - - - - - -
ifr-;--luMailt
Recommendations for using an

electric submersible pump
•
!
i
I
j
RECOMMENDATIONS FOR USING AN ESP

,,!~ - - - - -- - ~<~1/_8_) _ _ _ _ _ _ __
m;.,_ ••
- GENERAL:
• The installation of the equipment is a very important factor
for the success of the submersible operations
• Do not rush the work
• Ensure that the equipment is handled with care
• Do not exert excessive tension on the electric cable
• Manreuvre the tubing slowly
• Band the cable correctly to the tubing
• It is important to handle pumping equipment with as much
care as if it were a precision instrument
• Always protect the electric cable against impacts
• The interior of the electric control panel (switchboard) must
be kept dry and damp-free
• The surface junction box is ventilated
~ --R_e_c_o_m_m_e_n_d_a_t_io_n_s_fo
_r _u_s_in
_ g_a_n_ E_S_P__
(2_,a
_ )_ ,
~=
- ASSEMBLING A PUMPING ASSEMBLY:

• Handle the pumping assembly with care
• Check that the shafts rotate freely
• Prevent foreign bodies from falling onto the rotating
parts
• Keep all the assembly flanges clean
• Tighten the flanges on either side, as per the
specifications
• When filling the motor with dielectric oil, there must be
no air bubbles present
.
PAO(l1329- Elecbic•11,1t,,,m.,~~
I
~ - -R_e_c_o_m
_ m_e_ n_d_a_t_io_n_s_ fo
_ r_u_s_i_n_g _a_n_ E_S_P
__(J_I_B)_
iITTTIIAININii
- CONNECTING THE CABLE TO THE MOTOR:

• There are two types of connections for connecting the
flat cable to the motor:
- tape in (no connector)
- plug in
• Tape in:
- phase-by-phase connection
- banding of the 3 phases inside the motor - long and delicate
operation
- the cable from the motor is short: take your time when making the
connections
• Plug in:
- this connection consists of 3 female connectors on the top of the
motor and 3 male connectors at the flat cable head
- for the connection, work slowly and exert an even pressure
- the positions of the connectors means that there is a risk of dirt
being present in the female connectors on the top of the motor
PA001329 - Elecbie submeJsible SR,i_,IJ

~ --R_e_c_o_m
_m_ e_n_d_a_t_io_n_s_f_o_r_u_s_i_n_g_a_n_E_S_P_(_4_JS_)_
~Fi.~
- RUNNING THE UNIT INTO THE WELL:

• For 9m-long tubings, install 2 to 3 collars to secure the
cable to the tubing
• If no prior pump has been run into the well, send down a
sizing gauge (dummy) before carrying out all operations
• To cool the motor, always place the pump above the
perforations
• Use a centering system at the base of the motor to
correctly position it in the technical column
• Regularly check the cable electrical isolation
• On the surface, check all the settings on the control
panel
PR001::J29- Electric u ilfll•fr.l• 1)1.,lr,:t',ng
~ - -R_e_c_o_m
_m_ e_n_d_a_t_io_n_ s _f_o_r_u_s_i_n_g_a_n_E
_S_ P_(_s_,a_)_
;,-j-,--r,r,;111,~a
- STARTING:
• The voltmeter must remain connected to check the load
voltage
• The pump must start up within 2 seconds
• During starting, set the overcurrent relay to a high value
• If the direction of rotation is reversed, the sequence can
be changed by reversing two (any two) of the three
conductors and by leaving the third in its initial position
• Always insist on having a pressure indicator at the
wellhead
• The pump must be started up on-load: therefore provide
an adjustable choke at the wellhead
PR001329- Eleclric autwMniUo ~fflPf\111
L.
~ - -R_e_c_o_m
_m_ e_n_d_a_t_io_n_s_f_o_r_u_s_i_n_g_a
_ n_E_S
_P_(_6_ta_)_
1f'Poii.Aiiiooi
- FINAL INSPECTION OF THE INSTALLATION:

The following must be checked (among other things):
• that the control panel is correctly earthed
• a recording ammeter is present
• the overcurrent and undercurrent safety devices are
correctly adjusted
• the unit must be closely monitored during the two days
following start-up
• the regular periodic checks must then be carried out
• if the well is equipped with a pump which is unsuitable,
do not hesitate to change it
PA001329- El!!Cbic submersible ~miwlQ
!h Recommendations for using an ESP (7/8)

,11, ...........
!. ! ~ - - - - - - - - - - - - - - - - -1
·---
- REMOVING A PUMP:
• The seal section must be drained
• The pump must be rinsed with fresh water then oiled
• If the dielectric oil in the motor contains water or is too
contaminated, the motor must be flushed with clean oil and
be then resealed
• The seal section must not be reused without being
overhauled, unless the user takes responsibility for this
• The seal section must also be inspected (always in vertical
position) to determine if the liquid from the well has
penetrated the lower section •
§
• If water enters the motor, it is located at the bottom:
- this can be checked by removing the plug at the base of the motor
I
ii'
- if the motor oil is dirty, change it I

• The electric power cable must be stored away from direct f
sunlight :!i
.i
~ --R_e_c_o_m
_m_ e_n_d_a_t_io_n
_ s_f_o_r_u_s_i_n_g_a_ n_E
_S_ P_(_a_,a_)_
~
- ELECTRICAL ISOLATION:
• Cable and motor in series:
- between phase and earth = resistances oc
- between two phases =ohmmeter close to zero
(motor resistance given by the manufacturer)
• Cable only:
- a new cable must Indicate an Isolation of approximately oc
between phase / earth as well as between phase / pliase.
~ - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
F.miim

Well operation
•
I
!
! f
To Summary
f;
i
~ _ _ _ __W_e_l_lo_p_e_r_a_t·_1o_n_ _C_O_N_T_E_N_T_S_ _ __ 1
1ni.T~Miiiio
- LIFETIME OF A PUMPING UNIT

- WELL MONITORING
- TROUBLESHOOTING
Electric submersible pumping: Operation

~ _ _S_E_R_V_IC_ E_ L_I F_E_ O_F_A_ P_U_M_P_I_N_G_ U
__NIT----=--(1_/___,
3)'--_1
li"Ti"fAAJftTiiQ
- INTRODUCTION:
• One important parameter is the pump lifetime (running
time)
• It may vary between several weeks and several years
according to:
- the fluid abrasivity and the well temperature
- the motor power may also have an effect
• The estimations from different sources indicate a
lifetime:
- of one year and more in sandy conditions
- to 3 years an more in limestone reservoirs
• When used offshore in high flow rate deviated wells
(60012000 m3/d), pump service life is generally less than
8 months (North Sea)
PR001329- Electric I 1 1 ~ p . , ~
~ ____L_if_e_t_im_e_o_f_ a~p_u_m~p_in~g_u_n_i_t~(2_/3~)_ __
1ti,* 1u• • •
- MAIN CAUSES OF
FAILURE:
t:onruinn
0
Electncnl fo nlts ll
60 lo 70 % of failures are of
i
electrical origin
i
I
;
PR001329 - 8eclric submersiblo pm~

f

~ _ _ __L_if_e_t_im_e_ o_f _a~p
~ u_
m~p~i_n~g~u
_ n_
i t_(~l _/3~)_ _ _ ,
ifi-iriAiN1N6
- PUMP LIFETIME:
• Each field is a specific case
• The following factors have an effect:
- motor operating T°
- presence or not of abrasive elements in the effluent
- corrosiviness of the effluent
- number of shutdowns / restarts
- use of a VSC or not
- well architecture (including inclination)
- quality of the electrical supply
• Importance of the human factor:
- design (having the well productivity data and production profiles)
- care taken during implementation
•
ii
- good monitoring of the units Is Important (analysis of the causes of the
failures) I
• Learning curve in all companies, on new lifted fields f
• The personnel in charge of pumping must be stable J
ii
PR001329- Electric submersible Pll ~
I
j-
~ _ _ _ _ _W_e_l_lo--'pa.-e_r_a_ti_o_n_ _C_O
_ N_T_E
_ N_T_S_ _ __
fW.TftA7iiijj"ljj

- WELL MONITORING
- TROUBLESHOOTING
!
§
I
f
j

~~ _ _ _ _W
_ E_
LL_ M_O_N_I_T_O_R_I_N_G~ (1_/3~)_ _ _ _
1¥~11111'\
• The analysis of the operation of a lift method and of the

well performance is only reliable if all the measurements
are taken simultaneously
• It is essential to have the following elements
simultaneously:
- current consumed by the motor
- flowing bottomhole pressure
- a test of this well with a record of its production
• NB:
- It is important to know the motor's nominal current, it must be
mentioned on the well's current diagram
~ ______W_e_ll_m_o_n_i_to_ri_n~g~(2_/_3~) _ _ _ __
~~
- PRODUCTION DATA WHICH MUST BE KNOWN:
• This data is the following:

- 0-BSW-GOR
- tubing and casing pressures
- wellhead temperature
- frequency
- current consumed by the motor
- bottomhole flowing pressure or dynamic level (to know the pump's
submergence)
- knowing if the gas is ventilated or not via the annulus
- knowing if additives are injected or not downhole
• All anomalies concerning the following points must be
reported as quickly as possible:
- current
- liquid flow rate
- Q gas (tubing and casing)
- tubing and casing pressures
- wellhead temperature
- downhole pressure
- type of effluent produced (sampling) !

~~ _ _ _ _ _ _W_e_l_l _m_o_ n_ i_t_o_ri_n~g~<~J_/3~) _ _ _ __
ii-P'-IO riw"1-~·ci
- FAILURE DATA:
• To improve the design and operation of electric
submersible pumps we must have data which must be
analysed on an annual basis
• We must know the lifetime, type and reason for the
failures for:
- the different types and sizes of cable used
- the different series of pumps used
- the different series of motor used
- the different types (labyrinth or bag) of protector (seal section) used
• If after pulling out of the well a failed pumping unit, there
is a doubt about the cause of the failure, a tear-down
(disassembly of the unserviceable unit in the supplier's workshop with
the user present) must be carried out for diagnostic
purposes
~ _ _ _ _ _W_e_l_l o-----'pC---e_r_a_ti_o_n_ _C_O_N_T_E_N_T_S_ _ __
~~~

- WELL MONITORING
- TROUBLESHOOTING
•
l!
i
i
f~
PR001329- Electric adttttr~ p,011t,,nQI
I

~~ _ _ _ _T_ R
_O_U
_ B_
LE_S
_H_O
_O_ T I_N_G~ (1_/4
~)_ _ __
if,,-----.--fli;i;iNiiia
• To analyse pump operation the following must be

considered:
- the surface (electricity network) and downhole electrical power supply
conditions
- the whole pumping chain (downhole and surface equipment)
- the well productivity (IP, flow rate, pressures):
• if a permanent downhole pressure sensor is present (which is favourable),
use the values read or recorded to assist with the diagnostic
- the surface tubing and casing pressures
- the type of effluent pumped at the pump's intake:
single phase I 2-phase
• density, viscosity
• presence of sediments I debris •~
• injection or not of additives downhole in service
- The production evacuation system in the well and at the surface i
(abnormal pressure drops, plugging, closed valve)
f
fi;
PR001329- Electric submBfsibla ~Jill
f
~ _ _____T_r_o_u_b_l_e _s _h_o_o_ti_n....:,g"--'(~2_/4~)_ __ _ _
17ii.---..».iifri«i
• It is the current consumed by the motor which is mainly

used to monitor the operation of the electric submersible
pumping:
- Recording the current can provide invaluable information for
detecting and correcting minor operating problems before they
become major costly problems
- The ammeter is very useful for showing at which moment there Is a
change in the pump operation or pump characteristics
• See the following current diagrams as an illustration of
this
PR001329- Electric submorslbla Plll''ONJ
~--------E_x_a_m
_ p
_ le_s
_ o_f _c_u_r_r_e_n
_ t _d_i_a_g
_ ra
_ m_s___________
1
1f, 0T,Mllllllti
0
l
j
i
Normal operation Power fluctuations at the primary
(periodic starting of large surface units)
ri
PA001329 - 8ecbic subrnorslblo plfflf)tlg
I
~ - - - - -- -E
_ x_a_m
_ p_l_e_s_ o_f_c_u_r_r_e_n_t_d_i_a_g_ra_ m_s___________
j,i,--.-Jii~IIIINCI
Shutdown due to the gas Trip-out due to undercurrent (pump

(pump oversized)
oversized or wellbore-formatlon interface
damaged)
PR001J29- E!eclric submersible (l(Jff'pllQ
~ -- -- - - - -E_x_a_m
_ p_le_s_ o_f_ c_u_r_r_e_n
_ t_d_·_,a_g_ r_a_m
_s __________
ITTO-frn"iii'iio
Very short operating times (wellhead Free gas pumped along

valve closed or hole in tubing) with the liquid
PA001329 - Electric submarslbl o p;,,-pln,u

~ Examples of current diagrams
enspm
~~
- - - - -- - - - - - - - - - - - - - - - --------------1
Unit which pumps debris Pump oversized for the well and whose
undercurrent relay is badly adjusted or
which did not operate
, ) ~ _______E_x_a_m_p
_ le_s_ o_f_c_u_r_r_e_n_t_d_ia
_ g_r_
a_m_s__________
lrPofll.AINIMG
Pump which stops due to an overcurrent Unit which stops due to an overcurrent
{then followed by several unsuccessful
manual starting attemps)
PR001329 - Electric submersible OtJll".dN,I
~~ _ _ _ _ _T_r_o_u_b_l_e_s_h_o_o_ti_n_g_(3_/4_)_ _ _ __
ifi•TIWlliN-1:1
- SUMMARY (1/2):
• The nominal and off-load motor current must be known
• The current protection relays must be set to the correct
values:
- lmax. < lnomlnal of the motor+ 5 to 10 %
- lm1n. > 1011.ioad of the motor
There may be a relay operating problem
• When there is a trip-out due to overcurrent:
- do not restart before the cause has been found
- this type of incident is dangerous for the electric motor and the
cable which are expensive
PR001329 - Electric suMlersibla ~

~ _ _ _ _ _T_r_o_u_b_l_e _s _h _o _o _ti_n_g_ (4_/4_)_ _ _ __
irTTT;:~i"TiiO
- Summary (2/2):
• When the anomaly is recurrent, do not continue:
- stop everything and find the cause before restarting
- the more you try to restart, the greater the damage to the
equipment
• Do not forget that there may also be:
- mechanical wear in the pumping unit (friction, imbalance, vibration) for
the bearings, axial thrust bearings and vanes
- leaks at the shaft seals, particularly at the seal section
• At electrical level, there may be ageing of the insulations
(loss of cable and motor isolation)
• If scale is present in the pump, it may seize
• Also, do not forget that there may be a deterioration in
the well productivity index
~=-:r.:r.: - - - - - - - - - - - - - - - - - - - -

Overview
! To Summary !

~ _ _ _ __O
_v_ e_ rv
_ i_
e___
w C_O
_N_ T_E_N_T_S_ _ _ __
=:,"'~
- PROCESS ADVANTAGES, DISADVANTAGES &

EFFICIENCY
- SUMMARY
1.
!h Electric submersible pumping: Overview
~ADVANTAGES, DISADVANTAGES & EFFICIENCY (1/3)
1iiiaTIA1iiiiia
- ADVANTAGES:
• Can produce high flow rates (however, it has many lower flow
rate applications)
• The surface installations are compact (transformer, electrical
control panel or VSC)
• Favourable when we must produce with a high % of
water
• Low sensitivity to wellhead and downhole pressures
• Requires only minimum maintenance during normal
operation
0
i
!<
I
f
.f;
PRO<J1329 - Eleclric submersitfo p.ui~
I
Electric submersible pumping: Overview

~ __A_d_v_a_n_t_a_,g__e_ s.,,_,_d_is_a_____,~---~.....,~~')-t_a_..g._e_s_ &_ e_f_fi_c_i_e_n_c__y'----------
- DISADVANTAGES:
• Cannot be used for high downhole T°
(max. T°: 140°C for standard motor)
• Low tolerance to sand
• Accepts little free gas at the pump intake unless special
measures are taken
• Not recommended for flow rates < 25 / 30 m3/d
• Flexibility limited if no VSC used
• The downhole electrical part (motor, electric cable, electric
penetrators) is the weak link in the system
• The opex and the dead times can be high, particularly
offshore (limited process lifetime)
• Cannot be used with double completion
PR001329- Electric submersible wlftPl"IIII

Electric submersible pumping: Overview
~ Advantages, disadvantages & efficiency (3/3)
1r, 1t,.11.1iiu10
- PROCESS EFFICIENCY:
• Electric motor efficiency = 0.85
• ESP pump efficiency = 0.60
• Transformer efficiency = 0.99
• VSC efficiency = 0.96
• Overall efficiency (with the voltage drop in the electric power cable
and the pressure drops due to friction in the delivery column): 40 to
45%

~ _ _ _ _ _O_v_e_rv
_ ie_w
___
C_O_N_T_E
_N_ T_S_ _ __
ifril'uTiiiiHi
- PROCESS ADVANTAGES, DISADVANTAGES &

EFFICIENCY
- SUMMARY
*.!!I Electric submersible pumping: Overview
~--------=-
S-=-
U.;M
:. c.; ;.;M
. ; .=-
A=-
Rc.Y
. .cc.._ _ _ __ _ I
l,..oHA.IIIIIIQ
• The electrical energy coming from the surface is transported to the

electrical motor via a 3-phase cable which is unwound and secured
to the tubing as the unit is run in the well
• For each stage, the pump transmits energy in the form of speed to
the fluid to be pumped, via the impeller which rotates at
approximately 2,900 rpm for a 50 Hz electrical supply
• This kinetic energy is converted into potential energy in the diffuser
• At 50 Hz, the dynamic headJ'rovided by a stage depends on the
diameter of the assembly an on the geometry of the impeller and
diffuser, it Is lndependant of the density of the pumped fluid
• If the downhole unit fails, the tubing-pump assembly must be pulled
out for repair
• This lift method has a low tolerance to the presence of sand and gas
unless special measures are used
• The limit for standard equipment is a downhole temperature of 140°C
• For shallow wells, it is possible to reach a flowing bottomhole
pressure less than that which can be obtained by gas lift (with
reasonable GLR)
PR001329 - Electric submo,sible 1)1,r~

Electric Submersible Pumping, Ifp Trainning, 80 PGS, 2x1

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~

Electric submersible pumping:

- GENERAL CONFIGURATION of the installation

PR001329 - Elecbic submersible ~

-,::... General electric submersible pumping:

General electric submersible pumping:

- A PUMP STAGE (impeller & diffuser):

Each pump stage consists of a rotating

General electric submersible pumping:

- GENERAL CONFIGURATION of the installation

PR001329- Eleclric submersible J»IJINlill

General electric submersible pumping: Principle (2/3)

Fixed vane diffuser

PR001329- Electric submersible~

Spec. grav. = 1.0 Spec. grav = 0.80 Spec. giav. = 1.35

PR001329- Electric u ll,mlfllltl4 Ctl1'1111119

Characteristic curves of an ESP pump

- CHARACTERISTIC CURVES: GENERAL

- HYDRAULIC POWER OF AN ESP PUMP:

P[kWJ = O[m31hJ x AP[barJ I 36 T)

H • The manufacturer also

~ Pump operating range

-- >--- - ' - i;>tl'tj .

All11>,,-,1blt f1c:~d,now 111,

0 B~rrels per day

PR001329 - Electric: submersible~

Retla Pump Performance Curve IH•J011 $

IIVIJ j()() 1000 1100 2000 BOO JOOO J/00 4000

- CHARACTERISTIC CURVES: GENERAL

EFFECT OF PUMP ROTATIONAL SPEED on

• When an ESP pump's rotational speed is changed its

• Using these proportionalities we can construct the

~ Construction of the 70 Hz characteristic curve from the

CENTRlllFT PUIIP FOR lollNll,IUl.l 1%' 0.0. W£U CASING

Effect of pump rotational speed

- RECOMMENDED CASES FOR USING A VARIABLE

- CHARACTERISTIC CURVES: GENERAL -

EFFECT OF PU MP DIAMETER ON THE

Diameter change: Speed change: Diameter & speed

H2 /H 1 =(D 2 / D1)2 H2 IH1 =(N2 / N1) 2 H2 /H 1 =(D2 / D1) 2 x (N2 / N1)2

a, : initial flow rate

Electric submersible pumping:

Electric submersible pumping:

Electric submersible pumping: Equipment

- PUMP WITH PACKER S:tfoty \'alv,:: - - ,- "

~ 1---l f) ,lu,ulic duublc l

PA00 10:2'il • Elomfc•~PJtt"*!f

- COMPLETION WITH A "Y"

PR001329- Electric submersible f]Wt.dJl',I

Electric submersible pumping: Equipment

Note the presence of a shroud

Electric submersible pumping: Equipment

- DIAMETERS OF THE PROPOSED EQUIPMENT (for

• Pump 6.75 11 / motor 5.62 II ~ casing 9 5/8 11

Electric submersible pumping: Equipment

- ELECTRIC MOTOR (1/3):

PA001329- El!iK:trie i.ubl!Cf:rtl.1 ~,nolni;I

- Electric motor {2/3):

Electric submersible pumping: Equipment

- Electric motor {3/3):

PR001329- EJecbic •ubme<slbh1 ~

- ROLE OF THE PROTECTOR OR SEAL SECTION

Electric submersible pumping: Equipment