ESP Problem & TS

Advanced Artificial Lift Methods
The E.S.P.
Problems & Troubleshooting
Petroleum Engineering Lecture
Prof. Hussain Ahmed M.B.E.
Saturday 10/10/2020
5 pm. London time.
ZOOM ID: 823 9642 1478
Electrical Submersible Pump

Hussain H. Ahmed M.B.E.

BSc, MSc, PhD, PGCE, MSc Mngnt, PGDip HSE. MIChemE, MSPE
Professor of Petroleum Engineering
Director of International Education & Training
North-West Education and Training (NWEAT)
Liverpool – L31 8BT.
England; UK.

ESP Overview
Agenda
• ESP Main parts

• ESP; How it works
• When do we need ESP
• The major operational problems
• Troubleshoot the problems
• Solution suggestions
• What is next

Problems
ESP
• Operational
• Design
• Manufacturer
Problems
ESP
• Symptoms
• Diagnose
• Remedy
ESP PROBLEMS AND MAINTENANCE
What is Troubleshooting ?
Troubleshooting is the systematic search

for the source or causes of a problem so
that it can be solved.




ESP Application Considerations

Motor Control Typical Range Maximum*
Vent Box Operating
Depth 1,000’ - 10,000’ TVD 15,000’ TVD
Produced
Hydrocarbons Out Operating
Volume 200 - 20,000 BPD 30,000 BPD
Production Operating
Tubing Temperature 100° - 275° F 400° F
Wellbore 10° 0 - 90° Pump
Pump
Deviation Placement -
<10° Build
Flat Cable Angle
Extension
Seal Section Corrosion Handling Good
Gas Handling Poor to Fair
Solids Handling Poor to Fair
Fluid Gravity >10° API
Motor Servicing Workover or Pulling Rig

*Special
Analysis
Prime Mover Type Electric Motor
Required
Offshore Application Excellent
System Efficiency 35%-60%

2. Elimination Process
Rod Lift Progressing Gas Lift Plunger Hydraulic Hydraulic Electric

Cavity Lift Piston Jet Submersible
Operating 100’ - 2,000’ - 5,000’ - 8,000’ - 7,500’ - 5,000’ - 1,000’-
Depth 16,000’ TVD 6,000’ TVD 15,000’ TVD 19,000’ TVD 17,000’ TVD 15,000’ TVD 15,000’ TVD
Operating 5 - 5000 5 - 4,500 200 - 30,000 50 - 4,000 300 - >15,000 200 - 30,000
1 - 5 BPD
Volume (Typical) BPD BPD BPD BPD BPD BPD
Operating 100° - 100° - 120° - 100° - 100° - 100° -
75°-250° F
Temperature 550° F 400° F 500º F 500° F 500° F 400° F
Corrosion Good to Good to
Fair Excellent Good Excellent Good
Handling Excellent Excellent
Fair to Poor to
Gas Good Excellent Excellent Fair Good
Good Fair
Handling
Fair to Poor to Poor
Solids Excellent Good Poor Good
Good Fair to Fair
Handling GLR Required -
Fluid >8° API <35° API >15° API 300 SCF/BBL/ >8° API >8° API >10° API
1000’ Depth
Gravity
Workover or Workover or Wireline or Wellhead Hydraulic or Hydraulic or Workover or
Servicing Pulling Rig Pulling Rig Workover Rig Catcher or Wireline Wireline Wireline Pulling Rig
Gas or Gas or Wells’ Natural Multicylinder Multicylinder Electric
Compressor
Prime Mover Electric Electric Energy or Electric or Electric Motor
Limited Good Excellent N/A Good Excellent Excellent

Offshore
Application
45% - 60% 40% - 70% 10% - 30% N/A 45% - 55% 10% - 30% 35% - 60%
Overall System
Efficiency

Barrels per Day

35,000
High
Volume 30,000
Hydraulic ESP Gas Lift

Jet Pumps, 25,000
ESP
20,000
Gas lift
15,000
Hydraulic
Jet Pump
10,000
5,000
10,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
11,000
12,000
13,000
14,000
15,000
16,000
Lift Depth
Lower 4,500
Volume Barrels per Day

4,000
Reciprocating 3,500
Hydraulic
Pumps, 3,000
PC Pumps,
2,500
Rod Pumps &
Plunger Lift 2,000
Recip. Hydraulic
1,500
Recip. Rod Pump
1,000
PC Pumps
500
Plunger Lift
11,000
14,000
16,000
2,000
7,000
10,000
13,000
1,000
3,000
15,000
12,000
5,000
9,000
4,000
6,000
8,000
Lift Depth

Artificial Lift - Submersible Pumping (ESP)
▪ Consists of an electric motor

attached to a pump on the end
of the tubing string.
▪ The electric motor turns a
centrifugal pump which forces
oil from the bottom of the well,
up through the inside of the
tubing, and out at the surface.
▪ The electricity is supplied
through an electric cable
attached to the side of the
tubing and connected to the
electric motor.

Artificial Lift - Submersible Pumping (ESP)

ESP
Advantages:
1. The most efficient lift methods on a cost-per-barrel basis.
2. High rate: 100 to 60,000 B/D, including high water-cut fluids.
3. Work in high-temperature wells (<400 F) using high-

temperature motors and cables.
4. The pumps can be modified to lift corrosive fluids and sand.
5. ESP systems can be used in high-angle and horizontal wells if

placed in straight or vertical sections of the well.

Motor Control
ESP
Vent Box
Produced
Hydrocarbons Out
Production
Tubing
more Advantages
Pump
Low Maintenance
Flat Cable
 Minor Surface Equipment Needs
Extension
Seal Section
Adaptable to All Wells With 4-1/2”
Casing and Larger
 Use for Well Testing
Minimal surface equipment

Motor requirements.

More Benefits of ESPs
a) They can be economically designed for both oil and water wells,
up to 15,000 feet.
b) They have a relatively small “surface footprint,” and so are

appropriate for use in offshore, urban or other confined
locations. They are relatively simple to operate.
c) They generally provide low lifting costs for high fluid volumes.
d) They make it easy to apply corrosion and scale treatments.

Motor Control
Vent Box
Produced
Hydrocarbons Out
ESP
Production
Tubing
Limitations
Pump
 Available Electric Power

Flat Cable  Limited Adaptability to Major
Extension
Seal Section
Changes in Reservoir
 Difficult to Repair In the Field
 Free Gas and/or Abrasives
 High Viscosity
Motor
 Higher Pulling Costs
▪ Poor ability to pump sand

ESP
Disadvantages:
ESP pumps can be damaged from “gas lock”.

In wells producing high GOR fluids, a
downhole gas separator must be installed.
ESP pumps have limited production ranges

determined by the number and type of pump
stages; changing production rates requires
either a pump change or installation of a
variable-speed surface drive. The tubing must
be pulled for pump repairs or replacement.
ESP
Problems with sand production, high gas liquid
ratio and high bottom hole temperatures

Limitations of ESPs
a) They are generally limited to single-zone completions
b) They requires a source of high-voltage electric power
c) The presence of a power cable alongside the tubing string can make it
more difficult to run or pull tubing.
d) They are not particularly good at handling gas and solids production.
e) Analyzing the system performance can be a challenge.
f) Power cables may deteriorate in high temperature conditions—400 F

(about 200 C) is their general upper limit with respect to operating
temperature.

ESP
The ESP downhole assembly is located in the well
at the bottom of the tubing.
The motor, seal, protector ; intake and ;

pump assembly,
• intake that allows fluid to enter the pump.
• a protector or seal, which equalizes internal and

external pressures and protects the motor from
well fluids.
• 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
(ESP) assembly consists of a multi-
stage centrifugal pump driven by a
submersible electric motor, which is
connected to a power source at the
surface

ESP
surface equipment
includes:
• transformers,
• switchboard,
• junction box
• surface power
cables.
Power passes
through a cable
running from the
transformer to the
switchboard and
junction box, then to
the wellhead
Introduction to ESP
ESP Components
Power passes through a cable running from the transformer to the switchboard and
junction box, then to the wellhead.
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.
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.

Introduction to ESP
ESP Components
An ESP system can be divided into two categories:
− Surface components
• Transformers (Primary and Secondary)
• Switchboard or Variable Speed Drive or Soft Start
• Junction Box
• Wellhead
− Subsurface components
• Cable
• Cable Guards
• Cable Clamps
• Pump
• Gas Separator (Optional)
• Seal Section
• Motor
• Sensor (Optional)
• Drain Valve
• Check Valve

Introduction to ESP
Principles of an ESP
For a naturally flowing well the intersection of the IPR and OPR
curves defines the natural equilibrium flowrate
• For a naturally flowing well it is possible to produce a wide range of

flow rates smaller than the naturally flowing flowrate with the use of
a choke
• On the other hand, in a naturally flowing well without artificial lift

equipment, production flowrates higher than the natural flowrate
are impossible to be achieved since for those conditions, the OPR
pressures are bigger than the IPR pressures

Introduction to ESP

Introduction to ESP
In order to produce flowrates higher than the natural equilibrium

flowrate the use of an artificial lift system is necessary
• If an ESP is installed in the tubing string close to the perforations,

the discharge pressure of the pump must be equal to the OPR
pressure and the intake pressure of the pump must be equal to the
IPR pressure
• The difference between the OPR and IPR bottom hole flowing
pressure for flowrates bigger than the natural equilibrium flowrate
defines the pressure increment that the ESP must deliver

Introduction to ESP

Introduction to ESP
The submersible pumps are multistage centrifugal pumps operating in a vertical

position.
Produced liquids, after being subjected to great centrifugal forces caused by the high
rotational speed of the impeller, lose their kinetic energy in the diffuser where a
conversion of kinetic to pressure energy takes place. This is the main operational
mechanism of radial and mixed flow pumps.
The ratio between the centrifugal force and the gravitational force:
If w = 3600 RPM, r = 4’’ then this ratio is 131,673

Introduction to ESP
ESP Classifications
ESP centrifugal stages are classified according to their design as:
• Radial stages
• Mixed flow stages
Mixed flow stages Radial stages

Introduction to ESP
ESP Classifications
The performance characteristics of stages at the best efficiency point is a function of a
dimensionless number called specific speed

Introduction to ESP
ESP Classifications

Pump Stage
• Fluid enters impeller
through ‘eye’ near
shaft and exits
impeller on OD
• Diffuser (in blue)

redirects fluid into
next impeller

Pump Stage
• Cut-away view of two

impellers and diffusers
• By stacking impellers and
diffusers (multi-staging),
desired lift (TDH) is
achieved

Downhole Centrifugal Pump

• Centrifugal pump is
so named because
head added to fluid
is due largely to
centrifugal effects
• Characterized by:
– Small diameter
– Large number of
stages
– High design loads


• Normally driven by
a two-pole
submersible motor
at an operating
speed of 3,500 rpm
• Performance:
– Head = ƒ ( µ , glr )
– Flow = ƒ ( µ )
– Power = ƒ ( sg , µ )

A5000 ft oil well

producing with ESP
3000bpd
Determine
1.discharge head ft
2. Efficiency
3. HP
4. No of stages
Typical Performance Curve

p p p
Head = = =
 62.4 x / 144 .433x
Simple Sizing HP = HP from Chart x Sp.Gr.

Example will be
done here
TEST CURVE SHOWING API TOLERANCES


• May be driven at other speeds
either due to power source or
intentionally to modify performance
– Flow = ƒ ( rpm) = ƒ ( frequency )
– Head = ƒ ( rpm2 ) = ƒ ( frequency2 )
– Power = ƒ ( rpm3 ) = ƒ ( frequency3 )

If frequency jumped from

60 Hz to 80 Hz how much
Power increment %
Head increment %
1 HP = 745 watt

VSD Problem
VSD variable speed drive

Introduction to ESP
Cable Suspended ESP System
Cable Suspended ESP:
• The unit is lowered in the well without using a tubing. It is

suspended from a cable and the power cable is banded to it.
• A special seating element supports the pump and provides

locking to avoid excessive torque on the cable.
• Differently from the conventional installations, the motor is

located above the pump.
• The system produces through the annular.
• It main advantage is the reduction in al costs associated with

tubing pulling job, specially offshore

Cable
Spool
Conductors
Cable Splice
Pothead
Connection
• Cable can be round or flat
depending on allowable
clearance
• Upper and lower pigtails can be
spliced on to allow for packers
and wellhead connections

BANDING
AT /NEAR
PUMPING UNIT

BANDING ON
TUBING

Cable voltage
drop vs.
temperature
and depth for
various sizes
of cable

Introduction to ESP
Combination between ESP and Gas Lift
Some installations combine ESP

with other artificial lift methods
• ESP and Gas lift
• ESP and Jet pump

ESP Components

TRANSFORMER 12,500
TO 1000 VOLTS AS
FOR VSD 460 VOLTS

Introduction to ESP
Surface Components - Transformer
transformer system is used to

step-up or step-down the voltage
from the primary line to the
motor of the submersible pump.
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.

Introduction to ESP
Surface Components - Switchboard
The switchboard controls the pump

motor and provides overload and
underload protection.
Protection against overload is

needed to keep the motor windings
from burning.
Protection during underload is

needed because low fluid flow
rates will prevent adequate cooling
of the motor.

Introduction to ESP
Surface Components – Junction Box
The junction box connects the power cable from the switchboard to the power
cable from the well. It provides an explosion-free vent to the atmosphere for any
gas that might migrate up the power cable from the wellbore.

Introduction to ESP
Surface Components – Wellhead
Must provide means for installing the cable with adequate seal
May include adjustable chokes, bleeding valves
Onshore wellheads have a rubber seal and offshore have a electric mandrel

Introduction to ESP
Surface Components – Wellhead
The Safe-T-Lok is supplied with factory molded cable on both the top and the
bottom. The lower cable will be spliced to the ESP cable, and the top cable will
connected to the junction box.
The Safe-T-Lok is installed in the wellhead by feeding through the tubing hanger
from below

Introduction to ESP
Subsurface Components – Check Valve
A check valve is installed about two to three

joints above the ESP pump to maintain a full
liquid column in the tubing string during
equipment shut down periods. It prevent
leaking of the fluid from the tubing down
through the pump when the pump is not
running.

Introduction to ESP
Subsurface Components – Electric Cable
A power cable runs from the junction box then through

the wellhead and all the way to the bottom to supply
power to the pump motor.
Cable is available in round and flat styles

Introduction to ESP
Subsurface Components – Cable Protection
Cable Guards: Used to protect the

motor lead cable avoiding the
direct contact of the cable with the
casing standard. Standard length 8
ft.
Cable clamps: used to tie the cable

to the tubing.

ESP
Subsurface Components –ESP Bypass System
Wireline or coiled tubing plugs can be supplied to seat in a nipple

profile in the Y-tool to enable intervention or logging operations
without retrieval of the completion
Can be also used for installing two parallel ESPs in the well.

ESP
Subsurface Components – Electric Cable
The proper selection of the cable and the conductors depends on:
a) The expected amperage that will flow through the cable to the motor
b) The calculated voltage drop in the line from the surface to the pump.
c) 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).
d) The equipment operating environment - such as the operating pressure

and temperature at pump depth.

Introduction to ESP
Subsurface Components – Cable Amperage
The first consideration in selecting cables is amperage. The limits on

amperage for cables containing copper conductors are as follows:
Note that the cable with the smaller number has the larger diameter.
Thus, a Number 1 cable can carry a maximum of 115 amps.

ESP
Subsurface Components – 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.

Introduction to ESP
ESP Operating Principles
a) Electrical submersible pumps are multi-staged

centrifugal pumps Each stage consists of a rotating
impeller and a stationary diffuser.
b) The performance of the pump depends on the stage

design an size, rotational speed and fluid being
pumped
c) The rotating movement of the motor is transferred

through the shaft to the impeller
d) The overall length of a single pump section is limited

to 25-30 feet to facilitate assembly, transportation
and handling

Introduction to ESP
Each stage consists of an impeller and a diffuser
The rotating impeller takes the fluids and imparts kinetic energy from the
rotating shaft to the fluids
The stationary diffuser converts the kinetic energy of the fluids into
pressure

ESP
Electrical Submersible Pump 8 gpm = 275 bpd

Introduction to ESP
A pump’s impellers are designed to operate efficiently over a specific

capacity 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

ESP

Introduction to ESP
m ft

Introduction to ESP
ESP Classification
ESPs can be classified into two main categories: Radial flow and Mixed flow
Radial Flow Pump

Mixed Flow Pump

Introduction to ESP
Subsurface Components – Gas Separator

Gas Separator
• Used in applications
where free gas causes
interference with pump
performance
• Units separate some
of free gas from fluid
stream entering pump
to improve pump’s
performance

Introduction to ESP
Subsurface Components – Gas Separator
Separates the free gas in order to reduce the quantity of gas that flows into
the pump.
There are two types: static and rotary gas separator.
Static: No applying any additional mechanical force. They provide a

tortuous path that turns the fluid stream and moves it down toward the
inlet ports. Some of the free gas accompanies the liquid to the intake and a
portion is separated.
Dynamic gas separators, on the other hand, actually impart energy to the
fluid to separate the vapor from the fluid…

Seal Section
• Located between pump
and motor
• Main function is to protect
motor from contamination
by well fluid
• Absorbs thrust from pump
• Equalizes pressure
between wellbore and
motor

Seal Section
 Seal equalizes pressure and
prevents well fluid from entering
motor by using:
– Mechanical seals
– Bladder system
– Labyrinth system

Introduction to ESP
Subsurface Components – Protector or Seal
Serves as the connection between the motor

shaft and the pump shaft
• Prevents the entry of well fluid into the

motor
• Provides an oil reservoir to compensate for

expansion and contraction of motor oil
• Support the axial thrust developed by the

pump on the seal thrust bearing
• Pressure equalizer
• Use multiple redundant barrier chambers

isolate the fluidsto

ESP

The Y tool is
commonly used
offshore to allow
well work below
the ESP, without
pulling the ESP.

Centrifugal Pump Stage

• Works by transferring energy
provided by driver to fluid to
be moved
• Rotating impeller uses
centrifugal force it generates
to increase velocity (kinetic
energy) of fluid
• Stationary diffuser diffuses, or
reduces, velocity of fluid --
converting kinetic energy into
potential energy or pressure


Submersible Motor
• Motor is oil filled
• It is a two-pole, three
phase, 3,600 RPM design
• Motor components are
designed to withstand
500oF temperatures

Motor Components
Housing
Stator Laminations
Epoxy Encapsulation
Rotor Kapton-Wrapped
Bearing with T-ring Magnet Wire

Submersible Motor
• Motor cooling is
achieved by:
– Internal oil
circulation
– Flow of well fluid
along outside
skin

Downhole Motor
• 3-phase alternating current
creates revolving magnetic
fields in stator
• Magnetic fields cause rotor
and shaft inside stator to
spin
• Each rotor is then capable of
producing X number of
horsepower with given
voltage

Downhole Motor
• Voltages, on surface, may

be changed to adjust
horsepower capabilities and
performance of motor
• Motor speed = f (frequency)
• Horsepower = f (frequency)

TDH (Total Dynamic Head)

 Pump :
3
1 Distance from wellbore
producing fluid level to
surface 2 1
2 Friction loss in
production tubing
3 Pressure required to
overcome flow line back
pressure
 1 + 2 + 3 = TDH

Pump Sizing
Example
 1 impeller (stage)
capacity:
- 10 gallons per minute
- 10 feet of lift
- requires 2 hp to run it

Pump Sizing
Example
 5 impeller (stage) capacity:

- 10 gallons per minute
- 50 feet of lift
- requires 10 hp to run it

Motor Sizing
Example -- matching a motor to a pump
• One rotor, 10 HP,

drives 5 stages (5
impellers and 5
diffusers)
• If the pump has 50
stages, it needs 10
rotors (100 hp) to
Requirement: 2 hp per stage
run it.
Rated: 10 hp per rotor
Downhole Monitoring
• Simple, Reliable Pressure Monitoring

• Pump Intake Pressure (Standard)
•Well Temperature
•Motor Winding Temperature
•Free Water Detection in Motor

Lets discuss;
ESP PROBLEMS
• ESP low output
• Vibration
• Sand
• Cavitation
• Cable burnt
• Takes high voltage
• voltage unstability
• Over heated motor
• High GOR
• Corrosion – erosion – pitting
• Over-loaded motor
• Under loaded motor
• Sludge and asphaltene
• Broken seal
• High water cut
ESP PROBLEMS
Q&A

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Advanced Artificial Lift Methods

ZOOM ID: 823 9642 1478

Electrical Submersible Pump

Hussain H. Ahmed M.B.E.

Electrical Submersible Pump

• ESP Main parts

Electrical Submersible Pump

ESP PROBLEMS AND MAINTENANCE

Troubleshooting is the systematic search

Electrical Submersible Pump

Electrical Submersible Pump

Electrical Submersible Pump

Electrical Submersible Pump

ESP Application Considerations

Motor Servicing Workover or Pulling Rig

Electrical Submersible Pump

Rod Lift Progressing Gas Lift Plunger Hydraulic Hydraulic Electric

Limited Good Excellent N/A Good Excellent Excellent

Electrical Submersible Pump

Barrels per Day

Hydraulic ESP Gas Lift

Volume Barrels per Day

Electrical Submersible Pump

Artificial Lift - Submersible Pumping (ESP)

▪ Consists of an electric motor

Electrical Submersible Pump

Artificial Lift - Submersible Pumping (ESP)

Electrical Submersible Pump

1. The most efficient lift methods on a cost-per-barrel basis.

2. High rate: 100 to 60,000 B/D, including high water-cut fluids.

3. Work in high-temperature wells (<400 F) using high-

4. The pumps can be modified to lift corrosive fluids and sand.

5. ESP systems can be used in high-angle and horizontal wells if

Electrical Submersible Pump

Minimal surface equipment

Electrical Submersible Pump

More Benefits of ESPs

b) They have a relatively small “surface footprint,” and so are

d) They make it easy to apply corrosion and scale treatments.

Electrical Submersible Pump

 Available Electric Power

 Free Gas and/or Abrasives

▪ Poor ability to pump sand

Electrical Submersible Pump

ESP pumps can be damaged from “gas lock”.

ESP pumps have limited production ranges

Problems with sand production, high gas liquid

ratio and high bottom hole temperatures

Electrical Submersible Pump

a) They are generally limited to single-zone completions

b) They requires a source of high-voltage electric power

e) Analyzing the system performance can be a challenge.

f) Power cables may deteriorate in high temperature conditions—400 F

Electrical Submersible Pump

The motor, seal, protector ; intake and ;

• intake that allows fluid to enter the pump.

• a protector or seal, which equalizes internal and

• motor that drives the pump.

• The assembly is positioned in the well above

Electrical Submersible Pump