Electrical Submersible Pump
Electrical Submersible Pump
Electrical Submersible Pump
SUBMERSIBLE
PUMP
ELECTRICAL
SUBMERSIBLE PUMP
ESP SYSTEM
A high volume tool-can operate in
extremely deep wells.
Consist of rotating, high engineered
series of components.
Need very small space, operate in
deviated wells.
Adapted to wells with 4 casing.
Production capacity
The liquid producing capacity of an ESP pump depends
on the following factors:
the rotational speed provided by the electric motor,
the diameter of the impeller,
the design of the impeller (characterized by its specific
speed),
the number of stages,
the actual head against which the pump is operating,
and
the thermodynamic properties (density, viscosity, etc.)
of the produced fluid.
Advantage
ESP
High fluid volume capacity.
Can be fitted with downhole pressure
sensors ( through power cable.)
Compatible with crooked or deviated
wellbore.
Corrosion and scale treatment are relatively
performed.
Advantage.
Availble in range of sizes and capacities.
Lifting cost for volume ($ /bbl) typically
very low.
Disadvantage
Cable insulation detoriate in high
temperature.
System is depth limited (+ 10,000 ft) due to
cable cost and inability to provide sufficient
power.
Large casing / liner are required.
Entire system is downhole ,there fore
problems and maintenance require the unit
to be retrieved from wellbore.
Limitations
Electrical power.
Limited adaptability- reservoir parameters.
Difficult to repair at field.
Free Gas and Abrasive.
High Viscosity.
Higher Pulling Costs.
Introduction
Centrifugal pump powered by down hole
motor are commonly referred as Electrical
submersible pump or ESP.
Will it flow?
COMPONENTS: SURFACE
1.
2.
3.
4.
5.
6.
7.
8.
WELL HEAD
MINI MANDREL
UPPER PIG TAIL
SURFACE CABLE
JUNCTION BOX
BOOSTER
SWITCH BOARD
POWER TRANSFORMER
ELECTRIC MOTOR
constitutes the bottommost part of the ESP assembly
two pole-three phase squirrel cage induction type
nominal speed
--3500 rpm on 60 Hertz cycle
--2915 rpm on 50 Hertz cycle
--horse power: ranges from 15 HP to 1000 HP
--diameter:
-- available in different diameters
--smallest suitable for 4 1/2 casing (375 series)
--length :ranges from 5 ft to 100 ft depending on head and
volume requirements
--motor filled with highly refined mineral oil
--to provide necessary dielectric strength
--to serve as lubricant to motor bearings
PROTECTOR
-- placed immediately above motor
-- provides seal between well fluid and motor internals
-- acts as a pressure dampner/equalizer for the increasing/
decreasing pressure of the mineral oil in the motor
during running/stop conditions
--Two Types
--labyrinth type
--balloon type
-- can be of two,four, six, or eight chamber type
--more chambers means more sealing protection
POSEDION
70 % gvf
AGH
40-45% gvf
POWER CABLE
--supplies power from surface to the downhole motor
--thickness varies from # 1 AWG TO# 6AWG. More the gauge
number,less thicker and less current carrying capacity
--even though armored and insulated,most susceptible component
while lowering or pulling out the pump,by abrasion between
casing- tubing walls
--Two types
Round cable: __round in shape,three conductors placed side by
side at120 degrees to each other
__because of large diameter ,clearance becomes less specially
at the tubing coupling,hence more chances of abrasion
__gripping to the tubing is less because of less area of contact
Flat cable: __ flat in nature,three conductors placed side by side
__more commonly used because of i)firm gripping possible,
ii)availability of more clearance
CENTRALIZERS
--one below the motor and one above the pump will keep the
assembly in the center of the casing for better cooling affect
CABLE BANDS
-- though a small item,one of the vital component
--attaches the cable rigidly with the tubing
--about 3 to 4 cable bands are required per stand
--breaking down cable bands leads to serious problems
like i)shifting of cable weight to the next lower band,
which may lead to the failure of that band and the process
continues,ii)this leads to the coiling of cable while pulling
out tubings for any repair, warranting costly cable replacement
iii)may finally lead to the jamming of tubing iv)sometimes
responsible for even abandoning the well
-- one time use only,replaced for re-run of ESP
BLEEDER(DRAIN) VALVE(OPTIONAL)
PUMP TO SUB
-- connects pump to the tubing
--flanged on the pump side and box threaded on the tubing side
WELL HEAD
ESP well heads are different from normal well heads
Two Types
'Hercules' equivalent make
sub surface cable protrudes to the surface through the
well head.Sealing is achieved by rubber packings around
the cable. Requires to subdue the well for change of
packings in case of leakage.
can with stand pressures upto 1500 psi
to be specified for round or flat cable as well as AWG
of the cable
WELL HEAD(CONTD)
Seaboard or equivalent make
sub surface cable is joined to one end of the lower pig tail
and other end of the lower pig tail is inturn connected to
the minimandrel. Minimandrel is screwed in to the
wellhead with necessary O ring
can withstand much higher perssures of up to 3000 psi
MINI MANDREL
SURFACE CABLE
--Similar to power cable
-- connects either to switch board or junction box
-- preferable to lay through tubing from wellhead to switch
board to avoid any physical damage
JUNCTION BOX
-- required when Hercules or equivalent make well head
is used
--to connect the sub surface cable and surface cable at a
safe distance from the wellhead
-- it is a well ventilated box with a provision for venting the
gas which may get carried through the power cable
BOOSTER
--required to boost the surface voltage according to the
requirement of rated downhole voltage
-- connected preferably between the junction box and
the switch board
SWITCHBOARD
-- standard switchboards are weatherproof but not
necessarily flameproof
--available in voltage ranges from 440 volts to 4900 volts
--contains recording ammeter, fused disconnects, underload
and overload protections, signal lights, timers for
intermittent auto start
--shuts down the unit in both underload and overload conditions
--can be set to auto re start with time delay (with timer) in
case of underload trip
--to be manually re started in case of overload trip
POWER TRANSFORMER
--steps down the voltage to the required level
--available in different kW ranges
Hydro protector
Prevents well fluid entering the Motor
Provides a reservoir for motor oil
contraction and expansion caused by
temperature pressure changes.
Equalizes internal pressure in the
motor with the pressure in the annulus.
Installation procedures
The pumping rig should be centred all over the
wells as closely as possible. A guide wheel,
cable sheave should be secured safely to the rig
mast no higher than 30 to 45 ft above the
wellhead. The guide wheel should be at least 54
in. in diameter .
The cable reel or spooling truck should be
positioned about 100 ft from the wellhead in
direct line of sight of the rig operator
MONITORING
AND
TROUBLE SHOOTING
TROUBLE SHOOTING
--in trouble shooting any malfunctioning ESP, following data
will be very helpful in analysing the problem and thus avoid
costly workover jobs
rate of oil production
water cut
run life of ESP unit
dynamic and static fluid loads
GOR/GLR
pump setting depth
sand cut/ corrosive fluid etc.
how many times ESP has been serviced and for what reasons
Reservoir pressure/Reservoir drive mechanism/ rate of
fall of static pressure
bottom hole temperature
TROUBLE SHOOTING(CONTD)
-- recording ammeter, which continuously records the current
drawn by the pump,is also a very useful tool in analyzing the
problem of a faulty/underperforming ESP.
--many problems like, electrical supply fluctuation,gas locking,
fluid pump-off conditions,false starts,underload/overload
conditions can be diagnosed from the recorded ammeter charts.
5.265
NORMAL OPEARTION
5.266
5.267
Cyclic loading of slug and free gas-gas lock, under current tripping
5.268
5.269
Line choked
5.270
Gassy
5.271
DRY RUN
5.272
5.273
5.274
ESP DESIGN
Given Data
Well depth
Tubing
: 2 7/8 inch
Casing size
Reservoir pressure
Wellhead pressure
Water cut
: 60%
GOR
GLR
: 17 m3/m3 ( 96 SCF/b)
ESP DESIGN
Degree API of oil
Specific gravity of gas (Air = 1)
Specific gravity of water
Bottom hole Temperature
Wellhead temperature
Bubble point pressure
Electric supply system
Well profile
Build-down
= 114.3 mm
= 12.3 mm
= 2.0 mm (approx..)
= 128.6 mm
= 121.4 mm
= 785 Mts..
= 762 Mts..
Total = 1547 Mts..
Location of Pump
= 1600
Mts..
from surface
ESP DESIGN
STEP - 7 : MOTOR HORSEPOWER REQUIREMENT
From catalogue, 375 series motor has to be selected,
which has H.P. either equal to this valve or next higher
valve.
H.P. Motor selected
= 16.3 H.P.
It is always advisable to choose a motor with low amperage
rating, provided its voltage rating is not very excessive. So,
from two categories of 16.3 H.P., 50 Hertz motors,
That is from, 16.3 HP; 238 V ; 38 A; 50 Hertz
and
16.3 HP; 323 V; 25 A ; 50 Hertz
the motor of 16.3 H.P.; 323 V; 25 A; 50 Hertz is selected.
ESP DESIGN
STEP - 8 : MAIN CABLE SELECTION
From manufacturers catalogue "Redelene" type (can work
up to 2050 F, where B.H.T. is 1580F) flat cable and 4 AWG
(considering cost and voltage drop factor) has been
considered.
ESP DESIGN
STEP - 9 : SURFACE VOLTAGE CALCULATION
From cable voltage chart, supplied by the manufacturer,
Voltage drop
= 11 volt / 1000 ft.
Total cable length
= Subsurface cable length +
Surface cable length
= 1600 Mts.. + 100 Mts.. (say)
Total cable length
= 1700 Mts.. = 5576 ft
= 5600 ft
So, the total voltage drop = 11V/1000ft x 5600 ft.
= 61.6 v
Voltage required at the surface = name plate voltage +
Total Voltage drop
= 323 + 61.6
= 384.6 V
-----------------= 385 V