Mohammad Masadeh, Nelson Ruis, Diego Hernandez, Nurbol Bekbossinov, and Mohaned Hamoud
Baker Hughes Permian ALS
Main objective of this paper is to introduce oil and gas industry the new E3000 and E1000 pump models across multiple wells in the Permian and Delaware Basins in term of performance, and operation improvements. It is intended to show a reader pump performance enhancement and comparison to older models based on operator required production rates, pump loads, power consumption and other electrical and mechanical parameters that of the focus when designing and selecting an ESP.
New pump designs (low volume and high volume) entered the market offering wider range of operation and lower number of stages required to lift a given amount of fluid as opposed to older models, new pumps have steep and consistent rising head curve all the way to shut-in, A higher head rising steepness leads to more prompt H/Q response, delivers better controllability especially when PIP is low and/or the well is gassy. Some operators agreed to try and test new pump designs on different well pads. Opportunity presented itself to study different cases and evaluate the performance of new pumps. Team has decided to compare performance using Baker Hughes software and real-time pump performance curves.
Having a smaller number of cases with E1000 and E3000 400 series pumps their performance has been simulated on real conditions on wells that were installed with older pump models such as Flex31 and/or P35 by Baker Hughes. Different wells have been picked with relatively similar fluid production, setting depth, GLR, water cut, and other parameters to reduce the discrepancy as much as possible. From economical standpoint newer models offer less cost to an operator and higher system efficiency. From operational standpoint new models offer a smaller number of stages, thus more lift capacity per length. Another observed benefit is that operating range is much wider than on older designs and on multiple occasions older models end up close to the extreme or out of range based on the test flow data. This impacts the run-life of overall unit, reduces the number of shutdowns, and in turn lower operational costs for an operator. Wells with new pump designs will be presented to a reader with real-time operational pump curve electrical and mechanical values. New ESP systems showed up to 5-6% efficiency increase and almost 4-5% power consumption reduction using E3000 & E1000 pumps.
LiftPrime pumps E1000 and E3000 are new models and starting to slowly pick up by the market, more pumps will be also introduced to the market in 2023. Practicing engineers can learn about the performance of these units from real-time performance data, simulation cases, and comparison to older pump designs. The LIFTPrime high-efficiency pump lets operators optimize economics in both conventional and unconventional wells by lowers energy consumption, reduces pump downtime and brings new levels of efficiency, reliability and flexibility.