Electric Submersible Pump

ESP permanent magnet motors (PMMs) have been confirmed to conserve power when compared to conventional induction motors (IMs) in various industry papers and studies. However, most production comparisons comprise a snapshot in time or the partial life of a single ESP. This analysis is useful, but it doesn’t convey the full power-saving value of a PMM installation.

1. OBJECTIVES/SCOPE: Please list the objectives and scope of the proposed paper.

High volume, high water cut wells historically represent a challenge in terms of economic production, due to limitations with others artificial lift methods, ESPs are usually chosen for this type of application since it can move great volumes of fluid produced by longer laterals being drilled today.

This paper introduces a multi-layered application to tackle two major challenges in unconventional wells within the Permian Basin: gas slugs and high gas-liquid ratios (GLRs) that disrupt electric submersible pump (ESP) operations, and sand fallback during ESP shutdowns, which can cause equipment failures like plugged pumps and broken shafts. These issues reduce efficiency, increase downtime, and drive-up operational costs.

The installation and retrieval of Electrical Submersible Pumps (ESPs) equipped with Permanent Magnet Motors (PMMs) require robust barriers to prevent shaft rotation and the subsequent generation of voltage. Current methods to provide these barriers involve additional operations, equipment, and personnel, which increase associated risks. This paper introduces a new method that is safe, effective, and economical, improving both safety and operational efficiency during the installation, operation and retrieval processes.

Most frac hits are significant events with large pressure change, followed by enhanced flow of almost all water then declining with increasing oil at a level higher than before the event.  This study examines how best to “ride thru” the frac hit, but also how to manage ESP settings for the rapid fluid rate changes during and after the event.  The frac hits occurred at different points in the wells drawdown so The ESP operation was monitored and setpoints adjusted as needed with the changes in load.

In an effort to address safety concerns, PMM manufacturers and operators have worked together and developed API 11S9 Recommended Practice that covers many of the safety issues relative to PMM operations. The PMM is a very good generator due to “always on” permanent magnet rotor so presents a risk of electric shock and arc flash (AF) hazards if rotation occurs when service personnel handle the ESP cable conductors at surface. The primary methods to avoid these hazards is to insure an EquiPotential Zone (EPZ) is created at surface and to shunt the ESP cable leads.

Artificial lift systems in the oil and gas industry have long relied on Supervisory Control and Data Acquisition (SCADA) technology for monitoring and control. However, as the digital landscape continues to evolve, artificial lift systems must adapt to more dynamic and autonomous operations. In particular, leveraging cloud-native edge computing, microservices, and the Industrial Internet of Things (IIoT) offers the potential to enhance the real-time responsiveness and optimization of artificial lift systems.

In gas slugging conditions, conventional gas separators struggle to process and deliver liquid to the pump due to extremely high concentrations of gas within the separator. A prototype slug mitigation system replaced a conventional, high flow, tandem gas separator system in a slugging well. The initial field trial results are discussed in this paper.

The purpose of this paper is to present a solution to the adverse impact of fallback sand and debris on ESPs (Electrical Submersible Pumps). When these solids accumulate on an ESP during operational shutdowns, it poses a significant risk of damage and subsequent failures upon restarting the system. The problem arises when the friction force that the motor is required to overcome exceeds the material strength of the motor shaft. This large increase in amperage damages the motor and drive shaft of the ESP.