Advantages and Disadvantages of ESP Systems

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By admin 22 June 2017

Advantages & Disadvantages of Electrical Submersible

Pumping Systems
From Tables 10-5(a) – 10-5(j), 10-6(a) – 10-6(i), 10-7(a) – 10-7(l)

Artificial Lift Selection, SPE Handbook

Artificial Lift – Design Considerations and Overall Comparisons (Clegg, et al., 12/1993)

Category Consideration for ESP’s

Capital cost · Relatively low capital cost if electric power available.

· Costs increase as horsepower increases.

Downhole equipment · Requires proper cable in addition to motor, pumps, seals, etc.
· Good design plus good operating practices are essential.

Operating efficiency
(Hydraulic HP/Input HP)
· Good for high rate wells but decreases significantly for < 1000 BFPD.
· Typically total system efficiency is about 50% for high rate wells but for <
1000 BPD, efficiency typically <40%.
· Can be as high as 60% for large ID equipment.

Flexibility · Poor for fixed speed.

· Requires careful design.

· VSD provides better flexibility.

Miscellaneous problems · Requires a highly reliable electric power system.

· System very sensitive to changes downhole or in fluid properties.

Operating costs · Varies.

· If high HP, high energy costs.

· High pulling costs result from short run life especially in offshore
operation.

· Repair costs often high.

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Category Consideration for ESP’s

System reliability · Varies.

· Excellent for ideal lift cases.

· Poor for problem areas (very sensitive to operating temperatures and

electrical malfunctions).

Salvage value · Fair.

· Some trade in value.

· Poor open market values.

System (Total) · Fairly simple to design but requires good rate data.
· System not forgiving.

· Requires excellent operating practices.

· Follow API RP’s in design, testing, and operation.

· Each well is an individual producer using a common electric system.

Usage/outlook · An excellent high rate artificial lift system.

· Best suited for <200 0 F and >1000 BFPD rates.

· Most often used on high water cut wells.

· Used on about 5% of US lifted wells.

Casing size limits · Casing size will limit use of large motors and pumps.
(Restricts tubing size) · Avoid 4.5” casing and smaller.

· Reduced performance inside 5.5” casing depending on depth and rate.

Depth limits · Usually limited to motor HP or temperature.

· Practical depth about 10,000 feet.

· 1000’ – 10000’ TVD is typical, Max is 15,000 ‘ TVD.

Intake capabilities · Fair if little free gas (i.e. >250 PSI pump intake pressure).
(Ability to pump with low · Poor if F = 666*(Qg/Ql)/Pip > 1.0
pressures at pump intake)
Where: Pip: intake psi; Qg: gas vol; Ql: liquid vol @ intake conditions.

· 5% gas at low pressures can cause problems.

Noise level · Excellent.

· Very low noise.

· Often preferred in urban areas if production rate high.

Obtrusiveness · Good.
· Low profile but requires transformer bank.

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Category Consideration for ESP’s

Prime mover flexibility · Fair.

· Requires a good power source without spikes or interruptions.

· Higher voltages can reduce losses.

Surveillance · Fair.
· Electrical checks but special equipment needed otherwise.

Relative ease of well · Good.

testing · Simple with few problems.

· High water cut and high rate wells may require a free water knock out
(three-phase separator).

Time cycle and pump off · Poor.

controllers application · Soft start and improved seal/ protectors recommended.

Corrosion/scale handling · Fair.

ability · Batch treating inhibitor only to intake unless shroud is used.

Crooked/deviated holes · Good.

· Few problems.

· Limited experience in horizontal wells.

· Requires long radius wellbore bends to get through.

10° typical,

0 – 90° < 10° / 100 build angle maximum.

· However must set in section 0 – 2° max deviation.

Duals application · No known installations.

· Larger casing required.

· Possible run & pull problems.

Gas handling ability · Poor for free gas (i.e. >5% through pump).
· Poor if F = 666 * (Qg/Ql)/Pip > 1.0

Where: Pip: intake psi; Qg: gas vol; Ql: liquid vol, @ intake conditions.

· Rotary gas separators helpful if solids not produced.

Offshore application · Good.

· Must provide electrical power and service pulling unit.

Paraffin handling · Fair.

capability · Hot water/oil treatments, mechanical cutting, batch inhibition possible.

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Category Consideration for ESP’s

Slim hole completions · No known installations.

(2 7/8″ tubing, casing)

Solids/sand handling · Poor.

ability · Requires <100 – 200 PPM solids for standard construction.

· 200 – 2000 ppm possible with special bushings, stage materials,

coatings, and thrust supporting bearings or fixed pumps employed.

· A maximum of about 5000 ppm might be possible depending on pump

and sharpness and angularity of sand.

Temperature limitation · Limited to <250 0 F for standard & <400 0 F for special motors & cable.
· 100 – 275°F typical.

High viscosity fluid · Fair.

handling capability · Limited to as high as 1000 cp.

· Depends on economics. (~>7-9°API)

· Increases HP and reduces head.

· Potential solution is to use “core flow” with 20% water.

High volume lift · Excellent.

capabilities · Limited by needed HP and can be restricted by casing size.

· In 5.5” casing can produce 4000 BFPD from 4000 feet W/240 HP.

· Tandem motors increase HP & operating costs.

200 – 20,000 bpd typical, ~30,000 bpd max.

52,000 bpd, shallow, 10.25” equip has been done.

Low volume lift · Generally poor.

capabilities · Lower efficiencies and high operating costs <400 BFPD.

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