Proceedings OMAE 2018

37th International Conference on Ocean, Offshore & Arctic Engineering

June 17-22, 2018, Madrid, Madrid, Spain

78565

EXPERIMENTAL STUDY AND MODELING OF HEATING EFFECT IN

ELECTRICAL SUBMERSIBLE PUMP OPERATING WITH ULTRA-HEAVY OIL
Jorge Luiz Biazussi
University of Campinas
Campinas, São Paulo, Brazil
biazussi@unicamp.br
William Monte Verde
University of Campinas
Campinas, São Paulo, Brazil
williammonteverde@gmail.com
Paulo S. Rocha
Queiroz Galvão E&P S.A.
Rio de Janeiro, RJ, Brazil
psrocha@qgep.com.br
Cristhian Porcel Estrada
University of Campinas
Campinas, São Paulo, Brazil
cristhi8n@gmail.com
Antonio Carlos Bannwart Valdir Estevam
University of Campinas University of Campinas
Campinas, São Paulo, Brazil Campinas, São Paulo, Brazil
bannwart@fem.unicamp.br Valdir_e@hotmail.com
Salvador J. A. Neto Alexandre Tavares
Queiroz Galvão E&P S.A. Queiroz Galvão E&P S.A.
Rio de Janeiro, RJ, Brazil Rio de Janeiro, RJ, Brazil
sneto@qgep.com.br atavares@qgep.com.br

ABSTRACT
Nomenclature
A notable trend in the realm of oil production in harsh ESP Electrical Submersible Pump
environments is the increasing use of Electrical Submersible BEP Best Efficiency Point
Pump (ESP) systems. ESPs have even been used as an artificial- VSD Variable Speed Drive
lift method for extracting high-viscosity oils in deep offshore ∆𝑃 total differential pressure (Pa)
fields. As a way of reducing workover costs, an ESP system may ∆𝑇 differential temperature (oC)
be installed at the well bottom or on the seabed. A critical factor, 𝜀 superficial roughness (m)
however, in deep-water production is the low temperature at the 𝜂 efficiency (-)
seabed. In fact, these low temperatures constitute the main 𝜌 density (kg/m3)
source for many flow-assurance problems, such as the increase 𝜇 dynamic viscosity (cP)
in friction losses due to high viscosity. Oil viscosity impacts 𝜔 rotational speed (rad/s)
pump performance, reducing the head and increasing the shaft 𝜔𝑠 specific speed (-)
power. This study investigates the influence of a temperature 𝜈 kinematic viscosity (ft2/s)
increase of ultra-heavy oil on ESP performance and the heating 𝛹 dimensionless head (-)
effect through a 10-stage ESP. Using several flow rates, tests are Π dimensionless power (-)
performed at four rotational speeds and with four viscosity 𝛷 dimensionless flow rate (-)
levels. At each rotational speed curve, researchers keep constant 𝑐𝑃 heat capacity (J/kg.K)
the inlet temperature and viscosity. The study compares the 𝐷 impeller diameter (m)
resulting data with a simple heat model developed to estimate the head (m)
𝐻
oil outlet temperature as functions of ESP performance
𝑘1,2,…,𝑛 dimensionless geometric constants (-)
parameters. The experimental data is represented by a one-
𝑚̇ mass flow rate (kg/s)
dimensional model that also simulates a 100-stage ESP. The
𝑃ℎ hydraulic power (Watts)
simulations demonstrate that as the oil heat flows through the
𝑄 volumetric flow rate (m3/s)
pump, the pump’s efficiency increases.
𝑅𝑒𝜔 Rotational Reynolds number (-)
𝑇𝐼𝑛𝑙𝑒𝑡 Inlet Temperature (°C)
Key Words: electrical submersible pumps, ultra-heavy oil,
heating effect. 𝑧1,2,…,𝑛 dimensionless geometric constants (-)
𝑊̇𝑠 shaft power (Watts)

1 Copyright © 2018 by ASME

 INTRODUCTION LITERATURE REVIEW

In oil production, reservoirs often have insufficient energy to For a centrifugal pump, the pump Head (𝐻) and the shaft
permit fluids to rise to the surface. At other times the naturally power (𝑊̇ ) are functions of the following: flowrate (𝑄), impeller
produced flow rate is not economical for production. In such diameter (𝐷), rotational speed (𝜔), density (𝜌), dynamic
circumstances, engineers often make use of artificial lift viscosity (𝜇), and superficial roughness (𝜀). Therefore, we can
methods. One of the most important of these methods is the write the following functional relations:
Electric Submersible Pump (ESP). Researchers estimate that
ESPs operate in, worldwide, between 150,000 and 200,000 wells 𝑔𝐻 = 𝑓1 (𝑄, 𝐷, 𝜔, 𝜌, 𝜇, 𝜀) (1)
(Flatern, 2015).
An ESP consists of centrifugal pump stages mounted in series 𝑊̇ = 𝑓2 (𝑄, 𝐷, 𝜔, 𝜌, 𝜇, 𝜀) (2)
and joined to a submersible electric motor. An ESP system is For each function, there are seven parameters and three
composed of both downhole and surface equipment. The primary dimensions. The Buckingham’s Pis theorem results in
production bottom hole assembly (length and diameter) are four dimensionless groups. These dimensionless function forms
designed based on the desired flow rate, necessary power, well are:
conditions, and geometry. The assembly is connected to surface
controls and electric power. 𝑔𝐻 𝑄 𝜌𝜔𝐷2 𝜖
= 𝑔1 ( , , ) (3)
Originally, this technology was widely applied to oil well 2
𝜔 𝐷 2 𝜔𝐷 3 𝜇 𝐷
pumping (onshore) and dewatering mines and ships. Today,
though, the conditions under which oil is extracted are severe and 𝑊̇ 𝑄 𝜌𝜔𝐷2 𝜖
the methods aggressive. These adverse conditions include = 𝑔2 ( , , ) (4)
𝜌𝜔 3 𝐷5 𝜔 𝐷3 𝜇 𝐷
pumping high viscous liquids or heavy crude oil from deep
offshore fields. These sources represent 60% of the world’s The variables 𝜌𝜔𝐷2 /𝜇 and 𝜀/𝐷 are the rotational Reynolds
unconventional resources and 40% of the total world oil reserves number (𝑅𝑒𝜔 ) and the relative roughness, respectively. The other
(Alboudwarej et al., 2006). To get at these reserves, ESP dimensionless ones are defined as:
technology has also had to evolve.  Head coefficient (𝛹):
An ESP’s performance is negatively impacted by an increase
in viscosity, reducing the head, flow rate, efficiency, and raising 𝑔𝐻
𝛹= (5)
the shaft power. On the other hand, an increase in the oil’s 𝜔 2 𝐷2
temperature as the oil moves from stage to stage through the  Flow rate coefficient (𝛷):
pump, causes a decrease in viscosity and, especially in the last
stages, an improvement in pump performance. 𝑄
𝛷= (6)
During its operation, the centrifugal pump converts 𝜔𝐷3
mechanical energy, provided by the submersible motor, into an  Power coefficient (𝛱):
increase in the pressure of the fluid pumped, but this also
involves energy losses. These losses end up as heat dissipated in 𝑊̇
the pump—heat that is absorbed by the flow and thereby 𝛱= (7)
𝜌𝜔 3 𝐷5
decreasing the fluid viscosity in the last stages.
For many decades, researchers have devoted attention to the Rewriting Equations (1) and (2) as a function of these
influence of fluid viscosity on centrifugal pump performance. To dimensionless numbers gives us the following:
predict the pump performance with viscous oils, researchers 𝛹 = 𝑔1 (𝛷, Χ, 𝜀/𝐷) (8)
have come up with different approaches. The most common are
empirical methods that adjust the pump performance by using as 𝛱 = 𝑔1 (𝛷, Χ, 𝜀/𝐷) (9)
a reference the water baseline curve. All such procedures,
however, ignore the increase in temperature experienced by the where 𝑋 = 1/𝑅𝑒𝜔 . The pump efficiency (𝜂) is defined by:
fluid as it flows through the stages. This increase is quite 𝛥𝑃 𝑄 𝛷 𝛹
important, because the oil has an exponential-decay temperature- 𝜂= = (10)
dependent viscosity. In other words, the warming effects of the 𝑊̇ 𝛱
first stages can improve the performance of the last stages, Finally, the last dimensionless parameter described in this
because the pump is delivering a less viscous oil, which work is the specific speed (𝜔𝑠 ), which is defined by:
facilitates the flow (Amaral et al., 2009).
𝛷 0.5
This paper is divided into three main parts. The first part 𝜔𝑠 = (11)
reviews the literature. The second part presents the experimental 𝛹 0.75
pump bench test, the test matrix, and the test procedure. The last Stepanoff (1948) verified that, for a conventional centrifugal
part presents a discussion of the results and our conclusions. pump with constant rotational speed, the head capacity and the
flow rate decrease with increasing viscosity of the fluid pumped,

2 Copyright © 2018 by ASME

so that the specific speed remains constant at the best efficiency
point (BEP); therefore:
𝜔 √𝑄𝑤 𝜔 √𝑄𝑜
𝜔𝑠 = = (12)
𝐻𝑤 3/4
𝐻𝑜 3/4
where the subscripts w and o represent the operation with water
and oil, respectively. Stepanoff (1948) defined a constant
rotational speed as the relation
𝑄𝑜 𝐻𝑜 1.5
=( ) (13)
𝑄𝑤 𝐻𝑤
Stepanoff performed tests with eleven oil types with
viscosities between 1 and 2020 cSt (1 to ~1900 cP). Then, the
authors elaborated an abacus, relating a modified Reynolds
number (sometimes called Stepanoff’s Reynolds) with pump
efficiency and correction factors for head and flow rate.
Based on the experimental results of oil with different
viscosities being pumped through conventional centrifugal
pumps of simple stages, the Hydraulic Institute USA (1955)
created two abacuses. These abacuses determine correction
factors of flow rate, head capacity, and efficiency, which are used
to correct the pump performance curve when its operating with
viscous fluid. The abacuses are valid for a pumping rate range of
100 to 10,000 gpm (21.6 to 2160 m³/h), for head capacity of 6 to
600 ft (1.8 to 183 m) and kinematic viscosity between 4 to 3,300
cSt.
To obtain new pump operational conditions when working
with viscous fluids, Paciga (1967) defined his own Reynolds
number by suggesting a procedure quite similar to Stepanoff’s.
However, the viscosity range does not apply to crude oils with
high viscosity or to liquids commonly found in the petroleum
industry.
Based on a viscous losses analysis, Gülich (1999a, 1999b)
developed an empirical procedure for predicting performance of
centrifugal pumps. Gülich affirmed that the main deterioration
factors of the performance of the pumps operating with high
viscous fluids are disc friction and viscous dissipation due to
friction in the pump channels.
Turzo et al. (2000) stated that it is impossible to determine
the performance curves of a centrifugal pump through
calculations. This is because these viscous losses are affected by
several design and manufacturing parameters. The authors then
used the HI-USA database to digitize the curves of these
abacuses and to regress the data before the implementation of an
automated calculation procedure.
In determining the performance of a centrifugal pump
operating with viscous oil, Li et. al. (2002) affirmed that, based
on the performance curve of the pump with water, an error may
occur of 10% or more. The researchers then performed
experiments with a standard type 65Y60 API610 pump with
water and oils with viscosities up to 240 cP. The authors
compared their results with the correction factors obtained using
the abacuses of the Hydraulic Institute. The relative mean
deviations for flow rate, head, and efficiency were -10%, -5%
and -9.7%, respectively.
To gather data and study the influence of the viscosity in ESP
pumps at oil well conditions, Amaral et al. (2009) developed a
theoretical-experimental work. They proposed a generalist
modeling to represent the process of performance, performing its
validation through experimental data.
Solano (2010) studied the effect of viscosity on the
performance of a 7-stage ESP pump used in the petroleum
industry. The study was based on conservation equations applied
to the pump impeller. Solano (2010) verified that the pump
performance could be defined by the pump’s dimensionless
parameters.
Among the works cited, most of them have proposed
investigating the influence of viscosity on the performance of an
ESP pump. These works adopted empirical and semi-empirical
approaches, based on the results of test and the dissipation of
energy inside the pump, respectively. These works were
performed mostly in conventional pumps. These geometric
characteristics, however, are different from those of pumps that
are used in the petroleum industry. Consequently, applying the
studies cited above to predict the performance of ESPs operating
with oil can result in considerable errors. The works of Amaral
(2009) and Solano (2010) alone are works specifically for the
petroleum industry.
Ofuchi et. al (2017) conducted a numerical studies to
investigate the performance degradation of an ESP operating
with viscous fluid. Comparison of numerical pressure head
curves with data from literature showed good general agreement.
The author observed the flow field pattern found for the best
efficiency point changes significantly with the rotational
Reynolds number. The simulation did not considered the
temperature increasing thought the multiple stage pump.
To represent the pump performance under viscous flow,
Biazussi et al. (2013), Paternost (2013), Biazussi (2014),
Paternost et al. (2015) and Monte Verde (2016) have been
working on a one-dimensional model based on the simple losses
approach. In this one-dimensional model, the pump head can be
understood as the pressure gain by Euler equation deducting the
losses. The shaft power can be calculated as the minimum power
needed by Euler theory adding the main power losses. These
approaches lead to two main equations that may represent the
performance of the pump in viscous flows:
1
𝛹= − 𝑘4 + (−𝑘1 − 𝑋𝑘2 + 2𝑘4 𝑘5 )𝛷
4
𝑋 𝑛 (14)
+ [− ( ) 𝑘3 + 𝑘4 𝑘5 2 − 𝑘6 ] 𝛷 2
𝛷
𝛱 = 𝛹𝑧0 + 𝑧1 + 𝑋𝑧2 + (𝑧3 − 𝑋𝑧4 )𝛷
(15)
+ [𝑋𝑧6 + 𝑧5 ]𝛷 2 − 𝑧7 𝛷 3
where 𝑘1,2,…,𝑛 and 𝑧1,2,…,𝑛 are geometric constants specific to the
pump model.
Considering an adiabatic flow, Monte Verde (2016) presented
a heat model based on the energy balance between the inlet and
outlet of the pump. Hence, the temperature increase per stage can
be estimated by:
3 Copyright © 2018 by ASME

(𝑊̇ − 𝑃ℎ ) 1 ∆𝑃
∆𝑇𝐴𝑑𝑖𝑎𝑏𝑎𝑡𝑖𝑐 = = ( − 1) (16)
𝑚̇ 𝑐𝑝 𝜂 𝜌𝑐𝑃
In this context, the study of heating effect in ESPs presented
in this work use Equations (14) and (15) to estimate the pump
performance at each stage and Equation (16) to estimate
temperature increase in each stage. As the temperature increases
and the fluid flows through the pump, the viscosity lessens.
MATERIALS AND METHOD
This section describes the experimental facilities, the
measuring instruments, the test matrix and finally, the procedure
adopted to perform the experiments.
Experimental Facilities
The experimental study was conducted in the Experimental
Laboratory of Petroleum – LabPetro at UNICAMP. The loop
facility was especially design to measure ESP performance with
ultra-heavy oil.
The ESP loop test is shown schematically in Figure 1. The
facilities are composed basically of a tank, a two-screw booster
pump, a heat exchanger, chiller, an ESP skid, VSDs, valves,
instrumentations, and a power generator. The booster pump is
used to pump the fluid from the tank through installation up to
the ESP suction. This equipment is driven by a VSD, allowing
Figure 1 – Layout of heavy-oil ESP bench test.
flexible operation. Because it is a closed loop, the oil tends to
heat up during the tests. So, a temperature control system,
composed of Chiller and heat exchanger, is used to keep the fluid
temperature constant. This issue is fundamental, because the oil
viscosity is controlled by its temperature.
Before ESP intake, the oil flow rate is measured and then
pumped back to the tank. The 10-stage ESP is driven by an
electric motor and controlled by a VSD. The experimental
apparatus has an electric generator for its operations.
The main equipment is described below:
- ESP model HC20000L series 675 – 10 stages, with 6-
inch flange connectors, outlet pressure ± 80 bar and an
electric 3 phase motor 2 poles 150 KW/380 V.
- Variable frequency drive of ESP, rated voltage 380-480V
/ 206-260 KVA / 329 Amps / 50-60 Hz.
- Two-screw positive displacement pump (Booster),
nominal flow rate 200 m³/h, maximum pressure work 25
bar, with an electric 3-phase motor 8 poles 220
KW/380V.
- Variable frequency drive of Booster, rated voltage 380-
480 V / 477 Amps / 50-60 Hz.
- Horizontal Stationary Tank of 6.7 m³ storage capacity.
- Heat exchanger with 230000 kCal/h of capacity.
- Chiller with 208000 kCal/h of capacity.
- Mass flow and density meter type Coriolis, nominal
liquid flow rate 115 kg/s.
4 Copyright © 2018 by ASME
 The valves, temperature control system, and VSDs are
Measuring instruments
remotely actuated by analog signals of current and voltage. The
The acquisition instruments used are shown in Table 1. Each temperature and pressure sensors that the ESP is equipped with
of the 10 ESP stages is equipped with a differential pressure are shown in Figure 2. All measurement instruments and remote
gage. At the ESP intake and discharge are installed absolute drives are integrated into a data-acquisition system designed
pressure gages. specifically for the experimental apparatus.
In Stages 2, 4, 6, and 8 PT100 thermo-resistances are
installed to measure the temperature. The ESP drive power is
calculated by measuring the torque on the motor shaft.
Table 1– Features of the measuring instruments
Instrument Brand/Model Range Uncertainty
Flow meter MicroMotion 2700R 0 - 545000 kg/h ± 0.2%
Thermocouple PT 100 RTD 0 - 100 ºC ± 0.07%
Manometric Pressure transducers Rosemount 2051 TG 0 - 4000 kPa ± 0.073%
Differential Pressure transducers Rosemount 2051 CD [-]300 – [+]300 kPa ± 0.088%
Torque Transmitter MCRT 390041X 0 – 1130 N.m ± 0.026%
Tachometer MDT 2238A 2.4 - 99999 rpm ± 0.05%

Figure 2 – ESP Pressure and Temperature sensors.

In order to evaluate the reliability of the data obtained from

Experimental matrix
The tests were carried out using two types of fluids. The first
was diesel oil type S500 of 7.9 cP at 15 °C. The second one was
an ultra-heavy crude oil and diesel blend. Figure 3 and Figure 4
show the correlation between viscosity and temperature for the
diesel oil and the blend, respectively. The crude oil was provided
by the sponsor company (Queiroz Galvão E&P).
the ESP, the performance curve was raised with the first fluid
(Diesel S500). This curve was obtained at four rotational speeds
(3500, 3000, 2400, 1800 rpm) and at 15 °C, that represents ±
7.97 cP. This experimental matrix is shown in Table 2.
Subsequently, the working fluid was changed, and tests were
performed with other viscosities. For this fluid, the experimental
matrix is shown in Table 3.

5 Copyright © 2018 by ASME

 The objective of these tests was to analyze the effect of the 2 – Turn on the booster pump and then the ESP; set a rotating
change of viscosity through the pump. For a Newtonian fluid, speed for the ESP through the VFD (Velocity frequency driver);
such as crude oil, it is fixed by the state of the substance; i.e., it choose a suitable rotation for the booster pump corresponding to
is a function of temperature and pressure. For liquid substance the flow to be measured; finally set the desired temperature for
operating at relative low pressures, the behavior of viscosity is a the test.
function only of temperature. 3 – When the system reaches stabilization, the collection of
points begins, varying the pumped flow (moving the booster
rotation and the choke valve) from its maximum value to the
zero.
4 – During Stage 3 of this procedure, data is saved only when
the system reaches the conditions stabilization. These data are
stored in text files, to be processed later. Due to the friction of
the oil with the piping and inefficiency in the pump, the oil tends
to heat up, and cooling it is necessary, keeping its viscosity
constant throughout the entire flow range tested.
Table 3 – Matrix of experimental tests for oil.
𝝎 Viscosity 𝑸𝒎𝒂𝒙 𝑸𝒎𝒊𝒏
[𝑹𝑷𝑴] [𝒄𝑷] [𝒎𝟑 /𝒉] [𝒎𝟑 /𝒉]
3500 162.09 4.84
3000 139.53 5.13
230 ± 9
Figure 3 – Diesel S500 Viscosity as function of temperature. 2400 106.67 2.44
1800 74.43 2.64
3500 155.39 5.58
3000 132.26 3.13
319 ± 10
2400 100.30 3.18
1800 72.57 2.16
3500 146.69 5.87
3000 124.45 3.99
447 ± 30
2400 93.83 2.76
1800 56.73 0.83
3500 136.95 6.23
3000 104.54 3.37
645 ± 35
2400 76.81 0.80
1800 54.67 1.45

RESULTS AND DISCUSSIONS

Figure 4 – Blend Oil/Diesel Viscosity as function of To analyze the heating effect and the influence on pump
temperature. performance, it is necessary to fit the geometrical constants as
presented in the Eq. (14) and Eq. (15). The set of data is
Table 2 – Matrix of experimental tests for diesel. composed of 334 measurements of diesel performance and 769
measurements of ultra-heavy oil performance. These were
𝝎 Viscosity 𝑸𝒎𝒂𝒙 𝑸𝒎𝒊𝒏 collected following the experimental procedure as previously
[𝑹𝑷𝑴] [𝒄𝑷] [𝒎𝟑 /𝒉] [𝒎𝟑 /𝒉] presented and are represented in the matrices in Table 2 and
3500 8.0 ± 0.5 203.38 2.34 Table 3.
3000 8.0 ± 0.2 175.71 3.44 Figure 5 shows a comparison between the head model
2400 8.0 ± 0.2 139.50 3.01 presented in Eq.(14) and the experimental data for all the
1800 7.9 ± 0.3 105.18 2.11 operational points tested. The region formed by the dashed red
line represents a deviation of ±10 %. It is possible to observe that
Experimental Procedure this simple one-dimensional model could estimate the pump
To carry out the tests, the following steps were adopted: head for most of the experimental data, with a deviation of less
1 – Start the electric generator to energize the experimental than 10 %. The experimental data near zero head has a larger
bench; check if all valves are open; turn on the air compressor to deviation. These operational points are also the most
drive the pneumatic valves. complicated data to collect because the instruments were

6 Copyright © 2018 by ASME

selected for a wide range of pressures and near the zero values All the simulation results were performed for 3500 rpm with
the uncertainty increases. an oil density of 930 kg/m³ and specific heat of 1845 J/(kg°C).
Figure 6 presents a comparison of the shaft power model These properties belong to the crude oil used in the experimental
according Eq. (15) and all the experimental data collected. The tests and were measured in the laboratory.
majority of data present a deviation of less than 10 %.
Table 4 – Geometric constant fitted with experimental data.
A wide range of operating conditions and viscosities could be
reasonably represented by a simple one-dimensional model with Head Model Eq.(14) Shaft Power Model Eq.(15)
an easy numerical solution. The geometric constants obtained in 𝑘1 = 3.5598 𝑧0 = 0.0022122
the fitting process of the experimental data set for both models 𝑘2 = 7679.1 𝑧1 = 0.0024034
can be seen in Table 4. 𝑘3 = 368.56 𝑧2 = 16.024288
𝑘4 = 0.1358 𝑧3 = 0.0804957
𝑘5 = 14.950 𝑧4 = 353.38061
𝑘6 = 0.0346 𝑧5 = 0.2378390
𝑛 = 0.4403 𝑧6 = 6047.3070
𝑧7 = 15.917800

Start

Data:
RPM
Flow Rate
Pump Geometry
Inlet Temperature

Figure 5 – Experimental versus model dimensionless head.

I=N
N(Total Stages)

No

Yes
Calculate:
1) Oil Viscosity
2) X Parameter
3) Head Model
4) Shaft Power Model
5) Efficiency
6) Thermal Model
7)New Outlet Temperature

Figure 6 – Experimental versus model dimensionless shaft
power.
Simulating an ESP oil field size
To observe the influence of the heating effect on pump
performance, an ESP with 100 stages was simulated. The
numerical simulation consisted of solving Eq. (14) and Eq. (15)
stage by stage, correcting the oil viscosity with the stage outlet
temperature calculated with the heating model, as proposed in
Eq.(16). This procedure can be better presented as a flowchart,
as shown in Figure 7.
End
Figure 7 – ESP model flowchart.
Figure 8 shows the ESP outlet temperature as a function of
the stage number, for three different flow rates at the same inlet
temperature (𝑇𝑖𝑛𝑙𝑒𝑡 = 30 °𝐶). The temperature gain is inversely
proportional to the mass flow rate, then as the oil flow rate
increases, the outlet temperature decreases. Over 100 stages, the
outlet temperature can reach a difference of 29 °C, when the
liquid flow rate changes from 75 m³/h to 25 m³/h. For 50 m³/h,

7 Copyright © 2018 by ASME

the oil temperature increases 25.8 °C through the pump, reaching shown in the Figure 14. For 100 stages, the ESP shaft power was
55.8 °C over 100 stages. calculated as 972 kWatts, 924 kWatts and 887 kWatts for 25 °C,
30 °C, and 35 °C of inlet temperature, respectively.

Figure 8 – ESP outlet temperature for different oil flow rate.

Figure 9 – ESP pressure gain for different oil flow rate.
As can be seen in Figure 9, the combined effect of liquid flow
rate and heating through the pump can lead, especially for 100
stages, to a different outlet pressure. For this case, ESP pressure
gain can reach 251 bars operating with 25 m³/h, but only 175 bars
with 75 m³/h.
One of the desired effects of heating crude oil is to increase
the pump's efficiency, due to decreasing the viscosity over the
pump stages.
Low flow rates give rise to a higher temperature increase, as
shown in Figure 8. However, Figure 10 shows that the highest
improvement in the ESP efficiency was achieved for the
simulated high flow rate. For 100 stages, the efficiency
improvement was 21.6 % for 75 m³/h while for 50 m³/h and 25
m³/h efficiency improved by 17.2 % and 12.2 %, respectively.
Figure 11 shows the ESP shaft power as a function of stage
number. As the liquid flow rate increases the ESP shaft power
increases as well. This result was expected, as the hydraulic
power is a function of the liquid flow rate. Figure 10 – ESP efficiency for different oil flow rate.
Figure 12 shows the ESP outlet temperature as a function of
the number of stages for three different inlet temperatures. As the
stage number increases, the temperature difference decreases.
Initially the temperature difference between curves was 5°C but
for 100 stages the outlet temperatures were 58.9 °C, 55.8 °C, and
53.4 °C for inlet temperatures of 35 °C, 30 °C, and 25 °C,
respectively. The differences were 3.1 °C and 2.4 °C less than
the inlet temperature difference.
For the same flow rate but different inlet temperatures, the
ESP efficiency ratings at earlier stages are different but, as shown
in Figure 13, these differences decrease as the stage numbers
increase. The ESP efficiency improvement is related to the
increase in temperature and the decrease in oil viscosity as the
oil flowed through the multi-stage pump. As the oil viscosity
decreased, the influence on the head and shaft power also
decreased.
The ESP’s shaft power may suffer a considerable reduction
as a function of the oil temperature as it enters the pump, as Figure 11 – ESP shaft power for different oil flow rate.

8 Copyright © 2018 by ASME


Figure 12 – ESP outlet temperature for different inlet
temperature.
Figure 13 – ESP efficiency for different inlet temperature.
Figure 14 – ESP shaft power for different inlet temperature.
CONCLUSIONS
This work has carried out an experimental and numerical
analysis of how heating ultra-heavy oil affects the performance
of electrical submersible pumps (ESPs). Researchers tested a 10-
stage ESP with diesel and ultra-heavy oil at four rotational
speeds (3500 rpm, 3000 rpm, 2400 rpm and 1800 rpm) and five
viscosities (one for diesel, four for ultra-heavy oil). Viscosity
was controlled by changing its temperature.
The head and the shaft power models were used to represent
the pump with reasonable accuracy, as shown in Figure 5 and
Figure 6. The geometrical constants were fitted with all the
experimental data collected.
A numerical procedure was adopted to calculate the heating
of the fluid through the stages of the pump. These procedures
consisted of calculating, stage by stage, the pump performance
and correcting the viscosity.
A hypothetical 100-stage ESP was used to represent real
equipment in operation, based on experimental data and ultra-
heavy oil properties measured in laboratory.
The simulations suggested that, as oil flowed through the
pump, incremental rises in oil temperature could be very
significant, especially for low flow rates.
For all the cases simulated, researchers observed the pump’s
efficiency improve through the progressive stages and, as the
stage number increased, the improvement was at times
significant.
The inlet temperature is related to the oil viscosity in the
pump inlet. The performance degradation observed in the early
stages were observed in efficiency analysis. When the oil entered
at a high temperature (low viscosity), the shaft power dropped
significantly.
The heating model used does not take into account the energy
lost to the environment, leading to theoretical maximum
temperature results.
ACKNOWLEDGMENTS
The authors thank Queiroz Galvão E&P and ANP
("Compromisso de Investimentos com Pesquisa e
Desenvolvimento") for providing financial support for this work.
Acknowledgments are also extended to ALFA – Artificial Lift &
Flow Assurance Research Group.
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