Training

Electrical Submersible Pumping: Design, NODAL Analysis and Advanced Applications

• 5 days
• 4 sessions of 6 hours over four consecutive days (virtual)
• Level: Intermediate to Advanced

Synopsis

ESP is one of the predominant forms of artificial lift used for lifting prolific quantities of liquids from conventional, unconventional, onshore, and offshore assets. Proper application of ESP is a must in any environment to improve the profitability of an oil-producing asset. ESP in its various configurations allows the life of well lift-possibilities when selected and applied correctly. This course gives trainees a thorough understanding of ESP artificial lift technology and related application concepts.

The course covers the basic design principles of one of the most common artificial lift methods, Electrical Submersible Pumping, illustrated with many classroom examples. The proper design of ESP installations is a technical and economic problem. The course starts with a short overview of fundamentals and deals with well inflow performance, hydraulics, electrics, and a basic description of NODAL Analysis principles. The basic components of the ESP system (the pump, motor, protector, and electric cable) are fully described by introducing their main structural and operational features. Trainees solve examples and class problems throughout the course. Animations and videos reinforce the concepts under discussion.

Most oil and gas wells require artificial lift at some point and for most of the life cycle to achieve production objectives. There are at least eight forms of artificial lift technologies available in the market. Each lift system’s applicability often overlaps with another lift system(s), and it is crucial to understand the positioning and strength of a particular lift form. ESP (Electrical Submersible Pumping) is the most essential and often considered artificial lift around the globe for producing liquid quantities above 500 bbls/days from deep and shallow reservoirs. When properly selected and operated, it can deliver significant hydrocarbon volumes that can improve the initial rate of returns (IROR) of challenging to produce assets. That is why it also commands the most significant capital expenditure allocations in global artificial lift markets on an annualized basis. On the other hand, poor selection and management can lead to suboptimal production rates with poor operational efficiencies and higher failures leading to deferred production with higher CAPEX/OPEX. It is vital to understand the interdependency between reservoir, wellbore, and surface installations with ESP equipment.

Special well conditions like high viscosity fluids, free gas production, and abrasive materials require special equipment, completely covered during the course. A brief discussion on ESP applications in unconventional wells is included. The course covers the application of Variable Speed Drives and their advantages in producing oil wells. The course covers the main components, application envelope, relative strengths, and weaknesses of ESP in its different forms. While providing intermediate-level instructions, the training arms attendees with sufficient detail to participate in the informed decision-making process. A special feature of this course is a discussion of the digital oilfield and a brief review of machine learning applications in the operations of ESPs.

Learning outcomes

• Understand the basic fundamental theories and procedures related to ESP operations.
• Provide a thorough introduction to the theory and application of ESP, and demonstrate the advantages and limitations of ESP systems.
• Become acquainted with ESP system evaluation, design, installation, and operation concepts.
• Easily recognize the different components of the ESP system and their basic structural and operational features.
• Understand how special well conditions (high fluid viscosity, free gas production, abrasives in well fluids, unconventional developments) can be handled by properly designed ESP systems.
• Have a working knowledge of the types, the application, and the advantages of Variable Speed Drives.
• Be able to design an ESP installation and select the optimum components of the ESP system.
• Be able to use NODAL Analysis program packages to describe the operation of ESP installations.
• Have a basic understanding of the ESP system’s power efficiency and system losses.
• Be able to conduct basic troubleshooting of ESP installations.
• Understand how digital oilfield tools help address ESP challenges.
• Learn recent advances in real-time approaches to production monitoring and lift management.

Who should attend

• Production, reservoir, completion, drilling and facilities engineers, analysts, and operators
• Anyone interested in learning about implications of ESP systems for their fields and reservoirs.

Prerequisites

• Understanding of petroleum production concepts.

Course outline

• Pre-test
• Introduction
  • Artificial Lift: When / Why / What of Lift Mechanisms; Types
  • How ESP is the same as and different from other lift forms; relative market position
  • Well Life Cycles and hydraulic lift applicability vis-a-vis other lift methods
• Introduction to ESP Operations
  • ESP Basics
  • Advantages, Limitations and Operating Principle
  • System Components: Downhole and Surface
• Well Inflow Performance
  • The Productivity Index Concept
  • Inflow Performance Relationships (Class Problem)
• Hydraulic Fundamentals
  • Tubing Flow Calculations (Class Problem)
  • Operational Basics of Centrifugal Pumps (Class Problem)
• Electrical Fundamentals
  • Alternating Current
  • Transformers
  • Induction Motors
  • Electric Cables
• Application of NODAL Analysis
  • Basic Principles
  • Systems/NODAL Analysis
  • Reservoir Performance
  • Vertical Lift Performance
  • Total Dynamic Head (TDH)
• ESP Components and Their Operational Features
  • The ESP Pump
    • Performance Curves and their Use
    • Pump Types
  • The ESP Motor
    • Performance Curves, Startup Conditions
    • Motor Temperature Calculations
  • Protectors (Seal Sections)
    • Functions, Types, and Main Parts
  • The ESP Cable: Materials, Constructions and Features
  • Other Surface and Downhole Components
• ESP Installation Design
  • Design and Optimization
    • Pump Curve
    • Affinity Laws
    • Equipment Selection and Sizing
    • VSD Application Concepts
• Use of ESP Equipment in Special Conditions
  • Pumping Viscous Fluids (Class Problem)
  • Producing Wells with High GLRs
    • Free Gas Volume Calculations (Class Problem)
    • Pump Performance Degradation
    • Utilization of Natural Gas Separation
    • Rotary Gas Separators
    • Gas Handling
    • Use of Motor Shrouds
  • High Well Temperature
  • ESP Systems for Abrasive Service
  • ESP Challenges in Unconventional Wells
    • Lessons from Unconventional Fields
• Variable Speed Applications
  • Variable Speed Drives
    • Constructional Details
    • Available VSD Types
  • Operational Characteristics
  • Variable Frequency Generators
  • Interaction of VSD/VFG and ESP Units (Class Problem)
  • Benefits of using VSD/VFG Units
• ESP Operations
  • Role of Real-Time Measurements and SCADA Applications
  • Challenging Applications and Mitigation Approaches
  • Importance of ESP Reliability and DIFA (Dismantle Inspection Failure Analysis)
  • ESP Lift Lifecycle
• Advances in ESP and Emerging Applications
  • Permanent Magnet Motors
  • Wireline and Coiled Tubing Deployed Systems
  • High-Temperature and High-Viscosity Applications
  • Ultra-High-Speed Applications
• Digital Oil Field in ESP
• ML/AI ESP Application Review
• Post-test

Formats and customization

• In-person (ESP using NODAL Analysis variant): 5 days.
• Virtual (Advanced Artificial Lifting with ESP variant): taught using MS Teams (arranged by the instructor) over 4 sessions, each of 6 hours, over four consecutive days. Alternatively, it could be taught over 6 sessions of 4 hours or 8 sessions of 3 hours each.
• Course level: Intermediate to Advanced.
• Software: PROSPER software package is used to demonstrate the effective use of NODAL analysis.
• Option: Client’s real-time system-based workflows and examples can be incorporated in the class discussions. Requires two days of consulting and access to the client system at least 4 weeks before the class.

Request this course in-house