ESP Design and Troubleshooting

Training Hours        

25 Training Hours (9:00 AM to 2:00 PM daily)

Specific Learning Objectives:

1.     Analyze Well Performance: Calculate the required pump head and flow rate by integrating the well's Inflow Performance Relationship (IPR) and Vertical Lift Performance (VLP).

2.     Select Components: Accurately size the pump stages, select the appropriate motor and cable type, and specify surface equipment for a given well application (e.g., high GOR, high temperature, corrosive fluids).

3.     Evaluate Pump Performance: Interpret pump curves (Head vs. Flow, Efficiency vs. Flow, Power vs. Flow) and adjust system parameters for optimal efficiency.

4.     Identify Failure Causes: Diagnose ESP failures based on teardown reports and operational data (e.g., identifying causes like surging, gas locking, or electrical fault).

5.     Troubleshoot Operation: Apply logical troubleshooting techniques using protection relay alarms, motor current, and voltage readings to identify the root cause of an underperforming or failed ESP system.

Course Content (Outline):

Day 1 – ESP Fundamentals and Well Performance Analysis

·       ESP System Overview: Components (Pump, Intake, Protector, Motor, Cable, Surface Equipment) and operational principles.

·       Well Performance Review: Understanding IPR, VLP, and their integration for artificial lift.

·       Required Pump Head: Calculation of Total Dynamic Head (TDH) based on desired flow rate and fluid properties.

·       Gas Handling: Effects of free gas on pump performance (gas locking, surging) and introduction to gas handlers.

Day 2 – Pump and Intake Selection & Sizing

·       Pump Curves Interpretation: Analyzing H-Q, $\eta$-Q, and P-Q curves; understanding the operating range.

·       Sizing the Pump: Determining the number of stages and selecting the correct pump series based on TDH and target rate.

·       Intake and Separators: Selection of the correct intake, gas separators, and gas handlers for high gas volume fraction (GVF) applications.

·       Protector/Seal Section: Functions (thrust bearing, pressure equalization) and types (labyrinth, bag type).

Day 3 – Motor, Cable, and Surface Equipment Sizing

·       Motor Sizing: Calculating required motor horsepower (HP) and selecting the motor based on temperature limits and thrust load.

·       Electrical Systems: Understanding three-phase power, voltage drop, and electrical balance.

·       Power Cable Selection: Types of cables (Round vs. Flat), sizing based on current, voltage drop, and temperature derating.

·       Surface Equipment: Functions of the Variable Speed Drive (VSD/VFD) and switchboard. VSD programming and protection settings.

Day 4 – ESP Installation, Monitoring, and Failure Analysis

·       Installation Best Practices: Downhole setting depth, proper handling, and cable securing procedures.

·       Monitoring and Control: Using downhole gauges (pressure/temperature) and surface monitoring systems.

·       Data Analysis: Interpreting motor amps, voltage, and temperature trends for early warning signs of failure.

·       Failure Analysis: Review of common failure types (e.g., electrical, mechanical, wear) and interpreting Failure Analysis Reports (FAR).

Day 5 – Troubleshooting and Optimization Techniques

·       Troubleshooting Methodology: Step-by-step approach for diagnosing performance issues (low production, high amps, cycling).

·       Gas-Related Issues: Troubleshooting gas locking and techniques for recovery.

·       Electrical Troubleshooting: Identifying issues related to the cable, motor, or VSD using resistance and insulation tests.

·       Optimization: Using the VSD to adjust the operating frequency (speed) to match changing reservoir conditions and maintain peak efficiency.

·       Case Studies: Practical exercises using operational data logs to diagnose and recommend solutions for real-world ESP failures.