Electric Submersible Pumps: Control and Protection

Introduction

The Electric Submersible Pump System (ESP) is considered an effective and economical means of lifting large volumes of fluids from great depths under a variety of well conditions. Over the years, the ESP companies, in conjunction with the major oil companies, have gained considerable experience in producing high viscosity fluids, gassy wells, high-temperature wells, etc. With this experience and improved technology, wells that were once considered non-feasible for submersibles are now being pumped economically.

Electric Submersible Pumps (ESPs) are used in most global oil production operations. This training course is a complete package of topics that cover all aspects in relation to ESP; fundamental knowledge, equipment selection, installation, commissioning, operation monitoring, control, and maintenance.

In addition, this training course will familiarize the user with the ESP system and its application by; a detailed description of components and design features analysis. Recent innovations in ESP technology will also be presented and discussed so that the delegates are updated with current developments in the ESP industry.

Objectives

Provide theoretical and practical knowledge of the advantages and limitations of the Electric Submersible Pumps in order to develop the required skills to design, optimize, and diagnose wells producing with Electric Submersible Pumps.

You, Will, Learn How To:

• Using below learned subjects and course components, maximize oil production using ESP Systems
• Identify components of the ESP system
• Learn about the different types of ESP systems and their specific applications
• Understand the components and equipment used with ESP
• Be aware of the innovations in ESP pump technology
• Selection of proper ESPs for specific purposes
• Carry out ESP performance calculations
• List the advantages and limitations of various ESP drive systems
• Outline the power supply requirements of ESP installations
• Maintain and troubleshoot ESP systems
• Design and analyze a system using up to date computer programs
• Implement best practices for longer system life
• Improve the power efficiency of the system
• Combat gas, solids, corrosion, and viscosity in the produced fluids
• Compare to other artificial lift methods

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This training course is tailored to provide practical and detailed insight for professionals who actually involved in the; selection, installation, operation, and maintenance of ESP.

This training course is suitable for a wide range of professionals but will greatly benefit:

• Design and maintenance professionals
• Petroleum, chemical, and mechanical engineers
• Electrical engineers
• Field operators and technicians
• Maintenance engineers and personnel

Course Outline

Day 1: Fundamentals and Applications of ESP

•  Historical review of ESPs
• Definitions and basic terminology
• Introduction to ESPs and ESP Systems
• Challenges for ESP applications
• Requirements for mainstream ESPs (pump design, electric motor, cabling and connections, motor control, associated components)
• Various ESP types (inverted/bottom intake, inverted/ bottom discharge, dual and triple, booster ESP, tubing, conveyed ESP)
• Application of ESPs (challenges for ESP, on-shore applications, off-shore applications, multiphase fluids, viscous fluids, emulsions, applications with abrasive contaminants, high temperature and high applications, corrosive substances)

Day 2: ESP Pump Technology and Equipment used with ESP

• Evolving ESP pump technology
• Improving pump design
• Down-hole monitoring
• Surface control
• Expanding the realm of applications
• Improving well performance
• Components and equipment used with ESP
• Download sensors (pump intake and discharge pressures, internal motor temperature, download flow rate, equipment vibration)
• ESP packers (anti preset, high boost, lockout, anti-drug)
• ESP wellheads (low pressure, high pressure)
• Centralizer
• Check/ drain tubing (check and drain valves)
• Motor shroud/recirculation systems
• Screens and filters
• Y-tool or by-pass

Day 3: ESP System Performance Calculations and Equipment Sizing

• Basic requirements from ESP
• Well production capacity
• Fluid composition and volume, including the volume of free gas
• Dynamic head calculation
• Optimization of; pump type, motor type, and size of pump and motor
• Downhole cable configuration and sizing
• Optimization of; drive systems, power supply, and accessories
• Variable speed drive (requirements, advantages, and disadvantages)
• ESP performance calculations
• Examples

Day 4: ESP Monitoring, Control, and Protection, Installation

• Downhole Monitoring and Sensors
• Embedded Fibre Optic Cable for Downhole Monitoring and Sensors
• Earthed (Grounded) and Unearthed (Ungrounded) ESP motors
• Earthing and Lightning Propagation in ESP Circuits
• Electrical Protection Equipment for ESPs
• SCADA/EMS (ESP Management System) for Local and Remote Installations
• Safety and Shut-Down Systems

Day 5: Commissioning, Operation, and Maintenance

• Commissioning requirements
• Commissioning procedures
• Regular safe operation
• Operation monitoring (detecting abnormal conditions)
• ESP Maintenance management (servicing equipment, well work-over rigs, cable reels, reel supports, cable guides)
• Troubleshooting ESP
• Case Studies (examples of ESP problems and failures)
• Factory Repair and Reconditioning