Spring-2024

Part- 2

Production Engineering Design #2

PE473

Instructor :
Tarek . N . A . Daw
Production Operations & Workover Engineer Specialist
 Typical ESP Installation ?
 The ESP- unit is run on tubing string and is submersed in
well fluids.
 The electric submersible Motor is at the bottom of the unit,
it is connected to the Protector (seal section).
 On top of the protector a Pump Intake or Gas Separator is
situated which allows well fluids to enter the Centrifugal
Pump that is located at the top of the ESP string.
 The submersible motor is supplied with three-phase AC
current via an Electric Cable running from the surface all
along the tubing string.
 Produced fluids flow through the tubing string to the
surface, where a special Wellhead ensures feeding of the
electric cable into the surface.
 A Junction Box connects the down-hole and surface electric
cables and a control unit called Switchboard that provides
measurement and control functions.
 The ESP unit is powered by AC electricity from a set of
Transformers which supply the required voltage by stepping
up or down the voltage available from the surface electric
network. But it can be provided by a portable engine
generator unit. T.N.Daw
 Course Objectives

1- List the major components of surface & sub-surface of an ESP system.

2- Overview of accessory equipment and each components function.
3- Completely understand ESP performance curves.
4- Explain the causes & remedies of ESP failures.
5- Understand TDH & the head-volume relationship.
6- Describe how the pumping unit operates.

T.N.Daw
Typical ESP Installation ? Switch Board or Power Source
(VSD)
Junction
(Vent) Box Power Cable Transformer

15 feet- min 35 feet -min

 In continuous ESP pumping operations system,

The electric energy is transported to the down hole
electric motor through the electric cable.
 The cable is attached to the production tubing and
provide the electrical energy needed to start the
down-hole electric motor to drive the pump and
the pump imparts energy to the fluid in the form of
hydraulic power, which lifts the fluid to the surface.
T.N.Daw
 Typical ESP Installation ?
 The ESP- unit is run on tubing string and is submersed in
well fluids. Power
Cable
 The electric submersible Motor is at the bottom of the unit,
Check
it is connected to the Protector (seal section). Valve
Bleeder
 On top of the protector a Pump Intake or Gas Separator is Valve

situated which allows well fluids to enter the Centrifugal

Pump that is located at the top of the ESP string.
 The submersible motor is supplied with three-phase AC Pump Pump
current via an Electric Cable running from the surface all Intake
along the tubing string.
 Produced fluids flow through the tubing string to the surface,
where a special Wellhead ensures feeding of the electric Protector
cable into the surface.
 A Junction Box connects the down-hole and surface electric Sensor
cables and a control unit called Switchboard that provides Motor
measurement and control functions.
 The ESP unit is powered by AC electricity from a set of
Transformers which supply the required voltage by stepping
up or down the voltage available from the surface electric
network. But it can be provided by a portable engine
generator unit. T.N.Daw
 Attentions for ESP Operated

 The annulus is open to atmosphere for gas venting.

 Special well head is required for cable sealing.
 Power cable protection is very important.
 Motor cooling must be adequate.
 The tubing size must be adequate to handle large
volumes with minimum backpressure on the pump.

T.N.Daw
 How the ESP Unit works ?

 When the ESP is started it draws the required voltage

from the source.

 This powers generates pump and motor thus rotation.

 As the fluid comes into the well through the
perforations it passes by the motor and into the
pump. This fluid flowing past the motor brings
about a natural cooling process, critical for long
and efficient motor life. The fluid then enters the
intake and is taken into the centrifugal pump.
 Each stage (impeller/diffuser combination) adds
pressure or head to the fluid at a given rate.
 The fluid will build up enough pressure as it reaches
the top of the pump to lift it to the surface and
into the separator .
The"standard“ ESP-Unit configuration requires motor to be set above the
perforations, in such a way that the well fluid moves up-ward around the motor
housing allowing excess heat generated to be dissipated in the produced fluid.
GL Pressure
SFL

DFL

Gas
Submergence Depth
(FOP)

Depth
Pump Setting
Depth

Pwf Pr
Where Set The ESP-Pump Suction ? ∆Pr
 Set the pump below perforation maximises potential draw dawn
(increase production). And provide max. area for gas separation.

GL Pressure
SFL

DFL

Gas
Submergence Depth
(FOP)

Depth
Pwf Pr

∆Pr

Reservoir
Fluid Where Set The ESP-Pump Suction ?
 ESP System Application
Constraints Typical Range Maximum
Operating Depth 1,000’ - 10,000’ TVD 15,000’ TVD

Operating Volume 200 - 20,000 BPD 60,000 BPD

Operating Temperature 100° - 275° F 400° F

Wellbore Deviation 10° 0 - 90°

Corrosion Handling Good
Gas Handling Poor to Fair
Solids Handling Poor to Fair
Fluid Gravity >10° API
Servicing Workover Rig
Prime Mover Type Electric Submersible Motor
Offshore Application Excellent
10
System Efficiency 35%-60% depending on pump type, fluid volume
 Advantages Of ESP Pump

Suitable (Adaptable) for all Wells With above 5” Casing and high
water cut.

High Volume and Depth Capability.

Minor Surface Equipment Needs.

Simple to design, operate and low maintenance.

Can be used in horizontal and deviated wells, but must be set in

straight section .
Spring-2024
Part- 2
 Dis-advantages Of ESP Pump
Only applicable with high voltage electric power.
Repair of ESP equipment in oilfield conditions is difficult.
Faulty equipment must be sent to the manufacturer’s repair shop.

Expensive to change equipment to match declining well

productivity.
The use of VSD can eliminate most of these problems but at an extra cost

Gas, sand and solids production are restrict capacity and

operating efficiency.
Not suitable to deep and high temperature oil reservoirs, any
type of survey test can be conducted only through ( Y-Tool ).
Costly to install ESP systems have higher horsepower, tubing has
to be pulled to replace pump (need Workover rig, cost of rig time).
 ESP System Limitations

(Temperature at pump seating depth)

Cable insulation weakens and will limit the life of the thrust
bearing.
(Production casing / liners)
Are required fit with pumping unit to avoid damage cable and good
result for fluid velocity (Motor cooling).

(Free gas in oil)

Excessive free gas results in pump cavitation that leads to motor
fluctuations and reduces run life and reliability.
(Viscosity of oil)
Reduces the total head that the pump system can generate, which
leads to an increased number of pump stages and horsepower
requirements (high cost ). T.N.Daw
 ESP Surface Components

The Electric Power Supply ( High Line or Generator )

The Electric Transformer.

The Control Switchboard or VSD (Motor controller ).

The Junction (Vent) Box.

The Well Head Assembly.

Spring-2024
Part- 2
Electric Power Supply
(High Line 11 kv)

Spring-2024
Part- 2 15
 Fuel Tank

Electric
Generator
Set-up Transformer
700 KVA
Spring-2024
Part- 2 16
 Electric Transformer

 The transformer sends the correct

desired surface operating voltage to the
switch board.
 The propose of the transformer is to
provide correct surface voltage to
proper submersible motor operation
by changing electric power from a high
voltage to low (Down-stepping).
 Or from a low voltage to high (Up-step).
 This based on power rating in KVA.

Spring-2024
Part- 2
 Control Switch Board (Fixed Speed Drive) Status Lights

Switch Board Selected by voltage & HP Uniconn

values for the motor pump. Multisensor

What does a Switch board Do ??

- Power Supply Of ESP Unit.

(provide accurate current & voltage for the motor).
- Protection Of ESP Unit ( monitors) :-
a- The running current (Overload & Under load). Main Switch
b- The voltage(Over volt & Under volt).
c- The frequency.

- Control of ESP Unit (Motor starter ).

Ammeter Chart Recorder
- Diagnostics Of ESP Unit. (Pump & Motor Performance)
T.N.Daw
 Status lights

Potential
Transformer
Start button

 Used to step-down
Hand/Off/Auto the high voltage to
120 volt.
 120 volt used to run
all the control circuit
Ammeter
in switchboard.
Record

Backspin Relay Power Fuses

Fuse Block
Current
Transformer

Under load protection Over load protection

(Motor shuts down) to (Motor shuts down)to
prevent motor damage. prevent motor burn 19
 High Line

Transformer

Switch Board
Spring-2024
Part- 2
 Control Power Skid
(Switch Board)

Generator Switch Board

Transformer
21
 Variable Speed Drive (VSD)

Introduction:
An ESP-system can be operated by using power supply with fixed
(speed) frequency 50 or 60 Hz or using a VSD which is used to
change the fixed frequency to other frequencies (record by SCADA).

What does a VSD Do ??

• It allow to adjustments the pump capacity ( BEP )by changeable the

motor speed ( RPM ) to achieve best run life.
• As the pump wears, the speed can be adjusted to maintain
production (WOR, GOR, Pr,….etc) are not stabilized.

• To minimize operational costs and maximize run life.

22
Control Power Skid (VSD) Satellite

Set-up Transformer VSD

700 KVA
23
 Variable Speed Drive Operation

ESPs may also be run at variable speeds.

Changing the speed or frequency of an ESP
system.
“Affinity Laws”

 New.Hz 
New. flow  Old . flow
 Old .Hz 

2
 New.Hz 
New.head  Old .head 
 Old .Hz 

3
 New.Hz 
New.Break.HP  Old .Break.HP 
 Old .Hz 
24
 Junction (Vent) Box
Located between the well head & switch board for safety reasons.

What does a Junction Box Do ??

1-To provide an electrical connection between surface and down hole

cables.

2- Provides a vent to the atmosphere for any Free gas that might
migrate through the power cable into switchboard to avoid sparks
(separates the surface cable from the down-hole cable).

3- Test point to change the motor rotation.

4-Test point for electrically checking the ESP – down-hole equipment.

Spring-2024
Part- 2
A junction (Vent) Box
will preventing gas
migration through the
power cable into
control switchboard.

Power Cable
Power Cable (From Switch Board)
(To Wellhead)

26
 Hole Vents
Terminal Strips

eliminates the danger

of fire or explosion,
since the gas does not
reach the
Three- Phase switchboard.

Power Cable
(From Switch Board)

Junction (Vent) Box Spring-2024

Part- 2 27
 ESP- Well Head
The ESP- wellhead is to maintain tubular control, as well as providing a
positive seal around the cable and the tubing. There exist many
different wellheads, with different types. The Hercules wellhead feeds
the down-hole power cable directly through the wellhead. In other
wellheads, the power cable is cut and its end is equipped with a power
connector.
Power
Cable

Hercules ESP- Hercules Well Head

Well Head

T.N.Daw
ESP- Cosco Well Head

Fixed Choke

Upper pig tail

From Junction Box

Pressure
Switch
Tubing Head Check Valve 29
ESP- Cosco Well Head Tubing Upper
Hanger Bowel

Tubing Head
Seal
Element

Upper pig tail

From Junction Box

Production
Tubing

Adapter
(Spool)

Tubing
Hanger Seal
T.N.Daw Element
 Penetrator Tubing Hanger

O-Ring

Sub-Surface
Power Plug

Production
Tubing

ESP- Connector Well Head Spring-2024

31 Part- 2
32
 Junction
Box
Surface Choke

Pressure
Switch

High pressure acur our prevents pressure build up if

production flow line, valves and manifold station are
closed or plugged . In this case a max. pressure is set
in the switch at for example ( + or –300 psi) well head
Spring-2024
pressure which reading open the switch removing Part- 2 33
power from the control switch board .
 ESP- Well (Christmas Tree)
Pressure
Gauge

Kill Valve

Production
Loop

Adapter
(Spool)
Upper
pig tail

Check Valve

Spring-2024
Tubing Head Part- 2 34
 Pressure
Switch

Surface Choke

Pressure
Gauge

Spring-2024
Part- 2 35
ESP- Down Hole Equipment

Power Cable
Pump
discharge head

Centrifugal
Pump
Pump Intake or
(Gas Separator)

Electric
Protector
Motor
(Seal Section)

T.N.Daw
 ESP Centrifugal Pump
 Hangs from the production tubing.
 Lifts the fluid through the tubing to the surface.
 Is a multi-stage centrifugal or dynamic pump type,
operating in a vertical position driven by motor.
 The electric motor connects directly to the centrifugal
pump. This means that the electric motor shaft Pump
connects directly to the pump shaft by protector.
So, the pump rotates at the same speed as the electric
motor. Intake
 The stage Is constructed from rotating impellers and
stationary diffusers.
 To supplies energy (Kinetic) in the form of velocity by
rotation the fluid passing through it (impellers).
T.N.Daw
 Rotating
Impeller

Stationary
Diffuser

Impeller
The pump capacity (volume)
increases as the diameter of
the impeller increases. 38
 Convert the kinetic energy from the rotating shaft into centrifugal
forces to pressure (potential) energy (change the high velocity energy to
low velocity energy to direction the flow to next impeller) that lift well fluids
to surface and raising discharge pressure (diffusers).

 There are two types of impeller designs.

 The type or Geometry of the stage controls the volume of fluid

production that can go through it.

 Number of stage determine the total dynamic head ( TDH )

generated and the motor horsepower required.
 The pumps can be connected together to create more lifting
pressure. (Tandem Pump)

 The range of pump stages between 10 and more than 100

(depending on the pressure increase required).
T.N.Daw
 Stationary
Diffuser

Rotating
Impeller

Pump
Shaft

Pump
Pump Stage Housing
Stages are set in series a long an axial shaft
and compressed in a housing, increase the
pressure of produced fluid and drive by the
submergible electric motor.
T.N.Daw
 Impeller Geometries

Mixed flow Impeller Radial flow Impeller

A mixed flow impeller (The flow going A radial flow impeller (The flow going
from impeller and go 45 degree to the from impeller and go 90 degree to the
shaft) and give more head. shaft) and give less head.
Usually found in pumps designed for Usually found in pumps designed for
higher flow rates (>1,700 bpd). lower flow rates (<1,200 bpd).

Fluid flow path in

a "mixed flow Spring-2024
Part- 2
impeller"
 ESP Standard Pump Intake (BOI)

 Where the well fluid enters the pump

and is directed into the impellers.
 Different types of intakes are used
depending on fluid properties.
Screen
 BOI is simply a perforated tube with
a shaft connection between pump and
protector
 Is screened to block large particles that
would damage internal pump
components.
 Designs do not separate gas.
 Using in wells that produce low GLR.
Pump Intake  Transmits torque from seal section
(BOI) (Protector) to pump.
T.N.Daw
 ESP Gas Separator
Introduction:
 When free gas (Slug Flow) enters the pump section, the pumps
performance is reduced. This is caused by the big difference in the
specific gravities of liquids and gases. The existence of free gas at
pump suction conditions, pressure and temperature affects the
ESP pump in several ways:

 The head developed by the pump decreases.

 When producing gassy fluids, cavitation can occur at higher flow

rates causing mechanical damage of the pump stages.

 When producing with very high gas rates, gas locking may occur
when no pumping is taking place.
 In case the GLR high and low BHP, the well fluid contain amount
of free gas. This effect on pump performance, the intake replaced
by a gas separator.

 Gas separator designed to separate any free gas in liquid before

enter to the pump.

 This minimizing the potential of gas locking.

Gas separator do not used when install Hydo-Paker.

(Where is the gas will be go ?? )
Gas separator types include:
 Reverse Flow ( Vortex ).

 Rotary (Dynamic ).

 Advanced Gas Handle ( AGH ).

 Poseidon Multi-Phase Pump (MPP).

44
 Well Fluids Gas Bubbles
to pump
Ledges
Drive Shaft
Perforations

Separator Tube

Well Fluids
Screw
Impeller

Protector
Drive Shaft

Reverse Flow - Gas Separator 45

Rotary Gas Separator Pump

Oil, water
mixture

Free
Gas

Centrifugal
Force

Oil, water &

Gas mixture

Screen 46
 What Can We Do About Gas ?

Options Available
 Avoid It → -Increase Pump Seating Depth.
- Used Mixed Flow Impeller.

 Separate It → -Install Gas Separator.

( Rotary or Reverse)

 Handle It → -Multi-Van Pump (MVP)

- Advanced Gas Handle (AGH)

 The AGH does not separate gas - but conditions it by

compressing the total fluid, So it can be produced by the pump.
47
 ESP Protector (Seal Section)
 The main purpose is to protect the submersible motor,
is located between the pump and motor.

 Transfers the motor torque (Rotary Motion) to the pump shaft.

 Filled with (Di-electric oil) that create a pressure

equalizing between motor oil (internal pressure) and
well bore pressure. Protector

 Provides area for thermal expansion and contraction of

the motor oil.

 Provides the absorbs for any (Up or Down axial thrust load)
that transfers through pump shaft. (Pump thrust bearing)

 Isolates the well fluid from the clean motor oil (protect
the electric motor from damage). T.N.Daw
 Protector
Drive Shaft

Coupling
Coupling

Motor
Drive Shaft

Autumn-2023
Part- 2 49
 Mineral oil circulation
from Motor to Protector
Mechanical
Drive Shaft Seal

Thrust
Bearing
Di-Electric
Oil

Electric
Motor

MLC
Motor Thrust
bearing 50
T.N.Daw
Labyrinth chamber
(66L)
Mechanical
Seal
Head

Housing

Drive
Shaft
Thrust
Bearing

Base
51
 Protector Types
Motor
Drive Shaft
 Labyrinth chamber (66L)

 Positive Seal chamber

(Elastomer Bag ).

 The advantages of a
bag type over the
Labyrinth type is that
can be used in highly
deviated wells
Motor Thrust Bearing application.
is installed at the top of the
rotor string and carry the
load of the motors rotors. T.N.Daw
 ESP Submersible Electric Motor
 Its providing the HP (10 -750) & 10 -100 A , 230-5000 V
necessary to turn the pump.
 The motors can be run tandem to create more HP.
 3400 to 3500 RPM @ 60 HZ (North America)
2850 to 2950 RPM @ 50 HZ (Europe).
 Is made-up of rotating part (Rotor) and stationary part
(Stator). Non-conductive
 The motor is filled with a mineral (Di-electric) oil that
has a specific gravity between 0.8 and 0.83 for
lubrication, insulation and cooling. Motor

 The minimum fluid velocity of 1.0 ft/sec is recommended for

cooling the motor.
 The motor is manufactured in four different diameters
3.75, 4.56, 5.40 and 7.38 inches. T.N.Daw
 Rotor
(rotating part)
Copper
Usually about 12 – 18” long
Ring
located in an electric field
generated by the stator

Housing
Cover for the motor and
is threaded at both ends
for head & base

Windings

Stator Motor Drive Shaft

(stationary part)
T.N.Daw
Radial Bearing Mechanical Seal

Bearing
between Rotors
T.N.Daw
 Electric Motor Cooling & Lubrication

Cooling:
 Electric motor require fluid flowing through the surface to reduce the operating
temperature (prevent motor from overheating).
 The motor is cooled by heat transfer from the motor housing to the well-bore fluid.
 To accomplish adequate cooling, a fluid velocity past the motor of one ft/sec.
 For this reason, submercible pumping units should be set above the perforations
zone, So all reservoir fluid must pass by the motor.

Lubrication:
 The motor oil circulates up the hollow motor shaft, out on the rotor bearing,
down the rotor stator gap and through a filter at eye base of the shaft.

Di-Electrical Oil:
1- To prevent short circuits between motor parts (isolate motor electrically).
2- Proper lubrication for the bearings & drive shaft.
3- To transferring the heat generated from motor to the outside of the housing in
the wellbore.
4- Dissipates the heat that generated from bearings. T.N.Daw
Motor Size
The motor size depends on casing size & fluid velocity.

Motor Cooling
Reservoir fluid flowing past
the motor provides cooling
essential for submersible
operation.

 In order to have some cooling,

I need motor temperature is
Motor
go-out from this area . Temperature
We need the fluid which pass generated
around the motor to carry hot
fluid temperature to go-up and
compensate with another fluid Bottom hole Fluid
from the formation. Temperature
T.N.Daw
 ESP Electric Motor Cooling
Annular velocity equation used to determine fluid velocity around
the motor.

 Q 
 0.0119x 
V

ft 

 sec 
 
 IDC  OD M 
2 2

Where;
V = annular velocity, ft/sec.
Electric
Q = well flow rate, BBL/Days.
Motor ODM
IDc = casing inside diameter (inches).
ODm = Motor Outside diameter (inches).
The above Equation From ( Graft, Holden and Graves )
IDc
 Quantity.Disch arg e 
Cooling.Flow   
 Ring .Space 
58
 Fluid Velocity Past Motor-Chart

1-0 ft/sec
ROT

Fluid Velocity
ft/sec

Flow Rate
59
B/D
Example:-

CASING = 7” OD , 23 Lb/ft , 6.366” ID , N-80

MOTOR = 450 Series (OD) = 4.5”
Flow Rate = 2200 B/D
What is the fluid velocity passing to the motor?
Solution

 2200 
 0.0119x 
V

ft 

 sec   
6.3662
 4.5 
2 


V  1 .3 ft
sec

* This velocity adequate for cooling the motor

60
 ESP Power Cable
 The electric power is transmitted current from the switch board at
the surface down to electric motor housing through Three Conductor
electric cable at the Pothead.
 Especially designed for oil field application.
 Power cable is a available in three voltage ratings 3000, 4000 and
5000 volt & different conductor sizes #1, #2, #4.
 Is constructed of three insulated , jacketed, conductor copper
wires. contained by metal armor (outer material).
 Proper applications must address electrical ( Volt & Amp), physical
size, H2s and operating temperature requirements.
 Cable is available in round and flat styles & must have small
enough diameter to fit in the annulus along the well tubing.
 Depending on the type of insulation used cables may be installed
in oil wells with temperatures in excess of 300 F.

 Is strapped or banded to the out side of production tubing by

cable bands at the middle of the joint and below the tubing collar
at steady intervals (2 bands /Jts) to prevent mechanical damage
during running & pull out of hole in workover.

 Penetrates the well head by special Tubing Hanger.

Upper Connection
From Junction Box

Lower
Connection
From Motor

Tubing Cable Bands

Hanger 62
Motor Lead
Cable (MLC)

Cable Bands

Spring-2024
Part- 2
 Flat Cable
Construction

Armor Conductor
Jacket Insulation

Round Cable
Construction
 Types: Black Steel - Stainless Steel - Monel armor
 Cable is selected based on (well fluid properties & BHT),
 Size of cable depended on ( A, V, HP & space between tubing collar and casing).
T.N.Daw
 Cable Armor
• Protect cable from mechanical damage.
• Protection for corrosive oil wells.
•Armor is available in different material s
( stainless steel, Galvanized and Monel).

Flat Cable
needs less radial distance
but are more expensive
than the round.

Flat Cable Round Cable

Used where clearance Used where clearance
between casing & tubing between casing & tubing
collars is a problem. collars is not problem.
 Real Flat
Cable

Cable
Spooler

Spring-2024
Part- 2 66
 ESP Motor Lead Cable
(MLC)

Poth head

MLC (FCE) →Is the part of the ESP main cable running along the ESP
unit and is directly connected to the motor pothead. 67
Motor Lead
Cable

Poth head

Spring-2024
Part- 2
Reda Lead: 400-450°F (203-232°C) Reda Black: 300-400°F (149-204°C)

Stranded
Conductor

Armor

Lead
Solid
Conductor

Jacket
69
Tape
Reda Hot: 250-350°F (121-177°C) Reda Lene: 205°F (96°C)

70
 Sleeves

Lead Insulation
Rubber Insulation

Cable Splicing
We performed splicing to connect two different type of cable
(Flat or round) by a pump company serviceman.
T.N.Daw
 ESP Standard & Optional Installations
(Miscellaneous Equipment)

► Check Valve.  Motor Shrouded.

► Bleeder (Drain) Valve.  Centralizer.

► Y-Tool.  Down Hole Desander.

► Down Hole Sensor.  Twin Seal Packer (Hydro ll).

Spring-2024
Part- 2
Introduction:
 When the motor is switched off .
 The head of fluid present in the tubing will reverse the flow direction
through the pump as it flows back into the well bore .
 This will cause the motor to turn backwards.
 Trying to restart the motor while it is rotating backwards will lead to the
motor burning out very quickly. This can be avoided by installing a check
valve in the tubing.
 Or using a sensor to detect backspin and preventing motor restart.
 It is located 2-3 joints above the pump Check Valve
assembly. (For Gassy oil wells) The C.V
should be installed from 7-8 Joints above
the pump. Disc

 To prevent the pumped fluid from flowing

back down during shutdown.(Reverse
Rotation).
 prevents any solids in the produced fluid 1- Swing 2- Ball
3- Spring 4- Disc .
from setting back into the pump.
Introduction:
 When check valve is used in tubing string, it is necessary to install a Drain valve
immediately above the C.V .
 If C.V is not run and the well has no Sand problem, then No reason to run B.V , as
the produced fluid in the tubing will drain through the pump intake while pulling.

 It is located 2-3 joints above the check

Shear Pin
valve.
 To pull out the pumping unit with tubing
empty.
 Nneedle sheers by a steel bar (Sinker bar)
prior to pulling pumping during workover
operations.

Bleeder (Drain)
Valve
T.N.Daw
 Bolt-on-head
Shear Pin

Check & Drain Valve

Drain Valve
Check Valve

T.N.Daw
 Backspin Relay
When plugging of ESP unit with scale, sand
and we cleaning by pumping down chemical
would be impossible because the check
valve installed on the tubing string.
During the ESP is shutdown the fluid flowing
turns the pump and motor in the wrong
direction .
Check Valve
Power generation from motor is detected by
the backspin relay and controller prevents
restarting the ESP unit.
 ESP- Y-Tool (By-pass)

Is a device to allow wire line or coiled tubing access below the ESP unit.

Install CV above
the Bolt on head 1- Running pressure and temperature
survey tool by using wire line tool

2- Running well logging or coiled

Blanking
Plug
tubing tool.
3- Can be also used for installing two
parallel ESPs in the well.

4- Running down hole sampling.

.
This by-pass tubing plugged
when the pump running. 77
Pump
Head

Spring-2024
Part- 2 78
 ESP- Y-Tool
needs a blanking plug to
provide a seal while ESP
is running

Y- Tool
Balking Plug

79
 By-pass
Tubing

Clamps

Re-Entry
Guide
Cable
Pocket

80
 ESP Down hole Multi-Sensors

The Down-hole sensor is located below the motor and transmits

important well and system data by the main power cable to the
surface. Down hole sensors measure well parameters and provide
critical data to increase ESP system efficiency and reliability.

Measures Type 0 Type 1 Type 2

Pump Intake Pressure, PIP Yes Yes Yes

Pump Discharge Pressure, PDP No Yes Yes

Fluid Intake Temp, Ti Yes Yes Yes

Electric Motor Temp, Tm Yes Yes Yes

Flow Rate, q No No Yes

Motor Vibration, Vib Yes Yes Yes

Control Line

82
 Discharge- Sub

Connect with
Control Line

83
 Multi Sensor
connect with
Motor

Uniconn
Multisensor
84
 Control Line
connect to
Discharge Sub

Discharge
Sub Universal Motor Base
(UMB)
It is connected at the
end of motor to close
the sensor connection

Spring-2024
Part- 2
 Down hole Multi-Sensors

What Can We Do From Multi-Sensor Data…?

 Increased Production.( Monitoring )

To Optimized ESP Performance.

(use the analysis result for optimization)

To Identification Of Pump Wear.

( Protection )
The time between date
To Increased Pump Run Life. put on production and
date failure.
(Result)
 ESP- Multi-Sensors Output Data

Time Pi Pd Ti Tm Vib Cl

9:56:34 3029 4414 125.6 133.8 0.23 0.1

9:56:55 3027 4426 125.8 134 0.253 0.102

9:57:16 3026 4410 125.8 134.1 0.249 0.105

9:57:36 3031 4418 125.5 133.8 0.24 0.101

9:57:57 3024 4408 125.8 134 0.231 0.105

9:58:17 3023 4404 125.5 133.8 0.246 0.102

9:58:38 3033 4420 125.8 134.1 0.251 0.099

9:58:58 3029 4410 125.6 134 0.262 0.096

87
 ESP- Motor Shrouded

 Motor Shroud is a short sections of pipe around the length of the

ESP unit (that is bolted on the pump intake or gas separator and
covers with protector and motor).
 Motor Shroud Can not be used in casing smaller than 5 ½” OD.

 Directs fluid past the motor for cooling when fluid velocity is low
(below minimum range).

 Allows pumps to be set below perforations .

 Reducing the annular area between the motor and production

casing (larger annular clearances).
T.N.Daw
ESP- Motor Shrouded Configuration

Top
Shroud

Motor
Shroud

T.N.Daw
 Gas
Shroud
separation
Housing
Out let
Slips
7” (Twin-Seal) Hydrow II ESP- PKR

91