SPE-214713-MS

Enhancing Production from High-Enthalpy Geothermal Wells with New

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

Electric Submersible Pump Technology

M. Radov, SLB, Singapore Product Center, Singapore; Y. Hamitoglu, SLB, Ankara, Türkiye; E. Şentürk and M. K.
Tüzen, ZORLU Enerji, Denizli, Türkiye; J. L. Holzmueller, W. K. Goertzen, and V. Nyayadhish, SLB, Lawrence,
United States; O. S. Kulkarni, V. Amutha Nilavazhagan, J. Wu, P. Tan, and A. R. Rao, SLB, Singapore Product
Center, Singapore; A. T. Usta, SLB, Ankara, Türkiye

Copyright 2023, Society of Petroleum Engineers DOI 10.2118/214713-MS

This paper was prepared for presentation at the SPE Gulf Coast Section - Electric Submersible Pumps Symposium held in The Woodlands, Texas, USA, 2–6 October,
2023.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
This paper presents advancements in electrical submersible pump (ESP) technology that were specifically
designed for use in high-enthalpy geothermal wells. It discusses the unique challenges associated with
geothermal operations and highlights the opportunities offered by the new ESP technology to enhance
production from these wells. The paper also provides a comprehensive overview of the key components of
the ESP system, including the motor, protector, pump, power cable, motor lead extension, and downhole
sensors. The new ESP system demonstrates improved reliability, power density, and operational efficiency
by using high-efficiency permanent magnet motors, innovative encapsulation technologies, and optimized
pump designs. The paper also highlights the successful field trial of the newly developed geothermal ESP
in Kizildere Field that showcased its enhanced reliability and increased production in a high-temperature
environment. The findings from this trial have paved the way for the design and implementation of the
new ESP system in additional high-enthalpy wells, further expanding the application of ESP technology
to geothermal energy extraction. Overall, this paper underscores the transformative potential of ESP
technology in enhancing the use of geothermal resources for sustainable energy production.

Introduction
Geothermal fields often require pumping systems to achieve commercial production rates and pressures.
In lower- enthalpy fields, line-shaft pumps (LSPs) have traditionally been used to supply brine to binary
plants, while self- flowing production wells have been relied on in higher-enthalpy fields to power flash
plants. However, the use of LSPs is impractical in deviated wells because of the limited length of the pump
shafts. Additionally, the evaporation of a portion of the produced mass in flash geothermal power plants
can lead to declining reservoir pressures and reduced flow rates. Despite their historical use, the use of
LSPs poses significant challenges in geothermal applications. The maintenance and servicing of LSPs can
be complex and time-consuming, requiring frequent interventions and potential production disruptions.
2 SPE-214713-MS

Moreover, LSPs are often limited in terms of their depth capability, preventing their deployment in deep
geothermal wells where enhanced production potential could exist. These limitations have created a need
for innovative technologies to overcome the constraints associated with LSPs and optimize geothermal
production.
To address these challenges and enhance geothermal production, a new, innovative technology in the form
of ESPs has emerged. Unlike LSPs, ESPs can be installed in deviated wells, enabling continued production

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

from self-flowing geothermal wells and production in wells where flow has diminished as a result of pressure
depletion. This breakthrough in ESP technology provides a reliable and efficient solution for geothermal
operators, unlocking new opportunities for reservoir optimization and energy extraction.
During a recent field test conducted in Türkiye, six ESPs were successfully installed in high-enthalpy
geothermal wells, resulting in a remarkable boost in production rates. This successful deployment in Türkiye
states the immense potential of ESPs in enhancing geothermal production and rejuvenating reservoir
performance.
In the sections that follow, the design and components of the geothermal ESP will be presented,
highlighting its capabilities in operating at elevated temperatures of up to 240°C (437°F) and handling the
high flow rates typical of geothermal applications. In addition, the advantages of ESPs—including their
ability to optimize reservoir management, improve energy extraction efficiency, and reliably operate in
challenging geothermal environments— will also be discussed.

Introduction to ESP Technology

The issue of declining reservoir pressures has long been recognized in the oil industry. Approximately a
century ago, ESP was proposed as the most-effective solution to extract wellbore fluids from reservoirs with
depleted pressure. Today, approximately 50% of all oil wells worldwide use artificial lift methods to enhance
fluid extraction, with a substantial proportion of these wells using ESP technology. ESPs have become an
indispensable component in the drive to optimize production and prolong the operational life of oil wells.
An ESP system includes components both on the surface and within the wellbore (Fig. 1). Its design
specifications, including overall length and diameter, are contingent on the horsepower required to achieve
the target flow rate.
SPE-214713-MS 3

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

Figure 1—Principle downhole components of an ESP

The principal downhole components of an ESP are the pump, seal or protector, and motor. In some
cases, additional gas-handling devices can be included to manage specific quantities of noncondensable
gas. Moreover, downhole gauges can be installed for temperature and pressure measurements.
The pump, a multistage centrifugal device, features stacked stages. These stages are determined by the
well's operational needs and the completion design. Each stage comprises a stationary diffuser and a rotating
impeller, typically crafted from high-nickel iron. As fluid enters the first pump stage, its velocity is converted
into pressure, which incrementally increases (or lifts) in each stage until the total developed head (the
specified discharge pressure) is achieved, providing the fluid with the energy to reach the well's surface.
A seal or protector section is located between the pump intake and the motor. This component primarily
acts to prevent well fluids from entering the motor, where they could potentially trigger a failure. Moreover,
the protector absorbs the thrust generated by the pump, regardless of its direction, and transmits the motor
torque to the pump.
The pump is powered by a downhole submersible motor, typically an induction electric motor or a
permanent magnet motor (PMM), available from 50 to 2,000 hp. The motor's size is determined by the
power required to drive the pump and lift the required fluid volume out of the well. The motor is cooled
by the wellbore fluids passing over its housing.
Operators can install downhole sensors to continuously collect real-time system and reservoir data, such
as pump intake and discharge pressures and temperatures, vibration, and the current leakage rate. A real-
time surveillance service can be used to remotely monitor all the data using automated systems and human
expertise, enhancing ESP run time and offering continuous opportunities for parameter optimization to
ensure system reliability and maximized production.
Power is delivered from the surface to the motor via a specialized three-phase electrical cable designed
for downhole environments. This cable also carries the sensor data back to the surface. The cable comprises
multiple layers of materials suitable for the temperature and environment. It must pass through the wellhead
to connect to the surface power supply.
4 SPE-214713-MS

The motor lead extension (MLE) is where the electrical cable enters the motor. Historically, MLE has
been a frequent failure point, especially in high-temperature conditions, but this risk has been mitigated by
MLEs specially designed for extreme conditions.
ESP surface components include an electrical power supply system. In onshore oil and gas operations,
commercial power-distribution systems typically provide electricity. For geothermal projects, the power
plant usually supplies electricity, representing a parasitic load. Drives for the motor can be either fixed speed

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

or variable speed. Variable speed drives (VSDs) are particularly beneficial because they enable flexibility in
the flow rate because RPM adjustments can be made when required. The speed control provided by VSDs
enhances system efficiency and the ESP system's operational life while reducing downtime incidence. The
power quality of the latest-generation VSDs has been ensured through the inclusion of output sinewave
filters aimed at improving operational success and reliability. (Heninger et al, 2019)

Challenges and Solutions

Although ESPs are the most frequently used tool for extracting well fluids in the oil industry's artificial lift
sector, in geothermal applications, typical oilfield ESPs have limited applicability. The primary challenges
for ESPs in geothermal wells include;

• High temperatures in high-enthalpy geothermal wells: Typically, these range from 200 to 250°C
(392 to 482°F), conditions that necessitate equipment with exceptional thermal resilience.
• Specific chemical environment: Equipment with robust corrosion resistance is required, ensuring
the durability of operation in hot water.
• High flow rates (up to 1,000 tons per hour or more): This necessitates a pumping system with high
flow capacities to manage such substantial volumes.
• High motor power and high efficiency: Motors need to have capacities of 1,000 hp and more
to manage the high flow rates, and high efficiency to minimize power consumption for cost-
effectiveness and sustainability.
• High reliability: Downhole equipment should operate for 1 year or more without requiring
maintenance or replacement. This factor is essential to reducing operational interruptions and
maintaining production levels.
In the sections that follow, the identified challenges and their successful resolutions will be discussed
in detail.

High Temperatures
Historically, ESP development primarily catered to oil production, with a focus on low-temperature
operations, typically those under 150–160°C (302-320 °F). The run life of these traditional ESP systems
varies between 2 and 5 years, and it is affected by factors such as sand, gas, corrosive elements, and high-
viscosity fluids. High-reliability equipment, designed for offshore subsea applications, has demonstrated life
spans exceeding 5 years, and some of these ESPs have even run for up to 10 years. (Vasilache et al, 2021).
In geothermal applications, ESP systems have operated successfully at less than 150°C (302°F) for more
than 5 years (Lovekin et al, 2021). However, operating in temperatures greater than 150°C (302°F), becomes
challenging. Specifically, in the range of 170 (338°F) to 180°C (356°F), which is common in geothermal
applications, these challenges become even more pronounced. The life span of ESPs in this environment has
often been less than 2 years, leading to a problematic operational scenario that necessitated modifications
in ESP design.
High-temperature ESPs do exist in the oil industry; for example, those used in steam-assisted gravity
drainage (SAGD) applications can operate with fluid temperatures of 250°C (482°F). However, despite
their high-temperature design, these ESPs are still largely underutilized in geothermal applications. This
SPE-214713-MS 5

is primarily because these units typically have relatively low power, usually less than 300 hp, but the
geothermal industry requires greater submersible motor power to operate centrifugal pumps capable of
providing significantly higher fluid delivery, 1,000 tons per hour and more. Additionally, ESPs for SAGD
typically have designs optimized for reliable operation in horizontal wells, which are typical for SAGD
applications, while vertical wells are more common in geothermal applications. Nevertheless, the successful
use of these ESPs in high-temperature SAGD applications has demonstrated an opportunity to adapt certain

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

high-temperature solutions for a new ESP specifically designed for use in geothermal applications.
Thus, several key elements of the geothermal submersible system are based on proven ESP components
that have been successfully used in SAGD. To enhance the reliability of these elements, their designs
and materials have been optimized with the high-temperature geothermal well environment in mind. One
such component is the thrust bearing assembly. The SAGD ESPs use a highly reliable thrust bearing
assembly constructed of the most-durable materials available in the industry, capable of operating reliably
at very high temperatures. However, the downthrust from the pumps in SAGD is significantly lower than
that experienced in high-flow-rate geothermal centrifugal pumps. To address this issue, the design of the
protector and motor's thrust bearing sections was enhanced using innovative mechanical solutions.
Another critical component of the system that must withstand high temperatures is the rotary shaft seals.
The design for geothermal shaft seals is also based on those used in SAGD ESP applications, with further
enhancement of the mechanical design and modifications for high temperatures and geothermal specifics.
The geothermal ESP's protector uses shaft seals with metal bellows made of highly reliable materials with
high corrosion resistance and an extended service life. Metal bellows are also used in the protector to
compensate for the volume of motor oil that expands when heated, while conventional ESPs for the oil
industry use elastomer bags as oil expansion tanks in the protector. Although elastomer bags can be a reliable
technical solution for lower-temperature applications, for high-temperature geothermal wells, metal bellows
provide significantly improved reliability and service life.
Several technical challenges had to be addressed to ensure reliable operation of the submersible electric
motor in high- temperature geothermal wells:

• Efficient heat dissipation from the motor's stator winding because the motor's reliability heavily
depends on the insulating properties of the stator winding. The lower the winding temperature, the
more reliable the motor.
• The stability of the insulating materials of the stator winding, slot insulation, lead ends, MLE, and
cable. Because insulation materials tend to degrade under high-temperature conditions, a special
approach to the development of insulation materials and ESP electrical system units was required
to ensure long-term operation in geothermal applications.
• The rotor's sustained operation using permanent magnets. Rotors with rare-earth magnets, used in
PMMs, are sensitive to high temperatures and have a tendency to demagnetize in strong electrical
fields combined with elevated temperatures.
• The mechanical design of the entire system, taking into account factors such as the thermal
expansion of materials and differences in the thermal expansion coefficients of the system's mated
components. The ESP for geothermal applications is a high-power system with relatively large
dimensions. Accounting for changes in the geometric dimensions of the nodes over a wide range
of temperatures is an important factor in developing a reliable system.
Several types of submersible motor stators based on the type of stator slot filling are available:

• Stators in which the inner space of the slots is filled with lubricant fluid or motor oil.

• Varnished stators, in which the winding wires are covered with a special varnish that secures the
conductors inside the slot and fills part of the space in the slot.
6 SPE-214713-MS

• Encapsulated or compounded stators, in which all space inside the slot is completely filled with
a special encapsulant.
The efficiency of heat dissipation from the winding directly depends on the thermal conductivity of the
material filling the slot. The most effective technology in terms of heat dissipation is the encapsulation of
stators because the thermal conductivity coefficient of the encapsulation material is typically significantly
greater than the thermal conductivity of motor oil or varnish. However, for geothermal applications, it was

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

necessary to take into account specific requirements, such as the high temperature. As a result, a new,
proprietary encapsulation material and an encapsulation manufacturing process were developed. At the
same time, it was important to ensure the compatibility of the encapsulation material and the insulating
materials used for the stator winding and slot. The special encapsulation material and manufacturing process
developed for high-temperature geothermal motors, combined with specially developed and tested highly
reliable high-temperature insulation materials for slot insulation, provides an effective method to dissipate
heat generated in the stator winding wires. This ensures the lowest winding temperature and enables the
motor to deliver higher output power.
In addition to improving the thermal design of the engine, the encapsulation of the stator protects the stator
winding from the external environment. The motor is filled with a special oil, but in the unlikely event of well
fluid penetrating the motor, encapsulation can shield the winding from water impacts, reducing the effect of
winding insulation degradation resulting from the hydration process. This is particularly important because
prolonged contact with water or well fluid can result in serious damage to the electrical insulation, potentially
leading to motor failure. Hence, the proprietary encapsulation method provides additional protection and
enhances the overall reliability and operational longevity of the motor in challenging geothermal conditions.
To ensure reliable operation of the motor's electrical system under high-temperature conditions, optimal
combinations of materials for the motor's insulation, as well as the MLE and submersible cable, were used.
Insulation materials must exhibit high stability and maintain their insulating properties for a long time under
exposure to high voltages up to 5,000 V (root mean square) and high temperatures up to 300°C (572°F).
To confirm the reliability of the insulation system, each component of the system underwent thorough
qualification testing.
These tests involved exposing the insulation materials and system components to high voltages and
temperatures for extended periods of time and then assessing the performance and integrity of the insulation
materials and components following the test period. Rigorous testing ensures that the components are able to
withstand the harsh conditions they will encounter in geothermal applications, thereby helping to maintain
the reliability and longevity of the entire electrical system.
Special attention during the development of the system for geothermal applications was required to
design the rotor with permanent magnets. The primary technical challenge for rotors is to maintain their
stability under extreme temperatures and strong magnetic fields. Magnetic materials can demagnetize or
remagnetize under a combination of these two factors, especially over prolonged periods of exposure.
The problem of rotor demagnetization under the influence of high temperatures has been a subject of
serious study and required engineering efforts to overcome it. For the development of permanent-magnet
rotors for geothermal applications, advanced analysis methods and modern specialized software packages
were used. The magnetic design of the rotors was optimized to ensure the absence of the demagnetization
effect, even with prolonged operation at temperatures exceeding the normal working temperatures expected
in geothermal wells. Magnetic materials for rotors have been selected for extremely high temperatures,
excluding degradation of magnetic properties within working temperatures. Extensive high-temperature and
high- magnetic-field testing, including aging tests, were successfully completed to confirm all theoretical
calculations and analyses.
In addition, the rotors must protect the magnetic materials from the effects of the environment, motor oil,
and—in the unlikely event of well fluid penetration into the motor—well fluid. Design solutions that ensure
SPE-214713-MS 7

this protection require the rotor enclosure to be able to withstand pressure and temperature fluctuations.
Therefore, the mechanical design of the rotors accounts for possible temperature changes, the thermal
expansion of various rotor components, as well as mechanical stresses resulting from external pressure when
operating in a deep well with high downhole pressure.
To ensure a long run life for the ESP, it is critical that the electrical power delivery system, comprising
downhole cables and the MLE, is also designed considering the specific requirements of geothermal

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

applications. Therefore, a new high-temperature geothermal cable and MLE using innovative design
solutions and advanced insulation materials and elastomers were developed and qualified.
The thermal expansion of components such as shafts, housings, and bearings at elevated operating
temperatures can be critically important for mechanical system integrity, due to thermal expansion,
potentially compromising the integrity of the assembly This technical challenge is especially critical in
high-temperature geothermal applications. Unlike in typical ESP applications in oil wells, geothermal ESPs
operate at higher temperatures, and they feature a more-substantial mechanical construction, with longer
shafts, stators, and housings. The increase in the linear dimensions of the components can lead to the
misalignment and malfunctioning of shaft seals in the protector, the overloading of thrust bearings, and other
undesirable consequences. To address this issue, specialized design methods, calculations, and analysis of
individual components and assemblies and modeling of the entire assembled system for the geothermal ESP
were used. In addition, prototypes underwent testing in test wells to confirm the accuracy of theoretical
calculations.

Chemical Environment
To reliably operate an ESP, the long-term resilience of its electrical insulation system, particularly under
high temperatures and high voltages, is required. In oil wells, wellbore fluids often promote the degradation
of insulating materials, leading to motor electrical failure. As a result, the motor is filled with electrically
insulating lubricant fluid for protection, while a protector, or shaft seal module, prevents well fluid ingress.
Each interface between ESP system units is equipped with O-rings made of elastomeric materials, creating a
barrier against well fluid penetration. However, the elastomers typically used in oil wells could be unsuitable
for geothermal applications because of the different chemical compositions of geothermal well fluids; the
high temperatures further exacerbate the chemical degradation of the elastomers. Thus, a key factor to ensure
ESP reliability is the robustness of the O-rings and their resistance to the corrosive effects of wellbore fluids.
To address this challenge in the development of the geothermal ESP, data on the chemical composition of
geothermal well fluids were collected and thoroughly analyzed. Specially developed elastomers, designed to
withstand these unique conditions, underwent rigorous endurance testing in high- temperature, geothermal
fluid environments and demonstrated satisfactory performance, enhancing the overall reliability of the
geothermal ESP.

High Flow Rates

One distinctive feature of most geothermal wells is the requirement for high flow rates, sometimes exceeding
1,000 tons per hour, for the efficient operation of geothermal power plants. Such high flow rates are
uncommon in the oil industry. To accommodate these elevated flow rates, A new pump stage capable of
handling a flow rate of 1,200 tons per hour has been developed for geothermal industry. For lower flow
rates, highly efficient pumps have been engineered, using some of the top-performing stages available
in industry. The design of these pumps has been enhanced for improved reliability in geothermal wells.
Notably, they feature materials with higher abrasion resistance for the bearings and incorporate the use of
specialized geothermal elastomers. These advancements collectively increase the pump's resilience to the
unique challenges presented by geothermal wells.
8 SPE-214713-MS

High Horsepower, High Efficiency

Operating pumps at high flow rates requires motors with high output power, 1,000 hp and above, capable
of functioning in wells with fluid temperatures of more than 200°C (392°F). The high-temperature ESPs
used in SAGD applications cannot satisfy the power requirements of geothermal operations. SAGD uses
single-section asynchronous motors, and the power of these motors does not typically exceed 300 hp.
This limitation stems from the relatively low power density and efficiency, usually less than 88%, of

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

asynchronous motors.
To overcome this limitation, PMM technology was used for the high-temperature geothermal application.
PMMs have higher efficiency, up to 95%, and significantly superior power density. Optimization of the
electromagnetic design of the geothermal motor facilitated increased values for efficiency and output
mechanical power. Because of the use of innovative insulating and heat-conductive materials in the
geothermal PMMs, an optimally efficient thermal operating regime was developed, enabling high reliability
and ensuring longevity of the motor operation even under extremely high temperatures.

Reliability
The use of innovative materials, the electromagnetic design, and the mechanical and hydraulic design of
the ESP components have resulted in a unique solution capable of addressing the critical challenges of the
geothermal industry. After rigorous testing of each new component comprising the geothermal ESP, as well
as the testing of subassemblies, assemblies, and the entire system, the ESP underwent a final validation
stage, which involved a field test in an actual geothermal well.

Field Trial and Results

Zorlu Enerji operates 56 geothermal wells in Kizildere geothermal field in Türkiye, 43 of which are high
enthalpy with fluid temperatures exceeding 200°C (392°F). During prolonged extraction, the pressure in
the Kizildere reservoir was depleted, leading to an average drop of 6 bar per year in well production and a
consequent decrease in electricity generation—but the electricity generation demand to efficiently operate
the power plants at the designed capacity remains constant. Several years ago, the operator began using
ESPs to enhance output from medium-enthalpy geothermal wells up to 200°C (392°F), with positive results.
However, the high-enthalpy wells exceeded the operational capacity of these ESP systems. Therefore, the
new high-temperature geothermal ESP system provides the opportunity to increase production in high-
temperature wells using artificial lift methods.
For the field trial, it was essential to choose a well with operational conditions closest to the tested ESP's
extreme specifications. Well KD-9A from the Kizildere geothermal field was selected; it was self-flowing
with a flow rate of 126 tons per hour and had the potential for greater production, which would increase the
low-carbon energy flowing into the power grid. The well temperature at the pump installation depth was
213°C (415°F), and the pump was installed at a depth of 750 m (2461 ft). This well's casing size was 9⅝ in
with 1.76 deg inclination. The well schematics with first installed geothermal ESP string is shown in Fig 2.
SPE-214713-MS 9

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

Figure 2—Well and ESP diagram (KD-9A).

The field prototype selected for this well comprised a high-temperature, 600-hp geothermal PMM,
geothermal protector, and geothermal pump with 14 stages. To provide corrosion protection for the
10 SPE-214713-MS

equipment, Nickel-based alloy coating was applied to the equipment surface. A diagram of the first installed
geothermal ESP string is shown in Fig 3.

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

Figure 3—Geothermal ESP schematic used in KD-9A.

The first high-temperature geothermal ESP was installed and put into operation in the KD-9A well on 3
July 2022. At the time of writing, the unit has been in continuous operation for more than 350 days. The
application of the high- temperature geothermal ESP in the KD-9A well proved to be effective, resulting in
a 56% production increase from 126 to 196 tons per hour. This contributed to the generation of 4.1 MW of
SPE-214713-MS 11

electricity from this well, while the ESP consumes less than 0.4 MW. The wellhead pressure for KD-9A is
maintained at approximately 7.8 bar, and the wellhead fluid temperature is 172°C (342°F).
Following the successful pilot of the novel ESP in the KD-9A well, Zorlu Enerji the operator made
the strategic decision to enhance production in an additional 14 high-temperature wells in the Kizildere
geothermal field. The new ESPs, coupled with digital services for monitoring and surveillance, offer an
innovative solution to drive performance and productivity for Zorlu Enerji, Türkiye.

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

The temperatures in these 14 wells range from 200 to 240°C (392 to 464°F), presenting unique operational
challenges that the new ESP design is well suited to address. As of the date of this writing, 5 of the planned 14
ESPs have been successfully installed and are operational. Details regarding the Kizildere high-temperature
wells that currently have geothermal ESPs are provided in Table 1.

Table 1—Data for wells with operating high-temperature geothermal ESPs.

Deviation
Pump Intake Pump Setting
Well ID Temperature Depth Dogleg Severity Dogleg Severity
(°C) (m) Inclination(degree) (Pass Through) (Operation)
(°/30 m) (°/30 m)

KD-9A 213.0 750 1.76 0.78 0.31

KD-63 232.1 1,275 3.00 0.22 0.22

KD-55 226.3 1,154 0.50 - -

KD-90B 229.7 1,363 13.81 2.14 0.81

R-5 224.3 1,362 10.56 2.44 0.62

KD-61A 228.7 1,354 16.07 2.38 0.29

The ESPs for the 14 wells have different configurations and use two types of pumps:

• Motors: geothermal high-temperature PMM motors with a nominal power of 850 hp at 225°C
(437°F), and 1,000-hp motors
• Protectors: geothermal protectors with metal bellows and enhanced dual seals

• Pumps: number of stages varies depending on the required lift

For corrosion protection, the equipment is covered with nickel-based alloy coating.
The implementation of high-temperature ESPs in the Kizildere wells has demonstrated a significant
increase in fluid production, which in turn generates clean electric power. At the same time, the energy
consumption for the operation of ESPs accounts for 8 to 14% of the total electricity produced from each
well, or 21 to 35% of the additional electricity generated as a result of the use of ESPs. The use of ESPs
to enhance production in these wells has a positive economic impact of around 51% of increase on yearly
revenue generated from those six wells for ZORLU Enerji. Consequently, the program to install ESPs in
the remaining 14 planned wells is ongoing, and there are plans to further increase the number of wells using
geothermal ESPs. Fig. 4 provides a summary of the results of the ESP implementation in Kizildere Field
for six of the wells from 2 to 11 months of operation.
12 SPE-214713-MS

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

Figure 4—Electrical power production and consumed power.

Environmental Impact and Sustainability

The new high-temperature geothermal ESP is specifically designed for green-energy applications,
facilitating the creation of clean power. The ESP, when applied in geothermal settings, is powered directly
by the geothermal plant, thereby eliminating the reliance on energy generated through the burning of fossil
fuels.
The high-temperature geothermal ESP has been awarded the Solar Impulse Foundation's prestigious
Solar Impulse Efficient Solution Label. This recognition, following a thorough evaluation process, is
a testament to the technology's environmental and economic impact and assists decision-makers in
recognizing and selecting efficient solutions that meet both economic and environmental commitments.

Conclusion and Future Outlook

The key findings from this study demonstrate the remarkable success of the newly developed ESP in high-
enthalpy geothermal wells in Türkiye. The field trial results from Well KD-9A in the Kizildere geothermal
field have shown that this new, high-temperature ESP can significantly increase production rates. The
introduction of this technology boosted production by 56%, demonstrating its potential to tackle the critical
challenges faced by the geothermal industry.
The technology's promising performance opens numerous avenues for its further expansion and adoption
in geothermal power plants worldwide. With the operational temperature range of the geothermal ESP
surpassing the limitations of previous ESPs, operators are now able to use artificial lift in high-temperature
wells previously inaccessible to this technology. The successful trial in Well KD-9A and the subsequent
decision to enhance production in an additional 14 high- temperature wells in the field demonstrate that this
technology offers an important solution for the geothermal industry.
Further development in geothermal energy production is key to promoting sustainable and renewable
energy, and the creation and application of high-temperature geothermal ESPs are central to this effort.
SPE-214713-MS 13

References
Heninger, M., Grande, S. F., and Shipp, D. D. 2019. Identifying and Preventing ESP Failures Resulting from Variable
Speed Drive Induced Power Quality Issues. Paper presented at the SPE Gulf Coast Section Electric Submersible Pumps
Symposium, The Woodlands, Texas, USA, 13–17 May. SPE-194392-MS. https://doi.org/10.2118/194392-MS.
Lovekin, J. W., Dagistan, Ö. F., Ari, C. et al. 2021. Geothermal Applications of Electric Submersible Pumps (ESPs) in
the USA and Türkiye. Proc., World Geothermal Congress 2020+1, Reykjavik, Iceland, 7 pages.
Vasilache, L. C., Radov, M., and Lovekin, J. 2021. Enabling Geothermal Energy Growth with Electric Submersible Pumps

Downloaded from http://onepetro.org/SPEESP/proceedings-pdf/23ESP/3-23ESP/D031S008R001/3267179/spe-214713-ms.pdf/1 by Schlumberger Oilfield UK Plc user on 17 January 2024

at 225 degC. Presented at the Geothermal Rising Conference, San Diego, California, USA, 3–6 October.