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Electrical Submersible
Pumps Manual
Design, Operations, and Maintenance
Second Edition
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording, or any information storage
and retrieval system, without permission in writing from the publisher. Details on how to
seek permission, further information about the Publisher’s permissions policies and our
arrangements with organizations such as the Copyright Clearance Center and the Copyright
Licensing Agency, can be found at our website: www.elsevier.com/permissions.
This book and the individual contributions contained in it are protected under copyright by
the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and
experience broaden our understanding, changes in research methods, professional practices,
or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in
evaluating and using any information, methods, compounds, or experiments described
herein. In using such information or methods they should be mindful of their own safety and
the safety of others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors,
assume any liability for any injury and/or damage to persons or property as a matter of
products liability, negligence or otherwise, or from any use or operation of any methods,
products, instructions, or ideas contained in the material herein.
ISBN: 978-0-12-814570-8
Electrical submersible pumping (ESP) is the only kind of artificial lifting for
which the original time of invention is known exactly and can be attributed to one
man, Armais Arutunoff. He made his first experiments in the Baku oilfields at
the Caspian Sea in the late 1910s, and was later the founder of the company
“Russian Electrical Dynamo of Arutunoff” whose acronym REDA is still very
well known all over the world. Arutunoff’s (who alone received about 90 patents
related to submersible equipment) pioneering work started an industry that today
lifts w10% of the world’s crude oil production.
From their early days on, ESP units have excelled in lifting much greater
liquid rates than most of the other types of artificial lift and have found their best
use in high-rate onshore and offshore applications. Continuous technological
development in the last almost 100 years has enormously modified the appli-
cation ranges for ESP equipment. High gas production, quickly changing liquid
production rates, viscous crudes, etc., conditions once very detrimental to ESP
operations, are now easily handled by present-day units. All these end up in the
indispensability of ESP equipment in the petroleum industry not only today but
in the foreseeable future as well.
I wrote this book with the needs of a petroleum engineering graduate student
in mind and with the objective of covering all aspects of up-to-date theories and
practices in ESP technology. While working on the manuscript, I used parts of
it in industrial short courses and I always considered the feedback from
participants when improving the material. This way, I believe, the target
audience of the book is even broader and includes practicing engineers as well.
Throughout the text, worked examples help readers understand basic principles
as well as design and analysis procedures.
This book, along with its two predecessors (Modern Sucker-Rod Pumping,
PennWell, 1993 and Gas Lift Manual, PennWell, 2005), concludes my coverage
of the three most important artificial lift methods: sucker-rod pumping, gas
lifting, and submersible pumping. Because these are the very technologies used
on the majority of artificially lifted oil wells, anyone studying these books will
have readily available a complete and up-to-date knowledge base encompassing
the major artificial lift technologies. I sincerely hope that readers will appreciate
the advantages of a uniform approach and treatment of the different topics
coming from a single author.
xv
Preface to the Second Edition
Since the publication of the first edition of this book in 2009 many important
developments have occurred in the electrical submersible pumping (ESP) in-
dustry. Most of them are evolutionary, but there are at least three revolutionary
technological changes that may shape the future. These are the use of powder
metallurgy in manufacturing submersible pump stages, the application of per-
manent magnet synchronous electric motors, and the rise of a new pump tech-
nology: the V-pump. The new stage manufacturing process produces more
complex pump stages (which are more and more frequently designed by CFD
methods) and permits to reach very high pump efficiencies never seen before.
Such stages are inherently more balanced than their casted counterparts and can
be used at exceptionally high speeds. At high speeds, pump stages develop
greatly increased hydraulic heads, so less stages are required and the length and
weight of submersible pumps decrease significantly.
The application of permanent magnet motors in other industries is quite
widespread: the ESP industry has just started using them. Their advantages are
numerous, but the most important is the lower power requirement and the longer
service life, as compared with present-day induction motors. In the present
scenario of low oil prices the proven 10%e30% reduction in production costs is
so desirable that the number of ESP installations using permanent magnet motors
grows exponentially.
The totally new pump type called V-Pump excels in conditions detrimental
for centrifugal pumps: high viscosity fluids, abrasive solids, or gas problems.
Driven by a usual ESP motor, this pump can work under such adverse conditions
where no submersible centrifugal pump could operate; it surely will expand the
application ranges of ESP operations in the near future.
One does not need ESP (this time extra-sensory perception) to predict that
these revolutionary developments will soon become part of the daily routine in
ESP operations.
This completely revised and expanded second edition of Electrical Sub-
mersible Pumps Manual describes in detail the new developments just
mentioned along with all the significant advancements in other areas. As before,
my objective was to provide the reader a clear assessment of state-of-the-art ESP
technology, which is a very important part of the artificial lift discipline. For this
reason I surveyed all available sources for new ideas, equipment, and procedures
and condensed my findings in this book for the benefit of fellow engineers. The
xvii
Contents
1. Introduction
1.1 Artificial Lifting 1
1.1.1 Gas Lifting 1
1.1.2 Pumping 2
1.1.3 Comparison of Lift Methods 3
1.1.3.1 Lifting Capacities 3
1.1.3.2 System Efficiencies 5
1.1.3.3 Further Considerations 6
1.2 Short History of Electrical Submersible Pumping Applications 6
1.3 Basic Features of Electric Submersible Pumping Installations 8
1.3.1 Applications 8
1.3.2 Advantages and Limitations 9
References 10
2. Review of Fundamentals
2.1 Introduction 11
2.2 Well Inflow Performance 11
2.2.1 Introduction 11
2.2.2 The Productivity Index Concept 12
2.2.3 Inflow Performance Relationships 14
2.2.3.1 Introduction 14
2.2.3.2 Vogel’s Inflow Performance Relationship
Correlation 15
2.2.3.3 The Composite Inflow Performance
Relationship Curve 16
2.3 Hydraulic Fundamentals 21
2.3.1 Tubing Flow Calculations 21
2.3.2 Electrical Submersible Pumps 23
2.3.2.1 Operational Basics of Centrifugal Pumps 23
2.3.2.2 Specific Speed 27
2.3.2.3 Pump Performance 28
2.3.2.4 Cavitation 31
2.3.2.5 Axial Thrust Forces 32
2.3.2.6 Affinity Laws 34
v
vi Contents
9. Special Installations
9.1 Introduction 449
9.2 Tubing Deployed Installations 449
9.2.1 Producing a Single Zone 449
9.2.1.1 Shrouded and Horizontal Well
Installations 449
9.2.1.2 Parallelly Connected Installations 450
9.2.1.3 Series-Connected Installations 451
9.2.2 Dual Zone Installations 453
9.2.2.1 Production Commingling 453
9.2.2.2 Selective Production 455
9.3 Alternative Deployed Installations 456
9.3.1 Cable Suspended Units 457
9.3.2 Coiled Tubing Installations 458
9.3.2.1 Cable Led Outside the Coiled Tubing
String 458
9.3.2.2 Cable Led Inside the Coiled Tubing String 460
9.3.3 Thru-Tubing Deployed Systems 462
9.3.3.1 Retrievable ESP Pumps 462
9.3.3.2 Retrievable ESP Systems 464
9.3.4 Conclusions 467
Contents xiii
Appendices 471
Class Problems 497
Index 545
xviii Preface to the Second Edition
close to 300 references cited in the text prove that all significant contributions to
the advancement of our industry were detected and properly considered.
While researching for the book, I received tremendous amounts of help from
too many individuals to name; their contributions are gratefully appreciated.
My work on this project spanned several years and I started writing the book
while heading the Petroleum Engineering Department of the Miskolc University,
Hungary. Final chapters, however, were written in Abu Dhabi where, from
August 2007 on, I assumed the position of acting Director of the Petroleum
Engineering Program at The Petroleum Institute. My sincere thanks are due to
the management of both institutions for their continuous support.
Last but not least the everlasting patience and understanding of my wife Bea
and a loving family is earnestly appreciated.
Gabor Takacs
Abu Dhabi, May 2008
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CHAPTER CCXXXIII.
TACITUS.
“We have long been accustomed to laugh at the pride and poverty of
petty German Princes,” says one of the most sensible and right
minded travellers that ever published the result of his observations in
Germany;1 “but nothing,” he proceeds, “can give a higher idea of the
respectability which so small a people may assume, and the quantity
of happiness which one of these insignificant monarchs may diffuse
around him, than the example of the little state of Weimar, with a
Prince like the present2 Grand Duke at its head. The mere pride of
sovereignty frequently most prominent where there is only the title to
justify it, is unknown to him; he is the most affable man in his
dominions, not simply with the condescension which any prince can
learn to practise as a useful quality, but from goodness of heart.” The
whole population of his state little if at all exceeds that of
Leicestershire; his capital is smaller than a third or fourth rate county
town; so in fact it scarcely deserves the name of a town; and the
inhabitants, vain as they are of its well earned reputation as the
German Athens, take a pride in having it considered merely a large
village: his revenue is less than that of many a British Peer, great
Commoner, or commercial Millionist. Yet “while the treasures of more
weighty potentates were insufficient to meet the necessities of their
political relations, his confined revenues could give independence
and careless leisure to the men who were gaining for Germany its
intellectual reputation.” It is not too much to say that for that
intellectual reputation, high as it is, and lasting as it will be, Germany
is little less beholden to the Duke of Weimar's well-bestowed
patronage, than to the genius of Wieland, and Schiller and Goëthe.
“In these little principalities, the same goodness of disposition can
work with more proportional effect than if it swayed the sceptre of an
empire; it comes more easily and directly into contact with those
towards whom it should be directed: the artificial world of courtly rank
and wealth has neither sufficient glare nor body to shut out from the
prince the more chequered world that lies below.”
1 RUSSELL.
2 A. D. 1822.
Alas no Prince either petty or great has followed the Duke of Saxe
Weimar's example! “He dwells,” says Mr. Downes, “like an estated
gentleman, surrounded by his tenantry.” Alas no British Peer, great
Commoner, or commercial Millionist has given to any portion of his
ampler revenues a like beneficent direction.
A good old Bishop3 quoting the text “not many wise men after the
flesh, not many mighty, not many noble are called,” cautions us
against distorting the Scripture as if it pronounced nothing but
confusion to the rulers of the earth, “let not the honourable person,”
said he, “hang down his head, as if power and wisdom, and noble
blood, and dignity were causes of rejection before God: no beloved!
Isaiah foretold that Kings should be nursing fathers, and Queens
should be nursing mothers of the Church, but it is often seen that the
benignity of nature and the liberality of fortune are made
impediments to a better life; and therefore Nobles and Princes are
more frequently threatened with judgment. I adjoin moreover that the
Scriptures speak more flatly against illustrious Magistrates, than the
common sort; for if God had left it to men, whose tongues are
prostituted to flattery, they had scarce been told that their
abominable sins would bring damnation.”
3 BISHOP HACKET.
When our philosopher considered the manner in which large
incomes are expended, (one way he had opportunities enough of
observing at Doncaster) he thought that in these times high birth
brought with it dangers and evils which in many or most instances,
more than counterbalanced its advantages.
et aillieurs,
Sir Robert Cotton once met with a man driving the plough, who was
a true and undoubted Plantagenet. “That worthy Doctor,” (Dr.
Hervey) says that worthy Fuller (dignissimus of being so styled
himself,) “hath made many converts in physic to his seeming
paradox, maintaining the circulation of blood running round about the
body of man. Nor is it less true that gentle blood fetcheth a circuit in
the body of a nation, running from Yeomanry, through Gentry to
Nobility, and so retrograde, returning through Gentry to Yeomanry
again.”
Et pour vous donner à entendre de moy qui vous parle, je cuide que
suis descendu de quelque riche Roy, ou Prince, au temps jadis; car
oncques ne vistes homme qui eust plus grande affection d'estre Roy
ou riche que moy, afin de faire grand chere, pas ne travailler, point
ne me soucier et bien enrichir mes amis, et tous gens de bien et de
sçavoir.”
CHAPTER CCXXXIV.
BRANTÔME.
In his speculations the separation of soul from body is total, till their
re-union at the day of judgment; and this unquestionably is the
christian belief. The fablers of all religions have taken a different
view, because at all times and in all countries they have
accommodated their fictions to the notions of the people. The grave
is with them a place of rest, or of suffering. If Young had been a Jew,
a Mahommedan, or a Roman Catholic, he might be understood as
speaking literally when he says,
The fable which St. Augustine seems to have believed, was either
parent or child of the story told under the name of Abdias, that when
the Beloved Disciple had attained the postdiluvian age of ninety
seven, our Lord appeared to him, said unto him, “come unto me, that
thou mayest partake at my feast with thy brethren,” and fixed the
next Sunday, being Easter, for his removal from this world. On that
Sunday accordingly, the Evangelist after having performed service in
his own temple at Ephesus, and exhorted the people, told some of
his chosen disciples to take with them two mattocks and spade, and
accompany him therewith. They went to a place near the city, where
he had been accustomed to pray, there he bade them dig a grave,
and when they would have ceased from the work, he bade them dig
it still deeper. Then taking off all his garments except a linen
vestment, he spread them in the grave, laid himself down upon
them, ordered his disciples to cover him up, and forthwith fell asleep
in the Lord. Abdias proceeds no farther with the story; but other
ecclesiastic romancers add that the evangelist enjoined them to
open the grave on the day following; they did so and found nothing
but his garments, for the blessed virgin in recompence for the filial
piety which he had manifested towards her in obedience to our
Lord's injunctions from the cross, had obtained for him the privilege
of an Assumption like her own. Baronius has no objection to believe
this, but that St. John actually died is, he says more than certain,—
certo certius; and that his grave at Ephesus was proof of it, for certe
non nisi mortuorum solent esse sepulchra.
Yet the Cardinal knew that the historian of his Church frequently
represented the dead as sentient in their graves. The Jews have
some remarkable legends founded upon the same notion. It is
written in the book of Zohar, say the Rabbis, how when Abraham
had made a covenant with the people of the land, and was about to
make a feast for them, a calf which was to be slaughtered on the
occasion, broke loose and ran into the cave of Machpelah. Abraham
followed, and having entered the cave in pursuit, there he discovered
the bodies of Adam and Eve, each on a bed, with lamps burning
between them. They were sleeping the sleep of death, and there
was a good odour around them, like the odour of repose. In
consequence of having made this discovery it was that he desired to
purchase the cave for his own burial place; and when the sons of
Jebus refused to sell it, he fell upon his knees, and bowed himself
before them, till they were entreated. When he came to deposit the
body of Sarah there, Adam and Eve rose up, and refused their
consent. The reason which they gave for this unexpected prohibition
was, that they were already in a state of reproach before the Lord,
because of their transgression, and a farther reproach would be
brought upon them by a comparison with his good deeds, if they
allowed such company to be introduced into their resting place. But
Abraham took upon himself to answer for that; upon this they were
satisfied with his assurances, and composed themselves again to
their long sleep.
The Rabbis may be left to contend for the authority of the book of
Zohar in this particular against the story of the Cabalists that Adam's
bones were taken into the Ark, and divided afterwards by Noah
among his sons. The skull fell to Shem's portion; he burnt it on the
mountain which for that reason obtained the name of Golgotha, or
Calvary,—being interpreted, the place of a skull, and on that spot, for
mystical signification the cross whereon our Saviour suffered was
erected;—a wild legend, on which as wild a fiction has been grafted,
that a branch from the Tree of Life had been planted on Adam's
grave, and from the wood which that branch had produced the cross
was made.
And against either of these the authority of Rabbi Judas Bar Simon
is to be opposed, for he affirms that the dust of Adam was washed
away by the Deluge, and utterly dispersed.
The Rabbis have also to establish the credit of their own tradition
against that of the Arabs who at this time shew Eve's grave near
Jeddah;—about three days journey east from that place, according
to Bruce. He says, it is covered with green sods, and about fifty
yards in length. The Cashmerian traveller Abdulkurreem who visited
it in 1742, says that it measured an hundred and ninety-seven of his
footsteps, which would make the mother of mankind much taller than
Bruce's measurement. He likens it to a flower-bed; on the middle of
the grave there was then a small dome, and the ends of it were
enclosed with wooden pales. Burckhardt did not visit it; he was told
that it was about two miles only, northward of the town, and that it
was a rude structure of stone, some four feet in length, two or three
in height and as many in breadth, thus resembling the tomb of Noah,
which is shewn in the valley of Bekaa, in Syria. Thus widely do these
modern travellers, on any one of whom reasonable reliance might
have been placed, differ in the account of the same thing.
CHAPTER CCXXXV.
We have got from the West Riding of Yorkshire, to the Eastern shore
of the Red Sea, without the assistance of mail-coach, steam-packet,
or air-balloon, the magical carpet, the wishing-cap, the shoes of
swiftness, or the seven-leagued boots. From Mr. Bacon's vicarage
we have got to Eve's grave, not per saltum, by any sudden, or
violent transition; but by following the stream of thought. We shall get
back in the same easy manner to that vicarage, and to the quiet
churchyard wherein the remains of one of the sweetest and for the
few latter years of her short life, one of the happiest of Eve's
daughters, were deposited in sure and certain hope. If you are in the
mood for a Chapter upon Churchyards, go reader to those which
Caroline Bowles has written;—you will find in them every thing that
can touch the heart, every thing that can sanctify the affections,
unalloyed by anything that can offend a pure taste and a masculine
judgement.
But before we find our way back we must tarry awhile among the
tombs, and converse with the fablers of old.
The lady in whose journal these lines were written lies buried in the
Campo Santo at Milan, with the following inscription on her tomb;
Priez pour une jeune Française que la mort a frappée à vingt ans,
comme elle allait, après un voyage de huit mois avec un epoux
chéri, revoir son enfant, son pere et sa mere, qui venaient joyeux au-
devant d'elle. Her husband wished to have her remains burnt, in
conformity to her own opinion respecting the disposal of the dead,
and to his own feelings at the time, that he might have carried her
ashes to his own country, and piously have preserved them there, to
weep over them, and bequeath them to his son; mais les amis qui
m'entouraient, he says, combatterent mon desir, comme une
inspiration insensée de la douleur.
The Moors say that the dead are disturbed if their graves be trodden
on by Christian feet; the Rabbis that they feel the worms devouring
them.
The custom evidently implies an opinion that though soul and body
were disunited by death, they kept close company together till after
the burial; otherwise a passport which the Soul was to present at
Heaven's gate, would not have been placed in the hands of the
corpse. In the superstitions of the Romish church a re-union is
frequently supposed, but that there is an immediate separation upon
death is an article of faith, and it is represented by Sir Thomas More
as one of the punishments for a sinful soul to be brought from
Purgatory and made to attend, an unseen spectator, at the funeral of
its own body, and feel the mockery of all the pomps and vanities
used upon that occasion. The passage is in his Supplycacyon of
Soulys. One of the Supplicants from Purgatory speaks:
* * * * *
EVLIA EFFENDI.
Once in their life time, the Jews say, they are bound by the Law of
Moses to go to the Holy Land, if they can, or be able, and the bones
of many dead Jews are carried there, and there burnt. We were
fraughted with wools from Constantinople to Sidon, in which sacks,
as most certainly was told to me, were many Jew's bones put into
little chests, but unknown to any of the ship. The Jews our
Merchants told me of them at my return from Jerusalem to Saphet,
but earnestly intreated me not to tell it, for fear of preventing them
another time.
Going on, one of my companions said, if you will take the trouble of
going a little out of the way, you will see a most remarkable thing.
Well, said I, what should be the object of all pains taken in travelling,
if it were not to admire the works of God. So we went on for an hour
to the north, but not taking the great road leading to the Plain of
Moosh, we advanced to a high rock that is a quarter of an hour out of
the road. To this rock, high like a tower, a man was formerly chained,
whose bones are yet preserved in the chains. Both bones and
chains are in a high state of preservation. The bones of the arms are
from seven to eight cubits in length, of an astonishing thickness. The
skull is like the cupola of a bath, and a man may creep in and out
without pain through the eye-holes. Eagles nestle in them. These
bones are said to be those of a faithful man who in Abraham's time
was chained by Nimrod to this rock, in order to be burnt by fire. The
fire calcined part of his body, so that it melted in one part with the
rock; but the arms and legs are stretching forth to the example of
posterity. We have no doubt that they will rise again into life at the
sound of the trumpet on the day of judgement.
EVLIA EFFENDI.
HASSELQUIST.
At the time of the deluge the wife of Noah being pregnant, was
through the hardships of the voyage delivered of a dead child to
which the name of Tarh was given, because the letters of this word
form the number 217 which was the number of days he was carried
by his mother instead of the full time of 280 days, or nine months.
This child was buried in the district now called Djezere Ibn Omar, the
Island or Peninsula of the son of Omar, and this was the first burial
on earth after the deluge. And Noah prayed unto the Lord, saying,
Oh God thou hast given me a thousand years of life, and this child is
dead before it began to live on earth! And he begged of the Lord as
a blessing given to the burial-place of his child, that the women of
this town might never miscarry, which was granted; so that since that
time women, and female animals of every kind in this town are all
blessed with births in due time and long living. The length of the
grave of this untimely child of Noah is 40 feet and it is visited by
pilgrims.
EVLIA EFFENDI.
They suppose that a few souls are peculiarly gifted with the power of
quitting their bodies, of mounting into the skies, visiting distant
countries, and again returning and resuming them; they call the
mystery or prayer by which this power is obtained, the Mandiram.
CRAUFURD.
The plain of Kerbela is all desert, inhabited by none but by the dead,
and by roving wild hounds, the race of the dogs which licked the
blood of the martyrs, and which since are doomed to wander through
the wilderness.
EVLIA EFFENDI.
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