ESP System Design — Complete Training Course Oil & Gas Artificial Lift Engineering

ESP SYSTEM DESIGN

Complete Training Course

Zero to Hero | Oil & Gas Artificial Lift Engineering

8 Modules · 52 Lessons · ~120 Hours

Reservoir Analysis · Pump Design · Motor & Cable · Nodal Analysis · Troubleshooting

Electrical Submersible Pump Design for Petroleum Engineers

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ESP System Design — Complete Training Course Oil & Gas Artificial Lift Engineering

Table of Contents
MODULE 1 — Foundations of ESP Systems
• What is an ESP? History and oilfield context
• ESP application range: flow rates, depths, temperatures
• ESP vs. other artificial lift methods
• Major ESP component overview
• Wellbore fundamentals for ESP engineers
• Fluid properties that affect ESP selection

MODULE 2 — Reservoir & Well Inflow Analysis

• Reservoir pressure: static, flowing, and shut-in
• Inflow performance relationships (IPR): Vogel, Fetkovitch, Darcy
• Productivity index (PI) and how to determine it
• Multiphase inflow: free gas, GOR, watercut effects
• Constructing the IPR curve from well test data
• Future IPR and declining reservoir pressure
• Case study: IPR analysis from field data

MODULE 3 — ESP Pump Design & Selection

• Centrifugal pump theory: head, flow, efficiency, BEP
• Reading and interpreting pump performance curves
• Specific gravity and fluid correction for pump curves
• Calculating total dynamic head (TDH)
• Friction losses in tubing: Darcy-Weisbach
• Pump stages: determining the correct number
• Series vs. parallel pump configurations
• Selecting pump type: standard, mixed-flow, radial flow
• Case study: full pump sizing for a vertical oil well

MODULE 4 — Motor, Cable & Transformer Design

• ESP motor fundamentals: induction, poles, slip, torque
• Motor sizing: HP, voltage, current, power factor
• Motor temperature rating and heat management
• Power cable selection: size, voltage drop, ampacity
• Voltage drop calculations and surface voltage requirements
• Surface transformer sizing and power factor correction
• Variable speed drive (VSD/VFD) fundamentals and design

MODULE 5 — Gas & Solids Handling

• Free gas at pump intake: causes and consequences
• Gas separators: natural, rotary, and advanced types
• Gas separator sizing and selection criteria
• Solids (sand, scale, asphaltene) and ESP erosion
• Sand-resistant pump selection and materials
• Intake design for high-GOR wells

MODULE 6 — System Nodal Analysis & Optimization

• Nodal analysis fundamentals for artificial lift
• Outflow performance curve (OPC/TPC) construction
• Operating point: intersection of IPR and OPC
• Speed sensitivity: effect of VSD on system performance
• Optimizing ESP design for current and future production
• Using PROSPER / OFMwell for ESP design

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• Case study: nodal analysis optimization

MODULE 7 — Completion, Installation & Commissioning

• Wellbore completion considerations for ESP deployment
• ESP string assembly sequence and pre-job checks
• Running ESP into the well: procedures and precautions
• Surface electrical testing and pre-startup checks
• Startup procedure, ramp-up, and initial well monitoring

MODULE 8 — Monitoring, Troubleshooting & Advanced Topics

• Downhole gauges and SCADA: interpreting real-time data
• Common failure modes: overload, underload, gas lock, burnout
• ESP run life analysis and failure root cause methods
• Corrosive environments: H2S, CO2, high-salinity design
• Advanced: ESP design for deviated, horizontal & thermal wells

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MODULE 1

Foundations of ESP Systems

Understanding what ESPs are, where they fit in oilfield operations, and the
fundamentals every ESP engineer needs.

Lesson 1: What is an ESP? History and Oilfield Context

An Electrical Submersible Pump (ESP) is a multistage centrifugal pump driven by an electric motor,
deployed downhole in an oil or gas well to lift reservoir fluids to surface. It is one of the most widely used
artificial lift methods in the oil industry, capable of handling high liquid volumes from deep reservoirs.

Historical development
ESP technology was pioneered by Armais Arutunoff, a Russian-born inventor who founded Reda Pump
Company in 1916. The first commercial ESP installation occurred in the 1920s in oil wells in the United
States. Through the 20th century, ESP technology evolved rapidly with improvements in motor
insulation, metallurgy, cable design, and electronics. Today, ESP systems routinely operate in wells
exceeding 3,000 m depth, at temperatures above 150°C, and in highly corrosive environments.

Where ESPs fit in the oilfield

When a reservoir no longer has sufficient natural energy to produce oil at economic rates, artificial lift is
required. ESPs are selected when:

• High liquid production rates are needed (typically 150 to 30,000 barrels per day)
• Well depth is moderate to deep (500 m to 4,500 m)
• The fluid has moderate GOR (gas-oil ratio) — not gas-dominant
• Offshore wells where other lift methods are impractical
• Wells with high watercut where electrical efficiency matters

First commercial ESP 1920s — United States (Reda Pump)

Major manufacturers Baker Hughes (Centrilift), Schlumberger (REDA), Weatherford, Borets
Global ESP installations ~120,000 active units worldwide (as of recent estimates)
Typical production range 150 to 30,000 BPD liquid
Typical depth range 500 m to 4,500 m
Power consumption 15 kW to over 1,000 kW per unit

Lesson 2: ESP Application Range: Flow Rates, Depths,

Temperatures
Matching an ESP to the correct application window is the first step in system design. ESPs have defined
operating envelopes beyond which performance degrades or reliability suffers.

Flow rate range

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Individual pump stages are manufactured for specific flow ranges. Pumps are catalogued by their best
efficiency point (BEP) flow rate. Connecting multiple stages in series delivers head (pressure), while
parallel installations can increase flow in special configurations. Typical single-string ESP flow ranges:

Category Flow Range (BPD) Typical Application

Mini/Slim ESP 150 – 800 Low-rate wells, slim-hole completions
Standard ESP 800 – 5,000 Most onshore oil wells
High-volume ESP 5,000 – 15,000 High-PI wells, waterflood producers
Ultra-high volume 15,000 – 30,000+ Offshore, water injection, mature fields

Depth and temperature constraints

Temperature is the primary enemy of ESP reliability. Motor winding insulation, cable insulation, and
elastomeric seals all degrade with heat. Downhole temperature has two contributions: the geothermal
gradient of the formation, and heat generated by the motor itself.

• Standard motor insulation: rated to 120°C (Class H insulation)

• High-temperature motors: rated to 150°C–180°C (with special insulation)
• Ultra-high-temperature systems: rated to 200°C+ (for thermal EOR, steam-assisted wells)
• Cable temperature rating must match or exceed motor rating
• Each 10°C above rated temperature roughly halves motor insulation life
Note: Minimum flow rate past the motor is critical for cooling. Motor shrouds or tailpipes are used in
large-casing wells to force produced fluid past the motor for cooling.

Lesson 3: ESP vs. Other Artificial Lift Methods

Choosing the right artificial lift method is a strategic decision driven by well characteristics, reservoir
performance, surface facilities, and operating costs. Understanding where ESPs excel — and where
they do not — is essential for the design engineer.

Parameter ESP Gas Lift Rod Pump (SRP) PCP

Flow rate Very high (150–30k BPD)
High (up to 20k BPD) Low-medium (10–3k BPD)
Low-medium (50–3k BPD)
Depth Up to 4,500 m Up to 3,000 m Up to 3,500 m Up to 2,500 m
GOR tolerance Moderate High (gas used as energy)
Low-moderate Very low
Sand tolerance Poor–moderate Good Poor (wear) Good (progressive cavity)
Offshore suitability Excellent Good Poor Moderate
Capital cost Medium-high High (compressor) Low-medium Low-medium
Operating cost Medium (power-intensive)
Medium Low Low
Monitoring/control Excellent (SCADA, VSD)
Good Good Moderate

Key decision rule: ESPs are preferred for high-rate, deep offshore wells and any well where
high electrical infrastructure already exists. For high-GOR wells or wells with limited power
supply, gas lift or beam pumping may be more appropriate.

Lesson 4: Major ESP Component Overview

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An ESP system consists of downhole components (in the wellbore) and surface components (at the
wellhead and power supply). Understanding each component's function is prerequisite to design.

Downhole components (bottom to top)

Intake / Perforated Shroud Entry point for reservoir fluid into the ESP system. May include a gas separator or a standar
Pump The core component: a multistage centrifugal pump that adds head (pressure energy) to the
Protector / Seal Section Sits between pump and motor. Functions: (1) equalises internal motor oil pressure with wellb
Motor A two-pole, three-phase squirrel-cage induction motor. Very slim and long (OD: 86–172 mm
Motor Flat Cable Short flat cable connecting the main power cable to the motor head. Allows the cable to lie fl
Downhole Gauge (optional)Measures pressure, temperature, vibration, and motor current downhole. Essential for mode

Surface components
Wellhead / Cable Clamps Seal the annulus and provide cable exit points.
Power Cable Three-conductor armoured cable (round or flat) running from surface to motor. Must handle
Surface Transformer Steps up or steps down grid voltage to match motor requirements (typically 600–5,000 V at m
Motor Control Unit (MCU) Houses overload protection, underload protection, and switching equipment.
Variable Speed Drive (VSD)Adjusts motor frequency (and therefore speed) to optimise pump performance. Modern ESP
Junction Box Weatherproof enclosure connecting the surface cable to the VSD/MCU.

Lesson 5: Wellbore Fundamentals for ESP Engineers

ESP design requires understanding the wellbore as the physical environment in which the system
operates. Key parameters include casing size, completion type, deviation, and fluid column
characteristics.

Wellbore geometry
The ESP outside diameter must fit within the production casing (or liner) internal diameter with adequate
clearance for the cable and clamps. Standard casing sizes and typical maximum ESP ODs:

Casing OD (inches) Casing ID (approx.) Max ESP OD Remarks

4.5" 3.92" 3.38" Slim-hole / mini ESP only
5.5" 4.89" 4.00" Standard slim ESP
7" 6.18" 5.38" Most common onshore casing
9.625" 8.53" 7.31" Allows large-bore ESP
13.375" 12.34" 11" Large OD offshore or high-rate

Completion considerations
• Perforations must be above the pump setting depth to allow inflow
• Gas anchor or separator should be as close to perforations as possible
• Tubing size dictates friction loss; must be designed together with ESP
• Wellbore deviation affects cable installation and thrust loads on pump bearings
• For deviated wells (>30 deg), specialised ESP designs with increased bearing capacity are used

Key depth definitions

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Measured Depth (MD) Total length along the wellbore path from surface to a given point.
True Vertical Depth (TVD) Vertical height from surface. Used for hydrostatic pressure calculations.
Pump Setting Depth TVD and MD at which the pump intake is positioned. Should be below the dynamic fluid leve
Dynamic Fluid Level (DFL) The depth at which the fluid surface stands during production. Must be above the pump intak
Perforations / Pay Zone The producing interval. Pump set below dynamic fluid level but above perforations.

Lesson 6: Fluid Properties That Affect ESP Selection

The properties of the produced fluid directly govern pump hydraulics, motor sizing, cable selection, and
material choice. An ESP design based on incorrect fluid properties will underperform or fail prematurely.

Key fluid properties

Specific Gravity (SG) Ratio of fluid density to water density at standard conditions. Affects TDH calculation and moto
API Gravity Measure of oil density. API = (141.5 / SG) - 131.5. Light oil > 40 API; heavy oil < 20 API.
Viscosity Resistance to flow. High-viscosity crudes (>30 cP) drastically derate pump performance and in
Water Cut (WC%) Percentage of water in produced fluid. High watercut increases average SG toward 1.0. A wel
Gas-Oil Ratio (GOR) Volume of gas (in SCF) produced per barrel of oil. High GOR leads to free gas at pump, causi
H2S content Corrosive, requires special elastomers, metals, and motor winding protection. NACE MR0175
CO2 content Causes carbonic acid corrosion in wet conditions. Affects material selection for pump stages a
Produced water salinity High TDS (total dissolved solids) water is denser and more corrosive. Affects pump curves (SG
Sand / solids content Abrasive particles erode impellers and diffusers. Drives selection of hardened alloys (Ni-Resis
Temperature (BHT) Bottomhole temperature governs motor/cable rating. Must include geothermal gradient and mo

Design tip: Always design for worst-case fluid conditions. Use the maximum watercut
anticipated over the well's production life for SG calculations, and the minimum watercut
for viscosity calculations (oil-dominated at low WC).

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MODULE 2

Reservoir & Well Inflow Analysis

Understanding how the reservoir delivers fluid to the wellbore — the foundation of
every ESP design.

Lesson 1: Reservoir Pressure: Static, Flowing, and Shut-in

Reservoir pressure is the driving energy that moves fluid from the formation into the wellbore. Three
pressure states define the well's deliverability:

Static Reservoir Pressure (Ps)

Pressure measured when the well is shut-in long enough for pressure to stabilise. Represen
Flowing Bottomhole Pressure
Pressure
(Pwf) at the perforations during production. The difference (Ps - Pwf) = the drawdown, w
Shut-in Wellhead Pressure Surface
(SIWHP)pressure after shut-in. Useful for estimating static gradient and reservoir pressure in
Average Reservoir Pressure
Volume-averaged
(Pr) pressure throughout the drainage area. Used in material balance and long

Pressure gradient review

Hydrostatic Pressure (psi) = 0.433 x SG x TVD (ft)

Hydrostatic Pressure (bar) = 0.0981 x SG x TVD (m)

A 1.0 SG fluid exerts 0.433 psi/ft (0.0981 bar/m) of hydrostatic pressure. This gradient is used to convert
surface pressures to bottomhole pressures and vice versa.

Lesson 2: Inflow Performance Relationships (IPR)

The IPR curve describes how the well's flow rate varies as a function of flowing bottomhole pressure. It
combines reservoir rock and fluid properties into a single deliverability model.

Darcy's law (single-phase, incompressible fluid)

For wells producing oil below bubble point or producing 100% water, the linear IPR applies:

q = PI x (Pr - Pwf)
Where: q = flow rate (STB/day), PI = productivity index (STB/day/psi), Pr = reservoir pressure (psi), Pwf
= flowing bottomhole pressure (psi).

The linear IPR gives a straight line from (Pr, 0) to (0, AOF) on a Pwf vs q plot, where AOF = Absolute
Open Flow (maximum theoretical flow at Pwf = 0).

Vogel correlation (solution-gas drive, two-phase)

When reservoir pressure drops below the bubble point, gas comes out of solution in the reservoir,
increasing viscosity and reducing effective permeability to oil. Vogel's equation accounts for this:

q/qmax = 1 - 0.2(Pwf/Pr) - 0.8(Pwf/Pr)^2

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Where qmax is the maximum flow rate at Pwf = 0 (AOF). The Vogel curve bows toward higher flow
rates compared to the linear IPR, reflecting the beneficial effect of gas expansion near the wellbore.

Fetkovich method (general flow equation)

Fetkovich extended the IPR concept to cover both laminar (Darcy) and turbulent (non-Darcy) flow
regimes using a two-term equation applicable to gas wells and high-rate oil wells:

q = C x (Pr^2 - Pwf^2)^n
Where C is the deliverability coefficient and n is the flow exponent (0.5 for fully turbulent, 1.0 for fully
laminar flow). Values of C and n are determined from multi-rate well tests.

Lesson 3: Productivity Index (PI) and How to Determine It

The productivity index (PI or J) quantifies how easily a well delivers fluid for a given drawdown. It
integrates reservoir permeability, thickness, viscosity, and wellbore geometry.

Calculating PI from Darcy's law

PI = (0.00708 x k x h) / (mu x Bo x [ln(re/rw) - 0.75 + S])

k Effective permeability to oil (md)

h Net pay thickness (ft)
mu Oil viscosity at reservoir conditions (cP)
Bo Oil formation volume factor (RB/STB)
re Drainage radius (ft)
rw Wellbore radius (ft)
S Skin factor (positive = damage, negative = stimulation)

Measuring PI from well tests

In practice, PI is measured directly from production tests:

PI = q / (Ps - Pwf)
Conduct a stabilised flow test at one rate, measure Pwf with a downhole gauge, and calculate PI. For
better accuracy, conduct multi-rate tests (Rawlins & Schellhardt) and plot log-log deliverability curves.

Important: Skin factor (S) dramatically affects PI. A skin of +10 (damaged well) can reduce
PI by 50-80% compared to an undamaged well. Always plan for stimulation (acidising,
fracturing) to remove damage when designing ESP installations.

Lesson 4: Multiphase Inflow: Free Gas, GOR, and Watercut

Effects
Real reservoir fluids are multiphase. The presence of gas and water in the produced stream changes
the effective properties seen by the ESP and must be quantified carefully.

Free gas calculation

Gas exists in two states in the produced fluid: gas dissolved in oil (solution gas) and free gas (bubbles).
Free gas forms when the wellbore pressure drops below the bubble point pressure (Pb). The fraction of
free gas at the pump intake is calculated as:

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Free Gas Fraction = (Total Gas - Solution Gas) / Total Fluid Volume
Solution gas is calculated using the Standing correlation or similar PVT correlations. If pump intake
pressure (PIP) > Pb, no free gas exists and the fluid is single-phase (with dissolved gas).

Composite fluid properties

When oil and water are present together, the mixture specific gravity is:

SG_mix = (WC x SG_water) + ((1 - WC) x SG_oil)

Where WC = watercut fraction (0 to 1). As watercut increases, the mixture SG increases toward that of
formation water (typically 1.05–1.15 SG).

WC (%) SG_oil = 0.85 (33 API) SG_water = 1.07 SG_mix

0% 100% oil — 0.850
30% 70% oil 30% water 0.916
60% 40% oil 60% water 0.982
90% 10% oil 90% water 1.048
100% — 100% water 1.070

Lesson 5: Constructing the IPR Curve from Well Test Data

Constructing an accurate IPR curve is the most important input to ESP design. The curve must be built
from actual well test data, not just assumed from analogues.

Step-by-step IPR construction (Vogel method)

Step 1 Measure or estimate current reservoir pressure Pr (from buildup test or material balance).
Step 2 Conduct a stabilised production test: measure stable rate q_test and corresponding Pwf using a downhole g
Step 3 Calculate q_max (AOF) by rearranging Vogel: q_max = q_test / [1 - 0.2(Pwf/Pr) - 0.8(Pwf/Pr)^2].
Step 4 Generate IPR curve: for Pwf values from 0 to Pr, calculate q using Vogel equation with the determined q_ma
Step 5 Plot Pwf (y-axis) vs q (x-axis). The point where the desired ESP operating rate crosses this curve gives the r

Lesson 6: Future IPR and Declining Reservoir Pressure

An ESP system designed only for today's reservoir conditions may be oversized or undersized as the
reservoir depletes. Good ESP design considers the full life-of-well production forecast.

Standing's future IPR method

Standing extended Vogel's equation to predict future IPR when reservoir pressure has declined from
initial pressure Pr to a future pressure Pr_f:

q_max(future) = q_max(present) x (Pr_f/Pr) x [1 + 0.2(Pr_f/Pr) + 0.8(Pr_f/Pr)^2]

This method shows that as reservoir pressure declines, AOF decreases faster than proportionally. A
20% pressure decline can reduce AOF by 35–45%.

Design strategy for declining reservoirs

• Design ESP for the expected mid-life operating rate, not peak rate
• Use a VSD to allow operating across a range of speeds as conditions change

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• Plan for workovers (ESP replacement) at predicted intervals

• Size motor and cable for the maximum HP demand, which often occurs at early-life high GOR
• Conduct sensitivity studies: design must work at Pr ± 300 psi from base case

Lesson 7: Case Study: IPR Analysis from Field Data

Well: Vertical oil well, Middle East carbonate reservoir

Parameter Value
Reservoir pressure (Pr) 3,200 psi
Bubble point pressure (Pb) 1,800 psi
Test rate (q_test) 2,400 STB/day
Test Pwf 2,500 psi
Oil SG 0.87 (31 API)
Water SG 1.08
Watercut 45%
GOR 350 SCF/STB

Calculation
Since Pb = 1,800 psi, the reservoir is above bubble point at Pr = 3,200 psi. For Pwf above Pb, the IPR is
linear (Darcy). For Pwf below Pb, Vogel applies to the solution-gas drive portion.

PI (above Pb) = 2,400 / (3,200 - 2,500) = 3.43 STB/day/psi

q at Pwf = Pb: q_Pb = 3.43 x (3,200 - 1,800) = 4,800 STB/day

Below bubble point, Vogel is anchored at (Pb = 1,800 psi, q = 4,800 STB/day). Composite IPR is a
straight line from Pr to Pb, then a Vogel curve from Pb to AOF.

AOF (approx) = 4,800 / (1 - 0.2(0) - 0.8(0)) x correction = ~7,200 STB/day

Target ESP operating rate: 4,000 STB/day (total liquid). From composite IPR at q = 4,000, Pwf =
approximately 2,680 psi. This is the required pump intake pressure at the target production rate.

Composite (Vogel below Pb + linear above Pb) is the most accurate IPR for solution-gas
drive reservoirs. Never use a single linear IPR for a well producing below bubble point — it
significantly overestimates AOF.

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MODULE 3

ESP Pump Design & Selection

The core engineering module: sizing the pump, calculating TDH, selecting stages,
and matching the pump to the well.

Lesson 1: Centrifugal Pump Theory: Head, Flow, Efficiency,

BEP
An ESP pump is a centrifugal pump. Understanding centrifugal pump theory is essential before any
sizing work can begin.

How a centrifugal pump works

Fluid enters the eye of a rotating impeller. Centrifugal force flings the fluid outward, converting rotational
kinetic energy into velocity. A stationary diffuser then converts this velocity energy into pressure (head).
This process repeats through each stage.

Key performance parameters

Head (H) The pressure energy added per unit weight of fluid, expressed in feet or metres of fluid. Head
Flow Rate (Q) Volume of fluid passing through the pump per unit time. Typically expressed in BPD (barrels p
Efficiency (Eta) Ratio of hydraulic power delivered to fluid vs. shaft power input. Peaks at BEP. Eta = (Q x H x
BEP (Best Efficiency Point)
The flow rate at which the pump operates at maximum efficiency. Operating far from BEP cau
Power (HP) Shaft power required to drive the pump at a given flow and head. HP = (Q x H x SG) / (3,960 x

Lesson 2: Reading and Interpreting Pump Performance

Curves
Every ESP pump model has a manufacturer-supplied performance curve — a set of curves showing
Head, Efficiency, and Power vs. Flow Rate at the rated speed (typically 3,500 RPM for 60 Hz, 2,917
RPM for 50 Hz systems).

What the curve tells you

• Head-flow curve (H-Q): Shows head added per stage vs. flow rate. Highest head at minimum flow;
head decreases as flow increases. Steep curve = stable operation; flat curve = sensitive to pressure
changes.
• Efficiency curve: Bell-shaped curve peaking at BEP. Operating at BEP maximises energy
efficiency and minimises heat generation.
• Power curve: Shows shaft HP required at each flow rate. Usually increases with flow. Identifies
maximum power draw (important for motor sizing).
• Recommended operating range: Manufacturer marks the allowable operating band on the curve,
typically 65–130% of BEP flow.
• Curve validity: Curves are valid only at the rated speed and for water (SG = 1.0). Corrections
needed for other speeds (Affinity Laws) and viscous fluids.

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Affinity laws (speed changes via VSD)

When pump speed changes from N1 to N2:

Q2 = Q1 x (N2/N1) Flow scales linearly with speed

H2 = H1 x (N2/N1)^2 Head scales with speed squared

HP2 = HP1 x (N2/N1)^3 Power scales with speed cubed

Note: These laws show that a 10% speed reduction cuts power consumption by 27% — a major energy
saving potential with VSD operation.

Lesson 3: Specific Gravity and Fluid Correction for Pump

Curves
Manufacturer pump curves are published for fresh water (SG = 1.0). When pumping fluids with different
SG (which is almost always), head correction is NOT needed — the head (in feet) is the same — but
power and pressure ARE affected.

Head, pressure, and power relationships

Pressure (psi) = Head (ft) x SG x 0.433

HP_actual = HP_water x SG_fluid

Differential pressure (psi/stage) = Head_per_stage (ft) x SG x 0.433

For a pump delivering 35 ft/stage head at BEP, pumping a mixture with SG = 0.95:

Pressure per stage = 35 x 0.95 x 0.433 = 14.4 psi/stage

If the same pump handles SG = 1.08 produced water:

Pressure per stage = 35 x 1.08 x 0.433 = 16.4 psi/stage

Viscosity correction
For crude oils with viscosity > 5 cP, pump performance degrades significantly. The Hydraulic Institute
(HI) method or manufacturer-specific viscosity correction charts must be applied:

• Flow correction factor (Cq): reduces BEP flow point

• Head correction factor (Ch): reduces head at all flow rates
• Efficiency correction factor (Ce): reduces efficiency
• For viscosity > 200 cP, pump head may reduce to 40-60% of water performance

Critical: Viscosity corrections for ESP pumps are different from surface pump corrections.
Always use manufacturer's viscosity correction data or the API recommended practice for
the specific ESP model.

Lesson 4: Calculating Total Dynamic Head (TDH)

TDH is the total pressure (expressed as head of fluid) that the ESP must overcome to lift fluid from the
pump to the surface and deliver it at the required wellhead pressure. It is the single most critical
calculation in ESP design.

TDH components

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TDH = Net Vertical Lift (NVL) + Tubing Friction Losses (Hf) + Wellhead Back Pressure
(Hwh)

Net Vertical Lift (NVL) The vertical height the fluid must be lifted from the pump discharge to the wellhead. NVL = P
Tubing Friction Losses (Hf)Pressure energy lost to friction as fluid flows up the tubing. Depends on flow rate, tubing ID,
Wellhead Back Pressure (Hwh)
The wellhead flowing pressure that the pump must overcome. Expressed as equivalent head

Step-by-step TDH example

Parameter Value Notes
Pump setting TVD 6,500 ft True vertical depth of pump
Dynamic fluid level TVD 3,200 ft Fluid surface above pump
Net vertical lift (NVL) 3,300 ft 6,500 - 3,200
Tubing ID 2.992 in (3.5 in OD) Standard tubing
Total liquid rate 3,000 BPD Design rate
Fluid SG 0.93 Mixed oil + water
Friction loss (Hf) 280 ft From friction correlation
Wellhead pressure 150 psi Flowline back pressure
WHP as head 372 ft 150 / (0.433 x 0.93)
TOTAL TDH 3,952 ft 3,300 + 280 + 372

Lesson 5: Friction Losses in Tubing: Darcy-Weisbach

Friction losses represent energy consumed by fluid flowing through the tubing string. They add directly
to TDH and become significant at high flow rates or when producing from deep wells.

Darcy-Weisbach equation
Hf = f x (L/D) x (v^2 / 2g)

f Darcy friction factor (dimensionless) — from Moody chart or Colebrook equation

L Length of tubing (ft or m)
D Internal diameter of tubing (ft or m)
v Average fluid velocity (ft/s or m/s)
g Gravitational acceleration (32.174 ft/s2 or 9.81 m/s2)

Fluid velocity in tubing

v (ft/s) = (Q in BPD x 5.615) / (86,400 x A)
Where A = cross-sectional area in ft2 = pi/4 x D^2. For 3.5-inch OD tubing (ID = 2.992 in = 0.2493 ft), at
Q = 3,000 BPD:

A = pi/4 x (0.2493)^2 = 0.04878 ft^2

v = (3,000 x 5.615) / (86,400 x 0.04878) = 4.00 ft/s

Reynolds number: Re = (rho x v x D) / mu. For most ESP applications, Re > 4,000 (turbulent flow), and
friction factor is found from the Colebrook-White equation or Moody chart.

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Note: Use simulator software (PIPESIM, OLGA) for accurate multiphase friction loss calculations in
production systems. Hand calculations are useful for first-pass estimates and checking software outputs.

Lesson 6: Pump Stages: How to Determine the Correct

Number
Once TDH is known and a pump model selected, the number of stages is straightforward to calculate.

Number of stages formula

Number of Stages = TDH / Head_per_stage_at_design_rate
The head per stage is read from the pump performance curve at the design flow rate (after viscosity and
SG corrections if applicable). Always read head at the design rate, not at BEP — unless the design rate
IS BEP.

Stage count example

Using the TDH example from Lesson 4: TDH = 3,952 ft. Selected pump model delivers 28.5 ft/stage at
3,000 BPD (design rate, water basis, no viscosity correction needed for SG = 0.93 light oil).

Stages = 3,952 / 28.5 = 139 stages (round up to 140)

The pump manufacturer supplies this model in pre-assembled housings of fixed stage counts. If the
available housing sizes are 100, 125, 150 stages, select 150 stages, which will slightly over-perform —
fine-tuned with VSD speed reduction.

Practical constraints on stage count

• Maximum pump length: limited by wellbore dogleg severity and casing dimensions
• Maximum pump HP: must match available motor HP
• Temperature at pump depth: more stages = more pump length = lower temperature at motor
• Burst and collapse rating of housing must exceed operating pressure
• Standard housing lengths: typically 10–30 stages per housing section

Lesson 7: Series vs. Parallel Pump Configurations

In most ESP installations, a single pump string in series stages is used. However, some applications
call for modified configurations.

Series configuration (standard)

All stages are in series — each stage adds head to the fluid. Flow rate is determined by the pump curve;
head is multiplied by stage count. This is the standard configuration for all ESP applications.

Tandem motor + pump configuration

For very deep wells requiring very high TDH, two pump/motor pairs can be installed in tandem (stacked)
on the same tubing string. The lower pump's discharge flows into the upper pump's intake, doubling the
available head. Requires careful cable design and wellbore geometry.

Twin installations (parallel wells)

In some high-volume offshore applications, two wells are produced in parallel into the same flowline.
This is not a parallel pump configuration per se, but the system analysis must treat both wells' IPR and
outflow curves simultaneously.

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Lesson 8: Selecting Pump Type: Standard, Mixed-Flow,

Radial Flow
ESP impellers are classified by their specific speed (Ns), which determines the geometry and the flow
rate / head characteristics of the pump.

Ns = N x sqrt(Q) / H^(3/4) [US units: N in RPM, Q in GPM, H in ft/stage]

Impeller Type Specific Speed (Ns) Flow Range Head/Stage Best For
Radial flow 500 – 2,000 Low High Deep wells, low-rate, high pressure
Mixed flow 2,000 – 5,000 Medium Medium Most standard ESP applications
Axial / propeller 5,000 – 10,000 High Low Very high rate, shallow, low TDH
Pancake (float) — Medium Medium Abrasive service; floating impeller ab

Most oilfield ESP applications use mixed-flow impellers. Radial flow designs are used for slim-hole
high-pressure applications. Pancake (floater) designs are selected for abrasive, high-sand-content wells
because the floating impeller can shift axially to avoid grinding against diffusers.

Lesson 9: Case Study: Full Pump Sizing for a Vertical Oil

Well
Integrating all concepts from this module into a complete pump design.

Well and reservoir data

Parameter Value
Well type Vertical, cased hole, 7-inch casing
Reservoir pressure (Pr) 3,800 psi
Bubble point (Pb) 2,200 psi
PI 2.1 STB/day/psi (above Pb)
Target production rate 3,500 STB/day total liquid
Watercut 55%
Oil SG 0.86 (33 API)
Water SG 1.07
GOR 280 SCF/STB
Pump setting TVD 7,200 ft
Wellhead pressure 180 psi
Tubing 3.5-inch OD (ID = 2.992 inch)

Step 1: Fluid properties

SG_mix = (0.55 x 1.07) + (0.45 x 0.86) = 0.5885 + 0.3870 = 0.976

Step 2: IPR and required Pwf

q at Pb = PI x (Pr - Pb) = 2.1 x (3,800 - 2,200) = 3,360 STB/day
Since target rate (3,500 STB/day) > q_at_Pb (3,360), we need Pwf below bubble point. Using Vogel
anchored at (Pb, q_Pb):

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AOF = q_Pb + (AOF_Vogel from Pb) = 3,360 + additional Vogel capacity

Solving composite IPR at q = 3,500 STB/day, required Pwf ≈ 1,950 psi.

Step 3: Dynamic fluid level

Fluid level TVD = Pwf / (0.433 x SG_mix) = 1,950 / (0.433 x 0.976) = 4,610 ft

Step 4: TDH
NVL = 7,200 - 4,610 = 2,590 ft

Hf (friction in 3.5-inch tubing at 3,500 BPD, SG 0.976) = approx 380 ft

Hwh = 180 / (0.433 x 0.976) = 425 ft

TDH = 2,590 + 380 + 425 = 3,395 ft

Step 5: Pump selection and stages

Select a mixed-flow pump with BEP range 3,000–4,000 BPD in 7-inch casing. Example: Manufacturer
catalog shows pump GN4000 with head/stage of 27.2 ft at 3,500 BPD (design rate).

Stages = 3,395 / 27.2 = 125 stages

Motor HP required = (Q x H x SG) / (3,960 x Eta) = (3,500 x 3,395 x 0.976) / (3,960 x 0.68) =
4,408 HP -> select 450 HP motor (with VSD headroom)
This case study demonstrates the full design chain: reservoir → IPR → TDH → pump
selection → motor sizing. In practice, this workflow is iterative and is performed in design
software with manufacturer-specific pump curves imported.

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MODULE 4

Motor, Cable & Transformer Design

Electrical system design: from downhole motor sizing to surface power supply and
VSD selection.

Lesson 1: ESP Motor Fundamentals: Induction, Poles, Slip,

Torque
The ESP motor is a three-phase, two-pole squirrel-cage induction motor. It is the longest, slimmest
electric motor manufactured — with OD ranging from 3.38 to 7.31 inches and lengths of 10 to 40 feet
per section. Multiple motor sections can be tandem-coupled for higher HP.

Induction motor operating principles

Stator The fixed outer winding that carries three-phase AC current. Creates a rotating magnetic field
Rotor The inner rotating conductor (squirrel cage). Currents induced in the rotor bars by the rotating
Synchronous Speed (Ns)Speed of the stator's rotating magnetic field: Ns = 120 x f / P. For 2-pole motor at 60 Hz: Ns =
Slip (s) Difference between synchronous and actual rotor speed, expressed as fraction: s = (Ns - N) /
Torque Proportional to rotor current x magnetic field. At motor start, current is high (6-8x full load) and

Motor dielectric oil

ESP motors are filled with high-dielectric mineral or synthetic oil. This oil (1) insulates the motor
windings, (2) lubricates the rotor bearings, and (3) conducts heat from windings to the motor casing.
Motor oil must be replaced when contaminated by wellbore fluids entering through a failed seal section.

Lesson 2: Motor Sizing: HP, Voltage, Current, Power Factor

Motor HP is determined by the pump hydraulic power requirement plus mechanical losses. The motor
must be sized to handle the maximum HP demand at any operating condition over the well's life.

HP calculation
Hydraulic HP = (Q x TDH x SG) / 3,960 [Q in BPD, TDH in ft]

Shaft HP required = Hydraulic HP / Pump Efficiency

Motor nameplate HP >= Shaft HP / Motor Efficiency

Typical pump efficiencies at BEP: 50–70%. Typical motor efficiencies: 85–93%. Combined system
efficiency: 42–65%.

Voltage and current

ESP motors are available in voltage ratings from 230 V to 5,000+ V. Higher voltage motors draw less
current, allowing smaller-diameter cable (lower cost, lower voltage drop). For deep wells or high-power
motors, high voltage (2,300–4,500 V) is preferred.

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Motor Current (A) = HP x 746 / (sqrt(3) x V x PF x Eta_motor)

V Motor terminal voltage

PF Power factor (typically 0.85 for ESP motors at full load)
Eta_motor Motor efficiency (0.85–0.93)
746 Conversion factor: 1 HP = 746 Watts

Motor selection guidelines

• Select motor HP 10–15% above calculated requirement for reliability margin
• Motor temperature class must exceed anticipated BHT + motor heat rise
• Two-motor tandem configurations available for HP requirements above single motor limits
• Motor OD must fit within casing with cable clearance (minimum 0.2-inch gap each side)
• For high-temperature applications: premium motor oil + high-temperature lead wire extensions

Lesson 3: Motor Temperature Rating and Downhole Heat

Management
Temperature is the primary cause of ESP motor failure. Motor winding insulation life degrades
exponentially with temperature, following the Arrhenius relationship: every 10°C increase approximately
halves insulation life.

Temperature sources
Geothermal temperature The natural temperature of the formation at pump setting depth. Geothermal gradient varies by
Motor self-heating Electrical losses in the motor generate heat. A 200 HP motor operating at 90% efficiency gene
Cable heating I2R losses in the power cable also contribute heat to the wellbore fluid.
Fluid cooling Produced fluid flowing past the motor carries heat away. Minimum required flow velocity past m

Motor temperature classes

Class Max Winding Temp. Insulation Type Application
Standard 120°C Class H epoxy BHT < 90°C
High temp 150°C High-temp varnish BHT 90–120°C
XT (Extra) 180°C Specialty polymer BHT 120–150°C
Ultra-HT 204°C+ PEEK/advanced polymer Thermal EOR, steam wells

Motor shroud for cooling

In large casing (9.625-inch+) wells where the annular space is large and fluid velocity past the motor
would be insufficient, a motor shroud (a close-fitting sleeve around the motor) forces produced fluid to
flow past the motor in a narrow annulus, increasing velocity and improving cooling.

Lesson 4: Power Cable Selection: Size, Voltage Drop,

Ampacity
The power cable connects the surface switchboard to the downhole motor. It must carry the full motor
current at rated voltage over the entire depth, withstand downhole temperature, pressure, and produced
fluid environment, and fit within the casing-tubing annulus.

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Cable construction
Conductors Three copper conductors (one per phase). Size expressed in AWG (American Wire Gauge) or mm
Insulation Primary electrical insulation around each conductor. Materials: EPDM (standard, rated to 200°C), P
Jacket Outer jacket protects insulation from abrasion and wellbore fluids. Lead alloy jacket provides H2S a
Armour Galvanised or stainless steel interlocked armour provides mechanical protection and crush resistan
Configuration Round cable (standard, easier to handle) or flat cable (for tight annular clearances). Flat cable pref

Cable ampacity
Ampacity is the maximum continuous current a cable can carry without exceeding its temperature
rating. Ampacity in downhole service is derated from surface ratings because heat dissipation is limited
in the wellbore environment. Always use manufacturer downhole ampacity tables, not surface electrical
codes.

Lesson 5: Voltage Drop Calculations and Surface Voltage

Requirements
Voltage drop along the cable reduces the voltage available at the motor terminals. If motor terminal
voltage is too low, the motor draws excessive current (potentially causing overload), runs hot, and loses
efficiency.

Cable voltage drop formula

Voltage Drop (V) = sqrt(3) x I x R_cable x L / 1,000

I Motor current (A)

R_cable Cable resistance per 1,000 ft at operating temperature (ohm/1000ft) — from cable tables
L Cable length (ft) = well depth (MD) + surface pigtail
sqrt(3) Factor for three-phase system = 1.732

Surface voltage requirement

V_surface = V_motor + Voltage_Drop_in_cable
Example: Motor rated 2,300 V, current 45 A, cable #2 AWG (R = 0.511 ohm/1000ft at 120°C), cable
length 8,000 ft:

VD = 1.732 x 45 x 0.511 x 8,000 / 1,000 = 318 V

V_surface required = 2,300 + 318 = 2,618 V

The surface transformer secondary tap must deliver at least 2,618 V. Transformers have multiple tap
positions (typically ±5% in 2.5% steps) to allow field adjustment.

Lesson 6: Surface Transformer Sizing and Power Factor

Correction
The step-up transformer converts the distribution voltage (typically 11 kV, 33 kV, or 6.6 kV in oilfield
applications) to the correct motor voltage. It must handle the full ESP power load plus losses.

Transformer kVA sizing

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kVA = (HP x 0.746) / (PF x Eta_motor x Eta_cable)

For a 300 HP motor, PF = 0.85, motor efficiency = 0.90, cable efficiency = 0.96:

kVA = (300 x 0.746) / (0.85 x 0.90 x 0.96) = 223.8 / 0.7344 = 305 kVA
Select the next standard transformer size above: typically 315 kVA or 350 kVA.

Power factor
Induction motors inherently have lagging power factor (typically 0.80–0.87 at full load). Low power factor
means more reactive current flowing in the circuit, increasing cable losses and utility penalties. Power
factor correction capacitors can be added at the surface to bring PF toward unity, reducing overall
current draw and cable heating.

Lesson 7: Variable Speed Drive (VSD/VFD): Fundamentals

and Design
The Variable Speed Drive (VSD), also called Variable Frequency Drive (VFD), is now standard on
virtually all modern ESP installations. It converts fixed-frequency grid power into adjustable-frequency
output, allowing the motor and pump speed to be varied continuously.

How a VSD works

• Rectifier: converts incoming AC (50 or 60 Hz) to DC using diode or SCR bridge
• DC bus: smooths and stores DC energy in capacitors
• Inverter: converts DC back to AC at the desired output frequency (typically 30–90 Hz for ESP
service)
• Output filter: conditions the voltage waveform to reduce harmonics that damage motor insulation

Benefits of VSD in ESP design

Benefit Engineering Explanation
Optimise production rate Speed can be adjusted daily/weekly as reservoir conditions change, w
Soft starting Motor ramped up slowly, avoiding high inrush current and mechanical
Underload/overload protection VSD monitors current continuously and trips if limits exceeded
Energy savings Operating at lower speed reduces power by cube of speed ratio — ma
Gas lock recovery Speed can be reduced then ramped up to clear gas lock without pulling
Condition monitoring Modern VSDs log current, voltage, power, and vibration for trend analy

VSD sizing
VSD kVA rating must match or exceed transformer and motor kVA. VSD output voltage must cover the
required motor terminal voltage range. Always specify a VSD rated for the full output frequency range
needed (e.g., 30–90 Hz), harmonic filters if required by utility, and appropriate enclosure class for the
surface environment (NEMA 4X for offshore, NEMA 3R for sheltered onshore).

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MODULE 5

Gas & Solids Handling

Designing ESP systems to handle the two most common causes of premature
failure: free gas and abrasive solids.

Lesson 1: Free Gas at Pump Intake: Causes and

Consequences
Free gas at the pump intake is one of the most challenging problems in ESP design. Centrifugal pumps
are designed to handle liquid — introducing gas causes a cascade of problems ranging from reduced
efficiency to complete pump failure.

Why free gas appears at the pump intake

• Reservoir pressure drops below bubble point: gas comes out of solution in the formation itself
• Pressure drop from perforations to pump intake: even if reservoir Pr > Pb, the flowing bottomhole
pressure (Pwf) may fall below Pb
• Casing annulus gas migration: in high-GOR wells, gas rises through the casing to the pump intake
area
• Gas coning: if the gas cap is close to the perforations, gas can be dragged into the wellbore

Consequences of gas ingestion

Reduced head Gas bubbles take up space in the pump impeller, reducing the effective fluid volume and therefor
Gas locking If the gas fraction exceeds approximately 25–30%, the pump can completely fill with gas and sto
Cavitation Gas bubbles collapsing (imploding) in high-pressure zones damage impeller and diffuser surface
Motor overheating With no liquid flowing past the motor, cooling stops. Motor can burn out within minutes.
Motor underload trip VSD detects low current (low power consumption from no liquid load) and trips the ESP.

Lesson 2: Gas Separators: Natural, Rotary, and Advanced

Types
Gas separators (also called gas handlers or intake sections) are installed below the pump to separate
free gas from the liquid before it enters the pump, diverting the gas into the casing annulus for
production through the casing or for disposal.

Natural gas separator (static)

The simplest separator — essentially a specially designed intake section that allows gravity to separate
gas from liquid. Works by providing a low-velocity entry zone where gas bubbles can rise and separate
from the liquid. Effective at lower GOR (< 10–15% free gas at intake). Very low cost, no moving parts.

Rotary gas separator (dynamic)

A motorised centrifuge below the pump impeller stages. The rotating element flings liquid outward
(higher density, centrifugal force) and allows gas to migrate inward and upward to the casing annulus.

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Effective up to 50–60% free gas at intake. Most widely used gas separation device for moderate-to-high
GOR wells.

Vortex (Vortech) separators

Use a vortex chamber to create a cyclonic separation effect. Suitable for wells with high free gas
fractions but where a rotary separator's complexity is undesired. Some designs are rated for up to 75%
free gas inlet.

Advanced gas handling pumps

Specially designed pump stages with modified impeller/diffuser geometry that can handle gas-liquid
mixtures without locking — used when separation alone is insufficient. Examples include the Baker
Hughes GasHandlerTM and SLB gas handler stages. These stages do not separate gas but can pump
mixed-phase fluid up to 75–80% free gas fraction.

Lesson 3: Gas Separator Sizing and Selection Criteria

Selecting the correct gas separator requires knowing the free gas fraction at the pump intake — not the
GOR at surface, but the actual gas void fraction under downhole conditions.

Free gas fraction calculation

Free Gas Fraction (%) = Qg_free / (Qg_free + Ql_downhole) x 100
Where Qg_free = volume of free gas at pump intake conditions (after subtracting solution gas),
Ql_downhole = liquid volume at pump intake conditions (expanded from surface barrel by formation
volume factor).

Selection guide
Free Gas at Pump Intake Recommended Solution
< 10% Standard intake — no separator needed
10–25% Natural (static) gas separator
25–50% Rotary gas separator
50–75% Rotary separator + gas handling pump stages
> 75% Advanced gas handler pump + possible velocity string for gas venting

Always check separator efficiency. A rotary separator rated for 50% inlet gas fraction with
90% separation efficiency will only reduce free gas to 5% before the pump. But 10%
efficiency loss means 5% of 50% = 2.5% bypass — check this is within pump tolerance.

Lesson 4: Solids (Sand, Scale, Asphaltene) and ESP

Erosion
Solid particles in the produced fluid are the second major threat to ESP longevity. They cause abrasive
wear of rotating components, can block narrow flow passages, and accelerate corrosion when coupled
with chemically aggressive fluids.

Types of solids
Formation sand Quartz and feldspar grains from unconsolidated sandstone reservoirs. Most damaging due to h

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Scale (inorganic) Calcium carbonate, barium sulphate, or iron sulphide deposits that form when incompatible wat
Asphaltenes Heavy organic compounds that precipitate from oil when pressure drops below the asphaltene o
Corrosion products Iron oxides and sulphides from tubular corrosion. Soft but can accumulate in large volumes.
Proppant Fracturing sand or ceramic proppant from hydraulically fractured wells. Very abrasive if flowbac

Lesson 5: Sand-Resistant Pump Selection and Materials

When sand or abrasives are expected, pump material selection is critical. Standard ESP impellers and
diffusers are made from grey cast iron, which is adequate for clean service but quickly eroded by sand.

Material Hardness (HRc) Sand Resistance Corrosion ResistanceCost

Grey cast iron < 25 Poor Moderate Low
Ni-Resist iron ~30 Moderate Good Moderate
Alloy 17-4PH SS 35–40 Good Good Moderate-high
Tungsten carbide 70+ Excellent Moderate Very high
Abrasion-resistant
55–65 Very good Variable High
coating

Floating vs. fixed impeller (abrasive service)

In abrasive service, floating (pancake) impellers are strongly preferred. The impeller floats axially
between diffusers, never touching them, so abrasive particles do not get ground between fixed surfaces.
Fixed impellers in abrasive service experience rapid wear at the impeller-diffuser interface.

Lesson 6: Intake Design for High-GOR Wells

For wells with GOR exceeding 500 SCF/STB, a holistic intake design approach is needed that
considers both the gas separation strategy and the pump's ability to handle residual gas.

Integral approach
• Calculate free gas fraction at multiple points in the production forecast (current, 2 years, 5 years)
as GOR may change
• Select pump setting depth to maximise pump intake pressure (PIP) — deeper setting = higher PIP
= less free gas
• Use downhole pressure gauge to monitor PIP in real time; VSD control loops can maintain PIP
above set point
• Consider Y-tool completions (allows both ESP and gas production through casing) for very high
GOR wells
• In extreme cases (GOR > 5,000 SCF/STB), a velocity string or gas anchor tubing system may be
required to vent free gas past the ESP

Rule of thumb: Pump intake pressure should always be maintained above the bubble point
pressure if possible. If this cannot be achieved economically, ensure free gas fraction at
intake stays below the selected separator's rated capacity.

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MODULE 6

System Nodal Analysis & Optimization

Integrating the entire ESP system: IPR, pump curve, tubing curve, and VSD to find
the optimal operating point.

Lesson 1: Nodal Analysis Fundamentals for Artificial Lift

Nodal analysis is a systems approach that views the entire production system — reservoir, wellbore,
artificial lift equipment, and surface facilities — as a single connected flow path. By analysing pressure
at a chosen 'node' (typically the bottom of the tubing, just above the pump), the engineer can determine
the natural operating point of the system.

The concept of the node

Choose the pump discharge as the node. Two curves meet at this node:

• Inflow side: The IPR curve describes how the reservoir delivers fluid to the pump intake. The pump
adds TDH (converted to pressure) to this inflow energy. Together, these define the
'pump-plus-reservoir' delivered pressure at the node as a function of flow rate.
• Outflow side: The tubing performance curve (TPC, also called the outflow performance curve,
OPC) describes the pressure required at the pump discharge to lift fluid to surface and overcome
wellhead back pressure. This pressure increases with flow rate (due to friction).
• Operating point: Where inflow equals outflow — the intersection of the two curves. This is the
natural producing rate and pressure of the system.
Note: If the IPR + pump head curve lies entirely below the TPC (no intersection), the well cannot produce
at the current pump setting or rate. Increase pump stages, increase speed, or reduce wellhead back
pressure.

Lesson 2: Outflow Performance Curve (OPC/TPC)

Construction
The Tubing Performance Curve (TPC) describes, for a given wellhead pressure and completion
geometry, the bottomhole pressure required to sustain each possible flow rate. It includes hydrostatic
pressure of the fluid column and friction losses.

Key factors affecting TPC shape

Tubing size Larger tubing reduces friction at high rates but increases hydrostatic head (slower velocity, more
GOR Higher GOR means lighter fluid column (lower hydrostatic head) but may cause liquid holdup at l
Watercut Higher watercut increases average fluid density, increasing hydrostatic head.
Wellhead pressure Shifts the entire TPC up uniformly — higher WHP requires more pump head.
Flow rate At very low rates, friction is negligible but liquid holdup causes high hydrostatic head. At high rate

Generating the TPC

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For each assumed flow rate Q, calculate the required bottomhole flowing pressure using a multiphase
flow correlation (Hagedorn-Brown, Beggs-Brill, or mechanistic models). Plot required pressure vs. flow
rate. The result is the TPC. Modern nodal analysis software (PROSPER, PIPESIM) generates this
automatically from well and fluid data.

Lesson 3: Operating Point: Intersection of IPR and TPC

The operating point is found by overlaying the inflow (IPR + pump head) and outflow (TPC) curves on
the same graph. The intersection defines the natural producing rate and pressure.

Graphical analysis
Construction on a Pwf vs Q graph (pressure at pump node on y-axis, flow rate on x-axis):

• Plot IPR curve: from Pr on y-axis at Q=0, curving down to AOF on x-axis
• Plot pump curve: for each flow rate, add pump head (converted to psi) to the flowing bottomhole
pressure — this shifts the effective inflow curve upward
• Plot TPC: rising curve from minimum rate upward
• Intersection of (IPR + pump head) with TPC = operating point
• If pump head is increased (more stages or higher speed), intersection moves right and up (higher
rate)

Lesson 4: Speed Sensitivity: Effect of VSD on System

Performance
One of the most powerful advantages of VSD-equipped ESPs is the ability to change the pump speed
and observe how the operating point shifts. Speed sensitivity analysis is used to identify the optimal
operating speed.

Pump curve family at different speeds

Using Affinity Laws, a family of pump curves can be generated at different speeds:

At speed N2: Q2 = Q1(N2/N1), H2 = H1(N2/N1)^2

Plotting the TPC and the pump curves at 60 Hz, 50 Hz, 45 Hz, and 40 Hz gives multiple intersection
points, showing the range of achievable production rates.

VSD Frequency (Hz) Pump Speed (RPM) Flow Rate (BPD) Power (HP) Notes
60 Hz 3,500 3,800 280 Maximum speed — high rate, maxim
55 Hz 3,208 3,485 215 Near-design operating point
50 Hz 2,917 3,165 160 Moderate rate — good efficiency
45 Hz 2,625 2,850 116 Low rate — reduced power, reservoi
40 Hz 2,333 2,530 82 Minimum recommended — risk of m

Lesson 5: Optimising ESP Design for Current and Future

Production
An ESP system that is perfectly matched to today's conditions may be poorly suited to conditions 2–3
years from now. Optimisation requires designing for the full production forecast, not just a snapshot.

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Life-of-well optimisation strategy

• Develop production forecast: rate vs. time, watercut vs. time, GOR vs. time, reservoir pressure vs.
time
• Calculate TDH and HP requirements at each future time step
• Design ESP for the mid-life or maximum HP condition; verify it can operate at start-of-life
conditions (often with VSD at reduced speed)
• Identify the ESP replacement trigger: when VSD is at maximum speed and still cannot meet target
rate, it is time for a workover with a higher-capacity ESP
• Consider phased design: first ESP sized for early high-GOR period; replacement at waterflood
breakthrough sized for high-watercut, high-volume service

Lesson 6: Using PROSPER / OFMwell for ESP Design

Manual calculations are essential for understanding fundamentals and for checking software outputs —
but real ESP design is done in specialised software that integrates reservoir, wellbore, and equipment
models.

PROSPER (Petroleum Experts)

The most widely used ESP design and nodal analysis software in the industry. Key capabilities:

• Import manufacturer pump curves directly from database

• Generate IPR from test data using multiple correlations
• Multiphase TPC using Beggs-Brill, Hagedorn-Brown, or OLGAS correlations
• VSD speed sensitivity plots generated automatically
• Motor and cable sizing integrated with pump design
• PVT fluid property modelling using EOS or correlations
• Match to measured well test data for model validation

OFMwell (Schlumberger/SLB)
Primarily a production data management and decline analysis tool, OFMwell integrates with Avocet and
PIPESIM for full field production optimisation. Often used alongside PROSPER for field-level ESP fleet
management.

Other tools
Baker Hughes JewelSuite, Weatherford Perform (COMPASS), and Echometer (for acoustic fluid level
measurement) are other common tools in the ESP engineer's toolkit. For offshore applications, OLGA
dynamic simulation is used for slugging and transient flow analysis.

Lesson 7: Case Study: Nodal Analysis Optimization in a

GOR-Changing Well
Scenario: An oil producer with increasing GOR due to gas cap breakthrough.

Condition Year 1 Year 3 Year 5

Reservoir pressure (psi) 3,200 2,900 2,600
GOR (SCF/STB) 350 1,200 2,500
Watercut (%) 20% 40% 60%

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Target liquid rate (BPD) 4,500 4,000 3,500

TDH required (ft) 2,850 3,100 3,350
Required ESP speed (Hz) 58 62* 65*

*Above 60 Hz requires a 60 Hz VSD capable of 65 Hz output — specify this at design stage.

Year 1: ESP operating at 58 Hz. Nodal analysis shows intersection at 4,500 BPD. System is stable, free
gas at pump intake = 8% (no separator needed).

Year 3: GOR has increased. Free gas fraction rises to 32%. Rotary gas separator now critical. ESP
speed increased to 62 Hz to overcome higher TDH. Power increases by 12%.

Year 5: GOR = 2,500. Free gas fraction at intake = 51%. Rotary separator + gas handling stages now
required. ESP speed at 65 Hz — approaching mechanical limit. Workover planned for Year 6 with larger
pump sized for high-GOR, high-watercut fluid.

This case study shows why a full life-of-well analysis — not just initial conditions — is
essential. The Year 1 ESP cannot handle Year 5 conditions. Planning for the workover at
Year 1 allows procurement and logistics preparation, minimising deferred production.

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MODULE 7

Completion, Installation &

Commissioning
From wellbore preparation to first production: safe and effective ESP deployment
procedures.

Lesson 1: Wellbore Completion Considerations for ESP

Deployment
A well must be properly prepared before an ESP can be successfully installed. Wellbore condition
directly affects ESP run life and production performance.

Pre-installation wellbore checks

Casing integrity Pressure-test the casing to confirm no leaks. Inspect for corrosion, deformation, or restrictions u
Wellbore deviation survey
Confirm dogleg severity (DLS) profile. High DLS sections impose bending loads on the ESP str
Scale and debris removal
Run a cleanout trip if scale, wax, or fill is present. ESP cannot run through restrictions. A tubing
Perforation condition Confirm perforations are open and not plugged. Consider stimulation (acid job) before ESP inst
Fluid level Measure static fluid level before pulling existing lift equipment. Confirm well has sufficient fluid c
Temperature profile Run a temperature survey (if possible) to confirm BHT. Compare with design assumptions.

Lesson 2: ESP String Assembly Sequence and Pre-job

Checks
The ESP string is assembled at the wellsite in a specific sequence, working upward from the bottom
(motor) to the top (pump discharge connector). Correct assembly is critical — errors discovered
downhole require a complete pull.

Assembly sequence (bottom to top)

1. Motor flat cable
Attach the motor flat cable (lead extension) to the motor head terminal. Ensure correct phase connections
2. Motor section(s)
Lower the motor(s) onto the wellhead stand. Check oil fill level and condition. Record motor serial numbe
3. Seal section Connect
(protector)
seal to motor head. Verify shaft make-up torque. Check equalisation ports are unblocked.
4. Gas separator
Connect
/ intakeseparator to seal section. Confirm intake screens are clear. Verify rotation direction arrow aligns
5. Pump section(s)
Connect pump to separator/intake. Verify shaft make-up and rotation. Count and record housing, stages,
6. Check valve Install check valve (prevents backflow through pump when ESP stops — protects pump from reverse spin
7. Bleeder valveAllows
(optional)
tubing pressure to bleed off when pump is stopped, enabling safe workover.
8. Tubing connector
Connect ESP string to first joint of production tubing.

Pre-job checks
• Megger test (insulation resistance test): >100 MOhm between each phase and ground, before and
after assembly. Values < 1 MOhm indicate insulation failure — do not run.

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• Continuity check: resistance between phases should be balanced (within 5% of each other)
• Shaft rotation check: rotate shaft by hand or with rotation tool — should spin freely with no binding
• Cable armor and jacket inspection: no cuts, kinks, or abraded spots
• Check valve test: verify it holds pressure in one direction and opens in the other

Lesson 3: Running ESP into the Well: Procedures and

Precautions
Running the ESP string into the well requires a workover rig or hydraulic workover unit. The cable is
clamped to the tubing as each joint is made up and lowered.

Running procedure
Cable clamping Cable is clamped to tubing every 2–3 ft near the ESP string, then every 15–30 ft up the tubing st
Cable protectors Rubber cable protectors installed in the coupling area prevent cable damage as the string is run
Torque and make-up All tubing connections must be made up to correct torque. Under-torqued connections can back
Running speed ESP string should be run slowly (< 100 ft/min) through doglegs and tight spots. Avoid jarring or im
Fluid fill-up As the string is run, the wellbore fluid level may be displaced upward. Monitor fluid returns at sur
Cable monitoring Monitor cable insulation resistance at surface while running. Any sudden drop indicates cable da
Final depth confirmation
Verify setting depth with tubing tally. Confirm pump intake is at or below the design depth.

Lesson 4: Surface Electrical Testing and Pre-startup

Checks
Once the ESP is at depth and the wellhead is dressed, a comprehensive electrical test must be
performed before energising the system.

Electrical tests at depth

Test Procedure Acceptance Criteria
Insulation resistance (MO) Megger at 500V or 1000V between each
> 100
phase
MOhm
and(new),
ground> 10 MOhm (used)
Phase balance (Ohm) Measure resistance of each phase: A-B,
Within
B-C,5%
C-A
of each other
Phase sequence Confirm phase rotation matches motorA-B-C
design
sequence
rotation
Open-circuit voltage Apply rated frequency, measure no-load
Within
voltage
±2%atofMCU
nominal
No-load current Measure current with pump spinning freely
< 50%(no
of production)
full load current

VSD pre-startup configuration

• Set start ramp-up time: typically 60–180 seconds for soft start
• Set minimum frequency: 35–40 Hz (to ensure adequate motor cooling flow)
• Set maximum frequency: per design (typically 60 or 65 Hz)
• Set overload trip: 110–120% of full load current
• Set underload trip: 60–70% of full load current (detects gas lock or pump-off)
• Configure communication protocol (Modbus, Profibus, or proprietary) for SCADA integration

Lesson 5: Startup Procedure, Ramp-up, and Initial Well

Monitoring

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The first hours of ESP operation are critical. Damage occurring during startup — due to incorrect
frequency, insufficient fluid level, or unexpected downhole conditions — can cut run life dramatically.

Startup sequence
Step 1: Pre-startup Confirm
fluid level
fluid level is above the pump intake. If fluid level has been swabbed down, allow recovery tim
Step 2: Initial speedStart at minimum frequency (35–40 Hz). This reduces inrush current and allows the well to establish
Step 3: Monitor current
Watch motor current at each frequency step. Current should be smooth and balanced between phas
Step 4: Ramp to target
Increase
speedspeed in 2–5 Hz increments, holding 15–30 minutes at each step to allow the well to stabilis
Step 5: Establish production
Once at target speed, measure surface production rate, flowing wellhead pressure, and monitor dow
Step 6: Verify operating
Compare
pointmeasured flow rate and PIP against design predictions. Discrepancies indicate incorrect IP
Step 7: First-week monitoring
Monitor motor current trend, PIP, temperature, and production rate daily for the first week. Most infan

A well-designed startup protocol has prevented more ESP failures than any other single
intervention. Never rush the ramp-up. Each step builds confidence in the system and allows
safe intervention if abnormal conditions are detected.

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ESP System Design — Complete Training Course Oil & Gas Artificial Lift Engineering

MODULE 8

Monitoring, Troubleshooting &

Advanced Topics
Keeping ESPs running at peak performance, diagnosing failures, and designing for
the most demanding applications.

Lesson 1: Downhole Gauges and SCADA: Interpreting

Real-Time Data
Modern ESP installations are equipped with downhole monitoring gauges and connected to SCADA
(Supervisory Control and Data Acquisition) systems. Real-time data is the foundation of proactive ESP
management.

Downhole gauge parameters

Pump intake pressure (PIP)
The most important downhole parameter. Compares directly to IPR design. Rising PIP sugges
Pump discharge pressurePressure
(PDP) above the pump. PDP - PIP = differential pressure across the pump. Compares direc
Motor temperature (Tmot)Winding or oil temperature. Rising temperature trend warns of insufficient fluid cooling or incre
Vibration (g) Accelerometer signal. High vibration indicates mechanical issues: bent shaft, worn bearings, c
Downhole current (I) Some systems measure current at motor level. Surface MCU current is more commonly used.
Casing pressure (Pc) Pressure in the casing annulus above the packer (if installed). Monitors for gas cap production

SCADA integration
SCADA systems aggregate data from all ESP wells on a field, allowing production engineers to monitor
fleet health from a control room. Key SCADA functions for ESP management:

• Real-time current, voltage, power, and frequency display for each well
• Automated alarms for overload, underload, phase imbalance, and low insulation resistance
• Trend plots for PIP, production rate, and motor temperature over time
• Automated speed adjustments (closed-loop control) based on PIP set points
• Event logging: records every trip, restart, speed change, and alarm for post-event analysis

Lesson 2: Common Failure Modes: Overload, Underload,

Gas Lock, Burnout
Understanding ESP failure modes allows the engineer to diagnose problems from surface data and plan
appropriate interventions — sometimes avoiding a costly workover by making operational adjustments.

Failure Mode Symptoms Likely Cause Intervention

Overload Current > 110% FLA, VSD trips
Pumpon blocked,
OL scale, wrongReduce
fluid SG,speed,
VSD frequency
backwash,too
chemical
high treatm
Underload Current < 60% FLA, VSD trips
Pump-off
on UL (low fluid level), gas
Reduce
lock, check
speed,
valve
cycle
stuck
pump,
open
wait for fluid l

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ESP System Design — Complete Training Course Oil & Gas Artificial Lift Engineering

Gas lock Current drops sharply, PIP drops,

Free gas
no flow
fraction too high, separator
Reduce speed,
failure cycle, check separator
Motor burnout Phase imbalance, insulation Winding
resistance
failure
dropsfrom overheating
Pull and
or water
replace
ingress
— full ESP workover
Cable failure Phase fault, low IR, current imbalance
Cable damage during run, corrosion,
May be repairable
thermal cycling
at wellhead
fatigue— check ar
Seal failure PIP drops (fluid entering motor),
Sealburnout
face wear,
follows
pressure differential
Pull and failure
replace ESP
Pump wear Declining head at constant speed,
Abrasion
falling
from
rate
sand/scale Increase speed, then plan workover when

Lesson 3: ESP Run Life Analysis and Failure Root Cause

Methods
Improving ESP run life is one of the most impactful activities an ESP engineer can undertake. The mean
time between failures (MTBF) for a field's ESP fleet directly determines workover costs, deferred
production, and overall field economics.

Run life benchmarking

Industry average ESP run life varies significantly by field type. Onshore heavy oil with sand: 6–18
months. Offshore deepwater clean crude: 3–5 years. High-temperature geothermal: 6–24 months. The
goal is continuous improvement beyond field average.

Failure root cause analysis (RCA) process

Step 1: Pre-pull data Before
review pulling the ESP, collect all data: run life, operating history, alarm events, current trends, PIP
Step 2: Pull and shipping
Carefully pull the ESP, preventing further damage. Mark orientation. Ship to teardown facility witho
Step 3: Visual inspection
Systematic inspection of each component: erosion, corrosion, scale deposits, burnt insulation, sea
Step 4: Failure classification
Classify failure as mechanical, electrical, chemical, or operational. Assign primary cause and contr
Step 5: Corrective action
Modify design (materials, component selection), operational procedures (setpoints, chemical treatm
Step 6: Track MTBF trend
Measure MTBF before and after corrective actions. A sustained improvement of >20% in fleet MTB

Lesson 4: Corrosive Environments: H2S, CO2,

High-Salinity Design
Many oilfield environments contain corrosive species that require specific material selections, chemical
treatment programs, and design modifications. Failure to account for corrosion leads to premature
failures invisible to performance monitoring until catastrophic.

H2S (sour service)

H2S causes sulphide stress cracking (SSC) in high-strength steel components and can destroy
elastomeric seals. Design requirements for sour service:

• All carbon steel and low-alloy steel components must comply with NACE MR0175 / ISO 15156
• Maximum hardness limits: HRC 22 for carbon steel in direct H2S contact
• Lead alloy cable jacket provides excellent H2S barrier for cable insulation
• Elastomers: Aflas or HNBR preferred over EPDM in high H2S
• Motor terminal blocks must be sealed against H2S ingress
• Stainless steel (316L or duplex) preferred for pump stages in high H2S

CO2 (sweet corrosion)

CO2 dissolved in water forms carbonic acid (H2CO3), causing general and pitting corrosion in carbon
steel. At high temperatures and CO2 partial pressures, corrosion rates can exceed 10 mm/year.

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Mitigation:

• Corrosion-resistant alloys (CRA) for pump stages in high-CO2 wells (13Cr, Duplex SS, Alloy 718)
• Continuous corrosion inhibitor injection via chemical injection mandrel below the ESP
• Monitor corrosion coupons in flowline to track effectiveness
• De Waard-Milliams model used to predict CO2 corrosion rates for material selection

High-salinity brine
Formation water with TDS > 100,000 mg/l is highly corrosive and may cause scale deposition (CaCO3,
BaSO4). Design for high-salinity:

• Scale inhibitor squeeze treatment before ESP installation

• Continuous scale inhibitor injection
• CRA or epoxy-coated components in flow path
• Monitor scaling tendency with Langelier Saturation Index (for carbonate scale)

Lesson 5: Advanced: ESP Design for Deviated, Horizontal

& Thermal Wells
ESP design for non-standard well geometries and high-temperature applications requires modifications
to the standard design workflow.

Deviated and horizontal wells

When wellbore deviation exceeds 30 degrees, ESP design must address additional mechanical
challenges:

• Gravity loads: the ESP weight acts perpendicular to the wellbore axis, creating bending moments
at connections
• Cable damage risk: cable can be pinched between tubing and casing in high-angle sections — use
cable flatpacks and wear-resistant protectors
• TDH calculation: use TVD (not MD) for all hydrostatic head calculations; use MD for friction loss
calculations
• Pump bearing loads: side loads from deviation increase radial bearing wear — use extra
heavy-duty (XHD) bearings
• Motor cooling: fluid velocity past motor depends on annular geometry, which changes with
deviation and centralizer placement
• In horizontal sections: ESPs are sometimes set in the vertical or near-vertical portion of the
wellbore above the kickoff point, with horizontal wells drilled to drain into the sump

Thermal EOR applications

Steam-assisted gravity drainage (SAGD) and cyclic steam stimulation (CSS) wells operate at
temperatures of 180–250°C — well beyond standard ESP ratings. Specialised design elements for
thermal applications:

• Ultra-high-temperature motor insulation (PEEK, ceramic-coated windings)

• High-temperature dielectric motor oil (synthetic POE or silicone-based)
• Metal-to-metal seal protectors (no elastomers) for steam compatibility
• Flat cable with Teflon insulation and lead alloy jacket rated to 230°C

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ESP System Design — Complete Training Course Oil & Gas Artificial Lift Engineering

• Downhole gauges rated to 250°C+

• Thermal expansion joints to accommodate steel elongation
• Continuous monitoring of motor temperature as primary intervention trigger

SAGD ESP design is one of the most demanding applications in the industry. Motor failures
in thermal wells are typically caused by temperature excursions during steam injection
cycles when hot steam contacts the cooler motor. Thermal cycling causes insulation
cracking and accelerated ageing. Always design with 20-30°C margin above anticipated
peak BHT.

Course Summary & Next Steps

Congratulations on completing the ESP System Design training course. You have covered the full
engineering design workflow from reservoir analysis through component selection, nodal analysis,
installation, and advanced applications.

Key skills acquired

• Build IPR curves from well test data using Vogel, Darcy, and Fetkovich methods
• Calculate TDH including NVL, friction losses, and wellhead back pressure
• Size and select ESP pump stages, motor HP, cable AWG, and transformer kVA
• Perform nodal analysis and VSD speed sensitivity analysis
• Design gas separation and solids-handling strategies for challenging wells
• Interpret downhole gauge and SCADA data for proactive ESP management
• Apply NACE-compliant materials selection for sour and corrosive service
• Adapt ESP design methods to deviated, horizontal, and thermal wells

Recommended next steps

• Practice TDH and nodal analysis calculations on real well data from your field
• Obtain access to PROSPER or equivalent software and replicate your hand calculations
• Review manufacturer pump curve catalogues (Baker Hughes, SLB REDA, Borets, Weatherford)
• Study API RP 11S series: Recommended Practice for ESP System Design
• Pursue SPE (Society of Petroleum Engineers) continuing education on artificial lift
• Participate in ESP post-mortem reviews to build failure analysis experience
• Study NACE MR0175 for sour service material requirements in depth

End of ESP System Design — Complete Training Course

All content is for educational purposes. Always refer to manufacturer specifications,
applicable API/ISO standards, and company engineering policies for field design work.

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