ESP

Centrifugal
Pump
PREPARED BY: BASHAR K.MUSTAFA
Table Content
• Electric Submersible Pump (ESP) Introduction.

• Pump Components.
• ESP Pump Stage Deigns (Radial, Mixed & Axial).
• Impeller Thrust (Up & Down).
• Tornado Curve.
• Pump Performance Curve with Example.
• Total Dynamic Head (TDH) Calculation.
• Deference Between Floater & Compression Pump and Uses.
Electric Submersible Pump (ESP)
Electric Submersible Pumps (ESP) are an effective
and economic method of producing large volume of
fluid’s from wellbore to surface.
Surface Components: Transformers, surface power
cable, variable speed drive, junction box & wellhead
penetrator.
Downhole Components: Motor, Seal, Intake, Pump,
motor lead extension(MLE), ESP cable, and sensor.
Centrifugal Pump
Pump is one of the ESP downhole components and its
multistage centrifugal design uses to lift fluid from the
wellbore to surface which contain a number of stages.

Pump located between intake and pump discharge at the

lower bolted with intake and upper of pump connected
with discharge head.
Pump Component
Main Pump components are the following:
1- Flange Head
2- Housing
3- Shaft
4- Stages (Impeller & Diffuser)
5- Bearing
6- Pump Base
7- Coupling
8- Nameplate
Pump Component
Flange Head: Flange head located on top of centrifugal
pump it’s the connection point between pump and
discharge head.
Pump Housing: is the body of the pump
which covered the whole pump.
Pump Component
Shaft
Shaft transfer the torque from motor through the seal and
intake to the pump which provides torque to rotating the
Impellers inside diffusers, normally shaft are manufactured
from (K-Monel) and high strength shafts manufactured from
Inconel generally Inconel can handle more torque than k-
Monel.
shaft diameter also determines the maximum torque
capacity depending on the metal that manufactured from.
Pump Component
Pump Stage
Pump contain a number of stages each stage contains a
rotational impeller and stationary diffuser, the impeller sets
inside of diffuser, and fluid inters in the impellers eye then
pressurizes by the vanes and raises to next stage, impellers
are connected with shaft which rotates at the motor rpm
rotation, stacking impeller and diffuser provides head.
Diffuser Impeller
A Pump Stage
Stage Component’s
Hub

Top shroud

Bottom
shroud

Vane
Impeller flow passage
Pump Stage Designs
Radial Flow Impeller, Mixed Flow Impeller, Axial Flow Impeller.
Radial Stage Design
Radial Stage Design: In radial flow the fluid enters the impeller
axially and leaves radially, vane angle close to 90 and usually
found in pump for low ranges flow rate, and gas handle capacity
is 10% and Poor handling of fluid problems (Gas, and solids,
Viscous fluids).
Mixed Stage Design
Mixed Stage Design: Fluid enters axially then leaves axial &
radially and its vane angle close to 45 and usually found in
pump ranges for higher flow rate, and gas handle capacity is
20-25%, can handle better than radial impellers of fluid
problems (Gas, and solids, Viscous fluids).
Axial Stage Design
Axial Stage Design: axial Impeller pushes the fluid in
a parallel direction to the pump shaft, and fluid
inters and leaves the impeller axially, axial pumps
are most efficient in applications requiring high
rates of flow to be pumped at low pressures.
Gas handle capacity 75%
Impeller Thrust
There are three forces effecting on impeller.
1- Gravity Gravity
Upper
2- Pressure shroud
3- Momentum

lower
shroud

Momentum
Impeller Thrust
The Sum of all Three Forces Called Net Thrust.
1- Pressure: the difference between the pressure above and the pressure below
acting on the impeller area causing down thrust.
2- Gravity: is the weight of the impeller.
3- Momentum: Change in fluid momentum (This reaction the force required to direct
the fluid into a radial direction) causing up thrust
Impeller Thrust
Low pressure
Up-Thrust is when the bottom pressure or lower
shroud pressure becomes higher than discharge
pressure which pump produces while pumping
fluid. High pressure
Down-Thrust when the fluid pressure on the High pressure
upper impeller shroud(discharge pressure)
becomes higher than lower shroud pressure it
cause to down-thrust.
Low pressure
Pump Bearing’s
There's two types of radial bearings
1- Radial Bearing: Insures radial rotation only to pump components.
2- Mushroom Bearing: Insures both radial rotation & axial thrust.
Bearing Configuration
• SND: Stabilize normal Duty 1:3
• SHD: Stabilize Heavy Duty 1:3
• SSD: Stabilize Superior Duty 1:1
• SXD: Stabilize Extreme Duty 1:1
Pump Stage & Bearing
Pump Component
Coupling
Coupling is the mechanical part of pump which uses to
connect two shafts to transfer power which provided by
the motor,
coupling in tandem pump will be longer and stronger then
single pumps due to be able to handle the power and
torque which is higher than the single pump,
shims placed in coupling to raise the shaft, usually
shimming uses between (pump to pump) and (intake to
pump).
Pump Component
Pump Base:
Pump base is the base of the pump which bolted with intake
or gas separator or gas handler if there’s a gassy wells.
Tornado Curve
Pump Performance curve
On Pump curve we can determine the following; Y-Axis

1- Flow (bbl/day). (X-Axis)

2- Head (feet or m). (Y-Axis)
3- Head (Blue curve).
4- Efficiency (Green line).
5- Horsepower HP (Red line).
6- Shaded area (Recommended Operating Range,
ROR) X-Axis
Q/In TD1750 pump at 60hz 3500RPM and Sp.gr 1.0 at 1800bbl/day on the pump curve.
1- Head per Stage ?
2- horsepower HP/stage ?
3- Efficiency(%) ?
@1800bbl/d
@1800bbl/d, head per stage = 20ft
@1800bbl/d, head per stage = 20ft
@1800bbl/d, head per stage = 20ft HP=0.38hp/stg
@1800bbl/d, head per stage = 20ft HP=0.38hp/stg
k @1800bbl/d, head per stage = 20ft HP=0.38hp/stg Efficiency =68%
 Pump Calculations
Head per stage: can be determines from the pump curve directly.
Total Dynamic Head = Net lift + Friction loss + wellhead pressure.
Net lift: Measures the height from production fluid level to surface (flow line
gauge) and in deviated wells only vertical distance will be measure.(annulus).
Friction loss: is the friction of the fluid inside tubing, measures from pump
discharge to wellhead.
Wellhead Pressure: is the pressure which formed because of fluid pumping
while operation.
Net Vertical Lift
Net Vertical Lift:

2100ft
Measures the height from production
fluid level to surface(out of tubing),
but In deviated wells only vertical
distance will be measure.
all these measurements will be done
from outer of tubing or in annulus.
Lets Assume that Net lift =2100ft
TVD=MD TVD = MD

TVD=1325 TVD=993m
MD=1325 TVD=993 MD=1325m

TVD: measures only the

MD: measures the total
vertical distance of the
distance of the well
well.

MD=1325m
Total Friction Loss
Friction loss:
While operating the pump and lifting fluid there will
be friction between the fluid and tubing.
friction measured from the pump discharge to
wellhead or under Christmas tree.

Friction loss
Calculating the total friction loss it will be in a Fluid level
chart by knowing the flowrate(Q). pump
discharge
 Note:
First find flow on X-axis
Second go up till your tubing
size
Third on Y-Axis determine the
50 friction loss

Tubing size=2 3/8” and Q=1800bbl/day

Tubing length= 4500ft
1800 bbl/day 4500 ft
Tubing length= 1000 = 4.5‘
Friction loss= 70ft
For 2 3/8” Friction= 70x 4.5 = 315 feet
of loss
Wellhead Pressure
Wellhead Pressure: Wellhead pressure
gauge
Is the pressure which formed because of fluid
pumping while operation,
wellhead pressure can be taken directly from
wellhead flow line gauge on surface and it must be
in(feet) unit while using in TDH calculation.
 Equation to converting from psi to feet

𝑊𝑒𝑙𝑙ℎ𝑒𝑎𝑑 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒(𝑝𝑠𝑖) 141.5

Wellhead Pressure(ft)= sp.gr=
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥 𝑆𝑝.𝑔𝑟 131.5+𝐴𝑃𝐼
Wellhead Pressure
Example:
𝑊𝑒𝑙𝑙ℎ𝑒𝑎𝑑 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒(𝑝𝑠𝑖)
1- Wellhead pressure=220psi Wellhead pressure (feet)=
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥 𝑠𝑝.𝑔𝑟
Specific gravity = 1.07
220 𝑝𝑠𝑖
Wellhead Pressure (ft)= =
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥1.07

If sp.gr was not given we can find out with sp.gr equation
Wellhead pressure= 220 psi 141.5 141.5
sp.gr= sp.gr= Sp.gr0.876
API =30 131.5+𝐴𝑃𝐼 131.5+30
Note: Now sp.gr can be
use in the equation to
find WHD(ft)
Wellhead Pressure
Example:
𝑊𝑒𝑙𝑙ℎ𝑒𝑎𝑑 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒(𝑝𝑠𝑖)
1- Wellhead pressure=220psi Wellhead pressure (feet)=
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥 𝑠𝑝.𝑔𝑟
Specific gravity = 1.07
220 𝑝𝑠𝑖
Wellhead Pressure (ft)= =
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥1.07

If sp.gr was not given we can find out with sp.gr equation
Wellhead pressure= 220 psi 141.5 141.5
sp.gr= sp.gr= Sp.gr0.876
API =30 131.5+𝐴𝑃𝐼 131.5+30
Wellhead Pressure
Example:
𝑊𝑒𝑙𝑙ℎ𝑒𝑎𝑑 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒(𝑝𝑠𝑖)
1- Wellhead pressure=220psi Wellhead pressure (feet)=
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥 𝑠𝑝.𝑔𝑟
Specific gravity = 1.07
220 𝑝𝑠𝑖
Wellhead Pressure (ft)= = 475 feet
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥1.07
Wellhead Pressure
Example:
𝑊𝑒𝑙𝑙ℎ𝑒𝑎𝑑 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒(𝑝𝑠𝑖)
1- Wellhead pressure=220psi Wellhead pressure (feet)=
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥 𝑠𝑝.𝑔𝑟
Specific gravity = 1.07
220 𝑝𝑠𝑖
Wellhead Pressure (ft)= = 475 feet
0.433 𝑝𝑠𝑖/𝑓𝑡 𝑥1.07

2- If sp.gr was not given we can find out with sp.gr equation by having API.
Wellhead pressure= 220 psi 141.5 141.5
sp.gr= sp.gr=
API =1 131.5+𝐴𝑃𝐼 131.5+1

Sp.gr 1.07 Note: Now sp.gr can be use in the equation to

find WHD(ft)
Total Dynamic Head (TDH) Calculation
Net lift =2100ft
Friction loss = 315ft
Wellhead pressure= 475ft

Net Lift’
TDH= Net lift + Friction loss + wellhead pressure
TDH=
Total Dynamic Head (TDH) Calculation
Net lift =2100ft
Friction loss = 315ft
Wellhead pressure= 475ft

TDH= Net lift + Friction loss + wellhead pressure

TDH= 2100’ +
Total Dynamic Head (TDH) Calculation
Net lift =2100ft
Friction loss = 315ft
Wellhead pressure= 475ft

TDH= Net lift + Friction loss + wellhead pressure

TDH= 2100’ + 315’ +
Total Dynamic Head (TDH) Calculation
Net lift =2100ft
Friction loss = 315ft
Wellhead pressure= 475ft

TDH= Net lift + Friction loss + wellhead pressure

TDH= 2100’ + 315’ + 475’
Total Dynamic Head (TDH) Calculation
Net lift =2100ft
Friction loss = 315ft
Wellhead pressure= 475ft

TDH= Net lift + Friction loss + wellhead pressure

TDH= 2100’ + 315’ + 475’
TDH= 2890feet
 Example
For Example: TDH= 2890 feet and head per stage =20ft Tubing
well
𝑇𝑜𝑡𝑎𝑙 𝑑𝑦𝑛𝑎𝑚𝑖𝑐 ℎ𝑒𝑎𝑑 .𝑚
Total required stages = = =
ℎ𝑒𝑎𝑑 𝑝𝑒𝑟 𝑠𝑡𝑎𝑔𝑒 20𝑓𝑡

TDH= 2890ft
20ft/Stage
40ft two
stages 20ft/Stage
 Example
For Example: TDH= 2890 feet and head per stage =20ft Tubing
well
𝑇𝑜𝑡𝑎𝑙 𝑑𝑦𝑛𝑎𝑚𝑖𝑐 ℎ𝑒𝑎𝑑 2890𝑓𝑡
Total required stages = = =
ℎ𝑒𝑎𝑑 𝑝𝑒𝑟 𝑠𝑡𝑎𝑔𝑒 20𝑓𝑡

TDH= 2890ft
20ft/Stage
40ft two
stages 20ft/Stage
 Example
For Example: TDH= 2890 feet and head per stage =20ft Tubing
well
𝑇𝑜𝑡𝑎𝑙 𝑑𝑦𝑛𝑎𝑚𝑖𝑐 ℎ𝑒𝑎𝑑 2890 𝑓𝑡
Total required stages = = =
ℎ𝑒𝑎𝑑 𝑝𝑒𝑟 𝑠𝑡𝑎𝑔𝑒 20𝑓𝑡

TDH= 2890ft
20ft/Stage
40ft two
stages
20ft/Stage
 Example
For Example: TDH= 2890 feet and head per stage =20ft Tubing
well
𝑇𝑜𝑡𝑎𝑙 𝑑𝑦𝑛𝑎𝑚𝑖𝑐 ℎ𝑒𝑎𝑑 2890𝑓𝑡
Total required stages = = =145 Stages
ℎ𝑒𝑎𝑑 𝑝𝑒𝑟 𝑠𝑡𝑎𝑔𝑒 20𝑓𝑡

TDH= 2890ft
20ft/Stage
40ft two
stages 20ft/Stage
 Example
For Example: TDH= 2890feet and head per stage =20ft Tubing
well
𝑇𝑜𝑡𝑎𝑙 𝑑𝑦𝑛𝑎𝑚𝑖𝑐 ℎ𝑒𝑎𝑑 2890 𝑓𝑡
Total required stages = = =145 Stages
ℎ𝑒𝑎𝑑 𝑝𝑒𝑟 𝑠𝑡𝑎𝑔𝑒 20𝑓𝑡

TDH= 2890ft
Total Hp required = hp per stage x total stages x sp.gr
Horsepower per stage = 0.38hp x 145sgt x 1 = 55hp
Efficiency = 68%
20ft/Stage
Total required stages is 145 Stages, 40ft two
stages 20ft/Stage
Total required HP =55hp
Efficiency =68%
Pump Types
Floater pump
In floater pump impellers are free to move up and
down on the shaft. the only thing to stop the
upper or lower thrust is the thrust washers are
provided at surfaces between the impeller and
diffuser to absorb any thrust generated the stage
the thrust is transferred through the thrust
washers to the diffuser to the housing..
 Up and Down Thrust Washer of an Impeller
.
Down thrust
washer
Up thrust
washer
Why Use Floater Pumps?
 Since each stage handles its own thrust, a very large
number of stages can be put in a pump without having to
worry about protector bearing capacity.
 Easier field assembly – no shimming and less time less cost
required.
 Only thrust that the seal section thrust bearing sees is
shaft thrust
Pump Types
Compression Pump
In a compression pump, all the impellers are rigidly fixed
to the shaft. therefore if an impellers want to move up or
down, it will take the shaft with it.
The impeller is normally sitting down on its lower
diffuser during assembly due to gravity. because of this
the pump shaft is “raised” with shims in the coupling so
that the impeller is not allowed to touch the diffuser after
final assembly, this allows all thrust developed in the
pump shaft to be transferred to the protector shaft
directly.
Compression Pump
Pump shimming: There is a small amount of free play of the shaft in
pump, to eliminate this free movement small circle plate replaces on the
coupling.

Before shimming After Shimming

Why Use Compression Pumps?
 Some stages generate too much thrust to be handled by a thrust
washer in the stage.
 Some fluids like (liquid propane) do not have enough lubricity to
properly lubricate a thrust washer.
 If abrasives or corrosives are present, it may be beneficial to handle
the thrust in an area lubricated by motor oil rather than well fluid.
 Seal section thrust bearing holds both hydraulic thrust and shaft
thrust.
 They may have a wider operating range (ROR) than pumps with
floating impellers.
THANK YOU !