bluuebunny/crossref_metadata_2025_split huggingface dataset:
Gas Purging System to Extend Thrust Bearing Life in ESPs
Authors: Caridad Jose , Watson Arthur , Shang Song , Nguyen Eric , Chochua Gocha 
Published: September 2021

Abstract
Electric submersible pump (ESP) systems use thrust bearings in the seal section to handle the thrust generated by the pump stages. Thrust bearings are subjected to harsh operating conditions, including high loads, poor oil circulation, and motor oil viscosity degradation. A less-recognized issue is gas becoming centrifugally trapped under the thrust runner. The gas may be present because of incomplete purging of air during filling, permeation of well gas into the motor oil, or gradual gasification of motor oil at high temperatures. Because thrust bearings are such critical components, it is of interest to increase their reliability, which in turn will increase ESP life.
A novel gas purging system (GPS) was designed to alleviate stressors on thrust bearings, including gas accumulation, viscosity deterioration and gasification at high temperature, and low working oil volume. GPS circulates oil along with any gas that accumulates under the thrust runner up to a quiet separation chamber. Degassed oil circulates back to the thrust bearing, while accumulated gas eventually purges to the wellbore through relief valves on subsequent on/off cycles. GPS also improves viscosity and reduces gasification by cooling the oil, and it provides a greater working volume of thrust bearing oil to reduce the effects of oil deterioration.
This paper details the GPS design principles as well as the optimization of the different design parameters that affect its performance conducted via computational fluid dynamics (CFD). Observations captured on a test fixture built using the final configuration are also presented, validating the intended functionality.
Permanent Magnet Motors: The Future of ESP Applications?
Authors: Villalobos Leon Jorge Luis , Ruales Fernando , Miranda Sebastian , Godin Francisco , Velasquez Efrain , Shirikov Denis , Anaya Oscar , Forero Nini , Estupiñan Diego , Peña Lenin , Gonzalez Leonardo 
Published: September 2021

Abstract
Permanent magnet motors (PMMs) have been used in electrical submersible pump (ESP) applications worldwide, but the oil and gas industry still has questions about the value of the technology in terms of power savings; return on investment (ROI); and evaluation of power consumption, operational considerations, and reliability. Is this technology the future for ESPs? This paper will provide a real analysis based on more than 200 PMM installations in the Quifa and Rubiales Fields in Colombia, South America.
The fields of study are located in a remote location in Colombia where 90% of the total oil production is achieved with ESPs, so power consumption and its efficiency became a focus to optimize the lifting cost of each barrel produced. As a standard in both fields of study, PMMs are installed in all initial completions. Part of the methodology explained in this paper covers electrical power evaluation, including a power factor study, total harmonic distortion (THD) measurements, and criteria for comparing real power savings vs. expected savings as per initial designs. The systematic approach can be used by any other company that wants to evaluate this technology in their fields.
Deploying PMM technology in both fields of study has demonstrated, through formal and systematic analysis, the real efficiency that can be achieved by using this technology. Among the measurements confirmed in the field are power factors very close to 1, reactive power savings as high as 40% and active power saving as high as 10.5% (as compared with conventional induction motors). Additionally, the field case studies demonstrate that not all applications will see a direct energy in active power savings (kW) although total required surface apparent power (kVA) in all cases were reduced. An evaluation of total cost of ownership confirmed that in the field of study and similar operational conditions, PMM technology brings the best value for ESP applications.
The authors evaluate several of the 239 cases of ESP applications with PMMs, disclosing best practices for performance evaluation and lessons learned while deploying this technology, including safety and economics evaluation to understand the conditions that maximize return on investment (ROI) and total cost of ownership (TCO).
Improving Motor Performance and Runtime in ESP Applications with Novel Sinewave Filter
Authors: Hoevenaars Anthony Tony , McGraw Mike , Burley Colt , Bierhaus Elizabeth 
Published: September 2021

Abstract
In recent years, the Oil and Gas Industry has greatly improved efforts in evaluating the electrical system involved in operating Electrical Submersible Pumps (ESP). The negative effects that poor power quality has on ESP motors equipped with variable speed drives is generally understood by the industry. However, with a strong focus on optimization and reliability, improvements of the power quality provided to our ESP systems has tremendous potential to enhance the ESP lifecycle. This paper will provide a detailed description of the current mitigation technique involving the conventional designs of PWM sinewave filters. Additionally, this paper will outline multiple Case Studies that have been conducted on several wells with ESPs installed, that demonstrate the success of a new design approach for PWM sinewave filters yielding lower electrical distortion and significantly improved motor performance.
A detailed analysis evaluating problems and premature failures was performed on existing ESP wells equipped with both "6-step" and PWM operation. Computer simulations executed to analyze the new sinewave filter design showed much lower voltage distortion (&lt; 2%) as well as other important improvements in performance included a very low insertion loss (ie. &lt; 3% drop in voltage at full load) and improvement in PF to near unity at the inverter output. To complete the study, sinewave filters were built, tested and installed in several wells. Field data was gathered providing power quality measurements for electrical distortion, current imbalance, motor temperatures, motor vibration and production rates.
The successful sinewave filter design used different tuned frequency parameters than conventional sinewave filters with clear data providing performance improvement. These results showed a substantial reduction in motor temperature leading to confidence in operations regarding the positive effect this would have on lifecycle of downhole equipment. The improvements can be streamlined across other ESP wells in the field leading to improved runtime, decrease in CAPEX & OPEX cost associated with ESPs and other surface equipment eventually leading to a strong cash flow performance for operators.
Demonstration of Advanced Magnetic Technologies for a Highly Reliable and Retrievable Electric Submersible Pump Topology
Authors: McMullen Patrick , Biddick David 
Published: September 2021

Abstract
This effort designs, builds and tests key enabling technology components of the magnetic drive system (MDS) electric submersible pump (ESP) concept, an advanced high speed ESP that differs from conventional ESP topologies in using magnetic technologies to increase reliability and retrievability. The enabling components include a radial passive magnetic bearing (PMB) system, allowing for a contact-less bearing system and remote removal of rotating components, and magnetic vibration sensors (MVS), enabling prognostics for higher reliability.
An MDS ESP preliminary design has been developed through a DeepStar program, from which the size and integration requirements of the PMB and MVS have been defined. These requirements guide the analysis, design and testing of the full-scale components. Empirical analysis tools are used for initial iterations in size and performance of the PMB and MVS, followed by detailed magnetic finite element analysis (FEA) using commercial validated tools for the final performance prediction. With analytical validation of performance, detail designs are developed and hardware fabricated. Hardware testing is done to validate performance predictions and alignment with system requirements.
The PMB performance results include testing of stiffness capability. These characteristics are used to validate the integration requirements for load capability and deflection during static load events, all in relation to validating performance for use in the MDS system. This test data is used to validate the analysis approach used as well as to finalize the integration size of the PMB to meet the performance requirements of the MDS system. To identify rotor operating speed and rotor vibration magnitude and frequencies, the MVS is tested for sensing rotor motion rate and frequency, including sub-synchronous and super synchronous frequencies. Identifying data reduction needs, i.e. how data is compiled and presented to focus on specific areas of interest, is also critical to determine the vibration characteristic of specific events happening in the ESP, such as bearing wear or dynamic fluid changes. Testing also includes variations in tubing materials to assess performance impact.
These technologies offer bearing and sensor technologies that enhance ESP reliability and active performance monitoring. The PMBs offer a contact-less bearing system that does not require lubrication, can operate with large clearances to allow free fluid flow, and has no operating life limits. The compact MVS offers rotor vibration diagnostics throughout the ESP, including between pump stages, for monitoring performance, detecting ESP mechanical issues or process fluid variations allowing immediately response to increase operational life.
Development of a 1,000-hp High-Power Density PMM for Deepwater Wireline Retrievable ESP Systems
Authors: Cheblak Samer , Benzaid Omar 
Published: September 2021

Abstract
Electric submersible pumps (ESP) are frequently used in offshore high-volume oil-producing wells that do not flow to the surface or in offshore wells with production rates that must be boosted to enhance financial returns. An operator in the deepwater Gulf of Mexico decided to install rigless ESP completions in its wells to mitigate the rig workover cost of interventions and ESP replacements by using slickline rather than more costly workover rigs. However, the solution required the development of a new single-section motor that could deliver 1,000 to 1,200 hp.
This paper discusses the development and qualification of a new ultrahigh-power-density permanent magnet motor (UHPD PMM) for wireline-retrievable ESP systems installed through tubing as small as 5.5 in. The UHPD PMM design can produce significantly greater output than any other ESP technology in a single-section motor short enough to fit in a wireline lubricator. The high-power motor in a short length was achieved by integrating advanced motor technologies and materials. The challenges associated with this development are discussed along with the evaluation of tradeoffs between cost and performance. This paper also discusses the testing and qualification programs, as well as the results obtained during the various development phases.
Perdido GoM Total Field ESP Integrated Full-Field Modeling for Surveillance and Forecast Prediction
Authors: Barrios Lissett , Pydah Vinay 
Published: September 2021

Abstract
The paper reports on the integrated modeling approach for the Gulf of Mexico ultra-Deepwater Perdido Electrical Submersible Pump (ESP) meant for performance surveillance and operational predictions n viscous fluid and multiphase flow regimes. The ESP system uses in Perdido field are multistage centrifugal pumps for high flow rate and high boost applications. Multiphase flow and viscous fluids introduce challenges for ESP operations such as performance degradation and system inefficiency which are imperative and to be considered in modeling work for accuracy and proper surveillance.
The effect results from free gas and viscous fluid could be difficult to model and if not considered can result in wrong prediction of pump performance and power estimation over promising forecast and incorrect performance for surveillance and optimization. The objective of modelling work is aimed to correctly predict ESP performance by using proper modeling equations and correction factors that to understand the degradation on head, flow and horsepower, therefore further guide offshore surveillance activities and near and long term forecast predictions.
The ESP system used in Perdido Field is 1025 series tandem P360 mixed flow type pumps with a 725 series 1600 hp motor. The modeling work revealed mathematical relationships among pump performance parameters (pump speed/frequency, brake horsepower, pump head and pump capacity) and free Gas/Viscosity correction factors required to accurately predict pump performance and forecasting.
Using the correct approach for modeling high boost ESPs, an accuracy of 5% or less can be aimed with field operation for precise pump performance troubleshoot, optimization and long term forecast for economic analysis.
The main technical contributions of this work are the detail modelling approach, analysis and data comparison with Field operation for predicting pump and motor performance under two important variables, high viscosity and two-phase flow inside the ESP.
Hybrid Permanent Magnet Motor Application to Electric Submersible Pumps in SAGD wells
Authors: Mansir Hassan , Rimmer Michael , Waldner Leon , Hong Claire , Graham John , Wolanski Michelle , Duong Bruce 
Published: September 2021

Abstract
A Permanent Magnet Motor (PMM) designed to break the 300°C barrier was previously presented that included many advancements to greatly improve the operating temperature and reliability beyond the ability of current equipment [1]. A key design element is the inclusion of a squirrel cage in the PMM rotor that results in a hybrid construction. This paper will delve into the rationale for the hybrid configuration and will assess motor performance using electromagnetic simulations and validation testing.
PMMs are used in many industrial applications and have recently started to gain traction in oil and gas upstream production applications. A significant issue is the PMM compatibility with existing motor drive equipment and their need for special provisions to operate at the end of long cables without position sensors. A hybrid configuration help overcome these limitations and allows operation with conventional variable speed drives using a standard scalar controller as used with induction motors.
The design, development, and qualification of the hybrid PM rotor construction were undertaken using a rigorous analytical approach combined with extensive validation testing.
The motor is designed to maintain stability under the severe transient conditions in the SAGD environment, where the produced emulsion rich in gas and solids creates highly variable conditions for the motor and controller.
A detailed electromagnetic model of the motor for configurations with or without the squirrel cage was undertaken to demonstrate the effectiveness of the hybrid configuration to maintain speed control stability. A time stepped method was used to simulate the motor start with simulated loading conditions, reflecting the starting and operating conditions with breakaway torques up to full load torque condition and 50% transient loads.
The squirrel cage was successfully integrated within the rotor structure of a 150hp PM motor. Extensive design and thermal-structural analysis ensured the construction was acceptable for operation in the ranges −40°C to 350°C. Validation testing was then performed to demonstrate the hybrid PM motor construction functioned for use with conventional and legacy variable frequency drives.
Forty-Seven–Well Case Study: How a Holistic ESP Design for Deep Deviated Wells with Low Flow Rates Achieved Economic Production
Authors: Camilleri Lawrence , Villalobos Jorge Luis , Escalona Pedro Luis , Correal Alvaro , Reyes Carlos , Enriquez Luis Carlos , Gallegos Apolo Johanna del Cisne 
Published: September 2021

Abstract
The Shaya wells have vertical depths of 11,000 ft and are heavily depleted. They, therefore, require 10,000 ft of lift to achieve the target drawdown. Electrical submersible pumps (ESPs) were deployed, but because of the low flow rates (80 B/D), produced solids, and high free gas content, initial run lives were uneconomical. This 47-well case study demonstrates how a holistic design and operating procedure achieved both the target drawdown and an economical mean time between failure (MTBF).
"Learning from history" was the key method as there was sufficient ESP data to determine the root cause of ESP failures based on a combination of dismantle inspection and failure analysis (DIFA) and operating conditions. Moreover, production testing combined with real-time downhole gauge data enabled inflow characterization with both nodal and pressure transient analysis, thereby establishing the well potential and ensuring that the new proposed design was not only reliable but also achieved the targeted drawdown. An additional requirement was to handle both the current low rates and higher rates associated with future waterflooding.
A historical review of 9 wells was conducted, followed by a new ESP design that was proposed and installed in 47 wells, which achieved an MTBF of over 940 days, whereas previous designs in the same wells had an MTBF of only 650 days. This substantial improvement was achieved without compromising drawdown as the wells were produced with a flowing intake pressure of approximately 250 psia at setting depths of 9,500 ft. This result is particularly noteworthy when one considers the harshness of the well conditions and, in particular, bottom-hole temperatures of 240°F, fines migration, deviated wells with doglegs above 2.5°/100ft, intake pressures below bubble point and low productivity indices (PIs) of 0.2 B/D/psi. The high depletion combined with low PIs, which resulted in very low flow rates of as low as 50 B/D, was the most challenging factor of this application. Outflow modeling and wellbore hydraulics were also important considerations to limit solid fallback due to insufficient velocity in the production tubing as well minimize heat rise caused by startup transients, which can be long in low-PI wells.
ESPs are traditionally best suited to wells with liquid rates providing sufficient cooling for both the motor and the pump as well as short unloading transients during startup. This success story, therefore, provides an important reference for future ESP applications in very low flow rates in deep wells, which are beyond the recommended application envelope of alternative low flow rate artificial lift solutions such as progressive cavity pumps and sucker rod pumps.
Fault Identification in a Subsea ESP Power Distribution System Using Electrical Waveform Monitoring
Authors: Obst Larry , Merlino Andrew , Parlos Alex , Rubio Dario 
Published: September 2021

Abstract
This paper describes the technology and processes used to identify in a timely matter the source of an Instantaneous Over Current (IOC) trip during an ESP re-start at Shell Perdido SPAR. Monitoring health condition of subsea ESPs is challenging. ESPs operate in harsh and remote environments which makes it difficult to implement and maintain any in-situ monitoring system. Shell operates five subsea ESPs and implemented a topside conditioning monitoring system using electrical waveform analysis. The Perdido SPAR had a scheduled maintenance shutdown in April 2019. While ramping the facility down on April 19, 2019 the variable frequency drive (VFD) for ESP-E tripped on a cell overvoltage fault. The cell was changed, but the VFD continued to trip on instantaneous overcurrent. During ramp up beginning April 29, 2019 most equipment came back online smoothly, but the VFD of the particular ESP labeled ESP-E continued to experience the problem that was causing overcurrent trips, preventing restart. Initial investigations could not pinpoint the source of the issue. On May 1, 2019 Shell sought to investigate this issue using high-frequency electrical waveform data recorded topside as an attempt to better pinpoint the source of this trip. Analysis of electrical waveform before, during and after the IOC trip found an intermittent shorting/arcing at the VFD and ruled out any issues with the 7,000-foot-long umbilical cable or ESP motor. Upon further inspection, a VFD technician was able to visually identify the source of the problem. Relying in part on electrical waveform findings, VFD technician found failed outer jackets in the MV shielded cables at the output filter section creating a ground path from the VFD output bus via the cable shield. The cables were replaced, and the problem was alleviated allowing the system to return to normal operation. Shell credits quick and accurate analysis of electrical waveform with accelerating troubleshooting activities on the VFD, saving approximately 1-2 days of troubleshooting time and associated downtime savings, that translate to approximately 50,000 BOE deferment reduction. Analysis of high-frequency electrical waveform using physics-based and machine learning algorithms enables one to extract long-term changes in ESP health, while filtering out the shorter-term changes caused by operating condition variations. This novel approach to analysis provides operators with a reliable source of information for troubleshooting and diagnosing failure events to reduce work-over costs and limit production losses.
Automated ESP Failure Root Cause Identification and Analyses Using Machine Learning and Natural Language Processing Technologies
Authors: Karnik Saniya , Yenuganti Navya , Jusri Bonang Firmansyah , Gupta Supriya , Nirgudkar Prasanna , Mohajer Mahyar , Malik Asim 
Published: September 2021

Abstract
Today, the Dismantle, Inspection, and Failure Analysis (DIFA) process for electrical submersible pump (ESP) failure analysis is a tedious, human-intensive, and time-consuming activity. The activity involves a set of data and various information formats from several activities in the ESP operation lifecycle. This paper proposes a novel artificial intelligence workflow to improve the efficiency of the DIFA process using an ensemble of machine learning (ML) algorithms. This ensemble of algorithms brings together structured/unstructured data across equipment, production, operations, and failure reports to automate root-cause identification and analysis post breakdown. As a result, the time and human effort required in the process has been reduced, and process efficiency has drastically improved.