Analysis of the Correlation Between Solids Management and Vibrations in Electric Submersible Pumps

Abstract The vibration measured by the ESP downhole sensor is a function of numerous variables, mostly operational, including frequency, flow rate, gas presence, fluid level, pump design, equipment position, electrical changes, etc. The primary objective of this research is to determine if there is a loss of efficiency in the ESP by monitoring this parameter trend and to establish a flow chart that assists in predicting potential failures or enhancing operational conditions. Using the Recommended Practice on Electric Submersible System Vibrations (API RP11S8) as a guide, this investigation has found a wide range of vibration values where ESP operation affects efficiency and energy consumption. In addition to this theory, the other element necessary for the study is availability of downhole sensors installed in wells. Two types of analysis need to be performed - current operation and post failure for DIFA process. The main result is that vibration data need to be studied considering the tendency in well operation during its run life and not a punctual value. More information can be extracted from a variation than from a single value of G. In sand management, this value can be increased a 100%, for example, there were cases were having 1 or 2G, after some changes associated to abrasive solids management, the value increased between 3-4G. Other factors were considered as scale and gas presence, which interfere with motor cooling and affecting vibration trends. Another lesson learned was that at certain frequencies the equipment begins to resonate and damages the integrity of seals and bearings (premature contamination) and the common response registered to high wear in pump stages is not only over current, but also can elevate the G value from 1-2 up to 10 and it is only correlated during the dismantle for inspection after failure. Categorizing for a specific field or asset the values of G or analyzing its trends in order to deliver a flowchart to take proper decisions during ESP behavior analysis is the main product of this case study. Focusing on the main characteristics of the field the study can be expanded to others adjusting the parameters analyzed.