Optimize Hybrid ESP System Installation Process

Electrical submersible pumps (ESPs) have been a part of artificial lift in production operations for decades. They are designed to handle production volumes ranging from approximately 200 barrels per day (B/D) to 15,000 B/D. ESPs are very versatile, offering flexibility based on the operator's goals and desired outcomes, and are installed in both conventional and unconventional wells. Permanent magnet motors (PMMs) are being used in ESP applications worldwide. Deploying PMM technology has demonstrated significant efficiencies. Field measurements have confirmed power factors approaching 1, reactive power savings up to 40%, and active power savings as high as 10.5% (compared with conventional induction motors), as shown in Table 1 (Harris et al. 2017). A hybrid ESP system combines a power end from one vendor and a fluid end from another, to improve equipment performance, reduce costs, enhance safety, and improve overall reliability. To make these improvements, however, a new installation process had to be created. This paper describes the new process developed to reduce the number of on-site field personnel, enhance permanent magnet motor (PMM) safety, minimize costs, improve vendor performance, and streamline the installation process. Performance optimization opportunities include tailoring equipment to specific well conditions such as heavy volumes of sand, high temperatures, and/or presence of gas. Sourcing the power end and fluid end from different vendors gives operators the benefit of technological innovation, enabling optimization of system performance for various field challenges, leading to improved reliability, reduced costs, and enhanced production results. Vendor competition and flexibility allow operators to negotiate and ensure compatibility of equipment.