A Safe, Effective, and Economical Approach to Running, Operating, and Retrieving ESPs with Permanent Magnet Motors

Abstract The installation and retrieval of Electrical Submersible Pumps (ESPs) equipped with Permanent Magnet Motors (PMMs) require robust barriers to prevent shaft rotation and the subsequent generation of voltage. Current methods to provide these barriers involve additional operations, equipment, and personnel, which increase associated risks. This paper introduces a new method that is safe, effective, and economical, improving both safety and operational efficiency during the installation, operation, and retrieval processes. Installing ESPs with PMMs typically involves surface monitoring techniques and control barriers, such as blanking plugs and sliding sleeves, to manage communication between the tubing and casing. After installation, these barriers must be removed to produce the well and then reinstalled before pulling the equipment, requiring at least four slickline interventions and extended operation times. The proposed method utilizes a single tool that acts as a positive flow barrier during installation, which is removed by pressurizing the tubing before production begins. This initial barrier maintains minimal differential pressure from top to bottom and offers ten times greater pressure resistance from bottom to top, ensuring a complete seal. Similarly, before retrieval, a dart is used to create a mechanical block and a positive flow seal in both directions, while also opening a drain sleeve. This allows the pump to be pulled with dry tubing and a plug in the production tubing, eliminating the need for slickline intervention and maintaining on-site safety standards. After multiple installations of this new method in the Permian Basin, analysis has shown zero safety incidents during the operation of ESPs with PMMs. Proper training, socialization, and discussion of this method with field personnel have increased awareness of associated risks and promoted responsible operations, resulting in no reported accidents to date. Implementing this method has also shortened installation and retrieval times, reducing rig time by up to 50%, which in turn lowers operational costs, reduces emissions by minimizing the number of intervention units required, and accelerates the timeline for bringing wells online. This document will present practical applications and guidelines to clearly explain how this technology can be adapted for various operations, making it easier for operators to use worldwide. As the adoption of PMMs increases, it is crucial to continue developing not only surveillance measures but also mitigation strategies to effectively prevent unforeseen events at well sites.