2021/11/5 ESP system selection and performance calculations - PetroWiki

ESP system selection and performance

calculations
Proper sizing and selection of an electrical submersible pump (ESP) sy stem is essential to efficient and cost-
effectiv e performance. Selection and sizing of proper ESP equipment for a particular application should be based
on a nine-step design procedure. [1 ] This page outlines the procedure as a manual process to illustrate the ESP
design steps. While it is accurate for simple water and light-crude designs, there are commercially av ailable ESP
design software programs that giv e accurate designs for wells with:

High gas/oil ratios (GOR)

Viscous crudes
High temperature
Operation on variable speed controllers (VSC)
This nine-step procedure helps the engineer design the appropriate submersible pumping sy stem for a particular
well. Each of the nine steps is explained below, including gas calculations and v ariable-speed operations. Specific
examples are worked through in ESP design.

Contents
Step one: basic data
Step two: production capacity
Productivity index
Inflow performance relationships
Step three: gas calculations
Gas volume factor
Formation volume factor
Total volume of fluids
Step four: total dynamic head
Step five: pump type
Variable-speed submersible pumping (VSSP) system and pump selection
Step 6: optimum size of components
Pump
Separator
Motor
Seal selection
Step 7: electric cable
Cable size
Cable type
Cable length
Cable venting
Step 8: accessory and optional equipment
Downhole accessory equipment
Motor controllers
Single-phase and three-phase transformers
Surface cable
Wellheads and accessories
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Servicing equipment
Optional equipment
Step 9: variable speed submersible pumping system
Nomenclature
References
Noteworthy papers in OnePetro
Noteworthy books
External links
See also
Page champions
Category

Step one: basic data

The design of a submersible pumping unit, under most conditions, is not a difficult task, especially if reliable data
are av ailable. Although, if the information, especially that pertaining to the well’s capacity , is poor, the design
will usually be marginal. Bad data often result in a misapplied pump and costly operation. A misapplied pump
may operate outside the recommended range, ov erload or underload the motor, or draw down the well at a rapid
rate that may result in formation damage. On the other extreme, the pump may not be large enough to prov ide
the desired production rate.

Too often, data from other wells in the same field or in a nearby area are used, assuming that wells from the same
producing horizon hav e similar characteristics. Unfortunately , for the engineer sizing the submersible
installations, oil wells are much like fingerprints (i.e., no two are quite alike).

The actual selection procedure can v ary significantly depending on the well-fluid properties. The three major
ty pes of ESP applications are wells with single-phase flow of oil and/or water, wells with multiphase flow of
liquids and gas (especially high free-gas rates), and wells producing highly -v iscous fluids ty pically much greater
than 10 cp. A list of required data is outlined next.

Well data: Casing or liner size, weight, grade; tubing size, weight, grade type and thread, plus condition; pump
setting depth (measured and vertical); perforated or openhole interval; well plugback total depth (measured and
vertical).
Production data: Wellhead tubing pressure; wellhead casing pressure; present production rate; producing fluid level
and/or pump-intake pressure at datum point; static fluid level and/or static bottomhole pressure at datum point;
datum point; bottomhole temperature; desired production rate (target); GOR; and water cut.
Well-fluid conditions: Specific gravity of water; oil °API or specific gravity; specific gravity of gas; bubblepoint
pressure of gas; viscosity of oil (dead); and other available pressure/volume/temperature (PVT) data.
Power sources: Available primary voltage, frequency, and power source capabilities.
Possible production problems: Sand, scale deposition, corrosion, paraffin/asphaltenes, emulsion, gas, high reservoir
temperature.

Step two: production capacity

The following is a simplification of procedures for predicting well performance. This discussion assumes little or
no well skin. A damaged wellbore or other factors affects the well flow performance.

Productivity index
When the well flowing pressure (Pw f) is greater than bubblepoint pressure (Pb ), the fluid flow is single-phase flow,
and the inflow performance relationship is a straight line with slope J, as giv en by the productiv ity index (PI).
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....................(1)

Inflow performance relationships

If Pw f is less than Pb , resulting in multiphase flow in the reserv oir, the inflow-performance-relationship (IPR)
method should be used. The relationship is giv en by Eq. 2.

....................(2)

This relationship was first used by Gilbert[2 ] and further dev eloped by Vogel. [3 ] Vogel dev eloped a
dimensionless reference curv e that can be used to determine the IPR curv e for a particular well. Others hav e
dev eloped v ariations of the IPR equation. (See Reserv oir inflow performance) .

Step three: gas calculations

The presence of free gas at the pump intake and in the discharge tubing makes the process of equipment selection
much more complicated and v oluminous. As the fluid (liquid/gas mixture) flows through the pump stages from
the intake to the discharge and through the discharge tubing, the pressure and, consequently , fluid properties
(such as v olume, density , etc.) are undergoing continuous change. Also, the presence of free gas in the discharge
tubing may create a significant "gas lift" effect and considerably reduce the required discharge pressure or TDH of
the pump.

Ideally , a well is produced with a submergence pressure abov e the bubblepoint pressure to keep gases in
solution at the pump intake. This is ty pically not feasible, so the gases must be either handled by the pump or
separated from the other fluids prior to the pump intake.

It is essential to determine the effect of the gas on the fluid v olume to select the proper pump and any auxiliary
equipment. The following calculations y ield the approximate percent free gas by v olume.

If the solution GOR (Rs ), the gas v olume factor (Bg ), and the formation v olume factor (Bo ) are not av ailable from
reserv oir data, they must be calculated, and there are a number of multiphase correlations to select from. The
correlation selected will affect the design, so select the one that best matches the conditions. Standings
correlations for solution GOR and formation v olume factor are shown next.

Solution GOR

....................(3)

Or, in metric,

....................(4)

Note: pump-intake pressure should be substituted for bubblepoint pressure when calculating pump-intake
conditions.

Gas volume factor

The gas v olume factor, Bg , is expressed in reserv oir scf/bbl gas (m3 /m3 ).

....................(5)

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Or, in metric,

....................(6)

Formation volume factor

The formation v olume factor, Bo , represents the increased v olume that a barrel of oil occupies in the formation
as compared to the stock-tank barrel of oil (STBO).

....................(7 )

where

....................(8)

Or, in metric,

....................(9)

Total volume of fluids

When these three v ariables: Rs , Bo , and Bg are known, the v olumes of oil, water, and free gas can be determined
and percentages of each calculated. The total v olume of gas (both free and in solution) can be determined as

....................(10)

The gas in solution at submergence pressure can be determined as

....................(11)

The free gas equals the total gas minus the solution gas. The v olume of oil (V o ) at the pump intake is equal to
stock-tank barrels multiplied by Bo , the formation v olume factor. The v olume of gas (V g ) at the pump intake is
equal to the amount of free gas multiplied by Bg , the gas v olume factor. The v olume of water (V w ) in the
formation is approximately the same as stock tank barrels. Total fluid v olume (V t) can now be determined.

....................(12)

The percentage of free gas to total v olume of fluids can now be calculated as

....................(13)

Step four: total dynamic head

The next step is to determine the total dy namic head (TDH) required to pump the desired capacity . The total
pump head refers to feet (meters) of liquid being pumped and is calculated to be the sum of: net well lift, HL; well-
tubing friction loss, Ft; and wellhead pressure head, Hw h . The simplified equation is written as

....................(14)

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Step five: pump type

Refer to the manufacturer’s catalog for pump ty pes, ranges, and pump-performance curv es (60 Hz and 50 Hz).
On the basis of expected fluid production rate and casing size, select the pump ty pe that will, at the expected
producing rate, be operating within the pump’s operating range and near to the pump’s peak efficiency .

Where two or more pump ty pes hav e similar efficiencies at the desired v olume, certain conditions determine the
pump choice:

Pump prices and corresponding motor sizes and prices may differ somewhat. Normally, the larger-diameter pump
and motor are less expensive and operate at higher efficiencies.
When the well’s capacity is not known, or cannot be closely estimated, a pump with a "steep" characteristic curve
should be chosen. If the desired volume falls at a point where two pump types have approximately equal efficiency,
choose the pump type that requires the greatest number of stages. Such a pump will produce a capacity nearest
the desired volume even if the well lift is substantially more or less than expected.
If gas is present in the produced fluid, a gas separator may be required to achieve efficient operation. Note that the
free gas is vented up the casing annulus. Refer to Step 3 to determine the effect of gas on the produced volume. The
adjusted volume affects pump selection and the size of the other system components.
In wells where the fluid is quite viscous and/or tends to emulsify, or in other extraordinary circumstances, some
pump corrections may be necessary to ensure a more efficient operation. In such cases, contact the manufacturer
for engineering recommendations.

Variable-speed submersible pumping (VSSP) system and pump selection

Under the prev ious or other pumping conditions, also consider the VSSP sy stem. Such sy stems must be justified.
For instance, if the production rate is not accurately known, a VSSP sy stem may be applicable. A VSC effectiv ely
conv erts a single pump into a family of pumps, so a pump can be selected for an estimated range and adjusted for
the desired production lev el, once more data are collected.

Rev iew Step 9 when considering the VSSP sy stem. Variable-frequency performance curv es are included in most
manufacturers’ information. The VSSP sy stem with the VSC may prov ide additional economies of capital
expenditure and operating expenses and should be considered in Step 6. The VSC and transformers for the VSSP
sy stem are discussed in Steps 8 and 9.

Step 6: optimum size of components

ESP components are built in a number of sizes and can be assembled in a v ariety of combinations. These
combinations must be carefully determined to operate the submersible pumping sy stem within production
requirements, material strength, and temperature limits. While sizing components, refer to the manufacturer for
the following information: equipment combinations in v arious casings, maximum loading limits, maximum
diameter of units, v elocity of a fluid passing a motor, shaft HP limitations at v arious frequencies.

Pump
Refer to the manufacturer’s performance curv e of the selected pump ty pe, and determine the number of stages
required to produce the anticipated capacity against the prev iously calculated total dy namic head. Usually ,
performance curv es for 60-Hz, 50-Hz, and v ariable-frequency operations are prov ided in the manufacturer’s
catalog. The pump characteristic curv es are stage performance curv es based on water with a specific grav ity of
1.0. At the intersection of the desired production rate (bottom scale) and the head-capacity curv e (v ertical
scale), read the head v alue on the left scale. Div ide this v alue into the TDH to determine the number of stages:
total stages = TDH/(head/stage).

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Separator
Refer to the manufacturer’s catalog for gas-separator information. Make the necessary adjustments in HP
requirements and housing length.

Motor
To select the proper motor size for a predetermined pump size, the BHP required by the pump must be
determined. The HP per stage is obtained by referring to the performance curv e for the selected pump. The BHP
required to driv e a giv en pump is easily calculated by the following formula: BHP = total stages × (BHP/stage) ×
SG.

Refer to the manufacturer’s information for motor specifications. Select a motor size that closely meets the
design conditions. The maximum load conditions should not exceed 110% of rating. Minimum operating loads
should not put the motor into an idle condition, otherwise protection monitoring is nullified. Manufacturers
should be contacted for specific operating ranges. Ty pically , operators try to select a motor that operates in the
range from 7 0 to 100% of its rating.

Seal selection
Refer to a manufacturer’s catalog for selection of the proper seal section.

Step 7: electric cable

ESP electric cables are normally av ailable in conductor sizes 1, 2, 4, and 6. These sizes are offered in both round
and flat configurations. Sev eral ty pes of armor and insulation are av ailable for protection against corrosiv e fluids
and sev ere env ironments.

Cable selection inv olv es the determination of cable size, cable ty pe, and cable length.

Cable size
The proper cable size is dependent on combined factors of v oltage drop, amperage, and av ailable space between
tubing collars and casing.

Refer to the cable v oltage drop curv e (samples are shown in Fig 1[4 ] ) for v oltage drop in cable. At the selected
motor amperage and the giv en downhole temperature, the selection of a cable size that giv es a v oltage drop of
less than 30 v olts per 1,000 ft (305 m) can be used as a guideline. This curv e determines the necessary surface
v oltage (motor v oltage plus v oltage drop in the cable) required to operate the motor.

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Fig. 1-ESP-power-cable voltage drop (after

Centrilift).[4]

Finally , check the manufacturer’s information to determine if the size selected can be used with the proposed
tubing and well casing sizes. The cable diameter plus tubing-collar diameter must be less than the ID of the
casing. To determine the optimum cable size, consider future equipment requirements that may require the use
of a larger-sized cable.

Where power cost is a major concern, kilowatt-hour loss curv es can be used to justify the cable selection.
Although power rates v ary widely , this information is v aluable in determining the economics of v arious cable
sizes.

Optimization procedures [5 ][6 ] are based on finding the least v alue of total operating costs ov er the expected life
of the cable. The total operating cost is the sum of the capital and operating expenses and these v ary with cable
size. Since an increase of the conductor size inv olv es increased capital costs but decreased operating costs, a
cable prov iding the minimum of total costs can surely be found. It is easy to see that, contrary to the rules
prev iously used, the smallest possible size may not be the best selection.

Cable type
Selection of the cable ty pe is primarily based on fluid conditions, bottomhole temperature, and space limitations
within the casing annulus. Carefully select the ty pe of cable for hostile env ironments. Refer to the manufacturers
catalog for cable specifications. Where there is not sufficient space to run round cable, use electric cable with a
flat configuration. The flat cable configuration induces a v oltage imbalance. If it is significant, a transition splice
may be required. Verify this with the manufacturer.

Cable length
The total cable length should be about 100 ft (30 m) longer than the measured pump setting depth to make
surface connections a safe distance from the wellhead. Check the v oltage av ailable at the motor terminal block to
av oid the possibility of low v oltage starts. The av ailable motor terminal v oltage is the surface supply v oltage
minus the cable v oltage drop.

Cable venting
In all wells, it is necessary to v ent gases from the cable prior to the motor controller to av oid explosiv e
conditions. A cable v enting box is av ailable to protect the motor controller from such gases.

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Step 8: accessory and optional equipment

Downhole accessory equipment

Flat cable (motor lead extension). Select a length at least 6 ft (1.8 m) longer than the pump intake (standard or
gas separator) and seal section for the motor series chosen. Refer to the manufacturer’s information for
dimensions.

Flat cable guard (optional). Choose the required number for 6-ft (1.8-m) guard sections to at least equal the flat-
cable length. Do not use guards for installation of a 400 series pump and seal section with 5 1/2-in. outside
diameter (OD) and 20-lbm casing, and a 513 series pump and seal section with 6 5/8-in. OD and 26-lbm casing.

Cable bands. Use one 30-in. (7 6-cm) cable band ev ery 2 ft (60 cm) for clamping flat cables to pumps. The 22-in.
(56-cm) length can be used for all tubing/cable combinations through 3½-OD tubing. For 4 1/2-in.- and 5 1/2-
in.-OD tubing, use 30-in. (7 6-cm) bands. One band is required for each 15 ft (5 m) of setting depth. Refer to the
manufacturer’s information for dimensions.

Swaged nipple, check valve, and drain valve (optional). Select these accessories on the basis of required ODs
and ty pe of threads.

Motor controllers
Motor controllers are ty pical state-of-the-art digital controls consisting of two components.

System unit. This unit performs all the shutdown and restart operations. It is mounted in the low-v oltage
compartment of the control panel.

Display unit (optional). This unit display s readings, set points, and alarms. It is normally mounted in the amp
chart enclosure for easy access. It prov ides all the basic functions, such as underload, ov erload, phase
imbalance, phase rotation, and many other parameters including password and communication protocols.

Single-phase and three-phase transformers

The ty pe of transformer selected depends on the size of the primary power sy stem and the required secondary
v oltage. Three-phase isolation stepup transformers are generally selected for increasing v oltage from a low-
v oltage sy stem, while a bank of three identical single-phase transformers is usually selected for reducing a high-
v oltage primary power source to the required surface v oltage.

On existing sy stems, some ESP units operate without the use of an additional transformer. For new installation of
units with higher v oltages, it is usually less expensiv e to install three single-phase transformers, connected wy e,
to eliminate the auto-transformer.

In choosing the size of a stepup transformer or a bank of three single-phase transformers, Eq. 15 is used to
calculate the total kilowatts/v olts/amps (KVA) required.

....................(15)

Surface cable
Choose the approximate length required for connecting the controller to the primary power sy stem or
transformer. Two pieces are generally required for installations using an auto-transformer. Size should equal the
well cable size, except in the case of stepup or auto-transformer, where the primary and secondary currents are
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not the same.

Wellheads and accessories

Select the wellhead on the basis of casing size, tubing size, maximum recommended load, surface pressure, and
maximum setting depth. Electric cable passes through the wellhead where pressure fittings are not required.

Electric-feed-through (EFT) mandrels are also av ailable. The electric cable is spliced to pigtails. The EFT
wellheads seal against downhole pressure and prev ent gas leaks at the surface.

Servicing equipment
Cable reels, reel supports, and cable guides. Select the size of cable reel required to handle the prev iously
selected cable size. Select a set of cable-reel supports on the basis of cable-reel size. Cable guides are designed to
handle cable sizes 1 through 6. Normally , customers retain one cable reel, one set of reel supports, and one cable
guide wheel for future use.

Shipping cases. Select the ty pe and length of the case required accommodating the prev iously selected motor,
pump, gas separator, and seal.

Optional equipment
Bottomhole sensing device. The downhole sensor prov ides continuous measurement of parameters such as:

Wellbore pressures
Wellbore or ESP temperature
Discharge flow rates
Water contamination of the motor
Equipment vibration
Automatic well monitoring. Motor controllers are av ailable for the continuous monitoring of pump operations
from a central location.

Step 9: variable speed submersible pumping system

The ESP sy stem can be modified to include a v ariable-frequency controller so that it operates ov er a broader
range of capacity , head, and efficiency . Most of the ESP manufacturers and sev eral third parties hav e
computerized pump-selection programs to assist in VSSP-sy stem selection; what follows is a basic explanation of
the principles inv olv ed.

Variable frequency. The VSC is commonly used to generate any frequency between 30 and 90 Hz. Pump-
performance curv es for frequencies other than 60 Hz can be generated with the affinity laws (Eqs. 2 through 4 in
ESP centrifugal pumps). The output rating of the motor is also affected by the operating frequency (Eq. 3 in ESP
motors).

A set of curv es can be dev eloped for an arbitrary series of frequencies with these equations, as shown in the
v ariable-frequency performance curv es at the end of this step (Fig. 2). Each curv e represents a series of points
deriv ed from the 60-Hz curv e for flow and corresponding head points, transformed using the prev iously
mentioned equations.

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Fig. 2-FC-1200 stage variable-speed performance

curve [after Centrilift Graphics, Claremore,
Oklahoma (2003)].

Suppose we are giv en the following data at a frequency of 60 Hz: rate = 1,200 B/D; head = 24.5 ft (from FC-1200
curv e at 1,200 B/D); BHP = 0.34 BHP (from FC-1200 curv e at 1,200 B/D). If a new frequency of 50 Hz is chosen,
the data will be: new rate = (50/60) × 1,200 B/D = 1,000 B/D; new head = (50/60)2 × 24.5 ft = 17 ft; and new
BHP = (50/60)3 × 034 BHP = 0.20 BHP.

By performing these calculations at other production rates, a new curv e for 50-Hz operation can be plotted. Start
by locating the existing points on the one-stage 60-Hz curv e:

Q1 rate, B/D: 0; 950; 1,200; 1550; and 1,875.

H1 head, ft: 32, 28.6, 24.5, 15, and 0.
Efficiency, %: 1, 63.5, 64, 49, and 0.
Following the prev ious equations, calculate the corresponding v alues at 50 Hz:

Q1 rate, B/D: 0; 792; 1,000; 1,292; and 1,563.

H1 head, ft: 22.2, 19.9, 17, 10.4, and 0.
Efficiency, %: 0, 63.5, 64, 49, and 0.
Plotting these coordinates giv es the one-stage FC-1200 head-capacity performance curv e an operation at 50 Hz.
Similar calculations prov ide coordinates for curv es at other frequencies, as shown by the FC-1200 v ariable-
speed performance curv e (Fig. 2). The v ortex-shaped window is the recommended operating range for the
pump. As long as the hy draulic requirement falls within this range, the pump is within the recommended
operating range.

Nomenclature
Am = motor amperage, amps
Bg = gas volume factor, scf/bbl [m3/m3]
Bo = oil volume factor, bbl/STBO
3
C = constant = 3,960, where Q is in gal/min, and TDH is in ft [= 6,750, where Q is in m /D,
and TDH is in m]
D = diameter, in. [cm]
F = correlating function for Eq. 7
Ft = well-tubing friction loss
H = head, ft [m]
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HL = net well lift

Hwh = wellhead pressure head, ft [m]
J = slope
N = rotating speed, rev/min
P = pressure, psi [kg/cm2]
Pb = bubblepoint pressure, psi [kg/cm2]
Pdischarge = pump-discharge pressure, psi [kg/cm2]
Pr = well static pressure, psi [kg/cm2]
Pwf = well flowing pressure, psi [kg/cm2]
Q = flow rate, B/D [m3/d]
Qd = estimated production rate
Qo = maximum production at Pwf = 0, B/D [m3/D]
Rs = solution gas/oil ratio, scf/bbl [m3/m3]
T = torque, ft-lbf
Tconductor = wellbore temperature at the ESP setting depth
TC = temperature, °C
TF = temperature, °F
TG = total volume of gas
TK = temperature, K
TR = temperature, °R
V = voltage, volts
VFG = volume of free gas
Vg = volume of gas
VIG = volume of free gas at the pump intake
Vo = volume of oil, bbl [m3]
Vs = surface voltage, volts
VSG = solution gas volume
Vt = total volume
Vw = volume of water
Z = gas-compressibility factor (typically 0.50 to 1.00)
ηm = motor efficiency
ηp = pump efficiency

References
1. The Nine Step. 1999. 1-27. Claremore, Oklahoma: Centrilift.
2. Gilbert, W.E. 1954. Flowing and Gas Lift Well Performance. API Drilling and Production Practice, 143. Washington,
DC: API.
3. Vogel, J.V. 1968. Inflow Performance Relationships for Solution-Gas Drive Wells. J Pet Technol 20 (1): 83–92. SPE
1476-PA. http://dx.doi.org/10.2118/1476-PA
4. Electrical Submersible Pumps and Equipment. 2001. 11. Claremore, Oklahoma: Centrilift.
5. Vandevier, J. E. 1987. Optimum Power Cable Sizing for Electric Submersible Pumps. Paper SPE 16195 presented
at the Production Operations Symposium held in Oklahoma City, March 8-10.

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6. French, S. W. 1991: Optimum Cable Selection of Electrical Submersible Pumps. Paper SPE 21693 presented at
the Production Operations Symposium held in Oklahoma City, April 7-9.

Noteworthy papers in OnePetro

Takacs, G. (2011): How to Improv e Poor Sy stem Efficiencies of ESP Installations Controlled by Surface Chokes.
Journal of Petroleum Exploration and Production Technologies: Vol. 1, Issue 2, p 89-97 . DOI 10.1007 /s13202-
011-0011-9

Clegg, J. D., Bucaram, S. M., & Hein, N. W. (1993, December 1). Recommendations and Comparisons for Selecting
Artificial-Lift Methods(includes associated papers 28645 and 29092 ). Society of Petroleum Engineers.
doi:10.2118/24834-PA

Lea, J. F., & Nickens, H. V. (1999, January 1). Selection of Artificial Lift. Society of Petroleum Engineers.
doi:10.2118/52157 -MS

Lee, H. K. (1988, January 1). Computer Modeling and Optimization for Submersible Pump Lifted Wells. Society of
Petroleum Engineers. doi:10.2118/17 586-MS

Romer, M. C., Johnson, M. E., Underwood, P. C., Albers, A. L., & Bacon, R. (2012, January 1). Offshore ESP
Selection Criteria: An Industry Study . Society of Petroleum Engineers. doi:10.2118/146652-MS

Noteworthy books
Takács G. (2009): Electrical submersible pumps manual. ISBN 97 8-1-85617 -557 -9. Gulf Professional Publishing,
An Imprint of Elsev ier, 440p.

External links
Use this section to prov ide links to relev ant material on websites other than PetroWiki and OnePetro

See also
ESP design

Electrical submersible pumps

Alternate ESP configurations

Use of ESPs in harsh env ironments

PEH:Electrical_Submersible_Pumps

Page champions
Jose Caridad (https://www.linkedin.com/in/jose-caridad-49080265), BSME & MSc ME

Category
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