An electric submersible pump (ESP) is an artificial lift pump that uses a motor to power

a centrifugal pump through a series of stages to draw fluids and other materials out of a
well. An ESP is a type of water pump that is designed to be immersed in a body of liquid
and operates using an electric motor. The motor is connected to the pump and is sealed
in a watertight casing, allowing the pump to be placed deep in wells, tanks, or
reservoirs. ESPs are commonly used for pumping water or oil in oil wells, water wells,
and other industrial or agricultural applications.

It is a multistage centrifugal pump that provides engineers with a flexible flow range and
head. In addition, their high degree of energy economy makes them a good choice for
various applications. An electrical submersible pump converts the liquid’s kinetic energy
into work to increase pressure. These artificial lift pumps have recently gained
popularity because of their widespread use on farms.

Historical Overview of Electrical Submersible Pump

In 1916, Russian inventor Armais Arutunoff was credited with developing the first
electrical submersible pump. After moving to the United States in 1923, he established
a company called the Russian Electrical Dynamo of Arutunoff (REDA). In the USA, he
began seeking funders for his apparatus.

Initially, he presented his concept to Westinghouse, but it closed because the

company’s engineers considered it impossible due to the principles of electronics. Later
on, Arutunoff provided the solution to Phillips Petroleum’s problem in 1927 when the
company was looking for a high-volume production method to make its high water-cut
wells more profitable. 

In the late 20th century, the company was a subsidiary of Schlumberger and held the
title of the world’s largest manufacturer of electrical submersible pumps. There was no
connection between REDA Pump Company and any other business until 1969. It was
acquired by Schlumberger in 1998 when that firm bought CAMCO.

Electrical Submersible Pump (ESP) System

A multistage centrifugal pump powers an ESP system’s series of centrifugal pumps to
draw fluid to the surface of the well.   The ESP system is discussed as follows:

Turning on the ESP system

Even though the electrical submersible pump will run on a constant frequency supply, a
soft starter or VSD can be used to get it going and clean out the well before the
operation. It will allow the well to be cleaned up, production to begin at a low flow rate,
and then ramped up as the well is rehabilitated.

Working Principle of ESP

A vertically oriented centrifugal pump in a borehole is the heart of an electrical
submersible pump, which increases the speed of fluids with the help of impellers. The
diffuser takes the fluid pumping energy created by the impellers and transforms it into
pressure energy. 

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In addition, the stages of an ESP System are typically configured with an impeller and
diffuser. When liquid is pumped through the first stage’s impeller, its radial outward
velocity is increased and centrifuged in the process. The fluid’s kinetic energy is turned
into pressure as it reaches the diffuser from the impeller’s sharp edges.

Components of Electrical Submersible Pump

The components are typically comprised of tubing hung from the wellhead. The pump is
attached to the tubing above the motor, and the motor is attached to the tubing below.
Refer to Fig. 1 which shows the components of a typical electrical submersible pump
system.

The following is a closer look at each component.

1.     Centrifugal Pump

The pump’s job is to provide the fluid with additional lift or transfer pressure to get the
fluid to flow out of the wellbore at the required pace. It achieves this goal by first
incorporating the fluid with kinetic energy by applying centrifugal force and then
transforming that kinetic energy into potential energy by applying pressure. Pumps are
manufactured in various diameters, so they may be used in the most common casing
sizes.

2.     Electric Motor

An electric motor drives the electrical submersible pump. Several steps are required to
generate adequate head pressure to raise the liquid to the surface. The motor size and
horsepower determined the number of stages.

Moreover, motor size is the primary factor in determining ESP bottom-hole equipment’s
total length and diameter. As the motor’s temperature rises during operation, the fluid is
pulled into the pump to cool it.

Fig. 1: Typical Electrical Submersible Pump System

3.     Power Cable

ESP motors receive the necessary surface power through the ESP power cable. As it is
not meant to bear any weight, it is usually banded or fastened to the production tubing
running from the wellhead to the ESP unit. The three-phase electrical wire builds under
the harsh conditions of a well.
Similarly, an electrical submersible pump has a strong power cable with an outer
covering resistant to mechanical and electrical stress. Due to the harsh conditions in the
well, the cable must be designed to be tiny in diameter, guarded against mechanical
abuse, and resistant to physical and electrical damage.

4.     Controllers
The surface controller of an artificial lift pump is responsible for supplying power to the
ESP motors and protecting the downhole ESP components from environmental
hazards. Depending on the task, either variable-speed controllers or soft-start
controllers are used.

 A VSD, or variable speed drive, can be operated either mechanically or electronically

in an electrical submersible pump.
 The operating speed of a soft-start controller is fixed. Slowly but surely, it brings the
pump motor up to its optimal operating speed and holds it there in a multistage
centrifugal pump.

5.     Sensor
Installing a bottom-hole sensor that relays information in real-time about system
parameters, including pump intake and output pressures, temperatures, and vibrations,
can help operators maximize efficiency.

A sensor on the pump sends a real-time alarm to the operator if the reading is outside of
the preset range, and the surface controller can make adjustments remotely or
automatically.

ESP Installation
1.     Refueling the Engine
In the pump, set the motor in a vertical position on its base, double-checking and
retightening any bolts as necessary. Ensure the engine is well hydrated by adding
clean, cold water, rock the motor back and forth to remove any trapped air, and screw
the plugs back in. Moreover, make sure there is no water leakage, and fix it.

2.     Waterproofing the Wires

The flat, three-core PVC-insulated cable connecting the submersible motor to the
surface is three meters long. Therefore, make a watertight connection between the free
end of the motor cable and the supply cable from the control panel in an artificial lift
pump.

3.     Take a Look at the Valves

Ensure the well’s valves are closed while the electrical submersible pump is not in use
to keep water from leaking back into the well.
4.     Testing the Motor’s Rotational Direction
Verify the submersible motor’s rotational direction after connecting the supply cable and
motor cable watertight. According to the markings on the cable box, the proper
rotational movement is anticlockwise. Now plug the motor into the control box and turn
the switch on for a moment. To validate the sand guard’s rotational axis, clean water
should pour over it. Then change the direction of rotation by switching any two lead
wires in the control panel if the markings on the cable box are incorrect.

5.     Controlling for Rotational and Tactical Freedoms

In an electrical submersible pump, make sure the shaft of the pump and motor may
freely spin and move up and down.

6.     Connecting the Pump to the Submerged Motor

After that, put together the tripod and the chain link and disconnect the submersible
pump’s cable guard and filter. Maintain a vertical position of the artificial lift pump using
the submersible motor and use a grub screw to attach the connection to the drive shaft
or pump shaft. Screw the delivery pipe into the delivery casing after applying the
threading compound. Raise the shaft once it’s assembled, and look for wiggle room.

Furthermore, install the connection onto the pump’s motor shaft, and lower the pump
until it is flush with the inlet bracket. Finally, suspend the submersible pump from the
chain block, and secure the supply hose with the clamp.

7.     Installing an Electrical System

In installing an electrical submersible pump, connect the submersible motor’s control
panel to the engine with a single cable and then protect the underwater motor with
grounding. Insist on a watertight connection at the cable’s end. Afterward, remove any
excessive cable length and secure it to the engine’s starter terminals. When deciding on
a wire size, keep low-voltage operating in mind.

8.     Lowering the Pump Securely

Lastly, connect a T-handle end of a poly rope to the pump’s lug and attach the end of
the safety rope to the inner well cap on both ends. Make sure the outer well cover is
securely fastened on the pump, and finish connecting the power wires.

Maintenance of Electrical Submersible Pump

There are certain guidelines on how to operate and maintain a facility and how to
resolve any difficulties that may develop. After the ESP has been extracted from the
well, its components can be disassembled and analyzed for information. It is true
whether the structures are salvageable or have suffered a complete collapse. Some
guidelines for maintaining a multistage centrifugal pump are discussed below:

a.     Check for Indications of Overheating

Check for indications of overheating the multistage centrifugal pump. If there is
inadequate water in the well to cool the pump, or if the pump is faulty, the pump may
overheat.

b.     Create Oil and Start the Motor

It is essential to regularly grease your pump to ensure its smooth operation.

c.      Examine the Engine

The pomp’s motor must also inspect often. Ensure that all connections of the artificial lift
pump are tight and that the starter is not overheated.

d.     Replace the Hoses and Fix the Leaks

The seals and hoses of the electrical submersible pump are susceptible to wear and
strain. If they are not periodically inspected, they can cause significant damage once
they begin to fail.

Applications of Electrical Submersible Pump

The artificial lift pump is superior to other types because it may be used in various flow
rates and depths and produce a significant artificial lift. A multistage centrifugal pump
increases output by creating a more substantial bottom pressure than the natural
production dynamic.

Moreover, these artificial lift pumps are used for various applications, including

drainage, irrigation, water wells, slurry pumping, fire-fighting, sewage pumping, artificial
lifts, seawater handling, oil wells, sewage treatment, deep well drilling, mine dewatering,
offshore drilling rigs.

 The artificial lift pump provides power for agricultural and industrial irrigation systems
 Flooded areas are pumped out at construction sites
 Sewage and sludge are common uses for these pumps. Pressure and level sensors
are installed beneath the sewage levels to control the system.
 A multistage centrifugal pump transports the crude oil to surface processing and
storage tanks.
 Oil is piped from deep underground wells to aboveground storage tanks
 Submersible pump cables must be dependable and resistant to the elements if they
are to be used in harsh environments. The power cables of the multistage centrifugal
pump are suitable for use in both fresh and saline water.

Advantages of ESP
The benefits of an artificial lift pump are mentioned below:

 Installed in straight sections, it can accommodate wells with a maximum inclination of

horizontal
 The multistage centrifugal pump allows for higher output despite inevitable water cuts
due to pressure checks and secondary recovery
 Being low-noise, low-risk, and low-impact means it can use in offshore and
environmentally sensitive locations without causing too much disruption
 Artificial lift pumps can withstand high GOR fluids, high temperatures, and corrosive
acid gases found in good settings.
 The electrical submersible pump has the capacity for large volumes, allowing for
adaptation to changing fluid characteristics and flow rates over the well’s operational
lifetime

Disadvantages of ESP
The disadvantages of multistage centrifugal pumps are mentioned below:

 The well’s curvature limits its usability during deployment and landing.
 Particles in production must keep to a minimum; fluids containing even trace
amounts of sand and solids can significantly affect the system.
 When a motor’s seals erode, water might seep inside and stop it from working until
they’re fixed. The pump’s construction makes repairs tricky.
 Equipment with moderate to high output rates necessitates casings with large outside
diameters (more than 4.5 inches).
 When calculating the tension and deflection of a part, manufacturers must take
dogleg severity into account to guarantee correct assembly and functionality.

Conclusion
When selecting a pumping system, engineers and operators increasingly discover
multistage centrifugal pump is the optimum option for downhole and surface
applications. The electrical submersible pump industry is developing more durable
pumps to make ESP systems more practical under conditions of high solids flow. To
significantly extend the lifespan of artificial lift pumps, ongoing research focuses on
enhancing the dependability of both individual components and integrated systems, as
well as creating improved algorithms for operating surveillance and control.

Frequently Asked Questions (FAQs)

Q1: What are the primary reasons a multistage centrifugal pump stops
functioning?
A: There are typically five leading causes for an artificial lift pump to stop working.
Among these are issues associated with heat and overload, fluid pressure, motor
seals, power surges, and stable voltage.

Submersible Pump System Overview

The submersible pump system consists of both downhole and surface components. The main surface
components are transformers, motor controllers, junction box and wellhead. The main downhole
components are the motor, seal, pump and cable. Additional downhole components may be
included to the system: data acquisition instrumentation, motor lead extension, cable bands
and protectors, gas separator, check and drain valves.

The following video gives a quick equipment overview of the ESP submersible pumping system:

The following figure shows schematic diagram of a submersible pump installation:

 Components of an Electrical Submersible Pumping System (source: API RP 11S3)

The Pump discharge head:

The pump discharge head is usually a separate component that bolts onto the top of the pump
section. Occasionally, the pump is built in either an upper tandem or single configuration. In these
cases, the discharge head as an integral part of the pump assembly.

The Pump:
The pump is a multi-stage centrifugal pump and is generally built as center tandem configuration.
The pump may be a single piece of pump or it may be made of two or more pumps bolted together.

The Pump Intake:

Fluid enters the pump through the pump intake. Usually, the pump intake is a separate component
that bolts onto the bottom of the pump section. Occasionally, the pump is built in either a lower
tandem or single configuration. In these cases, the pump intake as an integral part of the pump
assembly.
A bolt-on intake is usually a standard screened intake but sometimes a gas separator is used instead.

The Seal:
The seal section is located between the pump intake and the motor. It is also named: motor
protector or equalizer. the main functions of the seal are detailed in the post titled ” Motor
Protectors “. The seal section can be a single unit or may be run in tandem where it is desired to
additional seals and oil volume capabilities for high horsepower motor or more protection.
The Motor:
The motor is connected to the bottom of the seal. ESP motor is a two-pole, three-phase, squirrel
cage induction design filled with high dielectric strength oil. A two-pole design means that it runs at
3600 rpm synchronous speed at 60-Hz power or roughly between 3400 to 3500 rpm actual
operating speed, depending on the load. It operates on three-phase power at voltages as low as 230
and as high as 5000, with amperages between 12 and 200.
The motor may be a single motor or it may be made up of two or more motors bolted together in
tandem.

Motor Base/data acquisition instrument:

The bottom of the motor may have an integral base (a bolt on base) or a downhole sensing device
attached.

Electrical Power Cable:

Power is supplied to the electric motor by an electrical power cable. A special cable called a motor
lead extension (MLE) or flat cable is installed from the motor terminals (or motor pothead) to above
the end of the pump where it connects with the power cable. At this point, the main power cable is
spliced to the MLC. The cable is banded to the pump and tubing up to the wellhead. The number of
bands per joint of tubing depends on the size and type of cable and the well bore configuration.
Production Tubing:
The tubing conveys the produced fluid from the pump to the surface, into a flow-line. The type of
tubing used will depend on well bore constrictions, fluid rates, and economics.

Wellhead:
The wellhead must have a provision for the electrical cable to pass through the hanger assembly to
the surface. The tubing hanger holds a feed-through mandrel (also called: well penetrator) equipped
with the proper seals to contain well pressure and prevent gas leaks at the surface. The power cables
are connected to the two ends of this device via their three-phase connectors (also called: lower and
upper pigtails).

Junction Box:
The power cable coming from the well should be connected to a surface electric cable leading to the
motor starter (switchboard or VSD). The two cables are joined in the junction box, also called “vent
box”. This allows any gas that might have migrated up the cable to escape and vent to the
atmosphere.

The remaining surface equipment consists of a motor controller and transformer(s). For more details,
refer to the posts: Introduction to transformer: How it works? and Variable Frequency Drive Basics.