Electronic Submersible Pump (ESP) Technology and Limitations

with Respect to Geothermal Systems

The possibilities and challenges increased at greater depths from lateral movement at startup
due to the higher head demand. Depth aside, LSPs are incapable
with ESPs for geothermal electricity of operating in horizontal wells or other highly deviated wells.
production LSP shaft bearings also require lubrication which can cause well
contamination (Jenne 2014b). ESPs, on the other hand, have all
ESP: A Solution to Artificial Lift mechanical components downhole, leaving only the controller
NREL analyzed current ESP technology to understand the above ground. The technology can also function in angled or
capabilities and limitations with respect to geothermal electricity horizontal wells. For this reason, ESP technology has been
production. Current geothermal technology has limitations widely adopted for oil extraction. ESPs consist of five major
that hinder the expansion of utility-scale power generation. components (Baillie 2002):
Developers note that one limitation is artificial lift (Jenne 2014). • Power supply/controller
With the exception of a few geothermal fields, line shaft pumps • Power cable
(LSPs) dominate the production of artificial lift. • Pump
The motor in an LSP assembly is above ground, requiring • Seal/bearing package
the power shaft to extend to the depth of the pump. This
• Electric motor.
configuration puts a high strain on the power shaft and limits
LSPs to approximately 2,000 feet (Culver and Fafferty 1998). However, the operating conditions in an oil field vary
As enhanced geothermal systems (EGS) reach greater depths, significantly from a geothermal system. One of the most notable
LSPs are at greater risk of failure due to the high angle of twist differences with respect to artificial lift is that geothermal
as a result of both torque and shaft length. Shaft stress is also systems operate at significantly higher flow rates, and with
potential advancements from EGS, at even greater depths. The
large flow rates associated with geothermal systems require
horsepower ratings which can exceed 1,000 horsepower (hp)
per well. While oil wells can be at greater depths, the lower
flow rates allow for lower-hp motors. Geothermal systems also
operate in a variety of harsh conditions including, but not limited
to: high temperature, high salinity, high concentrations of total
dissolved solids (TDS), total suspended solids (TSS), and non-
condensable gases.

Challenge: Operating Conditions

Extensive work has been done to increase the operating
temperature and the power capacity for all components within
the ESP system, as well as the ability to operate in harsh
environments.
Steam assisted gravity drain (SAGD) oil recovery has paved the
way for high-temperature ESPs. The current market includes
motors that are capable of operating up to 482°F (250°C). While
these motors far exceed the temperatures of typical hydrothermal
systems, they are limited to approximately 250 hp (Schlumberger
2013).

NREL is a national laboratory of the U.S. Department of Energy,

Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
On the other end of the spectrum, the
current market includes motors that are
rated up 1,500 hp (Wood Group 2004),
and ratings up to 2,800 hp can be achieved
with multiple motors in series (Baker
Hughes 2011). However, at these ratings,
motors are typically limited to below 325°F
(163°C). Some of this temperature de-rating
is due to material selection, but high-hp Geothermal plant located
motors inherently put out more heat, and at Stillwater, Nevada.
therefore high-temperature motors would Photo from Sierra Pacific,
still require a de-rating if simply scaled up NREL 07209
(Burleigh 2013).
Regardless of temperature or power rating, with less access to capital find it difficult to Culver, G.; Raafferty, K. (1998). “Well Pumps.”
one of the biggest concerns with the current compete without access to full-scale testing Geo-Heat Center Bulletin. Accessed June 20,
ESP marketplace is the operational life (required by some investors). And as the 2014: http://geoheat.oit.edu/bulletin/bull19-1/
at these extremes. Current ESPs have art2.pdf.
need to test more extreme temperature,
a typical operational life of only two to Hooker, M. (2011). “High-Temperature
power rating, and environmental extremes
Motor Windings for Downhole Pumps
three years, and as temperature increases, continues, the need for advancements in Used in Geothermal Energy Production.”
life expectancy is further reduced ESP testing facilities could grow. Composite Technology Development, Inc.
(Vandevier 2010). 2011 Geothermal Technology Program Peer
One solution could be a third-party
Some new R&D efforts are looking at new Review. Accessed June 30, 2014: http://www4.
testing facility that can replicate the harsh eere.energy.gov/geothermal/sites/default/files/
design and material configurations to push conditions for geothermal ESP applications. documents/High%20Temp%20Motor%20
high-temperature and high-hp boundaries Although a large investment, access to such Windings%20for%20Downhold%20Pumps_
even higher. Novel designs such as hollow a testing facility could potentially reduce Hooker_Composite.pdf.
core motors (Turnquist 2013) and advanced entry barriers by allowing more researchers Schlumberger. (2012). “REDA HotlineSA3:
polymer compounds (Hooker 2011) are to solve and test ESP design challenges High Temperature Electric Submersible Pump
being considered to reduce the failure rates for geothermal applications. This could System.” Accessed June 30, 2014:
and increase performance. http://www.slb.com/~/media/Files/artificial_
be a critical component for geothermal lift/product_sheets/hotline_high_temperature_
industry growth. submersible_pump_ps.pdf.
Technology and R&D
Turnquist, N. (2013). “High-Temperature-High-
Opportunities References Volume Lifting for Enhanced Geothermal
The ESP research to date has focused on Baker Hughes. (2011). “XP Xtreme Systems.” 2013 Geothermal Technology Office
individual problems for oil wells—not Performance Series 880 Motor System.” Peer Review. Accessed June 30, 2014:
Accessed June 30, 2014: http://energy.gov/sites/prod/files/2014/02/f7/
an integrated, comprehensive solution so turnquist_high_temp_tools_peer2013.pdf.
http://assets.cmp.bh.mxmcloud.com/system/
that an ESP system can operate reliably f772b99800f9f0721c4c2ccd41eafc01_ Vandevier, J. (2010). “Run-Time Analysis
for geothermal electricity production. 31179-xp-high-hp_overview-0611.pdf. Assesses Pump Performance”. Oil and Gas
Additionally, testing for new ESP designs Jenne, S. (Dec. 5, 2013). Phone conversation Journal 108.37; pp. 76-79.
is expensive and a large barrier for new with Burleigh, L., Baker Hughes ESP Product Vandevier, J.; Gould, B. (2009). “Application
participants. Line Manager. of Electric Submersible Pumping Systems in
The ESP market is dominated by a small Jenne, S. (July 23, 2014). Personal interview High Temperature Geothermal Environments.”
with Price, B., Vice President of Engineering Geothermal Resource Council Transactions 33;
number of OEMs that have the ability
and Construction at ENEL Green Power. pp. 649-652.
to perform accelerated testing at full
Jenne, S. (Jan. 9, 2014b). Personal interview Wood Group. (2004). “Electric Submersible
scale. Large OEMs that have invested
with Nordquist, J., Director of Business Pumps for the Petroleum Industry.” Oklahoma
in multimillion-dollar facilities have the City, OK: Wood Group. Accessed July 17, 2014:
Development at Ormat Technologies, Inc.
ability to test ESPs at extreme conditions http://www.oilproduction.net/files/
(Vandevier and Gould 2009). Companies ESP-WoodGroup.pdf.

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy

Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
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