Lab 4

Electrical Submerible Pump (ESP)

Objective
1. To develop the performance curve of an ESP
2. To study the effect of rotation speed and examine the Affinity Law
Centrifugal Pump Theory
A centrifugal pump is one of the simplest pieces of equipment in any process plant. Its purpose is to
convert energy of a prime mover (a electric motor or turbine) first into velocity or kinetic energy and
then into pressure energy of a fluid that is being pumped. The energy changes occur by virtue of two
main parts of the pump, the impeller and the volute or diffuser. The impeller is the rotating part that
converts driver energy into kinetic energy. The volute or diffuser is the stationary part that converts the
kinetic energy into pressure energy.

Centrifugal pump Different types of impellers

Figure 1 – Basics of Centrifugal pump

When the impeller rotates, it spins the liquid sitting in the cavities between the vanes outward and
provides centrifugal acceleration. As liquid leaves the eye of the impeller a low-pressure area is created
causing more liquid to flow toward the inlet. Because the impeller blades are curved, the fluid is pushed
in a tangential and radial direction by the centrifugal force.
The key idea is that the energy created by the centrifugal force is kinetic energy. The amount of energy
given to the liquid is proportional to the velocity at the edge or vane tip of the impeller. The faster the
impeller revolves or the bigger the impeller is, then the higher will be the velocity of the liquid at the
vane tip and the greater the energy imparted to the liquid. This kinetic energy of a liquid coming out of
an impeller is harnessed by creating a resistance to the flow. The first resistance is created by the pump
volute (casing) that catches the liquid and slows it down. In the discharge nozzle, the liquid further

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decelerates, and its velocity is converted to pressure according to Bernoulli’s principle. Therefore, the
head (pressure in terms of height of liquid) developed is approximately equal to the velocity energy at
the periphery of the impeller expressed by the following well-known formula
𝑣2
𝐻=
2𝑔
where H is the total head developed in feet; v is the velocity at periphery of impeller in ft/sec; and g is
the acceleration due to gravity, g = 32.2 ft/sec2.
This head can also be calculated from the readings on the pressure gauges attached to the suction and
discharge lines. Pump curves relate flow rate and pressure (head) developed by the pump at different
impeller sizes and rotational speeds.
Centrifugal pumps can be single-stage or multi-stage units. Single-stage pumps are mainly used when
low to medium discharge pressure is required, while multi-stage pumps are designed to overcome higher
discharge pressures. This is the case of Electric Submersible Pumping (ESP) used in the petroleum
industry where fluids must be lifted from deep formations.

Figure 2 – Water performance of curve of the ESP GC6100 at Hz, one stage

A Basic ESP System

ESP is the second most commonly used artificial lift method in oil and gas industry. ESP has been used
massively in Russia and in significant number of wells in US. It is responsible for the highest amount
of total fluids produced (oil and water) by any artificial lift method and an ideal method for high water
cut wells. The problems with ESPs are that they are not suitable for high gas liquid ratio and high bottom
hole temperature wells

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Figure 3 – A basic ESP system

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 Radial Flow Type ESP Pump Mixed Flow Type ESP Pump
Figure 4 – Types of ESP

The radial flow stage design develops pressure/head through only centrifugal forces. This pump design
is generally used where a low flow, high head installation is required. This design is accomplished by
allowing the fluid to be discharged at a 90° angle from the eye of the impeller. The liquid rates are in
the range of from 100 bpd to 2,000 bpd with pump efficiencies in the order of 60%. The radial stage is
a flat stage and is the most efficient design for these lower flow rates.
The mixed flow stage design develops pressure/head through centrifugal and axial forces. This design
is generally used where a High Flow – High Head installation is required. The angle at which the fluid
is discharged at an angle less than 90° from the eye of the impeller. Liquid rates are generally in the
range from 1,000 bpd to 50,000 bpd. Pump efficiencies for this design are normally greater than 60% at
the best efficiency point. In addition, the mixed flow stage pump is capable of handling gas and solids
more efficiently.
When handling free gas, the centrifugal pump head performance curve suffers degradation. The design
of an ESP system using the water information for oil wells with some free gas fraction at pump intake
conditions is a harder task, and is based on the prediction of performance curves by modification of the
water curves

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The most important parameter is the density of the mixture at the flow conditions of each stage. Applying
this procedure, the ESP system often shows some degree of under or over sizing, under field operations.
This can be observed comparing the expected and the real produced flow rates, and also by the amperage
consumption fluctuation of the motor due to the presence of the gas phase

Figure 5 – Pump Performance – Effect of Gas

The centrifugal pump operation should conform to the pump curves supplied by the manufacturer. In
order to read and understand the pump curves, it is very important to develop a clear understanding of
the terms used in the curves.
Capacity, Q, GPM
Capacity means the flow rate with which liquid is moved or pushed by the pump to the desired point in
the process. It is commonly measured in either gallons per minute (gpm) or cubic meters per hour
(m3/hr). The effect on the flow through a pump by changing the outlet pressures is graphed on a pump
curve.
Head, H, ft
The pressure at any point in a liquid can be thought of as being caused by a vertical column of the liquid
due to its weight. The height of this column is called the static head and is expressed in terms of feet of
liquid. The same head term is used to measure the kinetic energy created by the pump. In other words,
head is a measurement of the height of a liquid column that the pump could create from the kinetic
energy imparted to the liquid. Head is a term that has units of a length or feet and pressure has units of
force per unit area or pound per square inch

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 Figure 6 – Definition for head

𝑃𝑢𝑚𝑝 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 (𝑝𝑠𝑖𝑔)

𝐻𝑒𝑎𝑑 (𝑓𝑡) =
0.433 × 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑔𝑟𝑎𝑣𝑖𝑡𝑦
Pump pressure is the difference between outlet pressure and inlet pressure

Brake Horse Power (BHP) and Hydraulic Horse power (HHP)

The work performed by a pump is a function of the total head and the weight of the liquid pumped in a
given time period. Pump input or brake horsepower (BHP) is the actual horsepower delivered to the
pump shaft. Pump output or hydraulic or hydraulic horsepower (HHP) is the liquid horsepower delivered
by the pump. These two terms are defined by the following formulas.
𝑄×𝐻×𝛾
𝐵𝐻𝑃 = , 𝐻𝑃
3960 × 𝐸
𝑄×𝐻×𝛾
𝐻𝐻𝑃 = , 𝐻𝑃
3960
Where Q is the capacity in gallons per minute (GPM); H is the head in feet; γ is the specific gravity of
the liquid; and E is the pump efficiency, %.
The constant 3960 is obtained by dividing the number of foot-pounds for one horsepower (33,000) by
the weight of one gallon of water (8.33 pounds). BHP can also be read from the pump curves at any
flow rate. Pump curves are based on a specific gravity of 1.0. The brake horsepower or input to a pump

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is greater than the hydraulic horsepower or output due to the mechanical and hydraulic losses incurred
in the pump. Therefore, the pump efficiency is the ratio of these two values (HHP/BHP).
Best Efficiency Point (BEP)
Best Efficiency Point (BEP) is defined as the capacity at which the efficiency of the pump is highest.
All points to the right or left of BEP have a lower efficiency. The BEP is the area on the curve where
the change of velocity energy into pressure energy at a given gallon per minute is optimum; in essence,
the point where the pump is most efficient. The impeller will be subject to non-symmetrical forces when
operating to the right or left of the BEP. These forces manifest themselves in many mechanically
unstable conditions like vibration, excessive hydraulic thrust, temperature rise, and erosion and
separation cavitation. Thus the operation of a centrifugal pump should not be outside the furthest left or
right efficiency curves published by the manufacturer. The centrifugal pump should be operated in a
range of ±20 % of the maximum efficiency Emax. The -0.2Emax is called the lower operating range and
the +0.2Emax is called the upper operating range. If the ESP is operated out of the operating range, it will
suffer under either upthrust or downthrust which causes the damage of the impellers.

Figure 7 – Best efficiency point

The Affinity Laws

The Affinity Laws are mathematical expressions that define changes in pump capacity, head, and BHP
when a change is made to pump speed, impeller diameter, or both. According to Affinity Laws:
Capacity, Q changes in direct proportion to speed N ratio:

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𝑄2 𝑁2
=
𝑄1 𝑁1
Head, H changes in direct proportion to the square of speed N ratio:
𝐻2 𝑁2 2
=( )
𝐻1 𝑁1
BHP changes in direct proportion to the cube of speed ratio:
𝐵𝐻𝑃2 𝑁2 3
=( )
𝐵𝐻𝑃1 𝑁1
The Affinity Laws are valid only under conditions of constant efficiency and very low viscosity of fluids.

Experimental Procedure
1. The ESP and 1’’ pipe will be used for the tests.
2. Start the data acquisition system.
3. Set all the valves in the right positions so we can have the flow through the 1’’ pipe. Make sure
there is no flow through the orifice and the elbow-system pipe.
4. From the Production Lab program, open the control panel.
5. Set the pump speed to:
a. Group 1 – 1000, 1200, 1400, 1600, 1800, 2000, 2200, 2400, 2600 RPM
b. Group 2 – 1100, 1300, 1500, 1700, 1900, 2100, 2300, 2500, 2700 RPM
6. Stop the saving mode and then stop the program.

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Calculation
1. Convert the flow rate to barrel per day (BPD) and m3/s
2. Convert the differential pressure between intake and discharge pressure to head in the unit of ft
and meter.
3. Calculate the hydraulic horsepower developed by the pump.
4. Develop the performance curve of the pump by plotting these relationships in one graph: head
(ft and meter) vs. flow rate (bbl/day and m3/s); hydraulic horsepower vs. flow rate (bbl/day).
5. Using Affinity Law to predict the performance of the pump at different rotational speeds.

Questions
1. What is the principle of building head in a centrifugal pump?
2. What are the differences between a conventional centrifugal pump and an ESP?
3. What are the advantages and disadvantages of an ESP.
4. What are the problems if the ESP is operated out of the operating range?
5. How does the pump speed change the pump performance curves? Why?
6. How does the Affinity Law match with the experimental data? What may cause the discrepancy
between the prediction of Affinity Law and the experimental data