ESP Support Services

The design, installation and eventual removal of Electric Submersible Pump systems is fraught with risk. This is because not only are these multi-stage pumps complex in design, but they often have to fit into a really tight space, which may also be tortuous. The reliability and durability of an ESP is highly dependent on the conditions it operates in and the fluids it pumps – it is generally not possible for the designers to consider every possible use scenario a priori. During installation and removal, these tools are subject to bending and twisting forces as they make their way through the well that can have a lasting effect on their performance. These effects are dependent on well geometry and cannot be considered specifically in ESP design other than accounting for a maximum bend, twist or combination. In some cases, the fit is so tight that hang-up due to geometric interference is a possibility.

There, however, is a way to manage these risks through simulation of the installation, operation and removal. Engenya’s advanced simulation capabilities have been put to use in the verification of ESP component design, in the redesign of the assembly process, in the determination of the root causes of installation failure and in the verification of the installation process. Engenya works with the relevant stakeholders to manage the risk by installing, running or removing the ESP virtually and verifying the installation process steps along the way. Investing in these kinds of activities can ultimately save you millions in rework or recovery costs, and can ensure that your system meets its design life with ease.

Read on for more detail of what we can do to support your ESP installation…

Services

Whether tubing conveyed or slickline, for installations with complex designs, long tools or parts, centralizers or deformation-sensitive equipment, simulation can answer questions, remove uncertainty and help to manage risk effectively.

Engenya offers a range of services in support of ESP benchmarking, installation or removal that are based on its advanced modelling and simulation capability:

  • Simulation of run-in process.
  • Simulation of pull out process.
  • Verification of component design to specifications.
  • Riser dynamics.
  • In-situ component stress/strain.
  • Pump efficiency at operational conditions.
  • Multi-phase flow analysis for efficiency and durability.
  • Fatigue and damage tolerance assessments.
  • Quantitative risk assessment.
  • Failure root cause analysis.
Forced Dynamic Response Due To Rig Motion

ESP run-in process simulation

Non-linear dynamic analysis of run in process accounting for:

  • Contact and friction.
  • Geometric fit and interference.
  • Material yield and plastic deformation.
  • Insertion rate.

Analysis outputs:

  • Deformation of ESP and components through run in process.
  • Forces and moments generated on ESP through run in process.
  • Stresses and strains generated on fully modelled components through run in.
  • Effective weight of string through run in.

All analyses are customizable.

ESP Assembly
BOP and Alignement Helix Profile
Run-in Simulation

ESP pull out of hole process simulation

Non-linear dynamic analysis of pull out process accounting for:

  • Initial condition of installed production string.
  • Contact and friction.
  • Geometric fit and interference.
  • Material yield and plastic deformation.
  • Pull out rate.

Analysis outputs:

  • Deformation of ESP and components through pull out process.
  • Forces and moments generated on ESP through pull out process.
  • Stresses and strains generated on fully modelled components through pull out.
  • Effective weight of string through pull out.

All analyses are customizable.

Bending Moment at Clamp Locations
Maximum Bending Moment on ESP

ESP component design and verification

Independent stress/strain analysis of ESP components:

  • Verification of design limits and safety margins.
  • Verification of structural integrity.
  • External and/or internal components.
  • Design audits.

In-situ stress/strain analysis of ESP components:

  • Components integrated into string model.
  • Verification of structural integrity during run in or pull out.
  • Transient stress/strain response through run in or pull out.
  • Calculation of operational margins of safety.
  • External and/or internal components.
Clamp Geometry
Bolt Stress at Limit Load
Mesh Detail
Clamp in String Assembly

Riser dynamics

Offshore installations of ESP’s are generally done through a riser. The riser has a dynamic response to the sea currents as well as the rig motion that can have a significant effect on the ESP installation.

Independent stress/strain analysis of ESP components accounting for:

Constraints

  • Rig position.
  • Rig motion.
  • Rotary joint motion.
  • BOP profile.
  • Etc.

Loads

  • Hydrodynamic loads.
  • Axial loads.
  • Pressure.
  • Temperature.
  • Loads due to equipment in riser.
  • Etc.
Interpretation of Riser Dynamics
Vortex Shedding in Sea Current

Additional capabilities

Fluid dynamics – CFD

  • Single or multi-stage flow simulations for verification of pump efficiency and pressure head at specific downhole conditions.
  • Multi-phase (gas/liquid/solid) analysis for verification of performance at downhole conditions as well as estimates of component erosion.
  • Failure analyses.

Structural mechanics – FEA

  • Evaluation of expected fatigue life of critical compoentns at operational conditions.
  • Evaluation of ESP damage tolerance at operational conditions.
  • Failure analyses.

Risk analysis and management

  • Quantitative assessment of risk of failure during operation.
  • Evaluation of effects of string/ESP/tool design changes on operational risk.
  • System analysis and identification of risk in operational conditions.

References

Engenya GmbH partners with different service providers to extend their range of simulation services in support of ESP installations, risk management and problem solving. The images below link to partners as well as relevant materials connected with Engenya's ESP Support Services.