Comparative Simulation Analysis of Permanent Magnet Esp Systems Using Lutz Methodology and Temperature Analysis, Enhancing Energy Efficiency

Abstract

The oilfields in Colombia where Ecopetrol operates are mostly mature fields that, by presenting a decline in production, energy consumption and limitations in electrical infrastructure represent one of the most relevant aspects in lifting costs greater than 50% and the challenge in reducing the carbon footprint. For this reason, energy consumption, environmental impact and lifting costs are being analyzed in depth to achieve and increase efficiencies through the oil production process. In response to cost and carbon footprint reductions and efficiencies goals, as new global trend, since 2020, Ecopetrol has promoted the implementation of new technologies in significant points through the oil production process. It is the case of the Electric Submersible Pumps Systems (ESP) which produces the oil from the well to the surface, and their Permanent Magnet Motor (PMM) technology as an alternative and complement to reduce energy consumption of the current Artificial Lift Systems (ALS) installed. To achieve the successful implementation of ESP PMM technology it was vital to consider the hazards related to the installation and operation. In general terms, the installations were carried out according to the well plan, following HSE and quality global procedures and verifying electrical measurements during the operation. After the installations, successful functional tests were conducted, and the equipment was started up in accordance with the design and planned specifications. The Lutz methodology was applied, incorporating advanced techniques to simulate consumption per well groups by flow rates, the data from the ESP installations with PMM and IM motors were analysed and through lutz, flow rates and different data fittings and data regression. The application of the Lutz measurement methodology proves to be an effective tool for evaluating and optimizing the energy performance of permanent magnet motors in an oil field, especially in well clusters with varying flow rates. This methodology enables detailed monitoring of key parameters, such as system efficiency and energy consumption, facilitating the identification of opportunities for improving energy efficiency for the customer. On the other hand, a comparative analysis between IM and PMM ESP applications is presented to enhancing energy efficiency in oil wells through the implementation of Permanent Magnet Electrical Submersible Pump (ESP) systems in different regions and wells where the customer operates. The results show significant improvements in ESP equipment efficiencies and great energy savings compared to having IM instead of PMM. After 3 years of operation, significant data has been gathered, revealing stable equipment operation and fluid production meeting expectations. Some relevant ESP performance parameters achieved so far: the pump and motor work within recommended operating range with better system efficiency (+12%) and less power consumption compared with the correlations wells (-14%) and the kilowatts billed has been reduced by 14%. Moreover, by implementing adjustments based on the collected data, such as speed modulation and precise fluid production control, significant energy savings can be achieved and motor operation in the field optimized, thereby contributing to a more profitable and sustainable operation. Based on the analysis results, accurate recommendations could be given to the customer to improve the ESP systems in different fields and contribute to achieve efficiencies and reduce costs related to power consumption, resulting in important oil production process optimizations.