Innovative Approach to Optimize ESP Power Consumption through Developed Software

Abstract

Maintaining oil production while both water cut and reservoir pressure are changing with time is a challenging task especially for fields equipped with artificial lift systems such as Electrical Submersible Pump (ESP). ESPs have a defined recommended operating range (ROR) that can reduce the flexibility of the system therefore a variable speed drive (VSD) unit is being used to extend the ROR. A surface choke is also another option to adjust the flow rates and control the ESP to operate within its recommended range. However, inefficient use of both options can be detrimental on the life cycle of the production system. High VSD Frequency will increase the motor speed which leads to increased power consumption. Low choke setting causes high hydraulic losses across the choke that can lead to wastes of energy. In oil fields equipped with ESPs, power consumption as well as ESP run life play a significant role in specifying the operation cost and economical life of the field. Therefore, it's essential to optimize the operation conditions of the ESP to optimize the operation conditions of the ESP through minimizing power consumption while maintaining a production rate that fall within the pumps ROR. Utilizing a technique that can quickly provide the best choke and frequency setting is a key to achieving more optimized operation in a dynamic field. This paper will discuss an in-house developed application that can calculate the minimum ESP motor operating frequency and the optimum choke setting point required to maintain the production rate at the minimum power consumption and lower motor speed. With the availability of real-time data from the surface and down-hole equipment, the optimization process was automated by collecting data and modeling surface equipment and ESP. this application is being used to optimize an entire field and the pilot test showed very promising results. A substantial 2000 KVA, which is equivalent to 1600 KWh, was saved by adjusting only 57 wells.

Optimization of Energy Consumption in Oil Fields Using Data Analysis

“…ESP is typically employed in high-production wells and offshore applications. However, its small size can significantly reduce the efficiency of ESP, leading to increased energy consumption [31,66]. Due to lower production levels in the oil field, only 304 wells utilized the ESP system.…”

“…A new intelligent tracking software for the pump (ESP) system has been developed to reduce energy consumption [30]. The authors have set up a variable-speed drive unit to optimize operation conditions [31]. Zhang et al have also developed a quick solution to optimize the oil block.…”

Improving the Energy Efficiency of An Electric Submersible Pump Installation Using an Integrated Logistics Support Approach

“…; P bp -bubble point pressure, Pa; P ESP -the power required to drive the ESP, W; P SEM -active power consumed by the SEM, W; Q SEM -the reactive power consumed by the SEM, VAR; ∆U CL -voltage loss in the cable line, V; P CL -active power on the HV side of the transformer, W; Q CL -reactive power on the HV side of the transformer, VAR; ∆U T -voltage loss in the transformer, V; P T -active power on the LV side of the transformer, W; Q T -reactive power on the LV side of the transformer, VAR; P ESPI -active power of ESP installation, W; Q ESPI -reactive power of ESP installation, VAR. Unlike the known approaches [4,5,[7][8][9][10][11][12][13][14][15][16][17], the ILS approach provides regular (fixed in enterprises' standards) monitoring, diagnostics and analysis of the technical condition of the structural elements of the ETC. It will also make it possible to evaluate the efficiency of the operation of the ETC in order to verify the compliance of the actual and calculated values of their characteristics.…”

“…In paper [13], the authors consider the issues of voltage regulation at terminals and rotation speed of a submersible electric motor; other paper [14,15] investigate the issues of maintaining equipment in optimal condition based on monitoring data. In paper [16], the issue of selecting the optimal frequency of the control station and the diameter of the choke is considered, while the magnitude of the impact on the choke is calculated based on the archived data. In paper [17], the application of the control laws of electric motors is considered.…”