September 25, 2024

PowerSaveESP – A Complex Technology for Reducing Production Costs

Up to 61% of the energy consumed by a standard ESP system is lost to heating the fluid and equipment, with only 39% of the power used directly for hydrocarbon extraction. This is typical across the industry, and oil companies have long been working to reduce specific energy consumption. Various methods are employed, such as using high-voltage motors in the ESP systems, pumps with higher efficiency, changing equipment selection criteria, and others.

Novomet has taken a step further by creating the PowerSaveESP technology – energy- efficient installations. Its uniqueness lies in a complex approach that enables maximum reduction of oil extraction costs.

Firstly, it involves the proper selection in specialized software and operating equipment at maximum efficiency, which is ensured through special control station algorithms. Specialized software can define precise parameters for conditions and select an installation that will operate at the point of maximum efficiency.

Secondly, operation at high speeds (over 3000 RPM) has been researched at the company to determine the impact of rotational frequency on ESP efficiency. Tests confirmed that higher pump speeds lead to increased efficiency and head, allowing for a reduction in ESP length by up to 60%. An effective design simplifies installation, placement in wells, and replacement.

Thirdly, the installation incorporates pumps of a new design and valve electric motors. Energy-efficient pumps feature more complex, optimized geometries that reduce losses and increase stage efficiency by 10-15 points. A reinforced construction is used for operation at elevated rotational frequencies, ensuring necessary reliability. The advantages of valve motors are well-known – a wide range of regulation, lower losses, reduced heat generation, and consequently, higher efficiency.

Additionally, as part of the comprehensive approach to combat gas issues, solutions such as additional energy-efficient pre-installed devices – gas stabilizers and gas separators – are utilized. These devices are characterized by increased wear resistance and reduced energy consumption. The claimed specifications are confirmed by full resource testing and real-world operating conditions with clients.

All these solutions in total can reduce the energy consumption of ESP systems by 25- 30%, and in some cases, up to 35%. Furthermore, the pumps and motors included in the PowerSaveESP system manufactured by Novomet have a high energy efficiency class specified in their documentation and may qualify for various tax incentives. Novomet’s PowerSaveESP installations offer a very wide range, produced in sizes from 2A to 8 with flow rates ranging from 15 m³/day to 4000 m³/day.

- Thus, switching to energy-efficient ESP systems will reliably save up to 25% of electricity when lifting fluids from wells, - summarizes Novomet's Chief Designer Konstantin Saveliev. - It will enhance the reliability of submerged equipment, especially in challenging conditions, allow for stable operation at maximum efficiency or maximum extraction rates, and ultimately increase production volumes through effective selection.