REDUCE ESP POWER COSTS BY 25% OR MORE
 

POWERSAVE ESP SYSTEMS

Reduce Your Carbon Emissions with the PowerSave ESP System

The PowerSave ESP System combines proprietary pump-stage design, precision parts manufactured using powder metallurgy, and advanced permanent magnet motor (PMM) technology to lower electrical submersible pumping (ESP) system power consumption by 25–30% or more. Reducing your electrical consumption is an effective way to reduce your carbon emissions.

 

It takes energy to produce energy

ESPs provide reliable artificial lift for a broad range of flow rates and well conditions. When a downhole system runs 24 hours a day, 7 days a week, the electricity bill can be significant. Electricity costs reduce profits, particularly for operators that run hundreds of ESPs or have to make regular trips to refuel onsite generators.

 

A full 61% of the power consumed in a conventional ESP system is lost to heat. Only 39% of the power is used to actually produce hydrocarbons. This is consistent across the industry in conventional ESPs running a three-phase, two-pole, oil-filled induction motor driving a multistage centrifugal pump. The pump alone is responsible for losing 29% of all electricity to heat, and the motor loses 13%.

BENEFITS

Lowers energy use by 25% or more

With PMM motors, superior stage design, and precision powder metallurgy
Reduces ESP length by 60%


Efficient design simplifies installation and improves ESP placement
Reduces heat and vibration


Extends motor life, reduces scaling, offers superior gas handling, and improves reliability



applications

  • Conventional and unconventional wells
  • Standard casing sizes

capabilities

  • Flowrates from 63 to 37,700 bbl/d (10 to 6000 m3/d)
  • Fluid head up to 11,400 ft (3500 m)

features

  • Powder mettalurgy manufacturing produces ultra-smooth components that reduce heat and vibration
  • High-RPM pumps and superior stage design reduce ESP length by 60%
  • PMMs reduce electromagnetic loss and improve efficiency
  • High-efficiency pumps and PMMs combine to reduce power consumption by 25% or more while increasing reliability and runtime
Power Save ESP system being run in hole on land rig

Stop wasting electricity

Losing 61% of the electricity you buy is unacceptable. Novomet attacked the two biggest energy wasting components in an ESP—the pump and the motor—to develop the PowerSave system.

 

We started by designing an energy-efficient, high-speed pump that would operate at higher RPMs. Using powder metallurgy, we manufacture parts with a level of precision that is not possible using industry-standard sand-cast manufacturing. This enabled us to redesign the pump using new geometries, and to reduce the overall pump length to one-third its previous size—while maintaining pump capacity. Advanced pump stage geometries and an upgrade in materials combined with the shorter pump length to dramatically reduce heat and wasted electricity.

 

The next step was the motor. Typical induction motors use motor windings to create magnetic induction. Having to create this induction causes heat, wasting electromagnetic energy. So we designed and developed a permanent magnet motor that eliminates the need for motor windings entirely. The rotor uses rare-earth alloy magnets with two ports where north and south poles interlace to reduce the power needed to turn the rotor. Stator laminations are made from proprietary Novomet material, further reducing drag. As with the pump, PowerSave permanent magnet motors are shorter and lighter than induction motors. The result is a light-weight, powerful motor that runs cooler and uses less electricity.

The most efficient electricity is the electricity you never use

The high-speed pump and permanent magnet motor combine to reduce ESP power consumption by 25–30% and reduce overall system length by 60%. Put another way, the PowerSave system can reduce your carbon emissions related to running ESPs by 30%.

TECHNICAL CHARACTERISTICS

PowerSave ESP 3D rendering

Size (RU)

Size

Capacity

Head

Efficiency rate

2A

2.72 in.

151-755 bbl/d (@60Hz)

11,483 ft

45-57%

69 mm

20-100 m3/d (@50Hz)

3500 m

3

3.19 in.

189-2,415 bbl/d (@60Hz)

11,483 ft

40-70%

81 mm

25-320 m3/d (@50Hz)

3500 m

5

3.62 in.

251-3,019 bbl/d (@60Hz)

11,483 ft

46-66%

92 mm

20-400 m3/d (@50Hz)

3500 m

5A

4.06 in.

755-3,774 bbl/d (@60Hz)

11,483 ft

67-71%

103 mm

100-500 m3/d (@50Hz)

3500 m

7A

5.35 in.

2264-16,982 bbl/d (@60Hz)

9,843 ft

67-76%

136 mm

300-2250 m3/d (@50Hz)

3000 m

8

6.77 in.

12,076-18,869 bbl/d (@60Hz)

8,202 ft

74-76%

172 mm

1600-2500 m3/d (@50Hz)

2500 m

Need more info?

Contact us for more information about how our highly efficient PowerSave ESP systems can help you save 25% or more on your ESP power costs
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