Electrical Submersible Pump Complete Characteristics

ESP Workshop, Houston Texas, May 2002

B.L. Wilson


Abstract:

The Q-H or the characteristic pump curve shows the head, flow and power relation for a
particular pump design. It generally will only cover the quadrant for positive head and positive
flow. It can not therefore show the effect of flowing liquid up through an idle pump, or injecting
liquid down through an idle pump.

A set of tests were performed to determine the reaction of an electrical submersible pump to
forced fluid flow in the positive direction and negative direction. This data was compared to
published data performed on surface pumps.

The tests confirmed the general characteristics of the historic data, but also indicated areas
where the submersible system was significantly different.

This allows the identification of safe operating windows when gas lifting, or injecting through an
installed submersible pump.

Introduction

The traditional presentation of pump performance in the ESP industry (fig 1) is a curve showing
the flow as the abscissa and the head is the ordinate. Additional curves representing efficiency
and input power are normally included, however they are often dispensed when trying to show
the families of curves representing performance at various driving frequencies. The curve may
also show the operating range indicating where the equipment may be run with out damage.
This representation is intended for normal operation of the pump, that is the pump turning in the
correct direction at an appropriate speed, producing positive head (higher at the discharge than
the intake) and positive flow (flowing from the intake to the discharge)..

For abnormal operation, the representation might have to be extended into other regions. A
four-quadrant representation would include the extension of the axis into the negative head and
flow regions (fig 2).

The four-quadrant representation is of little use in ordinary pumping situations, however with the
expanding of the use of the ESP, knowing the limits of safe operation in the other quadrants is
becoming necessary.

Background:

The problem that initiated the investigation involved ESPs that were installed but power was not
immediately available. Gas lift valves had been installed on the tubing string to produce the fluid
in the case of ESP failure. It was crucial that fluid production be started so it was proposed to
gas lift the fluid through the unenergized ESP.

The flow is still in the positive direction, but since the pump is not energized, it is an impediment
to the flow and creates a pressure drop. This places the operation of the unit in the second
quadrant. The thrust forces in the pump are effected. The pressure created down thrust is now
negative and acts with rather than balances the up thrust forces. The stages can be damaged
due to the heavy up thrust forces.




A second concern with this operation is related to the rotational speed. Unlike the pump, the
motor bearing load is not speed dependent. Previously experience had shown that low speeds
may not be sufficient to generate the required hydrodynamic film in the motor thrust bearing.
The thrust bearing can be destroyed at prolonged low speed operation.

If instead of gas lifting through the pump, it was desired to inject fluid through the pump, the
pressure across the pump would be positive, but the flow would be in the negative direction.
This would place the operation in the forth quadrant. The concerns about damage are similar.
Inadequate speed will fail to develop lubrication on the thrust bearings. The thrust component is
the pump in now reversed. All of the thrust is now in the downward direction, with no upward
component to help balance. Heavy down thrust wear could result.

Previous Literature:.

Literature on the subject was limited. Two A.S.M.E. papers, one from 1939 by R.T. Knapp
1
, and
the other from 1951 by W.M. Swanson
2
. were used by Stepanoff in his book on centrifugal
pumps
3
. Both of these papers attempt to present represented complete pump characteristics
curves, that is flowing in each direction, positive and negative head as well as various shaft
rotation speeds.

Both sources used pumps that were significantly different from the ESP. The Knapp data was
chosen for study even though it was based on a double suction pump. Its specific speed (1800)
was much closer than the pumps examined in the other publication. Two of his graphs are
presented showing performance for positive RPM (fig 3) and for negative RPM (fig 4)

Two curves on these graphs are of interest. The zero RPM line which represents the pumps
flow resistance with the shaft not turning, and the zero torque line which indicates Q-H relation
without having to put torque on the shaft. These curves help to define the window of safe
operation. The lower flow limit is defined by the zero RPM curve. Any Q-H point below this
curve should present no problem because the unit is not turning. The upper flow limit is more
difficult. The shaft will be turning. It must be turning fast enough to lubricate the motor thrust
bearing, but the pressure drop across the stage should not be so great that the impellers do not
develop thrust problems.

Testing:

An instrumented pump test facility was available were data could be obtained for testing the
pumps. This particular facility was capable of forcing flow through the pump and could
adequately replicate the second quadrant flow. A 15 Hp pump of approximately 2200 specific
speed was already installed. It was just a matter of a few man-hours to initiate the test.

The first results looked disappointing. The instruments did not indicate that the pump rotated.
The motor was energized to assure that the pump was not stuck. After numerous bumps it
was decided to remove the pump for examination.

The source of the problem turned out to be a motor- pump mismatch. A 15 Hp pump could not
generate the torque to rotate a 75 Hp motor. The data produced two curves (fig #5) which
clearly bracket the performance for zero and 100 % RPM for this pump.






The motor was replaced with one sized for the pump horsepower. Tests were run with and
without a coupling to obtain data on the zero torque curve and to determine where a typical ESP
would perform. These results were complied with data from subsequent tests with other pumps
and are presented in figure #6.

To complete the project it was necessary to test the pumps with negative flow. This was
accomplished by building the pumps with the stages upside down and re-running the tests.
Figure #7 presents a generalized ESP four quadrant performance curve.

Discussion:

The form of this curve was simplified to present the data in an uncluttered manner. The curve is
valid only for the pump designs that were tested and should not be loosely extrapolated.

Safe operating zones depend greatly on the magnitude of thrust that the flow generates. This is
unique to each design and system. The manufacturer should be consulted. No generalized
recommendation has been presented for a safe operating zone except for the area of zero
rotation.

The ESP should suffer no damage if the fluid flow is low enough that it produces no rotation.
This covers a flow range from approximately 25% flow to + 30% flow.

A minimum rotation to guarantee development of the lubrication boundary for the thrust bearing
could be approximately 28-35% (1,000-1,200 RPM), depending on the manufacturer.

For flowing up through the pump, this defines a rather wide prohibited zone from approximately
30% to 80% of BEP flow.

For injecting fluid down through a pump the prohibited zone is narrow and in the range of 25%
BEP flow.

No generalization for a maximum positive or negative flow will be presented because of the
variety of designs. The equipment manufacture should be consulted for information.

Conclusion:

The experimental data shows similar, but not identical characteristics to the Knapp data. The
testing of each stage type would be necessary for complete accuracy.

Safe operation of ESPs can be conducted in the second and fourth quadrants if care is taken to
avoid operation in the danger zones.

References:

1. R.T Knapp, Complete Characteristics of Centrifugal Pups and Their Uses in the Prediction
of Transient Behavior. Trans. A.S.M.E., pp. 683-689, November 1937
2. W.M. Swanson, Complete Characteristics Circle Diagram for Turbo-Machinery, Trans.
A.S.M.E., Vol. 75, pp. 819-826, 1953
3. A.J. Stapanoff, Centrifugal and Axial Flow Pumps, Fig 13.1-13.4, New York, John Wiley and
Sons, 1957





FLOW (Q)
H
E
A
D

(
H
)
60 Hz
75 Hz
70 Hz
65 Hz
55 Hz
50 Hz
45 Hz
PUMP PERFORMANCE
0
0
Fig. 1


60 Hz (100%)
75 Hz (125%)
45 Hz (75%)
+Q -Q
2nd Quadrant 3rd Quadrant
4th Quadrant 1st Quadrant
Fig. 2
FOUR QUADRANT PUMP PERFORMANCE
+H
-H





Four Quadrant Curve for + RPM, after Knapp Fig 3







Four Quadrant Curve for - RPM, after Knapp Fig 4




0 0.5
5
1.0 1.5 2.0 2.5
-1
-0.5
0
0.5
1
1.5
2
Forced Positive Flow, n
s
=1800
Flow (Normalized)
H
e
a
d
/
s
t

(
N
o
r
m
a
l
i
z
e
d
)
Std
T t
1st
S t
2nd
S t

Fig. 5


-1 0 1 2 3
-2
-1
0
1
2
100%
75%
50%
25%
Forced Positive Flow, n
s
=1800
Flow (Normalized)
H
e
a
d
/
s
t

(
N
o
r
m
a
l
i
z
e
d
)
Pump Curve 0 Torque 0 RPM
0 Torque
0 RPM
Pump Curve

Fig. 5





-1 -0.5 0 0.5 1 1.5
2
-1
-0.5
0
0.5
1
1.5
ESP Four Quadrant Performance
Flow (Normalized)
H
e
a
d
/
s
t

(
N
o
r
m
a
l
i
z
e
d
)
Std Curves
Free Rotation No Rotation
-90% RPM
-80%
-70%
-60%
-50%
-40%
-30%
5%
10%
15%
20%
30% RPM
40%
-1.5
-1.5
100% RPM
75% RPM
50% RPM
Reverse Flow
Normal Pump
Reverse Turbine
Energy Dissipation
No Operation
This Quadrant
Quadrant
Quadrant


Fig. 7