ESP Application Engineering AI Lab
Platform Features
Advanced ESP Sizing
Complete ESP system sizing with comprehensive pump database
Pump Curve Analysis
Interactive analysis with 12+ pump models
Affinity Laws Simulator
Calculate frequency effects on pump performance
VSD 3D Expert System
Baker Hughes VSD troubleshooting with 3D interface
AI Well Monitoring
Real-time well monitoring with AI alerts
IPM Automation
PROSPER, GAP, MBAL integration with 3D visualization
Information
Mohamed Shanees - ESP Application AI Expert
Experience: 15+ years in ESP Applications and AI Integration
Previous Roles: Aramco project (10 years), OXY project, Riyadh Sales projects,KOC, IRAQ Project
International Experience: Saudi Arabia, Iraq, UAE, Bahrain, India, Africa
ESP Sizing Calculator
Well & Fluid Parameters
Pump Selection
Formula Reference
ESP Sizing Formulas:
Hydraulic Horsepower: HHP = (Q × TDH × SG) / 136,000
Pump Efficiency: Eff = HHP / BHP
Stages Required: N = TDH / Head_per_Stage
Motor Input Power: KW = (HP × 0.746) / Motor_Efficiency
Fluid Velocity: V = 0.0093583 × (Q / Annular_Area)
Monthly Power Cost: Cost = KW × 730 × Power_Cost
Pump Curve Analysis
Affinity Laws Calculator
Base Parameters
Affinity Laws Results
Affinity Laws Formulas
Affinity Laws:
Flow: Q₂ = Q₁ × (N₂/N₁)
Head: H₂ = H₁ × (N₂/N₁)²
Power: P₂ = P₁ × (N₂/N₁)³
Efficiency: Efficiency remains constant (theoretically)
Where: Q = Flow rate, H = Head, P = Power, N = Speed (Hz)
VSD 3D Expert System
Troubleshooting Guide
Common ESP Problems
Gas Locking
Solution:
1. Install gas separator or gas handler
2. Increase tubing pressure by choking back
3. Lower pump setting depth
4. Consider variable speed operation
AI Recommendation:
Use gas-handling pump or install rotary gas separator for GOR > 500 scf/bbl
Sand Erosion
Solution:
1. Install abrasion-resistant pump
2. Add sand control screens
3. Optimize production rate
4. Monitor sand production rates
AI Recommendation:
Use hardened materials (tungsten carbide) for stages in sandy wells
Scale Formation
Solution:
1. Chemical injection program
2. Periodic acid treatments
3. Increase fluid velocity
4. Scale inhibitor injection
AI Recommendation:
For carbonate scale, use phosphonate-based inhibitors at 10-20 ppm
Motor Overheating
Solution:
1. Install motor shroud
2. Increase fluid velocity (>1 ft/sec)
3. Reduce pump size
4. Implement pump-off controller
AI Recommendation:
Minimum fluid velocity of 1.5 ft/sec required for adequate motor cooling
AI Diagnostic Tool
Case Studies
Case Study Database
AI Case Analysis
AI Well Monitoring Dashboard
IPM Suite Automation Dashboard
GAP (General Allocation Package) Integration
Network modeling and optimization for production systems.
MBAL (Material Balance) Integration
Reservoir material balance analysis and prediction.
AI Analysis Center
ESP Training Program
Day 1: ESP Fundamentals & Equipment
Topics Covered:
- ESP system components and functions
- Pump types: Radial vs. Mixed flow
- Motor theory and construction
- Seal section and thrust bearing
- Gas handling equipment
Practical Exercise: Identify ESP components in 3D viewer
Day 2: Pump Curve Analysis & Sizing
Topics Covered:
- Understanding pump performance curves
- Calculating hydraulic horsepower
- Determining number of stages
- Motor selection criteria
- Affinity laws application
Practical Exercise: Complete ESP sizing calculation
Day 3: Advanced Sizing & System Design
Topics Covered:
- Total dynamic head calculations
- Cable sizing and voltage drop
- Transformer selection
- Variable speed drive considerations
- Special applications (gas, abrasive fluids)
Practical Exercise: Design complete ESP system
Day 4: Installation & Startup Procedures
Topics Covered:
- Well preparation and equipment handling
- Running procedures and precautions
- Startup sequence and checks
- Initial optimization
- Safety procedures and best practices
Practical Exercise: Simulate ESP installation
Day 5: Troubleshooting & Optimization
Topics Covered:
- Ammeter chart analysis
- Common failure modes and diagnosis
- Preventive maintenance
- Optimization techniques
- Case study analysis
Practical Exercise: Troubleshoot simulated ESP problem