ESP Application Engineering AI Lab

Advanced platform for Electrical Submersible Pump sizing, analysis, and troubleshooting. Powered by Ellipzys AI with comprehensive pump database and real-time calculations.

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

Comprehensive ESP sizing calculator based on industry-standard formulas and pump database. Calculates stages, motor requirements, and operating parameters.

Well & Fluid Parameters

bbl/day
feet
SG (water=1.0)
°F
scf/bbl
%
°API
cp

Pump Selection

Hz
decimal (84% = 0.84)
USD per KWH
feet
psi

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

Interactive pump curve visualization with 3D impeller view and real-time parameter adjustments. Powered by Ellipzys AI for intelligent analysis.
Electric Submersible Pump Variable Speed Performance Curve — BKR 400 P60
Downhole Rate: BPD, Frequency: Hz, SpGr: , Viscosity: cP, Stages: , Motor HP: , TDH: ft
Inputs
Selected Pump: BKR 400 P60
Max Flow: 8200 BFPD | Max Head: 28.68 ft | Max Power: 1.33 HP

Affinity Laws Calculator

Calculate the effects of frequency changes on pump performance using the affinity laws. Visualize how flow, head, and power change with frequency adjustments.

Base Parameters

Hz
bbl/day
ft/stage
HP/stage
Hz

Affinity Laws Results

New Flow Rate
7467
bbl/day
New Head
38.24
ft/stage
New BHP
3.10
HP/stage
Speed Ratio
1.33
(New/Old)
Flow Ratio
1.33
(New/Old)
Head Ratio
1.78
(New/Old)²
Power Ratio
2.37
(New/Old)³

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

Baker Hughes ElectroSpeed Advantage VSD Expert System with 3D interface and Ellipzys AI integration. Based on 2018 troubleshooting manual.

Troubleshooting Guide

Comprehensive ESP troubleshooting guide with AI-powered diagnostics. Identify common issues and get step-by-step solutions.

Common ESP Problems

Gas Locking

Pump loses prime due to excessive gas in fluid stream. Symptoms: erratic ammeter readings, reduced production.
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

Abrasive wear on pump components from sand production. Symptoms: gradual production decline, increased vibration.
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

Mineral deposits reduce pump efficiency and flow area. Symptoms: gradual pressure increase, reduced efficiency.
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

Insufficient cooling causes motor temperature rise. Symptoms: high motor temperature, insulation failure.
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

Real-world ESP case studies with analysis and lessons learned. Powered by Ellipzys AI for intelligent case analysis.

Case Study Database

AI Case Analysis

AI Well Monitoring Dashboard

Advanced well monitoring with AI alerts, IPR analysis, pump performance curves, and real-time data transmission.

IPM Suite Automation Dashboard

Integrated Petroleum Management Suite with PROSPER, GAP, MBAL integration, 3D visualization, and AI-powered automation.
PROSPER Dashboard
GAP Integration
MBAL Integration
AI Analysis

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

Comprehensive 5-day ESP training program with interactive modules. Powered by Ellipzys AI for personalized learning.
1

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

2

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

3

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

4

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

5

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

Training Progress

Day 1: Fundamentals0%
Day 2: Pump Curves0%
Day 3: System Design0%
Day 4: Installation0%
Day 5: Troubleshooting0%