• Class and Course

    Electric Submersible Pumps - Practical Application Engineering Training with Manufacturing Plant Tour

    In this class, the participants will be introduced to the different types of Artificial Lift (AL) applications and then will focus on the practical background and hands-on exercises on the Electric Submersible Pumps (ESP) application engineering.

    The class includes comprehensive visits to the ESP Manufacturing Plant in Singapore (Plant Tour) so the participants can get practical experience working with the ESP application engineering.

    Day 1 - Introduction

    • Introduction / HSE Orientation / Welcome: The class will start with an informal introduction session.  This will include a brief outline of the history of the course and the main areas/topics that will be reviewed.  An overview of the training will be discussed with participants to determine if the agenda meets the needs of those attending the training. The goals and objectives of each client will be recorded to ensure the training meets expectations. If there are some requests not covered in the agenda, where possible, the agenda will be adjusted to accommodate additional requests.
    • HSE: Safety for the class will be of the upmost importance. Sections of the training that require PPE or special attention will be reviewed.  This will also include who to contact if any concerns arise.
    • Installation: The installation involves a number of procedures and step that occur in whether in the high pressure environment of an oil rig. Each step, if not done correctly, has the potential to negatively affect the run life of the ESP. The installation process will be reviewed and major areas of concerns will be discussed as to how the installation process can be improved.
    • Troubleshooting: Class room training will include a cause and effect session where students are required to analyze what will happen to the ESP under varying condition so ESP performance can be interpreted. This will be followed by why trouble shooting is so difficult and some steps that can be taken to help analyze data is such a way as to interpret what is happening downhole.
    • Plant Tour:

    Factory Acceptance Testing (FAT) will include observing the horizontal pump test system (HPTS), the motor idle slant test (MIST) and the vertical pump testing system (VPTS)


    • ESP Design (Hand Calculations): The fundamentals of design work and a hand design will be conducted using two methods. The first design will use the traditional Bottoms Up Method that focuses on TDH and the second method will use the newer Top Down method that focuses on Pressure. This is important so that output for ESP software packages can be understood and explained.
    • Overview: There will essentially be two software packages reviewed.  The first is a basic pump design software package that focuses on quick pump selection. This software can be used to perform basic evaluation on pump performance and comparison between different pump manufactures.

    The second software package is Design Pro (or equivalent, i.e. PIPESIM), one of the most advanced ESP design program available. During this training various ESP Design scenarios will be evaluated, the students may be provided with laptops/personal computers to use the software packages. The designs will become increasingly more difficult as familiarity with the software increases.

    • Plant Tour:
    • Oil Well Simulator: (when and where available) The simulator will be used extensively this day to simulate/visualize/replicate a number of operational conditions in the well.
    • Quiz

    • ESP Design: Design work outlined in Day 2 will carry over into part of Day 3.
    • Alternative ESP Installations: This section will include diverters, y-tools, dual ESP's, wireline deployed ESP and horizontal pumping systems (HPS).
    • Plant Tour:

    Quality and Testing (Q&T) Facility: This facility is where system integration testing (SIT) is conducted and involves the construction and testing of the entire ESP.  The ESP is assembled as it would be on the rig floor, installed in a test well and run through various testing criteria.

    • Quiz

    • Monitoring, Run Life and Questions: there are two critical areas when it comes to determining if monitoring will be successful – the first is the collection of quality data and the second is what is done with the data. The value of various data will be discussed and then a review of the stages available that allow for the highest production increase from that data.

    The economics of ESP’s will be discussed focusing on the areas of run life, incentive contacts, tendering processes and types of contracts that could be implemented.

    This will also be a day where problems that attendees of the class can bring forward and an analysis of the data can be done as a group.

    • Plant Tour:
    • Y-tools: This will include viewing of the y-tools, plugs, flapper and bypass tubing. Gas Lift - will include witnessing the assembly and test of a gas lift valve and the machining processes involved in the construction of a mandrel.
    • Quiz

    Day 5 - Optional Plant Tour Day

    Plant Tour: (optional for those who have already attended the Manufacturing Plant Tour in the Practical Equipment Training course - PE-TC2-NXT176600)

    • Quality Control (QC) - one of the key differences between an ESP running a short or long time is the quality control implemented during the construction and assembly of the ESP components. During this tour the quality control practices and equipment used to ensure confirm specifications will be demonstrated.
    • Foundry  & Finishing: (PPE Required – Safety Shoes, Safety Glasses, Fume Mask and Headset with Communication). First part of this tour is a review of the foundry area which starts in the Green Sand Lab; where the quality  of the cast parts are controlled including metallurgy, hardness, finish, etc. The foundry area will be toured where raw materials such as iron, zinc, nickel, chromium, etc. are melted and formed into impellers and diffusers.  It will include a review and observation of the casting process from start to finish.
    • Head and Base Machining - two of the most complicated parts to manufacture for any ESP component is the head and base - this process will be observed. Pump assembly will be observed as to what steps are required to build the pump, including observing the impeller/diffusers installed in the housing.
    • Protector Assemble will include a review of the parts used to manufacture a protector followed but observation of one section of the protector constructed and tested. Motor - stator winding will be followed by motor assembly. Included in this step will be the witnessing of the auto shaft straightening process. Gauge - will include a review of how the electronic parts are first tested/vetted for selection followed by the assembly and final test of the gauge.
    • Gauge - will include a review of how the electronic parts are first tested/vetted for selection followed by the assembly and final test of the gauge. A VSD will be reviewed including the controller, components and step up transformer.

    Production/Artificial Lift Engineers

    Production Operations Engineers

    Production Optimization Engineers

    Production Technologists

    None.  Knowledge of Artificial Lift systems and ESP is a plus.

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