🎯 Course Description:
This focused 5-day course provides participants with comprehensive knowledge of Electrical Submersible Pump (ESP) systems, including design principles, component selection, system sizing, operational strategies, and troubleshooting techniques. Designed for engineers and technical personnel in the oil & gas, water, and industrial sectors, this course delivers the tools needed to ensure efficient ESP deployment, performance optimization, and extended service life.
Through in-depth lectures, real-world design problems, and interactive workshops, participants will gain hands-on experience in ESP system analysis, pump curve interpretation, motor sizing, and field operation challenges.
👥 Who Should Attend:
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Petroleum and production engineers
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Electrical and mechanical engineers
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Artificial lift specialists
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Facilities and field engineers
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ESP service and maintenance technicians
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Energy professionals responsible for pump system design or optimization
🗓️ Day 1: Introduction to ESP Systems and Components
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | ESP Overview – History, applications, and selection criteria |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Key ESP Components – Pump, motor, seal/protector, intake, cable, VSD |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | ESP System Configuration – Surface and downhole integration |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Identifying ESP system components and field layout |
🗓️ Day 2: ESP Pump Design and Hydraulic Sizing
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Hydraulic Fundamentals – Head, flow rate, NPSH, efficiency |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Pump Curves and Performance Matching – BHP vs flow, system head curve |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | ESP Sizing Calculations – Fluid properties, TDH, well depth, losses |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Case Study: Design and selection of pump stages for oil well application |
🗓️ Day 3: ESP Motors, Cables, and Power Systems
| Time | Topic |
|---|---|
| 08:30 – 10:00 | ESP Motor Selection – Types, voltage, HP, derating, temperature effects |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Power Cable Design and Voltage Drop Analysis |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Variable Speed Drives (VSDs) – Soft start, ramping, performance tuning |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Motor power requirements and cable voltage drop calculation |
🗓️ Day 4: ESP Operation, Monitoring, and Troubleshooting
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Start-Up and Shutdown Procedures – Sequencing and system checks |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | ESP Monitoring and Control Systems – SCADA, sensors, alarms, remote control |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Failure Modes and Troubleshooting Techniques – Sand, gas lock, overheating |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Case Study: Diagnosing ESP failure using historical performance data |
🗓️ Day 5: Optimization, Maintenance, and Field Applications
| Time | Topic |
|---|---|
| 08:30 – 10:00 | ESP Optimization Strategies – Gas handling, inflow profiling, well design |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Preventive and Predictive Maintenance – Run life extension best practices |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Integrated Workshop: Design, size, and validate an ESP for a real well |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Final Q&A, Feedback, Course Wrap-Up & Certificates |
📂 Course Materials Provided:
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ESP system design handbook
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Stage-by-stage ESP sizing worksheets (Excel)
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Sample pump/motor/cable selection catalog
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Troubleshooting flowcharts and fault analysis sheets
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ESP well optimization best practices guide
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Interactive ESP performance analysis case files
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Voltage drop and power system sizing calculator
