Evaluating the intake plugging effects on the electrical submersible pump (ESP) operating conditions using nodal analysis

The intake plugging of an electrical submersible pump (ESP) has presented a formidable challenge to conventional ESP wells. Attention to cumulative solid deposition is essential since it intensifies the intake plugging severity and impedes ESP performance. We present a new approach to evaluate the ESP performance degradation during increased intake plugging severity. In particular, we employ the intake plugging factor, rate-derating factor, and affinity law to calculate the new ESP speed at different plugging conditions. We used Schlumberger PIPESIM software to perform nodal analysis of the newly calculated ESP speed. The result was validated using the actual field data and compared to the field cases that reported the intake plugging issue. The nodal analysis showed a steady maximum ESP head with zero rate derating at the shut-in point. The intake plugging factor caused a significant reduction in the ESP operating rate and increased pump intake pressure and annulus liquid level. Based on the existing intake plugging field data, we established the quantitative standard for the normal and abnormal intake plugging factor range. The observed results agreed with the field downhole data recorded during the intake plugging problem. We identified that regulating the ESP speed to the reduced operating rate could minimize unexpected pump stoppage. It is also possible to carefully monitor the intake plugging problem by combining the annulus liquid level, the signature of pump intake pressure, and a deadhead test.