The influence of wear on the pressure-flow characteristics of electrical submersible pumps when pumping coarsely dispersed gas-liquid mixtures

UDK: 622.276.53.054.5:658.011.4

DOI: 10.24887/0028-2448-2025-9-86-90

Key words: electrical submersible pump (ESP), wear, gas-liquid mixture, pressure-flow characteristics, gas lock, flow path, wear coefficient

Authors: E.V. Yudin (Gazprom Neft Companу Group, RF, Saint Petersburg); B.M. Latypov (Ufa State Petroleum Technological University, RF, Ufa); V.E. Chernyshov (Association «Digital technologies in industry», RF, Saint Petersburg); M.V. Verbitsky (Gubkin University, RF, Moscow); D.A. Gorbunov (Gubkin University, RF, Moscow); M.D. Shabunin (Research and Education Center Gazprom Neft – UGNTU, RF, Ufa); A.V. Ryzhikov (Association «Digital technologies in industry», RF, Saint Petersburg)

This study investigates the impact of operational wear on the pressure-flow characteristics of electrical submersible pumps (ESP) when pumping coarse-dispersed gas-liquid mixtures. While the degradation of ESP performance due to gas presence is well-documented, this research specifically examines how mechanical wear significantly exacerbates this issue, reducing gas tolerance compared to new equipment. The experimental work was conducted on a specialized test facility at Gubkin University, which enables precise control of parameters. Results demonstrate that worn ESPs experience performance degradation (gas lock) at substantially lower gas volume fractions compared to their original specifications. The critical gas content threshold for worn pumps was found to be significantly reduced, with performance collapsing more abruptly than in new equipment. The research shows that energy efficiency of worn ESPs decreases more rapidly when handling gas-liquid mixtures, necessitating operational adjustments to maintain efficiency. These findings underscore the necessity of developing methodologies to assess pump wear and corresponding correction coefficients for existing performance degradation models obtained through experimental methods. Regular monitoring of downhole equipment condition and timely replacement of worn stages are essential for maintaining efficient operation in high gas-content environments, particularly in late-stage field development where gas-liquid ratios are elevated. The research provides critical insights for optimizing ESP selection, operation, and maintenance strategies.

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