In the shale era, electric submersible pumps (ESPs) have become the workhorse of the beginning phase of a well, which is its most productive. New types of ESPs using highly efficient permanent magnet motors (PMMs) are gaining acceptance for their ability to boost production along a shale well’s production decline curve.
Dana Meadows, Baker Hughes’ artificial lift portfolio director
As wells age and production drops, gas production rises, creating gas-locking issues. These are being addressed by contra-helical pump systems designed to reduce gas locking. Baker Hughes and Extract Production, an NOV company, are advancing the industry in these and other areas.
PMM energy savings, efficiencies make them a viable option
For almost a decade, developers have known that powering ESPs with PMMs instead of traditional induction motors (IMs) can cut po
wer consumption and reduce the size of equipment inserted downhole. Early-day drawbacks included the shorter run life of PMMs and safety concerns due to the possibility of generating electrical charges when not running. So, PMMs remained under the radar while developers who saw their potential continued to improve them.
In the last few months, PMMs have become a hot commodity, said Dana Meadows, Baker Hughes’ artificial lift portfolio director. In 2023, the company’s PMM, branded as Magnefficient, accounted for only 3% of Baker Hughes-installed ESPs. This year, PMM installations have ballooned to 11% of ESP installations, and that number is growing.
Three reasons for sudden growth
There are multiple drivers for this increase, Meadows said, including improved safety devices, concerns about power grid overloads and the need to extend the economic life of producing wells. Baker Hughes has spent the last three years developing a complete system involving PMMs, the E2000 ESP and variable speed drives.