The authors discuss how advanced electric submersible plunger pump (ESPP) solutions—featuring permanent magnet motors (PMMs) and linear PMM technologies—are tackling industry challenges, enhancing production across diverse applications, and supporting global sustainability objectives.
PAVEL SVIRIDOV, WALTER DINKINS, JOHN DAVIS and MARCO CARRASQUERO, Levare USA
The oil and gas industry is facing unprecedented challenges, including grid oversaturation, tightening environmental regulations, and rising demand for sustainable operations. Artificial lift plays a crucial role in this landscape, requiring advanced technologies that enhance both efficiency and environmental performance. Innovations, such as Permanent Magnet Motors (PMMs) and Linear PMM (LPMM) technologies, are reshaping well operations by significantly improving energy efficiency and sustainability. Recent advancements like the Electric Submersible Plunger Pump (ESPP) system meet the growing need for low-maintenance, energy-efficient solutions adaptable to a wide range of applications, including those in environmentally sensitive areas.
ESPP SYSTEM OVERVIEW
The ESPP system is an innovation in artificial lift technology, integrating PMM technology for efficient and reliable operation. Permanent magnets made of sintered hard-magnetic materials are incorporated into the design of the PMM rotor. It is the rotor flux produced by these magnets that interacts with the stator magnetic field to produce motor torque. Power consumption and heat rise are both reduced, since no current is induced in the PMM rotor. The proven technology of PMMs has shown to reduce operating expenses attributable to electric submersible pump (ESP) power consumption up to 20%. The higher HP rotor density means PMMs are also significantly shorter than an IM equivalent, which enables deeper pump setting depths, as well as facilitating better clearance through severe doglegs or tortuous well paths.
Designed to replace traditional sucker rod pumps, the ESPP system uses a downhole LPMM (Fig. 1) to drive a reciprocating plunger, eliminating the need for sucker rods and surface pumpjacks. The system configuration resembles that of a conventional ESP, comprising an insert or tubing pump, LPMM, motor compensator, and sensor, with a power cable running parallel to the production tubing to supply electrical power. At the surface, a variable speed drive (VSD) manages power and operational parameters. This setup not only simplifies installation but also reduces environmental impacts by eliminating fluid leaks and emissions typically associated with stuffing boxes.
A key operational feature of the system is its precise motor control, enabling adaptability across diverse well conditions. The LPMM’s stator and slider convert electrical energy into linear motion, driving the plunger with optimized stroke cycles. Adjustable parameters, such as acceleration, speed, and idle times, are programmable to ensure compatibility with complex well inflow and operating scenarios. The system also incorporates advanced sensors to measure downhole conditions, such as intake pressure, motor temperature, and vibration, providing real-time data for enhanced operational control and optimization.
This technology proves especially effective in challenging applications, including low-flow wells, deviated and horizontal wells, or environmentally sensitive locations. Notably, by eliminating rod and tubing wear, it extends equipment lifespan and minimizes failures. Its efficiency is demonstrated in gas well dewatering, where it has achieved substantial increases in production while reducing power consumption by half. By combining innovative design and robust functionality, the ESPP system represents a significant step forward in artificial lift solutions.
KEY INDUSTRY CHALLENGES
Grid oversaturation continues to be a major challenge in regions like the Permian basin, where aging infrastructure is struggling to meet growing power demands. The integration of ESPs with PMMs has emerged as an effective strategy to optimize oil production while significantly lowering energy consumption. This combination offers a practical solution for easing the strain on overburdened power grids.
A standout advantage of PMM technology is its adaptability. Rather than relying on one-size-fits-all solutions, engineering teams are increasingly focused on customized approaches that address specific regional and client needs.
These technologies offer clear improvements in energy efficiency and reduced environmental impact, aligning with global goals for more sustainable energy practices. Despite its benefits, the adoption of PMM technology in the oil and gas sector has faced resistance, often due to reluctance to embrace change. To overcome this, comprehensive training is being emphasized, along with strict safety protocols, and adherence to industry certifications to foster trust and promote wider acceptance. Continued efforts to strengthen safety standards and address public concerns will be essential to accelerating adoption and ensuring PMMs have a lasting role in the industry's future.
CASE STUDIES
PMM power savings studies with leading U.S. operators have consistently demonstrated up to 20% energy savings, averaging around 13%, depending on well conditions. These savings translate to lower energy costs while maintaining stable production output.
A key challenge for operators has been managing high lease operating expenses, particularly with energy-intensive IM-driven ESPs. These systems lack the adaptability needed for unconventional wells with variable flowrates and motor load demands, resulting in inflated costs. PMM technology addresses these challenges with an advanced design that eliminates rotational losses found in conventional systems, improving operational efficiency.
A recent study compared 14 wells, split evenly between PMMs and IMs. Normalized data (kW/BL/TDH/SG) revealed an average power saving of 11% in PMM wells under consistent production conditions. In unconventional wells with declining production, PMMs achieved even higher savings, especially when operating below 60% load. This is due to PMMs maintaining high efficiency and power factors across a broader load range than conventional IMs.
The following case studies demonstrate how these advanced technologies are solving real-world challenges in the oil and gas sector. By harnessing innovations, such as ESPP, PMM and LPMM technologies, operators are enhancing energy efficiency without compromising production performance. These examples also highlight customized solutions designed to address regional limitations and meet the specific engineering needs of individual clients.
CASE STUDY 1: PERMANENT MAGNET VERSUS INDUCTION MOTOR EFFICIENCY
With an increasing number of operators exploring PMM-driven ESP systems, both lab and field trials have become essential to evaluate their real-world performance. This case study examines a field trial conducted by an operator in partnership with Levare to compare the efficiency and operational improvements of PMMs against legacy IM systems within their Permian basin operations.
From 2017 to 2018, the operator and Levare conducted a comprehensive field trial in Odessa, Texas, comprising two producing wells equipped with 400 series ESP systems. The trial followed a three-phase methodology for direct comparison between IM and PMM systems. Phase I involved establishing a baseline with the existing IM systems, driven by switchboards, running at a consistent 60 Hz. Phase II introduced VSDs alongside the IMs to isolate efficiency differences caused by control mechanisms. Finally, Phase III replaced the IMs with PMMs while maintaining identical downhole conditions, such as pump design, intake depth, and cable lengths. Data collected included power consumption, pump intake pressure, tubing pressure, and production rates at various rotational speeds.
The two wells yielded distinct results. While one consistently demonstrated a 15% efficiency improvement with the PMM, the second fell short of the target, with only a 2% improvement. Subsequent lab analysis identified motor fluid viscosity as a significant factor impacting PMM performance in the second well. By switching to a lower-viscosity oil, efficiency was improved by an additional 4.4%, aligning more closely with expectations. This finding underscores the importance of selecting motor fluids, based on wellbore temperature to maximize performance.
Following the findings from the initial two wells, five additional PMM systems were installed in a separate residual oil zone (ROZ) field in Texas. These deployments provided further data, affirming the advantages of PMMs in high-water-cut and fluctuating gas-to-liquid ratio environments. The results showed PMMs maintained a 13% higher efficiency, compared to IMs, even under variable loading conditions. Furthermore, PMMs exhibited reduced operating temperatures, which can significantly enhance the longevity of both motor components and insulation materials. Importantly, no failures were reported in these installations, demonstrating improved reliability and reduced operational costs.
CASE STUDY 2: ACHIEVING COST REDUCTION AND EFFICIENCY WITH PMMS
High production expenses, particularly electric power costs, have long been a challenge for companies utilizing ESPs in oil extraction. Another operator, in collaboration with Levare, sought to address this issue by integrating PMMs into their ESP-operated wells. This case study highlights the evaluation of PMM technology through field trials, showcasing its potential to revolutionize ESP operations with improved efficiency, reduced power consumption, and innovative design advantages.
Traditional IMs used in ESP systems are hindered by significant copper and iron losses in their rotors, along with heat-related inefficiencies. Conversely, PMMs eliminate copper losses and reduce rotor iron losses by operating at synchronous speeds. This unique design not only conserves energy but also allows PMMs to generate more horsepower per rotor while operating at cooler temperatures, making them a potentially groundbreaking solution.
To ensure credibility, the operator conducted robust field trials in September and November of 2011. The trials aimed specifically to measure energy savings by comparing the performance of a PMM against standard induction motors. Both motors were tested within identical conditions using the same ESP systems and pumps to eliminate variables. Detailed power consumption data from industrial-grade analyzers revealed that PMMs utilized nearly 20% less power, compared to IMs under similar operating conditions.
PMMs demonstrated a notable drop in power consumption over traditional motors in ESP applications, yielding savings of up to $3,053 per month at an energy rate of $0.10 per kWh. Over time, these savings accumulate into a substantial reduction in operating expenses. PMMs, with fewer and shorter rotors, due to their higher horsepower per rotor, allow for a shorter ESP assembly. This design is particularly beneficial for installation in deviated wells where space constraints often limit equipment options. Due to reduced friction, heat, and rotor losses, PMMs run cooler and experience extended operational lifespans. The absence of copper losses and the optimized rotor design ensure higher efficiency, even under challenging conditions.
Following the success of the initial field trials, the operator expanded its adoption of PMMs in various wells to explore their long-term reliability and performance. The ongoing evaluation includes the use of PMMs in highly deviated wells and assessments of their durability over time. Additionally, the compact design of these motors has significantly reduced installation challenges and extended the lifespan of well operations, further highlighting the value of this innovative technology.
CASE STUDY 3: ADVANCING ARTIFICIAL LIFT EFFICIENCY IN THE SAN JOAQUIN BASIN
Operators in the San Joaquin basin of California faced operational setbacks stemming from excessive energy use and mechanical failures in traditional rod lift systems. Frequent tubing and rod wear, along with inefficiencies in managing production decline curves, compounded the challenge. To address these issues, operators turned to Levare for a more durable and efficient solution.
The ESPP system, paired with a LPMM, provided an alternative. With the implementation of this technology, the operators achieved substantial energy savings of between 60% and 65%, while simultaneously addressing production inefficiencies and mitigating environmental impact.
Conditions in the Buena Vista reservoir were challenging, characterized by low flowrates under 80 bpd, steep production decline curves, and a lack of active aquifer support. Traditional rod pump systems struggled in these conditions, incurring high maintenance costs, due to mechanical failures and downtime. The ESPP system, designed for adaptability and precision, eliminated rod components prone to wear and delivered consistent performance, despite variable load conditions.
The improvements were enabled by the advanced technological features of the system. The ESPP’s design eliminated the stuffing box, effectively eliminating methane leaks, fluid spills, and reducing noise pollution. Real-time telemetry allowed operators to monitor critical parameters, such as pump intake pressure, motor temperature, and vibration, ensuring optimal performance. Precise speed control, facilitated by the VSD, further enhanced energy efficiency.
Two low-production wells were selected for the implementation. The systems were strategically placed to enhance submergence, minimize free gas entrainment, and support fluid lifting. Well-1 demonstrated significant improvements, reducing power consumption from 9.35 kW in the conventional rod system to 3.31 kW with the ESPP, delivering annual energy savings of 52,186 kWh and financial savings commensurate with local power costs. Additionally, reliability improved, with Well-1’s mean time between failures increasing by 660 hrs, while Well-2 exceeded 400 consecutive days of operation without failures.
The systems also contributed to environmental sustainability. Carbon emissions were reduced by 12.43 metric tons annually for Well-1 and 11.46 metric tons for Well-2, based on emissions metrics from the local utility provider. The ESPP system not only met operational objectives but also improved the aesthetic and environmental footprint of the wellsite, a significant factor in urban production settings.
CASE STUDY 4: ESPP SYSTEM ENHANCES GAS WELL DEWATERING FOR U.S. OPERATORS
Gas well dewatering presents significant challenges for operators, particularly when dealing with low-flow or deviated wells. The complexity of these reservoirs often exceeds the capacity of conventional rod lift systems, which are prone to mechanical failures, surface leaks, and increased downtime. Recognizing these operational hurdles, a group of U.S. operators sought a solution capable of sustaining production while simultaneously reducing environmental and financial costs. This pursuit led to the adoption of the ESPP system.
The ESPP system is designed to operate at depths of up to 6,000 ft (1,830 m) and manage flow rates of up to 160 bpd (25 m³/day). It is capable of withstanding fluid temperatures as high as 266°F (130°C) and tolerating water cuts of up to 99% at the pump intake.
The distinctive features of the ESPP system proved essential in overcoming the operators’ challenges. By eliminating sucker rods, the system drastically reduced issues, such as rod and tubing wear, which are often responsible for downtime and high maintenance costs. Additionally, the system’s absence of stuffing boxes mitigated the risk of surface leaks and methane emissions, offering an environmentally compliant solution. The incorporation of a motor compensator within the system further enhanced operational reliability, effectively managing thermal expansion and removing the need for mechanical seals or thrust bearings.
Integration of the ESPP system enabled operators to streamline their dewatering processes. Its compatibility with standard API subsurface tubing and insert pumps simplified deployment, while customizable motor parameters, such as acceleration and idle time, allowed for adaptability across varying well conditions. The system’s advanced downhole sensor technology facilitated real-time monitoring of critical parameters, including intake pressure, vibration, and motor temperature, granting operators the ability to optimize performance proactively.
Results from the implementation of the ESPP system were noteworthy. Operators reported a 300% increase in gas production alongside a 50% reduction in power consumption, leading to significant operational cost savings. Additionally, the environmental impact of dewatering operations was minimized, as the system successfully eliminated methane emissions and prevented fluid leaks. Running uninterrupted for over 600 days, the ESPP system demonstrated exceptional reliability and endurance, further reinforcing its suitability for addressing the complex demands of modern gas well dewatering applications.
CONCLUSION
The integration of advanced technologies, such as PMMs, LPMM, and the ESPP system, is shaping the future of artificial lift in the oil and gas industry. These innovations address critical challenges, such as grid oversaturation, operational inefficiencies, and environmental impacts. By combining energy efficiency with robust operational capabilities, they provide practical solutions that enhance production, reduce costs, and support global sustainability goals.
PMM and LPMM technology, with their excellent energy savings and adaptability, offer customized solutions for diverse well conditions, demonstrating their value in unconventional and environmentally sensitive applications. Meanwhile, the ESPP system introduces a low-maintenance alternative that extends equipment lifespan and reduces environmental risks, driving forward the adoption of more sustainable practices in well operations.
While resistance to change in the industry persists, early adoption by leading operators and case studies showcasing tangible benefits emphasizes the potential of these technologies. Levare continues to focus on advancing energy solutions, using innovative technologies and precision engineering. While the company has established expertise in the oil and gas sector, particularly in gas handling, energy efficiency, and reliability, it is also diversifying its efforts. Current areas of exploration include geothermal energy, with a focus on high-temperature and industrial applications, and the mining industry, where existing technologies are being adapted for new markets. WO
PAVEL SVIRIDOV is director of Technology applications at Levare US (formerly Borets US Inc.), a position he has held since May 2023. Previously, he worked at the company for eight years, in positions of increasing responsibility, ranging from senior application engineer to director, Technology Application. He also spent time at Borets in Moscow, from November 2011 to March 2015. Mr. Sviridov began his career at JSC Oil and Gas Company Slavneft, working from August 2009 to November 2011. He graduated from Tyumen State University in Tyumen, Russia, with a masters degree in petroleum engineering in 2009. He is also due to earn an Executive MBA, Business Administration and Management, General, from Texas A&M University in May 2026.
WALTER DINKINS is senior domain champion at Levare International Limited, a position he has held since January 2022. He began his industry career in May 1988 at SLB and spent three years as a cable design engineer. Mr. Dinkins went on to work 17 years at Baker Hughes as an application engineer. In addition, he worked another five years between 2015 and 2020 as research and development manager at Summit ESP. Mr. Dinkins earned BS and MS degrees in electrical and electronics engineering from Oklahoma State University in 1985 and 1987. He also earned an MS degree in ceramic sciences and engineering from Georgia Institute of Technology in 1995.
JOHN DAVIS is senior technical support engineer at Levare US Inc. (formerly Borets US Inc.), a position he has held for nearly 10 years. In addition, he has worked at Borets US Inc. in similar capacities. Mr. Davis began his career at SLB as a field service manager/trainer from mid-2005 to the end of 2014. He earned a BS degree in electronics engineering from DeVry University in 2005.
MARCO CARRASQUERO is ESP Operation & Sales director, US, at Levare International Limited (formerly Borets International Limited), a role he has filled since April 2025. Previously, he was US sales manager from September 2021 to April 2025. Mr. Carrasquero began his career with Baker Hughes in June 2000 and filled positions of increasing responsibility for the next 21 years, ranging from field service engineer to sales manager. During that period, he worked primarily in Venezuela and the Midland, Texas area. He graduated from Universidad Rafael Belloso Chacín in 2009, with a degree in computer engineering. He also earned an MBA from The University of Texas-Permian Basin in December 2023.