ESP Testing Facility Digital Twin

Jochen Peroutka

Research output: ThesisMaster's Thesis

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The ever-rising demand for energy requires the oil and gas industry to expand its operating procedures with new technologies not only to increase production efficiency and profitability but also to meet regulatory compliances and increasing requirements in health, safety, and environment. Several new technologies have emerged over the last years with one of them being very promising, the Digital Twin. A Digital Twin is a virtual representation designed to simulate and mirror a physical entity. As such, new operating procedures, the implementation of additional components, and variations in the workflow can be simulated without altering an already existing production system. Several different scenarios can be evaluated with a Digital Twin with the most promising one to be implemented while reducing costs since actual field tests are not required to be conducted anymore. This thesis aims to build a Digital Twin of the ESP testing facility located at the University of Leoben with the software program MATLAB Simulink. The Digital Twin consists of seven different subsystems that are based on mathematical formulations from literature covering all necessary parts required. This design offers high adjustability of parameters associated with the motor, the pump, and the hydraulic subsystem. Furthermore, it is possible to operate the Digital Twin by either setting a fixed voltage and frequency input or by utilizing a motor scalar control. In addition, the flow rate can be adjusted by two valves as part of the hydraulic subsystem. The simulation output offers detailed information about the stator and rotor currents, the electromagnetic torque as well as the rotating speed generated by the motor, head losses originating from the hydraulic subsystem, and the flow rate produced by the pump. Model validation is conducted by comparing the simulated flow rate with the flow rate measured from the pump test facility. With results being close to the actual behavior the MATLAB Simulink model can be considered an early stage Digital Twin.
Translated title of the contributionESP Prüfanlage Digitaler Zwilling
Original languageEnglish
Awarding Institution
  • Montanuniversität
  • Fruhwirth, Rudolf, Supervisor (internal)
Award date1 Jul 2022
Publication statusPublished - 2022

Bibliographical note

no embargo


  • ESP Testing Facility
  • Digital Twin
  • Simulation
  • MATLAB Simulink

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