Electrical Submersible Pumps Manual: Design, Operations, and Maintenance

by Takacs, Gabor

ISBN13: 9781856175579

ISBN10: 185617557X

Format: Hardcover

Pub. Date: 2009-03-13

Publisher(s): Elsevier Science Ltd

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Summary

Professor and Head of the Petroleum Engineering Department at the University of Miskolc, Hungary

Preface	p. xiii
Introduction	p. 1
Artificial Lifting	p. 1
Gas Lifting	p. 2
Pumping	p. 2
Comparison of Lift Methods	p. 4
Short History of ESP Applications	p. 5
Basic Features of ESP Installations	p. 6
Applications	p. 6
Advantages, Limitations	p. 7
References	p. 8
Review of Fundamentals	p. 9
Well Inflow Performance	p. 9
Introduction	p. 9
The Productivity Index Concept	p. 10
Inflow Performance Relationships	p. 12
Introduction	p. 12
Vogel's IPR Correlation	p. 13
The Composite IPR Curve	p. 15
Hydraulic Fundamentals	p. 21
Tubing Flow Calculations	p. 21
ESP Pumps	p. 23
Operational Basics of Centrifugal Pumps	p. 23
Specific Speed	p. 26
Pump Performance	p. 27
Cavitation	p. 30
Axial Thrust Forces	p. 31
Affinity Laws	p. 34
Electrical Fundamentals	p. 36
Alternating Current	p. 36
AC Circuits, AC Power	p. 37
Transformers	p. 40
Induction Motors	p. 41
Electric Cable	p. 43
Basics of Systems Analysis	p. 44
Introduction	p. 44
The Production System	p. 45
Basic Principles	p. 47
References	p. 48
ESP Components and their Operational Features	p. 51
Introduction	p. 52
The Submersible Pump	p. 53
Basic Features	p. 53
Pump Performance Curves	p. 57
Floating versus Fixed Impeller Pumps	p. 61
Pump Temperature	p. 62
The ESP Motor	p. 64
Motor Construction	p. 64
Operational Features	p. 68
Motor Performance	p. 70
Motor Testing	p. 71
Performance Curves	p. 72
Startup Conditions	p. 74
Motor Temperature	p. 76
Heat Transfer Calculations	p. 77
Allowed Motor Temperature	p. 83
The Protector or Seal Section	p. 84
Main Functions	p. 84
Basic Operation	p. 86
Main Parts	p. 88
The Thrust Bearing	p. 88
Isolation Chambers	p. 91
Labyrinth-type Chambers	p. 91
Blocking Fluids	p. 93
Bag-type Chambers	p. 95
Shaft Seals	p. 96
Other Features	p. 97
The Gas Separator	p. 99
The ESP Cable	p. 101
Cable Materials	p. 102
Conductors	p. 102
Insulator Materials	p. 102
Jackets	p. 103
Coverings	p. 104
Metal Armor	p. 104
Cable Construction	p. 104
Operational Features	p. 106
Miscellaneous Downhole Equipment	p. 110
Surface Equipment	p. 113
Wellhead	p. 113
Junction Box	p. 114
Switchboard	p. 116
Transformers	p. 117
Miscellaneous Equipment	p. 117
References	p. 117
Use of ESP Equipment in Special Conditions	p. 119
Introduction	p. 119
Pumping Viscous Liquids	p. 120
Introduction	p. 120
The Hydraulic Institute Model	p. 121
Other Models	p. 125
Production of Gassy Wells	p. 128
Introduction	p. 128
Free Gas Volume Calculations	p. 130
Pump Performance Degradation	p. 136
Gas Interference in Centrifugal Pumps	p. 136
Performance Criteria	p. 138
Possible Solutions	p. 140
Utilization of Natural Gas Separation	p. 140
Pump Set below the Perforations	p. 140
Use of Motor Shrouds	p. 141
Rotary Gas Separators	p. 145
Available Types	p. 145
Separation Efficiencies	p. 148
Gas Handling	p. 151
Overstaged Pumps	p. 151
Tapered Pumps	p. 151
Stage Recirculation	p. 152
Gas Handlers	p. 153
Special Pumps	p. 154
Conclusions	p. 154
Production of Abrasive Solids	p. 155
Introduction	p. 155
Characteristics of Abrasive Materials	p. 156
Sand Problem Areas	p. 158
Pump Erosion	p. 158
Abrasion in Radial Bearings	p. 159
Abrasion in Thrust Washers	p. 159
Solutions	p. 160
Reduction of Radial Wear	p. 161
Conclusions	p. 164
High Well Temperatures	p. 166
Variable Frequency Operation	p. 167
Introduction	p. 167
Variable Speed Drives	p. 170
Constructional Details	p. 171
The Rectifier	p. 171
The DC Control Section	p. 172
The Inverter	p. 172
Available VSD Types	p. 173
"Six-step" VSD	p. 173
Pulsed Width Modulation	p. 173
Sine Wave Generators	p. 175
Operational Characteristics	p. 176
Variable Frequency Generators	p. 177
Interaction of VSD/VFG and ESP Units	p. 178
Benefits of Using VSD/VFG Units	p. 183
References	p. 184
Design of ESP Installations	p. 187
Introduction	p. 187
Data Requirements	p. 188
Conventional Design	p. 189
Well Inflow Calculations	p. 189
TDH Calculations	p. 191
Selection of the Pump	p. 193
Pump Series	p. 193
Pump Type	p. 194
Number of Stages	p. 194
Checking the Pump's Mechanical Strength	p. 195
Selection of the Protector	p. 196
Motor Selection	p. 198
Selection of the Power Cable	p. 200
Cable Length	p. 200
Cable Type	p. 200
Cable Size	p. 200
Checking Motor Startup	p. 203
Switchboard and Transformer Selection	p. 203
Miscellaneous Equipment	p. 204
Downhole Equipment	p. 204
Surface Equipment	p. 205
Conventional Design Considering Motor Slip	p. 211
Interaction of the ESP Motor and the Pump	p. 211
Changes in the Conventional Design	p. 214
Finding Actual Motor Speed	p. 214
Finding Pump Head including Motor Slip	p. 215
Gassy Well Design	p. 218
Inflow and Free Gas Calculations	p. 219
Calculation of Total Dynamic Head	p. 221
The Rest of the Design Procedure	p. 222
Design of a VSD Installation	p. 230
Pump Selection for VSD Service	p. 231
Driving Frequency and the Number of Stages	p. 232
Checking Pump Operation at the Minimum Liquid Rate	p. 233
Motor Selection	p. 233
Switchboard and Transformers	p. 234
References	p. 247
Analysis and Optimization	p. 249
Introduction	p. 249
Nodal Analysis	p. 250
Using the Q-H Coordinate System	p. 252
Single-phase Cases	p. 252
Constant Pumping Speed	p. 254
Variable Pumping Speeds	p. 257
Variable Wellhead Pressures	p. 259
Multiphase Cases	p. 261
Calculation Model	p. 261
Applications	p. 264
Using the Rate/FBHP Coordinate System	p. 271
Single-phase Cases	p. 271
Multiphase Cases	p. 276
Determination of Well Inflow Performance	p. 278
The Conventional Method	p. 278
Use of VSD Drives	p. 281
Calculation of Bottomhole Pressures	p. 284
Introduction	p. 284
Annular Liquid Gradients	p. 285
Static Conditions	p. 285
Flowing Conditions	p. 286
Power Efficiency of ESP Installations	p. 291
Power Flow in the ESP System	p. 291
Energy Losses and Efficiencies	p. 295
Hydraulic Losses	p. 295
Tubing Losses	p. 295
Backpressure Losses	p. 296
Pump Losses	p. 296
Power Loss in Gas Separator	p. 297
Electrical Losses	p. 297
Motor Losses	p. 297
Cable Losses	p. 298
Surface Electrical Losses	p. 298
System Efficiency	p. 299
Optimization of ESP Operations	p. 301
Introduction	p. 301
Basics of Economic Optimization	p. 302
References	p. 306
Monitoring and Troubleshooting	p. 309
Introduction	p. 309
Monitoring of ESP Operations	p. 310
Acoustic Surveys	p. 312
Downhole Measurements	p. 314
Instruments and Communications	p. 314
Measured Parameters and their Use	p. 315
System Failures	p. 316
General Causes of Failures	p. 317
Improper Installation Design	p. 317
Faulty Equipment and/or Installation	p. 317
Well Conditions	p. 317
Electrical Problems	p. 318
Vibrations in the ESP System	p. 319
Typical Failures of System Components	p. 320
Shafts	p. 320
ESP Pump	p. 321
ESP Motor	p. 321
Protector (Seal) Section	p. 322
Rotary Gas Separator	p. 322
Electric Cable	p. 322
Troubleshooting ESP Installations	p. 323
Interpretation of Ammeter Charts	p. 323
Novel Techniques	p. 338
References	p. 341
Special Installations	p. 343
Introduction	p. 343
Tubing Deployed Installations	p. 343
Producing a Single Zone	p. 344
Shrouded and Horizontal Well Installations	p. 344
Parallel-connected Installations	p. 344
Series-connected Installations	p. 345
Dual Zone Installations	p. 347
Production Commingling	p. 347
Selective Production	p. 349
Alternative Deployed Installations	p. 350
Cable Suspended Units	p. 350
Coiled Tubing Installations	p. 351
Conventional ESP Unit with Cable Led Outside the CT String	p. 353
Conventional ESP Unit with Cable Led Inside the CT String	p. 353
Inverted ESP Units	p. 353
Conclusions	p. 354
References	p. 355
Appendices	p. 357
Class Problems	p. 379
Index	p. 417
Table of Contents provided by Ingram. All Rights Reserved.

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Electrical Submersible Pumps Manual: Design, Operations, and Maintenance

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