Takacs Electrical Submersible Pumps Manual

Design, Operations, and Maintenance
1. Auflage 2009
ISBN: 978-0-08-087813-3
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: 6 - ePub Watermark

E-Book, Englisch, 440 Seiten

Ideal for removing large amounts of liquids from wells, Electrical Submersible Pumps (ESP) are perhaps the most versatile and profitable pieces of equipment in a petroleum company's arsenal. However, if not properly maintained and operated, they could quickly become an expensive nightmare. The first book devoted to the design, operation, maintenance, and care, Electrical Submersible Pumps Manual delivers the tools and applicable knowledge needed to optimize ESP performance while maximizing of run life and the optimization of production.
The prefect companion for new engineers who need to develop and apply their skills more efficiently or experienced engineers who wish further develop their knowledge of best practice techniques, this manual covers basic electrical engineering, hydraulics and systems analysis before addressing pump components such as centrifugal pumps, motors, seals, separators, and cables. In addition, the author includes comprehensive sections on analysis and optimization, monitoring and trouble-shooting, and installation design and installation under special conditions.
* Apply the best operating practices to optimise production
* Track and troubleshoot problems such as gas, solids and corrosion
*Prevent expensive failures such as cable burn and impeller cavitation
* Design and analyze a system using up-to-date computer programs
* Establish ESP analysis monitoring methods and strategies
* Ensure optimum operator-vendor relationship for mutual benefits

Gabor Takacs is a professor and was head of the Petroleum Engineering Department at the University of Miskolc, Hungary from 1995 to 2012. He has more than 35 years of teaching and consulting experience in the production engineering field. He was acting director of the Petroleum Engineering program at The Petroleum Institute in Abu Dhabi, UAE from 2007 to 2010, and taught at Texas Tech University from 1988 to 1989. He is also currently a technical editor for an oil and gas journal, and received the Society of Petroleum Engineers Distinguished Lecturer award for 1995-96. Gabor regularly teaches short courses internationally and is a well-known consultant and instructor on production engineering and artificial lift topics. Gabor earned an MS and PhD degree in petroleum engineering, both from the University of Miskolc.

Autoren/Hrsg.

Takacs, Gabor

Inhaltsverzeichnis

1;Front Cover;1
2;Electrical Submersible Pumps Manual: Design, Operations, and Maintenance;4
3;Copyright Page;5
4;Contents;6
5;Preface;14
6;Chapter 1: Introduction;16
6.1;1.1 Artificial Lifting;16
6.1.1;1.1.1 Gas Lifting;17
6.1.2;1.1.2 Pumping;17
6.1.3;1.1.3 Comparison of Lift Methods;19
6.2;1.2 Short History of ESP Applications;20
6.3;1.3 Basic Features of ESP Installations;21
6.3.1;1.3.1 Applications;21
6.3.2;1.3.2 Advantages, Limitations;22
6.4;References;23
7;Chapter 2: Review of Fundamentals;24
7.1;2.1 Well Inflow Performance;24
7.1.1;2.1.1 Introduction;24
7.1.2;2.1.2 The Productivity Index Concept;25
7.1.3;2.1.3 Inflow Performance Relationships;27
7.1.3.1;2.1.3.1 Introduction;27
7.1.3.2;2.1.3.2 Vogel's IPR Correlation;28
7.1.3.3;2.1.3.3 The Composite IPR Curve;30
7.2;2.2 Hydraulic Fundamentals;36
7.2.1;2.2.1 Tubing Flow Calculations;36
7.2.2;2.2.2 ESP Pumps;38
7.2.2.1;2.2.2.1 Operational Basics of Centrifugal Pumps;38
7.2.2.2;2.2.2.2 Specific Speed;41
7.2.2.3;2.2.2.3 Pump Performance;42
7.2.2.4;2.2.2.4 Cavitation;45
7.2.2.5;2.2.2.5 Axial Thrust Forces;46
7.2.2.6;2.2.2.6 Affinity Laws;49
7.3;2.3 Electrical Fundamentals;51
7.3.1;2.3.1 Alternating Current;51
7.3.2;2.3.2 AC Circuits, AC Power;52
7.3.3;2.3.3 Transformers;55
7.3.4;2.3.4 Induction Motors;56
7.3.5;2.3.5 Electric Cable;58
7.4;2.4 Basics of Systems Analysis;59
7.4.1;2.4.1 Introduction;59
7.4.2;2.4.2 The Production System;60
7.4.3;2.4.3 Basic Principles;62
7.5;References;63
8;Chapter 3: ESP Components and their Operational Features;66
8.1;3.1 Introduction;67
8.2;3.2 The Submersible Pump;68
8.2.1;3.2.1 Basic Features;68
8.2.2;3.2.2 Pump Performance Curves;72
8.2.3;3.2.3 Floating versus Fixed Impeller Pumps;76
8.2.4;3.2.4 Pump Temperature;77
8.3;3.3 The ESP Motor;79
8.3.1;3.3.1 Motor Construction;79
8.3.2;3.3.2 Operational Features;83
8.3.3;3.3.3 Motor Performance;85
8.3.3.1;3.3.3.1 Motor Testing;86
8.3.3.2;3.3.3.2 Performance Curves;87
8.3.3.3;3.3.3.3 Startup Conditions;89
8.3.4;3.3.4 Motor Temperature;91
8.3.4.1;3.3.4.1 Heat Transfer Calculations;92
8.3.4.2;3.3.4.2 Allowed Motor Temperature;98
8.4;3.4 The Protector or Seal Section;99
8.4.1;3.4.1 Main Functions;99
8.4.2;3.4.2 Basic Operation;101
8.4.3;3.4.3 Main Parts;103
8.4.3.1;3.4.3.1 The Thrust Bearing;103
8.4.3.2;3.4.3.2 Isolation Chambers;106
8.4.3.2.1;3.4.3.2.1 Labyrinth-type Chambers;106
8.4.3.2.2;3.4.3.2.2 Blocking Fluids;108
8.4.3.2.3;3.4.3.2.3 Bag-type Chambers;110
8.4.3.3;3.4.3.3 Shaft Seals;111
8.4.4;3.4.4 Other Features;112
8.5;3.5 The Gas Separator;114
8.6;3.6 The ESP Cable;116
8.6.1;3.6.1 Cable Materials;117
8.6.1.1;3.6.1.1 Conductors;117
8.6.1.2;3.6.1.2 Insulator Materials;117
8.6.1.3;3.6.1.3 Jackets;118
8.6.1.4;3.6.1.4 Coverings;119
8.6.1.5;3.6.1.5 Metal Armor;119
8.6.2;3.6.2 Cable Construction;119
8.6.3;3.6.3 Operational Features;121
8.7;3.7 Miscellaneous Downhole Equipment;125
8.8;3.8 Surface Equipment;128
8.8.1;3.8.1 Wellhead;128
8.8.2;3.8.2 Junction Box;129
8.8.3;3.8.3 Switchboard;131
8.8.4;3.8.4 Transformers;132
8.8.5;3.8.5 Miscellaneous Equipment;132
8.9;References;132
9;Chapter 4: Use of ESP Equipment in Special Conditions;134
9.1;4.1 Introduction;134
9.2;4.2 Pumping Viscous Liquids;135
9.2.1;4.2.1 Introduction;135
9.2.2;4.2.2 The Hydraulic Institute Model;136
9.2.3;4.2.3 Other Models;140
9.3;4.3 Production of Gassy Wells;143
9.3.1;4.3.1 Introduction;143
9.3.2;4.3.2 Free Gas Volume Calculations;145
9.3.3;4.3.3 Pump Performance Degradation;151
9.3.3.1;4.3.3.1 Gas Interference in Centrifugal Pumps;151
9.3.3.2;4.3.3.2 Performance Criteria;153
9.3.4;4.3.4 Possible Solutions;155
9.3.4.1;4.3.4.1 Utilization of Natural Gas Separation;155
9.3.4.1.1;4.3.4.1.1 Pump Set below the Perforations;155
9.3.4.1.2;4.3.4.1.2 Use of Motor Shrouds;156
9.3.4.2;4.3.4.2 Rotary Gas Separators;160
9.3.4.2.1;4.3.4.2.1 Available Types;160
9.3.4.2.2;4.3.4.2.2 Separation Efficiencies;163
9.3.4.3;4.3.4.3 Gas Handling;166
9.3.4.3.1;4.3.4.3.1 Overstaged Pumps;166
9.3.4.3.2;4.3.4.3.2 Tapered Pumps;166
9.3.4.3.3;4.3.4.3.3 Stage Recirculation;167
9.3.4.3.4;4.3.4.3.4 Gas Handlers;168
9.3.4.3.5;4.3.4.3.5 Special Pumps;169
9.3.5;4.3.5 Conclusions;169
9.4;4.4 Production of Abrasive Solids;170
9.4.1;4.4.1 Introduction;170
9.4.2;4.4.2 Characteristics of Abrasive Materials;171
9.4.3;4.4.3 Sand Problem Areas;173
9.4.3.1;4.4.3.1 Pump Erosion;173
9.4.3.2;4.4.3.2 Abrasion in Radial Bearings;174
9.4.3.3;4.4.3.3 Abrasion in Thrust Washers;174
9.4.4;4.4.4 Solutions;175
9.4.4.1;4.4.4.1 Reduction of Radial Wear;176
9.4.5;4.4.5 Conclusions;179
9.5;4.5 High Well Temperatures;181
9.6;4.6 Variable Frequency Operation;182
9.6.1;4.6.1 Introduction;182
9.6.2;4.6.2 Variable Speed Drives;185
9.6.2.1;4.6.2.1 Constructional Details;186
9.6.2.1.1;4.6.2.1.1 The Rectifier;186
9.6.2.1.2;4.6.2.1.2 The DC Control Section;187
9.6.2.1.3;4.6.2.1.3 The Inverter;187
9.6.2.2;4.6.2.2 Available VSD Types;188
9.6.2.2.1;4.6.2.2.1 “Six-step” VSD;188
9.6.2.2.2;4.6.2.2.2 Pulsed Width Modulation;188
9.6.2.2.3;4.6.2.2.3 Sine Wave Generators;190
9.6.3;4.6.3 Variable Frequency Generators;192
9.6.4;4.6.4 Interaction of VSD/VFG and ESP Units;193
9.6.5;4.6.5 Benefits of Using VSD/VFG Units;198
9.7;References;199
10;Chapter 5: Design of ESP Installations;202
10.1;5.1 Introduction;202
10.2;5.2 Data Requirements;203
10.3;5.3 Conventional Design;204
10.3.1;5.3.1 Well Inflow Calculations;204
10.3.2;5.3.2 TDH Calculations;206
10.3.3;5.3.3 Selection of the Pump;208
10.3.3.1;5.3.3.1 Pump Series;208
10.3.3.2;5.3.3.2 Pump Type;209
10.3.3.3;5.3.3.3 Number of Stages;209
10.3.3.4;5.3.3.4 Checking the Pump's Mechanical Strength;210
10.3.4;5.3.4 Selection of the Protector;211
10.3.5;5.3.5 Motor Selection;213
10.3.6;5.3.6 Selection of the Power Cable;215
10.3.6.1;5.3.6.1 Cable Length;215
10.3.6.2;5.3.6.2 Cable Type;215
10.3.6.3;5.3.6.3 Cable Size;215
10.3.6.4;5.3.6.4 Checking Motor Startup;218
10.3.7;5.3.7 Switchboard and Transformer Selection;218
10.3.8;5.3.8 Miscellaneous Equipment;219
10.3.8.1;5.3.8.1 Downhole Equipment;219
10.3.8.2;5.3.8.2 Surface Equipment;220
10.4;5.4 Conventional Design Considering Motor Slip;226
10.4.1;5.4.1 Interaction of the ESP Motor and the Pump;226
10.4.2;5.4.2 Changes in the Conventional Design;229
10.4.2.1;5.4.2.1 Finding Actual Motor Speed;229
10.4.2.2;5.4.2.2 Finding Pump Head including Motor Slip;230
10.5;5.5 Gassy Well Design;233
10.5.1;5.5.1 Inflow and Free Gas Calculations;234
10.5.2;5.5.2 Calculation of Total Dynamic Head;236
10.5.3;5.5.3 The Rest of the Design Procedure;237
10.6;5.6 Design of a VSD Installation;245
10.6.1;5.6.1 Pump Selection for VSD Service;246
10.6.1.1;5.6.1.1 Driving Frequency and the Number of Stages;247
10.6.1.2;5.6.1.2 Checking Pump Operation at the Minimum Liquid Rate;248
10.6.2;5.6.2 Motor Selection;248
10.6.3;5.6.3 Switchboard and Transformers;249
10.7;References;262
11;Chapter 6: Analysis and Optimization;264
11.1;6.1 Introduction;264
11.2;6.2 Nodal Analysis;265
11.2.1;6.2.1 Using the Q-H Coordinate System;267
11.2.1.1;6.2.1.1 Single-phase Cases;267
11.2.1.1.1;6.2.1.1.1 Constant Pumping Speed;269
11.2.1.1.2;6.2.1.1.2 Variable Pumping Speeds;272
11.2.1.1.3;6.2.1.1.3 Variable Wellhead Pressures;274
11.2.1.2;6.2.1.2 Multiphase Cases;276
11.2.1.2.1;6.2.1.2.1 Calculation Model;276
11.2.1.2.2;6.2.1.2.2 Applications;279
11.2.2;6.2.2 Using the Rate/FBHP Coordinate System;286
11.2.2.1;6.2.2.1 Single-phase Cases;286
11.2.2.2;6.2.2.2 Multiphase Cases;291
11.3;6.3 Determination of Well Inflow Performance;293
11.3.1;6.3.1 The Conventional Method;293
11.3.2;6.3.2 Use of VSD Drives;296
11.3.3;6.3.3 Calculation of Bottomhole Pressures;299
11.3.3.1;6.3.3.1 Introduction;299
11.3.3.2;6.3.3.2 Annular Liquid Gradients;300
11.3.3.2.1;6.3.3.2.1 Static Conditions;300
11.3.3.2.2;6.3.3.2.2 Flowing Conditions;301
11.4;6.4 Power Efficiency of ESP Installations;306
11.4.1;6.4.1 Power Flow in the ESP System;306
11.4.2;6.4.2 Energy Losses and Efficiencies;310
11.4.2.1;6.4.2.1 Hydraulic Losses;310
11.4.2.1.1;6.4.2.1.1 Tubing Losses;310
11.4.2.1.2;6.4.2.1.2 Backpressure Losses;311
11.4.2.1.3;6.4.2.1.3 Pump Losses;311
11.4.2.1.4;6.4.2.1.4 Power Loss in Gas Separator;312
11.4.2.2;6.4.2.2 Electrical Losses;312
11.4.2.2.1;6.4.2.2.1 Motor Losses;312
11.4.2.2.2;6.4.2.2.2 Cable Losses;313
11.4.2.2.3;6.4.2.2.3 Surface Electrical Losses;313
11.4.3;6.4.3 System Efficiency;314
11.5;6.5 Optimization of ESP Operations;316
11.5.1;6.5.1 Introduction;316
11.5.2;6.5.2 Basics of Economic Optimization;317
11.6;References;321
12;Chapter 7: Monitoring and Troubleshooting;324
12.1;7.1 Introduction;324
12.2;7.2 Monitoring of ESP Operations;325
12.2.1;7.2.1 Acoustic Surveys;327
12.2.2;7.2.2 Downhole Measurements;329
12.2.2.1;7.2.2.1 Instruments and Communications;329
12.2.2.2;7.2.2.2 Measured Parameters and their Use;330
12.3;7.3 System Failures;331
12.3.1;7.3.1 General Causes of Failures;332
12.3.1.1;7.3.1.1 Improper Installation Design;332
12.3.1.2;7.3.1.2 Faulty Equipment and/or Installation;332
12.3.1.3;7.3.1.3 Well Conditions;332
12.3.1.4;7.3.1.4 Electrical Problems;333
12.3.1.5;7.3.1.5 Vibrations in the ESP System;334
12.3.2;7.3.2 Typical Failures of System Components;335
12.3.2.1;7.3.2.1 Shafts;335
12.3.2.2;7.3.2.2 ESP Pump;336
12.3.2.3;7.3.2.3 ESP Motor;336
12.3.2.4;7.3.2.4 Protector (Seal) Section;337
12.3.2.5;7.3.2.5 Rotary Gas Separator;337
12.3.2.6;7.3.2.6 Electric Cable;337
12.4;7.4 Troubleshooting ESP Installations;338
12.4.1;7.4.1 Interpretation of Ammeter Charts;338
12.4.2;7.4.2 Novel Techniques;353
12.5;References;356
13;Chapter 8: Special Installations;358
13.1;8.1 Introduction;358
13.2;8.2 Tubing Deployed Installations;358
13.2.1;8.2.1 Producing a Single Zone;359
13.2.1.1;8.2.1.1 Shrouded and Horizontal Well Installations;359
13.2.1.2;8.2.1.2 Parallel-connected Installations;359
13.2.1.3;8.2.1.3 Series-connected Installations;360
13.2.2;8.2.2 Dual Zone Installations;362
13.2.2.1;8.2.2.1 Production Commingling;362
13.2.2.2;8.2.2.2 Selective Production;364
13.3;8.3 Alternative Deployed Installations;365
13.3.1;8.3.1 Cable Suspended Units;365
13.3.2;8.3.2 Coiled Tubing Installations;366
13.3.2.1;8.3.2.1 Conventional ESP Unit with Cable Led Outside the CT String;368
13.3.2.2;8.3.2.2 Conventional ESP Unit with Cable Led Inside the CT String;368
13.3.2.3;8.3.2.3 Inverted ESP Units;368
13.3.3;8.3.3 Conclusions;369
13.4;References;370
14;Appendices;372
14.1;Appendix A;374
14.1.1;Description;374
14.1.2;Example problem;374
14.1.3;Solution;374
14.2;Appendix B;376
14.2.1;Description;376
14.3;Appendix C;380
14.3.1;Description;380
14.4;Appendix D;386
14.4.1;Description;386
14.5;Appendix E;392
14.5.1;Description;392
14.5.2;Example problem;392
14.5.3;Solution;392
15;Class Problems: ESP Design and Analysis;394
15.1;Class Problem Assignment;394
15.2;Problem Statement;394
15.3;Instructions;394
15.4;Solution;395
15.5;Class Problem Assignment;396
15.6;Problem Statement;396
15.7;Instructions;396
15.8;Solution;396
15.9;Class Problem Assignment;397
15.10;Problem Statement;397
15.11;Instructions;397
15.12;Solution;397
15.13;Class Problem Assignment;399
15.14;Problem statement;399
15.15;Instructions;399
15.16;Solution;399
15.17;Class Problem Assignment;401
15.18;Problem Statement;401
15.19;Instructions;401
15.20;Solution;401
15.21;Class Problem Assignment;402
15.22;Problem Statement;402
15.23;Instructions;402
15.24;Solution;402
15.25;Class Problem Assignment;404
15.26;Problem Statement;404
15.27;Instructions;404
15.28;Solution;404
15.29;Class Problem Assignment;405
15.30;Problem Statement;405
15.31;Instructions;405
15.32;Solution;405
15.33;Class Problem Assignment;411
15.34;Problem Statement;411
15.35;Instructions;411
15.36;Solution;412
15.37;Class Problem Assignment;413
15.38;Problem Statement;413
15.39;Instructions;413
15.40;Solution;413
15.41;Class Problem Assignment;420
15.42;Problem Statement;420
15.43;Instructions;420
15.44;Solution;421
15.45;Class Problem Assignment;422
15.46;Problem Statement;422
15.47;Instructions;422
15.48;Calculations;423
15.49;Class Problem Assignment;425
15.50;Problem Statement;425
15.51;Instructions;425
15.52;Solution;426
15.53;Class Problem Assignment;428
15.54;Problem Statement;428
15.55;Instructions;428
15.56;Solution;429
15.57;Class Problem Assignment;431
15.58;Problem Statement;431
15.59;Instructions;431
16;Index;432