电潜泵系统构成及工作原理

1、a typical esp installation2esp system technology overview3objective upon comletion of this course, you should be able to: explain the uses for electrical submersible pumps. list the major components of an esp system. explain the principle of an esp system.4esp downhole systemthe basic esp downhole s

2、ystem components are . nthe monitoring system (optional)nthe power cablenthe motorthe seal sectionnthe pump56built in discharge headtubing screws in herebolts to the sealpump shaftbuilt in intakepump housingrotating impellerstationary diffuser the pump7the pump hangs from the production tubing lifts

3、 the fluid through the tubing to the surface is a multi-stage centrifugal type is constructed from impellers and diffusers must be sized to match the well production has an intake and discharge that either bolts onto or is threaded into the pump housing normally be set above the perforation for suff

4、icient cooling.8lt = lower tandem pump ( with built in intake )the seal bolts on here9lt/mt = lower/middle tandem pumpheadshipping capif mt (middle tandem) or lt (lower tandem) then a flange face is the head of the pump.10if upper tandem (ut) then a discharge is built into the pump.ut pumpbuilt in d

5、ischarge head11middle tandem pump baseut or mt pumpshipping cap12the bolt on headthe middle tandem or lower tandem pump head13gas separator intake (cut away). may be bolted on to the base of a mt (middle tandem) or ut (upper tandem) pumpthe seal bolts on here.ut or mt pump bolts on here.14centrifuga

6、l ?15stages stacked on a shaft and compressed in a housing.centrilift submersible pump16rotating (right to left) impellersstationary diffuserscutaway of pump17impeller18pump stage hydraulic designesp stage designs fall into one of two hydraulic design categories mixed flow - flow path has both axial

7、 and radial direction with respect to the pump shaftradial flow - flow path is generally perpendicular (radial) with respect to the pump shaft19impeller terminologyimpeller hubbottom shroudtop shroudimpeller skirtimpeller eyeimpeller vanedownthrust washerupthrust washer20impellereyehubupper shroudva

8、neslower shroudskirt21impellerthe impeller rotates about the pump axis, with the shaftit provides the centrifugal force to the fluid - gives it energy.22impellerfluid enters the impeller through the eye near the shaft and exits the impeller on the outside. 23impeller - cut away24diffuser25diffuserth

9、e diffuser does not rotate, it turns the fluid up into the next impeller it transforms the fluid velocity, its energy, into head26diffuser - cut away27impeller & diffuserdiffuser directs fluid into the eye of the impellerimpeller spins and gives energy to fluid which exits around the outsidediff

10、user redirects the fluid up into the next impeller and turns fluid energy into head28impeller in diffuser - a pump stage29pump stage - cut away30flow, barrels per day (bpd)operating rangehead capacitypump efficiencybrake horse powerhead in feetbhppump curve80604020123efficiency %best efficiency poin

11、t(bep)total dynamic head ( tdh )tubing pressure32pump stagefluid reservoirdeveloping the pump stage head capacity curve33fluid reservoirhead (lift)1developing the pump stage head capacity curve34head in feetsingle stage performance for a given rpm and fluid viscositypump stage characteristics0102030

12、4050601flow, barrels per day (bpd)02004006008001000developing the pump stage head capacity curve35fluid reservoirhead1developing the pump stage head capacity curve36head flow12fluid reservoirdeveloping the pump stage head capacity curve37head in feetpump stage characteristics0102030405060flow, barre

13、ls per day (bpd)0200400600800100012developing the pump stage head capacity curve38head flow12fluid reservoirdeveloping the pump stage head capacity curve39head flow123fluid reservoirdeveloping the pump stage head capacity curve40head in feetpump stage characteristics0102030405060flow, barrels per da

14、y (bpd)02004006008001000123developing the pump stage - head / capacity curve41head in feetpump curve0102030405060flow, barrels per day (bpd)02004006008001000developing the pump stage - head / capacity curve42use the pump curve to size a pump we have a well, we want to produce 600bpd, and we need at

15、least 280ft pump head. how many stages do we need?43280 ft 600 bpdfluid reservoirusing the pump curve to size a pump44head in feetpump curve0102030405060flow, barrels per day (bpd)0200400600800100040 feet/stage 600 bpd56 feet/stage 0 bpdusing the pump curve to size a pump45280 ft 600 bpdfluid reserv

16、oirusing the pump curve to size a pump46280 ft 600 bpdfluid reservoir56 feet 0 bpdfor 600 bpdstages = 280/40 = 7using the pump curve to size a pump47280 ft 600 bpdfluid reservoirusing the pump curve to size a pump48280 ft 600 bpdfluid reservoirusing the pump curve to size a pump49multiple stagesthe

17、head that one stage develops is multiplied by the number of stages to determine the total head a pump will deliver. at a given flow rate !600 bpd40 ft80 ft40 ft50pump performancepump stage performance has three measured parameters which are flow rate head (discharge pressure can be calculated) brake

18、 horsepower or motor load from the above, pump efficiency may be calculated136000)(spgrbpdfeetphydraulichbhpphydraulichefficiency 51using the pump curveexample:a well will produce 4000 bpd when the pump produces a tdh (total dynamic head) of 5000 ft. specific gravity of the produced fluid = 1.00how

19、many stages we need?how big the motor should be?52pump curvegc3500single stage performance, 3500 rpm spgr = 1.0, 60 hertz 4000 bpd,42 ft/stg, 1.8 hp/stg, 70% efficient53using the pump curvestagesstagesstagelifttdh119425000/214)00. 1)(80. 1 (119)(spgrstagespumphpstagebhpso we need a motor bigger than

20、 214hp, say 255hp.54pump thrust55pump thrust pump thrust is made up of two components, hydraulic thrust and shaft thrust. in a floating impeller pump, the only thrust that the seal section thrust bearing sees is shaft thrust. in a compression pump or fixed impeller pump, the thrust bearing in the se

21、al section sees the hydraulic thrust and the shaft thrust.56in floating impeller pumps the impeller does not floatit is free to move up and down on the pump shaftimpeller position57pump thrust loadforces acting on the impeller58under normal operating conditions, fluid circulates on top and underneat

22、h the impeller shroudspump thrust load59the impeller discharge pressure is on the upper and lower impeller shroudspump thrust load60the larger cross sectional area on the upper shroud causes the net force to be downpump thrust loadthis causes the impeller to be moved down this is a positive downward

23、 force termed downthrust61pump thrust loadat some point the volume of fluid going up into the pump will lift the impeller up, overcoming the downthrust pressurethis causes the impeller to be moved up 62pump thrust loadthe downward force is now reversed (negative), it is termed upthrustthis causes th

24、e impeller to be moved up at some point the volume of fluid going up into the pump will lift the impeller up, overcoming the downthrust pressure63pump thrust loadthis increases the upthrustthis causes the impeller to be held up this creates a larger cross sectional area on the bottom shroud which in

25、creases the pressure underneath64hydraulic thrusttotal hydraulic thrust has two components, an up thrust component and a down thrust componentthe up thrust component is primarily created by the velocity through the impeller or hydraulic impact forcethe down thrust is primarily created by the pressur

26、e generated by the stagethese two components combine to make up total hydraulic thrustfluid viscosity has a dramatic affect on hydraulic thrust65flow from diffuserimpeller flow pathfluid velocity & viscousdrag forces add to upthrust.hydraulic thrustpressure generated bythe stage66shaft thrustsha

27、ft thrust is the result of the pumpdischarge pressure acting on the crosssectional end of the pump shaft the two things that determine shaftthrust is the pump discharge pressure(or tdh) and the diameter of the pumpshaft. this thrust is transmitted directlyto the seal section thrust bearing67thrust a

28、nd impeller positionin normal operation the larger cross sectional area on the upper shroud causes more pressure on top, pushing the impeller downthe pump is designed to operate in slight to moderate downthrust.68washers are fitted to prevent wear:downthrust washers upthrust washerpump thrust load69

29、downthrust washer70hub washereye washer71upthrust washer72impeller - topimpeller - bottom73hubupper shroudvanelower shroudskirteyeupthrust washerdown thrust washerimpeller - name the parts:74variable speed operationesps may also be ran at variable speeds. changing the speed or frequency of an esp sy

30、stem follows the “affinity laws” new flow rate = old flow (new hz/old hz) new head = old head (new hz/old hz)2 new brake hp = old bhp (new hz/old hz)375flow, barrels per day (bpd)operating rangehead capacitypump efficiencybrake horse powerhead in feetbhppump curve80604020123efficiency %best efficien

31、cy point(bep)76operating rangegc2200 single stage performance rpm 60hz = 3500 (sg = 1)77operating rangegc2200 single stage performance rpm 60hz = 3500 (sg = 1)78fluid reservoirnormal rpm79fluid reservoirfluid reservoirnormal rpmslower rpm80fluid reservoirfluid reservoirfluid reservoirnormal rpmslowe

32、r rpmfaster rpm81828384variable speed operationnew flow rate = old flow (new hz/old hz)new head = old head (new hz/old hz)2“affinity laws” 60hz operating rangemin flow = 1500bpd 54ftbep flow = 2200bpd 46ftmax flow = 3000bpd 25ftmin flow = 2000bpd 96ftbep flow = 2933bpd 82ftmax flow = 4000bpd 44ft80h

33、z operating range?858687tornado curvemin flowbep flowmax flow88the gas separator takes the place of a standard pump intake is used in applications where free gas causes interference with pump performance separates a portion of the free gas from the fluid entering the intake to improve pump performan

34、ce rotary gas separator types include: induced vortex with passive chamber rotating chamber89the gas separator90the seal chamber section is located between the pump and motor transfers the motor torque to the pump shaft isolates (seals) the well fluid from the clean motor oil equalizes the internal

35、unit and wellbore pressure provides area for motor oil expansion volume absorbs the pump shaft thrust load the four “shuns” - expansion, equalization, isolation, & “absorbsion” aka “equalizer”, “protector”, or “seal section”91motorpump92motorpump939495motorpump96motorsealpump97centriliftlocated

36、between the pump and motortransfers the motor torque to the pump shaftthe seal section98labyrinth chamber99labyrinth chamber100101double labyrinth chamber102103104105106pumpmotorlabyrinth chamber107108109pumpmotorbag or bladder110pumpmotor111112the seal chamber section is located between the pump an

37、d motor transfers the motor torque to the pump shaft isolates the well fluid from the clean motor oil provides area for motor oil expansion volume113114labyrinth chambermotor oil - heated115labyrinth chambermotor oil - cooling116double labyrinth chambermotor117bag (or bladder)motormotor oil - heated

38、118bag (or bladder)motormotor oil - heated119bag (or bladder)motormotor oil - heatedcheck valve120121122bag (or bladder)motormotor oil - heatedcheck valve123bag (or bladder)motormotor oil - heatedcheck valve124bag (or bladder)motormotor oil - heatedcheck valve125motormotor oil - cooling126motormotor

39、 oil - cooling127motormotor oil - heateddouble bags128motormotor oil - heateddouble bags129motormotor oil - heateddouble bags130131132motormotor oil - heatedparallel bags133motormotor oil - heatedparallel bags134the seal chamber section is located between the pump and motor transfers the motor torqu

40、e to the pump shaft isolates the well fluid from the clean motor oil provides area for motor oil expansion volume equalizes the internal unit and wellbore pressure135motor136n thousand feet137138139140the seal chamber section is located between the pump and motor transfers the motor torque to the pu

41、mp shaft isolates the well fluid from the clean motor oil equalizes the internal unit and wellbore pressure provides area for motor oil expansion volume absorbs the pump shaft thrust load141142143144compression, fixed impeller, pumps145compression, fixed impeller, pumps146motorsealpump147seal (lower

42、 chamber)motor148heat exchange areathrust bearing areaseal (lower chamber)motorthrust runnerthrust runner carbon facebearingbearing retainerscreen filterupthrust ring149seal unit base150bearing retainer151oil pump152bearing153carbon face154thrust runner155thrust runner carbon facethrust runner156upt

43、hrust bearing157upthrust bearingbearing runner158159bearing assembly complete160161the seal chamber section is located between the pump and motor transfers the motor torque to the pump shaft isolates the well fluid from the clean motor oil equalizes the internal unit and wellbore pressure provides a

44、rea for motor oil expansion volume absorbs the pump shaft thrust load162seal section components - reviewmajor components are . mechanical seals - prevents fluid migration down the seal shaft bag(s) or bladder(s) - provides expansion volume and isolation for clean motor oil labyrinth chamber(s) - pro

45、vides expansion and isolation volume in vertical or near vertical wells thrust bearing - carries the thrust load of the pump shaft and stages (fixed impeller type only)163seal section application use tandem seals in high pulling cost wells seals are relatively low cost items as compared w/the total

46、unit cost the more seal sections, the more mechanical seals and therefore, increased shaft isolation can be designed as a “thrust on lower” (tol) which gives added protection to the unit thrust bearing use single or multiple bag seals in highly deviated wells the isolation capability of a labyrinth

47、chamber is greatly reduced in deviations beyond 30 - 45 degrees from vertical164the motor drives the downhole pump and seal section is rated for a specific horsepower, voltage, & current is a two pole, three phase, ac, induction type rotates at approximately 3500 rpm at 60 hertz is constructed o

48、f rotors and bearings stacked on the shaft and loaded in a wound stator contains synthetic oil for lubrication relies on fluid flow past the housing od for cooling165motor componentsstator laminationskapton-wrapped magnet wirerotorbearing with t-ringhousingepoxy encapsulation166rotorbearing with t-r

49、ingstator167stator laminations on a mandrel168stator laminations pressed into the motor housing169a wound stator with leads attached170rotor copper end ringrotor laminationsrotor bearingrotor t ringrotor spacers171rotor bearingrotor172motor performance motors are rated by horsepower, voltage, &

50、current at a constant voltage, by varying the pump load or brake horsepower applied to the motor, current will change at a constant load, by varying voltage, current will vary, as well173motor applicationmotor operating temperature is determined by 5 factors wellbore temperature % load vs. nameplate

51、 rating fluid velocity past motor (flow rate vs. unit/casing diameter) cooling properties of the well fluid (% gas, water cut, scaling tendencies, etc.) power quality (3 phase voltage/current imbalance, wave form distortion, full nameplate voltage available, etc.)all of the above factors determine i

52、f, and when, a motor will overheat during operation 174sph p49175motor and vsd6060hznphpnphphz6060hznpvnpvhz60npanpahz176motor and vsd sizing the motor6060hznphpnphphzhzbhpnphphz6060substitute the pump bhphz at the maximum design hz for the nphphz and solve for nphp60177 the power cable is made up o

53、f the power cable and motor lead can be made in round or flat profile is constructed of three insulated & jacketed copper conductors contained by metal armor proper applications must address electrical, physical size, and operating temperature requirements178cable types - flatcomponents1 - condu

54、ctor (copper)2 - insulation (polypropylene or epdm) (ethylene propylene diene monomer) 3 - jacket (nitrile or epdm) & tape4 - armor (galvanized, stainless, or monel) benefits: low profile to fit in tight clearance installations 2 4 3 1179cable types - roundcomponents1 - conductor (copper)2 - ins

55、ulation polypropylene or epdm(ethylene propylene diene monomer) 3 - jacket (nitrile or epdm) & tape4 - armor (galvanized, stainless, or monel) benefits: less current imbalance & runs cooler than equivalent flat cable 3 24 1180cable types - motor lead extensioncomponents1 - conductor (copper)

56、2 - insulation film (polyimide)3 - insulation (epdm)4 - jacket / tape & braid or lead sheath (low temp or hi temp)5 - armor (low profile galv, ss, or monel) benefits: tape and braid provides added decompression resistance 1 2 35 4181cable types - extruded barriercomponents1 - conductor (copper)2

57、 - insulation (epdm)3 - extruded fluorobarrier (low or hi temp)4 - jacket (nitrile or epdm)5 - armor (galvanized, stainless, or monel)benefits: unlike tapes, the barrier blocks fluid, aids decompression resistance, and improves electrical properties12453182cable types - lead sheathcomponents1 - cond

58、uctor (copper)2 - insulation (polypropylene or epdm)3 - lead sheath4 - tape or braid (on epdm product only)5 - armor (galvanized, stainless, or monel) benefits: lead sheath blocks gasses & protects conductor from h2s attack available in round profile with epdm jacket 2 5 43 1 183cable types - ca

59、pillary tubefeatures & benefits available with any standard cable a variety of capillary tube sizes are utilized available in round or flat profile allows targeted delivery of treatment chemical single or dual capillary designs instrument wire can be inserted in some capillary tube sizes an oute

60、r layer of armor is applied to protect the capillary tubesstandard power cablecapillary tubescapillary tube184 power cable applicationproper application of esp cable requires . limiting voltage drop to no more than 30 volts per 1000 and less than 15% of motor volts by choosing a sufficiently large conductor (awg) size choosing the proper profile based