电潜泵系统构成及工作原理课件

1、电潜泵系统构成及工作原理第1页，共199页。ESP System Technology Overview2第2页，共199页。ObjectiveUpon completion of this course, you should be able to: Explain the uses of Electrical Submersible Pump. List the main components of ESP system. Explain the principle of an ESP system.3第3页，共199页。ESP Downhole SystemThe basic ESP d

2、ownhole system components are . The Monitoring System (optional)The Power CableThe MotorThe Seal SectionThe Pump4第4页，共199页。5第5页，共199页。Built in Discharge headTubing screws in hereBolts to the SealPump ShaftBuilt in IntakePump HousingRotating ImpellerStationary Diffuser The Pump6第6页，共199页。The PumpHang

3、s from the production tubingLifts the fluid through the tubing to the surfaceIs a multi-stage centrifugal typeIs constructed of impellers and diffusersMust be sized to match the well production rateThe intake and discharge that either bolts onto or is threaded into the pump housingNormally be set ab

4、ove the perforation for sufficient cooling.7第7页，共199页。LT = Lower Tandem pump ( with built in intake )The seal bolts on here8第8页，共199页。LT/MT = Lower/Middle Tandem pumpHeadShipping CapIf MT (middle tandem) or LT (Lower Tandem) then a flange face is the head of the pump.9第9页，共199页。If Upper Tandem (UT)

5、then a discharge is built into the pump.UT PumpBuilt in Discharge head10第10页，共199页。Middle Tandem pump BaseUT or MT pumpShipping Cap11第11页，共199页。The Bolt on HeadThe Middle Tandem or Lower Tandem Pump Head12第12页，共199页。Gas separator intake (cut away). May be bolted on to the base of a MT (Middle Tandem

6、) or UT (Upper Tandem) PumpThe Seal bolts on here.UT or MT pump bolts on here.13第13页，共199页。Centrifugal ?14第14页，共199页。Stages stacked on a shaft and compressed in a housing.Centrilift Submersible Pump15第15页，共199页。Rotating impellers (clockwise top view) Stationary diffusersCutaway of Pump16第16页，共199页。I

7、mpeller17第17页，共199页。Pump Stage Hydraulic DesignESP Stage designs fall into one of two hydraulic design categories Mixed Flow - flow path has both axial and radial direction with respect to the pump shaftRadial Flow - flow path is generally perpendicular (radial) with respect to the pump shaft18第18页，

8、共199页。Impeller TerminologyImpeller HubBottom ShroudTop ShroudImpeller SkirtImpeller EyeImpeller VaneDownthrust WasherUpthrust Washer19第19页，共199页。ImpellerEyeHubUpper ShroudVanesLower ShroudSkirtShaft20第20页，共199页。ImpellerThe impeller rotates about the pump axis, with the shaftIt provides the centrifug

9、al force to the fluid - gives it energy.Shaft21第21页，共199页。ImpellerFluid enters the impeller through the eye near the shaft and exits the impeller on the outside. Shaft22第22页，共199页。Impeller - Cut Away23第23页，共199页。Diffuser24第24页，共199页。DiffuserThe diffuser does not rotate, it turns the fluid up into th

10、e next impeller It transforms the fluid velocity, its energy, into head25第25页，共199页。Diffuser - Cut Away26第26页，共199页。Impeller & DiffuserDiffuser directs fluid into the eye of the impellerImpeller spins and gives energy to fluid which exits around the outsideDiffuser redirects the fluid up into the ne

11、xt impeller and turns fluid energy into headShaft27第27页，共199页。Impeller in Diffuser - A Pump Stage28第28页，共199页。Pump Stage - cut away29第29页，共199页。Flow, Barrels per day (BPD)Operating RangeHead CapacityPump EfficiencyBrake Horse PowerHead in FeetBHPPump Curve80604020123Efficiency %Best Efficiency Point

12、(BEP)30第30页，共199页。Total Dynamic Head ( TDH )Tubing Pressure第31页，共199页。Pump StageFluid ReservoirDeveloping the Pump Stage Head Capacity Curve32第32页，共199页。Fluid ReservoirHead (Lift)1Developing the Pump Stage Head Capacity Curve33第33页，共199页。Head in FeetSingle stage performance for a given RPM and fluid

13、 viscosityPump Stage Characteristics01020304050601Flow, Barrels per day (BPD)02004006008001000Developing the Pump Stage Head Capacity Curve34第34页，共199页。Fluid ReservoirHead1Developing the Pump Stage Head Capacity Curve35第35页，共199页。Head Flow12Fluid ReservoirDeveloping the Pump Stage Head Capacity Curv

14、e36第36页，共199页。Head in FeetPump Stage Characteristics0102030405060Flow, Barrels per day (BPD)0200400600800100012Developing the Pump Stage Head Capacity Curve37第37页，共199页。Head Flow12Fluid ReservoirDeveloping the Pump Stage Head Capacity Curve38第38页，共199页。Head Flow123Fluid ReservoirDeveloping the Pump

15、Stage Head Capacity Curve39第39页，共199页。Head in FeetPump Stage Characteristics0102030405060Flow, Barrels per day (BPD)02004006008001000123Developing the Pump Stage - Head / Capacity Curve40第40页，共199页。Head in FeetPump Curve0102030405060Flow, Barrels per day (BPD)02004006008001000Developing the Pump Sta

16、ge - Head / Capacity Curve41第41页，共199页。Use the pump curve to size a pumpA producing well, the expected producing capacity is 600BPD, and the pump head is at least 280ft.Q: How many stages should be installed in the pump?42第42页，共199页。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump43第

17、43页，共199页。Head in FeetPump Curve0102030405060Flow, Barrels per day (BPD)0200400600800100040 feet/stage 600 BPD56 feet/stage 0 BPDUsing the Pump Curve to size a pump44第44页，共199页。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump45第45页，共199页。280 Ft 600 bpdFluid Reservoir56 feet 0 BPDFor

18、600 BPDStages = 280/40 = 7Using the Pump Curve to size a pump46第46页，共199页。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump47第47页，共199页。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump48第48页，共199页。Multiple StagesThe head that one stage develops is multiplied by the num

19、ber of stages to determine the total head a pump will deliver. At a given flow rate !Shaft & Impellers600 bpd40 ft80 ft40 ft49第49页，共199页。Pump PerformancePump stage performance has three measured parameters which areFlow RateHead (Discharge pressure can be calculated)Brake Horsepower or Motor LoadFro

20、m the above, Pump Efficiency may be calculated50第50页，共199页。Using 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 many stages we need?How big the motor should be?51第51页，共199页。Pump CurveGC

21、3500Single Stage Performance, 3500 RPM SpGr = 1.0, 60 Hertz 4000 BPD,42 ft/stg,1.8 HP/stg,70% efficient52第52页，共199页。Using the pump curveSo we need a motor bigger than 214HP, say 255HP.53第53页，共199页。Pump Thrust54第54页，共199页。Pump ThrustPump thrust is made up of two components, hydraulic thrust and shaft

22、 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 seal section sees the hydraulic thrust and the shaft thrust.55第55页，共199页。In Floating Impeller Pumps the Impeller does

23、 not FloatIt is free to move up and down on the pump shaftImpeller Position56第56页，共199页。Pump Thrust LoadForces acting on the Impeller57第57页，共199页。Under normal operating conditions, fluid circulates on top and underneath the impeller shroudsPump Thrust Load58第58页，共199页。The impeller discharge pressure

24、 is on the upper and lower impeller shroudsPump Thrust Load59第59页，共199页。The 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 force termed Downthrust60第60页，共199页。Pump Thrust LoadAt some

25、 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 61第61页，共199页。Pump Thrust LoadThe downward force is now reversed (negative), it is termed UpthrustThis causes the impeller to be moved up At some poin

26、t the volume of fluid going up into the pump will lift the impeller up, overcoming the Downthrust pressure62第62页，共199页。Pump Thrust LoadThis increases the UpthrustThis causes the impeller to be held up This creates a larger cross sectional area on the bottom shroud which increases the pressure undern

27、eath63第63页，共199页。Hydraulic 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 pressure generated by t

28、he stageThese two components combine to make up total hydraulic thrustFluid viscosity has a dramatic affect on hydraulic thrust64第64页，共199页。Flow from DiffuserImpeller Flow PathFluid velocity & viscousdrag forces add to upthrust.Hydraulic ThrustPressure generated bythe stage65第65页，共199页。Shaft ThrustS

29、haft 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 bearing66第66页，共

30、199页。Thrust and 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.67第67页，共199页。Washers are fitted to prevent wear:Downthrust washers Upthrust

31、washerPump Thrust Load68第68页，共199页。Downthrust Washer69第69页，共199页。Hub WasherEye Washer70第70页，共199页。Upthrust Washer71第71页，共199页。Impeller - TopImpeller - Bottom72第72页，共199页。HubUpper ShroudVaneLower ShroudSkirtEyeUpthrust WasherDown thrust WasherImpeller - Name the parts:73第73页，共199页。Variable Speed Oper

32、ationESPs may also be ran at variable speeds. Changing the speed or frequency of an ESP system follows the “Affinity Laws” New Flow Rate = Old Flow (New Hz/Old Hz)New Head = Old Head (New Hz/Old Hz)2New Brake HP = Old BHP (New Hz/Old Hz)374第74页，共199页。Flow, Barrels per day (BPD)Operating RangeHead Ca

33、pacityPump EfficiencyBrake Horse PowerHead in FeetBHPPump Curve80604020123Efficiency %Best Efficiency Point(BEP)75第75页，共199页。Operating RangeGC2200 Single Stage Performance RPM 60Hz = 3500 (Sg = 1)76第76页，共199页。Operating RangeGC2200 Single Stage Performance RPM 60Hz = 3500 (Sg = 1)77第77页，共199页。Fluid R

34、eservoirNormal RPM78第78页，共199页。Fluid ReservoirFluid ReservoirNormal RPMSlower RPM79第79页，共199页。Fluid ReservoirFluid ReservoirFluid ReservoirNormal RPMSlower RPMFaster RPM80第80页，共199页。81第81页，共199页。82第82页，共199页。83第83页，共199页。Variable Speed OperationNew Flow Rate = Old Flow (New Hz/Old Hz)New Head = Old

35、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 44ft80Hz Operating Range?84第84页，共199页。85第85页，共199页。86第86页，共199页。Tornado CurveMin FlowBEP FlowMax Flow87第87页，共

36、199页。The Gas SeparatorTakes the place of a standard pump intakeIs 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 performanceRotary gas separator types include:Induced Vortex with pas

37、sive chamberRotating chamber88第88页，共199页。The Gas Separator89第89页，共199页。The Seal Chamber SectionIs located between the pump and motorTransfers the motor torque to the pump shaftIsolates (seals) the well fluid from the clean motor oilEqualizes the internal unit and wellbore pressureProvides area for m

38、otor oil expansion volumeAbsorbs the pump shaft thrust loadThe Four “Shuns” - expansion, equalization, isolation, & “absorbsion”aka “Equalizer”, “Protector”, or “Seal Section”90第90页，共199页。MotorPump91第91页，共199页。MotorPump92第92页，共199页。93第93页，共199页。94第94页，共199页。MotorPump95第95页，共199页。MotorSealPump96第96页，

39、共199页。Located between the pump and motorTransfers the motor torque to the pump shaftThe Seal Section97第97页，共199页。Labyrinth Chamber98第98页，共199页。Labyrinth Chamber99第99页，共199页。100第100页，共199页。Double Labyrinth Chamber101第101页，共199页。102第102页，共199页。103第103页，共199页。104第104页，共199页。105第105页，共199页。PumpMotorLaby

40、rinth Chamber106第106页，共199页。107第107页，共199页。108第108页，共199页。PumpMotorBag or Bladder109第109页，共199页。PumpMotor110第110页，共199页。111第111页，共199页。The Seal Chamber SectionIs located between the pump and motorTransfers the motor torque to the pump shaftIsolates the well fluid from the clean motor oilProvides are

41、a for motor oil expansion volume112第112页，共199页。113第113页，共199页。Labyrinth ChamberMotor Oil - Heated114第114页，共199页。Labyrinth ChamberMotor Oil - Cooling115第115页，共199页。Double Labyrinth ChamberMotor116第116页，共199页。Bag (or Bladder)MotorMotor Oil - Heated117第117页，共199页。Bag (or Bladder)MotorMotor Oil - Heated

42、118第118页，共199页。Bag (or Bladder)MotorMotor Oil - HeatedCheck valve119第119页，共199页。120第120页，共199页。121第121页，共199页。Bag (or Bladder)MotorMotor Oil - HeatedCheck valve122第122页，共199页。Bag (or Bladder)MotorMotor Oil - HeatedCheck valve123第123页，共199页。Bag (or Bladder)MotorMotor Oil - HeatedCheck valve124第124页，共

43、199页。MotorMotor Oil - Cooling125第125页，共199页。MotorMotor Oil - Cooling126第126页，共199页。MotorMotor Oil - HeatedDouble Bags127第127页，共199页。MotorMotor Oil - HeatedDouble Bags128第128页，共199页。MotorMotor Oil - HeatedDouble Bags129第129页，共199页。130第130页，共199页。131第131页，共199页。MotorMotor Oil - HeatedParallel Bags132第

44、132页，共199页。MotorMotor Oil - HeatedParallel Bags133第133页，共199页。The Seal Chamber SectionIs located between the pump and motorTransfers the motor torque to the pump shaftIsolates the well fluid from the clean motor oilProvides area for motor oil expansion volumeEqualizes the internal unit and wellbore

45、pressure134第134页，共199页。Motor135第135页，共199页。n thousand feet136第136页，共199页。137第137页，共199页。138第138页，共199页。139第139页，共199页。The Seal Chamber SectionIs located between the pump and motorTransfers the motor torque to the pump shaftIsolates the well fluid from the clean motor oilEqualizes the internal unit a

46、nd wellbore pressureProvides area for motor oil expansion volumeAbsorbs the pump shaft thrust load140第140页，共199页。141第141页，共199页。142第142页，共199页。143第143页，共199页。Compression, Fixed Impeller, Pumps144第144页，共199页。Compression, Fixed Impeller, Pumps145第145页，共199页。MotorSealPump146第146页，共199页。Seal (Lower Cham

47、ber)Motor147第147页，共199页。Heat Exchange AreaThrust Bearing AreaSeal (Lower Chamber)MotorThrust RunnerThrust Runner Carbon FaceBearingBearing RetainerScreen FilterUpthrust Ring148第148页，共199页。Seal Unit Base149第149页，共199页。Bearing Retainer150第150页，共199页。Oil Pump151第151页，共199页。Bearing152第152页，共199页。Carbon

48、Face153第153页，共199页。Thrust Runner154第154页，共199页。Thrust Runner Carbon FaceThrust Runner155第155页，共199页。Upthrust Bearing156第156页，共199页。Upthrust BearingBearing Runner157第157页，共199页。158第158页，共199页。Bearing Assembly Complete159第159页，共199页。160第160页，共199页。The Seal Chamber SectionIs located between the pump an

49、d motorTransfers the motor torque to the pump shaftIsolates the well fluid from the clean motor oilEqualizes the internal unit and wellbore pressureProvides area for motor oil expansion volumeAbsorbs the pump shaft thrust load161第161页，共199页。Seal Section Components - reviewMajor components are .Mecha

50、nical Seals - prevents fluid migration down the seal shaftBag(s) or Bladder(s) - provides expansion volume and isolation for clean motor oilLabyrinth Chamber(s) - provides expansion and isolation volume in vertical or near vertical wellsThrust Bearing - carries the thrust load of the pump shaft and

51、stages (fixed impeller type only)162第162页，共199页。Seal Section ApplicationUse tandem seals in high pulling cost wellsSeals are relatively low cost items as compared w/the total unit costThe more seal sections, the more mechanical seals and therefore, increased shaft isolationCan be designed as a “Thru

52、st on Lower” (TOL) which gives added protection to the unit thrust bearingUse single or multiple bag seals in highly deviated wellsThe isolation capability of a labyrinth chamber is greatly reduced in deviations beyond 30 - 45 degrees from vertical163第163页，共199页。The MotorDrives the downhole pump and

53、 seal sectionIs rated for a specific horsepower, voltage, & currentIs a two pole, three phase, AC, induction type Rotates at approximately 3500 RPM at 60 HertzIs constructed of rotors and bearings stacked on the shaft and loaded in a wound statorContains synthetic oil for lubrication Relies on fluid

54、 flow past the housing OD for cooling164第164页，共199页。Motor ComponentsStator LaminationsKapton-Wrapped Magnet WireRotorBearing with T-ringHousingEpoxy Encapsulation165第165页，共199页。rotorBearing with T-RingStator166第166页，共199页。Stator Laminations on a Mandrel167第167页，共199页。Stator Laminations pressed into

55、the motor housing168第168页，共199页。A wound Stator with Leads attached169第169页，共199页。Rotor Copper End RingRotor LaminationsRotor BearingRotor T ringRotor Spacers170第170页，共199页。Rotor BearingRotor171第171页，共199页。Motor PerformanceMotors are rated by horsepower, voltage, & currentAt a constant voltage, by va

56、rying the pump load or brake horsepower applied to the motor, current will changeAt a constant load, by varying voltage, current will vary, as well172第172页，共199页。Motor ApplicationMotor operating temperature is determined by 5 factorsWellbore Temperature% Load vs. Nameplate RatingFluid Velocity Past

57、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 if, and when, a motor will over

58、heat during operation 173第173页，共199页。SPH p49174第174页，共199页。Motor and VSD175第175页，共199页。Motor and VSD sizing the motorSubstitute the pump BHPHZ at the maximum design HZ for the NPHPHZ and solve for NPHP60176第176页，共199页。 The Power CableIs made up of the power cable and motor leadCan be made in round o

59、r flat profileIs constructed of three insulated & jacketed copper conductors contained by metal armorProper applications must address electrical, physical size, and operating temperature requirements177第177页，共199页。Cable Types - FlatComponents1 - Conductor (Copper)2 - Insulation (Polypropylene or EPD

60、M) (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 1178第178页，共199页。Cable Types - RoundComponents1 - Conductor (Copper)2 - Insulation Polypropylene or EPDM(Ethylene Pro