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1、A typical ESP installation,2,ESP System Technology Overview,3,Objective,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.,4,ESP Downhole System,The basic ESP dow
2、nhole system components are .,The Monitoring System (optional),The Power Cable,The Motor,The Seal Section,The Pump,5,6,Built in Discharge head,Tubing screws in here,Bolts to the Seal,Pump Shaft,Built in Intake,Pump Housing,Rotating Impeller,Stationary Diffuser,The Pump,7,The Pump,Hangs from the prod
3、uction tubing Lifts 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 p
4、erforation for sufficient cooling.,8,LT = Lower Tandem pump ( with built in intake ),The seal bolts on here,9,LT/MT = Lower/Middle Tandem pump,Head,Shipping Cap,If MT (middle tandem) or LT (Lower Tandem) then a flange face is the head of the pump.,10,If Upper Tandem (UT) then a discharge is built in
5、to the pump.,UT Pump,Built in Discharge head,11,Middle Tandem pump Base,UT or MT pump,Shipping Cap,12,The Bolt on Head,The Middle Tandem or Lower Tandem Pump Head,13,Gas separator intake (cut away). May be bolted on to the base of a MT (Middle Tandem) or UT (Upper Tandem) Pump,The Seal bolts on here
6、.,UT or MT pump bolts on here.,14,Centrifugal ?,15,Stages stacked on a shaft and compressed in a housing.,Centrilift Submersible Pump,16,Rotating (right to left) impellers,Stationary diffusers,Cutaway of Pump,17,Impeller,18,Pump Stage Hydraulic Design,ESP Stage designs fall into one of two hydraulic
7、 design categories ,Mixed Flow - flow path has both axial and radial direction with respect to the pump shaft,Radial Flow - flow path is generally perpendicular (radial) with respect to the pump shaft,19,Impeller Terminology,Impeller Hub,Bottom Shroud,Top Shroud,Impeller Skirt,Impeller Eye,Impeller
8、Vane,Downthrust Washer,Upthrust Washer,20,Impeller,Eye,21,Impeller,The impeller rotates about the pump axis, with the shaft,It provides the centrifugal force to the fluid - gives it energy.,22,Impeller,Fluid enters the impeller through the eye near the shaft and exits the impeller on the outside.,23
9、,Impeller - Cut Away,24,Diffuser,25,Diffuser,The diffuser does not rotate, it turns the fluid up into the next impeller,It transforms the fluid velocity, its energy, into head,26,Diffuser - Cut Away,27,Impeller & Diffuser,Diffuser directs fluid into the eye of the impeller,Impeller spins and gives e
10、nergy to fluid which exits around the outside,Diffuser redirects the fluid up into the next impeller and turns fluid energy into head,28,Impeller in Diffuser - A Pump Stage,29,Pump Stage - cut away,30,Flow, Barrels per day (BPD),Operating Range,Head in Feet,BHP,Pump Curve,80,60,40,20,1,2,3,Efficienc
11、y %,Best Efficiency Point (BEP),Total Dynamic Head ( TDH ),32,Pump Stage,Fluid Reservoir,Developing the Pump Stage Head Capacity Curve,33,Fluid Reservoir,Head (Lift),1,Developing the Pump Stage Head Capacity Curve,34,Head in Feet,Single stage performance for a given RPM and fluid viscosity,Pump Stag
12、e Characteristics,0,10,20,30,40,50,60,1,Developing the Pump Stage Head Capacity Curve,35,Fluid Reservoir,Head,1,Developing the Pump Stage Head Capacity Curve,36,Head,Flow,1,2,Fluid Reservoir,Developing the Pump Stage Head Capacity Curve,37,Head in Feet,Pump Stage Characteristics,0,10,20,30,40,50,60,
13、1,2,Developing the Pump Stage Head Capacity Curve,38,Head,Flow,1,2,Fluid Reservoir,Developing the Pump Stage Head Capacity Curve,39,Head,Flow,1,2,3,Fluid Reservoir,Developing the Pump Stage Head Capacity Curve,40,Head in Feet,Pump Stage Characteristics,0,10,20,30,40,50,60,Flow, Barrels per day (BPD)
14、,0,200,400,600,800,1000,1,2,3,Developing the Pump Stage - Head / Capacity Curve,41,Head in Feet,Pump Curve,0,10,20,30,40,50,60,Flow, Barrels per day (BPD),0,200,400,600,800,1000,Developing the Pump Stage - Head / Capacity Curve,42,Use the pump curve to size a pump,We have a well, we want to produce
15、600BPD, and we need at least 280ft pump head. How many stages do we need?,43,600 bpd,Fluid Reservoir,Using the Pump Curve to size a pump,44,Head in Feet,Pump Curve,0,10,20,30,40,50,60,Flow, Barrels per day (BPD),0,200,400,600,800,1000,40 feet/stage 600 BPD,56 feet/stage 0 BPD,Using the Pump Curve to
16、 size a pump,45,600 bpd,Fluid Reservoir,Using the Pump Curve to size a pump,46,600 bpd,Fluid Reservoir,For 600 BPD Stages = 280/40 = 7,Using the Pump Curve to size a pump,47,600 bpd,Fluid Reservoir,Using the Pump Curve to size a pump,48,600 bpd,Fluid Reservoir,Using the Pump Curve to size a pump,49,
17、Multiple Stages,The 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 bpd,50,Pump Performance,Pump stage performance has three measured parameters which are Flow Rate Head (Discharge pressure can be calculat
18、ed) Brake Horsepower or Motor Load From the above, Pump Efficiency may be calculated,51,Using the pump curve,Example: A well will produce 4000 BPD when the pump produces a TDH (total dynamic head) of 5000 ft. Specific gravity of the produced fluid = 1.00 How many stages we need? How big the motor sh
19、ould be?,52,Pump Curve,GC3500 Single Stage Performance, 3500 RPM SpGr = 1.0, 60 Hertz, 4000 BPD,42 ft/stg,1.8 HP/stg,70% efficient,53,Using the pump curve,So we need a motor bigger than 214HP, say 255HP.,54,Pump Thrust,55,Pump Thrust,Pump thrust is made up of two components, hydraulic thrust and sha
20、ft 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.,56,In Floating Impeller Pumps the Impeller does not
21、Float,It is free to move up and down on the pump shaft,Impeller Position,57,Pump Thrust Load,Forces acting on the Impeller,58,Under normal operating conditions, fluid circulates on top and underneath the impeller shrouds,Pump Thrust Load,59,The impeller discharge pressure is on the upper and lower i
22、mpeller shrouds,Pump Thrust Load,60,The larger cross sectional area on the upper shroud causes the net force to be Down,Pump Thrust Load,This causes the impeller to be moved down,This is a positive downward force termed Downthrust,61,Pump Thrust Load,At some point the volume of fluid going up into t
23、he pump will lift the impeller up, overcoming the Downthrust pressure,This causes the impeller to be moved up,62,Pump Thrust Load,The downward force is now reversed (negative), it is termed Upthrust,This causes the impeller to be moved up,At some point the volume of fluid going up into the pump will
24、 lift the impeller up, overcoming the Downthrust pressure,63,Pump Thrust Load,This increases the Upthrust,This causes the impeller to be held up,This creates a larger cross sectional area on the bottom shroud which increases the pressure underneath,64,Hydraulic Thrust,Total hydraulic thrust has two
25、components, an up thrust component and a down thrust component The up thrust component is primarily created by the velocity through the impeller or hydraulic impact force The down thrust is primarily created by the pressure generated by the stage These two components combine to make up total hydraul
26、ic thrust Fluid viscosity has a dramatic affect on hydraulic thrust,65,Flow from Diffuser,Impeller Flow Path,Fluid velocity & viscous drag forces add to upthrust.,Hydraulic Thrust,Pressure generated by the stage,66,Shaft Thrust,Shaft thrust is the result of the pump discharge pressure acting on the
27、cross sectional end of the pump shaft,The two things that determine shaft thrust is the pump discharge pressure (or TDH) and the diameter of the pump shaft. This thrust is transmitted directly to the seal section thrust bearing,67,Thrust and Impeller Position,In normal operation the larger cross sec
28、tional area on the upper shroud causes more pressure on top, pushing the impeller down,The pump is designed to operate in slight to moderate Downthrust.,68,Washers are fitted to prevent wear:,Downthrust washers,Upthrust washer,Pump Thrust Load,69,Downthrust Washer,70,Hub Washer,Eye Washer,71,Upthrus
29、t Washer,72,Impeller - Top,Impeller - Bottom,73,Hub,Upper Shroud,Vane,Lower Shroud,Skirt,Eye,Upthrust Washer,Down thrust Washer,Impeller - Name the parts:,74,Variable Speed Operation,ESPs may also be ran at variable speeds. Changing the speed or frequency of an ESP system follows the “Affinity Laws”
30、 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)3,75,Flow, Barrels per day (BPD),Operating Range,Head in Feet,BHP,Pump Curve,80,60,40,20,1,2,3,Efficiency %,Best Efficiency Point (BEP),76,GC2200 Single Stage Performance RPM 60Hz = 3
31、500 (Sg = 1),77,GC2200 Single Stage Performance RPM 60Hz = 3500 (Sg = 1),78,Fluid Reservoir,Normal RPM,79,Fluid Reservoir,Fluid Reservoir,Normal RPM,Slower RPM,80,Fluid Reservoir,Fluid Reservoir,Fluid Reservoir,Normal RPM,Slower RPM,Faster RPM,81,82,83,84,Variable Speed Operation,New Flow Rate = Old
32、 Flow (New Hz/Old Hz) New Head = Old Head (New Hz/Old Hz)2,“Affinity Laws” ,60Hz Operating Range Min flow = 1500bpd 54ft BEP flow = 2200bpd 46ft Max flow = 3000bpd 25ft,Min flow = 2000bpd 96ft BEP flow = 2933bpd 82ft Max flow = 4000bpd 44ft,80Hz Operating Range,?,85,86,87,Tornado Curve,Min Flow,BEP
33、Flow,Max Flow,88,The 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 performance Rotary gas separator types include: Induced
34、 Vortex with passive chamber Rotating chamber,89,The Gas Separator,90,The 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 unit and wellbore pressure Provides area f
35、or motor oil expansion volume Absorbs the pump shaft thrust load The Four “Shuns” - expansion, equalization, isolation, & “absorbsion” aka “Equalizer”, “Protector”, or “Seal Section”,91,Motor,Pump,92,Motor,Pump,93,94,95,Motor,Pump,96,Motor,Seal,Pump,97,Located between the pump and motor Transfers th
36、e motor torque to the pump shaft,The Seal Section,98,Labyrinth Chamber,99,Labyrinth Chamber,100,101,Double Labyrinth Chamber,102,103,104,105,106,Motor,Labyrinth Chamber,107,108,109,Motor,Bag or Bladder,110,Motor,111,112,The Seal Chamber Section,Is located between the pump and motor Transfers the mot
37、or torque to the pump shaft Isolates the well fluid from the clean motor oil Provides area for motor oil expansion volume,113,114,Labyrinth Chamber,Motor Oil - Heated,115,Labyrinth Chamber,Motor Oil - Cooling,116,Double Labyrinth Chamber,Motor,117,Bag (or Bladder),Motor,Motor Oil - Heated,118,Bag (o
38、r Bladder),Motor,Motor Oil - Heated,119,Bag (or Bladder),Motor,Motor Oil - Heated,120,121,122,Bag (or Bladder),Motor,Motor Oil - Heated,123,Bag (or Bladder),Motor,Motor Oil - Heated,124,Bag (or Bladder),Motor,Motor Oil - Heated,125,Motor,Motor Oil - Cooling,126,Motor,Motor Oil - Cooling,127,Motor,Mo
39、tor Oil - Heated,Double Bags,128,Motor,Motor Oil - Heated,Double Bags,129,Motor,Motor Oil - Heated,Double Bags,130,131,132,Motor,Motor Oil - Heated,Parallel Bags,133,Motor,Motor Oil - Heated,Parallel Bags,134,The Seal Chamber Section,Is located between the pump and motor Transfers the motor torque t
40、o 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 pressure,135,Motor,136,n thousand feet,137,138,139,140,The Seal Chamber Section,Is located between the pump and motor Transfers the motor torque to
41、the pump 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 load,141,142,143,144,Compression, Fixed Impeller, Pumps,145,Compression, Fixed Impeller, Pumps,146,Motor,Seal,P
42、ump,147,Seal (Lower Chamber),Motor,148,Heat Exchange Area,Thrust Bearing Area,Seal (Lower Chamber),Motor,149,Seal Unit Base,150,Bearing Retainer,151,Oil Pump,152,Bearing,153,Carbon Face,154,Thrust Runner,155,Thrust Runner Carbon Face,Thrust Runner,156,Upthrust Bearing,157,Upthrust Bearing,Bearing Ru
43、nner,158,159,Bearing Assembly Complete,160,161,The 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 area for motor oil expansion volume A
44、bsorbs the pump shaft thrust load,162,Seal Section Components - review,Major 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) - provides expansion and isolation vol
45、ume in vertical or near vertical wells Thrust Bearing - carries the thrust load of the pump shaft and stages (fixed impeller type only),163,Seal Section Application,Use tandem seals in high pulling cost wells Seals are relatively low cost items as compared w/the total unit cost The more seal section
46、s, 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 chamber is greatly reduced in deviations beyond 30 - 45 degrees from vertical,164,The Motor,Drives the downhole pump and seal section Is