Electrical Submersible Pumps Manual Design, Operations, and Maintenance

Download Free PDF | Electrical Submersible Pumps Manual Design, Operations, and Maintenance 2nd Edition by Gabor Takacs.

Contents of Electrical Submersible Pumps Manual

Introduction
Artificial Lifting
Gas Lifting
Pumping
Comparison of Lift Methods
Lifting Capacities
System Efficiencies
Further Considerations
Short History of Electrical Submersible Pumping Applications
Basic Features of Electric Submersible Pumping Installations
Applications
Advantages and Limitations
References
Review of Fundamentals
Introduction
Well Inflow Performance
Introduction
The Productivity Index Concept
Inflow Performance Relationships
Introduction
Vogel s Inflow Performance Relationship
Correlation
The Composite Inflow Performance
Relationship Curve
Hydraulic Fundamentals
Tubing Flow Calculations
Electrical Submersible Pumps
Operational Basics of Centrifugal Pumps
Specific Speed
Pump Performance
Cavitation
Axial Thrust Forces
Affinity Laws
Electrical Fundamentals
Alternating Current
Alternating Current Circuits Alternating Current Power
Transformers
Electric Motors
Induction Motors
Permanent Magnet Motors
Electric Cable
Basics of Systems Analysis
Introduction
The Production System
Basic Principles
References
Electrical Submersible Pump Components and Their Operational Features
Introduction
The Submersible Pump
Basic Features
Pump Performance Curves
Floating Versus Fixed Impeller Pumps
Pump Temperature
Novel Pump Stage Design and Manufacturing
The ESP Motor
Induction Type Asynchronous Motors
Motor Construction
Operational Features
Motor Performance
Motor Testing
Performance Curves
Startup Conditions
Motor Temperature
Heat Transfer Calculations
Allowed Motor Temperature
High Performance Motors
Permanent Magnet Motors
Introduction
Motor Controllers for Permanent Magnet
Motors
Scalar Control
Vector Control
Constructional Details
Operational Features
Ultrahigh Speed Permanent Magnet
Motor Applications
Comparison with Induction Motors
Case Studies
Conclusions
The Protector or Seal Section
Main Functions
Basic Operation
Main Parts
The Thrust Bearing
Isolation Chambers
Labyrinth Type Chambers
Blocking Fluids
Bag Type Chambers
Metal Bellows Type Chambers
Shaft Seals
Other Features
The Gravitational Gas Separator
The ESP Cable
Cable Materials
Cable Construction
Operational Features
Miscellaneous Downhole Equipment
Surface Equipment
Wellhead
Junction Box
Switchboard
Transformers
Miscellaneous Equipment
References
Use of ESP Equipment in Special Conditions
Introduction
Pumping Viscous Liquids
Introduction
The Hydraulic Institute Model
Other Models
Low or Changing Pumping Rates
Low Rate Pumps
Wide Operating Range Pumps
Production of Gassy Wells
Introduction
Free Gas Volume Calculations
Pump Performance Degradation
Gas Interference in Centrifugal Pumps
Performance Criteria
Possible Solutions
Utilization of Natural Gas Separation
Pump Set Below the
Perforations
Use of Motor Shrouds
Rotary Gas Separators
Available Types
The Role of Inducers
Separation Efficiencies
Gas Handling
Legacy Methods
Modern Solutions
Conclusions
Production of Abrasive Solids
Conventional Pumps
Introduction
Characteristics of Abrasive Materials
Sand Problem Areas
Pump Erosion
Abrasion in Radial Bearings
Abrasion in Thrust Washers
Solutions
Reduction of Radial Wear
Preventing Sand Accumulation Above
the Pump
Conclusions
Special Pumps for Abrasive Handling
High Well Temperatures
Temperature Problems and Solutions
Geothermal Steam Assisted Gravity Drainage
Applications
Variable Frequency Operation
Pump Performance at Variable Speeds
Variable Speed Drives
Constructional Details
The Rectifier
The Direct Current Control
Section
The Inverter
Available Variable Speed Drive Types
Six Step Variable Speed
Drive
Pulsed Width Modulation
Sine Wave Generators
Vector Control Devices
Operational Characteristics
Variable Frequency Generators
Interaction of VSD VFG and ESP Units
Variable Frequency Operation of
Electrical Motors
Interaction of ESP Motors and VSD VFG
Units
Benefits of Using Variable Speed Drive VariableFrequency Generator Units
Other Problems
References
Design of ESP Installations
Introduction
Data Requirements
Conventional Design
Well Inflow Calculations
Total Dynamic Head Calculations
Selection of the Pump
Pump Series
Pump Type
Number of Stages Pump Power
Checking the Pump s Mechanical Strength
Selection of the Protector
Motor Selection
Selection of the Power Cable
Cable Length
Cable Type
Cable Size
Checking Motor Startup
Switchboard and Transformer Selection
Miscellaneous Equipment
Downhole Equipment
Surface Equipment
Conventional Design Considering Motor Slip
Introduction
Interaction of the ESP Motor and the Pump
Changes in the Conventional Design
Finding Actual Motor Speed
Finding Pump Head Including Motor Slip
Gassy Well Design
Inflow and Free Gas Calculations
Calculation of Total Dynamic Head
The Rest of the Design Procedure
Design of a Variable Speed Drive Installation
Introduction
Pump Selection for Variable Speed Drive Service
Driving Frequency and the Number of
Stages
Checking Pump Operation at the Minimum
Liquid Rate
Motor Selection
Switchboard and Transformers
Design of a Permanent Magnet Motor Installation
Design Considerations
Selection of the Pump
Selection of the Permanent Magnet Motor
Comparison of Induction Motor and Permanent Magnet
Motor Installations
References
Analysis and Optimization
Introduction
NODAL Analysis
Using the HeadeRate Coordinate System
Single Phase Cases
Constant Pumping Speed
Variable Pumping Speeds
Variable Wellhead Pressures
Multiphase Cases
Calculation Model
Applications
Using the PressureeRate Coordinate System
Single Phase Cases
Multiphase Cases
Determination of Well Inflow Performance
The Conventional Method
Use of Variable Speed Drives
Calculation of Bottomhole Pressures
Introduction
Annular Liquid Gradients
Static Conditions
Flowing Conditions
Power Efficiency of ESP Installations
Power Flow in the ESP System
Energy Losses and Efficiencies
Hydraulic Losses
Tubing Losses
Backpressure Losses
Pump Losses
Power Loss in Gas Separator
Electrical Losses
Motor Losses
Cable Losses
Surface Electrical Losses
System Efficiency
Optimization of Electrical Submersible Pump Operations
Introduction
Basics of Economic Optimization
References
Operation Monitoring and Surveillance of Electrical Submersible Pumping Systems
Introduction
Guidelines for Running and Pulling
Transportation to the Wellsite
Equipment Installation
Motor Installation
Protector Installation
Pump Installation
ESP Cable Installation
Final Measures
Running Equipment in the Well
System Startup
Pulling ESP Equipment
Production Control
Introduction
The Effects of Using Wellhead Chokes
The Need for Wellhead Chokes
Use of Variable Speed Drive Units
Sample Calculations
Monitoring ESP Operations
Introduction
Acoustic Surveys
Downhole Measurements
Instruments and Communications
Measured Parameters and Their Use
Surface Controllers
Introduction
Fixed Speed Drives
Variable Speed Drives
ESP Controller Functions
Surveillance of ESP Operations
Introduction
Key Challenges and Requirements in Production
Operations
The Digital Oilfield
An Overview
Digital Oilfield Step by Step Progression
ESP Data Visualization
Well Status and Well Group Status
Analysis Using Data Trend Visualization
References
Failures and Troubleshooting
Introduction
System Failures
Contents xi
General Causes of Failures
Vibrations in the ESP System
Typical Failures of System Components
ESP Teardown Analysis
Introduction
General Considerations
Motor Inspection
Protector Inspection
Pump Inspection
Cable Inspection
Inspection of Other Equipment
Failure Tracking
Run Life Estimation
Introduction
Run Life Measures
Lifetime Distribution
Troubleshooting Electrical Submersible Pumping
Installations
Interpretation of Ammeter Charts
Nodal Analysis Techniques
Introduction
Applications
The Use of Measured Pump Intake and
Discharge Pressures
References
Special Installations
Introduction
Tubing Deployed Installations
Producing a Single Zone
Shrouded and Horizontal Well
Installations
Parallelly Connected Installations
Series Connected Installations
Dual Zone Installations
Production Commingling
Selective Production
Alternative Deployed Installations
Cable Suspended Units
Coiled Tubing Installations
Cable Led Outside the Coiled Tubing
String
Cable Led Inside the Coiled Tubing String
Thru Tubing Deployed Systems
Retrievable ESP Pumps
Retrievable ESP Systems
Conclusions
Horizontal Pumping Systems
Available Configurations
Typical Applications
References