Electrical submersible pumps manual : design, operations, and maintenance / Gabor Takacs.

Format:

Book

Author/Creator:

Takács, Gábor, 1947- author.

Language:

English

Subjects (All):

Oil well pumps--Handbooks, manuals, etc.

Oil well pumps.

Oil wells--Artificial lift--Handbooks, manuals, etc.

Oil wells.

Submersible pumps--Handbooks, manuals, etc.

Submersible pumps.

Physical Description:

1 online resource (565 pages) : illustrations

Edition:

Second edition.

Place of Publication:

Cambridge, Massachusetts ; Oxford, England : Gulf Professional Publishing, 2018.

Summary:

Electrical Submersible Pumps Manual: Design, Operations and Maintenance, Second Edition continues to deliver the information needed with updated developments, technology and operational case studies. New content on gas handlers, permanent magnet motors, and newly designed stage geometries are all included. Flowing from basic to intermediate to special applications, particularly for harsh environments, this reference also includes workshop materials and class-style examples for trainers to utilize for the newly hired production engineer. Other updates include novel pump stage designs, high-performance motors and temperature problems and solutions specific for high temperature wells.Effective and reliable when used properly, electrical submersible pumps (ESPs) can be expensive to purchase and maintain. Selecting the correct pump and operating it properly are essential for consistent flow from production wells. Despite this, there is not a dedicated go-to reference to train personnel and engineers. This book keeps engineers and managers involved in ESPs knowledgeable and up-to-date on this advantageous equipment utilized for the oil and gas industry.- Includes updates such as new classroom examples for training and more operational information, including production control- Features a rewritten section on failures and troubleshooting- Covers the latest equipment, developments and maintenance needed- Serves as a useful daily reference for both practicing and newly hired engineers- Explores basic electrical, hydraulics and motors, as well as more advanced equipment specific to special conditions such as production of deviated and high temperature wells

Contents:

Front Cover

Electrical Submersible Pumps Manual

Electrical Submersible Pumps Manual: Design, Operations, and Maintenance

Copyright

Contents

Preface to the First Edition

Preface to the Second Edition

1 - Introduction

1.1 ARTIFICIAL LIFTING

1.1.1 Gas Lifting

1.1.2 Pumping

1.1.3 Comparison of Lift Methods

1.1.3.1 Lifting Capacities

1.1.3.2 System Efficiencies

1.1.3.3 Further Considerations

1.2 SHORT HISTORY OF ELECTRICAL SUBMERSIBLE PUMPING APPLICATIONS

1.3 BASIC FEATURES OF ELECTRIC SUBMERSIBLE PUMPING INSTALLATIONS

1.3.1 Applications

1.3.2 Advantages and Limitations

REFERENCES

2 - Review of Fundamentals

2.1 INTRODUCTION

2.2 WELL INFLOW PERFORMANCE

2.2.1 Introduction

2.2.2 The Productivity Index Concept

2.2.3 Inflow Performance Relationships

2.2.3.1 Introduction

2.2.3.2 Vogel's Inflow Performance Relationship Correlation

2.2.3.3 The Composite Inflow Performance Relationship Curve

2.3 HYDRAULIC FUNDAMENTALS

2.3.1 Tubing Flow Calculations

2.3.2 Electrical Submersible Pumps

2.3.2.1 Operational Basics of Centrifugal Pumps

2.3.2.2 Specific Speed

2.3.2.3 Pump Performance

2.3.2.4 Cavitation

2.3.2.5 Axial Thrust Forces

2.3.2.6 Affinity Laws

2.4 ELECTRICAL FUNDAMENTALS

2.4.1 Alternating Current

2.4.2 Alternating Current Circuits, Alternating Current Power

2.4.3 Transformers

2.4.4 Electric Motors

2.4.4.1 Induction Motors

2.4.4.2 Permanent Magnet Motors

2.4.5 Electric Cable

2.5 BASICS OF SYSTEMS ANALYSIS

2.5.1 Introduction

2.5.2 The Production System

2.5.3 Basic Principles

3 - Electrical Submersible Pump Components and Their Operational Features

3.1 INTRODUCTION

3.2 THE SUBMERSIBLE PUMP

3.2.1 Basic Features

3.2.1.1 Pump Performance Curves

3.2.2 Floating Versus Fixed Impeller Pumps.

3.2.3 Pump Temperature

3.2.4 Novel Pump Stage Design and Manufacturing

3.3 THE ESP MOTOR

3.3.1 Induction-Type Asynchronous Motors

3.3.1.1 Motor Construction

3.3.1.2 Operational Features

3.3.1.3 Motor Performance

3.3.1.3.1 Motor Testing

3.3.1.3.2 Performance Curves

3.3.1.3.3 Startup Conditions

3.3.1.3.3.1 Across-the-Line Start

3.3.1.3.3.2 Soft Start

3.3.1.4 Motor Temperature

3.3.1.4.1 Heat Transfer Calculations

3.3.1.4.2 Allowed Motor Temperature

3.3.1.5 High-Performance Motors

3.3.2 Permanent Magnet Motors

3.3.2.1 Introduction

3.3.2.2 Motor Controllers for Permanent Magnet Motors

3.3.2.2.1 Scalar Control

3.3.2.2.2 Vector Control

3.3.2.3 Constructional Details

3.3.2.4 Operational Features

3.3.2.5 Ultrahigh Speed Permanent Magnet Motor Applications

3.3.2.6 Comparison with Induction Motors

3.3.2.7 Case Studies

3.3.2.8 Conclusions

3.4 THE PROTECTOR OR SEAL SECTION

3.4.1 Main Functions

3.4.2 Basic Operation

3.4.3 Main Parts

3.4.3.1 The Thrust Bearing

3.4.3.2 Isolation Chambers

3.4.3.2.1 Labyrinth-Type Chambers

3.4.3.2.2 Blocking Fluids

3.4.3.2.3 Bag-Type Chambers

3.4.3.2.4 Metal Bellows Type Chambers

3.4.3.3 Shaft Seals

3.4.4 Other Features

3.5 THE GRAVITATIONAL GAS SEPARATOR

3.6 THE ESP CABLE

3.6.1 Cable Materials

3.6.2 Cable Construction

3.6.3 Operational Features

3.7 MISCELLANEOUS DOWNHOLE EQUIPMENT

3.8 SURFACE EQUIPMENT

3.8.1 Wellhead

3.8.2 Junction Box

3.8.3 Switchboard

3.8.4 Transformers

3.8.5 Miscellaneous Equipment

4 - Use of ESP Equipment in Special Conditions

4.1 INTRODUCTION

4.2 PUMPING VISCOUS LIQUIDS

4.2.1 Introduction

4.2.2 The Hydraulic Institute Model

4.2.3 Other Models

4.3 LOW OR CHANGING PUMPING RATES

4.3.1 Low-Rate Pumps.

4.3.2 Wide-Operating-Range Pumps

4.4 PRODUCTION OF GASSY WELLS

4.4.1 Introduction

4.4.2 Free-Gas Volume Calculations

4.4.3 Pump Performance Degradation

4.4.3.1 Gas Interference in Centrifugal Pumps

4.4.3.2 Performance Criteria

4.4.4 Possible Solutions

4.4.4.1 Utilization of Natural Gas Separation

4.4.4.1.1 Pump Set Below the Perforations

4.4.4.1.2 Use of Motor Shrouds

4.4.4.2 Rotary Gas Separators

4.4.4.2.1 Available Types

4.4.4.2.2 The Role of Inducers

4.4.4.2.3 Separation Efficiencies

4.4.4.3 Gas Handling

4.4.4.3.1 Legacy Methods

4.4.4.3.1.1 Overstaged Pumps

4.4.4.3.1.2 Tapered Pumps

4.4.4.3.1.3 Stage Recirculation

4.4.4.3.2 Modern Solutions

4.4.4.3.2.1 The Poseidon Stage

4.4.4.3.2.2 Special Pumps

4.4.5 Conclusions

4.5 PRODUCTION OF ABRASIVE SOLIDS

4.5.1 Conventional Pumps

4.5.1.1 Introduction

4.5.1.2 Characteristics of Abrasive Materials

4.5.1.3 Sand Problem Areas

4.5.1.3.1 Pump Erosion

4.5.1.3.2 Abrasion in Radial Bearings

4.5.1.3.3 Abrasion in Thrust Washers

4.5.1.4 Solutions

4.5.1.4.1 Reduction of Radial Wear

4.5.1.5 Preventing Sand Accumulation Above the Pump

4.5.1.6 Conclusions

4.5.2 Special Pumps for Abrasive Handling

4.6 HIGH WELL TEMPERATURES

4.6.1 Temperature Problems and Solutions

4.6.2 Geothermal, Steam-Assisted Gravity Drainage Applications

4.7 VARIABLE-FREQUENCY OPERATION

4.7.1 Pump Performance at Variable Speeds

4.7.2 Variable-Speed Drives

4.7.2.1 Constructional Details

4.7.2.1.1 The Rectifier

4.7.2.1.2 The Direct Current Control Section

4.7.2.1.3 The Inverter

4.7.2.2 Available Variable-Speed Drive Types

4.7.2.2.1 "Six-Step" Variable-Speed Drive

4.7.2.2.2 Pulsed Width Modulation

4.7.2.2.3 Sine Wave Generators

4.7.2.2.4 Vector Control Devices

4.7.2.3 Operational Characteristics.

4.7.3 Variable-Frequency Generators

4.7.4 Interaction of VSD/VFG and ESP Units

4.7.4.1 Variable-Frequency Operation of Electrical Motors

4.7.4.2 Interaction of ESP Motors and VSD/VFG Units

4.7.5 Benefits of Using Variable-Speed Drive/Variable-Frequency Generator Units

4.8 OTHER PROBLEMS

5 - Design of ESP Installations

5.1 INTRODUCTION

5.2 DATA REQUIREMENTS

5.3 CONVENTIONAL DESIGN

5.3.1 Well Inflow Calculations

5.3.2 Total Dynamic Head Calculations

5.3.3 Selection of the Pump

5.3.3.1 Pump Series

5.3.3.2 Pump Type

5.3.3.3 Number of Stages, Pump Power

5.3.3.4 Checking the Pump's Mechanical Strength

5.3.4 Selection of the Protector

5.3.5 Motor Selection

5.3.6 Selection of the Power Cable

5.3.6.1 Cable Length

5.3.6.2 Cable Type

5.3.6.3 Cable Size

5.3.6.4 Checking Motor Startup

5.3.7 Switchboard and Transformer Selection

5.3.8 Miscellaneous Equipment

5.3.8.1 Downhole Equipment

5.3.8.2 Surface Equipment

5.4 CONVENTIONAL DESIGN CONSIDERING MOTOR SLIP

5.4.1 Introduction

5.4.2 Interaction of the ESP Motor and the Pump

5.4.3 Changes in the Conventional Design

5.4.3.1 Finding Actual Motor Speed

5.4.3.2 Finding Pump Head Including Motor Slip

5.5 GASSY WELL DESIGN

5.5.1 Inflow and Free Gas Calculations

5.5.2 Calculation of Total Dynamic Head

5.5.3 The Rest of the Design Procedure

5.6 DESIGN OF A VARIABLE SPEED DRIVE INSTALLATION

5.6.1 Introduction

5.6.2 Pump Selection for Variable Speed Drive Service

5.6.2.1 Driving Frequency and the Number of Stages

5.6.2.2 Checking Pump Operation at the Minimum Liquid Rate

5.6.3 Motor Selection

5.6.4 Switchboard and Transformers

5.7 DESIGN OF A PERMANENT MAGNET MOTOR INSTALLATION

5.7.1 Design Considerations

5.7.1.1 Selection of the Pump.

5.7.1.2 Selection of the Permanent Magnet Motor

5.8 COMPARISON OF INDUCTION MOTOR AND PERMANENT MAGNET MOTOR INSTALLATIONS

6 - Analysis and Optimization

6.1 INTRODUCTION

6.2 NODAL ANALYSIS

6.2.1 Using the Head-Rate Coordinate System

6.2.1.1 Single-Phase Cases

6.2.1.1.1 Constant Pumping Speed

6.2.1.1.2 Variable Pumping Speeds

6.2.1.1.3 Variable Wellhead Pressures

6.2.1.2 Multiphase Cases

6.2.1.2.1 Calculation Model

6.2.1.2.2 Applications

6.2.2 Using the Pressure-Rate Coordinate System

6.2.2.1 Single-Phase Cases

6.2.2.2 Multiphase Cases

6.3 DETERMINATION OF WELL INFLOW PERFORMANCE

6.3.1 The Conventional Method

6.3.2 Use of Variable-Speed Drives

6.3.3 Calculation of Bottomhole Pressures

6.3.3.1 Introduction

6.3.3.2 Annular Liquid Gradients

6.3.3.2.1 Static Conditions

6.3.3.2.2 Flowing Conditions

6.4 POWER EFFICIENCY OF ESP INSTALLATIONS

6.4.1 Power Flow in the ESP System

6.4.2 Energy Losses and Efficiencies

6.4.2.1 Hydraulic Losses

6.4.2.1.1 Tubing Losses

6.4.2.1.2 Backpressure Losses

6.4.2.1.3 Pump Losses

6.4.2.1.4 Power Loss in Gas Separator

6.4.2.2 Electrical Losses

6.4.2.2.1 Motor Losses

6.4.2.2.2 Cable Losses

6.4.2.2.3 Surface Electrical Losses

6.4.3 System Efficiency

6.5 OPTIMIZATION OF ELECTRICAL SUBMERSIBLE PUMP OPERATIONS

6.5.1 Introduction

6.5.2 Basics of Economic Optimization

7 - Operation, Monitoring, and Surveillance of Electrical Submersible Pumping Systems

7.1 INTRODUCTION

7.2 GUIDELINES FOR RUNNING AND PULLING

7.2.1 Transportation to the Wellsite

7.2.2 Equipment Installation

7.2.2.1 Motor Installation

7.2.2.2 Protector Installation

7.2.2.3 Pump Installation

7.2.2.4 ESP Cable Installation

7.2.2.5 Final Measures

7.2.3 Running Equipment in the Well.

7.2.4 System Startup.

Notes:

Includes bibliographical references at the end of each chapters and index.

Description based on online resource; title from PDF title page (ebrary, viewed October 19, 2017).

ISBN:

0-12-814571-4

0-12-814570-6