電潛泵系統(tǒng)構(gòu)成及工作原理課件

1、電潛泵系統(tǒng)構(gòu)成及工作原理第1頁(yè)，共199頁(yè)。ESP System Technology Overview2第2頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。ESP Downhole SystemThe basic ESP d

2、ownhole system components are . The Monitoring System (optional)The Power CableThe MotorThe Seal SectionThe Pump4第4頁(yè)，共199頁(yè)。5第5頁(yè)，共199頁(yè)。Built in Discharge headTubing screws in hereBolts to the SealPump ShaftBuilt in IntakePump HousingRotating ImpellerStationary Diffuser The Pump6第6頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。LT = Lower Tandem pump ( with built in intake )The seal bolts on here8第8頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。If Upper Tandem (UT)

5、then a discharge is built into the pump.UT PumpBuilt in Discharge head10第10頁(yè)，共199頁(yè)。Middle Tandem pump BaseUT or MT pumpShipping Cap11第11頁(yè)，共199頁(yè)。The Bolt on HeadThe Middle Tandem or Lower Tandem Pump Head12第12頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Centrifugal ?14第14頁(yè)，共199頁(yè)。Stages stacked on a shaft and compressed in a housing.Centrilift Submersible Pump15第15頁(yè)，共199頁(yè)。Rotating impellers (clockwise top view) Stationary diffusersCutaway of Pump16第16頁(yè)，共199頁(yè)。I

7、mpeller17第17頁(yè)，共199頁(yè)。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頁(yè)，

8、共199頁(yè)。Impeller TerminologyImpeller HubBottom ShroudTop ShroudImpeller SkirtImpeller EyeImpeller VaneDownthrust WasherUpthrust Washer19第19頁(yè)，共199頁(yè)。ImpellerEyeHubUpper ShroudVanesLower ShroudSkirtShaft20第20頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。ImpellerFluid enters the impeller through the eye near the shaft and exits the impeller on the outside. Shaft22第22頁(yè)，共199頁(yè)。Impeller - Cut Away23第23頁(yè)，共199頁(yè)。Diffuser24第24頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Diffuser - Cut Away26第26頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Impeller in Diffuser - A Pump Stage28第28頁(yè)，共199頁(yè)。Pump Stage - cut away29第29頁(yè)，共199頁(yè)。Flow, Barrels per day (BPD)Operating RangeHead CapacityPump EfficiencyBrake Horse PowerHead in FeetBHPPump Curve80604020123Efficiency %Best Efficiency Point

12、(BEP)30第30頁(yè)，共199頁(yè)。Total Dynamic Head ( TDH )Tubing Pressure第31頁(yè)，共199頁(yè)。Pump StageFluid ReservoirDeveloping the Pump Stage Head Capacity Curve32第32頁(yè)，共199頁(yè)。Fluid ReservoirHead (Lift)1Developing the Pump Stage Head Capacity Curve33第33頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Fluid ReservoirHead1Developing the Pump Stage Head Capacity Curve35第35頁(yè)，共199頁(yè)。Head Flow12Fluid ReservoirDeveloping the Pump Stage Head Capacity Curv

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

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

16、ge - Head / Capacity Curve41第41頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump43第

17、43頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump45第45頁(yè)，共199頁(yè)。280 Ft 600 bpdFluid Reservoir56 feet 0 BPDFor

18、600 BPDStages = 280/40 = 7Using the Pump Curve to size a pump46第46頁(yè)，共199頁(yè)。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump47第47頁(yè)，共199頁(yè)。280 Ft 600 bpdFluid ReservoirUsing the Pump Curve to size a pump48第48頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Using the pump curveSo we need a motor bigger than 214HP, say 255HP.53第53頁(yè)，共199頁(yè)。Pump Thrust54第54頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。In Floating Impeller Pumps the Impeller does

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

24、 is on the upper and lower impeller shroudsPump Thrust Load59第59頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Flow from DiffuserImpeller Flow PathFluid velocity & viscousdrag forces add to upthrust.Hydraulic ThrustPressure generated bythe stage65第65頁(yè)，共199頁(yè)。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頁(yè)，共

30、199頁(yè)。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頁(yè)，共199頁(yè)。Washers are fitted to prevent wear:Downthrust washers Upthrust

31、washerPump Thrust Load68第68頁(yè)，共199頁(yè)。Downthrust Washer69第69頁(yè)，共199頁(yè)。Hub WasherEye Washer70第70頁(yè)，共199頁(yè)。Upthrust Washer71第71頁(yè)，共199頁(yè)。Impeller - TopImpeller - Bottom72第72頁(yè)，共199頁(yè)。HubUpper ShroudVaneLower ShroudSkirtEyeUpthrust WasherDown thrust WasherImpeller - Name the parts:73第73頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Flow, Barrels per day (BPD)Operating RangeHead Ca

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

34、eservoirNormal RPM78第78頁(yè)，共199頁(yè)。Fluid ReservoirFluid ReservoirNormal RPMSlower RPM79第79頁(yè)，共199頁(yè)。Fluid ReservoirFluid ReservoirFluid ReservoirNormal RPMSlower RPMFaster RPM80第80頁(yè)，共199頁(yè)。81第81頁(yè)，共199頁(yè)。82第82頁(yè)，共199頁(yè)。83第83頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。85第85頁(yè)，共199頁(yè)。86第86頁(yè)，共199頁(yè)。Tornado CurveMin FlowBEP FlowMax Flow87第87頁(yè)，共

36、199頁(yè)。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頁(yè)，共199頁(yè)。The Gas Separator89第89頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。MotorPump91第91頁(yè)，共199頁(yè)。MotorPump92第92頁(yè)，共199頁(yè)。93第93頁(yè)，共199頁(yè)。94第94頁(yè)，共199頁(yè)。MotorPump95第95頁(yè)，共199頁(yè)。MotorSealPump96第96頁(yè)，

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

40、rinth Chamber106第106頁(yè)，共199頁(yè)。107第107頁(yè)，共199頁(yè)。108第108頁(yè)，共199頁(yè)。PumpMotorBag or Bladder109第109頁(yè)，共199頁(yè)。PumpMotor110第110頁(yè)，共199頁(yè)。111第111頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。113第113頁(yè)，共199頁(yè)。Labyrinth ChamberMotor Oil - Heated114第114頁(yè)，共199頁(yè)。Labyrinth ChamberMotor Oil - Cooling115第115頁(yè)，共199頁(yè)。Double Labyrinth ChamberMotor116第116頁(yè)，共199頁(yè)。Bag (or Bladder)MotorMotor Oil - Heated117第117頁(yè)，共199頁(yè)。Bag (or Bladder)MotorMotor Oil - Heated

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

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

44、132頁(yè)，共199頁(yè)。MotorMotor Oil - HeatedParallel Bags133第133頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Motor135第135頁(yè)，共199頁(yè)。n thousand feet136第136頁(yè)，共199頁(yè)。137第137頁(yè)，共199頁(yè)。138第138頁(yè)，共199頁(yè)。139第139頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。141第141頁(yè)，共199頁(yè)。142第142頁(yè)，共199頁(yè)。143第143頁(yè)，共199頁(yè)。Compression, Fixed Impeller, Pumps144第144頁(yè)，共199頁(yè)。Compression, Fixed Impeller, Pumps145第145頁(yè)，共199頁(yè)。MotorSealPump146第146頁(yè)，共199頁(yè)。Seal (Lower Cham

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

48、Face153第153頁(yè)，共199頁(yè)。Thrust Runner154第154頁(yè)，共199頁(yè)。Thrust Runner Carbon FaceThrust Runner155第155頁(yè)，共199頁(yè)。Upthrust Bearing156第156頁(yè)，共199頁(yè)。Upthrust BearingBearing Runner157第157頁(yè)，共199頁(yè)。158第158頁(yè)，共199頁(yè)。Bearing Assembly Complete159第159頁(yè)，共199頁(yè)。160第160頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Motor ComponentsStator LaminationsKapton-Wrapped Magnet WireRotorBearing with T-ringHousingEpoxy Encapsulation165第165頁(yè)，共199頁(yè)。rotorBearing with T-RingStator166第166頁(yè)，共199頁(yè)。Stator Laminations on a Mandrel167第167頁(yè)，共199頁(yè)。Stator Laminations pressed into

55、the motor housing168第168頁(yè)，共199頁(yè)。A wound Stator with Leads attached169第169頁(yè)，共199頁(yè)。Rotor Copper End RingRotor LaminationsRotor BearingRotor T ringRotor Spacers170第170頁(yè)，共199頁(yè)。Rotor BearingRotor171第171頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。SPH p49174第174頁(yè)，共199頁(yè)。Motor and VSD175第175頁(yè)，共199頁(yè)。Motor and VSD sizing the motorSubstitute the pump BHPHZ at the maximum design HZ for the NPHPHZ and solve for NPHP60176第176頁(yè)，共199頁(yè)。 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頁(yè)，共199頁(yè)。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頁(yè)，共199頁(yè)。Cable Types - RoundComponents1 - Conductor (Copper)2 - Insulation Polypropylene or EPDM(Ethylene Pro