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ESP COMPONENTS

© NOVOMET |WWW.NOVOMET.RU/ENG | 2017


ESP COMPONENTS Surface equipment

Downhole equipment consists of

1. Conventional,
Pump 2. Power save pump
Intake,
Gas separator, Advanced Gas handler,
Intake devices Multiphase pump, Slotted screen pump intake .

1. Modular protector,
Protector 2. Tandem modular protector

1. Induction (Asynchronous)
Motor 2. Permanent magnet

DH Sensor

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Centrifugal pump / Centrifugal-vortex pump

Pump consists
of diffusers and
impellers (ESP stages)
assembled on a shaft.
Pump is driven by
electrical motor and
well fluid flows to the
surface through tubing.

Diffuser

Impeller

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Stage construction
upthrust washer
(made from textolite or
keyway carbonite)

Impeller hub
inner and outer
downthrust washers
impeller (made from textolite or
carbonite)
Impeller vane

diffuser
inner and outer
downthrust pad

diffuser bore

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How does ESP stage operate?

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Types of stages 1/4

PANCAKE STAGE
Centrifugal design
(centrifugal design
of impeller) – standard
design when liquid lift is
generated under the action
of centrifugal forces.
Maximum gas content at
Pump intake is up to 25%.
Within Novomet product
range pancake stage is
typically powder-based.

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Types of stages 2/4
MIXED FLOW STAGE
(centrifugal design of impeller)
Mixed flow stages borrow
Centrifugal design characteristics from both radial
flow and axial flow stages. As
fluid flows through the impeller
of a mixed flow pump, the
impeller blades push the fluid out
from the pump shaft and to the
pump suction at an angle greater
than 90o.
Such design enables to increase
head per stage. These are cast-
based stages.

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Types of stages 3/4

Centrifugal-vortex VORTEX STAGE


(centrifugal vortex design) enhanced
design of stage impeller due to Vortex
crown application. The following
benefits have been gained because of:
Higher dynamic head and BEP due
to increased centrifugal force value
Increased maximum gas content
at Pump intake due to gas handling
by Vortex crown (up to 35%)
Both Pancake and Mixed Flow stages
can be either centrifugal or centrifugal-
vortex.

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Radial flow rate stages

Radial flow rate stage


with vortex

Radial flow rate stage

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Mixed flow rate stages

Mixed flow rate stage


with hydraulic seal

Mixed flow rate stage


with thrust washers

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Types of pump assembly
abrasion-resistant
Assembly
floater floater floater compression semi-compression
Particles
content

Pump
pump

pump

pump

pump

pump
assembly

protector
protector

protector

protector
protector

radial bearing
axial bearing stages stage packages

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Pump main components

подшипник
upper верхний
bearing колесо рабочее
impeller аппарат направляющий
diffuser

головка
head вал
shaft корпус
housing подшипник
radial bearing подшипник
radial bearing основание
base

• Upper bearing – compress diffusers together

• Radial bearing – reduce radial wear of the hubs of impellers and diffusers, make
less shaft vibration

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Pump main components

Stages (impellers
and diffusers)
Shaft
Sleeves

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Pump main components

Housing
Upper bearing
Base

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Pump main components

Head
Coupling

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Pump designs: floater

Floater design
Novomet floater design is abrasion-
resistant and it includes optimal number of
intermediate radial bearings.
Such construction allows to significantly
improve abrasion-resistance of the pump
due to increase of shaft hardness and radial
load is redistributed from stages onto radial
Axial thrust bearing

bearings.
Number of bearings is calculated based on
Protector

mathematic modeling and determined by


length of section, weight of impeller, shaft
hardness, balance of impellers and
clearance in stages.
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Semi-compression design 1/2

In semi-compression pump
design all stages are
assembled as a few
separate packs with radial
and axial bearings between
packs.

Axial thrust bearing

Protector
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Semi-compression design 2/2

During the initial phase of semi-


After assembly During assembly compression pump running cycle,
its impellers are functioning in the
same way as conventional floating
impellers. Each impeller is being
supported by appropriate diffuser.
During the ''wear-in'' phase thrust
washers get worn, and a pack of
the impellers located between one
pair of intermediate bearings rest
upon each other with their hubs.
The axial force generated by the
pack of impellers is being
transmitted to axial bearing.
axial bearing
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Compression design 1/2

In compression pump design all


impellers originally act as a single
pack in one pump tandem and stay in
one position.

Impellers are firmly fixed on the shaft


by sleeves and do not bear on
diffusers, while the axial force is
being transmitted onto pump shaft
and further onto axial thrust bearing

Axial thrust bearing


in the protector section.

Protector
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Compression design 2/2
This pump has no axial thrust bearings at all,
washers act only as seals. Wear-resistance of
this type of construction is improved because
of elimination of axial wear with extension of
operating range of flow rates.
Compression pump designs are selected for
application in the wells:
1) To operate with extended various flow rate;
2) With solids ratio of less than or equal to 350
ptb (1000 mg/l);
3) With high GOR;
4) After Hydraulic fracturing with proppant
production.

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Intake devices

The following intake devices are available:


- intake
- gas separator
- advanced gas handler
- multiphase pump
- slotted screen pump intake

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Intake

Intake is needed to let


the fluid get into the
pump.
Intake can be bolt-on or
integrated with a pump.
Intake can be used in
case free gas is 25%
(when centrifugal pump
is used) or 35% (when
centrifugal-vortex pump
is used).

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Gas separator
It is designed to separate gas into the annulus and not
to let gas get into the pump.
Novomet has abrasion-resistant version of gas
separator which is not cut by the abrasive flow.
Gas separator can be used in case free gas is 90%

Pump

- Oil, water and gas mixture


- Free gas
- Oil, water mixture

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Advanced gas handler

Advanced gas handler is intended for reservoir fluid


(mixture of oil, water and gas) conversion to
homogeneous fluid
Grinding of gas inclusions in reservoir fluid.
Advanced gas handler can be used in case free gas is 50%

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Downhole multiphase pumps (MPP)
Application
Oil-producing wells with high gas volume
Oil producing wells with nonvented packers
Extremely gassy wells where conventional
gas-handling devices are difficult to apply
Offshore installations

Benefits
It enables pump to continually operate in fluid
conditions up to 75% free gas
Extended pump run life
Due to gas-lift effect greater lift per stage and
efficiency are ensured
It stabilizes amp chart and enhances ESP run life

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How does MPP work?
MPP stage design has axial screw type impeller and gas handling diffuser
Operation:
Flow streams to the axial type impeller  gas volume is compressed
Compressed gas streams to the diffuser  gas bubbles break into small
Result: homogeneous gas-liquid mixture
MPP primes the ESP and pushes the gas-liquid flow stream into the
stages with no gas locks

Diffuser
Axial type impeller

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Slotted screen pump intake

Application Benefits
Slotted screen intake filter SFI is SFI has proven to be a reliable and
designed to ensure ESP protection successful solution for application as
in abrasive environments with intake in wells with severe solids content.
medium grained solids.
Slotted screen pump intake
primes the pump and protects
ESP stages from proppant and
solids.
The system includes the following
components:
• Wire-wrapped screen
• Sealing unit
• Protective bypass valve

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How does it work?

Design features
The intention of the protective valve is to enable continuous flow of
the fluid once the filter is plugged.
Filtering capacity depends on the slot size which is selected based
on solids size analysis.
Filter length is chosen to fit pump operating capacity.
Operation
Solids are retained between
wire winds of prismatic
profile. As slots can open
following fluid flow
direction, thereby back flush
allows low contamination by
solids and long durability of
the filter.
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Protector
Protector is a part of ESP system. It Pump
is installed between submersible
electric motor and intake device
Intake device
(intake, gas separator, etc).
Functions:
1. Torque transfer from motor Protector
to pump;
2. Prevention of reservoir fluid
penetration inside the motor;
Motor
3. Compensation of oil leakage and
volume thermal changes when the
motor is operating or shut-down;
4. Get the load from pump and intake
shaft;
5. Equalization of pressure in the
electric motor and annulus.
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Modular protector NMP
Shafts
Protector consists of Bag
module
unified units and
parts.
Labyrinth
module
The modular
principle allows for
quick repair and Head
modernization of the
protector depending Upper nipple
on the operating
Lower nipple
conditions.
Base

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Modular protector NMP
Deflector
When the shaft
rotates the deflector
creates centrifugal
forces.
As a result Solids
mechanical
impurities by this
forces are pushed to
the walls of the
nipple and deposited
on the bottom
removes into the
annulus through the
drainage holes in the
nipple.

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Modular protector (Mechanical seal)

Mechanical seal consist of two parts:


Stationary and Fixed.

Mechanical seal function: protection from fluid penetration


inside of the protector and motor

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Modular protector (Mechanical seal)

Example:
Mechanical seal

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Modular protector (Labyrinth)
Well fluid

The tubular
labyrinth locks the
well fluid,
preventing it from
entering the bag
module.

Tube

Well fluid
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Modular protector (Valves)

Valves are designed to


relieve excess oil
pressure inside of the
protector and motor.
Valves
These two valves are
opens when excess
pressure inside of the
bag more than 0.15 MPa
than out of the bag

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Modular protector (Bag)

The bag (diaphragm)


is designed to
separate well fluid
and motor oil, and
also to compensate
for the thermal
change in the oil
volume during
operation and motor
shutdown.

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Modular protector (Thrust bearing)
Upthrust bearing

Downthrust bearing

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Modular protector (Thrust bearing)

• Enhanced thrust • Thrust bearings


bearings of basic execution

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Modular protector (Thrust runner and Filter-
cooler) Gets the load which
transfer to the
protector (seal
section) shaft

Oil cooling and cleaning


from impurities

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Modular protector NMP
Protector consists of the
following modules:
- Labyrinth (L)
- Bag (diaphragm) (B)
Hydraulic scheme:
- Series connection (s)
- Parallel connection (p)
Typical hydraulic
schemes:
В
BsL
BpBsL
BsBsL
BsB
DEPENDING ON OPERATING
CONDITIONS THE NUMBER OF
MODULES AND TYPE OF THEIR
CONNECTIONS MAY CHANGE
B BsL BpBsL BsBsL
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Design characteristics
Normal operating mode of the ESP Start up Stop
(without stopping and starting)

Labyrinth
Mechanical
seal
Bearing
body
Valve

Bag

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Change in oil volume in the «motor-protector»
system

1 – ESP installation; 2
3
2 – RIH;
3 – ESP start-up; 1
4 – ESP shutdown; 5

Oil volume, %
5 – ESP operating;
4
6 – pulling.

tambient tbottom hole. tmotor wind.


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Tandem Protector

6
modules
4
protection barriers
2
thrust bearings

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Design characteristics

Most common hydraulic configuration of modules


is LsBpB+BpBsL

Upper protector
Labyrinth Two bags Thrust bearing

Lower protector
Two bags Labyrinth Thrust bearing

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Design characteristics

-ВsВ- (bag, series bag)


Application of two bags instead of one allows to fit extra
radial bearing and increase shaft rigidity;
Parts used are the same as in the rest of the protector
which narrows the list of repair parts.

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Design characteristics

-ВpВ- (bag, parallel bag)


Two bags work as one;
Compensates doubled oil volume;
Increases protector and motor runlife;
Allows to use protector with motor of higher power.

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Design characteristics
Upper labyrinth module
Separates reservoir fluid and motor oil;
Bag, mechanical seal and fill (check) valves operate
in motor oil.
Lower labyrinth module
Decreases motor oil heating from motor and runner;
Protects runner from solids and worn parts particles.
Upper labyrinth module Lower labyrinth module

Labyrinth
Mechanical seal
Nipple
Valve

Bag

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Design characteristics

Two thrust bearings


Bearings work in tandem increasing allowable axial load on
protector shaft;
In case one of the thrust bearings fails the second thrust bearing
will receive the load;
The system does not require preliminary preparation. Adjustment is
performed during protector manufacturing and assembly.

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Tandem modular protector NTMP
Two axial bearings
During assembling the clearance between the ends of the shafts of the upper
and lower protectors is eliminated by adjusting the bolt outreach in the shaft
of the lower protector.
Upper protector

Spline coupling
Adjustment bolt

Lower protector
Shims

© NOVOMET |WWW.NOVOMET.RU/ENG | 2017


Tandem modular protector NTMP
Two axial bearings
Initially the shaft of the upper protector is raised by 0.2 mm relative to its
axial support (bearing), bolt adjustment is also made within 0.2 mm.
This is done to compensate for wear of friction surfaces, deformation of the
shafts under the influence of load and temperature expansion of materials.
Over time the load is evenly distributed to both axial supports.
0,2 mm 0,2 mm

© NOVOMET |WWW.NOVOMET.RU/ENG | 2017


Tandem modular protector NTMP
Fill (check) valve for protector filling and pressure
testing during installation

Check
valve

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Tandem modular protector NTMP
Available series
(maximum motor power, kW at 50Hz)

272 319 362 406 449 535


(TBA) (180) (200) (360) (450) (700)

© NOVOMET |WWW.NOVOMET.RU/ENG | 2017


Possible configuration
For low power motors:
BsB+LsL

For high power motors


BpB+BpB+LsL

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Inverted tandem modular protector

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Protector assembly

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Protector acceptance tests

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Motor

An electric motor is an electric machine


that converts electrical energy into
mechanical energy of rotated shaft.
Novomet offers conventional Asynchronous
(induction) motors and Permanent Magnet
motors.
Novomet motors have varnished or epoxy
encapsulated stator winding, depending on
application conditions.
They are filled with synthetic oil to
dissipate the heat generated to the motor
housing.
Motors are available in a wide range of
series and configurations: from 319 up to
744 series in power from 14 up to 1286 hp.

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Motor
base
Oil purification filter

rotor
stator

motor terminals
Motor includes stator,
rotor, head, base and
motor terminals. Shaft
thrust bearing is located
head
in motor head and it
absorbs axial load from
shaft thrust bearing unit
rotor weight. Oil filter is
shaft splined end located in motor base.
Motor can consist of 1 to
3 motor sections.
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Permanent Magnet Motor

Permanent Magnet Motor is used as a drive for ESP


in replacement of induction motor due to its higher
efficiency and better reliability.
Permanent Magnet Motor (PMM) is a synchronous
AC motor, so its rotor rotates at the same speed as
the magnetic field produced by the stator windings.
PMM stator is similar to that of induction motor.
Rotor has permanent magnets made from rare-
earth alloys so rotor conductor losses are
eliminated.
At a single moment only two phases are controlled
by VSD vector system.

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Difference between PMM and Induction motor
PMM rotor
Sector type high-energy
permanent magnets

Induction motor rotor


Sheets of electrical steel
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Design features 1/3

Involute shaft splines and high-strength steel for


motor shaft allows to increase torque.

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Design features 2/3
Downthrust bearing coated with PEEK Victrex used
in all NOVOMET motors ensures high reliability.

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Design features 3/3

Flange type of a motor head simplifies


assembly and eliminates insulation
failure and breakage of leads.

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Losses in PMM are lower than
in Induction Motor
12 11.2 Permanent Magnet Motor:
10.4 460 series, 160 hp
10

8 Induction Motor:
7.1
460 series, 160 hp
6
3.9
4

2 1.3 1
0.9 0.8 0.8 0.8
0 0.3
0
1 2 3 4 5 6
1 - Losses in stator winding
2 - Losses in rotor
3 - Losses in steel
4 - Mechanical losses (friction losses)
5 - Hydraulic losses (friction of rotor on oil)
6 - Additional losses
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PMM vs. Induction Motor
Induction Motor N460AM160 2400V SGL (135hp@ 3000rpm)

25ft

PMM: N460PM160 3230V 3600RPM SGL (135hp@ 3000rpm)

18ft

PMM: N460PM135 2480V 6000RPM SGL (135hp@ 6000rpm)

10ft
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Permanent Magnet Motor benefits

Rated voltage, V
@3600rpm, hp

Power factor

Wt, lb ±0.5%
Efficiency, %
Rated rpm

Length,ft
Power

Inom, A
# Motor nameplate

1 N460AM160 2400V SGL 160 2400 40 3600 84 0.86 25 1244

2 N460PM160 3230V 3600PRM SGL 160 3230 27 3600 90.8 0.95 18 772

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Downhole Sensor System Measured Parameters

• Annulus and wellhead pressure

• Discharge pressure and temperature


• Pump vibration (axial and radial)
• Fluid flow at pump discharge
• Intake pressure
• Intake temperature
• Motor winding temperature
• Axial Motor vibration
• Radial Motor vibration
• Insulation resistance
• Current leakage
• Annulus pressure
• Wellhead pressure
• Watercut at pump discharge.
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Structural scheme of system with DH sensor

Zero Surface
Cable point panel
Tubing

Submersible equipment

SUT VSD

Surface equipment
Discharge
pressure sub

Capillary tube Pump discharge pressure

Motor
pressure, temperature, vibration at the
«0» pump intake
Downhole
sensor

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Power cable & MLE
The power cable, which supplies electricity Motor Lead Extension (MLE) is
to the ESP motor, is available in various of Plug-in type.
configurations, both flat and round, to High reliability under thermal
match the cable to specific well environ- stress due to adhesion of
ments. insulation to internal surface of
The cable is banded or clamped to the MLE plug.
production tubing and the ESP Wide temperature operating
components to support the weight of the range: from cold condition up
cable and to ensure protection during to 450 oF (232 oC).
RIH/POOH procedures. Higher heat dissipation due to
ribbed plug body.

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Layout of ESP system with Y-tool

RIH of ESP system with Y-


tool. Blanking plug
removal
Running of geophysical
tool on wireline or coiled
tubing with logging plug
ESP system start-up
Reservoir evaluation
(measurement of pressure,
temperature, gas-fluid
mixture flow, water cut)

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Benefits of Y-tool systems

Access to down hole zone


without ESP system
pulling out
ESP system protection
during natural flow or
injection under pressure
Well surveying during ESP
system operation with
operating mode change
Operation in casing 5¾”
(146 mm) and more

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Application range of Y-tool ESP systems

Wells surveying of several


opened reservoirs on operating
ESP system
Wells surveying at various
operational modes of ESP systems
Production well logging of
horizontal well sections
(geophysical tools RIH on coiled
tubing)
Pay zone treatment through
bypass line
Delivery of special tools for RIH
of packer equipment
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Miscellaneous equipment

Drain Valve Check Valve Bolt-on-head MLE Guard

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Surface equipment

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Electrical Equipment

Available: 115, 170, 260, 430, 525 KVA @380 V Skid-mounted VSD
Available: 130, 200, 300, 490, 605 KVA @480 V with SU and SD transformers,
with vector control mode. Air-conditioned, IP54, 12 pulse
In development: 650 KVA, 1300 KVA

Novomet is developing it’s own VSD to meet BP specifications


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Skid-mounted VSD

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Thank you for
your attention!

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