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Introduction

In Russia, among rodless pumps, the most common are installations of electric centrifugal pumps. They have equipped over 35% of the country's total well stock. Installations of electric centrifugal pumps (ESP) have a very large flow range (from 10 to 1000 m3 / day and more) and are capable of developing a head up to 2000 m. (efficiency) among all mechanized methods of oil production. In the range of feeds from 50 to 300 m3 / day. efficiency ESP exceeds 40%, but in the area of ​​low feeds efficiency ESP drops sharply. Whenever possible, the organization of remote monitoring of the condition, as well as regulation of the performance of the ESP, significantly surpasses the rod installations. Also, the efficiency of the ESP is less affected by the curvature of the wellbore.

The influence of the curvature of the wellbore on the performance of the ESP unit is mainly reflected during round-trip operations (ROP) due to the possibility of damage to the cable and is not connected (up to a certain value of the angle of inclination of the well and the rate of its curvature), as in the sucker rod pumping unit, with the operation itself. However, ESP units do not work well in a corrosive environment, when sand is removed, in conditions of high temperature and high gas-oil ratio.

ESPs are designed for pumping formation fluid from oil wells and is used to force the extraction of fluid.

For reliable operation of the pump, its correct selection to a given well is required. During the operation of the well, the parameters of the reservoir, the bottomhole formation zone, the properties of the withdrawn fluid are constantly changing: water content, the amount of associated gas, the amount of mechanical impurities, and as a result, there is a shortage of fluid or the pump is idling, which reduces the overhaul period of the pump. At the moment, there is an emphasis on more reliable equipment, to increase the overhaul period, and as a result, to reduce the cost of lifting the fluid. This can be achieved by using centrifugal ESPs instead of sucker rod pumps, since centrifugal pumps have a long overhaul period.

The ESP unit can be used for pumping liquid containing gas, sand, and corrosive elements.

1 . Device and technical characteristics of ESP

1.1 Namevalue and technical data of ESP

Submersible centrifugal units are designed for pumping formation fluid from oil wells. Submersible centrifugal electric pumps for oil production are designed for the operation of oil, sometimes heavily watered, wells of small diameter and great depth, they provide trouble-free and long-term operation in liquids containing aggressive formation waters with various salts dissolved in them, gas (including hydrogen sulfide), mechanical impurities in the form of sand. The immersion depth of the pump reaches 2500 m and more, and the temperature of the pumped-out fluid sometimes reaches 100 0 C. Requirements for the formation fluid for the operation of a well with installations of electric centrifugal pumps are given in Table 1.1.

Table 1.1 - Permissible characteristics of formation fluid for well operation with ESP units

Technical characteristics of formation fluid

The value of the technical characteristics

Maximum associated water content,%

Associated water pH, pH

Maximum density of liquid, kg / m 3

Maximum kinematic viscosity of a single-phase liquid, at which the pump operates without changing the pressure and efficiency, mm 2 / s

Maximum mass concentration of solid particles for pumps, g / l:

Regular execution

Corrosion-resistant execution

Wear-resistant, corrosion-resistant design

Increased corrosion and wear resistance

When the pumps are equipped with a fine filter

Microhardness of particles according to Morse, points, no more:

Conventional, corrosion-resistant design

Increased corrosion and wear resistance, wear-resistant, corrosion-resistant performance

Maximum free gas content at the pump intake,% by volume:

Regular execution

With the use of a gas separator as part of the installation

With the use of a gas separator-dispersant

Using the inlet dispersing module as part of the installation

Maximum concentration of hydrogen sulfide for pumps, g / l:

Normal, wear-resistant design

Corrosion-wear-resistant design, increased corrosion-wear resistance

Maximum temperature of the pumped-out liquid, С

Maximum hydrostatic pressure in the suspension zone of the unit, MPa

The number of aggressive components, no more (when using pumps with increased corrosion-and-wear resistance, corrosion-wear-resistant design), g / l:

Wells in which the installations are operated must meet the following conditions:

a) the minimum inner diameter of the well for each size of the installation according to the technical description for pumps and motors;

b) the maximum rate of borehole curvature gain is 2є by 10 meters, and in the operating area of ​​the installation - 3 minutes by 10 meters;

c) maximum hydrostatic pressure in the suspension zone of the installation - 40 MPa;

d) in the area of ​​the submersible installation, the deviation of the wellbore from the vertical should be no more than 60 degrees.

1.2 Advantages and disadvantages of ESP

Submersible installations of centrifugal electric pumps are widely used in our country. The average flow rate of an oil well equipped with such a unit is 120-140 tons / day, while the flow rate of wells equipped with sucker rod pumping units is only 15 tons / day. A great advantage of these installations is ease of maintenance, a long turnaround time of work - 1 year. It is not uncommon for installations to operate at some fields for more than 2-3 years without lifting.

1.2.1 Advantages of electric submersible pumps

Wells equipped with submersible centrifugal electric pump units compare favorably with wells equipped with deep pumping units.

Here on the surface there are no mechanisms with moving parts, there are no huge metal-consuming machine tools - rockers and massive foundations necessary for their installation.

The use of such equipment makes it possible to put wells into operation immediately after drilling at any time of the year, even in the most severe winter months, without spending a lot of time and money on the construction of foundations and installation of heavy equipment. During the operation of the ESP wells, the wellhead can be easily sealed, which allows the collection and removal of associated gas. ESP units are characterized by the absence of an intermediate link of sucker rods, which increases the turnaround time of wells.

The field of application of pumping production from deep wells and forced withdrawal of fluid from heavily flooded wells, as well as directional wells, is expanding.

1.2.2 Disadvantages of electric centrifugal pumps

The disadvantages of rodless pumping units include: complex well repair when pipes fall, sometimes not leading to a result; complex equipment that requires a highly qualified electrician.

At high speeds, oil mixes with water; a large amount of energy has to be spent to separate oil from water. ESPs can also be used for inter-reservoir water injection and for maintaining reservoir pressures in oil deposits.

a) in the fluids of which there is a significant amount of sand, which causes rapid wear of the working parts of the pump;

b) with a large amount of gas, which reduces the pump performance.

1.3 Part of the equipment

The set of a submersible installation for oil production includes: an electric motor with hydraulic protection, a pump, a cable line, ground electrical equipment, an automatic control station (Figure 1.1).

The pump is driven by an electric motor and supplies the formation fluid from the well through the tubing to the surface into the pipeline.

The cable line provides power supply to the electric motor. It is connected to the electric motor by means of a cable gland.

1 - electric motor; 2 - protector; 3 - pump strainer; 4 - submersible centrifugal pump; 5 - special cable; 6 - guide roller; 7 - cable drum; 8 - autotransformer; 9 - automatic control station; 10 - belt for fastening the cable

Figure 1.1 - Layout of ESP equipment

The cable is attached to the hydraulic protection, pump and compressor pipes with metal belts included in the pump delivery set.

Ground electrical equipment - a complete transformer substation or control station with a transformer converts the voltage of the field network to a value that provides the optimal voltage at the output to the electric motor, taking into account voltage losses in the cable, provides control of the operation of the submersible installation and its protection under abnormal conditions. The electric pump is a unit consisting of a special oil-filled submersible AC motor, a protector that protects the engine from penetration of the surrounding liquid into it, and a multistage centrifugal pump. The housings of the electric motor, protector and pump are interconnected by means of flanges. The shafts have spline connections. In the assembled unit, the electric motor is located at the bottom, above it the protector, and above the protector the pump.

The electric pump is lowered into the well on tubing and suspended on a suspension washer without additional fixing in the well. The engine is powered by a special oil-resistant round three-core cable of the KRBK brand in flexible tape armor, which passes through a suspension washer and is reinforced to the pumping pipes with metal belts. On the surface, only a control station and an autotransformer are installed, and a pressure gauge and a valve are installed at the wellhead. To minimize the diametrical size of the submersible unit, a special flat cable KRBP in flexible tape armor is laid along it, protected from damage by ribs welded to the pump and protective casings.

Complete transformer substation or control station

and the transformer is installed and fixed on a foundation or pedestal at a distance of at least 20 m from the wellhead. The height of the foundations (pedestals) should be such that water flooding and snow drifting of the equipment installed on them are excluded. At a distance of 15-20 m from the wellhead, place the drum with the cable on a specially prepared flat area, placing it on a mechanized cable reel or on the supports on which the drum will rotate. The drum should be positioned so that its axis of rotation is perpendicular to an imaginary line drawn from the wellhead to the middle of the drum. It will be more convenient to lower the unit if you position the reel so that the cable rolls up from the top of it.

For the convenience of directing the cable into the well during its descent, a so-called cable roller is used, suspended above the wellhead at a low height.

Prepare and position tubing and tubing subs on the walkways or stands so that the pipe couplings are facing the wellhead, so that the pipes are in the field of view of the lifting unit operator and do not interfere with work with the cable. The outside and inside of the pipes must be clean.

When operating wells with submersible centrifugal electric pumps, the wellhead can be easily sealed, which allows the collection and removal of associated gas. Ground electrical equipment, due to its small size, low weight and the presence of protective covers, depending on climatic conditions, can be installed either directly in the open air or in a small unheated booth, but so that neither snow drifts nor floods interfere with normal uninterrupted operation wells.

A characteristic feature of submersible centrifugal electric pumps is ease of maintenance, cost-effectiveness, and a relatively long overhaul period of their operation. The duration of operation of pumps between lifts for repair in most cases exceeds 200 days, in many wells they operate without lifting for 2-3 years.

1.4 Aboutoverview of foreign installations

In the USA, submersible pumps are manufactured both in single-section and in two-, three- and four-section designs, depending on the set head.

A characteristic feature of Byron Jackson pumps, which distinguishes them from other pump designs, is the absence of a heel at the pump shaft in both single-section and multi-section pumps. The axial force acting on the end of the shaft as a result of the pressure developed by the pump and the mass of the shaft itself is perceived by the fifth, located in the seal (protector) section. In sectional pumps, the shafts are joined, abutting against each other and forming, as it were, a single shaft of great length. It makes sense to place the pump axle support in the seal section because heel in this case works in pure oil. Consequently, its reliability should be greater than that of the heel operating directly in the formation fluid.

In the first designs of Reda pumps, the axial shaft support was made in the form of duplex angular contact ball bearings located in the lower part in a special chamber.

In Byron Jackson pumps, the shaft length of 3 - 4 sections can reach 25 ... 30 m. The shafts are connected to each other and to the shaft of the seal section by means of splined couplings, their ends abut against each other through a pin or washer in the splined coupling.

To give stability to the shaft during operation, Byron Jackson proposed to use intermediate rubber-metal bearings, placing them in 6 stages. Unlike domestic designs, Byron Jackson rubber-metal bearings are not installed instead of the corresponding stages, but are mounted in the guide vanes.

Reda Pump pumps differ in the design of individual parts. First of all, it should be noted that Reda Pump pumps have a left-hand direction of rotation of the shaft when viewed from above.

The fishing head and base are made as separate structural elements so that they can be connected to both a single-section and multi-section pump. This contributes to the unification of parts and assemblies.

Most Reda Pump designs lack a heel at the top. Instead of the heel, a part of the impellers (up to 40%) is strictly fixed in the axial direction on the shaft with the help of stops fixed in the grooves on the pump shaft. Thus, the upper part of the impellers, the bushings of which abut against each other, are kept from axial movement.

In Byron Jackson submersible pumps, the axial forces from the floating-type impellers are perceived by the guide vanes simultaneously on two surfaces of the supports when the force is directed downward and on one surface when the impeller floats upward. This stage design is called two-bearing.

Double-bearing stages are also used by Reda Pump Co., Oil Dynamics and Oilline in cases where it is necessary to reduce the specific load on the bearing.

In contrast to the single-support stage design, the two-support stage, in addition to the main support resting on the guide vane collar, has a second support resting on the guide vane bushing. Thus, the total area is increased, the specific load on the support is reduced, wear is reduced and the durability is increased.

The double-support stage allows the support to be put into operation one by one, due to the thickness of the support washers or the corresponding axial dimensions of the collars.

Stages with unloading holes in the impeller are widely used in pumps from Reda Pump, Oilline and Oil Dynamics.

A stage of this design reduces the axial force by up to 25% and therefore does not need a second support. However, this reduces the efficiency by 4 ... 6%. In submersible pumps, the efficiency of the stages of which is already low, unloading holes in the impellers are not made.

Foreign companies pay great attention to the cleanliness of the flow channels of the working elements of the pumps, since the efficiency of the stages depends on this. Byron Jackson, for example, casts impellers and vanes in a pre-cast manner to ensure a clean, smooth flow channel surface.

The impellers, cast by a precision method, have a uniform thickness of discs, blades, bushings, strict concentricity of elements, which ensures the necessary balancing of all impellers.

2 . Patent study

2.1 Options for patent elaboration

2.1.1 Patent 66417 Russian Federation,E21B43 / 38

Submersible borehole pumping unit for oil production, sludge trap and safety valve of the submersible borehole pumping unit. Govberg Artem Savelyevich, Terpunov Vyacheslav Abelievich; applicant and patentee "Center for the development of oil production equipment (CPRNO) (SC)". - No. 2007113036/22, application. 04/10/2007; publ. 10.09.2007.

Technical solutions relate to devices for cleaning formation fluid in oil wells and can be used in the oil industry to protect submersible pumping equipment from the effects of mechanical impurities contained in the pumped fluid, mainly after hydraulic fracturing, during well development, as well as during production oil from sand-producing wells with a concentration of solids up to 5 g / l, as well as to protect pumping equipment from abnormal operating conditions when separating devices are clogged. A submersible borehole pumping unit for oil production, ensuring the achievement of the above technical result, includes a submersible pump, an electric motor and a sludge trap. In this case, the pumping unit is equipped with a safety valve made with the possibility of hydraulic connection of the pump intake with the annular space behind the sludge catcher, provided that the movement of the pumped liquid through the sludge catcher stops. The achieved technical result is to ensure effective protection of submersible pumping equipment from the effects of solids contained in the pumped liquid, without contaminating the bottomhole zone of the well, as well as protecting the pumping equipment from abnormal operating conditions when the sludge collector is overfilled and / or clogging of the separator with solids particles.

The relief valve includes a body with a bypass and a spool sleeve with a bypass. The spool sleeve is made with the ability to move under the influence of the flow of the liquid pumped by the submersible pump. A differential cavity is formed between the spool sleeve and the housing. The achieved technical result is to increase the sensitivity and response speed of the safety valve.

Known safety valve of a submersible borehole pumping unit for oil production, described in US patent 5494109 A, 02/27/1996, including a housing made with the ability to connect to a pipeline for supplying the pumped liquid to the pump intake. Bypass holes are made in the side wall of the housing. The valve also includes a spool sleeve with a bypass hole, located in the body with the possibility of axial movement in such a way that in the upper position of the sleeve it is possible to move the pumped liquid through the said bypass holes of the body and the sleeve to receive the pump bypassing the filter elements located at the inlet of the said pipeline. This protects the pump from disruption of the flow and the submersible motor from overheating when the filter elements are clogged with particles of mechanical impurities. The displacement of the spool sleeve to the upper position occurs by increasing the pressure in the annular space under the action of a differential piston, the rod of which is located in the axial bore of the valve body.

The main disadvantages of the prototype are the insufficient sensitivity and speed of the valve, which responds to an increase in pressure in the annulus caused by the cessation of fluid movement through the filter, and not to the very absence of movement of the pumped fluid.

The technical result achieved by the implementation of the utility model consists in increasing the sensitivity and response speed of the safety valve.

The safety valve of a submersible borehole pumping unit for oil production, ensuring the achievement of the above technical result, includes a housing with a bypass hole, which is configured to be connected to a pipeline for supplying the pumped liquid to the pump intake, a spool sleeve with a bypass hole located in the housing with the possibility of axial movement in such a way that in one of the positions of the sleeve it is possible to move the pumped liquid through the aforementioned bypass openings of the housing and sleeve. In this case, in contrast to the prototype, the slide sleeve is made with the possibility of moving under the influence of the flow of the pumped liquid by the submersible pump to a position at which the possibility of movement of the pumped liquid through the bypass holes of the housing and the sleeve is excluded. A differential cavity is formed between the spool sleeve and the housing in such a way that the direction of the resulting force acting on the spool sleeve when the safety valve is placed in the well is opposite to the direction of the action of the pumped fluid flow on the spool sleeve.

The bypass openings are made in the side wall of the housing and the sleeve, and the possibility of the pumped liquid moving through the bypass openings of the housing and the sleeve is provided in the lowest position of the spool sleeve relative to the operating position of the valve in the well.

The spool sleeve is equipped with a ball check valve designed to close the central hole of the sleeve when the fluid moves in the direction opposite to the direction of the fluid flow being pumped by the submersible pump.

The spool sleeve is spring-loaded in the direction of the impact on the sleeve of the flow of the liquid pumped by the submersible pump, while the force created by the spring is less than the mentioned resultant force in any position of the spool sleeve.

The safety valve of the pump unit is designed to connect the pump intake with the annular space behind the sludge catcher in the direction of movement of the pumped liquid, provided that the movement of the pumped liquid through the sludge catcher stops.

The safety valve (Figure 2.1) includes a body 23 with bypass openings 24 in the side wall, made with the possibility of connecting to a branch pipe or a liner behind the hydrocyclone separator. A spool sleeve 25 with radial bypass holes 26 in the side wall is installed inside the housing 24. The sleeve 25 is mounted with the possibility of axial movement. In the extreme lower position of the sleeve, the bypass holes 24 and 26 are aligned and it is possible to move the pumped liquid from the annular space to the pump intake. A differential cavity 27 is formed between the sleeve and the body in such a way that the direction of the resulting force acting on the spool sleeve (if there is overpressure in the cavity of the safety valve, i.e. when the safety valve is placed in the well) is opposite to the direction of action on the spool sleeve of the flow of the pumped liquids. The spool sleeve 25 is spring-loaded in the direction of the action of the flow of the pumped medium, while the force created by the spring 16 is less than the said resultant force in any position of the sleeve 25. In addition, the sleeve is equipped with a ball check valve 22, made with the possibility of closing the central hole of the sleeve when the liquid moves in downward direction after stopping the pump.

Figure 2.1 - Safety valve

When the sludge trap is filled with particles of mechanical impurities, the movement of the liquid through the safety valve stops, as a result of which the ball valve 22 closes, and the spool sleeve 25, under the influence of the pressure difference arising from the presence of the differential cavity 27, goes down and takes the lowest position, compressing the spring 16. Through the combined bypass openings 24 and 26, the working fluid enters the pump intake.

A safety valve for a submersible borehole pumping unit for oil production, including a housing with a bypass hole, which is configured to be connected to a pipeline for supplying the pumped liquid to the pump intake, a spool sleeve with a bypass hole, located in the housing with the possibility of axial movement in such a way that in one of the bushing positions, it is possible to move the pumped liquid through the said bypass openings of the housing and the bushing, characterized in that the spool bushing is movable under the influence of the flow of the liquid pumped by the submersible pump into a position at which the pumped liquid cannot move through the bypass openings of the housing and bushings, while a differential cavity is formed between the spool sleeve and the body in such a way that the direction of the resulting force acting on the spool sleeve when the safety valve is placed in well, opposite to the direction of action on the spool sleeve of the pumped liquid flow.

2.1.2 Patent 2480630 Russian Federation, F04D15 / 02,F04 D13/10

Bypass valve for a submersible centrifugal electric pump. Shramek V.B., Sablin A.Yu., Matveev D.F., Smirnov I.G .; applicant and patentee, Limited Liability Company "Russian Electrotechnical Company". - No. 2011139811/06; application 09/29/2011; publ. 04/27/2013.

The invention relates to oil production equipment and can be used in the production of formation fluid from a well, in particular for passing fluid from the inlet module (filter) or gas separator to the reception of a submersible borehole centrifugal electric pump (ESP), and for supplying fluid from the annular space to the pump in the case clogging of filter elements with particles of mechanical impurities.

Known safety valve submersible borehole pumping unit (patent No. 66417, E21B 43/38, publication date 2007.09.10), taken as a prototype, including a housing with bypass holes in the side wall, which is configured

hydraulic connection of the pump intake with the annular space behind the sludge catcher in the direction of movement of the pumped liquid, provided that the pumped liquid stops moving through the sludge catcher, a spool sleeve with radial bypass holes in the side wall. The sleeve is installed with the possibility of axial movement. In the lowest position of the sleeve, the bypass openings of the housing and the sleeve are aligned, and it is possible to move the pumped liquid from the annular space to the pump intake. In particular, the bushing is spring-loaded and equipped with a ball check valve configured to close the central bore of the bushing when the fluid moves in the opposite direction after the pump is stopped.

The disadvantages of the known safety valve of a submersible borehole pumping unit are:

Low reliability of the valve due to jamming of the spool sleeve when particles of mechanical impurities contained in the liquid enter the gap between the body and the spool sleeve;

Low probability of failure-free operation of the known valve, associated with low sensitivity of the valve, due to the low speed of movement of the spool sleeve in case of filling the sludge trap or clogging the separator with mechanical impurities. In this case, a breakdown of the pump supply can occur earlier than the spool sleeve moves to the position of alignment of the bypass holes of the sleeve and the housing, in which the fluid flows from the annular space to the pump intake;

Low maintainability of the valve, since it is impossible to replace parts of the safety valve without first dismantling it from the separator pipe and packer plug or hollow cylindrical liner, while disassembling the valve body to replace parts;

Placing a safety valve between the submersible motor and the downstream sludge trap significantly increases the length of the entire ESP unit, which creates additional difficulties when running and pulling the unit in the well, and also leads to the possible destruction of the most loaded elements, for example, the submersible motor flange connection, with the subsequent fall of the downstream equipment to the bottom of the well ... An increase in the weight and size characteristics of the installation leads to increased wear of the pump parts and a decrease in the uptime of the pumping installation during its operation in the zone of increased curvature of the well.

The objective of the invention is the creation of a bypass valve that allows to ensure the flow of formation fluid to the pump intake in case of clogging of the filter element of the inlet module or gas separator, while eliminating the occurrence of an emergency situation associated with the disruption of the supply of formation fluid by the pump and the failure of the ESP installation, followed by its rise from the well ...

The technical result obtained when solving the problem is to increase the reliability of the valve, maintainability, ease of use, increase the mean time between failures of the ESP installation.

The specified technical result is achieved in that the bypass valve for a submersible centrifugal electric pump, containing a housing with bypass openings, which is configured to be connected to a pipeline for supplying the pumped liquid to the pump intake, according to the invention is provided with a shaft installed in the housing with the ability to rotate and connect one end shaft with the shaft of the input module or gas separator, and the other end of the shaft with the shaft of the electric pump, while the bypass holes are located in the stepped part of the body at an angle to the central axis of the valve in the direction of the flow of the produced fluid, in each bypass hole there is a check valve, including a seat and a shut-off valve element installed in the check valve body with the ability to move.

Making the bypass holes at an angle to the central axis of the valve in the direction of the produced fluid flow allows to reduce the hydraulic resistance of the fluid flowing from the annulus through the valve bypass holes in case of clogging below the located inlet module or gas separator, which increases the pump head, its productivity, and increases the reliability of the valve operation. preventing disruption of the pump supply, which increases the MTBF of the ESP installation.

Installation of non-return valves in the bypass openings allows to increase the sensitivity of the valve actuation when the pressure in the annular space rises, which increases the speed and reliability of the valve, preventing the pump from stalling.

The assembly / disassembly of the valve improves the conditions for assembly / disassembly of the valve, which increases the maintainability of the valve.

Installing a shaft support in the valve body using a detachable connection, for example a threaded one, increases the maintainability of the valve.

Installing a check valve in the bypass hole using a detachable connection, for example, using a thread, allows you to quickly replace or repair it.

The design of the check valve closure element in the form of a ball ensures the tightness of the check valve in the closed position, and also, when the valve is opened, ensures self-centering of the ball in the cavity of the valve body. Point contact between the ball and the body when the ball moves along the axis of the check valve does not allow it to jam in the body, which increases the reliability of the bypass valve as a whole.

Spring loaded check valve ball in the opposite direction

the direction of the impact on the ball of the fluid flow coming from the annular space allows the valve to be used both in horizontal and inclined wells, which expands the functionality of the valve.

Implementation of the bypass valve in the form of an independent product having connecting elements on the body and at both ends of the shaft, for example, splined couplings for connecting to the shaft of the input module or gas separator and a pump, increases the ease of operation and maintainability of the valve.

Figure 2.2 shows a general view of the bypass valve for a submersible centrifugal electric pump. The bypass valve contains a stepped body 1 with an opening for the passage of liquid 2, made, for example, prefabricated, including the upper part 3 and the lower part 4 of the body. The shaft 5 is installed in the housing 1, fixed, in particular, in the bearing support 6, in which the radial sliding bearings 7 are installed. In the support 6, channels 8 are made for the passage of the pumped liquid. The bearing support 6 is fixed in the housing 1 by means of a detachable connection, for example, a thread. At the ends of the shaft 5, splined couplings 9 and 10 are installed to connect the shaft 5 with the shaft of the input module or the gas separator and the shaft of the ESP pump, respectively (not shown). In the stepped part of the body 1, there are overflow holes 11 located at an angle to the central axis of the valve in the direction of flow of the produced fluid. A check valve 12 is installed in each bypass hole 11. The check valve 12 contains a valve pair including a seat 13 and a spring-loaded closing element (ball) 15 mounted in a hole 16 of the body 17 of the check valve 12 with the ability to move. The non-return valves 12 are installed in the overflow openings 11 using, for example, a threaded connection.

Figure 2.2 - Bypass valve

The body 1 contains a connecting flange 18 with holes 19 for fastening elements, allowing the bypass valve to be mounted to an inlet module (not shown). The body 1 is equipped with fasteners (pins) 20 for connection with the ESP pump body.

When the pumping unit is turned on, the formation fluid, which is under the pressure of the liquid column in the well, flows from the inlet module or gas separator (not shown), through hole 2 into the bypass valve, passes through the channels 8 of the bearing support 6 and enters the ESP intake. In this case, the ball 15 of the check valve 12 is pressed against the seat 13 by the spring 14, which excludes the supply of formation fluid from the annular space through the bypass holes 11 into the bypass valve and, accordingly, to the intake of the ESP pump. In the event of partial or complete clogging of the inlet module or gas separator (not shown) with particles of mechanical impurities, an increase in the pressure drop between the pressure of the liquid outside and the liquid in the inner cavity of the bypass valve occurs. In this case, the check valve 12 opens, in which the ball 15 moves from the seat 13, compressing the spring 14 of the check valve 12. The formation fluid through the hole 16 of the check valve 12 flows from the annular space into the body 1 of the bypass valve and further, passing through the channels 8 of the bearing support 6, leaves the valve and enters the pump intake, providing it with liquid to continue operation, which prevents the electric pump from stalling.

2.2 Patent studybypass valve

The purpose of the patent study is to improve the bypass valve for a submersible centrifugal electric pump (patent No. 2480630, F04D15 / 02, F04D13 / 10).

One of the main elements of the bypass valve (Figure 2.2) is a check valve, which serves to supply formation fluid in case of partial or complete clogging of the inlet module or gas separator with particles of mechanical impurities. The disadvantage of this design is the rapid clogging of the check valve due to the ingress of large particles into the check valve opening. This problem is very relevant for wear-resistant electric submersible pumps. The solution is to install a receiving filter mesh 13 (Figure 2.3) on the path of formation fluid movement into the check valve 1, which serves to filter from large mechanical particles. This constructive implementation will increase the operating time of the bypass valve in normal operation, and therefore the life of the pump.

The installation of the bypass valve of the considered design is complicated due to the absence of a groove for installation in the elevator mounting clamp. The solution is to cut a groove in the area of ​​the head 5 of the bypass valve, which will simplify the installation process, increase its speed and make it similar to the installation process of other pump sections.

Figure 2.3 - Upgraded bypass valve

Also, in the modernized design of the bypass valves, upper 9 and lower 10 covers are made, which serve to protect the internal cavity from contamination during storage and transportation.

The disadvantage of this design of the modernized unit is the increased overall size in the axial direction in comparison with the patent under consideration.

3 . The device and principle of operation of the pump

The ESP unit consists of a submersible pumping unit (an electric motor with hydraulic protection and a pump), a cable line (round and flat cable with a cable entry sleeve), a tubing string, wellhead equipment and ground electrical equipment: a transformer and a control station (or a complex device) ...

A submersible pumping unit, consisting of a pump and an electric motor with hydraulic protection, is lowered into the well on tubing. The cable line provides power supply to the electric motor. The cable is attached to the tubing with metal belts.

Along the length of the pump and protector, the cable is flat, attached to them with metal belts and protected from damage by casings or clamps.

Check and drain valves are installed above the pumps. The pump pumps fluid from the well and delivers it to the surface through the tubing string. The wellhead equipment provides suspension on the flange of the tubing casing with an electric pump and cable, sealing pipes and cables, as well as draining the liquid into the flowline.

Submersible pump, centrifugal, sectional, multistage. Submersible electric motor, three-phase, asynchronous, oil-filled with a squirrel-cage rotor. The hydraulic protection of the electric motor consists of a protector and a compensator. Two-chamber protector with rubber diaphragm and mechanical shaft seals, compensator with rubber diaphragm. Three-core cable with polyethylene insulation.

The transformer supplies the required voltage to the submersible electric motor, the control station is designed to control the submersible electric pump and turn off the entire installation when it is disconnected from its normal operation.

The submersible pump, electric motor and hydraulic protection are connected by flanges and studs. The shafts of the pump, motor and protector have splines at the ends and are connected by splined couplings.

The submersible centrifugal pump does not differ in its principle of operation from conventional centrifugal pumps used for pumping liquids. Its difference is that it is sectional, multistage, with a small diameter of working stages - impellers and guide vanes. Mainly for the oil industry, submersible pumps contain 130 to 415 stages.

A centrifugal pump is a simple hydraulic machine designed to lift and transport fluid from one location to another through a pipeline. The pump mainly consists of a vane impeller, a guide vane, a shaft and a casing.

The principle of operation of the pump, with some simplification, can be imagined as follows: the liquid sucked through the filter and the suction valve enters through the nozzle to the blades of the rotating wheel, under the action of which it acquires speed and pressure. The submersible pump has many stages and this process is repeated in each stage, gaining high speed and pressure. The kinetic energy of the fluid is converted into pressure in the spiral channel. At the outlet of the pump, the liquid stream is collected and directed to the tubing string.

The main parameters of the pump are: flow rate, head, suction head, power consumption and efficiency. Pump parameters indicate when it is running on water.

3.1 Pump layout

Submersible electric centrifugal pumps are designed according to the sectional principle and generally consist of an inlet module (MV), middle sections (CC), upper section (CB), check (KO) and drain (CC) valves (Figure 3.1, a). At a high gas content, the pump includes a pumping module - gas separator (MNG) (Figure 3.1, b). The design provides options for completing the pumps with the lower section (CH), which has a receiving grid, while the input module is excluded from the pump (Figure 3.1, c). When using the lower section, the gas separator cannot be included in the pump. A gas separator with a receiving grid (MNGN) can be included in the pump with a high gas content (Figure 3.1, d). There is no need for an input module.

Pumps, depending on the transverse dimensions, are manufactured in three groups: 5, 5A and 6. The group conventionally determines the minimum inner diameter of the production string, which is 123.7 mm for group 5, 130 mm for 5A, and 148.3 mm for 6. The pump casing diameters are respectively 92, 103 and 114 mm.

Figure 3.1 - ESP layout

3.2 Module structure and pump operation

The submersible pump is assembled from the MV inlet module, the MNG pump-gas separator module, the middle section CC (one + four), the upper section CB, which are connected to each other by flanges using pins and bolts.

The check valve is screwed into the fishing head of the upper section, the drain valve is screwed into the check valve. The pump is driven by a submersible electric motor. The pumped liquid through the inlet module enters the gas separator, where the associated gas is separated, then in the pump section, where the required pressure is created. Through the check and drain valve, the liquid enters the pressure pipeline-tubing string. The non-return and drain valves can be installed above the fishing head of the pump by 6 ... 7 tubing.

The input module is used to receive and roughly clean the pumped liquid, to connect the sections to the engine and transmit torque from the motor shaft to the pump section shafts. The input module is shown in Figure 3.2 and consists of a base 1, with holes for the passage of formation fluid, in which shaft 2 rotates on plain bearings. With studs 5, the upper end of the module is attached to the middle section of the pump or to the pump-gas separator module. The lower flange attaches the inlet module to the protector using studs and nuts. For the period of transportation and storage, the input module is closed with covers 6 and 7.

The pump-gas separator module (gas separator) is designed to reduce the volumetric content of free gas at the inlet to the pump section. The MNG gas separator is shown in Figure 3.3 and consists of a tubular body 1 with a head 2, a base 3 at its ends and a shaft 4 with parts located in it. A nut 5 is installed in the body, securing a package of working bodies through a stop 6, a bearing 7, a spacer sleeve 8, guide vanes 9, 10 and a support ring 11. On the shaft there are radial bearing bushings 12, a splined coupling 19, auger 13, an impeller 14, bushings 15, grid 16 and separators 17. A sub 18 is pressed into the head 2, forming a cross-flow coupling with the head, a perforated pipe 20 is fixed outside the head, which acts as an additional separating unit.

For the period of transportation and storage, the gas separator is closed with covers 21 and 22.

The base is attached to the gas separator with studs and nuts to the inlet module. The gas separator head is flanged to the middle section of the pump and is attached to it with pins or bolts. The shafts are connected using splined couplings. The base of the gas separator has a version with a receiving grid, in this case the input module is not needed and the gas separator is connected directly to the protector (MNGN version).

Figure 3.3 - Pump-gas separator module

The gas separator works as follows. The gas-liquid mixture flows through the inlet module or the mesh of the base of the gas separator onto the auger and further to the working elements. Due to the acquisition of pressure, the gas-liquid mixture enters the rotating chamber of the separator, equipped with radial ribs, where, under the action of centrifugal forces, the gas is separated from the liquid. Further, the liquid from the periphery of the separator chamber enters through the slots of the sub to the pump intake, and the separated gas-liquid mixture enters the cavity of the perforated pipe, where additional separation of gas and liquid takes place. This liquid flows out through the openings of the branch pipe, flows from the outside along the gas separator body and again enters the inlet. This reduces the content of gas in the mixture entering through the inlet module into the gas separator. Gas is discharged through the perforated branch pipe into the annular space. Gas separators MNG (K) 5, MNGN (K) 5 are used with pumps with a capacity of up to 250 m3 / day, and MNG (K) 5A, MNGN (K) 5A - with pumps with a capacity of up to 400 m3 / day.

The middle section is shown in figures 3.4 and is the main part of the pump. The middle section consists of a housing 1, a shaft 2, a package of stages (impellers 3 and guide vanes 4), an upper bearing 5, a lower bearing 6, intermediate bearings 17, an upper axial support 7, a head 8, a base 9, two ribs 10, rubber rings 11, 13, splined coupling 14 and covers 15 and 16. Impellers and guide vanes are installed in series. The guide vanes in the housing are pulled together by the upper bearing and the base and are stationary during operation. The impellers are seated through a key on a shaft that drives them into rotation. When the wheels rotate, the pumped liquid receives an increase in pressure from stage to stage.

The upper intermediate 5 and lower 6 bearings are radial bearings of the shaft, and the upper axial support 7 receives loads acting along the axis of the shaft. Rubber rings 11 seal the inner cavity of the section from leaks by the pumped and inlet module.

Spline clutch 14 is used to connect to the shaft of a docked section or inlet module or gas separator or protector and transfers rotation from one shaft to another. For the period of transportation and storage, the section is closed with lids.

Ribs 10 are designed to protect the electric cable located between them from mechanical damage to the wall of the casing pipes when the pump is running and ascending. The ribs are attached to the base of the section with a bolt and nut.

The check valve, shown in Figure 3.5, is designed to prevent reverse rotation of the pump impellers under the influence of the liquid column in the pressure pipeline when the pump stops and to facilitate its restart; it is used to pressurize the tubing string after running the unit into the well.

The check valve consists of a body 1, on one side of which there is an internal tapered thread for connecting a drain valve, and on the other side there is an external tapered thread for screwing into the fishing head of the upper section. Inside the body there is a rubberized seat 2, on which the plate 3 rests. The plate has the possibility of axial movement in the guide sleeve 4. Under the influence of the flow of the pumped liquid, the plate rises, thereby opening the valve. When the pump stops, the disc is lowered onto the seat under the influence of the liquid column in the pressure pipe, the valve closes.

Figure 3.5 - Check valve

The drain valve is shown in Figure 3.6 and is designed to drain fluid from the pressure pipeline (tubing string) when lifting the pump from the well. The drain valve consists of a body 1, on one side of which there is an internal tapered thread of the coupling for connection to the tubing, having a nominal diameter of 73 mm, and on the other side, an external tapered thread for screwing into the check valve.

Figure 3.6 - Drain valve

A choke 2 is screwed into the body, which is sealed with a rubber ring 3. Before lifting the pump out of the well, the end of the choke, located in the inner cavity of the valve, is knocked off (broken off) by a special tool, and the liquid from the tubing string flows out through the hole in the choke into the annulus. For the period of transportation and storage, the check valve is closed with covers 4 and 5. Submersible electric motors used to drive centrifugal pumps, asynchronous with squirrel-cage rotors, oil-filled. At a current frequency of 50 Hz, the synchronous shaft speed is 3000 rpm. The motors, as well as pumps, have small diameters, which are different for wells with casing strings of 140, 146 and 168 mm. At the same time, their power can reach 125 kW. In this regard, the engines are sometimes more than 8 m long.

To protect the electric motor from getting into its internal cavity of formation fluid, to compensate for changes in the volume of oil in the engine when it is heated and cooled, and also to avoid oil leaks through leaks, a hydraulic protection (protector) is used.

The hydraulic protection is located between the engine and the pump and, creating an overpressure, at the same time supplies thick oil to the gland of the centrifugal pump, preventing the leakage of the produced fluid.

Electricity is supplied to the submersible motor via a special armored cable. The main part of the cable has a circular cross-section. A flat cable is laid over the submersible unit (pump, hydraulic protection, motor head), corresponding to the required diametrical dimensions of the unit.

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I have long dreamed of writing on paper (printing on a computer) everything I know about ESPs.
I will try to tell you in simple and understandable language about the Installation of the Electric Centrifugal Pump - the main tool that produces 80% of all oil in Russia.

Somehow it turned out that all my conscious life I have been connected with them. From the age of five he began traveling with his father in the wells. At ten he could repair any station himself, at twenty-four he became an engineer at the enterprise where they were being repaired, at thirty - deputy general director, where they are made. Knowledge on the subject in bulk - it's not a pity to share, especially since many, many people constantly ask me about this or that concerning my pumps. In general, so that I do not repeat the same thing many times in different words - I will write it once, and then I will take exams;). Yes! There will be slides ... there will be no slides.


What it is.
ESP - installation of an electric centrifugal pump, she is a rodless pump, she is ESP, she is those sticks and drums. ESP - it is she (female)! Although it consists of them (male). This is such a special thing with the help of which valiant oilmen (or rather servicemen for oilmen) get formation fluid from under the ground - this is how we call that dummy, which later (after undergoing special processing) is called by all sorts of interesting words like URALS or BRENT. This is a whole complex of equipment, which would require the knowledge of a metallurgist, metalworker, mechanic, electrician, electronics engineer, hydraulics, cable operator, oilman and even a little gynecologist and proctologist. The thing is quite interesting and unusual, although it was invented many years ago, and has not changed much since then. By and large, this is a conventional pumping unit. Unusual in it is that it is thin (the most common is placed in a well with an inner diameter of 123 mm), long (there are installations of 70 meters long) and works in such filthy conditions in which a more or less complex mechanism should not exist at all.

So, each ESP unit has the following units:

ESP (electric centrifugal pump) - the main unit - all the others protect and provide it. The pump gets the most - but it does the main work - lifting the liquid - that's how it is with it. The pump is made up of sections, and the sections are made up of stages. The more steps there are, the more pressure the pump develops. The larger the stage itself, the greater the flow rate (the amount of liquid pumped per unit of time). The more flow rate and pressure, the more energy it consumes. Everything is interconnected. In addition to the flow rate and pressure, the pumps also differ in size and design - standard, wear-resistant, corrosion-resistant, wear-corrosion-resistant, completely wear-corrosion-resistant.

SEM (submersible electric motor) The electric motor is the second main unit - turns the pump - consumes energy. This is a conventional (electrically) induction motor - only thin and long. The engine has two main parameters - power and size. And again, there are different versions of standard, heat-resistant, corrosion-resistant, especially heat-resistant, and in general - not killable (as if). The engine is filled with special oil, which, in addition to lubricating, also cools the engine, and compensates for the pressure exerted on the engine from the outside.

The protector (also called hydraulic protection) is a piece that stands between the pump and the engine - firstly, it divides the engine cavity filled with oil from the pump cavity filled with formation fluid, while transmitting rotation, and secondly, it solves the problem of equalizing the pressure inside the engine and outside ( there generally it happens up to 400 atm, this is about a third of the depth of the Mariana Trench). There are different sizes and, again, all sorts of blah blah blah performances.

Cable is actually a cable. Copper, three-core .. It is also armored. Can you imagine? Armored cable! Of course, it will not withstand a shot even from Makarov, but it will withstand five or six runs into the well and will work there - for a long time.
His armor is somewhat different, calculated more for friction than for a sharp blow - but all the same. The cable can be of different cross-sections (core diameters), differs in armor (ordinary galvanized or stainless steel), and it also differs in temperature resistance. There is a cable for 90, 120, 150, 200 and even 230 degrees. That is, it can work indefinitely at a temperature twice the boiling point of water (note - we seem to be producing oil, and it doesn’t even burn very sickly - but we need a cable with a heat resistance of over 200 degrees - and almost everywhere).

Gas separator (or gas separator-dispersant, or just a dispersant, or a double gas separator, or even a double gas separator-dispersant). The thing that separates free gas from liquid .. or rather liquid from free gas ... in short, reduces the amount of free gas entering the pump. Often, very often, the amount of free gas at the inlet to the pump is quite enough so that the pump does not work - then they put some kind of gas stabilizing device (I listed the names at the beginning of the paragraph). If there is no need to install a gas separator, an inlet module is installed, how should liquid get into the pump? Here. They put something in any case .. Either a module, or a gazik.

TMS is a kind of tuning. Who decrypts how - thermomanometric system, telemetry .. who how. That's right (this is the old name - from the 80 shaggy years) - a thermomanometric system, and we will call it that way - it almost completely explains the function of the device - it measures temperature and pressure - there - right below - practically in the underworld.

There are also protective devices. This is a check valve (the most common - KOSH - ball check valve) - so that the liquid does not drain out of the pipes when the pump is stopped (lifting a column of liquid through a standard pipe can take several hours - it’s a pity for this time). And when you need to raise the pump - this valve gets in the way - something is constantly pouring out of the pipes, foul everything around. For these purposes, there is a knockdown (or drain) valve of the KS - a funny thing - which is broken every time when it is lifted out of the well.

All this economy hangs on tubing (tubing - fences from them are made very often in near-oil cities). Hangs in the following sequence:
Along the tubing (2-3 kilometers) - a cable, on top - KS, then KOSH, then ESP, then gas (or input module), then protector, then SEM, and even lower TMS. The cable runs along the ESP, gas and protector to the very head of the engine. Eka. Everything over and above is shorter. So - from the top of the ESP to the bottom of the TMS can be 70 meters. and a shaft passes through these 70 meters, and it all revolves ... and around there is a high temperature, a huge pressure, a lot of mechanical impurities, a corrosive environment .. Poor pumps ...

All the pieces are sectional, sections no more than 9-10 meters long (otherwise how can they be shoved into the well?) The installation is assembled directly at the well: a submersible motor, a cable, protector, gas, pump, valve, pipe sections are attached to it .. Yes! do not forget to attach the cable to everything with the help of clamps - (such special steel belts). All this is dipped into a well and (I hope) works there for a long time. To power all this (and somehow manage it), a step-up transformer (TMPN) and a control station are placed on the ground.

This is the kind of thing they get that then turns into money (gasoline, diesel fuel, plastics and other garbage).

Let's try to figure it out .. how it all works, how it is done, how to choose and how to use it.

The area of ​​application of centrifugal pumps in oil production is quite large: at a flow rate of 40-1000 m 3 / day; for heads 740-1800 and (for domestic pumps). These pumps are most effective when operating in wells with high flow rates. However, for ESP there are restrictions on well conditions, for example, high gas-oil ratio, high viscosity, high content of mechanical impurities, etc.

The creation of pumps and electric motors in a modular design makes it possible to more accurately select the ESP to the characteristics of the well in terms of flow rates and heads. All these factors, taking into account the economic feasibility, should be taken into account when choosing the methods of well operation.

Installations of submersible pumps are lowered into the well on tubing of the following diameters: 60 mm at a liquid flow rate Q No. up to 150 m 3 / day, 73 mm at 150< Q» < 300 м 3 , - сут. 89 мм при Q e >> 300 m 3 / day The design characteristics of the ESP are given for water, and for specific liquids (oil) they are refined using correlation coefficients. It is advisable to select a pump for flow rates and heads in the area of ​​the highest efficiency of the minimum required power. ESP units can handle liquids containing up to 1.25 g / l H, S, while conventional installations can handle liquids containing up to 0.01 g / l H: S.

Conventional pumps are recommended for wells with a content of mechanical impurities in the pumped liquid up to 0.1 g / l; pumps of increased wear resistance - for wells with a content of mechanical impurities in the pumped out fluid over 0.1 g / l, but not more than 0.5 g / l; pumps of increased corrosion resistance - for wells with a hydrogen sulfide content of up to 1.25 g. l and a pH value of 6.0-8.5.

For the selection of corrosive formation fluids or fluids with a significant content of mechanical impurities (sand), diaphragm borehole pumping units are used. They are electrically driven positive displacement plunger pumps.

The ESP installation includes a submersible electric pump unit that combines an electric motor with a hydraulic protection and a pump; cable line lowered into the well on lifting tubing; wellhead equipment such as OUEN 140-65 or Christmas tree. AFK1E-65x14; control station and transformer, which are installed at a distance of 20-30 and from the wellhead. Electricity is supplied to the engine via a cable line. The cable is attached to the pump and tubing with metal belts. A check and drain valves are installed above the pump. The pumped liquid from the well enters the surface through the tubing string. The submersible electric pump, electric motor and hydraulic protection are connected by flanges and studs. The shafts of the pump, motor and protector have splines at the ends and are connected by splined couplings.

ESP applicability criterion:

  • 1 The industry produces pumps for the extraction of liquid 1000 m3 per day at a head of 900 m
  • 2 The content of hydrogen sulfide in the extracted products - up to 0.01
  • 3 Minimum content of associated water up to 99%
  • 4 Content of mechanical impurities up to 0.5
  • 5 Content of free gas no more than 25%

The explanation of the symbols of installations is given on the example of U2ETsNI6-350-1100.

У - installation; 2 (1) - modification number;

E - driven by a submersible electric motor;

Ts - centrifugal;

H - pump;

I - increased wear resistance (K - increased corrosion resistance);

  • 6 (5; 5A) - installation group;
  • 350 - pump flow in optimal mode by water in m 3 / day;
  • 1100 - the head developed by the pump in meters of the water column.

The submersible centrifugal pump installation includes submersible and surface equipment. The submersible equipment includes: an electric pump unit, which is lowered into the well under the liquid level on the tubing string. The electric pump unit consists of: an electric motor with hydraulic protection, a gas separator, a centrifugal pump, as well as a check and drain valves. Surface equipment includes: electrical equipment of the installation and wellhead equipment of the well (casing head and wellhead fittings tied to a flow line). Electrical equipment, depending on the current supply scheme, includes either a complete transformer substation for submersible pumps (KTPPN), or a transformer substation (TP), a control station and a transformer. Electricity from the transformer to the submersible motor is supplied through a cable line, which consists of a ground power cable and a main cable with an extension cord. The connection of the ground cable with the main cable of the cable line is carried out in the terminal box, which is installed at a distance of 3-5 meters from the wellhead.