A new centrifugal pump has been devised to handle two-phase flow. However, it requires full scale testing to allow further development. Testing is required to verify performance and to gain information needed to apply this design in the field. Further, testing will allow mathematical models to be validated which will allow increased understanding of the pump's behavior. To perform this testing, a new facility was designed and constructed. This facility consists of a closed flow loop. The pump is supplied by separate air and water inlet flows that mix just before entering the pump. These flows can be controlled to give a desired gas volume fraction and overall flow rate. The pump outlet flows into a tank which separates the fluids allowing them to re-circulate. Operating inlet pressures of up to three hundred PSIG will be used with a flow rate of twelve hundred gallons per minute. A two-hundred fifty horsepower electric motor is used to power the pump. The loop is equipped with instrumentation to measure temperature, pressure, flow rate, pump speed, pump shaft horsepower, shaft torque, and shaft axial load. The pump itself has a clear inlet section and a clear section allowing visualization of the second stage volute interior as well as numerous pressure taps along the second stage volute. This instrumentation is sufficient to completely characterize the pump. Design and construction details are provided as well as a history of the initial operating experiences and data collected. A discussion of lessons learned is given in the conclusions. Future projects intended to use this facility are also given. Finally, detailed design drawings are supplied as well as operating instructions and checklists.

There are some alternatives of artificial lift methods to increase the production of oil well or to keep it producing. Sucker rod pumping (SRP) and electrical submersible pumping (ESP) systems are selected for the design and economical evaluation of thirteen oil wells of R field. Although selected wells are already producing artificially, they are redesigned for SRP and ESP. LoadCalC software developed by Lufkin and SubPUMP developed by DSSC are used for SRP and ESP designs respectively. For economic evaluation, the rate of return (ROR) of each design is calculated for ten year period. In technical comparison, advantage of higher production ability with lower power consumption was observed in ESP applications. In wells which have lower production than 100 bpd, SRP takes the advantage as it has the ability of low volume lifting. In economical comparison it was observed that using both methods together was given better result. By increasing the number of wells that were applied ESP, 3.61% of increment in ROR was obtained relative to the present status.

Orientadores: Antonio Carlos Bannwart, Marcelo Moreira Ganzarolli / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica e Instituto de Geociências / Made available in DSpace on 2018-08-22T03:35:14Z (GMT). No. of bitstreams: 1 Betonico_GustavodeCarvalho_M.pdf: 2382106 bytes, checksum: a84e8f76b2a2dcf28078dd9283ecef59 (MD5) Previous issue date: 2013 / Resumo: Neste trabalho foi desenvolvido um modelo para determinação da temperatura do motor de uma bomba centrífuga submersa (BCS) sob condições variáveis de vazão e carga. Este leva em consideração o comportamento acoplado entre o motor, a bomba e o sistema de produção. Assim, dada uma frequência ajustada no variador de frequência, a temperatura do motor é determinada como resultado do equilíbrio entre a produção de calor, calculada a partir da potência que a bomba demanda do motor, e a extração do calor, calculada a partir da vazão. Neste modelo, considera-se a BCS instalada num módulo de bombeamento submarino localizado perto do poço produtor. Foi estudada a transferência de calor por convecção no módulo de bombeio, onde um escoamento descendente ocorre no anular externo entre o revestimento e a camisa de refrigeração e um fluxo ascendente ocorre no anular interno entre a camisa de refrigeração e o motor. Um estudo de transferência de calor por convecção foi elaborado comparando modelos baseados no perfil de temperatura plenamente desenvolvido com modelos que consideram o desenvolvimento da camada limite térmica. Uma vez que o único ponto de medição da temperatura se localiza na extremidade inferior do enrolamento de estator, o modelo desenvolvido neste trabalho também determina a distribuição de temperatura do motor. Um estudo de caso foi realizado com diversas viscosidades de óleo e frações de água. Os resultados mostram a elevação da temperatura do motor, quando sua velocidade é continuamente aumentada. Também se mostrou que, negligenciar os efeitos do desenvolvimento da camada limite térmica, quando ocorre escoamento laminar, pode resultar num motor superaquecido, onde na verdade, a temperatura máxima do motor é muito menor do que o seu limite superior. Modelos baseados no perfil temperatura plenamente desenvolvidos sofrem de imprecisão, quando utilizados em aplicações de fluidos viscosos, devido ao grande comprimento entrada térmica / Abstract: A model to predict the motor temperature of an electrical submersible pump, under variable conditions of flow rate and loading, has been developed. This model takes into account the coupled behavior between motor, pump and production system. Thus, given a frequency set in the variable speed drive, the motor temperature is determined as a result of the equilibrium between the heat generation, calculated from the power that the pump demands from the motor, and the heat extraction, calculated from the flow rate. In this model, the electrical submersible pump is supposed to be installed in a subsea pumping module located near the producer well. It has been studied the convective heat transfer in the pumping module, where a downward flow occurs in the external annulus between the casing and the shroud, and an upward flow happens in the internal annulus between the shroud and the motor. A convective heat transfer study has been run comparing models based on fully developed temperature profile and models that consider the development of the thermal boundary layer. Since the only point of temperature measurement is located at the lower end of the stator winding, the model developed in this work also determines the temperature distribution of the motor. A case study has been run with several oil viscosities and water cut. The results show a motor temperature rise when motor speed is continuously increased. It is also showed that, when laminar flow occurs, neglecting the effect of the thermal boundary layer development may result in an overheated motor prediction where actually, motor maximum temperature is much smaller than its upper limit. Fully developed temperature profile models suffer of inaccuracy when used in viscous fluid applications, due to its big thermal entry length / Mestrado / Explotação / Mestre em Ciências e Engenharia de Petróleo

The Electrical Submersible Pump (ESP) manufactured by Baker Hughes, model no. WJE-1000 is designed for wells that are expected to have a high content of abrasive solids. It is a mixed flow, tandem compression type pump. Although the erosion of the pump diffuser and impeller stages are significant, the ESP study shows that the most sever failure is due to components that affect the pump’s rotor dynamics such as radial bearings and impeller seals when eroded with 100 mesh sand. Erosion of these seals will result in an internal leakage that can significantly affect stage pressure rise, efficiency, power consumption, vibration, pump life and running cost. The erosion study utilizing 100 mesh fracture sand at 0.2% concentration, with the pump operating at 3600 RPM, 40 PSI intake pressure, 1150 GPM for over 117 hours comparisons are made to the pump’s baseline performance. Measurements of the rotor bearings, impeller seals and their corresponding stators showed that the wear patterns generally increase with time and differ by location. Stage 1 bearings and seals suffered the least amount of erosion and stage 3 rotor components suffered the most erosion. The maximum change in stage 3 bearing clearances was 223% and the maximum change in stage 3 impeller seal clearances was 300%. Performance wise the total pump efficiency dropped by 6.77%, the total pressure rise dropped by 6.3%, the pump’s best efficiency point decreased by 0.78%, and the power consumption increased by 0.49%. Pump vibration patterns also changed with time and by location. The maximum shaft orbit diameter was at stage 3 and it grew 643% in diameter after 117 hours of erosion. The waterfall plots of the pump’s ramp up changed significantly with time. After 117 hours at 3600 RPM, sub-synchronous oscillations at 67% of the synchronous speed dominated the amplitude peaks showing that the rotor vibration locked with the rotor’s first natural frequency at around 2500 RPM. After 117 hours, another sub-synchronous started showing a peak at the rotor’s second natural frequency at 1500 RPM.

Variable frequency drives (VFD) and subsea (umbilical) cables are frequently used in electrical submersible pump (ESP) systems for offshore platforms. There are two basic system configurations for ESP systems; VFD can be installed on the platform and the motor is connected to it through an umbilical cable, and VFD and the motor are installed closely and they are connected to the system through an umbilical cable. In this thesis, the pros and cons of each configuration are mentioned, but the focus is on the system with a VFD controlled motor through a long umbilical cable. A 36-pulse VFD is studied. Since multilevel VFDs have high frequency harmonics, high frequency modeling of the umbilical cable is used, and skin effect is also taken into consideration in the cable. The effect of the interactions between the umbilical cable and high frequency harmonics on the motor terminal voltage is explored.

A polycrystalline diamond was tested as a bearing material for a tilting pad thrust bearing to be used in an electric submersible pump, which elevates process fluids from the bottom of well bores. The goal of this study was to compare the PCD to a current best of technology, which is stainless steel with an engineering polymer.This study found that PCD can handle larger loads than current technology but is limited in size due to diamond sintering and manufacturing constraints. The maximum size is Ø75mm.

A polycrystalline diamond was tested as a bearing material for a tilting pad thrust bearing to be used in an electric submersible pump, which elevates process fluids from the bottom of well bores. The goal of this study was to compare the PCD to a current best of technology, which is stainless steel with an engineering polymer.This study found that PCD can handle larger loads than current technology but is limited in size due to diamond sintering and manufacturing constraints. The maximum size is Ø75mm.

A computer program has been written to perform production optimization in submersible pump lifted wells.Production optimization was achieved by the principles of Nodal Analysis Technique which was applied between the reservoir and the wellhead ignoring the surface choke and separator.computer program has been written according to two lifting environment,which are:pumping with only liquid,pumping with both liquid and gas.

Submitted by Vanessa Christiane (referencia@ufersa.edu.br) on 2018-03-28T22:17:06Z No. of bitstreams: 1 AllisonCC_DISSERT.pdf: 23495470 bytes, checksum: 71481acfb5946c94f60433199d92a734 (MD5) / Approved for entry into archive by Vanessa Christiane (referencia@ufersa.edu.br) on 2018-06-18T16:53:38Z (GMT) No. of bitstreams: 1 AllisonCC_DISSERT.pdf: 23495470 bytes, checksum: 71481acfb5946c94f60433199d92a734 (MD5) / Approved for entry into archive by Vanessa Christiane (referencia@ufersa.edu.br) on 2018-06-18T17:02:20Z (GMT) No. of bitstreams: 1 AllisonCC_DISSERT.pdf: 23495470 bytes, checksum: 71481acfb5946c94f60433199d92a734 (MD5) / Made available in DSpace on 2018-06-18T17:02:29Z (GMT). No. of bitstreams: 1 AllisonCC_DISSERT.pdf: 23495470 bytes, checksum: 71481acfb5946c94f60433199d92a734 (MD5) Previous issue date: 2017-08-28 / The reduction of power consumption and operational costs in petroleum industry has become an increasingly concernment in the last years. Due to that the search for new petroleum production methods and the use of process controlling techniques integrated to its artificial lift systems for optimizing that process plays a main role, and the development of well pump controllers is the main study object. The work proposes the implementation of a control system for oil wells equipped with ESP (Electrical Submersible Pumping), having as main methodology the use of the Arduino® Platform. The desired result is the development of a low cost oil pump controller system, with software technology which brings easy configuration and remote operation, and validation of its use in a real oil well. The main goals are the cost reduction through the use of inexpensive hardware, and the the increase of developing speed by migrating to a higher level programming language, both compared to current well pumping controller solutions, based on use of PLC (Programmable Logic Controller). Other than that, the proposal represents a big step for the dissemination of open hardware philosophy for the petroleum production process control, opening doors for incoming implementation of new controllers for other artificial lift methods / A redução de consumo energético e do custo operacional na indústria de petróleo vem se tornando uma preocupação cada vez maior ao longo dos últimos anos. Nesse contexto a busca por novos métodos de produção de petróleo e a utilização de técnicas de controle integradas aos sistemas de elevação artificial para a otimização desse processo exercem um importante papel, e o desenvolvimento de controladores de bombeio é o principal objeto de estudo. O trabalho propõe a implementação de um sistema de controle para poços equipados com BCS (Bombeio Centrífugo Submerso), tendo como metodologia base o uso da plataforma Arduino®. O resultado desejado é o desenvolvimento de um sistema de controle de bombeio de baixo custo, com tecnologia de software que contemple fácil configuração e operação remota, e a validação do seu uso em um poço produtor de petróleo real. Os objetivos principais são a redução de custos através da utilização de hardware mais econômico, e a aceleração do desenvolvimento devida à migração para uma linguagem de programação de mais alto nível, ambos em relação às soluções de controle de bombeio atuais, baseadas no uso de CLP (Controlador Lógico Programável). Além disso, a proposta representa um grande passo para a disseminação do uso da filosofia de hardware livre para controle do processo de produção de petróleo, abrindo portas para a implementação de novos controladores para outros métodos de elevação / 2018-03-28

Made available in DSpace on 2014-12-17T14:55:40Z (GMT). No. of bitstreams: 1 EvellyneSBpdf.pdf: 1159066 bytes, checksum: 300fe338752c295fd279c5c695b984a8 (MD5) Previous issue date: 2009-09-26 / Petr?leo Brasileiro SA - PETROBRAS / The Electrical Submersible Pump (ESP) has been one of the most appropriate solutions for lifting method in onshore and offshore applications. The typical features for this application are adverse temperature, viscosity fluids and gas environments. The difficulties in equipments maintenance and setup contributing to increasing costs of oil production in deep water, therefore, the optimization through automation can be a excellent approach for decrease costs and failures in subsurface equipment. This work describe a computer simulation related with the artificial lifting method ESP. This tool support the dynamic behavior of ESP approach, considering the source and electric energy transmission model for the motor, the electric motor model (including the thermal calculation), flow tubbing simulation, centrifugal pump behavior simulation with liquid nature effects and reservoir requirements. In addition, there are tri-dimensional animation for each ESP subsytem (transformer, motor, pump, seal, gas separator, command unit). This computer simulation propose a improvement for monitoring oil wells for maximization of well production. Currenty, the proprietaries simulators are based on specific equipments manufactures. Therefore, it is not possible simulation equipments of another manufactures. In the propose approach there are support for diverse kinds of manufactures equipments / Bombeio Centr?fugo Submerso (BCS) tem se mostrado uma das solu??es mais adequadas como m?todo de eleva??o em aplica??es onshore e offshore. As caracter?sticas t?picas desssas aplica??es s?o condi??es adversas de temperatura, fluidos viscosos e ambientes gaseificados. As dificuldades encontradas na manuten??o e instala??o de equipamentos s?o fatores que oneram a produ??o de petr?leo em ?guas profundas, com isso, a otimiza??o via automa??o, pode ser um passo fundamental para a redu??o de custos e falhas nos equipamentos de subsuperf?cie. Este trabalho apresenta um simulador computacional relacionado ao m?todo de eleva??o artificial BCS. A ferramenta representa o comportamento din?mico, considerando a transmiss?o de energia el?trica da superf?cie ao motor, modelo do motor el?trico (incluindo o efeito t?rmico), simula??o do escoamento na tubula??o, simula??o do comportamento da bomba centr?fuga, levando em considera??o os efeitos da natureza do l?quido e os aspectos do reservat?rio. Adicionalmente, s?o encontrados anima??es tridimensionais para cada subsistema BCS (transformador, motor, bomba, selo ou protetor, separador de g?s e quadro de comando). O simulador computacional prop?e uma melhoria no acompanhamento de po?os de petr?leo visando o aumento da produtividade do po?o. Atualmente, os simuladores comerciais est?o baseados em equipamentos espec?ficos do fabricante, dificultando obter resultados com outros equipamentos. Na t?cnica proposta, existe suporte para diversos fabricantes