Inter-stage performance and energy characteristics analysis of electric submersible pump based on entropy production theory

The electric submersible pump(ESP) is a crucial apparatus utilized for lifting in the oil extraction process.Its lifting capacity is enhanced by the multi-stage tandem structure, but variations in energy characteristics and internal flow across stages are also introduced. In this study, the inter-stage variability of energy characteristics in ESP hydraulic systems is investigated through entropy production(EP) analysis,which incorporates numerical simulations and experimental validation. The EP theory facilitates the quantification of energy loss in each computational subdomain at all ESP stages, establishing a correlation between microscopic flow structure and energy dissipation within the system. Furthermore, the underlying causes of inter-stage variability in ESP hydraulic systems are examined, and the advantages and disadvantages of applying the EP theory in this context are evaluated. Consistent energy characteristics within the ESP, aligned with the distribution of internal flow structure, are provided by the EP theory, as demonstrated by our results. The EP theory also enables the quantitative analysis of internal flow losses and complements existing performance analysis methods to map the internal flow structure to hydraulic losses. Nonetheless, an inconsistency between the energy characterization based on EP theory and the traditional efficiency index when reflecting inter-stage differences is identified. This inconsistency arises from the exclusive focus of the EP theory on flow losses within the flow field, disregarding the quantification of external energy input to the flow field. This study provides a reference for the optimization of EP theory in rotating machinery while deeply investigating the energy dissipation characteristics of multistage hydraulic system, which has certain theoretical and practical significance.

Energy Consumption Analysis and Optimization of Electric Submersible Pump System

Electric submersible pumps account for a considerable proportion in the development of the Bohai Oilfield. Improving the system efficiency of the electric submersible pump wells, ensuring that the units operate in the high-efficiency zone, is essential. Analysis shows that the efficiency of the electric submersible pump system depends on the wear and tear of each component of the submersible pump equipment, the setting of operational parameters, and more importantly, the production status and daily management level of the oil well. Therefore, improving the structural performance of the submersible pump product, optimizing the parameters setting of the oil well, strengthening daily management, establishing a scientific management system, and improving the production management process and system can effectively improve the production efficiency and economic benefits of the oil well, and further achieve the goal of energy saving and emission reduction. In addition, it is necessary to actively promote the concept and technology of energy saving and emission reduction, encourage oilfield enterprises to explore effective measures to reduce the energy consumption of the electric submersible pump system by strengthening the scientific management system, and achieve a green, low-carbon, and high-quality development of oilfield production to achieve the unity of economic benefits, social benefits, and environmental benefits. This article applies the above measures in the P oilfield to achieve energy optimization of submersible electric pump systems, reducing the daily power consumption of single well submersible electric pump systems by 371 kWh per day, increasing the submersible electric pump's lifespan by 200 days, generating considerable project benefits.

A new diagnostic method for identifying working conditions of submersible reciprocating pumping systems

The submersible pumping unit is a new type of pumping system for lifting formation fluids from onshore oil wells, and the identification of its working condition has an important influence on oil production. In this paper we proposed a diagnostic method for identifying the working condition of the submersible pumping system. Based on analyzing the working principle of the pumping unit and the pump structure, different characteristics in loading and unloading processes of the submersible linear motor were obtained at different working conditions. The characteristic quantities were extracted from operation data of the submersible linear motor. A diagnostic model based on the support vector machine （SVM） method was proposed for identifying the working condition of the submersible pumping unit, where the inputs of the SVM classifier were the characteristic quantities. The performance and the misjudgment rate of this method were analyzed and validated by the data acquired from an experimental simulation platform. The model proposed had an excellent performance in failure diagnosis of the submersible pumping system. The SVM classifier had higher diagnostic accuracy than the learning vector quantization （LVQ） classifier.

Analysis of the Impact of the Space Guide Vane Wrap Angle on the Performance of a Submersible Well Pump

In order to study the influence of the wrap angle relating to the space guide vane of a submersible well pump(250QJ125)on the flow field and pump performance,seven possible configurations have been considered(obtained by changing the blade wrap angle while keeping unchanged all the other parameters).Such configurations have been numerically simulated in the framework of a computational model based on the Reynolds time-averaged N-S equations,the RNG k-εturbulence approach and the SIMPLE algorithm.The impact exerted by different wrap angles of the guide vane on the performance of the pump,the internal losses of the guide vane and the flow field distribution in the bladeless area at the guide vane outlet has been assessed via cross-comparison of all these cases.The results show that the wrap angle has a significant influence:the wrap angle with the highest head is different from that with the highest efficiency,and changes in this angle have a more significant effect on the head than efficiency.A moderate raise of the wrap angle can improve the properties of the flow,reduce turbulence losses and enhance the energy conversion rate inside the guide vane.Different wrap angles can also lead to different fluid circulation modes in the bladeless area from guide vane outlet to impeller inlet,while they have a weak influence on the absolute value of the velocity of the fluid entering the impeller.

Submersible direct-drive progressing cavity pump rodless lifting technology

Submersible electrical motor direct-drive progressing cavity pump (PCP) rodless lifting was studied to solve the traditional rod-drive pump problems, such as rod-tubing wearing, low efficiency and short running time. The theoretical researches and laboratory experiments of key tools such as submersible motor and the construction technology of lifting system were introduced. The field application and economic benefit were analyzed and compared with the traditional rod pumping unit. A new low speed and large torque permanent magnet synchronous motor was developed. This motor was used to drive PCP without gear reducer, which improved the reliability and feasibility. It can run at the speed from 50 to 500 r/min with stepless speed regulation, and it can perform high efficiency and large torque. Besides, other key supporting tools, such as motor protector and flex shaft, were developed. The submersible electrical motor direct- drive PCP technology can be used in a 139.7 mm (5.5 in) casing well, with daily output ranging from 5 to 50 m3. Until now, the technology has been deployed more than 100 wells. The field application results show that it eliminates the rod-tubing wearing and saves electric energy by more than 30% compared with the traditional rod pumping unit. And it also makes the oil produced in a safe and environmental friendly way.

Pressure pulsation in stages of electric submersible pump at shut-off under various speeds

Electric submersible pumps were widely used in agricultural fields,petroleum and various other industries. The pressure pulsation caused fatigue failure due to vibration in electric submersible pump and affects the life and performance of its system. The objective of this study was to experimentally investigate the characteristics of pressure pulsation which were generated at various stages of a multistage electric submersible pump during closed valve operation at different speeds. An electric submersible pump with five stages was selected for conducting experiments. A variable frequency drive( VFD)was used to operate the electric submersible pump at five different speed settings from 40 to 60 Hz. Piezoresistive pressure transducers were mounted at each stage of the electric submersible pump to capture the unsteady pressure signals. At each speed setting,the electric submersible pump was operated at the shut-off condition and the signals of unsteady pressure from all the five stages were captured. A fast fourier transformation( FFT) was carried out on the pressure signals to convert into frequency domain.From the spectra of pressure pulsation signals,the characteristics of pressure pulsation are obtained for each stage and for various speed settings which were then used to understand its variation with speed and stages.

Development and Application of a Surface High-pressure Injection Device Using a Submersible Electric Pump

Injection recovery is an important measure for increasing the oil recovery rate of an oil field. One way is that centrifugal pumps or plunger pumps are used in an injection station to responsible for injection over a large area under the same pressure. This method is ineffective for low-permeability layers. For the oilfields in dispersed distribution in the marginal areas of Daqing, the low water-absorbing section needs an injection with a high delivery pressure and a low discharge capacity; another way is to install the submersible electric pump upside down, but because the submersible electric pump and the motor are underground, it is difficult for installation and maintenance. Introduced in this paper is the development and application of a surface high-pressure injection device with a submersible electric pump. Bysuccessful resolving some problems, such as the axial force of the submersible electric pump, sealing, level regulation of the pump, coaxiality and vibration, the device has the good points of running smoothly, moving easily, installation and maintains quickly and long period of running. This device can effectively solve the injection of the low water-absorbing section and of oilfields in dispersed locations. The recovery rate of oilfields is also enhanced.

Dynamic Modelling of Submersible Pump Based Solar Water-Pumping System with Three-Phase Induction Motor Using MATLAB

The main purpose of this paper is to design and model a water-pumping system using a submersible multi-stage centrifugal pump driven by a three-phase induction motor. The system is intended for pumping water to the surface from a deep well using three power supply systems: a general network, a photo-voltaic (PV) system, and a PV system with a battery bank. These systems are used to compare two three-phase induction motors—namely, a motor with a drive and another one without a drive. The systems dynamic models are simulated in MATLAB/Simulink and the results compared with the manufacturer’s data for validation purposes. The simulation results generally show system dynamics and expected performance over a range of operation.

Effective Electrical Submersible Pump Management Using Machine Learning

Artificial lift plays an important role in petroleum industry to sustain production flowrate and to extend the lifespan of oil wells. One of the most popular artificial lift methods is Electric Submersible Pumps (ESP) because it can produce high flowrate even for wells with great depth. Although ESPs are designed to work under extreme conditions such as corrosion, high temperatures and high pressure, their lifespan is much shorter than expected. ESP failures lead to production loss and increase the cost of replacement, because the cost of intervention work for ESP is much higher than for other artificial lift methods, especially for offshore wells. Therefore, the prediction of ESP failures is highly valuable in oil production and contributes a lot to the design, construction and operation of oil wells. The contribution of this study is to use 3 machine learning algorithms, which are Decision Tree, Random Forest and Gradient Boosting Machine, to build predictive models for ESP lifespan while using both dynamic and static ESP parameters. The results of these models were compared to find out the most suitable model for the prediction of ESP life cycle. In addition, this study also evaluated the influence factor of various operating parameters to forecast the most impact parameters on the duration of ESP. The results of this study can provide a better understanding of ESP behavior so that early actions can be realized to prevent potential ESP failures.

Design and research on a variable ballast system for deep-sea manned submersibles

Variable ballast systems are necessary for manned submersibles to adjust their buoyancy.In this paper,the design of a variable ballast system for a manned submersible is described.The variable ballast system uses a super high pressure hydraulic seawater system.A super high pressure seawater pump and a deep-sea brushless DC motor are used to pump seawater into or from the variable ballast tank,increasing or decreasing the weight of the manned submersible.A magnetostrictive linear displacement transducer can detect the seawater level in the variable ballast tank.Some seawater valves are used to control pumping direction and control on-off states.The design and testing procedure for the valves is described.Finally,the future development of variable ballast systems and seawater hydraulic systems is projected.

The Design of a Mobile Phone-Based Remote-Control Application to Submersible Motor for Effective Water Supply

In the last few decades, several monitoring systems integrated with water level detection have been the major research focus. Production boost and its sustainability depend mainly on sustainable water supply, measuring water level, and avoiding waste of water is an essential task for all stakeholders. Therefore, the aim of this paper is to design and implement a mobile phone-based remote control. This will be applied to control the operation of a submersible motor in a water tank. The water level in the tank is detected and the device remotely turns the motor pump on/off. The design process is accomplished by developing an android application that works on GSM technology to manage the filling of water tank. An AT89C51 microcontroller is used for the desired programming. At the transmitting end, sensor is used for level detection and GSM module is used to send the information to user. According to this information, user controls the on/off operation of the pump. A SIM card is required for its operation and it works on attention (AT) commands. After the design and implementation of the device, the test results showed that all features of the device worked properly, and the device functions exactly as expected. More significantly, the paper has shown that ultrasonic sensors can be used to determine the level of water in a water tank and a GSM module can be used to control a submersible pump. The design and implementation of this device can help to reduce waste of time and power. Ultimately, it avoids water wastage thereby ensuring availability, conservation, and sustainability of water supply.

地浸采铀注液井小直径潜水泵抽水洗井试验

某地浸采铀试验采区注液井周边含矿层堵塞严重。注液井套管内径仅有80 mm,在常规空压机抽水洗井结束后,在3口注液井中开展了小直径潜水泵抽水洗井试验。初始抽水量均在4.5 m_(3)/h左右,期间最小抽水量为3.4 m_(3)/h,其中2口井的第1股最浑浊洗井水的含砂量分别为4.36、5.19 kg/m_(3)。粒度、电镜扫描和化学组成分析显示,洗井水沉降干渣中的矿物碎屑主要为粉砂、细砂碎屑,少量黏土碎屑;化学沉淀主要是CaCO_(3)、MgCO_(3)和FeCO_(3);潜水泵抽水洗井累计运行约27.5 h,未出现任何故障。试验表明,小直径潜水泵抽水洗井可行且投资少、成本低、安全性高、实施方便。

气液两相条件下叶片开孔对电潜泵性能和内部流场的影响

为了研究电潜泵内部流动机理,从而改善高含气工况下电潜泵的气液混输性能,文中基于欧拉-欧拉非均相流模型,对不同入口含气率工况下叶片开孔前后的气液两相流动特性进行了数值模拟分析,探究了气液两相流条件下叶片开孔对电潜泵性能和内部流场的影响.结果表明,在纯水工况以及低含气率、小流量工况下,叶片开孔会降低电潜泵性能;但是叶片开孔可以改善电潜泵在大流量下的气液混输性能.叶片开孔后会改变叶轮内部压力分布,使电潜泵叶轮内部平均压力升高,进而改善叶轮内部流态.叶片开孔后会冲散气相聚集,使气体分布更加均匀,叶轮流道内涡核分布明显减少,减少了能量耗散.该研究为改善电潜泵气液混输性能提供了理论依据.

地浸采铀用潜水电泵泵轴结构与材料优选

泵轴断裂、泵体腐蚀导致潜水电泵损毁率高。通过理论计算和ANSYS数值模拟,对六棱轴和圆柱轴结构的强度、刚度等力学特性进行了对比,并开展了304、316L、904不锈钢材料的耐腐蚀现场对比试验。结果表明:在同等载荷和等效直径条件下,圆柱轴的圆截面所受剪切应力为六棱轴的64.95%,且扭转角度仅为六棱轴的56.25%;模拟结果显示圆柱轴联轴器最大环向形变为六棱柱轴最大环向形变的68.4%,圆柱轴结构的抗扭性能更优;904不锈钢抗腐蚀性能最佳,但304和316L不锈钢对酸性介质具有类似抗腐蚀性能。综合考虑耐腐蚀余量和制造成本,建议在地浸采铀专用潜水电泵研发过程中选用圆柱泵轴结构,沿用现有316L不锈钢作为主材的选材方案。

空间导叶式多级离心泵级间能量损失机理

为探究空间导叶式多级离心泵级间能量损失的原因,以1个单级和1个3级潜水泵为研究对象,通过试验和数值模拟相结合的方法,分析其级间能量损失的机理.对单级和3级潜水泵分别进行全流场外特性试验.基于ANSYS软件对3级潜水泵不同流量点进行数值模拟和内流场分析,着重对各级叶轮进口流态、内部旋涡结构和叶片载荷分析比较.结果表明:小流量工况下,3级潜水泵各级扬程接近且与单级扬程相差不大;额定流量工况和大流量工况下,3级潜水泵第1级扬程与单级扬程仍相差不大,但后2级扬程相比于第1级降低了6%~10%.随着流量的增大,首级叶轮来流稳定性不受影响,其后各级叶轮进流流态变差.后2级叶轮进口液体介质冲角变化使其对叶片进口边的冲击增大.后2级叶轮进口处的涡在流量较大时发展为流向涡,从而引起叶片载荷突变,削弱了叶轮做功能力,导致后2级能量损失.研究结果可为多级离心泵的设计提供理论依据.

矢量泵喷推进潜航器回转性能研究

泵喷推进器已经逐渐成为现代潜航器的首选,矢量推进器也在航空航天领域得到了广泛的应用。为了解决传统依赖船舵控制在低航速下控制效率低的问题以及提高潜航器回转性能,矢量推进器在潜航器上的应用已逐步成为国内外关注的热点。本文考虑大舵角(喷管偏角)下潜航器各参数非线性的影响,建立潜航器水平面操纵运动的非线性模型。通过仿真研究分析船-舵-推进器、船-矢量推进器和船-舵-矢量推进器三种不同的控制方法下潜航器在低航速、控制泵喷推进器转速、控制潜航器轴向航速三种不同条件下作水平面回转运动时的回转性能,结果表明矢量泵喷推进器可以有效改进潜航器的回转性能。

地热井用潜水泵冲蚀磨损特性

为研究颗粒属性对地热井用潜水泵外特性和冲蚀磨损的影响,采用离散相模型和RNG k-ε湍流模型对两级潜水泵内流场进行了全流道数值模拟.结果表明:随着固体颗粒体积分数的增大,潜水泵各级扬程和效率均呈下降趋势,单级扬程最大下降1.68 m,单级效率最大下降5.18%;叶轮的冲蚀磨损主要出现在叶片工作面进口,导叶的冲蚀磨损主要出现在导叶工作面出口和导叶前盖板;随着固体颗粒密度的增大,各部件的平均冲蚀率增加明显;叶轮和导叶的最大冲蚀率均随固体颗粒粒径的增大呈增大趋势,其中导叶的最大冲蚀率随颗粒粒径变化相比叶轮更加明显,当颗粒粒径超过0.650 mm时,过流部件最大冲蚀磨损率急剧上升.

叶轮与导叶宽度匹配参数对LNG泵压力脉动特性的影响研究

应用CFD技术研究了叶轮和导叶宽度匹配设计对LNG潜液泵压力脉动特性影响,进行了宽度匹配设计,采用K-epsilon湍流模型进行了多工况数值模拟,引入无量纲参数R(导叶进口宽度/叶轮出口宽度)进行结果分析,分析验证了泵的外特性,得到了LNG泵的时、频域压力脉动特性等。结果表明:压力脉动主频为叶轮的叶频,次频为其倍频。时域峰值与监测点处的相对位置有关,相对于交界面越近,时域峰值越大。压力脉动幅值随R增加先减小后增大,存在最佳宽度匹配方案使得泵压力脉动峰值降低。

煤层气L型水平井电潜螺杆泵井清防砂工艺技术创新及应用

套管完井压裂投产的煤层气L型水平井出砂严重,倒置式电潜螺杆泵举升工艺受压裂砂影响故障频繁,影响了连续稳定排采,因此确定了倒置式电潜螺杆泵排采过程中由于压裂砂导致的故障点,并针对性创新应用了井筒内、导流罩及泵内清砂工艺技术,同时优化防砂管柱设计,确保了连续稳定排采。

地浸采铀工艺中电潜泵内流场数值模拟研究

电潜泵是我国地浸采铀工艺中实现浸出液有效提升的主要装备,但目前针对介质举升状态下电潜泵水力部件内部流场作用机制的研究较少。试验以叶轮-导叶内部结构为研究对象,应用CFD方法对介质流动特性开展非定常分析,研究了叶轮和叶轮出口段内部的压力脉动变化规律,并利用瞬态流场数据对叶轮截面压力流场进行动模态分解(DMD)与压力流场重构,揭示了介质举升状态下由动静干涉引起的压力脉动周期性变化规律与动静部件距离对动静干涉强度的影响规律。结果表明,叶片通过频率值与快速傅里叶变换(FFT)频率值基本一致。试验结果可对减少由压力脉动引发的泵体无效震动、优化电潜泵水力部件结构参数和提升系统效率提供一定理论参考。