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SPE 13805 Electrical Submersible Pump Performance Using Variable Speed Drives
SPE 13805 Electrical Submersible Pump Performance Using Variable Speed Drives
SPE
-of~ Gr@taamefAIME
SPE 13805
This paper wee presented at the SPE 19SS ProductionOperationsSympaium held in Oklahoma Cw, Oklahoma, March 10-12, 1S85. The material ie
subjectto Oorrtilon by the author. Permissionto copy ia restrictedto an abstractof not more than 200 worde. Write SPE, P.O. SoXS2SS3S,FUchardson,
Texsa 75082-3S36. Telex 730S8S SPE DAL.
.
.-.
~yL~tiL --
~~~ Pm
● The power required by a pump ia directly exceeds the bearing capacity or where the
related to the cube of the speed. performance curve is so flat that slight
variation in intake pressure produces wiid
Because the rotational speed of the ESP is fluctuation in flow. The maximum operating flow
related to the frequency of the power s’upplied, is generally set either at the zero thrust point,
these laws may be expressed either in terms of RPM or where the magnitude of the upthruet exceeds
ratios or frequency ratios. Using a pump its bearing capacity. The design of some pumps
performance curve generated for 3500 RPM (60 Hz), is such thst it either never reaches the zero
curves for any other frequency or speed can be thrust point, or reaches it very near its maximum
constructed using the following relations: flow. Operating close to maximum flow with
nearly zero head is not truly useful. In these
RPM
‘lOw= ‘10w(3500)x ()
HO= ‘10w(3500)x
Hz
()
m
(3) cases an arbitrary maximum flow is selected.
Although it is possible to operate some pumps
outside their given useful range, this should
never be done without authorization from the
‘cad = %3500)+% (J ‘Head(3500)x
~’
()
(4) manufacturer.
THE MOTOR
RPM 3
‘p = ‘P(3500)X ()
mo = ‘P(3500)X
Hz
a
()
=
(5) The motor is a three phase, two pole
squirrel cage, induction motor. It is designed
to operate on a sinusoidal power source. The
The firat two relations have proven to be true operating speed of these motors is governed by
over a wide range of speeds. The third is correct the physical design of the motor, the driving
for hydraulic horsepower output by the pump, but frequency and tile 5LLp.
-“- If thle SOtar iS
because the internal losses do not exactly obey the operating at full load, the slip is constant.
cube law, careful testing may show a small increase The speed is then a function of frequency only.
%ii F2ff5~5~iKZ~“WitklhCi~ZSed OP==u.
‘--”A 1%. ~~,~~~ Th.=~fi+mwa
“.”.- n-a ..-”-~
--- Ana+tnia.4
. . ..-. ~0 ZGI) f~~~y ~o=&~ ~~
~.,=
relation can be used for pump input power because 3500 RPM on a 60 Hz power source. The apeed of
these variations are slight. A family of variable any other frequency is found by the following
speed performance curves (2) are generated for a relation:
stage using these relations.
(6)
Pump Operating Ranges
There are points on the performance curve The flux density is held constant by keeping
where the pump cannot be continually operated. It the voltage/frequency ratio constant. The
is common practice for the manufacturer to define available torque ia proportional to the square of
one or two operating ranges. A “Best” operating the voltage/frequency ratio and is therefore also
range indicates that no other pump in that constant. The output horsepower is directly
manufacturer’s series has a higher efficiency for related to the torque times the speed. The
those flow rates. A “Useful” operating range ia horsepower will increase directly with the speed.
defined as the volume range over which a pump can The horsepower at any frequency can be found by
be operated without detrimental effects, however, the following relation:
()g
there are no industry-wide guidelines for
determining this range. There are several factors HP = ‘p(60 Hz)x 60 (7)
considered in determining the limits of the useful
range.
‘motorLimitations
Pump Thrust
The motor has mechanical and thermal
Without going into specific design, the total operating limits. The mechanical limitation are
unbalanced thrust can be represented as the baaed on design and fatigue life of the
summation of two components, upthrust and materials. The thermal limits are determined by
downthrust. Simply stated, the upthrust is a the temperature rating of the electrical
function of the velocity of fluid flowing through a insulation material. The internal motor
stage, and the downthrust is a function of the head temperature depends on the losses generated in
nrndnt.~~by
=----- the st~ge, AS flow is increased the the motor and the motor cooling rate. If the
magnitude of the upthrust increases and the motor exceeds Ita internal temperature limits,
magnitude of the downthrust decreases (3). At some the insulation will degrade and the motor will
point the two thrusts will be equal. The total fail.
resulting thrust will be zero. This zero thrust
point may or may not be in the operating range of The motor ia cooled by the well fluid
the pump. For practical consideration, most stages flowing past it. The cooling rate is a function
are designed so that they always operate in of the fluid velocity, the surface area and the
downthrust. well temperature. The manufacturers publish
minimum fluid velocities for proper operation.
-L ptIyt3iC6
—L - c z ---- -Y ------- . -- --- 1 J --
Pump Limitations ihe tO Kne 01 LOECeKJ UXIV~CtAVn UJU&L1&g,
increasing the velocity above the recommended
The minimum operating flow is generally set minimum value does not significantly increase the
where either the magnitude of the downthrust cooling. In designing motors, the diameter is
)
BKUWLN LILL WLLMJN ANII JOSEPH CHING-CHIO LIU 3
SPE 13805
limited by the casing size. Higher horsepowers are --- For 800 BPD at 50 Hz
obtained by increasing the length. The surface (Fig. 2) Stage Differential Head = 19.2 ft/stage
area is increased proportionally and the cooling Tubing Loss = 100 ft
rate remains constant. The well temperature (Eq. 1) Pump Differential Head = 19.2 ft/stage
directly affects the internal temperature of. the x 225 stages = 4320 ft
motor. A motor that is 6esigned for a maximum well
temperature of 250° F will run safely in a 250° (Eq. 9) Fluid Level = 5000 + 100 + 200 - 4320
well if it is not overloaded. = 980 ft
--- For 600 BPD at 50 Hz Required 60 Hz rating of motor for 250° well
(Fig. 2) Stage Differential Head = 22.5 ft/stage
Tubing Loas = 60 ft (Eq. 8) Derated Hp =~= 122 Hp
(Eq. 1) Pump Differential Head = 22.5 ft/stage
x 225 stagea = 5060 ft
A motor rated for 122 Hp at 60 Hz and 250° F
(Eq. 9) Fluid Level = 5000 + 60 + 200 - 5060 well temperature will operate in a 250° example
= 200 ft well at 74 Hz without excaeding ita internal
4 ELECTRICAL SUBMERSIBLE PUMP PERFORMANCE USING VARIARLE SPEED DRIVRS SPE 13805
temperature limits. This motor will be underloaded 3. Alcock, D. N.; “Operating Submersible Pumps
operating at 50 Hz in the initial well condition. with Closed-Loop Speed Control”, Oil & Gas
Journal (Oct. 1981).
Required pump horsepower at 50 Hz
4. Alcock, D. N.: “Application of Variable
(Eq. 5) Hp=77Hpx~
()
503=
44 Hp Frequency Drives to Deep Well Submersible
Pumps”, Petroleum Engineer International
(March, 1980).
Ava: lable motor horsepower at 50 Hz
5. Watson, A. J.: “ESP - The Electrical
50
(Eq. 7) Hp=122Hpx~ = 102 Hp Submersible Pump, Part 7 - Applying Variable
() Frequency Drives to ESP’s”, Petroleum
Engineer International (November 15, 1983).
The motor will be operating at 43% of its
available horsepower. In the case of a cool well, 6. Hickok, H. N.: “Adjustable Speed - A Tool
or one not requiring a derated motor for Saving Energy Losses in Pumps, Fans,
Blowers and Compressors”. IEEE PCIC-83-44.
50
(Eq. 7) Hp=l17Hpx~ = 97.5Hp
() 7. Brinner, T. R., Traylor, F. T. and Stewart,
R. E.: “Causes and Prevention of Vibration
The motor is operating at only 45% of its Induced Failures in Submergible Oilwell
-—- ..-.-
avaiiabie horsepower. Because of the underioad Pumping Equipment::,Faper SPE 11(.)43
presented
condition, the motor will not be operating at ita at the 1982 Annual Fall Technical Conference
design efficiency. This example demonstrates the and Exhibition of SPE, New Orleans, LA,
magnitude of the variations that can occur between Sept 26-29.
motor output and pump requirements when operating
with VSD.
ASSUMPTIONS
CONCLUSION
REFERENCES
RPM 9600
o
d
‘6
!0
Is
10
.9(
.21
6
.2(
.,
0
1000 1200 1400 1 eoo
0 200 400 600 Soo
BRAKE PUMP
PUMP TYPE 900 BPD
IN
: VARIABLE SPEED PERFORMANCE CURVE H.P. EFP.%
HEAD CApA
60
40
30
50
40
20 (46 Hz)
10
0
1000 1200 1400 1000 1800 2000
~QQ 400 eoo 800
e
SPE J3805
— ——
1.0
o.@
0.6
40 4s 50 65 ml 00 ,“ ,“
FREQUENCY (I+z)
BRAKE PUMP
PUMP TYPE 900 BPD
H.P. EPP.s
~ VARIABLE SPEED PERFORMANCE CURVE
so
90
80
40
70
60
20
.3 0 30
.2 0 20
10
0 1800 2000
~GG .fimrl $~g j A~Q 1600
400 600
‘-- , ““”
0 200