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Abstract
The majority of Western Desert wells (Agiba Petroleum Company) are completed with artificial lift systems and several kind
of pump: ESP, Sucker Rod, PCP (about 40 ESP, 250 Sucker Rod and 10 PCP). A new technology - Permanent Magnet Motor
(PMM) - has been developed for ESP motors as alternative to conventional asynchronous induction motor in the last years.
PMM is synchronous motor in which the stator manufacturing technique is similar to that of conventional asynchronous
motor, but rotor has permanent magnets (instead of copper winding). PMM has more benefit of conventional induction motor:
high efficiency (90-94%) vs. induction motors up to 86%; smaller size and weight; wider ranges of rotation frequency
regulation (100-1000, 1000-4200 and 3000-6000 r.p.m.); reduced energy consumption and rating of surface equipment (Power
Saving); stable torque over wide operation range; Power factor is near to 1; lower specific heat release due to higher
efficiency. Also indirect benefits are: a) low heat release (minimum cooling fluid velocity 0.05 ft/s); b) less size for cable and
lower power rating for transformer and VSD; c) decreased reactive power; d) improved system Power factor. All Agiba ESP
wells are equipped with conventional induction motor. In the middle of June of 2012 Agiba performed a trial installation of
Novomet PMM replacing an ESP unit with induction motor on well North Nada 1 x (oil well - Qg =315 BFPD, Qn=173
BOPD) of North Nada field. The installation was successful achieving the expected results and benefits in term of low power
consumption. Successful key point: keeping electrical system stability and minimize the number of shutdowns; minimum cost
for power consumption and production.
Introduction
Today when the Artificial Lift share in the global Oil Production industry is growing up the Electrical Power consumption and
its cost becomes of a major concern for Oil and Gas Operators. In this regard High Efficient and/or Power Saving techniques
more and more become of current interest. Electrical Submersible Pump (ESP) in its turn as a most focused part of Artificial
Lift and as a technically sophisticated system requires efficiency improvements in the first place.
As ESP manufacturer Novomet Group conducted several in-house tests (in Russia) of equipment power consumption
measurements and losses. The conclusions of these tests are the following:
The share of average total net power is 39% (useful power). The rest 61% are losses that turn into heat and warm up
the environment; in other words it is being wasted;
Submersible pump (transfers mechanical energy into hydraulic energy) 29% of 61%,
The remaining 19% of total losses are distributed in cable, transformer, switchboard (VSD) and filters.
Power losses distribution per component is showed in Fig.1
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(%)
Powerlosses%byESPsystemcomponent
50
45
40
35
30
25
20
15
10
5
0
29
13
19
8
PowerLosses
10
6
4
3
3
2
NetPower
2
1
Optimum designing of the pump operating point during equipment selection for the well;
Designing of the ESP system with a higher efficiency itself.
Optimization of the operating point of the centrifugal pump in the course of its sizing for the well is now the basis for the
proper design procedure widely used in most of the oil operating companies. Application of higher efficiency ESP systems is
the most prospective measure, though not widely applied due to the higher cost of the equipment. Novomet managed to
develop pump stages with high efficiency (up to 76 %) that is a part of approach to power saving, but the most significant and
major achievement is the development of Permanent Magnet Motor (PMM). This is a different motor principle applied in ESP
system. The new motor type is much more efficient than the Asynchronous Motor (94% vs. 86%).
Power SaveTM ESP system which comprises high efficiency Pump modification and PMM can reduce absolute power
consumption by 25-30%. The distinguishing feature of the Power SaveTM ESP system is the significant reduction of number of
working stages in the pump if compared to a conventional one with induction motor. The desired head is achieved through
increased rotation speed (r.p.m.) of the PMM Motor. When comparing the PMM and asynchronous motor, the first one
has a better efficiency and lower operating current. The reduced operating current in its turn allows reducing heat losses in
the cable line and losses in the control panel and transformer. Figure 2 gives a visual differentiation between conventional ESP
and Power SaveTM ESP.
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A detailed description of the above figure is reported in the next table:
Parameter
Flow rate, bbl/d
Average flow sp.gr. (60 F / 60 F)
Motor power- NPHP, HP
Efficiency of motor + protector (1), %
Power lost in motor & protector, HP
Shaft Power BHP, HP
Overall pump efficiency (2), %
ESP Hydraulic Horse Power -HHP, HP
Pump Total Dynamic Head -TDH, ft
speed rotation, r.p.m.
Conventional Design
3,145
0.85
128.6
84.1
20.4
108.2
70
75.7
3,841
2,910
.
135,625.73 2 %
HHP = NPHP * 1 * 2 * 10-4
TDH = 135,625.73 * HHP / Q / sp.gr.
As size of the modified design is 0.6083 times the conventional design and its TDH is less than that obtained by the
conventional design, so it must run at r.p.m. higher than 2,910 to meet same TDH as 3,841 ft. Accordingly its r.p.m is
calculated as following using affinity law (2):
r.p.m. modified = (conventional size / modified size) x conventional r.p.m.* (TDH modified / TDH conventional)0.5
r.p.m. modified = (1 / 0.6083) x 2910 * (3475 / 3841)0.5 = 4,550
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Permanent Magnet Motors
In the last years a new technology - Permanent Magnet Motor (PMM) - has been developed for ESP motors as alternative to
conventional asynchronous induction motor. PMM is synchronous motor in which the stator manufacturing technique is
similar to that of asynchronous motor, but rotor has permanent magnets (instead of copper winding) made from rare-earth
alloys forcing high level of magnet induction.
Design
Motor consists of a stator (Fig.3) with three-phase winding, rotor with the permanent magnets, head and base. Winding phases
are located at 1200 to each other and Y- connected.
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Figure 6. Vibration curve for motor without elements for vibration reduction
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Figure 7. Vibration curve for motor without elements for vibration reduction
Motor operation is based on electromagnetic interaction between two magnetic fields: stator and rotor. The stator rotating
magnetic field is created by system of three-phase AC current for both types PMM and induction one. The rotor magnetic field
in the conventional asynchronous motor is created by the induction currents which are generated in the rotors copper winding;
then currents create EMF, which in turn generates torque. In case of PMM the rotor has its own permanent magnetic field
created by the nature of permanent magnets. So there is no additional power spent on generating the induction current inside
the rotor, and no losses/resistance in rotor copper Thus an interaction between rotor and stator magnet fields creates an
electromagnetic torque which makes the rotor rotate.
Power Losses
In a rotor winding of permanent magnet motor, unlike asynchronous motor, there are no losses (Fig.8) because these rotor
packs consist of permanent magnets itself. Concerning other types of losses such as losses in stator winding and losses in steel
it is possible to mention that they are lower because current value is also lower and less steel losses because of lower stator
length. Finally, Permanent magnet motor is equipped with a special bearing which allows reducing mechanical losses as well
(see vibration comparison curves above).
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Permanent magnet motor control system contains power keys (in other words power switches): IGBT transistors. They are
VSD inverter components. The control device converts sensor signals into combination of control voltages which operate
power keys in the way that at each motor cycle two keys are operated and two out of three stator phases are connected
successively to the power network, as it is mentioned above (Fig. 10). Windings U, V, W are located on stator at 120 to each
other. Winding inputs and outputs are connected thus to create rotating magnet field during keys changeover. PMM control
system is placed far from the motor itself: it is a part of top side switchboard ESP drive.
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Supplied voltage value in VSD inverter can be regulated that is why it is possible to sustain motor rotating torque (Fig.11) at
the required level, so that if operating conditions change, these will not affect produced flowrate. In other words frequency of
voltage can be regulated due to the measured value of speed of rotor rotation by rotor positioning sensor as control system
understands that rotor rotation speed is decreasing. Automatic increasing of voltage frequency by the system allows sustaining
motor torque at required level even if there is pump stuck due to the solids. For induction motor it is not possible as system
does not measure rotor rotation speed, thats why torque for induction motor is limited by its load capacity.
Summary
As a short summary of what above mentioned, here-below the main benefits of PMM versus conventional induction motor:
-
High efficiency (90-94%).vs. induction motors up to 86% because of motor design (rotor construction and decreased
losses) and PMM system control;
Smaller size and weight at the same power output (excellent solution for offshore applications) due to the increased
efficiency and lower current consumed;
Wider ranges of rotation frequency regulation: 100-500 r.p.m., 500-1500 r.p.m. due to the 14 poles configuration and
1500-4500 r.p.m., 3000-6000 r.p.m. due to the 4 poles (the higher number of poles motor has the lower speed it
rotates);
Reduced energy consumption and reduced rating of surface equipment (Power Saving) due to the lower consumed
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current and lower power losses in the system: cable, transformer, VSD. Losses in cable, transformer and variable
speed drive are reduced as well because of lower current and lower rating itself.
Lower heat release due to the less consumed current and decreased losses value (losses generate the heat), which
allows operating in the well with lower cooling fluid velocity (0.05 ft/s) without shroud.
Less consumed current also let using smaller cable size, minimizing the cost of the system
Stable torque over wide operation range because of the control system voltage (r.p.m.) regulation;
Power factor is near to 1 as there is no reactive resistance in rotor copper as rotor consists of permanent magnets
Field trials in Egypt
Agiba petroleum company has two main production areas in Egypt: onshore in Western Desert area and offshore in Ashrafi
area, for a total production of about 56,000 BOPD and a total of about 300 wells. Western desert included five locations
Meleiha, Zarif, Aghar, Faras and Raml. The main location is Meleiha field with about 250 wells (70% of total Agiba wells).
The majority of Western Desert wells are completed with artificial lift systems and several kinds of pumps: ESP, Sucker Rod,
PCP (about 40 ESP wells, 250 Sucker Rod wells and 10 PCP wells).
In the middle of June of 2012 Agiba performed a trial installation of Novomet PMM replacing an ESP unit with induction
motor in well North Nada 1 x. North Nada 1x is an oil well (Qg = 315 BFPD, Qn =173 BOPD).
The installed equipment is the following:
Pump: NHV380, FLT, AR1, CR1, STD, 405stg
Motor: PMM (460 series): N460PM100, 2230V, 3600 r.p.m., SGL, CR2, UHT
In the next figure the pump performance curves:
Pump performance curves
Novomet NHV 380 405 stgs (9675 ft)
r.p.m.: 3143
HZ: 54.0
sp.gr.: 1.0 (60 F / 60 F)
Developed pressure: 4189.3 psi
Figure 12. Pump NHV380, FLT, AR1, CR1, STD, 405 stg performance curves
The parameter requested for design of Novomet installation is reported here-in under:
Operating
frequency,
HZ
54
Flow rate,
BFPD
350
Water
Cut,
%
Pump
setting
depth,
ft
45
8800
Top of
perf., Solids
ft
8912
No
GOR,
SCF/STB
Pf,
psi
WHP,
psi
100
1300
200
P.I.,
Casing O.D. BHT,
Viscosity,
Sp.gr.
BFPD/psi
, inch
F
cP
0.3
9 5/8
220
0.89
0.2
10
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The installation successfully achieved expected results and benefits in terms of low power consumption as documented in the
next table:
ESP operating parameters (comparison table)
Parameter
Production rate, bbl/d
Wellhead pressure, psi
Pump head/stage, ft
Required hp/stage, HP
Pump efficiency, %
Rated current, A
Operating current, A
Voltage, V
Apparent Power, KVA
Motor PF, %
Active Power, kW
Reactive Power, kVAR
Motor Efficiency, %
Motor Power Losses - MPL, kW (HP)
Heat released due to MPL, kBTU/hr
Useful motor power - shaft power, kW (HP)
ESP Hydraulic Horse Power - HHP, HP
Equipment length, ft
Motor OD, inch
Motor shroud application
Fluid cooling velocity, ft/s
Overall ESP efficiency may be used, %
Run life, days
With Induction
motor @50Hz
315
150
20.4
0.138
50
26
19
1,730
56.87
88
50.04
27.01
83
8.5 (11.4)
29.03
41.5 (55.7)
27.85
54.1
5.62
Yes
0.79 (in 7 shroud)
30.4
180
Lower heat release, that enables to operate without shroud even with 460 series of motor in 9 5/8 Casing (minimum
cooling fluid velocity 0.07 ft/s);
b) Less current consumption (16 amps instead of 19 amps) and less size for cable and lower power rating for transformer
and VSD;
c) Decreased reactive power in the ESP electrical system (please see Table 3 above);
d) More system stability and less vibration due to reduced reactive power;
e) Improved system Power factor (please see Table 3 above);
f) Less fuel consumption for the generators or turbines 10 % reduction of diesel/gas consumption;
The ESP unit is still running ad under monitoring and observation in order to evaluate the overall benefit of the installation.
3.
An alternative to conventional asynchronous induction motors has been developed. Its efficiency factor is
significantly higher than of conventional motor (from 88 up to 94% depending on motor series).
Power consumption is considerably low and high efficiency is observed due to the improvement of power factor
(from 0.88 up to 0.91) that significantly decreases the reactive power and heating of electrical system.
The expected results have been achieved: power consumption was reduced by 10 %.
Less power consumption allows increasing of the number of ESP wells by 10-15 % without change of power supply
system.
Acknowledgment
The author would like to thank Novomet R&D department namely, Santalov A.M., Khotsyanov I.D., Koshelev S.N. and
Novomet Egypt Workshop Manager Sergey Stolbov for provision of information related to the design and control operating
system of PMM and consultations during technical paper preparation. Also many thanks to ENI Milano, Italy-COMP
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11
department, namely Salvatore Pilone and Salvatore Spagnolo for the help and technical support during the installation phase
and revision of the paper. Thanks are convoyed to Eng. Ishak S. Attia, Agiba Petroleum Company for his technical support
and team leading.
References
1- http://www.gemi.org/waterplanner/calc-horsepower.asp
2- The Engineering ToolBox, http://www.engineeringtoolbox.com/affinity-laws-d_408.html
Nomenclatures
AM = Asynchronous Motor
AC = Alternating Current
API = American Petroleum Institute degree = [141.5 / sp.gr. (60 F / 60 F)] 131.5
bbl/d = Barrels Per Day
BHT = Bottom Hole Temperature
BHP= Brake Horse Power
BFPD = Barrel Fluid Per Day
BOPD = Barrel Oil Per Day
BTU = British Thermal Unit
cP = CentiPoise
EMF = Electromotive Force
ESP = Electric Submersible Pump
ft = foot
ft/s = foot per second
F = degree Fahrenheit
C = degree Celsius
GOR =Gas to Oil Ratio
HHP = Hydraulic Horse Power
HP = Horse Power
IGBT = Insulated Gate Bipolar Transistor
kVA = kilo Volt Ampere
kVAR = kilo Volt Ampere Reactive
kW = kilo Watt
NPHP = Nameplate Horse Power
MPD = Mid of Perforation Depth
O.D. = Outside Diameter
PCP = Progressive Cavity Pump
P.I. = Productivity Index, BFPD/psi
Pf = formation pressure, psi
PMM= Permanent Magnet Motor
psi = Pound force per square inch
Qgross = Gross fluid flow rate
Qnet = Net oil flow rate
P.I. = Productivity Index
r.p.m. = revolution per minute
RPS = Rotor Position Sensor
SCF = Standard Cubic Foot
STB = Stoke Tank Barrel
sp.gr. = Specific Gravity
TDH = Total Dynamic Head
VSD = Variable Speed Driver
WHP = Well Head Pressure
P, W = loss in power, Watt
= Efficiency, %
Subscripts
g = gross
n = net
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