Arsenal Light View Version

# 1 (03), January 2013
Complete ESP systems/Water injection systems/Production optimization/Field service facilities/Software tools

«Power Save» low rate ESP system
EFFICIENCY OF THIS LOW
FLOW PUMP STAGE IS
52%
Hydrodynamic optimization of the
stage design resulted in improved
efficiency by 15 points if compared
to other designs.
«Power Save» pump stage NF(130-250)H, 3640 rpm

This year Novomet has finalized development of 362 series stage
with efficiency increased by 1.5 times if compared to conventional
equipment.
IMPELLER WITH HIGHER SPECIFIC SPEED
■ Increased efficiency up to 52%
■ Reduced axial thrust
FLOW PATH HEIGHT HAS BEEN INCREASED

UP TO 0.138'' (3.5 MM)
■ Reduced clogging
■ Reduced scaling
OPTIMIZED DESIGN
■ Minimized losses
■ Improved maintainability
3
Novomet solutions ARSENAL #1(03) | January 2013
NOVOMET SOLUTIONS
ARSENAL
Novomet Solutions Arsenal
Novomet magazine # 1 (03),January 2013
Editor-in-Chief
Oleg Perelman
Commissioning Editor
Aleksey Maltsev
Design and prepress

Svetlana Starkova
Eduard Shidrikov
Authors:
Aleksandr Elizarov
CONTENTS
Aleksandr Mokshaev
Aleksandr Rabinovich
Anatoly Santalov 4 Innovations and Power Saving in Oil Production
Andrey Fedorov
Dmitriy Letunov 6 Multi-Zone Production
Evgenii Poshvin
Farkhat Khafizov ESP Operation Experience
Ivan Khotsyanov 8 in the Conditions of Oil-gas Condensate Field with High Content of
Maxim Perelman Sulphide Hydrogen
Mansur Gabnasyrov
Mikhail Politov 11 Slim-Line ESP systems
Nadezhda Bezmaternykh
Oleg Perelman 14 Influence of Viscosity
on Operating Characteristics of Centrifugal Pumps
Sergey Koshelev
Sergey Pescherenko Increase of motor temperature application range by means
Samir Abakhri 19
of motor cooling unit
Sharifzhan Ageev
Valeriy Minlikaev 22 Submersible Permanent Magnet Motors
Background, design characteristics, capabilities
Walid Reda
28 Permanent Magnet Motor application for ESP Artificial Lift

English version is prepared by International
Business Department:
Polina Plotnikova
Yana Batueva PLEASE KINDLY REFER TO PRODUCT SPECIFICATIONS
Elena Grebennikova
Ekaterina Nalimova 30 CONVENTIONAL PUMP SUMMARY (338 – 740 SERIES)
Editorial office 30 «POWER SAVE» PUMP SUMMARY (272 – 677 SERIES)

Shosse Kosmonavtov, 395, Perm, 614065,
Russia 30 ASYNCHRONOUS MOTOR SUMMARY (378 - 744 SERIES)
Tel: (342) 296 27 56, Fax: (342) 296 23 02
E-mail: maltsev@novomet.ru
31 PM MOTOR SUMMARY (319 - 512 SERIES)
www.novomet.ru
31 GAS SEPARATOR, MULTIPHASE PUMP

All rights reserved. No part of this
publication may be reproduced without the
31 PROTECTOR
prior written permission of the publisher.
32 SLOTTED SCREEN PUMP INTAKE

JSC Novomet-Perm, 2013
4 Complete ESP systems/Water injection systems/Production optimization/Field service facilities/Software tools
Oleg Perelman
General Director
of ZAO Novomet-Perm
INNOVATIONS
AND POWER SAVING
IN OIL PRODUCTION
In modern oil machine building production of reliable equipment for
Mansur Gabnasyrov various severe operating conditions is not enough. Today a winner is a
Director company which pays proper attention to innovations, which equipment
of Novomet-Kazakhstan
is ultimately the most power saving and allows to produce more oil and
which local service centers ensure the best ESP operating conditions.
Novomet Group is one of such companies. Its activities are based on
broad field experience and scientific investigations of employees.
Recently the company has worked on sumed current to save electric power.
increasing of design reliability. Reliable These data were obtained from test well
pumps designed for highly aggressive in strictly controlled conditions in Mos-
conditions like senoman or sulphide hy- cow R&D Center Konnas and indicated in
drogen have been developed. Series presentations for representatives of Rus-
range of pumps has been expanded sian and foreign oil operators.
regarding slim-line, high and low flow- In natural conditions commissioning
rates. Also we can mention replacement of new ESP systems with maximum ef-
of asynchronous motors by permanent ficiency ensured by proper sizing and
magnet motors and increasing of heat selection allows to increase savings up
and corrosion resistance. We have de- to 30-40%. Active power was reduced by
veloped new types of protectors, down- 21.7%, power intensity for 1 m3 of pro-
hole sensor systems and gas handling duced fluid was reduced by 41.2%.
devices; also we started applying smart We have already supplied 800 ESP
variable speed drives designed to ensure systems of this type. More than 300 ESP
ESP operation at BEP. systems have already been started up.
Herewith, we would like to cover some Average measured reduction of power
recent developments. consumption is approximately 25%.
«Power Save» ESP Systems Slim-line ESP Systems

Novomet has been producing equip- ESP system of 319 series is designed
ment allowing to save up to 20% of elec- for operation in wells with casing of 4" (or
tric power (it is called «power save») wells after workover with primary casing
since 2010. Application of more efficient of bigger diameter). Diameter of ESP
permanent magnet motor which efficien- system including cable is 3,74". Novomet
cy is 92-94% (versus 84-86% of asyn- has pioneered ESP industry with slim line
chronous motor), pump with new design ESP systems. Currently we are the only
stages which efficiency is by 5-6% higher company in the whole world which manu-
than that of current design and also re- factures such ESP systems.
duction of heat losses in a cable, VSD These ESP systems are also applicable
and transformer due to decrease of con- in side-track wells due to small cross-
5
section. The first ESP system of 319 se-

ries was installed in the side-track in
April 2010.
Novomet has also developed the ESP
system of even smaller diameter (OD
is 2.72") for casing OD 4" and flow rate
range 190-1000 bpd. As of September
2012 5 of such ESP systems are operat-
ing. Their flow rates are from 190 to 500
bpd and run life is up to 400 days (aver-
age run life is 200 days).
Bypass Systems
Novomet has developed its own de-
sign of Y-tool (bypass) systems to solve
the following challenges:
• Logging of multi-zone wells when
ESP system is operating before installa-
tion of equipment for multi-zone produc-
tion.
• Logging of a reservoir in different
modes in order to fully investigate opera-
tion of a system Reservoir-Well-ESP. Besides Novomet has developed technology allows to operate in wells
• Increase of well meantime between and applied the technology of produc- with leaky casings avoiding expensive
failures due to application of two ESP tion from wells with damaged casings. squeeze cementing and installation of
systems of the same series. When the In order to isolate the damaged area additional casing. It has been success-
first ESP system fails the other one starts the special design packer systems with fully implemented in 8 wells of OAO Sara-
operating. sealed cable feed-through are used. This tovneftegaz.
As of today we have supplied 15 sys-
tems and currently they are being active-
ly implemented and explored.
Multi-zone Production
Tubing
Novomet has developed dual systems
consisting of two complete ESPs for pro-
duction from two reservoirs. The major Cable
benefit of this technology is capability
of selective control of each ESP system. Pump
ESPs lift well fluid either through single
production string (fluid from two zones
is commingled), or through concentric Intake
production string (one tubing inside the
other tubing). Also there are parallel ESP Protector
systems which can produce to the sur-
face independently. Currently systems
for dual-zone production consisting of MLE Guard
two complete ESPs in wells with cas-
ing OD 53/4", 65/8" and 7" have been Permanent Magnet
developed. Motor
The first systems were commis-
Downhole Sensor
sioned in 2011 – 2012. System
Centralizer 1
Casing 4 or 4 /2 in
Producing formation
Multi-Zone Production
Development of technologies for dently. Application of systems with
Mikhail Politov
Design engineer Research multi-zone production is of big inter- concentric production string requires
and Development Department est today. This term means a full set the wellhead equipment of corre-
ZAO Novomet-Perm of technical and technological activi- sponding design. Currently Novomet
ties allowing to impact on each zone of has developed systems for dual-zone
multi zone oil field in order to produce production consisting of two complete
in the optimal mode. Application of ESPs in wells with casing OD 5 3/4",
technologies of multi zone production 65/8" and 7".
allows to increase oil-recovery ratio, Run life of a dual system installed
production rate and flow rate of a well. in casing with OD 5 3/4" was 223 days
It also helps to increase cost efficient as of the 17th of September 2012. This
operation life of a well.
ZAO Novomet-Perm pays a lot of at-
tention to this subject and develops its
own systems for dual zone production.
Dual ESP systems designed for dual
zone production were developed by
Novomet in 2010 (please refer to Fig.
1). The main benefit of this technology ESP
is a possibility of selective control of for fluid
each dedicated ESP system. Availa- production
from upper
bility of Novomet slim-line equipment
formation
allowed to implement this technol-
ogy in wells with casing OD from 51/2".
Bypass line
Additional application of permanent
magnet motors in dual ESP systems
allowed to control each dedicated
ESP in a wider operating range.
The main benefits of this technology
are as follows:
– decrease of CAPEX on construc-
tion of an additional well;
– increase of cost-efficient lead time
of oil field development;
– decrease of OPEX;
– separated production from two
reservoirs;
– increase of intensity of multi-reser-
voir oil field development due to simul- Packer
taneous production from separate thin assembly
reservoirs with different permeability;
– installation in wells with casings OD
from 51/2";
– differential effect on each reservoir
with possibility of fluid collection ad-
justment; ESP for
– short payback period. fluid
Systems are supposed to lift fluid production
through either single production string from lower
formation
(fluid from two zones is commingled),
or concentric production string (one
tubing inside the other tubing). There
are also parallel ESP systems which
can produce to the surface indepen-
Fig. 1. Dual zone ESP systems
Tubing 7
Drain valve
Check valve
Cable
Head of
submersible
module
system is still operating. Dual system ber. The upper ESP of 319 series with Hydraulic
flow control
installed in casing with OD 6 5/8" was flow rate of 315 bpd and head of 5400ft
pipe
operating for 296 days. It was retrieved set at depth of 8800ft. It is operating
on the 4th of September 2012 for revi- at frequency of 120 Hz or 3550 rpm Pump
sion. (PMM at 6000 rpm). The lower ESP in
For the first time in the world and a shroud was also of 319 series, flow
Russia two dual systems for casings rate was 315 bpd and head was 5080 ft
OD 53/4" and 6 5/8" were installed in the set at depth of 8900 ft. It is operating
oil field of OAO Surgutneftegas. at frequency of 120 Hz or 3550 rpm
Intake
Run life of dual system in casing OD (PMM at 6000 rpm).
of 53/4" was 223 days as of 17 Septem- Dual system in casing OD 6 5/8" con-
sisted of upper ESP of 319 series with
flow rate of 315 bpd and head of 5400 ft Protector
set at depth of 7700 ft. It was operat-
ing at frequency of 120 Hz or 3550 rpm
(PMM at 6000 rpm). The lower ESP in-
stalled below a packer was of 406 se-
ries, flow rate was 530 bpd and head Motor with
was 5080 ft set at depth of 9200 ft. It Downhole
ESP was operating at frequency of 50 Hz sensor
for fluid system
Bypass line (PMM at 3000 rpm). This system was
production
from upper
retrieved on the 4th of September due
formation to damage of cable line of lower ESP.
Its run life was 296 days.
The major effect of implementation
of multi-reservoir production technol-
ogy was significant increase of well Flow
capacity by 50% and more along with crossover
short payback period (from 40 days). tool
Installation of two dual systems in
casings with OD 6 5/8" and 7" has been
Safety valve
scheduled in Gaspromneft-Muravlenk-
ovsk-neft in November 2012.
ZAO Novomet-Perm is also redesign-
ing units of dual zone system with ap- Packer
plication of one electric pump (please configuration
refer to Fig. 2). Installation in the oil field

is supposed to be in Q2 – Q3 of 2013. In
this technology installation and opera-
tion are practically the same as those
of conventional ESP systems.System
ESP with ensures regulation of fluid production
leakproof from each reservoir, commingling of
shroud for fluid
production from each reservoir fluid at the pump intake
lower formation and lift of fluid via single tubing. A spe-
cial bench allowing to conduct diverse
exploratory, parametric and accept-
ance tests of different technological
Packer
configurations of dual ESP systems.
assembly This bench helps to approximate ESP
operation to the real well conditions
primarily it is provided by operation at
pressure of 250 atm (3674 psi). Fig. 2 ESP system for dual zone
production from the same well
Valeriy Minlikaev
Head of Gas and Gas Condensate (Oil)
Production Office OAO Gazprom
Aleksandr Mokshaev
Senior Engineer
OOO Gazprom dobycha Orenburg
Farkhat Khafizov
General Director
OOO Novomet-Service
Aleksandr Elizarov ESP Operation

Experience
Director of branch Novomet-South
Advisor of General Director in the Conditions of Oil-gas Condensate Field
ZAO Novomet-Perm
on innovative equipment with High Content of Sulphide Hydrogen
Nadezhda Bezmaternykh In this article we are considering experience of installation of artificial
Head of Materials Science Lab lift equipment in Orenburg oil-gas condensate field of OOO Gazprom
ZAO Novomet-Perm
Dobycha Orenburg. Operating conditions of this oil field are characterized
by high content of Sulphide Hydrogen in the produced fluid. It leads to
sulphide stress cracking of equipment. We have developed highly reliable
ESP systems of ultra corrosion resistant design combining efforts of oil
operator and manufacturer of oil producing equipment.
In 1966 the unique oil-gas condensate Initial attempts of implementation of ar-

field was discovered 30 km from Oren- tificial lift equipment in this oil field were
burg on the border between Europe and made in 2006-2007. At this stage jet and
Asia. It had uncommon reserves and progressive cavity pumps were selected
gas content. The special Office for De- for tests. At that time sucker rod pumps
velopment and Operation of Gas Field and ESP systems needed improvement
and Construction of Gas Pipelines was for operation in the conditions of high sul-
established in 1968. This company was phide hydrogen and were not considered.
called OOO Gazprom Dobycha Oren- Trial operation of jet and progressive
burg in 2008. Gas production was start- cavity pumps showed that these types of
ed in 1974. Gas processing and helium artificial lift production could be recom-
plants were constructed for recovery of mended for a wide or selective imple-
mentation.
products containing hydrocarbon com-
But given the recent work on improve-
ponents, hydrogen sulphide, sour sulfur
ment of pumping systems for oil produc-
and helium. The major challenge was
tion specialists of OOO Gazprom Doby-
high content of hydrogen sulphide in
cha Orenburg decided to conduct trial
produced gas (up to 6%).
operation of ESP systems.
Oil production has been also the ur-
They analyzed the information about
gent problem for the company since ESP manufacturers and also conducted
the middle of 2000s. Nowadays oil wells preliminary negotiations with them. Fi-
are produced by gas-lift only. However nally OOO Gazprom Dobycha Orenburg
amount of gas was limited and special- selected ESP systems produced by
ists of OOO Gazprom Dobycha Orenburg ZAO Novomet-Perm (hereinafter referred
sized and selected equipment for artifi- to as – Novomet).
cial lift production. This decision was caused by:
In accordance with project solutions • Novomet successful operating expe-
on development of Orenburg oil-gas rience in the oil fields characterized
condensate field the Central Committee by high gas-to-oil ratio and presence
planned to install artificial lift pumping of aggressive components in the res-
equipment. ervoir fluid;
9
• beneficial conditions of provision of ANO Technopark of Orenburg State Uni- more than 5 mcm was used to minimize
equipment during the trial operation versity. Internal components contacting risks of clogging pump components with
(provision of equipment on leasing with reservoir fluid and ESP housings solids contained in killing fluid.
conditions); were manufactured from stainless steel, The well was being commissioned
• full service maintenance of supplied pump components were made of special from 23.08.2010 to 03.11.2010. Dur-
equipment by Novomet-Service. It powder because it was proved that Nire- ing this period of time collection of pro-
includes sizing and selection of the sist which is usually a base material for cess water was 350 m3. It conformed to
equipment, delivery, installation/dis- manufacture of corrosion resistant stag- volume of killing fluid when conducting
mantling, start-up, commissioning, es was inappropriate in highly sulphide workover. The well reached capacity of
supervising (permanent technical environment. At the same time powder 23 m3/ day (145 bpd) on 03 Nov 2010.
control and maintenance during the overcame sulphide stress cracking tests Given characteristics of reservoir fluids
contract validity period) and RIH and at the load of 0.8σ0.2 during 720 hours. (presence of sulphide hydrogen, asphal-
POOH operations if required; Please refer to Fig. 1. Here you can see tic resinous paraffin deposits) the follow-
• convenient location of service center microstructure of Niresist sample after ing measures were undertaken during
Novomet-South (Sorochinsk, Oren- test 22 days long in sulphide environ- the ESP operation in order to increase
burg region close to this oil field). ment. During this period depth of cor- equipment run life:
Trial operation was conducted in the rosion affect reached ~1000 mcm, type • deposition of special coating on the
oil well # 558n of the Fallow Asselskaya is selective corrosion on the borders of ESP components;
oil field. graphite impurities and austenite matrix. • inhibition of the well against sulphide
Sizing and selection of the equipment Special hanger with cable feed through corrosion;
was based on provided initial reservoir was manufactured. Topside equipment • mechanical treatment of tubing from
and well data and properties of reser- comprised of VSD and step-up trans- asphaltic resinous paraffin deposits;
voir fluids. This well was produced by former. • hot oil treatment of discharge line and
gas-lift before. Capacity of this well was However despite taken measures dur- measuring device.
12 m3/ day (75 bpd). After replacement ing the trial operation several ESP fail- The contractor performed dewax-
according to the calculations it was sup- ures were registered. All the parties con- ing operations. OOO Gasprom Dobycha
posed to produce 21 m3/day (130 bpd). cerned performed trouble shooting. The Orenburg performed hot treatments and
In terms of the data provided by tech- root cause was sulphide stress cracking inhibition according to schedules devel-
nological service of OOO Gazprom Do- of certain components of downhole unit. oped.
bycha Orenburg the vortex ESP system In order to clarify causes led to sulphide According to «Program of Identifica-
with capacity of 25 m3/day (157 bpd) and stress cracking Perm and Orenburg R&D tion of Potential Capabilities of the Well
head of 850 m (2788 f) was offered for centers were involved. After required # 558n, selection of optimal operat-
the optimal operating mode. Consider- comprehensive analysis corrections ing mode of the system «well-ESP» the
ing high content of sulphide hydrogen were introduced. well was surveyed at different operating
all ESP system components (pump, mo- The latter workover of the well # 558n modes, frequency was increased gradu-
tor, protector, gas separator, check and caused by ESP failure was conducted in ally. Replicated survey was conducted
drain valves, downhole sensor system, August 2010. When selecting materials at decreasing frequency and stabilizing
cable line) were not only of corrosion re- for downhole equipment causes of pre- mode during more than 2 days.
sistant design but were produced from vious failures were considered and ESP Based on calculations of specialists of
materials in accordance with require- system NFV190, head 3345ft of proper OOO Gasprom Dobycha Orenburg run
ments of standard NACE MRO 175-01 design was selected and prepared. life of ESP system had to be more than
and tested in highly sulphide environ- Filter of Novomet design for treatment 136 days (taking into account costs of
ment in the laboratory Nadezhnost of of killing fluid with degree of filtration not workover, leasing and service) in order to
Sulphides around
graphite impurities
1000 mcm 100 mcm
Fig. 1. – Sulphide corrosion damage of Niresist

achieve cost efficiency. The ESP system ing between specialists of OOO Gazprom 1 Sept 2011. Total run life was 377 days.
had been successfully operating since Dobycha Orenburg and OOO Novomet- Visual corrosion traces were not discov-
August 2010 therefore its run life was Service was arranged. Trial operation re- ered. Then the ESP system was delivered
longer than mentioned above. Its aver- sults were encouraging. At that time the to the manufacturer for revision and lab-
age flow rate was 23.2 m3/day (146 bpd ESP system started up in August 2010 oratory analysis.
or 18 tons of oil per day), dynamic head had been operating around 300 days. Presence of asphaltic resinous paraf-
was 210 m, pump intake pressure was It was also decided to retrieve the ESP fin deposits in pump and gas separator
108 atm. (1587 psi), frequency was 53 system when its run life would reach internal cavities were revealed. Also spe-
Hz. During the period of trial operation 360 days in order to investigate state of cialists found insignificant traces of wear
(2010-2011) about 1.5 thousand tons equipment and ultra corrosion resistance of pump operating components. Motor
were produced. properties. and protector were not damaged.
At the beginning of June 2011 a meet- The ESP system was dismantled on The following results were obtained
during laboratory tests of ESP compo-
nents:
• inspection of high-loaded ESP com-
ponents (clamps, shafts, housings)
by means of metallographic analy-
sis and tension test did not reveal
degradation of strength properties,
corrosion damage and indications
of sulphide cracking (please refer
to Fig. 2);
• it is proved by metallographic analysis
that outside surface of pump operat-
ing components suffered from insig-
nificant selective corrosion (depth of
2 mm
effect is up to 150 mcm) (please refer

to Fig. 3). For comparison: depth of
Fig. 2. – Appearance and state of bolts surface
Niresist corrosion effect during the
less time in sulphide environment
Damage area is ~1000 mcm;
• traces of explosive decompression
are revealed on several rubber items.
It indicates lack of rubber ability to re-
tain its chemical and physical proper-
ties under the impact of gas in these
operating conditions. (Please refer
to Fig. 4).
Results of revision and laboratory tests
confirmed success of implementation of
Novomet ESP system in the well # 558n
300 mcm 100 mcm
of the Fallow Asselskaya. Operating re-
Diffuser hub (etched) Impeller hub (not etched) sults confirmed that run life of downhole
equipment selected for operation in the
Fig. 3. – Corrosion damage of operating surface of friction pair
conditions of high sulphide content is at
least a year. Materials and design are still
being improved.
Currently centrifugal equipment is still
operating in this oil field. In Sept 2011 a
new ESP system NFV190, head 4330ft
was commissioned in the well # 558n. Its
current run life is 368 days. Besides one
more ESP system NFV450, head 5315ft
was installed in the well # 501. Its current
run life is 182 days. Implementation of
ESP system in a gassy well of Orenburg
oil-gas condensate field is planned in
Oct 2012.
Trial operation of this equipment in two
wells of ZAO Gazprom Neft Orenburg is
Fig. 4. State of mechanical seal (operating and back surface)
planned in Nov 2012.
11
Slim-Line ESP systems

In the century of limited oil resources • increase productivity of low capac-
one of the challenges of the majority of ity wells;
mature Russian oil fields is failure of oil • increase oil production in mature oil Sharifzhan Ageev
wells casings leakproofness. Nature of fields; Deputy General Director of R&D
the failures varies. It can be leakage of • increase oil-recovery ratio; Center Konnas
thread connections, mechanical and • develop lower and upper producing
corrosion damage of tubing and cas- reservoirs;
ing displacement. • produce oil wells which could not be
Casings leakproofness is recovered produced before by other methods.
generally by the following methods: Thank to drilling of side-track wells,
• cement or high viscous composi- it becomes possible to produce from
tions squeezing; formation areas not developed before
• installation of metal patch; and from wells with hard-to-recover
• installation of smaller diameter oil reserves.
tubes; ESP system of 319 series is Novo-
All methods mentioned above lead met innovative development. It is de- Andrey Fedorov
to reduction of casings diameter. Giv- signed for operation in wells with cas- Head of Marketing Department of
Novomet Group of Companies,
en reduced inside diameter, wells de- ing ID 4"(100mm). PhD
viation and also presence of casings It is applied in exploratory wells
where drift angle intensity exceeds an with 4" casing or wells after workover
acceptable value it became necessary with main casing of bigger diameter.
to have a range of ESPs of 319 and 338 Diameter of the smallest ESP system
series being produced recently. Till the with cable is 3.74" (95 mm).
middle of 90s Russian manufacturers
produced ESPs of only three groups:
362, 406 and 449 series.
Currently side-track wells are drilled
in a number of oil fields because of wa-
ter cut increase in well fluid produced
from existing oil wells, limitation of new
oil fields development and in order to
maintain existing level of oil produc-
tion volumes. Practice of this method
implementation indicates its technical
and economic benefits compared to
new wells drilling due to lower drilling
costs and ability to use existing system
of collection and transportation of oil
and gas and communications. Side-
track wells can be produced only by
ESPs of 319 series and smaller for ex-
ample 272 series due to small diameter
of side tracks.
Besides oil operators are consid-
ering drilling of slim line wells in new
small oil fields and also for the purpose
of costs reduction drilling of mature oil
fields where areas of oil-filled forma-
tions are still present.
Technology of side-track wells drill-
ing is widely applied nowadays. It is
one of the most effective and allows to:
Application of traditional asynchro- if required (for example in wells with side-track well and set at the depth of
nous motors of the same series is not high GOR). On the 12th of April 2010 for 8015 ft. Flow rate appeared at frequen-
reasonable due to extremely low effi- the first time the ESP of 319 series was cy of 4500 rpm.
ciency and significant length of equip- commissioned in a side-track well (well After successful operation of ESP
ment. That’s why permanent magnet # 30220, cluster 781 of oil field Samot- system of 319 series in a side-track well
motors (OD 3.19", efficiency 88.6%) are lorskoe, OAO Samotlorneftegaz). Cas- it was decided to commission a few
applied as a drive. At rotation frequency ing diameter is 6 5/8" (168 mm), side- more wells abandoned before. There-
2850-6000 rpm pumps operating range track casing is 41/2". ESP was installed fore in the beginning of June installa-
is 250-1000bpd, efficiency is 52-63% with assistance of technical specialists tion and commissioning of the second
and maximum allowed head is 11 400ft. of OAO Samotlorneftegaz. ESP of 319 series in a side-track of well
Pump stages are manufactured Before that well # 30220 was aban- # 27212 of oilfield Samotlorskoe was
based on powder metallurgy technol- doned. After drilling of a side track on performed.
ogy that’s why they have high geo- the 1st of March 2010 hydraulic frac- It should be reminded that on the 2nd
metric accuracy and enhanced gas- turing was performed and then casing of October 2008 the first ESP of 319
handling capability. ESP systems can was set for small diameters of ESPs. series was installed in the main hole
be equipped with multiphase pumps ESP was successfully installed in a of well # 102 of oil field Spiridonovs-
13
Table 1 started up in that well. Due to ESP

installation in a side-track well fluid and
Parameter Before installation After installation oil capacity was doubled if compared
to the previous ESP system which was
Q fluid, bpd 220 480 operating in the main hole. As of today
Q oil, bpd 160 350 run life is 491 days. You can find and
F, Hz (rpm) 50 (2910) 160 (4800) compare data before and after ESP
of 272 series installation in Table 1.
PSD, ft 5000 6335
Every ESP installed in a side-track
Load, % 56 58 well is equipped with a special central-
I,current.,А 19 20 izer located on a motor base (downhole
sensor). It simplifies entry in a side-
H dynamic,ft 3920 5456
track well. Along the whole length of
a side-track MLE guards are installed.
koe NGDU Buzulukneft (OAO Oren- sidetrack window milled at 6430ft MD 21 ESPs were installed, 6 of them are
burgneft). Due to well intervention this (6332ft TVD). still operating (table 2).
ESP was dismantled on the 31st of 2010. ESP system NAV(190-380)H, Efficiency of side-track wells produc-
Its run life was 574 days. Equipment Q=315 bpd, H=7546 ft (@ 4850 rpm) tion is higher compared to production
was installed again after these activi- was installed. Setting depth was from the main hole of the same reser-
ties conduction. 7385 ft. During RIH strain relief oc- voirs due to possibility of high pressure
Experience of ESP of 319 series curred at depth of 6683 ft upper the drawdown generation.
operation in wells of Gazpromneft, calculated setting depth. After nego- It should be considered that deviation
Rosneft, Russneft, Slavneft, and Pe- tiations it was decided to start up and of side-track wells is high because
choraneft confirms high efficiency and commission the ESP. In two hours of equipment installation was not
reliability of this equipment. operation fluid started flowing at the planned when drilling. In accordance
As of today the total number of 319 well head. In 8 hours of operation the with technical conditions acceptable
series running is 120 ESPs. ESP stopped due to pressure drop at rate of hole deviation for slim-line
Development of ESP of 272 series the pump intake (a value of pressure equipment should not exceed 4o per
was started in February 2010 and in a became lower than acceptable). When 33ft of length. In the zone of tubing
year – in February 2011– the ESP sys- revising shaft breakage was revealed hanger hole deviation should not
tem was installed in the first time in the due to operation in extremely high de- exceed 15arc-minutes per 33ft. As
world in well # 37207 of TNK-BP Samot- viation. nowadays we have unique equipment
lorskoe oil field. Diameter of main hole Another well was selected for further enabling operation from side-tracks,
casing was 6 5/8" (168 mm), diameter operation, on the 20th of June, 2011; then while drilling more attention shall
of side-track casing was 4"(102 mm), ESP of 272 series was installed and be paid to their quality.
Table 2
Run life,
Oil field Well Cluster Status ESP system Start date
days
NAV(190-380)H
Uvakhskaya 75333u 4090 In operation 25.08.12 6
Q=315 bpd, H=7546 ft (@ 4850 rpm)
NAV(190-380)H
Samotlorskoe 26697 2143 In operation 21.12.11 254
Q=315 bpd, H=7546 ft (@ 4850 rpm)
NAV(190-380)H
Rechitskoe 88 In operation Q=190 bpd, H=7380 ft 06.03.12 178
(@2910 rpm)
NAV(190-380)H
Malobalykskoe 7966 583б In operation Q=380bpd, H=7874 ft 09.08.12 22
(@5820 rpm)
NAV(440-630)H
Priobskoe 5268 288а In operation Q=500bpd, H=6725 ft 23.08.12 8
(@4660 rpm)
NAV(190-380)H
Rechitskoe 36 In operation 26.07.12 36
Q=190 bpd, H=7380 ft (@ 2910 rpm)
Data as of October 2012

Influence of Viscosity
on Operating Characteristics of Centrifugal Pumps
Usually operating characteristics of submersible pumps in highly

viscous fluid are calculated on the base of operating characteristics in
water using empirical dependences established more than 50 years
Samir Abakhri ago. Error of this calculation is 10-25% and it is due to the change of
Research engineer of Engineering
Technical Center of R&D Department, pump construction within this period of time. We conducted direct
ZAO Novomet-Perm measurements of operating characteristics of serial pump stages of 319,
338, 362 and 406 series with rated flow rate of up to 1890 bpd in viscosity
range 10 – 400 cSt. Error of measurement of head, flow rate and power
was 5%. We suggested a method of pump selection and sizing for highly
viscous oil wells.
Influence of fluid viscosity on operat- One of empiric methods was sug-

ing characteristics of centrifugal pump gested by Mr. Stepanov [1] for submers-
was the issue of high interest for many ible pumps. The other method was sug-
decades. Every year reserves of easily gested by the USA hydraulic Institute [2],
Maxim Perelman producing lowly viscous oil reduce and where pumps of various OD were tested
VP International
ZAO Novomet-Perm production of highly viscous oil becomes in a wide range of flow rates and heads
more and more actual. Very often it can in fluid of various viscosity from 1 cSt
be produced by centrifugal pumps how- to 3600 cSt.
ever we should consider viscosity influ- Procedure of Mr. Gulich [3] is based
ence on operating characteristics when on assessment of viscous losses inside
selecting and sizing. a pump.
Currently two groups of models are ap- According to data of Mr. Gulich and
plied for forecasting of operating char- Mr. Lee [4] Hydraulic Institute carried
acteristics of pumps producing viscous out tests within narrow limits of pump
fluids. They are empiric and calculating. specific speed which were not common
Empiric methods allow to obtain char- to oil pumps. Mr. Lee collected data on
acteristics of pump producing viscous operation of conventional pump API in
Sergey Pescherenko
Head of Engineering Technical Center fluid on the base of recalculation of char- water and oil with viscosity form 1 to 200
of R&D Department, acteristics in water by unitless param- cSt. Its equalizing factors differed from
ZAO Novomet-Perm eters and equalizing factors obtained factors of Hydraulic Institute by 10% re-
PhD
from experiments in highly viscous fluid. garding head, 5% regarding flow rate and
Often such methods give acceptable re- 9.7% regarding efficiency.
sults only when a pump operates at best In the report [5], presented on the an-
efficiency point. It is sufficient constraint nual SPE Workshop, USA, 2007 it was in-
if a centrifugal pump is applied for lift of dicated that such methods of calculation
fluid from an oil well. It is caused by the of equalizing factors might be incorrect in
fact that equalizing factors were calcu- case of pumps different from models.
lated only for model pumps and not for Soviet scientist Mr. Lyapkov [6] sug-
pumps applied nowadays. Benefit of gested his own method based on ex-
this method is that it allows to determine perimental data of tests of submersible
Aleksandr Rabinovich characteristics if testing data in water are pumps in viscous fluid. It showed factors
Advisor of General Director
available. for recalculation of head and efficiency
on New Equipment
ZAO Novomet-Perm
1. L. Stepanov Centrifugal and Axial Pumps – theory, design and application, the second edition, State
Scientific and Technical Publishing House of Machine Building Literature, 1960.
2. Hydraulic Institute, Standard for Effects of Liquid Viscosity on Rotodynamic (Centrifugal and Vertical)
Pump Performance, 1983, USA.
3. Gulich J.F., Centrifugal pumps. Second Edition, Springer, 2010.
4. Li V.G. Experimental Research of Technical Characteristic centrifugal pumps. World Pumps, 2002, №26.
5. Gilmar Amaral, Valdir Estevam, Petroleo Brasileiro and Fernando A. Franco, SPE, State University
of Campinas, Influence of Viscosity on ESP Performance, 2007 SPE Annual Technical Conference and
Exhibition, Anaheim, California, 11 – 14 November.
15
10 Fig. 1. Scheme of bench for pumps testing in highly viscous fluid

for different flow rates depending on fluid 1 – Tank with viscous fluid, 2 – motor, 3,4 – pressure sensors,
viscosity. Many Russian companies use 5,6 – temperature sensors, 7,8 – tap valves,
recalculation methods based on method 9 – pump tested, 10 – flow meter
of Mr. Lyapkov.
Computation models use computa-
tional fluid dynamics, CFD for calculation
1
of flow in pump flow channels and esti-
mation of viscosity influence on the final
characteristics. Their main disadvan-
tages are as follows: high work content, 7
sufficient duration, usage of turbulence 2 3 9 4 8
empirical models tested for conditions
different from researched and that’s why
NOVOMET
very often results do not ensure correct
forecast of characteristics. 5 6
It is obvious that empirical model is
preferable because its accuracy and ap-
plicability is higher than those of compu-
tation model. As it is shown above results of empirical meth-
ods depend on pump construction and testing conditions and
500
they can differ from each other significantly. Construction
of oil pumps is constantly being enhanced. New technologies
of stages manufacturing, for example, powder technology [7], 400
or new centrifugal vortex and Power Save pump stages [8] ap-
pear. That is why it is not correct to apply generic methods de-
veloped many years ago to contemporary centrifugal pumps. 300
Viscosity, cSt
It is necessary to determine dependence of operating charac-

teristics change on fluid viscosity experimentally for accurate
200
recalculation of submersible pump characteristics. Develop-
ment of computerized benches with accurate electronic sen-
sors allows to read out actual parameters of stages quicker and 100
more accurate that by CFD calculation.
0
Experimental ESP system and Tests
70 105 140 175
Bench for direct determination of submersible oil centrifugal
Temperature, F
pumps characteristics in highly viscous fluid has been devel-
oped. Its scheme is presented in Fig.1. Pressure at the pump Fig. 2. Dependence of model fluid viscosity on temperature
intake is sustained due to fluid level in a container 1 at the level
of 0.1 atm. Diameter of supply pipeline is 2.4" for prevention
of cavitational breakdown production. Glycerin water solution Pressure generated by a pump was registered by pressure
is applied as power fluid. Viscosity of power fluid can be set up sensors installed before and after the pump. (Fig. 1, posi-
within limits of 1-1000 cSt due to system of temperature control tions 3, 4). This method was compared to a method of direct
(70 – 130F) located in container 1 and change of glycerin con- reading out of pump stage pressure through orifice in a diffuser.
centration. Accuracy of fluid temperature at the pump intake Data regarding a pump stage head were the same.
is ±3.6F. Heating of fluid when passing through a pump 9 con- Novomet serial pump stages were tested. List is presented
sisting of 3 – 7 pump stages does not exceed 5.4–7.2F. Typical in Table 1.
dependence of model fluid viscosity on temperature is present-
ed in Fig.2. Glycerin content is 95%, water content is 5%. Fluid Table 1. List of pump stages tested in highly viscous fluid
flow was measured by a flow meter of volumetric type with flow (rated flow rate, bpd is indicated)
rate range of 377 bbl/h (9056 bpd) – 3773 bls/h (90562 bpd), Series: 319 338 362 406
viscosity range was 1.1 – 6 cSt. In order to correct readouts
190, 315,
of flow meter at other flow rates and viscosity of pumped fluid Centrifugal radial stages 500 - 1260, 1420
500, 1260
measurement by means of gauge tank was performed. It was
90, 120, 160, 160, 210, 220,
determined that in flow rate range of 0 – 2500 bpd and pumped Centrifugal vortex 250 - 190, 280, 370, 315, 630, 780,
fluid viscosity of 1-400 cSt error of a flow meter was about 500, 630, 790 1000, 1250
3-5%. Frequency of pump shaft rotation was 2910 rpm. Pump Mixed flow stages - - 1260 2015
shaft torque was measured by torque-control clutch (accuracy
rating is 0.1). Partial stages - - - 160
When testing generic principles for some types of pump stages 35

were determined. The less specific speed of a pump the more
decrease of efficiency, it conforms to results [1]. For example 30
when increasing viscosity from 1 up to 40 cSt efficiency of pump
stage NHV 260 decreased by five times (Fig.4). At the same time 25
efficiency of pump stage NH (1600-2300)H decreased only by
2.7 times (Fig.6). 20
4
Head, ft
It is determined that viscosity does not influence on vortex ef-
fect in centrifugal vortex stages operating at low and medium flow 15
rates. Stages operating at rated flow rates of 160 bpd, 500 bpd
and 790 bpd with crowns and without them were tested. Charac- 10
teristics of corresponding stages were the same. Difference of 3
characteristics is compatible with measurement error. 5 2
In general generic principles about change of performance of 1
various pumps have not been traced (Fig 3, 5). 0
Comparison of method results [5] is presented in Fig. 7-8. In 0 50 100 150 200 250 300 350
operating range calculation leads to error of 10-25%. In practice it Capacity, bpd

leads to breakdown production and retrieval of ESP system. Fig. 3. Dependence of head on flow rate of pump stage
NH (1600-2300)H at different viscosities: 1 – 130 cSt, 2 – 55 cSt,
As a result of experiments polynomial dependence of each
3 – 40 cSt, 4 – 1 cSt
stage characteristics on fluid viscosity has been detected. It al-
lows to evaluate operating parameters of submersible pumps 40
such as head, flow rate and consumed power when pumping well 4
fluid in wide range of viscosity (1-400 cSt). It is confirmed that
similarity laws hold valid when pumping fluid of any viscosity but 30
Efficiency, %
accuracy is lower than that of water [1]. When increasing number

of revolutions power increases less than number of revolutions
raised to three and head increases more than number of revolu-
tions squared. 20
It was also consumed that the higher viscosity is the less its
harmful influence is. It means that if viscosity increases from
1 up to 20 cSt characteristics will worsen more that if viscosity 10
increases from 20 up to 40 cSt.
3
1 2
Method of viscosity consideration 0
0 50 100 150 200 250 300 350
when selecting ESP system
Capacity, bpd
During production oil is heated in a pump, its viscosity decreas-
Fig. 4. Dependence of efficiency on flow rate of pump stage
es that’s why operating characteristics of similar pump stages NH (1600-2300)H at different viscosities: 1 – 130 cSt, 2 – 55 cSt,
change according to pump length. For determination of total 3 – 40 cSt, 4 – 1 cSt
head and power consumption of the whole ESP system it is nec-
essary to calculate operating characteristics of each pump stage. 30
Input calculation parameters are as follows:
– characteristics of centrifugal stages obtained from high- 25
ly viscous fluid tests presented as dependences ,
, where H – head, Q – flow rate, v – viscosity of
20
4
pumped fluid, N – power of one stage, m – frequency of shaft ro-
tation during testing;
Head, ft
– dependence of well fluid viscosity v on temperature: v = v(T). 15

3
– dependence of well fluid density and heat ca-
2
pacity C on temperature: = (T), С = С(T) (depend- 10 1
ence on temperature is weak: at Т = 40°С: / = 0.02,
С/С = 0.06);
– temperature of well fluid T1 at pump intake. 5
The order of calculation of pump parameters with z stages op- 0

erating in highly viscous fluid at frequency m is as follows: 0 500 1000 1500 2000 2500
1. to determine fluid viscosity in the first stage: Capacity, bpd
v1 = v(T1), (1) Fig. 5. Dependence of head on flow rate of pump stage
NHV 260 at different viscosities: 1 – 130 cSt, 2 – 55 cSt,
2. to determine fluid temperature in every stage:
3 – 40 cSt, 4 – 1 cSt
17
80
, (2)
4
60 where – dependence of pump efficiency on flow
Efficiency, %
rate and viscosity of fluid penetrating into the pump.

Then we express efficiency in terms of flow rate and other
known dependences of head and power on flow rate and viscos-
40
ity recalculated for frequency of ESP shaft rotation:
3
20 2
1 (3)
Given this expression (3) we solve the equation (2):
0
0 500 1000 1500 2000 2500
Capacity, bpd
Fig. 6. Dependence of efficiency on flow rate of pump stage
NHV 260 at different viscosities: 1 – 130 cSt, 2 – 55 cSt, (4)
3 – 40 cSt, 4 – 1 cSt
30
3. Then we calculate fluid viscosity in each stage by the
known dependence
25 (5)
1 2
4. We determine total characteristics of the whole pump
20 given head and power of each stage:
Head, ft
n m
z 2
15 
H pump     H i  Q, vi 1  (6)
i 1  m  n 
10
 n  m
z 3

N pump     N i  Q, vi 1  (7)
5 i 1  m  n 
gQH pump 
 pump  (8)
0
N pump
0 500 1000 1500 2000
Capacity, bpd Example of calculation of pump NFV190 characteristics ac-
cording to the mentioned method is presented below. This pump
Fig. 7. . Dependence of head on flow rate of pump stage
consists of 200 stages, it operates in glycerin ( =1250 kg/m3),
NH (1600-2300)H: 1 – 40 cSt, experiment; 2 – 40 cSt,
recalculation according to the method [5] viscosity is 212 cSt, heat capacity is 2.43 J/(g*K) and tempera-
ture is 86F at flow rate of 95 bpd.
45
Table 2. Calculated Characteristics of Pump NFV190 Stages when
2 pumping highly viscous fluid
Viscosity of
Efficiency, % Head, ft Power, hp
pumped fluid, cSt
Efficiency, %
30 1
The first stage 0.3 2.3 0.75 212
The last stage 12.2 13.0 0.09 23.6
15 Pump averaging 5.3 9.2 0.14 63.67
Water 28.0 17.7 0.04 1
0 Head of such pump is 1800 ft.

0 500 1000 1500
Capacity, bpd Example of calculation of pump NH (1600-2300)H character-
istics according to the mentioned method is presented in Ta-
Fig. 8. Dependence of efficiency on flow rate of pump stage ble 3. It consists of 200 pump stages and operates on glycerin
NH (1600-2300)H: 1 – 40 cSt, experiment; 2 – 40 cSt,
recalculation according to the method [5]
( =1250 kg/m3), viscosity is 212 cSt, heat capacity is 2.43 J/ (g*K)
and temperature is 86F at flow rate of 330 bpd.
Table 3. Calculated Characteristics of Pump NH(1600-2300)H Stages

when pumping highly viscous fluid List of References
1. L. Stepanov Centrifugal and Axial Pumps – theory, design and
Viscosity of pumped
Efficiency, % Head, ft Power, hp application, the second edition, State Scientific and Technical
fluid, cSt
Publishing House of Machine Building Literature, 1960.
The first stage 12 11 0.53 212 2. Hydraulic Institute, Standard for Effects of Liquid Viscosity on
Rotodynamic (Centrifugal and Vertical) Pump Performance,
The last stage 22 19 0.18 44 1983, USA.
3. Gulich J.F., Centrifugal pumps. Second Edition, Springer,
Pump averaging 14 14.4 0.49 101 2010.
4. Li V.G. Experimental Research of Technical Characteristic
Water 48 22.6 0.21 1
centrifugal pumps. World Pumps, 2002, №26.
5. Gilmar Amaral, Valdir Estevam, Petroleo Brasileiro and
Head of such a pump is 2890 ft. Fernando A. Franco, SPE, State University of Campinas,
Influence of Viscosity on ESP Performance, 2007 SPE Annual
According to calculated data consumed power and head of the Technical Conference and Exhibition, Anaheim, California,
first and the last pump stages can differ several times. That’s why 11 – 14 November.
it is necessary to calculate operating parameters of every pump
6. P. Lyapkov, Influence of viscosity on submersible centrifugal
stage in highly viscous fluid for the objective assessment.
pumps performance. Research Institute, edition 41,
Subsurface Area, 1964
Conclusions 7. Sh. Ageev, E. Grigoryan, G. Makienko, Russian Rotary Vane-
Pumps, oil production and application. Encyclopedic reference
As a result of this research a testing bench has been developed
book, Perm, OOO Press-Master, 2007, p. 645
and dependences of head and power of oil pump stages on flow
rate in pumped fluids of various viscosity (1-400 cSt) have been 8. S. Yakimov, Main Directions of Activities on Increase of Energy
Efficiency of Artificial Production. // Engineering Practice –
measured. Also a method of ESP selection was suggested. It al-
2011 – No. 5 – p 45-48.
lows to determine required number of pump stages and best ef-
ficiency point more accurately. 9. L. Kaplan, A. Semenov, N. Rasgonyaev. Production from
abnormal wells by centrifugal electric pumps, Moscow,
Subsurface Area, 1994
10.G. Fuks, Viscosity and Plasticity of Oil Products. – Moscow-
Izhevsk, Institute of Computer Research, 2003, p.328
19
INCREASE OF MOTOR
TEMPERATURE Evgenii Poshvin
ZAO Novomet-Perm
APPLICATION RANGE R&D Director
BY MEANS OF MOTOR
COOLING UNIT
Novomet specialists carried out bench testing of motor cooling unit
with heat pipes. The tests showed that at 115 bpd (15 m3/day) flow rate
the stator winding temperature decreases by 60 F (15°C) comparing to
epoxy encapsulated motor.
Motor reliability is identified through its operating temperature. Winding overheating re-
duces its runlife [1] while oil heating in the bearing reduces the load-carrying ability of hy-
drowedge [2], which increases the possibility of dry friction and bearing wedging.
Today average motor operating temperature is increasing, which is caused by the follow-
ing reasons:
• Wide application of oil production intensification technology by means of reservoir
depression increase and decrease of pump intake pressure below bubble point pressure,
i.e. presence of undissolved gas in the produced fluid and decrease of motor cooling;
• Increase of oil wells depth
In order to improve motor runlife it was de-
cided to increase motor heat resistance and
heat conductivity of electrical insulating ma-
terials, reduction of possibility of gas storage
Condensation zone
in between the insulation layers [3]. However,

there is still a possibility of motor overheat in
low flow rate wells or at high undissolved gas
content when the produced fluid is not enough
for motor cooling.
In this case it is necessary to intensify heat
transfer from the motor to the cooling fluid by
means of heat exchanger application, such as
heat pipes.
Heat pipe configuration and function
Heat pipe is a leakproof metal pipe with wick
made of capillary-porous material attached to
the sides which is treated with heat-transfer
agent. The volume free of wick is a steam ca-
Evaporating zone
nal (see Fig.1 where 1 – metal pipe, 2 – wick,

3 – motor housing, 4 – steam canal, 5 – rib-
bing). Evaporative zone of the heat pipe is lo-
cated in the heat supply area – motor oil-filled
chamber. Condensation zone is located in the
heat sink zone, i.e. in the well fluid.
Inside the heat pipe there is a closed evap-
orating condensation cycle of heat-transfer
agent, which provides effective heat conduc-
tivity coefficient along the axes which is 2-3
times bigger than the one of aluminium or cop-
per rods. Fig. 1 Heat pipe
The testing was performed in the test well with the inside diam-
eter 5.8 in. Specialists measured relation of the average winding
temperature to motor shaft load at different speed of motor cooling
fluid (water).
Average winding temperature was calculated by the measured
electric resistance and the relation of wires material resistance to
the temperature.
The first resistance measurement was performed when the mo-
tor was cold (6 hours without operation). Winding temperature was
considered equal to ambient temperature.
Resistance of each motor winding (the phase pairs are connected
Pump serially) was measured at different direct current values not exceed-
ing 5% from the nominal and calculated the average value.
In order to measure the resistance in the heated condition there
was chosen a phase couple which ohmic resistance in a cold condi-
Heat tion had an intermediate value. There were six measurements being
taken every ten seconds. Load generator was used as a motor load,
pipes it returned the energy back into the network.
Winding temperature was calculated from the cooling fluid tem-
perature, which is basically calculating the winding heating value.
Testing was performed with the cooling fluid speed 0.05 and
0.2 m/sec. The results obtained are shown in Fig. 3 and Fig. 4.
It shows that oil circulation (hole inside the shaft – gap be-
tween the stator and rotor) reduced the stator temperature
at u = 0.05 m/sec (see Fig. 3), and did not do any changes
at u = 0.3 m/sec (see Fig. 4). Therefore, the heat flow coming from
the inner motor areas leading to the end parts was a lot less due to
oil circulation, than from the motor side surfaces.
Cooling with heat pipes decreased stator heating dramatically at

u = 0.05 m/sec and barely decreased at u = 0.3 m/sec. Lets analyze
the result.
Let’s formulate the heat flow from the motor to the cooling fluid
as: (1)
where – winding heating, – heat transfer coeffi-
cient, u – cooling fluid speed, S – side surface area.
Heat flow from motor to the cooling fluid does not depend on its
speed and at fixed motor load there is an equation:
Fig. 2 Scheme of motor heat sink (2)
At 60 kW load in Fig. 3 and Fig. 4 we get ∆T(0.05) = 48°С and

∆T(0.03) = 26°С. Substituting these values (2) we get:
Operating principle of motor heat
pipes cooling system (3)
During motor start-up oil circulates along the closed loop and which shows that according to the experimental data at cooling
heats up to T2 temperature. Heat pipes evaporators located in the fluid speed increase from 0.05 m/sec up to 0.3 m/sec the heat re-
oil-filled motor chamber also heat up to T2 temperature. Heat trans- lease coefficient doubled.
fer agent saturating the wick begins to boil and evaporates. The oil, In order to check the reliability of the data below let us use the re-
washing the evaporators, looses the heat equal to the heat of heat- lation of heat transfer coefficient and flow speed. Fist of all we need
transfer agent evaporation and oil is cooling. to clarify whether the flow was laminar of turbulent.
Condensation areas of the heat pipes washed by the reservoir
fluid keep the reservoir fluid temperature T1. The vapors produced At u = 0.05 m/sec, gap between motor and casing wall
by the heat-transfer agent get into a steam canal and move towards mm (0.6 in) the flow is laminar, because
the condensation zone of the heat pipe with lower steam pressure Reynolds number and is less than the critical
and Т1 temperature. Here the steams condensate and liquid heat- value Reкр ≈ 2000. Then, according to [5]
transfer agent absorbs into the wick pores. Released latent con-
densation heat of heat-transfer agent is transferred through the (4)
condenser wall to the reservoir fluid.
Heat-transfer agent, absorbed into the wick pores in the conden- l – motor length, λ – fluid heat transfer coefficient, Pr – Prandtl
sation zone, returns to the evaporator, being under the capillary number at cooling fluid temperature (Prж) and motor wall tempera-
forces and load, and evaporates again.
ture (Prc).From (4) we get:
Design of motor with built-in heat pipes and forced oil circulation
has been patented [4]. The target was to perform bench testing and
identify the operating effectiveness of the design. (5)
Motor bench testing which corresponds to the experimental data (3). The result (5)
Motor N460AM100 completed with a cooling unit with heat pipes is to be considered a rough evaluation of speed influence on heat
and a pump which provides oil circulation (see Fig. 2) was chosen transfer, as during speed increase the flow turbulizes while relation
for the bench testing. Motor stator was epoxy encapsulated [3]. (4) is true for laminar flow.
21
Average stator winding heating, °C
Motor load, kW Average stator winding heating, °C Motor load, kW
Fig. 3. Relation of epoxy encapsulated motor stator heating Fig. 4. Relation of epoxy encapsulated motor stator heating
at cooling fluid speed 0.05 m/sec: 1 – without additional heat at cooling fluid speed 0.3 m/sec: 1 – without additional heat
sink system; 2 – with oil circulation; 3 – with oil circulation sink system; 2 – with oil circulation and cooling pipes
and cooling pipes (no results with oil circulation as they barely matched curve 1)
At fixed load heat sink from the motor with and without heat pipes becomes worse.
is one and the same: This means that the provided design of heat sink with the heat
pipes is effective at low cooling fluid speed ≤ 0.05 m/sec. This
(6) gives us the reason to state that motor with outer diameter 4.6
where , – heat flow sunk by the heat in (117 mm) in 5.7 in (146 mm) casing (with inner diameter 5.1 in
pipes. (130 mm)) will be effectively cooled at flow rates Q < 115 bpd
At u = 0.05 m/sec, see Fig. 3, (6) is as follows: (15 m3/day). Stator winding temperature of the motor with cooling
heat pipes will be around 60 F (150°C) less.
where . The same was at u = 0.3 m/sec,

see Fig. 4, (6) is as follows:
where . These results together with (3) give:

(7)
Fig. 5. Scheme of fluid flow lines in the channel with the «step»
This means that heat flow, sunk by the heat pipes decreased two
times at cooling fluid speed increase from 0.05 m/sec up to 0.3 m/sec. Conclusions
1. Novomet provided new design of motor cooling with heat
In the first approach we can tell that is proportional to tempera- pipes with performance of all necessary bench tests.
ture difference in the area of evaporation and working fluid conden- 2. Novomet specialists performed evaluation of heat flows
sation ∆T, i.e. through the motor housing and the proposed cooling system. It is
(8) proved that the system effectiveness is reached at flow rates less
than 115 bpd (15 m3/day).
where αt(u) – effective heat transfer coefficient, St – heat pipe 3. Comparing to epoxy encapsulated motor the average stator
surface area. If we substitute (8) with (7) we will get: winding temperature decreases by approximately 60F (150°C).
(9)
Reference list
Fig. 4 leads to ∆T0.3 = 24°С, and Fig. 3 leads to ∆T0.3 = 34°С. If we
substitute these values in (9) we will get: 1. Ermolin N.P., Zhirikhin I.P. Reliability of electric machinery.
St. Petersburg: Energy. 1976. page 248.
,
2. Loytsyansky L.G. Mechanics of liquid and gas. Moscow: Drofa. 2003.
page 840.
i.e. effective coefficient of heat pipe heat transfer doubled at in-
crease of cooling fluid speed from 0.05 m/sec up to 0.3 m/sec. 3. Poshvin E.V. Heat-resistant submersible electric motor // Drilling and oil.
2011. No.11. page 46-49.
The explanation is that heat pipes are located in the pit, formed by 4. Russian Federation patent No. 2295190. Submersible oil-filled electric
the «step» in the motor housing, see Fig. 2. Flow behind the «step» motor. Published: 10.03.2007. Bulletin No.7.
carries a vortex, see Fig. 5. Liquid is heated inside the vortex, but 5. Mikheev M.A., Mikheeva I.M. Heat transfer grounds. Moscow: Energy.
is not carried away by the flow. Vortex makes heat sink worse. At 1977. page 344.
cooling fluid speed increase the vortex gets bigger and heat sink
Anatoly Santalov
Head of Submersible Motor
Department R&D center Konnas
Oleg Perelman
General Director of Novomet GC
Advisor of General Director
regarding new equipment,
ZAO Novomet-Perm SUBMERSIBLE
Evgenii Poshvin
Director of R&D Department,
ZAO Novomet-Perm
PERMANENT MAGNET
Sergey Koshelev MOTORS
Deputy Chief Designer regarding
submersible motors, Background, design characteristics,
ZAO Novomet-Perm
capabilities
Ivan Khotsyanov
Research engineer This article is devoted to analysis of innovative developments in
R&D center Konnas the area of permanent magnet motors, their design characteristics,
influence of VSD software on motors efficiency and calculations and
measurements of ESP power efficiency equipped with such machines in
the testing and operating conditions.
History of permanent magnet motors In 1997 the ESP equipped with PMM
development for ESP systems in Russia with rated frequency up to 9000 rpm and
counts more than 15 years. power of 47 hp, developed by Design Bu-
In October 1996 OAO Alnas and reau Neftemash, was manufactured [3]
ZAO Avanto for the first time demonstrat- and in 1998 it was run in hole. Currently
ed the ESP equipped with permanent small ESP batches «Tsunar» and «Akm»
magnet motor of power of 45 kW (60 hp) operating in frequency range of 7000-
and frequency of 6000 rpm at the exhibi- 10 000 rpm are manufactured. The total
tion «EXP Production and Operation. It number of such ESPs various modifica-
was carried out in Almetevsk in testing well tions manufactured was 180.
of OAO Alnas [1]. ESP (motor + protector The total number of operating PMM as
+ pump) was 18 ft long and provided flow of the end of 2010 came near to 5000 ac-
rate of 880 bpd and head of 3900ft. Trial cording to our data. There is a big num-
batch of 105 ESP systems with three-wire ber of articles about PMM, not less than
and single-wire supply line was manufac- 7 patents and 3 PhD theses. First com-
tured for trial operation. Despite positive mercial batches have been supplied into
testing results manufacturing of perma- international markets.
nent magnet motors was stopped due to Authors have got information about the
insufficient reliability of pumps. same machines in different countries.
At the end of 1996 PMM model was However we could not find data about
developed by OAO Aeroelektrik under manufacturing of such equipment and,
the order OAO Lukoil. In 1998 trial opera- moreover, its operation beyond the bor-
tion of ESPs with PMM at rated frequency ders of Russia.
of 3000 rpm was performed. The total Novomet started development and im-
number of electric motors with frequency plementation of permanent magnet mo-
of 3000 rpm [2] for ESPs and low-speed tors in 2005. Also a target was to cover
PMM for progressive cavity pumps, the series range from 3.19" to 7.44",
manufactured by Engineering Center rotation frequency range from 100 to
Ritek, had been 2000 motors by the year 6000 rpm and power up to 1600 hp Prior-
of 2011. ity of production implementation was de-
[1]. A. Santalov Permanent Magnet Motors for submersible pumps. Collection of reports of VI Russian
Technical Conference ESP Operation and Production, Almetyevsk, 1996.
[2]. V. Pavlenko, M. Ginsburg, Trend of replacement AM with PMM: the world is following Lukoil’s innovation.
Oil&Gas Vertical 2010, # 20.
[3]. N. Shengur, A. Ivanov Myths and reality of implementation of PMM in ESP. Engineering Practice, 2011, #
3.
23
fined by oil operators’ demand. Currently Design of permanent magnet motors magnetic clearance if compared to
company manufactures the following se- differs from that of asynchronous mo- permanent magnet motors of other
ries of permanent magnet motors: tors. The general difference is that per- manufacturers. They do not contain soft
• Series 319 with rated rotation fre- manent magnets are located on a rotor magnetic poles, therefore, their bearings
quency of 6000 rpm, power of up to instead of a short circuit squirrel cage. It are subjected to less loads by forces of
120 hp of a single section. leads to a range of benefits such as high- one-sided magnet attraction and po-
• Series 460 with rated rotation fre- er efficiency if compared to that of asyn- tentially have higher life time. Stator is
chronous motors, smaller dimensions encapsulated; a temperature sensor is
quency of 3000 rpm and 6000 rpm, pow-
and also some special features which located inside winding. Downhole sen-
er of up to 290 hp and 530 hp of a single sor systems are developed for all series
section respectively. can reduce life time and reliability if they
of motors, their average run life is more
• Series 512 with rated rotation fre- are not considered at the design stage.
than 700 days.
quency 3000 rpm and 6000 rpm, power • Firstly permanent magnets, espe- Electric motor rotor rotating at fre-
of up to 400 hp and 800 hp of a single cially NdFeB, are exposed to corrosion quency of up to 3000 rpm has conven-
section respectively. that’s why it is necessary to ensure reli- tional design with solid shaft and bear-
Preparation of production of perma- able magnet insulation. ings in stator counterbore. In design of
nent magnet motors of 406 and 744 se- • Secondly, there is magnetic attrac- motors rotating at frequency of more
ries at rotation frequency of 3000 and tion between rotor packs and stator in than 4000 rpm innovative solutions are
6000 rpm and low speed (100-1500 rpm) permanent magnet motors. Serial asyn- applied. Due to these solutions and pre-
permanent magnet motor of 460 series chronous magnet motors, as a rule, have liminary balancing of packs it is possible
with rated torque of about 800 N-m of a got one pair of poles that is why, despite to get low vibration level during initial mo-
single section. small electromagnetic clearance, mag- tor assembly and replacement of rotor
netic attractive forces between rotor and packs as well.
The main purpose of permanent mag-
stator are practically absent in perma- Dependence of vibration velocity on ro-
net motor at 6000 rpm is operation with
nent magnet motors. All known perma- tation frequency for permanent magnet
«Power Save» ESPs, complicated multi- motor of 530 hp (series 460) is present-
nent magnet motors have got more than
component pumping systems (Y– tool, ed in Fig.1. Its design is similar to motors
one pair of poles. It leads to appearance
multi-zone production, «tandem») and in rotating at frequency of 3000 rpm. For
of one-sided magnet attraction forces
side-track wells with OD 41/2" and 4". comparison the same characteristics of
which additionally load bearings shift-
For the moment Novomet is the only the same motor are presented in Fig.2.
ing rotor packs relative to the rotation
one company in the world, producing But here elements for vibration reduction
axis. It leads to increase of misbalance
ESP systems for side tracks of such small are installed. In both cases rotor packs
especially at high rotation frequency.
diameter. were balanced preliminarily. It is visible
The more mentioned forces are the less that level of vibration velocity in reso-
The total number of permanent mag-
electromagnetic clearance between sta- nance points is reduced by 2.5 times.
net motors supplied to our customers is
tor and rotor is and the higher magnetic Design reliability of permanent mag-
more than 1000.
conductivity of rotor elements faced to net motor exceeds total reliability of
Now application benefits of such mo-
stator is. ESP systems which they are applied in.
tors application is doubtless. In terms of
If due attention is paid to these features, Analysis of operation of 251 ESP systems
rotation frequency of 1500 – 4000 rpm
it is possible to achieve big run lives. equipped with such motors confirms this
their efficiency is higher by 6-9 % than
conclusion. Average total forecast reli-
efficiency of induction motor controlled
Design Features ability of this batch according to the cal-
by frequency converter. At the same sup- culations by Novomet is 594 days, aver-
ply voltage consumed current is lower In Novomet permanent magnet mo- age forecast design reliability of motors
by approximately 20%. There are no al- tors sealing of magnets is performed by exceeds 2500 days. In operation [4] it is
ternatives to these motors both at rota- elements of special design excluding showed that difference of forecast and
tion frequency from 100 to 1500 rpm and contact of permanent magnets with fluid actual value of reliability at these sample
more 4000 rpm. And it is also the best inside the motor and therefore corrosion sizes does not exceed 6-10%.
solution for ESPs of 272 and 319 series and bulging of magnets.
for all rotation frequencies.
Our motors have increased electro-
N460PM540, 3800V, 6000 rpm, SGL. Idle mode. Housing temperature is 203F N460PM540, 3800V, 6000 rpm, SGL. Idle mode. Housing temperature is 203F
Without elements for vibration reduction
12 12
10 10
Vibration velocity, mm/sec
Vibration velocity, mm/sec
8 8
6 6
4 4
2 2
0 0
0 2000 4000 6000 0 2000 4000 6000
Rotation frequency, rpm Rotation frequency, rpm
Head Middle Base Head Middle Base
Fig. 1 Fig. 2
[4] S. Slepchenko. Forecast Maths // Oil&Gas Vertical. 2006, No12, p.48-51

Testing and Repair vice company in successful implemen- In terms of mentioned above
tation allows to fully realize potential of Novomet new equipment is planning to
Developers of permanent magnet mo- implement its new equipment only with
new equipment. If we are talking about
tors together with service departments its own service.
permanent magnet motors we can take
of the company conducted technological
results of implementation of Novomet
analysis of special features of accept-
ESP systems (319 series) as an example.
ance tests and repair of these units, im-
ESP systems installed as of today are be- Characteristics
proved tooling and test benches. Since
ing leased (service Novomet projects) Operating characteristics of perma-
2009 it allowed to test successfully and
and have average run life of 368 days. If nent magnet motors with rated frequen-
conduct current and capital repair of
we are talking about similar ESPs imple- cy of 3000 rpm and 6000 rpm. They are
permanent magnet motors of full series
mented in other projects (where service presented in Fig.4. Rated power, voltage
range not only at the factory but at all
is not provided by Novomet) then aver- and rotation frequency are considered as
service bases as well.
age run life is 91 days. Design reliability base parameters. Efficiency has an ab-
Here it should be mentioned that poor
is the same, probably, interest of service solute value. Characteristics are present-
service can «shut down» any innovative
companies is different. ed for the most typical operating case
idea. At the same time interest of ser-
when rotation frequency is stabilized by
Novomet VSD.
1.0 Both motors have similar geometry of
stator and rotor active part. So from the
Probability of failure-safe operation
Design reliability
0.8 Taw=2540+1399 days point of view of mechanical conversion
Design failures - 4
of energy they differ only by winding pa-
0.6 rameters.
Comparison of characteristics shows
Total number of ESPs Total reliability that motor efficiency maximum (rated
0.4 with PMM is 251 Taw=594+108 days rotation frequency 3000 rpm) is shifted
Operating - 174
to the left, to the area of lower loads, dif-
0.2 Operation failures - 73
ferently from a motor with rated rotation
Dismantled - 77
frequency of 6000 rpm. It allows perma-
0 nent magnet motors with frequency of
0 200 400 600 800 1000 3000 rpm to operate in a mode closest to
Run life, days the maximum efficiency, in a wider range
of rotation frequencies than permanent
magnet motors with rated rotation fre-
- operating ESPs - retrieved ESPs quency of 6000 rpm.
Fig. 3
Currently power supply to electric mo-
tor is conducted according to so called
6-pulse scheme. Current switching is
Characteristics
Permanent Magnetof permanent
Motors magnet motor
Characteristics performed 6 times during a period in
with rated frequency 3000 and 6000 rpm this scheme. When switching peak over-
voltages occur, their amplitude exceeds
1.2 double voltage of motor power supply
and frequency is 6 times higher than
1.0 power supply frequency. Due to over-
voltage life time of transformer and ca-
ble decreases and due to nonsinusoidal
0.8 current additional losses occur in a mo-
tor. That’s why efficiency of permanent
magnet motors of well-known Russian
0.6 manufacturers is 91.5%-93% according
to their catalogs.
0.4
When producing latest permanent
magnet motors series measures to
increase efficiency were undertaken. We
0.2 used electric steel of different brands,
increased ratio of filling of slots with
copper and also we launched Novomet
0 VSD in August 2010. Vector control mode
0 0.2 0.4 0.6 0.8 1 1.2 1.4
allowed to supply sine-wave voltage to a
Shaft power motor. It led to elimination of over-voltage
3000 Efficiency 3000 Current, r.u. and dramatically reduced additional
3000 Voltage, r.u. Rotation frequency, r.u. losses in a motor. Besides VSD became
6000 Efficiency 6000 Current, r.u. universal, enabling to control both
6000 Voltage permanent magnet and asynchronous
motors.
Fig. 4
25
Measurements showed that at rotation Power Saving

velocity of 3000 rpm and low rated power 12
A range of articles de-
of permanent magnet motor its efficiency
scribes theoretical and ex- 84%
increased from 93.4% and reached 94% 10
perimental trials to appraise
at power of 80kVa. Efficiency of motors 85%
power saving obtained when
with frequency of 6000rpm is in the range
Power saving, %
8 86%
replacing ESP asynchro-
of 92-93%. So Vector type of control al-
nous motor with permanent
lowed to increase efficiency by 1.7-2.5%.
magnet one. Unfortunately 6
When discussing at workshop it was
controversial results were
said that increase of rotation frequency
achieved and controversial 4
led to overheat of stator winding. That
summaries were made as
is why application of additional heat
well. From saving of 3% [3] to
exchangers is required. In Novomet 2
power saving of 30% or even
motors overheat of anchor winding does
more [2 and 5] . Such a dis-
not exceed its overheat in asynchronous 0
persion was caused by vari- 88 90 92 94 96
motors due to reasonable selection of
ous well parameters because Efficiency, %
active part geometry.
of impossibility of having the
Here we are publishing data on effi-
similar well parameters in two Fig. 5
ciency and overheat of permanent mag-
experiments and theoretical
net motor with power of 530 hp in a single tiveness can be obtained if replacement
estimations have low accu-
section (460 series, length is 28ft, rated of one type motors with the other type
racy due to the lack of necessary experi-
rotation frequency is 6000 rpm). motors takes place in big volumes.
mental base.
Currently test bench for such power At the conference «Artificial Produc-
It is much easier and more correct to
at 6000 rpm does not exist and devel- tion 2011» Mr. Ginzburg suggested to ap-
compare power saving of ESP with asyn-
opment of this bench would require ex- praise energy efficiency of systems with
chronous and permanent magnet motors
tremely high costs. That’s why the mo- PMM with a ration of reduction of relative
in workshop or laboratories which well
tor was tested on the testing well in R&D losses according to Russian Standard
parameters are strictly controlled.
Center Konnas as a part of ESP system. GOST 51677-2000 [6].
It is well-known that saving value of
During tests the load was up to 600 hp in We believe that this suggestion is un-
ESP downhole part when other condi-
rated mode (flow rate is 9120 bpd, head acceptable. For systems considered val-
tions being equal depends on efficiency
is 4920 ft, pump efficiency is 61.5%), the ue of relative losses is more convenient
of asynchronous motor (ηa) and efficien-
maximum overheat of anchor winding at and transparent (3).
cy of permanent magnet motor (ηpmm) is
lubricoolant velocity of 0.4 m/sec is 111F, First of all it is much easier to measure
calculated by the following formula:
average is 100F. Motor efficiency was ex- consumed energy and power at the sys-
perimentally calculated. Idle mode loss- ΔSm=(1–ηa/ηpmm)×100% (2) tem input, determine their relations (3)
es Рim in rotation frequency function and and not to calculate losses in each ele-
The maximum value of power saving
motor temperature were measured with ment of the system.
depending on efficiency of permanent
high accuracy when operating a motor Secondly, if losses have been deter-
magnet motor is shown in Fig.5 (values
without a protector in the air. When oper- mined in each element it is better to use
of asynchronous motor efficiency are
ating motor as a part of ESP system ap- absolute values of these losses.
different).
plied power Р1, current I and motor tem- Thirdly if value of relative losses is
According to Fig.5 dependency of
perature were measured. known economic component of new de-
power saving on values of motor effi-
Efficiency was calculated by the fol- velopment is easy to calculate.
ciency in the considered range is linear. It
lowing well-known formula: And finally efficiency is the main pow-
means that average saving value despite
technological fluctuations of motor effi- er saving indicator according to GOST
η=(Р1-Рim-Рc-Рa)/Р1, (1) 51677-2000. There is no a ratio of relative
ciency is the nearest to calculated value.
where Рc = 3×I2×Rph – losses in copper But for certain extreme cases fluctua- losses reduction.
of anchor winding, tions can be sufficiently big. For example Attempts to replace value of specific
Rph – active resistance of phase at giv- when rated efficiency of asynchronous losses with other indicators lead to con-
en temperature, motor is 85% and that of permanent clusions misleading customers. So in
Рa – additional losses from reaction of magnet motor is 94% saving will fluctuate the article of Mr. Shengur and Mr. Ivanov
from 6.5% in unfavorable case to 10.5% [3] and in the report of the same authors
anchor in steel of stator, housing and ro-
at best (shaded area in Fig.5). These ap- at the conference «Artificial Production
tor. Only this relatively small percentage
praisals are based on an assumption that 2011» it is declared that «total theoretical
(about 10%) of total losses was calcu-
technological fluctuations of efficiency of increase of ESP efficiency is about 5-6%
lated. Motor temperature was estimat-
large series motors lie in limits of ±1 of ef- at difference of AM and PMM efficiency
ed and checked by resistance method
ficiency point. of 10-12%». Obviously, authors meant
according to data of downhole sensor
When estimating operational effective- difference of efficiency of ESPs with AM
system which downhole part included a
ness of motors replacement this circum- and PMM.
special sensor to measure winding tem-
stance has to be considered. Correct In our opinion, this indicator at best
perature. Efficiency calculated by this
confirmation of new equipment effec- is useless and only obscures the point
method was 92%.
[5]. M. Ignatyev. Power Saving and Energy Efficiency. Oil&Gas Vertical 2010, # 12.
[6] GOST 51677 – 2000 Electric Asynchronous Machines with Power of 1-400 kVA inclusive. Motors. Indicators of Energy Efficiency.
Megaohmeter
RS-485
Current Circuit
transformers of measurement Circuit
Variable CA_6547
of electricity of input mains of measurement
meters speed drive of motor input
#2 Oil-filled #3
#1 A1
transformer Cable Motor
Meter of torque and
ESP
Mains 380V
X3 X4 X5 X20
A A frequency of motor
X24 X27 X42 L1 Sensors LEM M1 P1
T3
X7 T X8
A Ph_A
A A
X9 A A2
B 3 1 B B B X21 2
X25 X37 X43 B Ph_B Current transformer
3
T 1 C Ph_C
C C
B
M
C X14 X17 O N C X10 C
X26 X41 X44 COM Voltage transformer X22 T F
4 2
X17 X16
4 2
Milliohmeter
X31
X38
X33
X46
X40
X28
X32
X34
X39
X45
X29
X30
X35
X36
X47
Relay
circuit GOM-802
of milliohm-
Current A
Current C
Current A
Current C
Current B
Current B
Voltage A
Voltage C
Voltage A
Voltage C
Voltage B
Voltage B
Current A
Current C
Current B
Voltage A
Voltage C
Voltage B
meter
control RS-485
HIOKI 3194
N10A analyzer analyzer of power and harmonics
Electricity of mains parametrs of drive
meter CE301
Current A I1 Current A I1
HIOKI 3194
U, I RS-485 U, I Torque_In
Current A Voltage A N10A Voltage A 0-10V Ch_A
I1 U, I
Ce301 U1 Ch_1
INTERFACE
RS-485
U1 Ch_1
Voltage A Ch_1 (MODBUS)
U1 Current B I2 Current B I2 Freq_In
U, I U, I
Current B I2 Voltage B Voltage B 1Hz-100kHz Ch_B
U, I U2 Ch_2 U2 Ch_2
Voltage B
U2 Ch_2 Current C I3 Current C I3 U, I GP-IB
RS-485 U, I Voltage C Ch_IB
Current C I3 U, I Voltage C Ch_3 Ch_3 Interface
RS-485
U3 U3
Voltage C Ch_3
U3 I-FACE Current A I4 U, I
Voltage A Ch_4 U4
Current B I5 U, I
From circuit feeder of the second bench motor Voltage B Ch_5 U5
Current C I6 U, I
To system of data
Voltage C Ch_6
U6 processing
and displaying
Fig. 6
because it does not characterize con- proportional to value of frequency raised depth of 164 ft. When operating ESP sys-
tribution of PMM in neither power, nor to 1.3-1.5 and induction value squared. tem water from pump discharge through
economic efficiency of ESP system. ESP Induction value is inversely proportional tubing flowed to a tank through flow and
efficiency is multiplication of all compo- to frequency [7] (again at constant volt- pressure metering system.
nents of this system: pump, motor, cable age value; it is widespread in practice). Electric circuit is presented in Fig.6.
(if define its efficiency as relation be- Therefore losses in steel decrease when Downhole part of ESP system includ-
tween power at input and output), trans- supply frequency increases (for example ed centrifugal pump with rated flow rate
former and VSD that’s why relation (1) up to 100-200 Hz). Conclusions about of 3100 bpd, head of 885 ft, motor with
between efficiency of ESPs with different ESP efficiency reduction does not con- rated power of 60 hp Topside equipment
motors will be equal to relation between form to the real situation. consisted of VSD (400A), step-up trans-
efficiency of motors if efficiency of other We can agree with the fact that weight former and cable (length is 3770 ft, sec-
components is equal. and dimensions of transformer are over- tion is 16 mm2). Trials were conducted at
Actually efficiency of ESP with perma- rated when increasing frequency. rotation frequency of 2910 rpm.
nent magnet motor increases addition- At the end of 2010 the range of dem- Power was measured at the VSD intake
ally due to decrease of losses in cable, onstrations «Comparison of power indi- (by grid analyzer LUMEL N10A, accuracy
transformer and VSD. The less efficiency cators of ESPs with AM and PMM» was rating is 0.2) and at motor intake (by elec-
of these components is, the more PMM conducted in testing wells of R&D Kon- tric power analyzer HiOKI 3194 MOTOR,
contribution is. nas based on the oil operators request. accuracy rating is 0.1). Additionally at
Also it is declared that «increase of ESP Technical specialists of the biggest Rus- VSD intake electric power was measured
efficiency due to replacement of induc- sian and CIS oil operators (Rosneft, Lu- with a meter Energomera CE301R33043,
tion motor with PMM is 3-4%» because if koil, Gaspromneft, TNK-BP, Rusneft, accuracy rating is 0.5. This measurement
voltage frequency increases transformer Ritek ETC, Turgai Petroleum, Belarus- scheme was carried out based on the re-
losses increase as well and its efficiency neft) visited these tests. quest of representatives of oil operators
deceases. It should be noted that the Initially it was planned for time saving which required to estimate power saving
same indicator is used here (difference purposes to test two ESPs installed in according to readouts of electricity me-
of ESPs efficiency). two testing wells simultaneously. How- ters.
In actual fact when increasing sup- ever because of difference of water tem- Testing well was equipped with flow
ply frequency for instance twice losses perature and too high but acceptable meter MAG6000, accuracy rating 0.25
in transformer are going down and effi- dispersion of API (±5%) and dispersion and pressure sensor YUMO dTRANS h02,
ciency is rising because losses in trans- of pumps power characteristics results accuracy rating 0.1.
former copper remain constant and loss- were similar to those of other research- After conduction of the first test the
es in steel decrease approximately by ers. That’s why we had to conduct tests ESP system was retrieved and the mo-
30% [7]. It can be explained that losses of one ESP system and accept time loss- tor was replaced with the other type mo-
in transformer steel at equal value of ap- es connected with motor replacement. tor then the second test was conducted
plied voltage and its sine wave form are ESP was installed in a testing well at during the same period of time. At the
[7]. G. Petrov. Electric Machines. Part I. Energy, Moscow, 1974, p. 34, p. 57.
27
same time flow and pressure at the pump asynchronous motor is 85% and that of 2. Novomet has the widest range of
discharge were equal to the first test cor- permanent magnet motor is 93.4%) sav- such motors namely series and rat-
responding values. Water temperature ing would be 9%, but we have only 8.7%. ed power.
was 46±3оС. Difference is connected with errors of 3. Firstly in the industry a frequency con-
Value of relative saving due to perma- efficiency calculation considering tech- verter of universal type with vector control
nent magnet motor was calculated by nological factors and other measurable method and sine-wave voltage supply has
formula: values. been developed. It allowed to increase
Ability of PMM to operate with high ef- PMM efficiency up to 93.4% and to make
ΔPSm=(NAM-NPMM)×100%/NAM VSD enable to control PMM and AM.
ficiency at increased rotation frequency
где NAM, NPMM – power measured at the is applied when making a range of pow- 4. PMM efficiency in the rotation range
intake of a corresponding type motor. er saving ESPs on the base of the best of 2000 – 3500 rpm is higher by 6-9%
Saving was 6.9 %. pump stages. In testing wells we dem- than that of asynchronous. At other rota-
Total relative saving is calculated by onstrated to our customers ESP system tion frequencies power saving of PMM is
formula: with PMM and pump which stage had more sufficient.
efficiency of 69%. At rotation frequency 5. It is correct to compare power con-
ΔPSsystem=(Wsys.AM–Wsys. PMM)×100%/Wsys.AM (3), sumption of ESPs with motors of different
of 4550 rpm this pump provided flow rate
where Wsys.AM, Wsys.PMM – energy con- of 3100 bpd, head of 3100 ft. ESP system types in testing wells. In operating wells it
sumed from a grid of ESP with asynchro- was shorter by 52% and provided more is practically impossible to have the same
nous and permanent magnet motor re- saving by 26% if compared to conven- well parameters for two experiments.
spectively. tional ESP system with an asynchronous 6. Program of power losses calculation
Saving can be defined by parameters motor and a pump with efficiency of 57% in all ESP components has been devel-
measured at the same point as well. Val- at the same flow rate and head. oped. We have demonstrated its good
ues of power and energy saving were convergence with experimental data.
practically the same -10.8%. 7. Due to replacement of asynchro-
Conclusions:
Curve of ESP downhole equipment nous motor with PMM power consump-
is presented in Fig.7, the whole system 1. Russian machine builders have got tion can be reduced by 10 – 13 %. When
curve is presented in Fig.8. These fig- leading position in terms of innovative applying motors and pumps with high ef-
ures show that power consumed by per- development of PMM at rotation fre- ficiency total saving can reach up to 26%
manent magnet motor and ESP is lower quency of 300 – 10000 rpm. (and in some cases even 30-40 %).
than that of asynchronous motor and
ESP but effective capacity is the same in η, % H, ft
60 1500
the whole range of flow rates. Analysis of
power consumed in Fig. 7 and 8 allows
to evaluate contribution of downhole and 40 1250
topside equipment in total saving.

For actual estimation a special ESP 20 1000
power saving calculation program has N, hp

been developed. It considers losses in 0 45 750
ESP components including cable, trans-

former and VSD. 30 500
Program calculation results and testing

results are the same. 15 250
Due to this program you can consider

two circumstances reduced difference 0 0
0 550 1100 1650 2200 2750 3300 3850 4400 4950 5500
of indicators against permanent magnet
Q, bpd
motor. In the company range of prod- Fig. 7
ucts there were no asynchronous and
permanent magnet motors of the same
voltage. When testing voltage of perma-
η, % H, ft
nent magnet motor was 1204 V and that 60 1500
of asynchronous was 1335 V. It increased
PMM current by 10%. Besides perma- 40 1250
nent magnet motor was filled with syn-
thetic oil, asynchronous motor was filled 20 1000
with mineral oil; at water temperature of
N, hp
115 F it led to increase of losses in PMM 0 45 750
by 0.8 hp according to the calculations.
Consideration of these losses and differ- 30 500
ence of voltage would lead to motor sav-
ing of 8.7% and total saving of 12.6%. If 15 250
cable length had been 6560 ft (instead
of 3770 ft when testing) total saving 0 0
would have been increased up to 13.8%. 0 550 1100 1650 2200 2750 3300 3850 4400 4950 5500
Q, bpd
Due to a motor (rated efficiency of Fig. 8
28 Complete
Com
Co
omple
om lle
ete
te ESP
ESP sy
ES ssystems/Water
s ms/Water injection systems/Production optimization/Field service facilities/Software tools
ste
Walid Reda,
Novomet Petroleum Services
Permanent Magnet
Motor
Egypt Country Manager
application for ESP Artificial Lift in Egypt
Abstract
This paper presents the results and conclusions of the latest field experience of
permanent magnet motors (PMMs) applied in the wells of Agiba Petroleum Company
(Agiba – Joint Venture with ENI, Italy), one of the biggest oil and gas operators in Egypt.
PMM has more benefits than conventional induction motor: High efficiency
(90- 94%) vs. induction motors up to 86%; Smaller size and weight at same power out-
put (excellent solution for offshore applications); Wider ranges of rotation frequency
regulation (100-500 rpm, 500-1500 rpm, 1500-4200 rpm, 4000-6000 rpm) reduced
energy consumption and reduced rating of surface equipment (Power Saving).
Dmitriy Letunov,
Novomet Petroleum Services In the middle of June of 2012 Agiba performed a trial installation of Novomet PMM
Application Engineer replacing an ESP unit with induction motor in well North Nada 1 x. North Nada 1x
is an oil well (Qgross=430 bpd, Qnet=239bopd) of North Nada field (Qgross=1500 bpd,
Qnet=850 bopd) located in Melehia. The installation successfully achieved expected
results and benefits in terms of low power consumption.
Introduction
Agiba Petroleum Company has two main fields in Egypt: onshore in Western Desert
area and offshore in Ashrafi area, for a total production of about 43000 BOPD and a
total of about 300 wells. Western desert included five locations Meleiha, Zarif, Aghar,
Faras & 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 sys-
tems and several kinds of pumps: ESP, Sucker Rod, PCP (about 40 ESP wells, 250
Sucker Rod wells and 10 PCP wells).
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 mo-
tor. 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)
made from rare-earth alloys forcing high level of magnet induction.
Rated motors power:
Type (all are single) RPM Range Eff., % Power, hp (kW) Sales, pcs
N319PM, 6000rpm 3000-6000 89-91 19-120 (14-90) 300
N460PM, 500rpm 100-500 83-85 Up to 55 1
N460PM, 1000rpm 500-1500 83-85 Up to 110 1
N460PM, 3600rpm 1000-4200 92-94 19-360 (14-270) 936
N460PM, 6000rpm 3000-6000 92-94 54-540 (40-400) 353
N512PM, 3600rpm 1000-4200 92-94 51-480 (38-360) 24
N512PM, 6000rpm 3000-6000 92-94 80-620 (60-465) 2

29
Design
∆P, W
Motor consists of stator with three-phase winding, rotor with 9000 Permanent Magnet Motor
permanent magnets, head and base. 8000 Asynchronous Motor
Magnetic core comprises electric steel plates with heat re-
7000
sistant coating, pressed into the tubular housing. Stator wind-
ing is made of heat resistant copper wire with zero-point termi- 6000
nal for ESP parameters control system. 5000
4000
Benefits 3000
Permanent magnet motors benefits vs. Asynchronous mo- 2000

tors:
1000
1. Higher efficiency factor (from 88 up to 94% depending on
motor series). 0
1 2 3 4 5 6
2. Less overall dimensions at the same power (as a result –
1- Losses is stator winding
less motor mass).
2 - Losses in rotor
3. Energy consumption reduction.
3 - Losses in steel (from hysteresis and Foucauit current)
4. Variable rotation speed range at the constant torque at
4 - Mechanical losses (friction losses)
the shaft (100-500 rpm, 500-1500 rpm, 1500-4200 rpm, 4000-
5 - Hydraulic losses (friction of rotor on oil)
6000 rpm).
6 - Addition losses
5. Reduced heat release.
6. Higher reliability.
Unlike asynchronous motor there are no losses in a rotor
winding of permanent magnet motor because these rotor packs
consist of permanent magnets. Concerning other types of loss- d) Decreased reactive power in the ESP electrical system;
es such as losses in stator winding and losses in steel we can f) Improved system Power factor;
mention that they are lower because current value is also lower. g) Less fuel consumption for the generators or turbines;
Permanent magnet motor is equipped with a special bearing al- The ESP unit is under observation and evaluation consider-
lowing to reduce mechanical losses as well. Rotor pack has got ing the following successful criteria: keeping electrical system
a stainless steel protective sleeve which prevents damage of a stability and minimize the number of shutdowns; providing a
rotor pack. Permanent magnets can operate at extremely high minimum cost for power consumption and any related cost for
temperature (up to 350oC) for the whole run life. production.
Application of permanent magnet motor allows to reduce di-
mensions and weight of the whole ESP system due to the possi-
Summary and Conclusions
bility of operation at high frequency (6000rpm). Losses in cable,
transformer and variable speed drive are reduced as well. 1. An alternative to conventional asynchronous induction mo-
tors has been developed. Its efficiency factor is significantly
higher than of conventional motor (from 88 up to 94% depend-
Agiba Field Results ing on motor series).
All Agiba ESP wells are equipped with conventional induc- 2. It was the third trial installation of Novomet PMM and was
tion motors. In the middle of June of 2012 Agiba performed performed in the middle of June of 2012. It replaced an ESP unit
a second trial installation of Novomet PMM replacing an ESP with induction motor on well North Nada 1 x of North Nada field
unit with induction motor on well North Nada 1 x. North Nada located in Melehia.
1x is an oil well (Qgross=430 bpd, Qnet=239bopd) of North Nada Power consumption is considerably low and high efficiency is
observed due to the improvement of Power Factor (from 0.86
field (Qgross=1500 bpd, Qnet =850 bopd) located in Melehia. The
up to 0.96) that significantly decreases the reactive power and
well was completed as sucker rod well since Dec 2001 and then
current harmonics rate (current Reactive power value in system
converted to ESP in Oct 2003. Several workover jobs were per-
is 9.3 kVAr instead of previous rate – 20.2 kVAr).
formed during the well life, the last of which due to problem
Less power consumption allows to increase the number of
in the ESP system. The highest ESP run life in this well was 6
ESP wells by 30 % without change of Power supply system.
months due to the problems with motor overheating.
3. The expected results have been achieved: power con-
The installation was successfully achieved expected results sumption was reduced by 32 % (current Power value is 55 kVA
and benefits in terms of low power consumption. This led also instead of previously consumed 81 kVA). Now the ESP unit is un-
to the following indirect benefits: der observation and evaluation.
a) Low heat release, that enables to operate without shroud Installed Novomet ESP with PMM highlighted very good re-
even with 460 series of motor in 9 5/8” Casing (minimum cooling sults and Agiba is interested in additional installations. Before
fluid velocity 0.1 ft/s); the end of 2012 extra several installations of ESP with PMM are
b) Less current consumption (14 amps instead of 26 amps) expected. After evaluation and assessment of Novomet ESP
and less size for cable and lower power rating for transformer systems operation results with PMM Agiba (JV with ENI) techni-
and VSD; cal/ operations team will recommend to convert significant part
c) No harmonics which can affect the system stability and of Agiba and other ENI Joint Ventures ESP wells to be replaced
might cause system vibration and motor shaft failure; with PMM by Novomet instead of Asynchronous type motors.
CONVENTIONAL PUMP SUMMARY (338 – 740 SERIES)

Pump Pump OD,
Capacity, Bpd @ 3500 rpm (60 Hz)
series inch
D (338) 3.38 230 1
6001 1450 15001
F (362) 3.62 110 150 190 230 260 330 380 450 600 760 940 1200 3800
H (406) 4.06 200 260 380 450 600 760 940 1200 1500 3000 3800 5300
J (449) 4.49 6050 7600 9400
L (484) 4.84 1000 1900
R (677) 6.77 3800 5660 7600 12000 15000 19000 22500 30000
T (740) 7.40 38000 47500
powder–based stages cast stages
Operating trequency, rpm

1
– at 3380 rpm
450 Bpd – preproduction stages
rpm – recommended frequency range
«POWER SAVE» PUMP SUMMARY (272 – 677 SERIES)

Pump OD,
ESP series Capacity, Bpd @ rpm
inch
Stage NAV(190–380)H NAV(440–630)H NA(630–1300)H
А (272) 2.72 Capacity 190 250 310 380 440 500 630 790 1000 1130 1260
rpm 2910 3880 4850 5820 4070 4660 5820 3640 4660 5240 5820
Stage NBV(250–500)H NB(630–1000)H NB (1100-1800)
B (319) 3.19 Capacity 250 310 380 500 630 790 1000 1130 1260 1570 1760
rpm 2850 3550 4300 5700 3230 4040 5170 3740 4160 5200 5820
Stage NF(130-250)Н NF(310-630)Н NF(900-1300)Н NF(1300–2000)H NF(2000–3100)H
F (362) 3.62 Capacity 130 160 190 220 310 380 500 630 880 1000 1130 1260 1380 1300 1570 2000 2000 2500 3100
rpm 2910 3640 4370 5100 2910 3490 4660 5820 2910 3330 3740 4160 4570 2910 3470 4430 2910 3640 4550
NH(2500– NH(2500– NH(4400–
Stage NH(1000-1600)Н NH(1600–2300)Н NHV(790–1000)Н
3100)Н 3800)Н 5000H
H (406) 4.06 Capacity 1000 1130 1260 1400 1600 1420 1570 1760 2500 630 790 880 1000 2500 3100 2500 3800 4400 5000
rpm 2910 3280 3640 4100 4550 2910 3620 4140 5170 2910 3640 4070 4660 3640 4550 2910 4370 4080 4660
NP(7900–
Stage NP(1900–2500)H NP(3100–4400)H NP(4700–6300)Н
10100) Н
NP(11300–15100) Н
P (535) 5.35 Capacity 1900 2000 2300 2500 3100 3800 4400 4700 5000 5700 6300 7900 10100 11300 12600 13800 15100
rpm 2910 3110 3500 3880 2910 3500 4080 2910 3110 3500 3880 3640 4660 3270 3640 4000 4370
NR(10000– NR(15700–
Stage 11300)Н
NR(12600–15700)Н
19000)Н
R (677) 6.77 Capacity 10000 11300 12600 13800 15700 15700 19000
rpm 2910 3280 2910 3200 3640 2910 3500
powder–based stages cast stages
NF(2000-3100)H – in development
*rpm – recommended frequency range at which capacity is indicated
ASYNCHRONOUS MOTOR SUMMARY (378 - 744 SERIES)

Power rating, hp @ 60 Hz (3500 rpm)
Motor series Motor OD, in
1–section 2–section 3–section
378 3.78 26 – 51 72 – 90 110 – 160
406 4.06 26 – 130 110 – 255 290 – 320
460 4.60 13 – 200 200 – 400 400 – 510
512 5.12 51 – 235 290 – 480 560 – 720
562 5.62 100 – 350 420 – 710 890
744 7.44 160 – 640 800 – 1050
890 – in development
31
PM MOTOR SUMMARY (319 - 512 SERIES)

Low speed (1000 and 500 rpm) PMM for PCP wells and Novomet solution for high–viscous applications
Motor series Motor OD, inch Speed range, rpm Power rating, hp
460 4.60 500 – 1000 Pmax = 107
460 4.60 100 – 500 Pmax = 54
PMM rated at 3600 rpm for ESP systems (Conventional + «Power Save») + Progressive Cavity Pump
460 4.60 1000 – 4200 19 – 360
512 5.12 1000 – 4200 51 – 480
PMM rated at 6000 rpm for ESP systems (Conventional + «Power Save»)
319 3.19 1000 – 6000 19 – 120
460 4.60 1000 – 6000 54 – 540
512 5.12 1000 – 6000 80 – 620
In development – PMM rated at 6000 rpm for ESP system (Convertional + «Power save»)
406 4.06 1000 – 6000 Pmax – 320
562 5.62 1000 – 6000 Pmax – 1140
744 7.44 1000 – 6000 Pmax – 1600
GAS SEPARATOR, MULTIPHASE PUMP

Model (N-Novomet, 338-series (3.38 inch), GS-gas separator, MPP- multiphase pump, 250-flow rate of single phase fluid, m3/day
Nomenclature Flow rate of single phase fluid at 50 Hz, m3/day
Gas separator N338GS1900 AR1 CR1 STD 250
N362GS1500 AR1 CR1 STD 200
N406GS3800 AR1 CR1 STD 500
N535GS6000 AR1 CR1 UHSS 950
N535GS8000 AR1 CR1 UHSS 1250
Multiphase pump N272MPP940 CMP AR2 CR1 125
N319MPP940 CMP AR2 CR1 125
N677MPP8000 CMP AR2 CR1 1250
N677MPP12000 CMP AR2 CR1 1900
PROTECTORS
Housing OD Shaft diameter Maximum motor power Installed length
Modular Protector Hydraulic scheme
in mm in mm hp @60Hz kW @50Hz ft m
N272MP LSB CR0 HT STL LSB 145 90 TBA TBA
N272MP BSB CR0 HT STL BSB 145 90 6.40 1.95
2.72 69 0.55 14
N272MP LSBPB CR0 HT STL LSBPB TBA TBA TBA TBA
N272MP LSBSB CR0 HT STL LSBSB 145 90 TBA TBA
N319MP LSB CR0 HT STL LSB 145 90 TBA TBA
N319MP LSBPB CR0 HT STL LSBPB 3.19 81 0.98 25 TBA TBA 7.56 2.31
N319MP LSBSB CR0 HT STL LSBSB 145 90 7.56 2.31
N338P LSBSL CR0 HT STL LSBSL 90 56 6.68 2.04
3.38 86 0.98 25
N338P LSBPBSL CR0 HT STL LSBPBSL 160 100 6.68 2.04
N362MP LSB CR0 HT STL LSB 130 80 5.66 1.73
3.62 92 0.98 25
N362MP LSBPB CR0 HT STL LSBPB 320 200 7.56 2.31
Housing OD Shaft diameter Maximum motor power Installed length

Modular Protector Hydraulic scheme
in mm in mm hp @60Hz kW @50Hz ft m
N362MP LSB CR0 HT HL LSB 130 80 5.66 1.73
N362MP BSB CR0 HT HL BSB 130 80 5.66 1.73
3.62 92 0.98 25
N362MP LSBPB CR0 HT HL LSBPB 320 200 7.56 2.31
N362MP LSBSB CR0 HT HL LSBSB 130 80 7.56 2.31
N406MP LSB CR0 HT STL LSB 200 125 5.66 1.73
4.06 103 0.98 25
N406MP LSBPB CR0 HT STL LSBPB 560 350 7.56 2.31
4.06 103 0.98 25
4.49 114 1.38 35
5.35 136 1.50 38
6.77 172 1.69 43
N362РP LSP CR2 UHT STL LSP 3.62 92 0.98 25 130 80 6.58 2.01
SLOTTED SCREEN PUMP INTAKE

Filtration
Series Capacity Shaft diameter
Description rating
in mm bpd m /day
3
mcm in mm
N362SFI 470BPD 100MCM CR0 0.79'' STD 3.62 92 470 75 100 0.79 20
Unique equipment for application
in casings 4'' and 4 1/2'' (102, 114 mm)
At present many oil producing companies drill side track wells to sustain and increase oil production
plans and also reduce capital investments in new wells. The experience of realization of this method
proves technical and economical benefits in comparison with drilling of new wells due to lower costs for
drilling and ability of using the existing communication, collection and transportation system of oil and
gas in the field. Diameter of side track wells allows operation of ESP systems of 319 (81 mm) series and
smaller ESPs, for example of 272 (69 mm) series.
CAPABILITIES
■ Starting up of idle wells, exploration and
wells after casing repair
■ Application in dual ESP systems for multi-
zone production and bypass systems (Y-tool)
■ ESP operation in highly deviated wells with
zenith angle of 90˚ (horizontal wells)
■ Drawdown in side track wells for effective
oil production
INNOVATEYOURPRODUCTIONWITHNOVOMET!
GLOBALFOOTPRINT
Headquarters: Novomet FZE S.C. Novomet Artificial Lift S.R.L.
395, Shosse Kosmonavtov, In charge of MENA region Bucharest, at district 5,

Perm, Russia PO Box 72685 Dr. Herescu Petre street,
International Department Office 1004, Executive Heights no. 15, floor 2
Telephone: +7 342 299 73 44/45 (DAMAC Bldg.) Telephone:+40 725 388 252
Fax: +7 342 296 23 02 Tecom Area, Dubai E-mail: parshakov@novomet.ru
E-mail: info@novomet.ru United Arab Emirates
www.novomet.ru/eng Telephone: +971 4 4541469
Fax: +971 4 4541468 Novomet-Argentina S.A
Novomet-Ecuador S.A. E-mail: info@novomet.ae
the City of Buenos Aires
Av. Republica with domicile at Maipu 1300,
de El Salvador 880 y Suecia Novomet NAP Oilfield Service 13th Floor
Edificio Almirante Colon, (Egypt) Telephone: +54 9 297 5923041
Piso 1, Ofc. 21 E-mail: mario.forchiassin@novomet.ru
Telephone: 593-2-2252069/70; Free Zone S.A.E
593-2-2465383 Cairo, 39 Road 83 Maadi,
Quito, Ecuador Telephone: +202 235 82587 New Lift Solution Mexico
E-mail: ecuador@novomet.ru Fax: +202 237 87616 S.A. de C.V.
Mobile: +201 009 602300
New Lift Solutions BV Sucursal E-mail: info@novometegypt.com Avenida Concordia No. 23, Piso # 4,
Service facility: Colonia Camaroneros II,
Bogota DC, Colombia Badr City - Industrial Zone, Ciudad del Carmen,
Teleport Business Park District 3, Block 8 Estado Campeche, Zip Code 24169
Calle 113 # 7 - 21, Torre A Office 501. Telephone: +52 938 286 0990
Telefax: +57 (1) 637 72 58 E-mail: mexico@novomet.ru
E-mail: info@novomet.com.co
| 2013

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# 1 (03), January 2013

Complete ESP systems/Water injection systems/Production optimization/Field service facilities/Software tools

«Power Save» pump stage NF(130-250)H, 3640 rpm

FLOW PATH HEIGHT HAS BEEN INCREASED

Design and prepress

28 Permanent Magnet Motor application for ESP Artificial Lift

Editorial office 30 «POWER SAVE» PUMP SUMMARY (272 – 677 SERIES)

31 GAS SEPARATOR, MULTIPHASE PUMP

32 SLOTTED SCREEN PUMP INTAKE

«Power Save» ESP Systems Slim-line ESP Systems

section. The first ESP system of 319 se-

refer to Fig. 2). Installation in the oil field

Aleksandr Elizarov ESP Operation

In 1966 the unique oil-gas condensate Initial attempts of implementation of ar-

1000 mcm 100 mcm

Fig. 1. – Sulphide corrosion damage of Niresist

effect is up to 150 mcm) (please refer

Slim-Line ESP systems

Table 1 started up in that well. Due to ESP

Data as of October 2012

Usually operating characteristics of submersible pumps in highly

Influence of fluid viscosity on operat- One of empiric methods was sug-

10 Fig. 1. Scheme of bench for pumps testing in highly viscous fluid

It is necessary to determine dependence of operating charac-

When testing generic principles for some types of pump stages 35

operating range calculation leads to error of 10-25%. In practice it Capacity, bpd

accuracy is lower than that of water [1]. When increasing number

– dependence of well fluid viscosity v on temperature: v = v(T). 15

The order of calculation of pump parameters with z stages op- 0

rate and viscosity of fluid penetrating into the pump.

The last stage 12.2 13.0 0.09 23.6

15 Pump averaging 5.3 9.2 0.14 63.67

Water 28.0 17.7 0.04 1

0 Head of such pump is 1800 ft.

Table 3. Calculated Characteristics of Pump NH(1600-2300)H Stages

APPLICATION RANGE R&D Director

in between the insulation layers [3]. However,

nal (see Fig.1 where 1 – metal pipe, 2 – wick,

Cooling with heat pipes decreased stator heating dramatically at

At 60 kW load in Fig. 3 and Fig. 4 we get ∆T(0.05) = 48°С and

Motor load, kW Average stator winding heating, °C Motor load, kW

where . The same was at u = 0.3 m/sec,

where . These results together with (3) give:

Head Middle Base Head Middle Base

[4] S. Slepchenko. Forecast Maths // Oil&Gas Vertical. 2006, No12, p.48-51

Measurements showed that at rotation Power Saving

topside equipment in total saving.

power saving calculation program has N, hp

ESP components including cable, trans-

Program calculation results and testing

Due to this program you can consider

application for ESP Artificial Lift in Egypt

Permanent Magnet Motors

N319PM, 6000rpm 3000-6000 89-91 19-120 (14-90) 300

N460PM, 500rpm 100-500 83-85 Up to 55 1

N460PM, 1000rpm 500-1500 83-85 Up to 110 1

N460PM, 3600rpm 1000-4200 92-94 19-360 (14-270) 936

N460PM, 6000rpm 3000-6000 92-94 54-540 (40-400) 353

N512PM, 3600rpm 1000-4200 92-94 51-480 (38-360) 24

N512PM, 6000rpm 3000-6000 92-94 80-620 (60-465) 2

Permanent magnet motors benefits vs. Asynchronous mo- 2000

CONVENTIONAL PUMP SUMMARY (338 – 740 SERIES)

Operating trequency, rpm