Analysis of Rosneft's mechanized well stock has shown that the main causes of failures of electric submersible pump (ESP) units are mechanical impurities, salt deposits and corrosion. Average mean time between failures of the equipment depends not only on well conditions, but also on the design of the pump, materials used for ESP stages, as well as the construction of ESP stages themselves. However, the essential difference of the data about the reasons of failures and operating conditions does not allow to provide the accurate analysis of the influence of the design of the pumps and the materials used on the ESP performance up to failure. In order to clarify the influence of negative factors on the ESP performance, a methodology and stands for comprehensive comparative testing of ESP units were developed within the framework of a targeted innovative project. The test results allow us to answer the questions about the applicability of ESP assembly materials and designs for operation in different field conditions with due regard to the complicating factors. The main statements of the methods are presented, including the methods of determining partial and integral equipment quality indices; the construction schemes of stands for hydrodynamic and endurance tests of ESP components and parts are shown. The results of the bench tests became the basis to draw conclusions about the construction of ESP stages and bearings preferable for working in the wells in the presence of complicating factors. The results of the bench tests have already started to be used to select the optimal ESP unit in terms of design and materials and will also be used for creating a new version of Rosneft's uniform technical requirements, which will further increase the efficiency of oil production with the use of ESP.
References
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