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The current state and prospects for the use of downhole electric motors to reduce OPEX and CAPEX when operating wells by ESP units at Rosneft Oil Company

UDK: 622.276.53.05-886
DOI: 10.24887/0028-2448-2018-11-58-63
Key words: efficiency of well operation, electrical submersible pump (ESP) unit, energy efficiency of oil production, production costs, high-voltage downhole electric motors, permanent magnet motors
Authors: A.B. Noskov (Rosneft Oil Company, RF, Moscow), D.A. Kosilov (Rosneft Oil Company, RF, Moscow), S.B. Yakimov (Rosneft Oil Company, RF, Moscow), M.N. Kaverin (RN-PRTDC LLC, RF, Tyumen), V.P. Tarasov (RN-PRTDC LLC, RF, Tyumen)

Cutting capital cost and lifting OPEX is one of the main tasks in artificial lift operations. A great attention is paid to the problem of how to increase energy efficiency as the share of OPEX for electricity is remarkably high. But the cost of power efficient equipment is usually higher than that of a standard one, and in light of this an issue arises as to how to determine areas where its employment could be economically viable. In the article, approaches used by Rosneft Oil Company when selecting one of the nodes of ESP units, namely the downhole electric motors, have been described in view of achieving an effect of lower aggregate costs.В  For the first time among the Russian oil and gas producing companies, Rosneft has conducted tests of high-voltage downhole electric motors, and currently occupies leading positions, as far as their number in use is concerned. Through an example of RN-Nyaganneftegas JSC, one of the crude oil and gas entities belonging to Rosneft Oil Company, a dynamic pattern of practical employment of high-voltage downhole electric motors has been shown, while highlighting that their use in the equipment set of ESPs has not resulted in a lower MTBF value. When using high-voltage downhole motors, the running current is going down which allows to make up an ESP unit with a cable whose conductor strands have a smaller cross-section. A transfer to the employment of cables with conductor strands of a smaller cross-section allows to cut CAPEX. In the article, the employment performance of energy-efficient motors at the fields of Rosneft Oil Company is being described, while providing a simplified matrix of their selection in view of economic feasibility, taking into account existing equipment prices and electricity tariffs for 2018. The article provides detailed reasons for a relatively decent application of submersible permanent magnet motors, while showing areas of a possible increase in their employment, and determining high-priority tasks for producers of such equipment and specialists of Rosneft Oil Company.

References

1. Ivanovskiy V.N., Sabirov A.A., Degovtsev A.V. et al., Problems of energy efficiency of electric-driven centrifugal pumping units (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2016, no. 4, pp. 25–30.

2. Maston L., Economic consideration for sizing tubing and power cable for electric submersible pumps, SPE 15423-PA, 1988.

3. Yakimov S.B., Kaverin M.N., Tarasov V.P. et al., Usage of submersible electrical motors with raised pressure provides double effect without investments (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2012, no. 3, pp. 75–81.

4. Ginzburg M.Ya., Selection of submersible electric motors: economic and technological criteria (In Russ.), Neftegazovaya vertikal', 2015, no. 9, pp. 7-12.

5. Yakimov S.B., Kaverin M.N., Tarasov V.P., Optimization of cable cross-section of electrical centrifugal pumping units is simple and efficient technology of energy saving (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2012, no. 3, pp. 53–57.

6. Rabinovich A.I., Tekhnologiya energosberegayushchey dobychi nefti s ispol'zovaniem pogruzhnykh elektroprivodnykh tsentrobezhnykh nasosov. Analiz problem i puti resheniya (The technology of energy-saving oil production using submersible electric drive centrifugal pumps. Problem analysis and solutions), Perm: Publ. of PSTU, 2017, 72 p.

7. Yakimov S.B., Kaverin M.N., Tarasov V.P., Analysis of efficiency of valve engines usage developed by "Borets" manufacturing company to decrease energy consumption in JSC "TNK-BP" (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2011, no. 3, pp. 44-48.

8. Poshvin E.V. Koshelev S., Khotsyanov I. et al., Submersible AC electric motor. History, design features, capabilities (In Russ.), Neftegazovaya vertikal', 2011, no. 12, pp. 58–65.

9. Yakimov S.B., Current state and prospects for reduce heat losses in cable lines of high power electric submersible pumping unit (ESP) in JSC "NK "Rosneft" (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2016, no. 3, pp. 40–46.

10. Eliseev D.B., Aygishev E.V. et al., On the influence of the fraction composition of abrasive particles in produced fluid on the wear types of the elements of electric centrifugal pumps (In Russ.), Territoriya Neftegaz, 2017, no. 11, pp. 32–38.

Cutting capital cost and lifting OPEX is one of the main tasks in artificial lift operations. A great attention is paid to the problem of how to increase energy efficiency as the share of OPEX for electricity is remarkably high. But the cost of power efficient equipment is usually higher than that of a standard one, and in light of this an issue arises as to how to determine areas where its employment could be economically viable. In the article, approaches used by Rosneft Oil Company when selecting one of the nodes of ESP units, namely the downhole electric motors, have been described in view of achieving an effect of lower aggregate costs.В  For the first time among the Russian oil and gas producing companies, Rosneft has conducted tests of high-voltage downhole electric motors, and currently occupies leading positions, as far as their number in use is concerned. Through an example of RN-Nyaganneftegas JSC, one of the crude oil and gas entities belonging to Rosneft Oil Company, a dynamic pattern of practical employment of high-voltage downhole electric motors has been shown, while highlighting that their use in the equipment set of ESPs has not resulted in a lower MTBF value. When using high-voltage downhole motors, the running current is going down which allows to make up an ESP unit with a cable whose conductor strands have a smaller cross-section. A transfer to the employment of cables with conductor strands of a smaller cross-section allows to cut CAPEX. In the article, the employment performance of energy-efficient motors at the fields of Rosneft Oil Company is being described, while providing a simplified matrix of their selection in view of economic feasibility, taking into account existing equipment prices and electricity tariffs for 2018. The article provides detailed reasons for a relatively decent application of submersible permanent magnet motors, while showing areas of a possible increase in their employment, and determining high-priority tasks for producers of such equipment and specialists of Rosneft Oil Company.

References

1. Ivanovskiy V.N., Sabirov A.A., Degovtsev A.V. et al., Problems of energy efficiency of electric-driven centrifugal pumping units (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2016, no. 4, pp. 25–30.

2. Maston L., Economic consideration for sizing tubing and power cable for electric submersible pumps, SPE 15423-PA, 1988.

3. Yakimov S.B., Kaverin M.N., Tarasov V.P. et al., Usage of submersible electrical motors with raised pressure provides double effect without investments (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2012, no. 3, pp. 75–81.

4. Ginzburg M.Ya., Selection of submersible electric motors: economic and technological criteria (In Russ.), Neftegazovaya vertikal', 2015, no. 9, pp. 7-12.

5. Yakimov S.B., Kaverin M.N., Tarasov V.P., Optimization of cable cross-section of electrical centrifugal pumping units is simple and efficient technology of energy saving (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2012, no. 3, pp. 53–57.

6. Rabinovich A.I., Tekhnologiya energosberegayushchey dobychi nefti s ispol'zovaniem pogruzhnykh elektroprivodnykh tsentrobezhnykh nasosov. Analiz problem i puti resheniya (The technology of energy-saving oil production using submersible electric drive centrifugal pumps. Problem analysis and solutions), Perm: Publ. of PSTU, 2017, 72 p.

7. Yakimov S.B., Kaverin M.N., Tarasov V.P., Analysis of efficiency of valve engines usage developed by "Borets" manufacturing company to decrease energy consumption in JSC "TNK-BP" (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2011, no. 3, pp. 44-48.

8. Poshvin E.V. Koshelev S., Khotsyanov I. et al., Submersible AC electric motor. History, design features, capabilities (In Russ.), Neftegazovaya vertikal', 2011, no. 12, pp. 58–65.

9. Yakimov S.B., Current state and prospects for reduce heat losses in cable lines of high power electric submersible pumping unit (ESP) in JSC "NK "Rosneft" (In Russ.), Oborudovanie i tekhnologii dlya neftegazovogo kompleksa, 2016, no. 3, pp. 40–46.

10. Eliseev D.B., Aygishev E.V. et al., On the influence of the fraction composition of abrasive particles in produced fluid on the wear types of the elements of electric centrifugal pumps (In Russ.), Territoriya Neftegaz, 2017, no. 11, pp. 32–38.


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