A new development by scientists from the Samara region will halve the accident rate at oil wells.

Specialists from Tolyatti State University (TSU), together with colleagues from Samara State Technical University (SamSTU), have created a unique engineering method that extends the service life of deep-sea oil production equipment. The developed technology makes it possible to increase the maintenance period of wells by 40-50% and reduce resonant voltage surges in submersible electric motors by three times. According to the press service of TSU (Tolyatti State University), the implementation of this solution will save oil companies from unscheduled production shutdowns and multimillion-dollar losses.

The main reason for the premature failure of mechanically serviceable pumping units is the electrical resonance that occurs during the operation of frequency converters. In combination with high-voltage transformers and long supply cables, the length of which reaches 5 kilometers, parasitic harmonics of current create the effect of "electric swings". As a result, the voltage at the nodes swings from the standard 2-3 kilovolts to the critical 15 kilovolts, which instantly destroys the insulation of the cable lines, leads to a short circuit and combustion of the motor windings.

To solve this problem, the scientists combined computer mathematical modeling with field measurements directly in the fields. The mathematical model created by them predicts the behavior of the entire electrical system with an accuracy of up to 18% even at the design stage. Based on these data, engineers receive precise instructions for synchronizing equipment elements: a method for calculating the correct capacitance of load filter capacitors and selecting the correct carrier frequency of the converter, which is guaranteed to block the development of harmonic resonance.

The proposed method has passed large-scale four-year tests in the period from 2020 to 2024 at the existing fund of producing wells in Tatarstan, Bashkortostan, Samara and Saratov regions. Using high-end measuring equipment (oscilloscopes, multimeters, and power quality analyzers), the specialists tested a total of 1,200 pieces of equipment. Statistical analysis confirmed the highest reliability of the results of the study, which reaches 95%, proving a three—fold drop in the amplitude of dangerous voltage surges to a safe 5 kilovolts.

For the Volga oil producing region, this applied development is of strategic importance due to the extreme production conditions: well depths up to 3,000 meters, reservoir temperatures up to 200 degrees and high concentrations of hydrogen sulfide and salts. The method of Samara scientists makes it possible to significantly increase the reliability of electrical installations and stabilize the extraction of raw materials without purchasing imported analogues or replacing units with more expensive ones. According to the authors, ready-made engineering solutions and proven settings can be implemented at any Russian oil fields right now, the TSU press service reported.