Vol. 336 No. 10 (2025)

DOI https://doi.org/10.18799/24131830/2025/10/5376

Assessment of the impact of stator iron losses on the energy performance of a submersible electric motor under a stochastic assembly procedure of a post-repair submersible electric motor

Relevance. In the Khanty-Mansi Autonomous Okrug–Yugra, there are more than 89 thousand units of the total operational fund of oil wells. This allows for stable production of about 41% of Russian oil. At present, a significant part of the exploited oil fields falls into the category of hard-to-recover reserves, which accounts for more than 70% of the total well fund. Most of the active production fund uses submersible electric motor units with induction submersible electric motor, as the tool for oil extraction. The technological challenges that have emerged at present require solutions for the renovation of the existing oil well fund. One such challenge is increasing the time between failures of post-repair submersible electric motor. Since currently after repair, the time between failures of an submersible electric motor usually decreases. In its turn, one of the main variable components of a post-repair submersible electric motor, namely rotor packages with a squirrel-cage winding, exhibit significant dispersion in their electromagnetic properties. The explanation for this lies in the specific manufacturing and maintenance technologies used during repairing rotor packages. It is known as well that post-repair show considerable variations in the magnetic flux density in the tooth-slot zone of the active part of their stator and rotor. The aforementioned circumstances allow us to propose the following hypothesis. Hypothesis. Within an operational batch of rotor packages with a short-circuited winding their electromagnetic parameters exhibit significant dispersion. The interaction and mutual influence of such rotor packages assemblies in a post-repair submersible electric motor, both among themselves and with the stator active part, lead to a high probability of forming areas in the stator core with locally abnormally high dissipation of eddy current and magnetization energy. Consequently, areas with locally abnormally high heat release develop in the stator iron. The appearance of areas with the above-mentioned properties in the stator iron leads to accelerated degradation of the adjacent local sections of the stator winding insulation. This phenomenon creates the conditions for the occurrence of a "fire in the stator iron". This, in its turn, creates the potential for the failure of the entire submersible electric motor. Aim. To assess the impact of variations in the electromagnetic parameters of rotor packages, combined with variations in the magnetizing circuit parameters, on the values of the integral and local energy indicators of the submersible electric motor. Methods. Systems analysis, statistical analysis, theory of electrical machines, theory of multi-motor electric drives, design of experiments, methods for identifying electric drive parameters. Results and conclusions. The authors have proposed the mathematical model of the induction submersible electric motor as a set of interacting and interdependent mathematical models of elementary electrical machines within the framework of multi-motor electric drive theory. A definition of the concept of an elementary electrical machine is provided. The paper demonstrates the probability of occurrences along the stator bore of areas with locally abnormally high energy release from eddy currents and magnetization energy, subsequently converted into thermal energy in the stator iron. The authors determined the conditions under which this effect arises. The paper shows the fundamental discrepancy between the ranges of local heat release in the active part of the submersible electric motor and the ranges detected by external devices. This leads to erroneous predictions of the insulation states of the stator windings and the stator and rotor «iron». 

Keywords:

induction post-repair submersible electric motor, descriptive statistics, system identification methods, forecast of stator winding insulation condition, fire in magnetic conductor iron, elementary electric machine, rotor package

Authors:

Vladimir Z. Kovalev

Alexander S. Glazyrin

Olga V. Arkhipova

Emil I. Khusainov

Vladimir A. Kopyrin

Evgeniy I. Popov

Rustam N. Khamitov

Alexander A. Filipas

Semen S. Popov

Evgeniy V. Bolovin

Evgeniia A. Beliauskene