Electrical Submersible Pumps 101

Issue Date: 06-09-2015 Rev.
Date: 06-09-2015 Revision: 01

Author: David Corona Page 1 of 85 Content ID:
Electrical Submersible Pumps

101
Rev. No. Effective Date Description

01 2015-06-08 First release
Page 2 of 85
Contents
Electrical Submersible Pumps ................................................................................ 1
101 ............................................................................................................................. 1
1.0 QHSE ................................................................................................................... 4
1.1 Safety Information ............................................................................................................ 4
1.1.1 Overview............................................................................................................................. 4
1.1.2 Danger to personnel ......................................................................................................... 5
1.1.3 Danger to equipments ................................................................................................. 8
1.1.4 Danger to environment ..................................................................................................... 10
2.0 Downhole equipments .................................................................................. 11
2.1 Electrical Submersible Pump (ESP) definitions: ..................................................................... 11
2.1.1 Centrifugal pump definition: .............................................................................................. 11
2.1.3 The Diffuser ...................................................................................................................... 12
2.1.4 Stage ................................................................................................................................... 13
2.1.5 Product Line ..................................................................................................................... 13
2.1.6 Single Pump...................................................................................................................... 13
2.1.7 Upper Tandem Pump ........................................................................................................ 14
2.1.8 Central Tandem Pump...................................................................................................... 15
2.1.9 Lower Tandem pump ........................................................................................................ 16
2.1.10 Pump stage types ............................................................................................................. 17
2.1.11 Mix flow impeller ................................................................................................................ 17
2.1.12 Radial flow impeller ............................................................................................................ 17
2.1.13 Pump construction ............................................................................................................. 18
2.1.13.1 Compression Pumps ...................................................................................................... 18
2.1.13.2 Floater construction pump ............................................................................................. 19
1.1.14 Pump descriptions and names ......................................................................................... 20
2.1.15 Total Dynamic Head (TDH) ................................................................................................... 23
2.1.15.1 Net vertical depth ........................................................................................................... 24
2.1.15.2 Tubing friction loss ......................................................................................................... 27
2.1.15.3 Tubing Head Pressure .................................................................................................... 29
2.2 Intake and gas separator ...................................................................................................... 32
2.2.1 Intake ................................................................................................................................ 32
2.2.2 Gas separator ................................................................................................................... 32
2.2.2.1 Static gas separator .......................................................................................................... 32
2.2.2.2 Dynamic gas separator ..................................................................................................... 33
2.2.3 Gas Separators Efficiency ................................................................................................ 33
2.2.5 Advanced Gas Handler (AGH) data ..................................................................................... 36
2.2.6 Application of AGH ........................................................................................................... 36
2.3 Protectors .............................................................................................................................. 38
Protector Functions ....................................................................................................................... 38
2.3.2 Protectors: Labyrinth Type ................................................................................................. 39
2.3.3 Protectors: Positive Seal – Bag Type ................................................................................. 40
2.3.4 Protectors: Thrust Bearing ................................................................................................. 41
2.3.5 The Modular Protector ....................................................................................................... 41
2.4 Submersible Motor ............................................................................................................... 42
2.4.1 Motor Parts ....................................................................................................................... 43
2.4.1.1 Motor-Housing .................................................................................................................. 44
2.4.1.2 Motor-Rotor ..................................................................................................................... 45
2.4.1.3 Motor – Thrust Bearing .................................................................................................. 47
2.4.1.4 Motor- Pothead .............................................................................................................. 47
2.4.2 Motor – Tandem................................................................................................................ 48
2.4.3 Motor Protection................................................................................................................. 49
2.5 Multisensor Downhole Tool .................................................................................................. 50
2.5.1 Multisensor Theory ........................................................................................................... 50
2.5.2 Multisensor Types ........................................................................................................... 50
Page 3 of 85
Multisensor Type 1........................................................................................................................ 50

2.5.3 Multisensor Parameters ..................................................................................................... 51
2.5.4 Cable-To-Surface CTS ........................................................................................................... 55
2.6 ESP Cables .......................................................................................................................... 57
2.6.1 Cable Selection ................................................................................................................... 57
2.6.2 Components of downhole ESP cable ............................................................................... 59
2.6.2.1 Conductor Selection ......................................................................................................... 59
2.6.2.2 Insulation Selection ......................................................................................................... 60
2.6.2.3 Barrier Selection .............................................................................................................. 63
2.6.2.4 Jacket Selection ............................................................................................................... 63
2.6.2.5 Armor selection ............................................................................................................. 65
2.6.2.6 Cable Nomenclature ........................................................................................................ 66
3.0 Surface Equipments. ................................................................................... 67
3.1 Variable Speed Drives (VSD). ............................................................................................... 67
3.1.1 Introduction. ....................................................................................................................... 67
3.1.2 VSD Benefits...................................................................................................................... 69
3.1.3 VSD types ......................................................................................................................... 69
3.1.4 VSD Mounting .................................................................................................................... 69
3.1.5 VSD Special Considerations ............................................................................................. 70
3.2 Switchboard (SWB) .............................................................................................................. 71
SWB Basic Operation ................................................................................................................... 72
3.2.2 VSD\SWB Controller (UniConn) .................................................................................... 74
3.3 Transformers ....................................................................................................................... 78
3.3.1 Transformers types ............................................................................................................ 79
3.3.2 Commissioning transformers ............................................................................................. 79
3.3.3 Theory of Operation ........................................................................................................... 80
3.3.4 Load Filter .......................................................................................................................... 81
3.3.5 Protection and control ....................................................................................................... 83
3.3.6 Junction Box ..................................................................................................................... 84
3.3.7 Surface Equipments enclosure .......................................................................................... 85
Page 4 of 85
1.0 QHSE
1.1 SAFETY INFORMATION
The following conventions are used to indicate precaution in this procedure.
Failure to heed precautions in this procedure can result in serious or possibly
even fatal injury or damage to the related equipment.
1.1.1 OVERVIEW
There are four indicators of special type of care needed with equipment that are
used in the text of this manual:
Potential Severity: Catastrophic

Potential Loss: Personnel
Hazard Category: electrical
Indicates major or catastrophic severity with high potential loss.
Potential Severity: Serious

Indicates danger to personnel and could possibly result in loss of life or

serious injury.
Potential Severity: Light

Indicates danger to equipment and could result in relatively serious or

minorinjury, or faulty operation.
Indicates special care needs to be taken.

Page 5 of 85
1.1.2 DANGER TO PERSONNEL

• Qualified personnel when working on or around a unit should follow the
following precautions.
• Never work alone on equipment that has power applied to it. Be sure
someone is nearby to give assistance in case of an accident.
• Ensure lockout, tag-out (LOTO) procedures are used whenever possible.
• Beware of defective equipment. If equipment components or connections
look loose, corroded, or damaged in any way, do not operate.
• Ensure that power to the system is OFF when connecting or disconnecting
equipment.
• The power terminals and control terminals may carry a voltage even when
the connected equipment is not active.
Qualified personnel are people entrusted by their employer with

installation,
assembly, commissioning, and operation of the equipment within the
intent
and constraints of the operating instructions in this manual and the
warning
Information on the equipment itself. Qualified personnel must have
the following minimum training and qualifications:
• Special training in electrical equipment, in accordance with the
standards of safety engineering
• CPR training
• First Aid training
• Personal Protective Equipment (PPE) training
• Fire Safety training.
Only Qualified Personnel are eligible to deal with ESP equipments, paying special
attention to warning notes located throughout the manual.
Qualified Personnel are people who are entrusted by their employer within the
meaning of these operating instructions and the warning information on the
equipment itself.

Hazard Category: machinery equipment hand tools
If a substitute extension bar is used, the front-end diameter must not be

greater than 0.75 in. The extension bar and opener head must maintain
a loose engagement to avoid personal injury during use.
Page 6 of 85

Ensure the power is off before working at any electrical device.
Potential Severity: Major

Hazard Category: fire flammable
Never use a megger on the rig floor. A spark generated by a megger

can ignite gasses emitted from the wellhead. Complete this test while
the motor is in the shipping box. Additional megger tests can be
completed safely at the cable reel once the cable is connected to the
motor.

Always discharge each winding after the megger test. The residual
high-voltage charge can shock personnel and/or damage other
meters.

Hazard Category: temperature
Always use caution when handling heated equipment.

Potential Loss: Assets, Personnel
Notify all personnel in the immediate area that electrical equipment will
been energized up to the junction box. Place a flashing beacon on the
junction box to further alert personnel in the area of danger.

Hazard Category: explosives
Gas accumulation in the VSD/Switchboard cabinet can cause an

explosion. A high-voltage junction box is required for all submersible
pump applications. A junction box will preventing gas migration through
the cable into the switchboard.
Page 7 of 85

High voltage is present in transformers. Always wear your hot gloves

and other personal protective equipment when working with
energized equipment.

High voltage is present in transformers. Qualified personnel must

preform Megger tests. All power must be disconnected and locked
out. Both primary and secondary bushings must be disconnected

High voltage is present in transformers. Qualified personnel must

perform Megger tests. All power must be disconnected and locked
out. Both primary and secondary bushings must be disconnected

The voltage must be properly applied to the transformer. Failure to do

so can result in serious personal injury, death or property damage. All
tests must be pre formed by qualified personnel.

Hazard Category: fire flammable
Before loosening any connection on the pumping unit, make certain

the temperature is cool to the touch. If there are pockets of contained
liquids under pressure, these could flash to vapors and cause a
severe injury.
Page 8 of 85
1.1.3 DANGER TO EQUIPMENTS

Observe the following precautions when working on or around a unit.
• Do not attempt to access voltage on the interface boards. The probes may
damage the board and cause a hazard or equipment failure. Terminals are
available external to the unit enclosure for measurement purposes.
• Ensure that the operating facility is dry and dust-free. Incoming airflow must
not contain any gases, vapors, or dusts that are electrically conductive or
detrimental to functioning. Air containing dust must be filtered.
• Ensure the operating environment is moisture free or non-condensing for high
humidity applications. Excessive humidity or condensation may cause
hazardous operation of the unit.
• Damage or destruction can result if the unit is incorrectly connected.
• The unit should be stored in the original transportation package to prevent
damage during handling.
Potential Loss: Assets
Certain concentrations of H2S will cause failure of stainless steel

bands.

Ensure the cable sheave is attached securely with a chain and has a
cable or chain safety backup.

The switchboard case should be grounded to the well casing.

Extreme care should be used in handling the switchboard. When

uncrating, pry bars should be used instead of a hammer. The interior of
the switchboard must be kept free of moisture. Always examine internal
components for possible shipping damage.
Page 9 of 85

Any cable damage should be located and repaired prior to installation.

Never take a chance that unprepared damage will have no effect.

If a protector is placed in a horizontal position without first being

drained, water will flow to the other section. If stored, this can cause a
seal to malfunction on the next installation, resulting in a burned motor.

The lower part of string should be covered while shimming.

Never reuse emery cloth when abrading different materials such as

copper, insulation or jackets. This will embed copper into the insulation
and degrade the integrity of the splice.

Cuts in the conductor insulation are not permitted past the bare conductor
area. If the insulation is damaged when removing the jacket, remove the
damaged area and start a new splice.

Don’t make any cable splices in rainy condition, any liquids drops got into the
splicing will be causing damage to the cable during power energizing.
Page 10 of 85

Improper installation of splicing sleeves can result in splice failure.

Always make a visual inspection, making certain all three-switch

contacts are open.
1.1.4 DANGER TO ENVIRONMENT

Potential Loss: Assets, Environmental
Failure to observe the following precautions may result in damage to

the environment.
Check with Local environmental law and Company HSE advisor for specific
procedures.
Page 11 of 85
2.0 DOWNHOLE EQUIPMENTS

2.1 ELECTRICAL SUBMERSIBLE PUMP (ESP) DEFINITIONS:
The ESP is unit consists of centrifugal pump, protector, intake, motor and other
accessories all attached together. This unit is submersed in wells to produce oil or
water through production tubing.
Production Tubing
Bolt On Head (BOH)
Pump
Intake
Protector
Motor Lead Extension (MLE)
Motor
Fig 2-1:ESP Downhole equipments
2.1.1 CENTRIFUGAL PUMP DEFINITION:

A Centrifugal Pump is a machine that moves fluid by spinning it with a rotating impeller
in a diffuser that has a central inlet and a tangential outlet. The path of the fluid is an
increasing spiral from the inlet at the center to the outlet tangent to the diffuser. The
pressure (head) develops against the inside wall of the diffuser because the curved
wall forces fluid to move in a circular path hence than by converting velocity head to
(pressure) head.
Schlumberger centrifugal pump is a multistage pump, containing a selected number
(application dependent) of impellers equipped with vanes, inside a closely fitted
diffuser, located in series on axial shaft, driven by the electrical motor.
Page 12 of 85
2.1.2 IMPELLER:
A centrifugal pump creates pressure by the rotation of a series of vanes in an
impeller.
Fig 2-2: The Impeller
The motion of the impeller forms a partial vacuum at the suction end of the impeller.
The impeller’s job is to transfer energy by rotation to the liquid passing through it, thus
raising the kinetic energy.
2.1.3 THE DIFFUSER

The diffuser section then converts this energy to potential energy, raising the fluid pressure.
Fig 2-3: The Diffuser
From there, the rotation of the high-speed impeller throws the liquid into the diffuser.
Page 13 of 85
2.1.4 STAGE
Each "stage" consists of an impeller and a diffuser. Again, the impeller takes the fluid
and imparts kinetic energy to it. The diffuser converts this kinetic energy into potential
energy (head).
Fig 2-4: The Stage

Number of stages determines the head developed, and is also the factor for the
horsepower requirement.
2.1.5 PRODUCT LINE
Schlumberger pumps come in several different configurations. Most pumps
(especially the smaller diameter ones) come as Center Tandems (CT).
other types are Upper Tandems (UT), Lower Tandems (LT) and Single (S) pumps. the
actual pump stages are no different regardless of what "type" it is. The difference in
the pumps depends on what it looks like on.
2.1.6 SINGLE PUMP

A "single" pump has an intake and discharge head intrinsic to the pump itself. No other
pumps can be attached to it.
Page 14 of 85
Fig 2-5: Single pump
All pumps require an intake and discharge with the single pump; these are inherent
to the pump itself. This offers a slight cost benefit since fewer bar stock pieces are
required but suffers in flexibility and creates inventory problems.
2.1.7 UPPER TANDEM PUMP

An upper tandem pump has a discharge head but no intake section. It can be placed on top
of another pump or an intake section.
Fig 2- 6: UT Pumps
Page 15 of 85
2.1.8 CENTRAL TANDEM PUMP

A "center tandem" pump has no intake or discharge inherent and must have these
provided in some fashion either with another pump or an intake section and/or bolt-
on head.
Fig 2- 7: CT Pump
The center tandem has either another pump above and/or below it or else a bolt-on
discharge to complete the top end and an intake to complete the bottom end. Center
tandem pumps offer the most flexibility. If the required number of stages for the well
cannot fit into a single section, more sections can be added until the stage
requirement is met. Since a CT pump can be either a single (with a bolt-on
discharge and intake added) or a part of a larger pump, inventory requirements are
greatly reduced.
Page 16 of 85
2.1.9 LOWER TANDEM PUMP

A lower tandem pump has an integral intake but no discharge head. It can go below
another pumps or else is completed with a bolt-on discharge head.
Fig 2-8: LT Pump
The lower tandem has either another pump above it or else a bolt-on discharge to
complete the assembly. lower tandems are especially common in the larger
diameter, higher flow rate pumps. This helps to reduce entrance losses associated
with higher flow rates and also, in some cases, allows a gas separator to be built
directly into the intake where a standard add-on separator could not handle the fluid
throughput.
Page 17 of 85
2.1.10 PUMP STAGE TYPES

There are two types of impellers that determine the amount flow available for the
specific design. The difference between these two types of designs is described by
the pump impeller vane angles and the size and shape of the internal flow passages.
2.1.11 MIX FLOW IMPELLER

Mixed flow impellers have vane angels at close to 45 degree, and therefore, are
usually found in pump ranges for higher flow rates.
Fig 2-9: Mix flow impeller
2.1.12 RADIAL FLOW IMPELLER

A radial flow (pancake) impeller has vane angels at close to 90 degree, and
therefore, is usually found in pump ranges for lower flow rates.
Fig 2-10: Radial flow impeller

Page 18 of 85
2.1.13 PUMP CONSTRUCTION

Schlumberger pumps come in two basic varieties:
Floater construction - Each impeller is free to move up and down so it is said to
"float" on the shaft.
Compression construction - Every impeller is fixed to the shaft rigidly so that it
cannot move without the shaft moving. All the impellers are "compressed" together
to make one rigid body.
2.1.13.1 COMPRESSION PUMPS

In a compression pump, all the impellers are rigidly fixed to the shaft so that if an
impeller wants to move up or down, it will take the shaft with it.
The impeller is normally sitting down on its lower diffuser during assembly due to
gravity. Because of this, the pump shaft is "raised" with shims in the coupling so that
the impeller is not allowed to touch the diffuser after final assembly. This allows all
thrust developed in the pump shaft to be transferred to the protector shaft directly.
Fig 2-11 Compression pump
Why use compression pumps?

Page 19 of 85
• Some stages generate too much thrust to be handled by a thrust washer in

the stage.
• Some fluids (e.g. liquid propane) do not have enough lubricity to properly
lubricate a thrust washer.
• If abrasives or corrosives are present, it may be beneficial to handle the thrust
in an area lubricated by motor oil rather than well fluid.
• Occasionally in very gassy wells, the flow volume changes so drastically
within the pump that parts of a floater pump could be in very severe thrust
while others are not so a compression pump could be one alternative.
• Since all the down thrust is handled in the protector, as long as the protector
has a great enough capacity, the pump operating range can be extended over
a much wider area without any increased wear or reduced life.
2.1.13.2 FLOATER CONSTRUCTION PUMP

Since a floating impeller is free to move up and down the shaft, the only thing to
stop it is either the upper or lower diffuser. "Thrust washers" are provided at all
mating surfaces between the impeller and diffuser to absorb any thrust generated.
Fig 2-12: Floater pump
Why use Floater pumps?

Page 20 of 85
• Since each stage handles its own thrust, a very large number of stages can
be put in a pump without having to worry about protector bearing capacity.
• Floaters are also very good with mild abrasives since they prevent material
from getting into the radial bearing area.
• Floaters are much more forgiving in manufacturing since tolerance stack-up is
not a concern.
• Easier field assembly, no shimming required.
1.1.14 PUMP DESCRIPTIONS AND NAMES

Schlumberger Artificial Lift uses alphabetic characters to describe the diameter or
series of each of the Stages available for catalogue description.
The series designations are defined as:
Type Series Pump ‘’OD” CSG. ‘’ID’’
A 338 3.38’’ 4 ½’’

D 400 4.00’’ 5 ½’’
G 540 5.13’’ 6 5/8’’
S 538 5.38’’ 7’’
H 562 5.63’’ 7’’
J 675 6.75’’ 8 5/8’’
L 738 7.25’’ 9 5/8’’
M 862 8.63’’ 10 ¾’’
N 950 9.5’’ 11 ¾’’
P 1125 11.25’’ 13 3/8’’
DN1300
D = 400 series, therefore, 4.0”in diameter

1300 = the best efficiency flow rate (60 Hz: 3500 RPM) in barrels per day
N = the material of the stage, in this case Ni-resist.
D950 defines
D = 400 series, or 4.0”diameter.
950 = 950 bpd flow rate.
Other Letters (Suffix only) used in pump curve database to describe

special pumps.
H (Extrude Honed).
E (Epoxy Coated Stages) SN3600E.
C (As Cast).
Page 21 of 85
2.1.14 Pump curve and applications
Fig 2-13: Pump curve
Immediately above the pump curve is a technical data section. This section is very
useful as it contains almost every piece of information necessary to make certain a
pump is suitable for an application.
The left column shows the recommended operating range and physical parameters
of the pump such as diameter and shaft size.
To the right column shows important physical limitations of the pump itself such as
shaft horsepower and housing burst pressure limits.
SN8500 60 HZ / 3500 RPM Pump Performance Curve 538 series - 1 Stage
Pump Operating Range (ROR) 6,000 -11,000 Shaft Brake Horsepower Limit: Standard 375hp
Nominal Housing Diameter 5.38 Inches High Strength 600 hp
Shaft Diameter 1.00 Inches Housing Burst Pressure Limit: Standard 5000 psi
Shaft Cross Sectional Area 0.785Inches Buttress 6000 psi
Welded 6000psi
Minimum Casing Size 7.000 Inches
Page 22 of 85
Always make certain to use the correct page when reviewing the technical data as
there are significant differences between the 60 Hz (3500 rpm) and 50 Hz (2917)
rpm curves.
The performance curve itself is plotted with respect to flow in cubic meters per day
and head in meters.
Although there is no "universally" accepted system of units, these units are more
commonly used in a 50 Hz environment than are BPD and feet of head. The 50 Hz
performances can also be read off the VSD curve, which is plotted in BPD and feet.
Page 23 of 85
2.1.15 TOTAL DYNAMIC HEAD (TDH)
TDH is the sum of three basic components:

Net Vertical Lift (NVL) = is the net distance where the fluid must be lifted.
Tubing Friction loss (FL) = net vertical distance in the tubing string during pumping
process.
Tubing Head Pressure (THP) = Pressure which the unit must pump against (back
pressure caused by choking on well head or surface facilities pressure)
Page 24 of 85
Fig 2-14: TDH Equation
2.1.15.1 NET VERTICAL DEPTH

Net Vertical Lift is the vertical distance in the tubing that the fluid must be lifted to
get to the surface.
The energy required lifting the vertical distance between dynamic fluid level and
the surface can be determined by the equation:
Work = mgDh
Where:
m = mass of fluid
g = acceleration due to gravity
Dh = height the fluid is lifted
Page 25 of 85
Fig 2-15: Net Vertical Lift
Fig 2-16: Pump setting depth will not affect the NVL
What about deviated wells?
Page 26 of 85
Fig 2-17: Net lift in deviated wells
Regardless of where the pump is set, or the angle of the well, the vertical
lift does
not change.
Page 27 of 85
Fig 2-18 VD & MD
Assume given fluid level of 4000 feet (TVD) from surface so:
Net Vertical Lift = 4000 feet
If the well is deviated, the total measured distance (MD) from surface could
be much greater but, since the work done in moving the fluid sideways is
zero, only the vertical distance matters.
2.1.15.2 TUBING FRICTION LOSS

Friction is an energy loss due to viscous shear of the flowing fluid. In a fluid,
molecules are free to move past each other but there will be a little resistance.
This resistance is due to shear forces that must be overcome. The higher the
shear forces, the higher the viscosity.
How to calculate friction loss?

Fortunately, there are many charts available for determining friction losses.
Page 28 of 85
• How to use the chart?

For example, we have a total tubing length (pump setting depth MD) of 6500 feet - and we
want to produce 5000 bpd.
In this case we have three sizes of tubing: 2-3/8”, 2-7/8" and 3- ½” available in
stock.
Page 29 of 85
What will the friction be for each size?

Since we have 6500 ft of tubing. Total Friction Loss on
2 3/8” tubing = 500 x (6500 Ft/ 1000) = 3250 Ft
2 7/8” tubing = 200 x (6500 Ft/ 1000) = 1300 Ft
3 ½” tubing = 73 x (6500 Ft/ 1000) = 474.5 Ft
2.1.15.3 TUBING HEAD PRESSURE

Up to this point, we have been calculating everything in terms of "feet". This is very
convenient when sizing a pump.
Fig 2-19: Pressure readings on wellhead
For example,
Page 30 of 85
Well head pressure = 200 psi

Water Cut (1.07 sp. Gr.) = 60%
Oil Cut =?
Assumed oil API = 30 °API
What is the wellhead pressure in feet?
Determine oil SG, use the API gravity equation:

Sp.Gr= 141.5/(131.5+API)
Oil Sp.Gr= 141.5/(131.5+30)= 0.876
Next, find the “composite” specific gravity of the fluid in the well?
The best way to do this is simply to take an "arithmetic average".
Average SG = (0.60 x 1.07) + (0.40 x 0.876) = 0.992

Wellhead pressure from [psi] to feet.
Wellhead Pressure*2.31
Wellhead "Feet" = ----------------------------------
Sp.Gr.
200 psi *2.31 ft/ psi

Wellhead "Feet" = ----------------------------- = 465 ft
0.992
Wellhead (feet) also can be determined by equation:
Well head pressure

Wellhead (feet) = -----------------------------
(SG * 0.433) Fluids density
200 psi
Wellhead (feet) = ----------------------------- = 465 ft
(0.992 * 0.433 psi/ ft)
Page 31 of 85
The TDH will be the sum of:
• Net Lift,
• Friction Loss, and
• Wellhead pressure.
We will assume 3-1/2” tubing since it provides the lowest friction losses
Fig 2-20: 4939Ft will be TDH for this application

Page 32 of 85
2.2 INTAKE AND GAS SEPARATOR

2.2.1 INTAKE
Is the entrance of the oil into the string in order to be lifted by the pump to the
surface (Standard operation). Separation efficiency: 0-20%
In some applications, there may be gas produced along with the oil and water
liquids.
2.2.2 GAS SEPARATOR
2.2.2.1 STATIC GAS SEPARATOR
A gas separator is still an intake, but with some special features designed to keep
free gas from entering the pump.
Original gas separator designs were based on increasing gas separation by forcing
the fluid flow to reverse in the wellbore. This is where the name of this type of gas
separator, REVERSE FLOW, comes from. Since this type of gas separator does no
real "work" on the fluid, it is also called a "static" gas separator.
Fig 2-21: Static gas separator

Page 33 of 85
2.2.2.2 DYNAMIC GAS SEPARATOR

The rotary gas separator design works in a similar fashion to a centrifuge. The
centrifuge “paddles” spinning depending on the frequency cause the heavier fluids to
be forced to the outside, through the crossover and up into the pump, while the
lighter fluid (vapor) stays toward the center, and exits through the crossover and
discharge ports back into the well.
Fig 2-22: Dynamic gas separator
2.2.3 GAS SEPARATORS EFFICIENCY

Testing conducted at Tulsa University actually showed that natural separation could be from
20% to 60 % and that with a Schlumberger rotary gas separator, total separation efficiencies
could be as high as 99 %.
The testing also indicated that gas separators (all types) do have definite flow ranges where
they are effective and other flow ranges where they are not. The TU tests agreed well with
Schlumberger recommendations.
Page 34 of 85
VGSA S70-150 Performance Curve for % Free Gas by Volume

After Total Separation
100
% Free Gas by Volume Before Any
80
5%
60 10%
15%
Separation
40
20%
20
0
0 5000 10000 15000
Liquid Flow Rate (BPD)
Comparision at 15 % Free Gas by Volume After

Total Separation
100
% Free Gas by Volume Before Any Separation
80
60 VGSA S70-150
VGSA S20-90
40 OLD TECH
20
0
0 3000 6000 9000 12000 15000
Liquid FLow Rate (BPD)

Page 35 of 85
2.2.4 Advanced Gas Handling Objectives

Increase a pump's ability to produce gas without "gas locking". Utilize gas to
improve overall lift efficiency.
Fig.2-23: Tapered configuration with gas separator
Fig.2-24: Reda AGH with gas separator

Page 36 of 85
Principles
• Homogenize the mixture
• Reduce bubble size
• Put gas back into solution
• Help gas to move to mainstream
2.2.5 ADVANCED GAS HANDLER (AGH) DATA
Model Outer Diameter Shaft Diameter Shaft Area Shaft HP Limit HP Required Min flow rate Max.flow rate
DN 5-21 4 0.6875 0.371 200 13 500 2100
GN 20-40 5.125 1 0.785 600 37.5 2000 400
GN 40-80 5.125 1 0.785 600 45 4000 8000
SN 70 100 5.375 1 0.785 600 53 7000 10000
2.2.6 APPLICATION OF AGH

The AGH can be used with a standard intake or with a gas separator. The choice will depend
on how much free gas will be present at the intake for producing condition and on whether
there is a packer preventing gas production up the annulus.
Fig 2-25: AGH & Gas separator on with DHE
2.2.7 Benefits of Schlumberger AGH

Page 37 of 85
• Expand applications that can be produced with an ESP

• Replace gas-lift
• De-water gas wells
• Produce gassy well below a packer
• Increase production in wells experiencing downtime due to gas locking
• Continuous stable operation
• Benefit of gas lift effect in the tubing
• Increase production in wells that have been limited to high intake pressures to
keep stable operation
• Continuous stable operation at lower intake pressures - higher production rate
possible
Page 38 of 85
2.3 PROTECTORS
Protectors are an often over looked piece of equipment in the Schlumberger Reda
system and are frequently miss-understood.
The Protector serves a vital link in the entire assembly and, if it is not properly
applied, can reduce the overall running life of the equipment.
There are several functions of a Protector and we need to consider each one in the
overall design and application process to select the right unit.
PROTECTOR FUNCTIONS
The Protector has three primary functions:
• To keep well fluid out of the motor.
• To carry the thrust developed in the pump.
• To couple the torque developed in the motor
• Act as an oil reservoir for the motor
• Equalize the pressure between motor and downhole
One of the main functions of the Protector is to keep well fluids out of the motor
where they could potentially do harm.
Some types of water well motors are actually open to the well fluid and no effort is
made to keep it out. Water however may affect insulation.
In the oil well environment, the produced fluids are much more aggressive than
typically found in water environments and, if allowed to contact the inside of the motor,
may cause a premature failure. When the unit is first installed in the well it goes from
atmospheric pressure up to the
Very high bottom hole pressure of the well. When the unit is operated, internal heating
causes the motor oil to expand which would add even more pressure if it did not have
some place to go. If the unit is stopped and allowed to cool down, the oil will contract
which would create a vacuum in a sealed system.
The Protector simply keeps the pressure on the inside of the unit the same as the
pressure on the outside of the unit regardless of what the external pressure is.
Since the bottom of the Protector is open to the motor, the motor pressure remains
the same as that in the well annulus around it.
Obviously the Protector must allow "communication" with the well fluid in some
fashion.
There are several Protector designs that allow the well fluid and motor fluid to transfer
pressure to each other without any mixing of the two fluids actually occurring.
Page 39 of 85
2.3.2 PROTECTORS: LABYRINTH TYPE

One such Protector type is the "Labyrinth" type. The labyrinth design uses the
difference in specific gravity of the well fluid and the motor oil to keep them apart
even though they are in direct contact.
Fig 2-26: Labyrinth type
With this design, the motor oil and well fluids are in direct contact. The labyrinth
chamber is isolated from the shaft rotation by the shaft tube so that no mixing will
occur by the unit turning. The well fluid is generally immiscible with the motor oil so,
even though there is direct contact; there is no tendency to contaminate the motor oil.
There will be cases where a labyrinth will simply not work. In cases where the well
fluid is lighter gravity than the motor oil (i.e. about 0.85), the motor oil will go to the
bottom of the chamber rather than the top causing the motor fluid to be displaced by
well fluid pretty quickly. If the well fluid is about the same gravity as the motor fluid or
lighter, this type of Protector should not be used.
Labyrinth Protectors also will not work in highly deviated wells. The gravity separation design
requires the unit to be mostly upright. This Protector can operate in some amount of deviation
but the expansion volume is somewhat reduced.
Many times the labyrinth protector is "checked" in the field to determine if water got into the
bottom of the unit. If this is done, always do it before the unit is laid down on its side. Once
on its side, water initially in the bottom of the chamber may redistribute itself since the U-tube
restriction is effectively removed.
Don’t use labyrinth type protectors in high deviated wells (more than 45
Degree of deviation)
Many times dismantle inspections show water in the lower portion of a labyrinth
Protector and this is mistakenly thought to have been there when the unit was
operating down hole. Always remember that a labyrinth protector will normally
operate with some water (well fluid) in the top end by design. If the unit is laid on its
side and transported, the water can move to the bottom.
Page 40 of 85
2.3.3 PROTECTORS: POSITIVE SEAL – BAG TYPE

For applications where the well fluid and motor oil gravities are similar or where a
well is highly deviated, a different Protector design uses a “positive seal” or “bag” to
physically separate the two fluids:
• High Temp / High Performance Elastomer
• Accommodate oil volume expansion/contraction
This is similar to the “bellows” found in some water well motors except that the bag
has a much greater capacity for expansion and contraction than a typical bellows.
The bag is made of a high temperature / high performance elastomer which can
withstand the harsh downhole environments typically encountered. The bag keeps
the well fluid on the outside and the clean motor oil on the inside. When the motor oil
expands or contracts, the bag simply flexes to accommodate the necessary volume
change.
Fig 2-27: The bag volume is changeable and keeps the fluids separated
The positive seal Protector offers a great deal of flexibility and is useful in a wide
variety of applications.
One area where care needs to be taken with this type of Protector is with harsh well
chemicals as may be experienced with a treatment program.
As with any oil field elastomer, care must be taken to ensure that the rubber will not
be damaged by anything it will encounter in the well. If the positive seal is breached,
the motor can easily be contaminated with well fluid.
Page 41 of 85
2.3.4 PROTECTORS: THRUST BEARING

Another function of the Protector is to absorb the thrust generated by the pump
whether it is up thrust or down thrust. The Protector thrust bearing gives a very large
surface over which to absorb thrust. In addition, it does so in a nice clean oil
environment that greatly prolongs the Reda unit life.
2.3.5 THE MODULAR PROTECTOR
The Protector is named for the type(s) of seal chambers available in D slim line 387 series
used and how those chambers are connected (i.e. in "series" or "parallel") from top to bottom.
Schlumberger modular protectors are available in 400, 540 and 562 Series. They come in
either standard or high thrust ratings as well as standard and high temperature material
configurations.
Using the modular system, the protector can be designed to meet specific
application requirements without unnecessary and expensive duplication of parts.
Chambers options:
L: Labyrinth
• B: Bag
• P: Parallel
• S: Series
• HL: High Load (Bearing)
BSBSL- HL
Three chamber design with a bag on top connected in series to another
bag that is then connected in series to a labyrinth chamber. Also it has a
high load thrust bearing.
Page 42 of 85
2.4 SUBMERSIBLE MOTOR

• It is simple in construction, rugged and reliable
• Classified as 3 phases, squirrel cage, 2-pole induction and alternating current
motor
Fig 2-28: Submersible motor

Page 43 of 85
2.4.1 MOTOR PARTS

The motor is basically made up of two parts:
• Stator (Stationary part)
• Rotor (Rotating part)
The stator is composed of:
• Housing
• Laminations
• Windings
Fig 2-29: Motor inner parts

Page 44 of 85
2.4.1.1 MOTOR-HOUSING
• The Housing forms the cover for the motor and is threaded at both ends for
head and base components
• The housing can be of five different diameters.
Fig 2-30: Motor housing

• 3.75” = 375 series
• 4.56” = 456 series
• 5.40” = 540 series
• 5.62” = 562 series
• 7.38” = 738 series
Fig 2-31: Motor inner parts

Page 45 of 85
2.4.1.2 MOTOR-ROTOR
The rotor is a device that rotates inside of the stator core and is keyed to the shaft.
The rotor is made up of
• Rotor laminations that are smaller in diameter from the stator laminations
• Copper bars with supporting copper end rings.
Fig 2-32: Laminations & copper bars
Fig 2-33: Rotor Laminations and Rotor Bars in various designs

Page 46 of 85
Fig 2-34: Rotor Bearings are one of the most vital parts of the motor
Rotor bearing
The main purpose is to provide the axial and radial support to the shaft and rotors
Fig 2-35: Rotor bearing

Page 47 of 85
2.4.1.3 MOTOR – THRUST BEARING

The motor thrust bearing is installed at the top of the rotor string. It is designed to
hold the weight of the entire rotor string.
Fig 2-36:Thrust bearing
2.4.1.4 MOTOR- POTHEAD

Schlumberger Artificial Lift Systems mainly use tape-in type potheads versus the
plug-in type pothead to connect the motor lead to the motor. This drawing shows the
construction of the pothead connection.
Fig 2-37: Pothead
Tape-In Pothead
Tape wrapped around individual connector leads inside motor.
• Plug-In Pothead - mating block mounted in motor.
• Direct Connect Pothead – For #1 cable and high amperage power cable
attached directly to the Pothead (Plug-In Type).
Advantages:
Page 48 of 85
• Most Reliable
• Highest breakdown strength in industry.
Disadvantages:
• Longer installation time on rig floor.
Plug- In Pothead
Advantages
• Ease of installation
Disadvantages
• Lower breakdown strength.
• Not as reliable as Tape- in.
Flat Cable Extension (FCE)

Flat Cable Extension (FCE) = Motor lead & Pothead Motor Lead - Typically smaller
conductor than power cable, thus runs hotter.
• KEOTB - 250°F (121°C)
• KELB - 450°F (232°C)
• KELTB - 450°F (232°C)
2.4.2 MOTOR – TANDEM
Submersible electric motors can be designed in tandem configuration to create the
desired Horsepower required for each application. Schlumberger manufactures
different motor sections:
• Single Tandem = S
• Upper Tandem = UT
• Center Tandem = CT
Single section:
• UT + UMB or DME
• UT + CT + UMB or DME
• UT + CT + CT + UMB or DME
• UMB = Universal Motor Base

• DME = Downhole Monitoring Equipment
How do we tandem motors?
Page 49 of 85
When putting more than one motor together in a tandem combination, always keep
the sections the same HP and voltage.
A 300 HP 540 series motor should be made up of two 150 HP motors rather
than something like a 100 HP motor in tandem with a 200 HP motor.
2.4.3 MOTOR PROTECTION

• In either type of controller, overload and under load protection is of primary
importance and it is critical that these both be set correctly in order to properly
protect the motor from damage.
• Overloads protection setting it should be 115% of the running current without
exceeding nameplate current.
• Underload protection setting should be 80% of the running current.
• Let's take a particular case: A145 stage DN1300 producing a fluid of 1.0
gravity on a 456 series PK type 50 Hp, 885V, 35.5A motor.
• Should we set the O/L at 115% of 35.5A and the U/L at 80% of
35.5A?
145 s ta ge DN1300 BHP vs . Flow 456 Motor % NP a mps vs . Loa d
50
1
45 0.8
Tota l BHP (s pgr=1.0)
Fra ction of NP Amps
40 0.6
35 0.4
30 0.2
25 0
0 1,000 2,000 0 40 80
500 1,500 20 60 100
Flow ra te - BP D % of Full Loa d
From the curves above, we can see that this pump will only require about 45 HP at
BEP flow. This will place about a 90% load on the motor that means the motor should
draw only 32 amps rather than the 35.5 of the nameplate. This should be the basis
for our calculations and settings.
• The point is that these standard rules-of-thumb are not always perfect.
• Every application should be considered independently to ensure that the
settings selected are adequate to properly protect the downhole equipment.
Page 50 of 85
2.5 MULTISENSOR DOWNHOLE TOOL

2.5.1 MULTISENSOR THEORY
• The MultiSensor downhole system measures up to 7 parameters, these being
Pi, Pd, Ti, Tm, Flow, vibration, plus one spare channel for future
development.
• Downhole sensors are calibrated to international standards
• Data is transmitted via the motor power cable to the surface
• The downhole electronics are proven for their operation in this environment.
• Operational limits 150C (302F) and 5600PSI (10000 PSI in high pressure
version)
2.5.2 MULTISENSOR TYPES
MULTISENSOR TYPE 1
Measured Parameters:
• Pump intake pressure
• Intake temperature
• Motor Oil temperature
• Current Leakage
• Vibration
• Pump discharge pressure
MEASUREMENT RANGE ACCURACY
Pressure 690 bar (10,000 psi) 0.1%
Temperature 150°C (302°F) 1%
Flowrate 4700 m3/d 5%
Vibration 12 g 1%
Current Leakage 25mA 0.05%

Page 51 of 85
Fig 2-39: Multisensor parts
2.5.3 MULTISENSOR PARAMETERS

Intake Pressure
• Measured using a 400 Bar (5800 psi) sealed strain gauge pressure
transducer. The voltage output from the transducer is near linear with
pressure.
• High pressure option with a 690 Bar (10000 psi) transducer
Discharge Pressure
• Measured in the same way as intake pressure but with a 1/4 inch sealed
control line extending to above the pump discharge
Intake Temperature
• This is measured by utilizing the semi-conductor temperature sensor that is
both linear and accurate in temperature measurement. The voltage output
varies with temperature. The temperature sensor is calibrated in an oven.
Motor Temperature
• Either motor winding with a thermocouple fitted in the motor winding, or motor
oil with the thermocouple fitted into the oil at base of the motor.
• Measured using J-type thermocouples and works by means of a temperature
difference system.
• For absolute temperature the Intake temperature is used as the reference.
The temperature sensor is calibrated in an oven.
Page 52 of 85
Vibration
• Measured by means of a calibrated accelerometer fitted inside the
Multisensor
Current Leakage
• The Multisensor system measures leakage to earth through the ESP system
and also when the MultiSensor is isolated from the rest of the system. This is
referred to as active and passive current leakage
Transformer
MDT Motor Cable
Choke
120 Vdc
ISP
Fig 2-40: MultiSensor & Surface equipments diagram
Page 53 of 85
VSD
ISP
Choke
Transformer
Cable
Motor
MDT
Fig 2-41: Signal path
Active Current Leakage

• With the system voltage reversed, the Diode on the MultiSensor will be
reversed biased allowing current leakage of the system to be measured.
• This value is unreliable with the ESP running, due to the effects of any
imbalance.
• This shows if there is any earth leakage with the system.
Passive Current Leakage
• The leakage current of the system is measure during the calibration frame
and this is compared with the active current leakage.
• This value is reliable with the ESP running.
• Any deviation from this value will mean a change in leakage current in the
system.
• When the motor is off the active current leakage will verify the leakage
Earth Faults
• MultiSensor sends current down the 3-phase power cable
• Current returns via earth
• A short (low megger reading) will mean that Phoenix current circulates from
phase to earth and all tool communications are lost
Page 54 of 85
• Repairing the fault should restore communications
VSD
ISP
Choke
Transformer
Cable
Motor
MDT
Fig 2-42:Communication lost
Transmission System
• The Multisensor signal transmission system is a Variable current, low
frequency analogue signal.
• A current value from 9 to 21 mA represents the parameter value. Each
parameter has its own unique calibration.
• Due to the high operating temperature range and the duration the equipment
is downhole, internal calibration references are used within the tool to
compensate for any changes in the downhole electronics with time (Cz and
Cf).
• The tool sensors and downhole electronics require only 7mA of current to
operate. The majority of the current is required for the communication system.
• System is Time Division Multiplexing (TDM) of analogue values
• Sequence begins at time 0 (power on)
• Each frame is 2 seconds
• At end of sequence there is a negative time for synchronisation and current
leakage measurement
• Current must be above 7 mA to keep tool powered on
Page 55 of 85
2
~
1
C C
f P Q
~
d
C P T V 1
T
i i
i 0
C
L +1
V 20
lt 0
Fig 2- 43: Transmission system

Current Signalling
• Cz is around 10 mA and Cf around 18 mA
• Signalling range is typically 9 to 21 mA for any parameter although above 18
mA not usually seen
2.5.4 CABLE-TO-SURFACE CTS
Fig 2-44: CTS can be used with all artificial lift methods
Fit for purpose Cable To Surface sensor system

• Digital Telemetry – Pressure transmitted every 2 seconds.
• Improved Metrology.
• Slim Line Design.
• Industry leading reliability through advanced environmental. Qualification and
accelerated testing.
• Compatible with existing surface equipment.
• Light Weight.
Page 56 of 85
• Designed to withstand the high vibration of reciprocating Lift systems.

Page 57 of 85
2.6 ESP CABLES

Factors to be considered when selecting cable:
• Electrical Properties
• Physical Dimensions
• Environmental Resistance
• Mechanical Strength
• Temperature
• Handling Condition
2.6.1 CABLE SELECTION
Cables can be installed in wells where bottom hole temperature is in excess of 400
degrees Fahrenheit.
Cable Type KV Raiting Configuration Max. Temp Insulation Material Jacket Material
Redalene 3KV Round & Flat 205F Ployethylene Nitrile
Redahot 4KV Round & Flat 220F EPDM Nitrile
Redablack 5KV Round & Flat 300F EPDM EPDM
Redalead 4KV & 5KV Round & Flat 400F EPDM Braid over Lead
Ployethylene 3KV Round 180F Ployethylene Ployethylene
The proper cable size is governed by the amperage required by the downhole motor,
the allowable voltage drop between motor and surface, and the space available
between the tubing collar and casing.
Page 58 of 85
#6 AWG #4 AWG
60
50
Voltage Drop (V, per 1,000 ft)
40 #2 AWG
#1 AWG
30
#1/0 AWG
20
10
0
0 20 40 60 80 100 120 140
Current (A)
Voltage Drop Graph
Cables are available in either flat or round configurations.

Page 59 of 85
Flat Round
Fig 2-45: ESP cables types (Flat &Round)
The most critical data values for selecting cable are:

• Down hole temperature and
• Type of fluid the cable will operate in
2.6.2 COMPONENTS OF DOWNHOLE ESP CABLE
Armor
Jacket
Barrier
Insulation
Conductor
Injection Tube
(Optional)
Fig 2-46:Cable component
2.6.2.1 CONDUCTOR SELECTION

Factors to be considered:
• Size
• Damage resistance
• Flexibility
• Cost
Solid Compacted Stranded

Page 60 of 85
Fig 2-47:Conductors shapes
Solid
• Smallest diameter / lowest cost
• Lower interfacial electrical stress
Stranded
• Greater flexibility
• Greater damage resistance
Compacted
• Up to 10% decrease in diameter versus round stranded conductor.
Cable Coating and Adhesive

• Alloy Coating for Chemical resistance
Adhesion & Standard blocking.

• Downhole Performance
• Gas transmission
• Gas entrapment/corrosion
• Corona discharge
2.6.2.2 INSULATION SELECTION

The purpose of the cable insulation is to provide protection to the current carrying
conductors from attack from well fluids that will result in a short circuit downhole. There
are many factors that can negatively affect the performance of cable downhole.
Amongst these are:
• Temperature
• Pressure attack
• Gas to oil ratio
• Carbon dioxide and H2S attack
• Oil attack
Insulation Type
1- POLYPROPYLENE CO POLYMER (THERMOPLASTIC)

Page 61 of 85
THERMOPLASTIC cables for lower temperature applications
2- ETHYLENE PROPYLENE DIENE METHYLENE (EPDM) (THERMOSET)
THERMOSET used in cables for higher temperature applications
THERMOPLASTIC
• Definite melt point
• Limited by temperature
• Ease of processing
• Simple formulations
• Thermal failure is often dramatic
THERMOSET
• No melting point
• Often-higher temperature rating
• More difficult to process
• Complex formulations
• Thermal failure is generally gradual
POLYPROPYLENE INSULATION.
• Excellent resistance to well fluids
• Excellent electrical properties
• Low cost
• Available in three different colors
Page 62 of 85
Disadvantages.
• Upper temperature range softens at 205°F (96°C) Subject to crazing in
certain environments.
>205°F/96°C
<205°F/96°C
Fig 2-48: Heat effect on cable isolations
EPDM insulation advantages:

• Excellent high-temperature stability, has been used at up to 550°F (288°C) in
geothermal wells.
• Excellent electrical properties, although higher power losses than
polypropylene. Available in three different colors.
Fig 2-49:EPDME Colors
Disadvantages:
• Limited well fluid resistance, oil swells EPDM compounds. Susceptible to
mechanical damage at elevated temperatures
Page 63 of 85
2.6.2.3 BARRIER SELECTION

Factors to be considered:
• Temperature
• Chemical environment
• Gas handling
Barrier
Fig 2-50: Barrier shape

Barrier Types
• POLYVINYLEDINE FLUORIDE EXTRUSION - 300°F (150°C)
• TEDLAR™ TAPE - 300°F (150°C)
• TEFLON™ FEP EXTRUSION - 350°F (175°C)
• PROPRIETARY HIGH TEMPERATURE TAPE - 400°F (205°C)
• LEAD - 550°F (288°F)
2.6.2.4 JACKET SELECTION

• The jacket is there mainly to provide mechanical protection to internal
components of the cable.
• The jacket also physically binds all three conductor strands together.
• It also allows armor to be applied to the cable without damaging the
conductors.
Factors to be considered when selecting jacket:

• Temperature
• Chemical environment
• Gas
• Handling condition
Jacket types
• 185°F (85°C), HIGH DENSITY POLYETHYLENE (HDPE)
• 250°F (121°C), NITRILE 1
• 275°F (135°C), NITRILE 2
• 350°F (176°C), NITRILE 3
• >350°F (176°C), EPDM
Page 64 of 85
Nitrile 3
Nitrile 2
Nitrile 1
EPDM
HDPE
Fig 2-51: Jacket types
EPDM Rubber Jacket (>350 F)

• Excellent high temperature stability
• Poor resistance to oil
NITRILE Rubber Jacket (< 275 F*)

• Excellent resistance to oil
• Good physical properties
• Poor electrical properties
• Poor resistance to water
+ Water =
Fig 2- 52: NITRILE Rubber Jacket have poor resistance to water

Page 65 of 85
EPDM & NITRILE Jackets offer different advantages.
Nitrile (NBR) EPDM

Physical properties Good Poor to fair
Oil resistance Good Poor to fair
Water resistance Poor to fair Good
Damage resistance Good Poor
H2S resistance Fair Good
Amine resistance Fair Good
Heat resistance Fair Good
Service temperature up to* Greater than
275°F/135°C 350°F/176°C
2.6.2.5 ARMOR SELECTION

Factors to consider:
• Damage resistance
• Decompression containment
• Corrosion resistance
Armor
Fig 2- 53: Armor shape

Armor types that available
• STANDARD GALVANIZED STEEL (CLASS I)
(GSA, 0.020"/0.51mm & 0.025"/0.64mm thick)
• HEAVY GALVANIZED STEEL (0.034"/0.86mm thick)
• HEAVY COATING CLASS II GALVANIZED STEEL
• STAINLESS STEEL
• MONEL
Page 66 of 85
Fig 2- 54:Standard crown profile interlocked
Fig 2- 55: Flat profile interlocked
Fig 2- 56: Flat Profile
2.6.2.6 CABLE NOMENCLATURE

In naming the cable, always start from the inside and work outward. The first step is
the size and type.
#4/1 KEOTB 0.015M5F represent:
#4/1 #4 AWG Solid conductor

K Polyimide (Kapton™) primary insulation
E EPDM secondary insulation
O Nitrile jacket
TB Tape (probably Tedlar™) & braid
0.015 Armor thickness (inches)
M Monel armor
5 5 kV Voltage rating
F Flat cable
Page 67 of 85
3.0 SURFACE EQUIPMENTS.

3.1 VARIABLE SPEED DRIVES (VSD).
Fig 3-1: VSD (Yaskawa P7) on site
3.1.1 INTRODUCTION.
A Variable Speed Drive (VSD) is an electronic device which synthesize a three
phase variable voltage, variable frequency power supply for induction motors
ESP & HPS applications use Induction three phase motors and benefit of use a VSD
to control their motor speed and torque.
As oil well characteristics change, the VSD is used to change SPS pump head and
flow optimizing the well output.
+ =
Page 68 of 85
Fig 3-2: Simple VSD block diagram
• Rectifier (Converter) It converts the input voltage from AC to DC

• Filter Capacitors (DC Link) It smoothes the DC Voltage.
• Inverters (IGPT’s) It inverts the DC voltage to adjustable AC
Converter
Fig 3-3: Output of converter
DC Link
Fig 3-4: Output of DC link
Inverter
Page 69 of 85
Fig 3-5: Output of Inverter
Insulated Gate Bipolar Transistor, IGBT

• Latest technology
• Fast switching speed. Turns on in less than 400 nanoseconds and off in 500
nanoseconds
• Low power required to turn it on and off
• Few switching losses, less heat
3.1.2 VSD BENEFITS

• Extend SPS equipment operating life.
• Improve SPS system efficiency.
• Enable oil production optimization as well conditions change.
• Provide inherent soft start. No inrush currents
• Improves lightning protection of down hole equipment
• Rocking start can break loose a stuck pump
• Protect the motor when pump-off condition.
• Makes possible remote flexible operation.
• Smooth and controlled response to pump torque changes.
• Eliminate the need of hydraulic choke at wellhead.
• Slow acceleration motor ramp reduces pump wear and prevents sand
infiltration.
• Permits a fine tune of production avoiding reservoir damage.
• In combination with proprietary DME it allows an efficient well production.
3.1.3 VSD TYPES

Currently, Schlumberger uses the SS2K, SWD, VariStar, Titan and MVD VSD’s.
Other VSD Types:
• Siemens
• Yaskawa G3, G5, P7
The VSD is available in different capacities from 175 KVA up to 800KVA and available
in 6 and 12 pulse.
3.1.4 VSD MOUNTING
Variable Speed Drives (VSD’s) should be mounted to skid bases or concrete pads
only. VSD’s should not be mounted directly on the ground. Mounting instructions for
switchboards, given above, should be followed. Mounting details for switchboards and
Page 70 of 85
VSD’s do not differ appreciably and the enclosures are very similar. Some smaller
VSD’s typically are packaged in wall mount type enclosures.
3.1.5 VSD SPECIAL CONSIDERATIONS
A note of caution should be applied when installing 12–pulse variable speed drives.
Typically, power is supplied to the drive through the use of a three winding isolation
transformer. Should the situation arise where two separate windings, transformers
supply power to one 12 pulse VSD, care should be taken when grounding the star
point of the transformer. For example, where the utility has supplied one delta-wye
transformer and one wye-wye transformer, do not ground the secondary wye-points
on both transformers. If both star points are connected to ground, two things occur.
First, any cancellation of 5th and 7th harmonics will not happen, and second
circulating currents will flow which can cause heating in cables, power transformers,
and control transformers. Should the supply authority require that at least one
transformer secondary be grounded, it may be necessary to apply ground monitoring.
Note that a ground fault anyplace on the system, including on the ungrounded
transformer, will cause the breaker on the grounded transformer to open. If the drive
is loaded, the ungrounded neutral transformer breaker is also likely to operate. If the
load is small the ungrounded neutral transformer breaker will not likely operate and
the system will run with the fault, unknown to the operator. It’s advisable to provide
ground fault monitoring by measuring three-phase voltage to ground on the
ungrounded neutral transformer bus to provide warning. As a minimum, three 480-volt
transformer light bulbs are acceptable. Some jurisdictions may require the use of
screened, or shielded, conductors in order to limit RF (radio frequency) interference.
Typically, this is the case in Europe not North America. If possible, do not install
screened conductors on the output of a VSD. If screened must be used it is important
that individual conductors NOT be installed. A better choice is three-conductor,
screened cable. As well, it is important to note that the screens only be grounded
(earthed) at one end, not both ends. Grounding both ends of the screen will cause
circulating currents and increase cable heat gain.
Page 71 of 85
3.2 SWITCHBOARD (SWB)

Most SLB SWBs are now supplied under the FixStar or MCP name with the UniConn
controller as the motor control device. For information on the FixStar SWB. Former
SLB SWBs had controllers that were the K095, K595, or the REDAlert motor
controller.
Fig 3-6: SWB
The SWB is used as starting switch for the downhole equipments. Its also provides
protections and control. The SWB runs the downhole equipments with fixed speed.
Switchboards should be mounted to steel skid bases or concrete pads only. Skid
bases may be mounted on piles or installed directly on the ground. Switchboards
should not be mounted directly on the ground as there is a possibility of leaning or
tipping over. In cases where the switchboard is small enough these units may be pole
mounted.
Page 72 of 85
Fig 3-7: SWB inner parts
SWB BASIC OPERATION

The basic circuit can be divided into two parts:
• The control circuit which operates at 120 Volts, and up to 5 Amps.
• The power circuit that operates at the voltage and current of the ESP
(allowing for cable loss).
Control Circuit
Each CT in the power circuit transmits current to one of the three overload relay coils.
The recording ammeter; and underload relay; are in series with two of these coils –
and allow recording of running current; and underload sensing. Each overload relay
has a normally closed contact, which are in series with one side of the 120V control
circuit. An overload causes the contact to open, turning off the control circuit; and
shutting down the motor.
Page 73 of 85
Power Circuit
Incoming power to the controller is applied to the manually operated disconnect
switch. A TVSS can be attached below here that gives protection against lightning
strikes. The power cables pass through current transformers (CT’s), which step the
current down to manageable levels. A potential transformer (PT) brings the voltage
down to about 120 volts for use by the control circuit.
Potential Transformers
• Used to step-down the high voltage (from between 330 to 4900 volts) to a
control voltage of 120 volts.
• The 120-volt control voltage is used to run all the control circuitry in the
Switchboard.
• Motor controllers will monitor the control voltage and using the P.T. ratio
calculates the line voltage in the switchboard.
It is not 120 volts. Fully loaded there is a 5 -7% secondary voltage loss through
the transformer. Therefore the voltage ratio should be obtained using 126
instead of 120 volts.
Current Transformers
Page 74 of 85
Another type of transformer that is used in the motor controller is the "current
transformer". This type of transformer changes one current to a different current.
Fig 3-8: Current transformer
To monitor the motor current it has to be reduced to a level that is easier to measure.
If this were not reduced then measuring devices would be large and cumbersome in
order to cope with the high currents. To reduce the level to a more manageable one
current transformers are used. A conductor passes through the winding of the CT and
energizes it. Typically the CT ranges used in the SPS controllers have a TR of 200:5,
300:5, 150:5, etc. although in VSD applications, the CT ratio can be much higher.
3.2.2 VSD\SWB CONTROLLER (UNICONN)

Monitoring and control, and data acquisition for fixed- and variable-speed three-phase
induction motor systems. This unit and its optional expansion cards monitors:
• Motor currents and voltages
• VSD/FSD parameters
• Control supply voltage
• External switch contacts
• Process analog signals
• Data collected from downhole monitoring system
• Backspin monitor inputs
• Remote SCADA commands.
The UniConn also provides motor and VSD shutdown under adverse conditions and
allows safe, automatic motor restarts. The UniConn expansion card system allows
plug-and-play interfacing to downhole tools and to communication systems.
Page 75 of 85
The UniConn is particularly suited for controlling oilfield production pump motors for
electric submersible pump (ESP) systems and variable speed drive (VSD) systems.
The self-contained unit incorporates a display and keypad for local control and
operation. The compact size makes it suitable for mounting in most VSD and
switchboard enclosures. The control wiring for the UniConn is connected to removable
terminal assemblies on the unit. The terminal assemblies snap in and out for easy
connection or removal. The assemblies are organized logically according to function.
The integrated keypad and display incorporates full Hand-Off-Auto and Start control
for the motor so externally wired switches are not required. External annunciation
lamps can be connected to the outputs on the UniConn for improved visibility to on-
site personnel.
Fig 3-9: UniConn

Page 76 of 85
Fig 3 -10: Digital & Analog Inputs
Fig 3-11:UniConn receptacles

Page 77 of 85
Fig3-12: UniConn Fuses

Page 78 of 85
3.3 TRANSFORMERS

Hazard Category: electrical, machinery equipment hand tools
The following precautions must be followed. Failure to do so can result in

death
serious injury or property damage.
• Only trained and qualified personnel should service transformers. Dangerous

voltages, pressures and other hazards are present that can result in death or
serious injury.
• Improperly performed work can result in catastrophic failure or explosion of the
transformer.
• All sources of power to transformers must be locked out and it must be
confirmed that there be no power at the input or output of the transformer.
• Before installing a transformer, be sure the transformer kVA, voltage, winding
configuration and other characteristics are suitable for the application. This
information is listed on the transformer nameplate.
• Always lift the transformer by all four tank-lifting lugs. Ensure the weight of the
transformer does not exceed the capacity of the equipment used to lift it.
• Do not lay a transformer on its side. Doing so will cause air to be trapped in
the windings resulting in the failure of the transformer. Solidly ground the
transformer tank before it is energized. Never operate a tap switch or a delta-
wye switch while the transformer is energized. The transformer can violently
fail if this is done.
• Before connecting any equipment to the secondary of the transformer,
measure the secondary voltage to ensure that it is suitable for the equipment
to be connected. Since deadly voltages will be present, use suitable measuring
equipment, hot gloves and observe all safety practices.
• When a transformer will be serviced, all sources of power must be
disconnected and locked out. The HV (high-voltage) and LV (low-voltage)
terminals should be grounded when you are positive there is no voltage
disconnected from the transformer bushings. Remove the grounds placed on
the terminals prior to reapplying power.
• The transformer tank cover or inspection access cover must not be removed
when conditions exist that may allow moisture, dirt, foreign objects or other
contamination to enter the transformer tank. You should remove loose items
from your pockets prior to opening the cover. The entry of these materials in
the transformer tank may result in the premature failure of the transformer.
Page 79 of 85
3.3.1 TRANSFORMERS TYPES

Pole Mount Transformers
There are many different types of installations dealing with pole mount transformers.
These installations range from single transformers mounted on a single pole with a
switchboard mounted below to large KVA transformers mounted on multi-pole
platforms with pad-mounted switchboards.
Installation of switchboards directly underneath pole-mounted transformers is

not recommended due to proximity of technician to falling debris in the event
of transformer failure.
Pad Mount Transformers

Pad mount transformers are constructed with enclosed bushing compartments.
Typically, there are compartments for the High and Low voltage sections of the
transformers. In some cases, both the sections are in the same compartments and
care should be taken when making connections in these types of transformers. Cable
entry into the transformer compartments should always be through the bottom to avoid
water entry during rain. With some transformers this may not be possible. When this
is the case, watertight glands should be installed to avoid water entry into the
enclosure. When transformers are sitting on a pad, they should be mounted to the pad
with sufficient bolts to keep the transformer in place is it should be struck by a service
vehicle, etc. To ensure that the transformers run cool, they should be placed in a
location where there is adequate ventilation for the units. This will also allow for service
personnel to inspect the transformers on all sides for damage, take temperatures, and
install cables.
3.3.2 COMMISSIONING TRANSFORMERS

• All bolted connections to be checked and tightened as per the Mfg. of the
transformer.
• Tank and fittings should be inspected for damage or leaks.
• Leaking bushings should be tightened prior to applying power to the
transformer.
• Tap settings should be recorded and measured voltages should be recorded.
• Resistance measurements should be taken on both primary and secondary
windings. Results should be recorded.
• Windings should be tested with 1000 volts DC Megger. Primary and secondary
phases may all be joined together for measurement. Readings should be
recorded.
• Remove backspin shunt if used. Readings are to be taken from Primary to
Ground, Secondary to Ground, and Primary to Secondary.
• Oil sample should be taken at customer’s request only.
• Operating temperatures should be recorded during loaded operation.
• All safety devices/shields should be replaced and secured.
Page 80 of 85
3.3.3 THEORY OF OPERATION

Transformer operation is based on the principle that electrical energy can be
transferred by mutual induction from one winding to another. When the primary
winding is energized from an alternating current source, an alternating magnetic flux
is established in the transformer core. This flux links the turns of both the primary and
the secondary windings, inducing voltages in them. Because the same flux cuts both
windings, the same voltage is induced in each turn of both windings. Therefore, the
number of turns in the secondary winding compared to the number of turns in the
primary winding determines how much voltage will be present across the entire
winding.
Fig. 3-13: The relationship between voltage and the number of windings turns
The formula is as follows for most of the transformers that are used in the industry:
The above transformer has 10 turns on the primary and 2 turns on the secondary. This
translates out to 10/2 = 5 or a 5:1 ratio. Basically, for every 5 volts on the input the unit
will output 1 volt. If the primary were 600 volts AC, then the secondary voltage would
be 120 volts AC or 600 / 5 = 120 volts AC. This would be considered a step-down
transformer as the voltage is reduced. If the same transformer was used and the
primary turns were 2 and the secondary turns were 10, this would be considered a
step-up transformer.
Step-up Transformer Application
On high horse power application involves using a 400V or 600V class inverter on an
existing medium voltage motor. Most medium voltage motor requires at least 2300,
2700, or 4160 (V AC) to power it. The HHP drive needs a Step-Up transformer to
properly power the motor adequately.
Page 81 of 85
Fig 3-14:Transformer
The normal drive output is connected to a 460V primary, 4160V secondary Step-Up
transformer
3.3.4 LOAD FILTER

ACA R-992 Capacitive Filter effective solutions to voltage stresses on VSD Operated
SPS. The ACA R992 Load Filter provides sinewave voltages and currents for
Electrical Submersible Pump systems. It is used with ESP systems using high carrier
frequency asynchronous PWM Variable Speed Drives with voltage step-up
transformers and long cables. The filter is installed between the step up transformer
and the downhole cable junction box as shown by drawing A-681-1.The theory of
operation is discussed in the paper “Voltage Stresses in Electrical Submergible
Pumps Operated by Variable Speed Drives” presented at the SPE ESP Houston
Workshop, April 1999. Capacitance is added to an ESP system to lower the natural
resonant frequency to less than one half of the drives maximum carrier frequency.
This alters the system frequency response to attenuate the carrier frequency and its
harmonic multiples to provide a sinewave output. The amount of capacitance required
depends on the transformer; cable length, the motor used, and the maximum drive
carrier frequency. The correct value can be calculated with the ACAESP model or
measured at the site with a Keltronics R991 Resonant Analyzer. The R992 Load
Filters are available in two standard voltage ranges, 3.5kV or 5.3kV RMS phase to
phase. They may be connected in Delta (D) and/or Wye (Y) combinations to provide
a wide variety of capacitance selections. The following table lists the standard type
arrangements for equivalent Wyes capacitance values and current ratings for 2 kHz
operations:
Page 82 of 85
ACA Part No. 1121 Capacitance Selection Std. Factory Connection

Voltage KV Type Microfarads/Current Rating
3.5 3DY1X5 5/27A, 15/47A 15/74A
3.5 3DY2X5 5/27A. 10/54A, 15/74A, 20/62A, 30/94A 10/54A
3.5 3DY1X10 10/45A, 30/78A 10/45A
3.5 3DY2X10 10/45A, 20/90A, 30/78A, 40/104A, 60/156A 20/90A
3.5 5DY1X5 5/32A, 15/55A 15/55A
3.5 5DY2X5 5/32, 10/64A, 15/55A, 20/74, 30/110 10/64A
Fig 3-15:Load filter terminations with VSD
Fig 3-16: Load filter

Page 83 of 85
3.3.5 PROTECTION AND CONTROL

Operating the R992 Load Filter with a low or synchronous carrier frequency can cause
excessive capacitor currents if the harmonics fall in the system resonant band. To
protect against this possibility, the filter includes an over current relay that shuts the
drive down and prevents restarts until the problem has been investigated and reset by
qualified electrical personnel. The current relay monitors the current passing through
the capacitors. If the current exceeds the relay set point, a latch relay is “set” and the
alarm circuit opens. The set point scale on the current relay is marked in 1/10
increments of the current transformer used. Dry contacts from the latch relay and a
control voltage relay are wired in series to provide a normally closed alarm circuit for
drive control. When connected to a drive normally closed digital input, the filter alarm
circuit opens in an alarm condition to shutdown the drive. The reset pushbutton on the
terminal strip inside.
Do not adjust the current overload set point higher then the current rating for the
selected capacitors.
Page 84 of 85
3.3.6 JUNCTION BOX

The junction box is used for connecting the power cable and venting gas (in case gas
has migrated up the power cable) between the well and switchboard. It should be in
line with the switchboard if possible, and at a distance of approximately 25 feet
(minimum 15 feet) from the well to permit a working area for the service rig. Junction
box mounting and dimensions are shown bellow.
• Provides a connection point for the surface cable from the motor control panel
to the power cable in the wellbore.
• Allows for any gas to vent that may have migrated through to the power cable.
• Provides easy accessible test point for electrically checking downhole
equipment
Fig 3-17: Junction box positioning
Ensure the power is off before working at the junction box.

Page 85 of 85
3.3.7 SURFACE EQUIPMENTS ENCLOSURE

This provides general information for NEMA enclosure types 3, 3R, and 4.
Additionally, their storage recommendations will be provided. Equipment in
discussion includes Load Filters, Variable Speed Drives, Junction Boxes, and
Switchboards.
1.TYPE 3 NEMA ENCLOSURES
Enclosures constructed for either indoor or outdoor use to provide a degree of
protection to personnel against incidental contact with the enclosed equipment; to
provide a degree of protection against falling dirt, rain, sleet, snow, and windblown
dust; and that will be undamaged by the external formation of ice on the enclosure.
2.TYPE 3R NEMA ENCLOSURES
provide a degree of protection against falling dirt, rain, sleet, and snow; and that will
be undamaged by the external formation of ice on the enclosure.
3.TYPE 4 NEMA ENCLOSURES
provide a degree of protection against falling dirt, rain, sleet, snow, windblown dust,
splashing water, and hose-directed water; and that will be undamaged by the external
formation of ice on the enclosure.
4.LONG-TERM STORAGE
All equipment departing from EPC will be packaged and/or crated for short-term
transportation purposes only. Equipment, such as Switchboards, is transported on
their sides and/or backs to eliminate tipping hazard during transport. Once the
equipment has been received at the final destination, and if it will be stored on a long-
term basis, it must be adequately protected against weather conditions

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Issue Date: 06-09-2015 Rev.

Date: 06-09-2015 Revision: 01

Electrical Submersible Pumps

Rev. No. Effective Date Description

Multisensor Type 1........................................................................................................................ 50

Potential Severity: Catastrophic

Indicates major or catastrophic severity with high potential loss.

Potential Severity: Serious

Indicates danger to personnel and could possibly result in loss of life or

Potential Severity: Light

Indicates danger to equipment and could result in relatively serious or

Indicates special care needs to be taken.

1.1.2 DANGER TO PERSONNEL

Qualified personnel are people entrusted by their employer with

Potential Severity: Serious

If a substitute extension bar is used, the front-end diameter must not be

Potential Severity: Catastrophic

Ensure the power is off before working at any electrical device.

Potential Severity: Major

Never use a megger on the rig floor. A spark generated by a megger

Potential Severity: Major

Potential Severity: Major

Always use caution when handling heated equipment.

Potential Severity: Serious

Potential Severity: Serious

Gas accumulation in the VSD/Switchboard cabinet can cause an

Potential Severity: Catastrophic

High voltage is present in transformers. Always wear your hot gloves

Potential Severity: Catastrophic

High voltage is present in transformers. Qualified personnel must

Potential Severity: Catastrophic

High voltage is present in transformers. Qualified personnel must

Potential Severity: Catastrophic

The voltage must be properly applied to the transformer. Failure to do

Potential Severity: Major

Before loosening any connection on the pumping unit, make certain

1.1.3 DANGER TO EQUIPMENTS

Certain concentrations of H2S will cause failure of stainless steel

Potential Severity: Serious

Potential Severity: Major

The switchboard case should be grounded to the well casing.

Potential Severity: Major

Extreme care should be used in handling the switchboard. When

Potential Severity: Light

Any cable damage should be located and repaired prior to installation.

Potential Severity: Light

If a protector is placed in a horizontal position without first being

Potential Severity: Serious

The lower part of string should be covered while shimming.

Potential Severity: Light

Never reuse emery cloth when abrading different materials such as

Potential Severity: Light

Potential Severity: Light

Potential Severity: Light

Improper installation of splicing sleeves can result in splice failure.

Potential Severity: Light

Always make a visual inspection, making certain all three-switch

1.1.4 DANGER TO ENVIRONMENT

Failure to observe the following precautions may result in damage to