esp1 overview with animation 08

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ESP System Technology Overview

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ESP Downhole SystemThe basic ESP downhole system components

are ...

The Monitoring System (optional)

The Power Cable

The Motor

The Seal Section

The Pump

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Product Identification Key

Equipment for 4.5 inch casing and larger

“300 Series”

SeriesDiameter model Type

338 3.375” D pump\seal

375 3.75” D motor

385 3.85” E pump

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Product Identification Key Equipment for 5.5 inch casing and larger

“400 Series”

Series Diameter model Type

400 4.00” F pump/seal

400 4.00” 400P Centurion Pump

450 4.50” F motor

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Product Identification Key

Equipment for 7.0 inch casing and larger

“500 Series”

Series Diameter model Type

513 5.125” G pump/seal

538 5.375” 538P Centurion Pump

544 5.438” G motor

562 5.625” K motor

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Product Identification Key Equipment for 8-5/8 inch casing and larger

SeriesDiameter model Type

675 6.75” H pump/seal

725 7.25” H motor

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Product Identification Key

Pumps only

SeriesDiameter model Minimum Casing

875 8.75” I 10-3/4”

900 9.00” N 10-3/4”

1025 10.25” J 13-3/8”

1038 10.38” M 13-3/8”

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Product Identification Key

Pump Stage Key

example 1: FC4300

F = 400 series, 4.00” pump

C = casting, S = synthetic impeller material

4300 BPD, best efficiency point (BEP) flow

except I and J pumps are in GPM

example 2: 538P17

538 = Series

P = Pump

17 = 17 hundred (1700) BPD @ BEP & 60 Hz

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Product Identification KeyModel Designation Key

1st Letter - Series D, F, G, K, H, I, J

2nd Letter - Product Type

P - pump, RS - rotary separator

S - seal, M - motor

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Product Identification Key

3rd, 4th, … Letters - Options, some of the most popular are …

LT - lower tandem, MT –middle tandem,

AR - abrasion resistant (pump),

X - corrosion resistant metallurgy, C - labyrinth type (seal),

M - modular AR style, C - ‘compression’ fixed impeller type (pump)

B - bag type (seal), G - high temperature option

B, C, E, F, H… in 3rd letter motor - rating ‘generation’

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LT = Lower Tandem pump

( with built in intake )

The seal bolts on here

12

LT/MT = Lower/Middle Tandem pump

Head

Shipping Cap

If MT (middle tandem) or LT (Lower Tandem) then a flange face is the head of the pump.

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If FP type or Upper Tandem (UT) then a discharge is built into the pump.

FP Pump

Built in Discharge head

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Middle Tandem pump Base

UT or MT pump

Shipping Cap

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The Bolt on Head FPHVDIS

The Middle Tandem or Lower Tandem Pump Head

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Gas separator intake (cut away). May be bolted on to the base of a MT (Middle Tandem) or UT (Upper Tandem) Pump

The Seal bolts on here.

UT or MT pump bolts on here.

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ESP Downhole SystemThe system …

Should be set above the perforations of the well for unit cooling

Must be sized to the well’s productivity

Should be monitored for changes in well and/or unit performance

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The Pump Hangs from the production tubing

Lifts the fluid through the tubing to the surface

Is a multi-stage centrifugal type

Is constructed from impellers and diffusers

Must be sized to match the well production

Has an intake and discharge that either bolts onto or is threaded into the pump housing

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Built in Discharge head Tubing screws in here

Bolts to the Seal

Pump Shaft Built in Intake

Pump Housing

Rotating Impeller

Stationary Diffuser

The Pump

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Rotating (right to left) impellers

Stationary diffusers

Cutaway of Pump

21Impeller

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Impeller

The impeller rotates about the pump axis, with the shaft

It provides the centrifugal force to the fluid - gives it energy.

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Impeller

Fluid enters the impeller through the ‘eye’ near the shaft and exits the impeller on the outside.

24Impeller - Cut Away

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Impeller

Eye

Hub

Upper Shroud

Vanes

Lower Shroud

Skirt

26Diffuser

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Diffuser

The diffuser does not rotate, it turns the fluid up into the next impeller

It transforms the fluid velocity, it’s energy, into head

28Diffuser - Cut Away

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Impeller & Diffuser

Diffuser directs fluid into the eye of the impeller

Impeller spins and gives energy to fluid which exits around the outside

Diffuser redirects the fluid up into the next impeller and turns fluid energy into head

30Impeller in Diffuser - A Pump ‘Stage’

31Pump Stage - cut away

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Pump Stage

Fluid Reservoir

Developing the Pump Stage

Head – Capacity Curve

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Fluid Reservoir

Head (Lift)

1

Developing the Pump Stage

Head – Capacity Curve

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The Seal Chamber Section Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates (seals) the well fluid from the clean motor oil

Equalizes the internal unit and wellbore pressure

Provides area for motor oil expansion volume

Absorbs the pump shaft thrust load

The Four “Shuns” - expansion, equalization, isolation, & “absorbsion”

aka “Equalizer”, “Protector”, or “Seal Section”

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The Seal Chamber Section Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates (seals) the well fluid from the clean motor oil

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MotorPump

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Motor

Pump

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39

40

Motor

Pump

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Motor

Seal

Pump

42C en tr ilift

Located between the pump and motor

Transfers the motor torque to the pump shaft

The Seal Section

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Labyrinth Chamber

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Labyrinth Chamber

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Double Labyrinth Chamber

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The Seal Section, purpose:

1. Isolation Isolates (seals) the clean motor oil from the well fluid

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Isolation

Labyrinth Chamber

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55

r

Isolation

Prevents fluid migration down the seal shaft

Mechanical Seals

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Pump

Motor

Labyrinth Chamber

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Pump

Motor

Bag or Bladder

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Pump

Motor

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62

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Isolation Bag (or Bladder)

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r

Isolation - Recap

3. Bag (or Bladder)

1. Labyrinth Chamber

2. Mechanical Seals

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The Seal Chamber Section Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates the well fluid from the clean motor oil

Provides area for motor oil expansion volume

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Labyrinth Chamber

Motor Oil - Heated

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Labyrinth Chamber

Motor Oil - Cooling

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Double Labyrinth Chamber

Motor

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2. Expansion Provides space for motor oil expansion

The Seal Section, purpose:

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Expansion

Labyrinth Chamber

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Bag (or Bladder)

Motor

Motor Oil - Heated

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Bag (or Bladder)

Motor

Motor Oil - Heated

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Bag (or Bladder)

Motor

Motor Oil - Heated

Check valve

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Bag (or Bladder)

Motor

Motor Oil - Heated

Check valve

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Bag (or Bladder)

Motor

Motor Oil - Heated

Check valve

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Bag (or Bladder)

Motor

Motor Oil - Heated

Check valve

79Motor

Motor Oil - Cooling

80Motor

Motor Oil - Cooling

81Motor

Motor Oil - Heated

Double Bags

82Motor

Motor Oil - Heated

Double Bags

83Motor

Motor Oil - Heated

Double Bags

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85

86Motor

Motor Oil - Heated

Parallel Bags

87Motor

Motor Oil - Heated

Parallel Bags

88

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Expansion

Bag (or Bladder)

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Expansion - Recap 2. Bag (or Bladder)

1. Labyrinth Chamber

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The Seal Chamber Section Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates the well fluid from the clean motor oil

Provides area for motor oil expansion volume

Equalizes the internal unit and wellbore pressure

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Motor

92‘n’ thousand feet

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95

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3. EqualizationEquals pressure between the outside casing and inside the motor housing

The Seal Section, purpose:

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Equalization 2. Bag (or Bladder)

1. Labyrinth Chamber

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The Seal Chamber Section Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates the well fluid from the clean motor oil

Equalizes the internal unit and wellbore pressure

Provides area for motor oil expansion volume

Absorbs the pump shaft thrust load

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Compression, Fixed Impeller, Pumps

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Compression, Fixed Impeller, Pumps

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Motor

Seal

Pump

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Seal (Lower Chamber)

Motor

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Heat Exchange Area

Thrust Bearing Area

Seal (Lower Chamber)

Motor

Thrust Runner

Thrust Runner Carbon Face

Bearing

Bearing Retainer

Screen Filter

Upthrust Ring

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Seal Unit

Base

108

Bearing Retainer

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Oil Pump

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Bearing

111

Carbon

Face

112

Thrust

Runner

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Thrust Runner Carbon Face

Thrust Runner

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Upthrust

Bearing

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Upthrust Bearing

Bearing Runner

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Bearing Assembly

Complete

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4. Absorption Absorbs the thrust of the pump

The Seal Section, purpose:

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Absorption

Thrust Bearingr

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The Seal Chamber Section Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates the well fluid from the clean motor oil

Equalizes the internal unit and wellbore pressure

Provides area for motor oil expansion volume

Absorbs the pump shaft thrust load

The Four “Shuns” - isolation, equalization, expansion, & “absorbsion”

Or “Equalizer”, “Protector”, or “Seal Section”

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Seal Section Components - reviewMajor components are ... Mechanical Seals - prevents fluid migration down

the seal shaft

Bag(s) or Bladder(s) - provides expansion volume and isolation for clean motor oil

Labyrinth Chamber(s) - provides expansion and isolation volume in vertical or near vertical wells

Thrust Bearing - carries the thrust load of the pump shaft and stages (fixed impeller type only)

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Seal Section Application Use tandem seals in high pulling cost wells

– Seals are relatively low cost items as compared w/the total unit cost

– The more seal sections, the more mechanical seals and therefore, increased shaft isolation

– Can be designed as a “Thrust on Lower” (TOL) which gives added protection to the unit thrust bearing

Use single or multiple bag seals in highly deviated wells

– The isolation capability of a labyrinth chamber is greatly reduced in deviations beyond 30 - 45 degrees from vertical

Match the seal and motor series, when in doubt

– Provides for maximum oil expansion / reservoir volume

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The Motor Drives the downhole pump and seal section

Is rated for a specific horsepower, voltage, & current

Is a two pole, three phase, AC, induction type

Rotates at approximately 3500 RPM at 60 Hertz

Is constructed of rotors and bearings stacked on the shaft and loaded in a wound stator

Contains synthetic oil for lubrication

Relies on fluid flow past the housing OD for cooling

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Motor Components

Stator Laminations

Kapton-Wrapped Magnet Wire

RotorBearing with T-ring

Housing

Epoxy Encapsulation

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rotor

Bearing with T-Ring

Stator

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Stator Laminations on a Mandrel

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Stator Laminations pressed into the motor housing

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A wound Stator with Leads attached

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Potted End Turns

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Rotor Copper End Ring

Rotor Laminations

Rotor Bearing

Rotor T ring

Rotor Spacers

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Rotor Bearing

Rotor

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Motor Performance Motors are rated by horsepower, voltage, & current

At a constant voltage, by varying the pump load or brake horsepower applied to the motor, current will change

At a constant load, by varying voltage, current will vary, as well

By plotting the above parameters we can obtain two different series of graphs called motor composite curves

SPH, p. 48

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Motor Volts vs. Amps

Optimum Voltage

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Motor ApplicationMotor operating temperature is determined by 5 factors Wellbore Temperature

% Load vs. Nameplate Rating

Fluid Velocity Past Motor (flow rate vs. unit/casing diameter)

Cooling Properties of the Well Fluid (% gas, water cut, scaling tendencies, etc.)

Power Quality (3 phase voltage/current imbalance, wave form distortion, full nameplate voltage available, etc.)

All of the above factors determine if, and when, a motor will overheat during operation

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The Power Cable Is made up of the power cable and motor lead

Can be made in round or flat profile

Is constructed of three insulated & jacketed copper conductors contained by metal armor

Proper applications must address electrical, physical size, and operating temperature requirements

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Cable Types - Flat

Components1 - Conductor (Copper)

2 - Insulation (Polypropylene or EPDM)

(Ethylene Propylene Diene Monomer)

3 - Jacket (Nitrile or EPDM) & Tape

4 - Armor (Galvanized, Stainless, or Monel)

Benefits: Low profile to fit in tight clearance installations

2 4

3 1

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Cable Types - Round

Components1 - Conductor (Copper)

2 - Insulation Polypropylene or EPDM

(Ethylene Propylene Diene Monomer)

3 - Jacket (Nitrile or EPDM) & Tape

4 - Armor (Galvanized, Stainless, or Monel)

Benefits: Less current imbalance & runs cooler than equivalent flat cable

3 2

4 1

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Cable Types - Motor Lead ExtensionComponents1 - Conductor (Copper)

2 - Insulation Film (Polyimide)

3 - Insulation (EPDM)

4 - Jacket / Tape & Braid or Lead Sheath (Low Temp or Hi Temp)

5 - Armor (Low Profile Galv, SS, or Monel)

Benefits: Tape and braid provides added decompression resistance

1 2 3

5 4

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Cable Types - Extruded Barrier

Components1 - Conductor (Copper)

2 - Insulation (EPDM)

3 - Extruded Fluorobarrier (Low or Hi Temp)

4 - Jacket (Nitrile or EPDM)

5 - Armor (Galvanized, Stainless, or Monel)

Benefits: Unlike tapes, the barrier blocks fluid, aids decompression resistance, and improves electrical properties

1

24

5

3

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Cable Types - Lead SheathComponents1 - Conductor (Copper)

2 - Insulation (Polypropylene or EPDM)

3 - Lead Sheath

4 - Tape or Braid (on EPDM product only)

5 - Armor (Galvanized, Stainless, or Monel)

Benefits: Lead sheath blocks gasses & protects conductor from H2S attack

Available in round profile with EPDM jacket

2 5 4

3 1

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Cable Types - Capillary TubeFeatures & Benefits Available with any standard cable

A variety of capillary tube sizes are utilized

Available in round or flat profile

Allows targeted delivery of treatment chemical

Single or dual capillary designs

Instrument wire can be inserted in some capillary tube sizes

An outer layer of armor is applied to protect the capillary tubes

Standard Power Cable

Capillary Tubes

Capillary Tube

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Power Cable ApplicationProper application of ESP cable requires ... Limiting voltage drop to no more than 30 volts per 1000’ and less than

15% of motor volts by choosing a sufficiently large conductor (AWG) size

Choosing the proper profile based on tubing thread size vs. casing ID & conductor size

Selecting a cable type based on operating conductor temperature &/or other wellbore factors, e.g., presence of H2S, high gas, etc.

SPH, pp. 100-102

144

Poly Cable KV Rating

3 KV

4 KV 5 KV

145

The Monitoring System Various downhole monitoring units can be attached to

the bottom of the motor &/or deployed separately in the wellbore

Signals are either impressed (DC) on the power cable or sent via separate instrument wire

Available monitoring options include …

– Pump Intake Pressure

– Motor Operating Temperature

– Discharge Flow Rate

– Discharge Pressure

– Unit Vibration

– Future -- Fiber optics

146

The Surface EquipmentThe surface equipment (beyond the wellhead)

consists of …

The Motor Controller

The Transformer(s)

The Junction or “Vent” Box

Wellhead

Surface Cable

147

The Controller SystemThe two types of controllers used with ESP systems

are … Switchboards (fixed speed)

Variable Speed Controllers (aka “drives”)

Both types of Controllers can be made to read monitoring system output signals

Both types generally require transformers to convert the supply or output voltage to the required unit voltage

148

The SwitchboardFeatures

Applies full voltage and current to the downhole system on start up (aka “across the line” starting)

Utilizes a motor controller unit for system protection and monitoring

Is hooked to transformers which convert the incoming voltage and current to the required voltage and current for the ESP system

Disadvantages

Starting across the line results in extremely high mechanical and electrical stresses on the system

Does not allow pump-well mismatch or fine tuning which results in unit cycling

Flow control can only be accomplished with a surface choke which may result in the pump operating outside of its recommended range

149

The Motor ControllerThe motor controller … Is the “brains” of the switchboard

Monitors incoming voltage and current to the downhole system

Can be set up to allow automatic restart under certain conditions

Protects the motor from voltage and current fluctuations and imbalance

Some models have RTU communication & data logging capability

Has auxiliary inputs for the various monitoring signals

150

The Variable Speed ControllerFeatures & Benefits Allows fine tuning of unit performance to the well which

can increase efficiency & minimize unit cycling

Soft starts the unit which reduces system mechanical and electrical stresses

Protects the downhole equipment from under & over current as well as voltage unbalance and transients

Delays pull and resize of equipment to restore production rate due to wear

151

Graphic display Interface

The VSC Graphic Control System

152

GCS Main MenuGCS Main Menu

The organization of parameters and information is common for the 9 main menu options on all GCS products.

153

GCS Status ScreenGCS Status Screen

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The TransformerThe transformer … Converts supply voltage and current to a level at or near

the required system voltage and current

Has multiple tap settings for flexibility

Must be of a special design to work properly with VSCs

Should be sized to be greater than or equal to the required total KVA of the downhole system

155

The Junction BoxThe Junction Box … Provides the main contact point between the downhole

unit cable and the surface equipment cable

Provides a point of separation to determine downhole or surface electrical faults

“Vents” gasses that escape through the cable insulation and jacket in certain low pressure wellhead designs