Electrical Submersible Pump (ESP)

COMPONENTS (EQUIPMENT
DESCRIPTION)

PTP- 6.1

Table of Contents
1
 Page Number

1. Introduction 03

2. Centrifugal Pump 04

3. Rotary Gas Separator 07

4. Seal Section 08

5. Electrical Submersible Motor 10

6. Motor Controllers 11

7. Variable Speed Controllers 12

8. Downhole Pressure and Temperature Monitor 13

9. Transformer 13

10. Junction Box 13

11. Wellhead 13

12. Check Valve 14

13. Drain Valve 14

14. Backspin Relay 15

15. Centralizer 15

16. Cable 15

17. Cable Band 16

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 Electrical Submersible Pump (ESP)

COMPONENTS (EQUIPMENT DESCRIPTION)

1. Introduction

The driving force, which displaces oil from a reservoir, comes from the natural energy
of the compressed fluids in the reservoir. The energy that makes the well to flow
results from a reduction in pressure between the reservoir and the wellbottom. If the
pressure reduction between the reservoir and the surface producing facilities is large
enough, the well will flow naturally to the surface using the natural energy supplied by
the reservoir.

When the natural energy associated with oil will not produce a pressure differential
between reservoir and wellbore sufficient to lift reservoir fluids to the surface and into
surface facilities, the reservoir energy must be supplemented by some form of artificial
lift.

The ESP is considered an effective and economical means of lifting large volumes of
fluids from great depths under a variety of well conditions. The submersible pump
companies, along with the major oil companies, have gained considerable experience in
producing high viscosity fluids, gassy wells, high temperature wells, etc. With the
improved technology, wells that were once considered non-feasible for submersible
pumps are now being pumped economically.

The pumping system is made up of several components. These components are: three-
phase electric motor, seal section, rotary gas separator, multi-stage centrifugal pump,
electric power cable, motor controller and transformers. Additional miscellaneous
components will normally include wellhead, cable bands, check and drain valves.
Optional equipment may include a downhole pressure and temperature sensor to
monitor wellbore conditions. The ESP is suspended from discharge tubing and
submerged in well fluids. A typical Electric Submersible Pump installation is shown in
figure 1

The picture shows a common type of installation and is more-or-less a standard one. In
this type of installation, the unit is placed above the perforation zone. The produced
fluid is forced to move upward from the perforations past the motor. In doing so the
produced fluid, while flowing past the motor, absorbs the heat generated in the motor
and thereby cools it.

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 TYPICAL INSTALLATION TRANSFORMERS

COMPONANTS MOTOR CONTROLLER

JUNCTION BOX

DRAIN VALVE
CASING CHECK VALVE
TUBING

CABLE BANDS
CENTRIFUGAL PUMP

ROTARY GAS SEPARATOR

FLAT CABLE
SEAL SECTION

ELECTRIC MOTOR

Figure 1- a (Components)

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 OIL OUT THROUGH
TUBING

CABLE BAND

GAS OUT THROUGH

CASING

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Figure 1-b (ESP Installation)

SHROUD

Figure 1-c ( Unit is placed below the perforation)

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2. Centrifugal Pump

Submersible pumps are mostly multi-staged centrifugal pumps. Each stage of a

submersible pump consists of a rotating part called impeller and stationary part called
diffuser. There are two components to the motion imparted to the liquid by the
impeller. One motion is in a radial direction outward from the center of the impeller.
This motion is caused by centrifugal force. The other motion moves in direction
tangential to the outside diameter of the impeller. As a result of these two components
is the actual direction of flow. The diffuser's function is to change the velocity energy
into pressure energy.

There are two general types of design for submersible pumps. The smaller flow pumps
are mostly of radial flow design. Figure 2-a shows such a stage configuration. In this
type the impeller discharges the fluid in mostly a radial direction. As the pumps reach
design flows of approximately 300 M3/d in the 400 series pumps and 550 M3 /d in
the larger diameter pumps, the design changes to a mixed flow. Figure 2-b shows this
configuration. The impeller in this stage design imparts a direction to the fluid that
contains substantial axial direction as well as radial direction.

ELECTRICAL SUBMERSIBLE PUMP (ESP)

CENTRIFUGAL PUMP STAGES

RADIAL FLOW MIXED FLOW

Figure 2-a Figure 2-b

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In many of the pump designs, the impeller is free to float axially on the shaft and the

individual impeller stage is absorbed on specially designed pads found on the diffuser.

A specially designed thrust bearing contained in the seal section carries only the thrust

of the pump shaft. This configuration is called a floating stage design. The benefit of

this design is that many stages can be stacked together without having to fix the

impellers axially on the shaft with precise alignment. As a result, pumps can be

manufactured having hundreds of individual stages.

As pump diameter increases beyond about 6 inches (1 50 mm), the impellers are locked

to the pump shaft in the axial direction and no thrust is absorbed by the impeller

rubbing on the diffuser. As a result, the thrust bearing contained in the seal section

must carry the impeller thrust in addition to shaft thrust. This configuration is referred

to as a fixed impeller or compression pump design. The impellers are of a fully

enclosed curved vane design, whose maximum efficiency is a function of the impeller

design and type and whose operating efficiency is a function of the percent of design

capacity at which the pump is operated. The mathematical relationship between head,

capacity, efficiency and brake horsepower is expressed as:

BHP = Q x H x Specific Gravity / Pump Efficiency

Q = Volume
H = Head

The diameter and configuration of the pump impeller determines the amount of
acceleration energy that is transmitted to the fluid. The pump size will be determined
by the well casing size. The internal diameter of the impeller is dependent on the
outside diameter of the shaft, which must be strong enough to transmit power to all
stages of the pump. Submersible centrifugal pumps are manufactured for various sizes
of well casings.

Stages are designed to have a downward thrust force on the impeller through the

operating range. This force would vary from low at maximum operating with

increasing force toward minimum operating. It is designed in this manner so as to

provide stable hydraulic operation. Therefore, the pump should be operated within the

stages recommended operating range to provide optimum life. Pumps operated outside
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this range will have a reduced life and may have a detrimental effect on other ESP

components.

The discharge rate of a submersible centrifugal pump depends on the speed (rpm),

stage design, the dynamic head against which the pump is operating, and the physical

properties of the fluid being pumped. The total dynamic head of the pump is the

product of the number of stages and the head generated by each stage. Figure-3 is a

typical 6O hertz, single stage, centrifugal pump performance curve showing the

recommended operating range, along with other pump characteristics.

ELECTRICAL SUBMERSIBLE PUMP (ESP)

PUMP CHARACTERISTIC CURVE

1500 --

Operating
1250 --
Range

1000 --

750-- -150

500--
-100

250--
-50

0 0
0 50 100 150 200 250 300 350 400 450 500
Flowrate m3/day

Figure -3

3. Rotary Gas Separator

ESP's can be used in wells having a high gas-oil ratio. The capability of a centrifugal
pump in handling gas without gas-locking is limited. With the attachment of a rotary
gas separator, ESP’s can work in high gas-oil ratio wells. The separators use
centrifugal force to separate the free gas (gas not in solution) from the well fluid before
entry into the pump.
Figure- 4, represents the common design of a typical rotary gas separator. The fluid
enters the separator and is forced into a rotating centrifuge chamber by the action of an
inducer. Once in the centrifuge, the fluid with the higher specificgravity is forced to
the outer wall of the rotating chamber by centrifugal force, leaving the gas in near
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the center. The gas is separated from the fluid by the splitter and is exhausted
back to the annulus of the well where it travels up the annulus. The heavier fluid is
directed into the intake of the pump where it is pumped to the surface.

Typical gas separator efficiencies range from 80% to 95%. The system efficiency is
affected by fluid volumes, composition and properties. Gas separator assemblies are
often connected in tandem to improve the overall efficiency in high gas applications.

ELECTRICAL SUBMERSIBLE PUMP (ESP)

ROTARY GAS SEPARATOR
LIQUID DISCHARGE

GAS DISCHARGE

BEARING
GAS PORT
LIQUID PORT

FLOW DIVIDER

BALANCED STEEL ROTOR

STEEL INDUCER

FLUID INTAKE
BEARING

Figure – 4

4. Seal Section

The seal section connects the drive shaft of the motor to the pump or gas separator
shaft and performs the following important functions:

(1). Seal section is to allow for expansion of the dielectric oil contained in the rotor gap
of the motor. Temperature gradients resulting from both the ambient and motor
temperature rise will cause the dielectric oil to expand. This expansion is taken in the
seal.

(2). Seal section is to equalize the casing annulus pressure with the internal dielectric
motor fluid. This equalization of pressure across the motor helps keep well fluid from
leaking past the sealed joints of the motor. Well fluids which get into the motor will
cause early dielectric failure. The rubber bladder shown in figure -5, as well as the
labyrinth style chambers, allows this pressure equalization to take place.

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(3). Seal section is to isolate the well fluid from the clean dielectric motor fluid. As
previously stated contamination of the motor insulation with well fluid will lead to
insulation failure. The seal section contains multiple mechanical shaft seals which keep
the well fluid from leaking down the shaft. The rubber bladder provides a positive
barrier to the well fluid. Labyrinth chamber provide fluid separation based on the
difference in densities between well fluid and motor oil. Any well fluid that gets past
the upper shaft seals or the top chamber is contained in the lower labyrinth chambers as
a secondary protection means.

(4). Seal section is to absorb the downthrust of the pump. This is achieved by a sliding

thrust bearing. The bearing utilizes a hydrodynamic film of oil to provide lubrication

to the bearing during operation. The downthrust is the result of the pressure developed

by the pump acting across the cross sectional area of the pump shaft and residual thrust

transferred from each individual pump stage impeller to shaft. Figure -5 shows a cross-

section of the seal section.

ELECTRICAL SUBMERSIBLE PUMP (ESP)

SEAL SECTION

MECHANICAL SEAL

ELASTOMER BAG

LABYRINTH CHAMBER

LSBYRINTH CHAMBER

THRUST CHAMBER

Figure - 5

Seal Section Thrust Bearing

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Thrust bearing designs are of the tilting pad type. The bearing consists of 6 to 9
individual shoes which are mounted on a pedestal located at the center of the shoe. The
pedestal is not so rigid that it cannot deflect and in effect this is what happens.

The operation of any bearing, is dependent up on the rotating member building and
maintaining an oil film across the bearing surface. In the case of a tilting pad bearing,
the thrust runner pulls fluid with it across the pad. In either case, an oil film is
built and maintained otherwise failure of bearing occurs. The thrust bearing pad's
deflect at the entrance edge, thus allowing the oil film to be built. An oil film
can be maintained for only a limited distance due to effects of viscosity, load,
temperature, etc.

5. Electrical Submersible Motor

The ESP motors are two pole, three-phase, squirrel cage, and induction type. These
motors are filled with a highly refined mineral oil with high dielectric strength. The
design and operating voltage of these motors can be as low as 230 volt or as high as
5,000 volt. Amperage requirement may vary from 12 to 200 amps. The required
horsepower is achieved by simply increasing the length of the motor section.

The motor is made up of rotors, usually about 12 to 18 inches in length, that are
mounted on a shaft and located in the electrical field (stator) mounted within the steel
housing. The larger single motor assemblies will approach 33 feet in length and will be
rated up to 400 horsepower while tandem motors will approach 90 feet in length and
will have a rating up to 750 horsepower. Figure -6 displays the stator, rotor and shaft
assembly of a submersible motor.

ESP MOTOR

THRUST BEARING
THRUST RUNNER

MOTOR HEAD
MOTOR LEADS
END COIL
STATOR LAMS
ROTOR
ROTOR BEARING
BRASS LAMS

SHAFT

Figure- 6

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The stator is made up of a group of individual electromagnets arranged such that they
form a hollow cylinder with one pole of each electromagnet facing toward the center of
the group. While no physical movement of the stator takes place, electrical movement
is created by progressively changing the polarity of the stator poles in such a manner
that their combined magnetic field rotates. In an AC motor, this is easily achieved
since reversing the current each half-cycle will automatically change the polarity of
each stator pole.

The rotor is also composed of a group of electromagnets arranged in a cylinder with the

poles facing the stator poles. The rotor rotates simply by magnetic attraction and

repulsion as its poles attempt to follow the rotating electrical field being generated by

the stator. There is no external connection to the rotor, the current flow through the

rotor's electrical poles is induced by the magnetic field created in the stator. The speed

at which the stator field rotates is the synchronous speed. This speed can be computed

with this equation:

N = 120 x f / p
Where:
N = speed in revolutions per minute.
f = frequency in cycles per second.
P = number of magnetic poles within the motor.

Since the number of poles the stator contains is determined by the manufacturer, and
are not easily changed, the only feasible way of changing the speed of the stator
magnetic field is by changing the applied frequency. The rotor will attempt to follow
the stator magnetic field, although due to the resistive component in the rotor
conductors it lags behind. This lag is usually specified by the manufacturer and is
known as slip. Even though the amount of slip varies from manufacturer to
manufacturer, it is approximately 3% of the motor's synchronous speed.

6. Motor Controllers

There are two basic types of motor controllers used on ESP operations. They include
the Fixed Speed Controllers, and Variable Speed Controller (VSC). Normally, all
utilize solid state circuitry to provide protection, as well as a means of control, for the
ESP system. The controllers vary in physical size, design, and power ratings.

Some motor controllers are simple in design, while others can be extremely
sophisticated and complex while offering numerous options that were designed to
enhance the methods of control, protection, and monitoring of the ESP operation. The
selection of one type versus the other depends on the application, economics and the
preferred method of control.

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Switchboards (Fixed Speed)

The switchboard (across-the-line starter) consist of a motor starter, solid state overload
and underload protection, a manual disconnect switch or circuit break circuitry and a
recording ammeter. Many control systems have surface equipment for use with
bottom-hole pressure and temperature monitoring equipment installed within the motor
controller cabinet. Fuses are provided for short circuit protection.

External control devices should be interfaced with the controller as recommended

and/or approved by the pump manufacturer to give dependable and trouble-free
operation. All external control devices are connected to a time-delay which activates or
deactivates the controller after a short time delay. Usual external control devices are
separator high/low level controls or flowline pressure switches.

Most solid state controllers offer time delayed underload protection on all three phases,
time delayed overload protection, and automatic protection against voltage or current
unbalance. Underload, or some type of pump off protection, is necessary since low
flow past the motor will not give adequate cooling. Circuits designed for automatic
restart after shut down are normally included.

7. Variable Speed Controller (VSC)

The Electrical Submersible Pump is very often not flexible when run at a fixed speed;
the unit is limited to a fixed range of production rates and a fixed head output at each
rate. The Variable Speed Controller (VSC) is designed to overcome these restrictions.
By allowing the pump speed to be varied, the rate, the head or both can be adjusted,
depending on the application, with no modification of the downhole unit.
The basic operation of the VSC is to convert the incoming 3 phase AC power, typically
at 415 volts, to a single DC power supply. Then using power semiconductors as solid
state switches, it sequentially inverts this DC supply to regenerate three AC output
phases of pseudo-sinewave power, whose frequency and voltage are controllable.
Pumping flexibility was the main purpose of applying the VSC to the ESP, but several
other benefits have become apparent. Of particular interest are those that can extend
downhole equipment life; soft start, automatically controlled speed, line-transient
suppression and the elimination of surface chokes.

The VSC isolates the load from incoming switching and lightning transients; balances
output volts to reduce motor heating; ignores frequency instability from generator
supplies; compensates for brown outs or takes the unit off line; and minimizes starting
stresses. In addition depending on the application, VSC's can improve overall system
efficiency, reduce required size of generator, obviate the need for a choke, reduce
downhole unit size and provide intelligent control functions to maximize production.
All these benefits cannot be simultaneously available; however, the user must pick and
chose the combination relevant to his application.

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 ESP POWER SUPPLY
MAIN
LOCAL
TRANSMISSION DISTRIBUTION
132 / 33 kV
11/132KV TRANSFORMER
GENERATOR TRANSFORMER

G
G
33 / 0.415 kV
TRANSFORMER

TRANSFORMER RECTIFIER

33 kV / 3.3 kV
INVERTER

ESP
FIXEDSPEED 0.415 kV / 3.3 kV
TRANSFORMER

ESP

VARIABLE SPEED

8. Downhole Pressure and Temperature Monitor

Reservoir and pump performance data can be acquired with the use of downhole
pressure and temperature monitoring systems. By correlating reservoir pressure with
the pumping rate, an operator can determine when to change pump size, change
injection rate or consider well workover.

Many types of downhole pressure and temperature sensors are available from
submersible pump suppliers. These systems vary in design, cost, accuracy, reliability,
operation and capabilities. A typical system has the capability of (1) continuously
monitoring bottom hole pressure and temperature, (2) providing detection of electrical
failures, and (3) can be interfaced with the Variable Speed Controllers to regulate
speed.

9. Transformer

The distribution of electrical power to the oil fields is usually accomplished at an

intermediate voltage, such as 33KV. Since ESP equipment operates at voltages
between 1000 and 3300 volts, transformation of the distribution voltage is required.

Transformers are commonly provided in either a bank of three single phases or in a

single three-phase configuration. These transformers are usually oil-filled, self cooled
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units and are unusual from the standpoint that they contain a substantial number of
secondary voltage taps which allow a wide range of output voltages. This wide range
of voltages is required in order to be able to adjust the surface voltage for a variety of
cable voltage drops that can occur due to varying setting depths.

10. Junction Box

The junction box (sometimes called a "Vent Box”) performs three functions:
(1) provides a point to connect the power cable from the controller to power cable from
the well (2) provides a vent to the atmosphere for any gas that might migrate up the
submersible power cable and (3) provides for easily accessible test points for
electrically checking downhole equipment.

11. Wellhead

The wellhead is designed to support the weight of the subsurface equipment and is used
to maintain surface annular control of the well. They must be equipped with a tubing
head bonnet or pack-off which provides for a positive seal around the cable and the
tubing, or a feed through mandrel. There are several methods available from wellhead
manufacturers for providing this pack-off. Depending on the method used, the pack-
off can sustain annular pressures up to 5,000 psi.

WELLHEAD

CABLE to VARIBLE
TUBING STEP UP SPEED DRIVE
TRANSFORMER PANEL
Cable
rack VENTED
JN BOX CONDUIT

BURIED
CABLE

15 m minimum

Figure – 7

Figure – 7 shows wellhead equipment of a Variable Speed Controlled ESP well.

The cable should be properly laid in a cable rack or buried for safety reason.
The control panel should be minimum of 15 m away from the x-mass tree.
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12. Check Valve

Check valve which is usually fixed 2 to 3 joints above the pump assembly, can be used
to maintain a full column of fluid above the pump. If the check valve fails or if it is
not installed, leakage of fluid down the tubing through the pump can cause a reverse
rotation of the subsurface unit when the motor is shut off. Start-up during the reverse
rotation can result in a motor burn, cable burn or broken shaft.

If a check valve is not provided, sufficient time must be allowed for the tubing to drain
back through the pump before the motor is restarted. A minimum of thirty (30)
minutes is typically recommended.

13. Drain Valve

When a check valve is used in the tubing, it is necessary to install a drain valve
immediately above the check valve to prevent pulling a wet tubing string. If a check
valve is not provided, there is no reason to provide a drain valve, as the fluid in the
tubing will generally drain through the pump while pulling.

14. Backspin Relay

In some cases installation of a check valve is impractical. For example, if you were
anticipating that the subsurface equipment could plug up with scale, sand, asphaltines,
etc., it may be desirable to pump produced fluid, acids or other chemicals down the
tubing to remove the foreign material. With a permanent check valve installed in the
tubing, this would not be possible.

There are electronic devices available that can detect a pump backspinning and will
prevent restarting an ESP during this condition. The backspin relay electronics are
provided in the controller and the unit is connected electrically to the ESP power cable.
When the ESP system shuts down, and the produced fluid is allowed to fall back down
the tubing, power is being generated by the motor and this power can be detected by
the backspin relay, preventing any attempt to restart until this condition stops.

15. Centralizer

Centralizers are used in ESPs to place the equipment in the centre of the wellbore,
especially useful in deviated wells, to eliminate external damage and insure proper
cooling of the equipment. Many types of centralizers available in the industry designed
to protect the ESP cable and prevent cable damage due to rubbing.

In corrosive conditions where coatings are used to protect the O.D. of the ESP
equipment, centralizers can be very effective in preventing mechanical damage to the
coating during the installation of the equipment. If the coating is damaged during

17
installation, the corrosion accelerates at the point of damage and the life of the
equipment will be affected.

16. Cable

Electric supply is transmitted to the submersible motor by banding a specially

constructed three phase electric power cable to the production tubing. This cable must
be small in diameter, well protected from mechanical damage and impervious to
deterioration of its physical and electrical properties by the hot corrosive well
environments.

Cables are available in a wide range of sizes, which permits matching to motor
requirements. They are either round or flat configurations using galvanized steel,
stainless steel, or monel armor capable of withstanding the hostile environments of an
oil well or water well. All cables are made to strict specifications using specially
formulated materials for different operating environments

CABLE

ROUND CABLE FLAT CABLE

Figure - 8
17. Cable Bands
Cable bands are used to strap the power cable to the tubing. One band per 5m interval
is normally used. Cable bands are also used to strap the motor flat cable to the pump
and seal. Use of one band per 50cm, protected with flat cable guards, is recommended
for maximum support and protection. Cable bands are made of carbon steel, stainless

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steel and monel. The materials also vary in width and thickness, providing additional
strength and support.

CABLE BAND

DIFFERENT TYPES OF BANDS

Figure- 9

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