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ESP System Applications PDF
ESP System Applications PDF
Key Features
• Rotors mounted on and keyed to a high strength steel shaft
• High-grade bronze sleeves and bushings
• High-strength 4130 alloy steel motor shafts
• High-load/high-temperature thrust bearings available
• Purest copper used for stator windings and rotor bars
• Magnet wire insulated with two wraps of bonded Kapton tape
Key Benefits
• Ability to increase horsepower by increasing the number of rotors or connecting
multiple motors in tandem
• Minimal vibration from the dynamically balanced rotors
• Continuous oil film lubrications due to lubricating grooves and oil holes in
bearings
• Full flow of oil to internal bearings with hollow motor shaft
• Secured winding package
• Performance tests conducted in winding process
• Confirmation testing of electrical integrity, idle performance and bearing system
performance on every motor
• Dynamometer testing to confirm performance at full-rated load on request
Due to the limited well casing diameter, the lift or head developed by
an individual stage is relatively low. This requires stages to be stacked
together to meet the lift requirements for various applications.
Floater Pump Design - The impellers are free to move axially along the shaft. Thrust
washers installed on the impeller support the axial thrust of each impeller.
Compression Pump Design - The impeller position is fixed to prevent axial movement
along the shaft. Since the axial thrust of each impeller is transferred through the shaft to
the thrust bearing located in the seal section below the pump, no down thrust washers
are used. A thrust bearing in the seal section supports the weight of the shaft and the
down thrust generated by the pressure acting on the end of the shaft.
Radially Stabilized Pump - For severe duty applications such as abrasive fluids and
when extended run life is desired.
Key Features
• Bolt-on or integral heads and bases available
• Corrosion-resistant stainless steel available
• Impellers and diffusers cast from high-nickel iron
• Stainless steel or other high-strength corrosion-resistant nickel based alloy Shaft
Key Benefits
• Ability to configure pump as a floater or fixed impeller compression pump
• Wide variety of corrosion resistant materials to address varying wellbore criteria
• Extended run life when utilizing the RS Pump
• Ability to join several pump sections to support multiple head requirements
SEAL SECTION
Key Features
• Carbon/ceramic and silicon carbide mechanical shaft seals with
either stainless steel or monel trim and spring
• Viton, Aflas, and other special compounds available for seal
bellows, o-rings, and expansion bags
• Seals can be used in tandem configurations for increased motor protection
• Largest diameter shaft available in the industry (AR Seals)
• Minimum unsupported shaft lengths on one-piece shafts (AR Seals)
• All AR Seals are equipped with radially stabilized bearings
Key Benefits
• Equalizes pressure inside the motor with the wellbore pressure
• Eliminates the pressure differential across shaft seals
• Provides compensation for the expansion and contraction of motor oil due to
heating and cooling of the motor when the unit is running or shut down
INTAKES/GAS SEPARATORS
Key Features
• Abrasion-resistant RS bearings for extended bearing life
• Stainless steel and dynamically balanced rotating assembly
• Advanced gas compression chamber for Extra-Capacity Gas Handling Separator
Systems
Key Benefits
• Superior shaft stability – 3 bearing system
• Tighter control of the finished product than is possible with older cast parts
• Increased pump ability to handle excessive gas resulting in steadier and
significantly increased production in Extra-Capacity Gas Handling Separator
Systems
• Prevention of gas locking and equipment cycling in Extra-Capacity Gas Handling
Separator Systems
• Significantly increased equipment runtimes in Extra-Capacity Gas Handling
Separator Systems
The Well Management System is compatible with any existing communication system,
and can be fully automated for either remote or wellsite operations.
Weatherford Variable Frequency Controllers (VFC) are available up to 1,000 KVA, 480
volt 60 Hertz/380 volt 50 Hertz primary power. During production, the variable
frequency drive controls flow rates from the well while avoiding pump-off and cycling
problems. By providing soft-start capability the Weatherford VFC prolongs the life of
drive components as opposed to "across the lines" startup used by other systems.
Programming and trouble shooting are simplified with easy access to all components
through the front of the drive.
Key Features
• Output contactor provides positive disconnecting of the motor from drive
• Microsecond response of the drive circuitry to fault conditions
• Safe shutdown Inducers
• A wave-form more suitable to long motor life with the provision of output
inductors
• Output transistors that are more efficient than SCR designs
Key Benefits
• Flexibility of pump range
• Cleaner power downhole
• Controls fluid levels and "free" gas at intake
The NEMA-type enclosure is welded 12-gage steel and provides motor protection, ease
of access and allows for the installation of accessories. Drip shields over the doors,
lifting lugs, vacuum contactors and an inside door that isolates the high-voltage and
low-voltage compartments are standard features. The inside door has a dual thickness
safety glass window for visual inspection without opening the high voltage door.
Several motor controller systems including the Vortex and Eliminator are available to
enhance overall performance.
Numerous protection and efficiency features are included with Variable Frequency
Controllers and Switchboard Control Panels.
Key Features
• Output contactor provides positive disconnecting of the motor from drive
• Microsecond response of the drive circuitry to fault conditions
• Safe shutdown Inducers
• A wave-form more suitable to long motor life with the provision of output
inductors
• Output transistors that are more efficient than SCR designs
Key Benefits
• Flexibility of pump range
• Cleaner power downhole
• Controls fluid levels and "free" gas at intake
Motor Testing
Testing the insulation and winding systems of submersible electric motors determines
the electrical integrity of the prime mover. Reductions in new motor start-up failures and
extended motor runlife are often the result of performance inspections of the electrical
and thrust-bearing assemblies. Dry-out service is performed for wet motors without
disassembling the motor. This process is designed to eliminate any possible defect in
reassembly. Minor repairs and maintenance services ensure integrity before returning to
the field. Motor tests conform to IEEE standards.
Pump Testing
Cleaning and testing services provide an inexpensive means of determining the condition
and performance of any brand of submersible pump. To validate pump performance
characteristics, all new pumps are tested to the original manufacturer's published data.
This process assists the operator in determining whether the pump should be re-run or
returned to the manufacturer for repair and exchange.
Seal Testing
Typically, seal sections are replaced after every use. By employing this testing
procedure, operators can make more accurate decisions on the true condition of the
piece of equipment. A seal that has passed this series of tests can be returned to service
with a high level of confidence. The cost of a test is minimal in comparision with the
expense of a repaired unit.
Well Testing
Whether defining the production characteristics of a new well or evaluating an old one,
custom-designed test programs provide an accurate test and proper equipment selection
to optimize the production potential of every well. A complete test unit is designed and
delivered to produce in a predetermined range of volumes. Static pressures and fluid
levels are recorded before startup. Production rates are recorded at several speeds or
frequencies, and an IPR curve is developed for the well. Economic evaluations are
provided to the operator upon request
ACCESSORIES
Transformers
Weatherford provides single-phase transformers, three-phase transformers and three-
phase auto transformers to transform the required supply voltage to the motor. These
oil-filled self-cooled units have taps for voltage adjustment. They are equipped with
lightning arresters and capacitors that reduce the possibility of severe damage to the
motor from power surges caused by lightning or line switching.
Power Cables
Power is transmitted from the surface controller to the submersible
motor by electric cable, which is critical to the entire system
efficiency and reliability. Weatherford offers a complete portfolio of
cables in a wide range of conductor sizes to permit an efficient
match to motor requirements. Cables may be installed in wells with
temperatures in excess of 300°F (150°C) dependent upon the type of insulation being
used.
Both round cable, which is recommended under normal conditions, and flat cable when
clearance could be a potential problem are available. Cable clamps or bands secure the
cable along the pump and tubing. Flat Cable extensions or motor lead cables connect
the power cable to the motor.
Other accessories include check valves, bleeder valves and tubing hangers.