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Surface Equipment
Surface Equipment Options for ESP’s
Power
50/60 Hz

High V

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33 KV
13.8 KV
200 V
11 KV

Low V
380
415 2000 V

460 60 amp
Junction box / Vent Box

• Provides a connection point for the

surface cable from the motor control
panel to the power cable in the wellbore

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coming from the wellhead .
• 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.
• Minimum required distance from
wellhead : 35 ft; minimum required
distance from switchboard: 15 ft.
Surface Equipment Options for ESP’s
Power Four Main
50/60 Hz Components

High V
1) Transformer

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33 KV Junction
Box
13.8 KV (2200 V
2) Switchboard 60 amp) 200 V
11 KV

3) VSD
Low V
380
4) Controller
415 2000 V

460 60 amp
Size of Surface Equipment

• Pumps are measured in terms of:

 TDH (feet)

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 Rates (BPD)
• Motors are measured in terms of:
 HP
• Surface Equipment is measured in terms of:
 kVA
Surface Equipment Options for ESP’s
Power
50/60 Hz
kVA = Volts x Amps x 3
High V 1000

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33 KV Junction
Box
13.8 KV (2200 V
kVA = 2200 x 60 x 1.732 60 amp) 200 V
11 KV
1000
Low V
380 kVA = 229 kVA
415 2000 V

460 60 amp
Motor Controller

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• The main function of the motor controller is to protect
the ESP motor (primarily) by measuring the surface
current and voltage (overload and underload)
• Other parameters can be added to the controller –
wellhead pressure, flow/no flow, etc.
• The controller also provides the capability to monitor
performance of downhole electrical system (current,
voltage, frequency, etc).
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Motor Controller
Transformer

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•A transformer will change voltage from
one value to another.

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•A transformer will not change amperage
or frequency
•A transformer will not add power to a
system
 How does it work?

Normally there is an iron core that has wire windings one side
and a different number wire windings on the other side to change

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the voltage.
Transformer with the same number of
windings:

1:1

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V = 11000V
P
VS = 11000V
Transformer with the different number of
windings:

5:1

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V = 11000V V = 2200V
 Transformer Types

• Dry Type (Air Cooled)

• Oil Filled

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• VSD Rated
• Need to consider:
 Temperature
 Paint
 Spill Pans
 kVA Size
 Efficiency
What Size Transformer is
Required for this system?

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• 229 KVA?

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• Only if there are no losses in any of the

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other surface components
• Only if temperature is not a concern
Switchboard

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•A switchboard is basically an on/off
switch.

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•A switchboard will not change amperage
or frequency
•A switchboard will not add power to a
system
 Switchboard Diagram

Main Disconnect

Power Fuses

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Main Contactor

Motor
 FixStar MCP Switchboards

• Major components
 Enclosure – 12 Gauge Metal Construction,

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NEMA 3
 Disconnect Switch – Mechanical, Fused
 Power Fuses – Short Circuit Protection
 Vacuum Contactor – Main Power Switching
 Lightning Arrestors – Voltage Surge Protection
 FixStar MCP Switchboards
• Auxiliary Equipment – Motor Control
 Control Power Transformer
 Instrument Potential Transformers – Voltage

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Monitoring
 Current Transformers – Current Monitoring
 Backspin Shunt – Backspin Detection
 Motor Controller
 Protection : primary transformer fuses, secondary
circuit breakers
 Pilot Devices: indicator lights and switches
 FixStar Switchboard Options
Internal SCB
• Antenna
• SCB Back Panel

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• Battery Enclosure
• UniConn Comm.Card
 FixStar Switchboard Options
Phoenix Surface Kit
• Choke
• UniConn Phoenix Interface Card

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• UniConn Memory Module
• Cable Pack
Surface Equipment Options for ESP’s
Power
50/60 Hz

High V

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33 KV Junction
Box
13.8 KV (2200 V
60 amp) 200 V
11 KV

Low V
380
415 2000 V

460 60 amp
 Medium Voltage Switchboard
Power
50/60 Hz

High V

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33 KV Junction
2200 Box
13.8 KV V (2200 V
60 amp) 200 V
11 KV

Low V
380
415 2000 V

460 60 amp
 Low Voltage Switchboard
Power
50/60 Hz

2200
High V
V

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33 KV Junction
480V 480V Box
13.8 KV (2200 V
60 amp) 200 V
11 KV

Low V
380
415 2000 V

460 60 amp
VSD

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•A VSD can turn an ESP on and off and
control the frequency

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•A VSD will not change amperage
•A VSD will not add power to a
system
Alternating Current
60 cycles = 60 Hertz

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20 cycles = 20 Hertz

Time, or "period" = 1 second

VSD’s also come in a low and medium
voltage design.

However, most VSD’s in the oil industry are

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low voltages.

New technology has allowed medium voltage

VSD’s to be become affordable and will likely
be the standard in the future.
 Low Voltage VSD
Power
50/60 Hz

2200
High V
V

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33 KV Junction
480V 480V Box
13.8 KV (2200 V
60 amp) 200 V
11 KV

Low V
380
415 2000 V

460 60 amp
 VSD Operation
Diode Capacitor IGBT
(Converter) (DC Bus) (Inverter)

MOTOR

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Control Logic

• Diode: to convert AC power to DC power

• Capacitors: to help smooth DC output
• IGBT (Insulated Gate Bipolar Transistor): to invert DC
power into a varying AC power
 What does the Converter do?
Converter is the Input end of VSD
Input: Output:

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AC, 480V, 60Hz, 3-phase DC with ripples

• Converter: to convert AC power to

DC power
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 What does the DC Link do?
Input: Output:
DC with ripples DC Link Smooth DC, like an ideal
“battery”

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• DC Link: 1. To help smooth out the
ripples
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• 2. Stores the electric
energy
 What does the Inverter do?
Input:
Smooth DC, like an ideal Inverter Output:
AC
“battery”

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• Inverter: to invert DC power into a varying AC
power
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VSD Harmonics – What Are They ?

Back Down to
into the the ESP

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power
system

One Type: Two Types:

Current 1) Mechanical
2) Electrical
(voltage)
 Operation of a Rectifier

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6-Pulse = 6 ripples in dc voltage per cycle of ac
voltage (= 3 phase input = one converter used in the system)
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On a 6 pulse VSD the Current would be:

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Sum begins to resemble
six-step VVI VSD output

1/5th x 5th Harmonic

1/7th x 7th Harmonic 1 x Fundamental

1/11th x 11th Harmonic

 Individual harmonics are
determined by:
h = np +/- 1
h = harmonic order

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n= positive integer
p = pulse number = Number of ripples in
dc voltage per cycle of ac voltage.

so a 6-pulse system will have 5th, 7th, 11th, 13rd, …

harmonics;

A 12-pulse system will have 11th, 13rd, 17th, 19th, …

harmonics
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 For a 6 Pulse VSD
Voltage Current
Voltage

400

200
0
Volts

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-200

-400
0° 90° 180° 240° 360°

Voltage

300
200
Volts

100
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Harmonic #

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12 Pulse VSD block diagram

A Phase
Inverter

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Rectifier
Input
480V 3 Phase
Transformer
Filter
B Phase
Inverter

480V 3 Phase
Phase Shift
by 30 deg. C Phase
Rectifier Inverter

VSD

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12 Pulses SS2k Electrical Diagram

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12-Pulse = 12 ripples in dc voltage per cycle of ac voltage = 6
phase input (30 degree) = two converters used in the system
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 800

600

400
Phs 1-A
200 Phs 1-B
VOLTAGE

Phs 1-C
0 Phs 2-A
Phs 2-B
-200
Phs 2-C

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-400

-600

-800
0 60 120 180 240 300 360 420 480 540 600 660 720

360 DEG = 1 CYCLE

12-Pulse = 12 ripples in dc voltage per cycle

of ac voltage = 6 phase input (30 degree)=
two converters used in the system
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 12 Pulse VSD Input Current
+500

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12-pulse Input Current

6-pulse Input Current

-500
0° 90° 180° 240° 360°
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 Harmonic Distortion from the
Input Side of the VSD

current Speedstar Speedstar

harmonic 6 pulse 12 pulse
1 100.0% 100.0%

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5 26.0% 3.2%
7 9.5% 2.0%
11 6.7% 6.2%
13 4.3% 3.4%
17 2.9% 0.8%
19 2.3% 0.6%
23 1.25% 0.9%
25 1.24% 0.7%

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 Output Harmoinics
• Comparator Logic: If A>B, C=+15VDC; If A<B, C=-15VDC

A = Reference Signal, Sine

wave at desired Running
frequency
+15 PWM signal with Carrier
+5V

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Frequency 2.2kHz
V
+15
A
-5V V
comparator C

B
+5V -
15V
-5V -
B42 =G Kappelhoff
Carrier Signal at Carrier 15V
Frequency 2.2kHz
 What is Insulated Gate Bipolar Transistor?
• Unlike the normal light switch, IGBT is controlled by the
voltage across the “Gate” and “Emitter” electrodes

• Important to remember:

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if VG-E = +15VDC, the switch is ON,

if VG-E = -15VDC, the switch is OFF

G
VG-E
43 G Kappelhoff E
 Pulse Width Modulation
B=
A=
Carrier
reference
Signal
signal

Pulse width

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C = A chain of
pulses with
vary width

In VSD, Carrier Signal B is kept constant.

If the voltage OR frequency of A change, the pulse width in C will
change accordingly
The sine wave A is “translated” into a chain of pulses C with vary
pulse width. In another word, the pulse width in C carries all the
waveform information of A
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 Making of the Square Wave

T1 T3 T5

Reference
Signals

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 PWM Power signal

PWM Power signal (Voltage) at 3 Phase of VSD

Output

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120°

120°

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 Average Voltage

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Average Voltage is proportional to the Pulse Width

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 PWM Voltage
Because the pulse width is resulted from the
modulation of a sine wave (reference signal),
so the Average Voltage is in sinusoidal wave
shape

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 PWM Voltage
While the voltage (PWM signal) applied to the motor windings is
NOT sinusoidal, the motor current is a function of the Average
Voltage applied. So the motor current is very sinusoidal in
nature.
t IIn another
th word,
d the
th motor
t will
ill see a sinusoidal
i id l current.
t

The motor will rotate smoothly due to the sinusoidal current.

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VSD output voltage Motor Current
dY: 613 Volt dY: 127 A
Y: 10.7 Volt Y: 0 A
T

T

 

1) Ref A: 200 Volt 2 ms 1) Ref A: 50 A 2 ms

1 G Kappelhoff
Harmonics to the ESP

There are two types:

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Electrical Resonance
Mechanical Resonance

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 Electrical Resonant Frequency

C F= 1
2p
Gain (Vo/Vi)

LC

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L

30 90
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VSD Output Waveform Control
Fc = 4000 Hz
Fo = 60/70 Hz
Fr = 4000 Hz

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Noisy waveform
2nd Carrier multiple
amplified
Solution 1 - Increase Carrier Frequency
Fc = 8000 Hz
Fo = 60/70 Hz
Fr = 4000 Hz

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=

Carrier freq above

resonant band
Sinewave without need
for filter
Solution 2 - Lower Resonant Frequency
Fc = 4000 Hz
Fo = 60/70 Hz
Fr = 1000 Hz

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=

Filter lowers resonant

band below max carrier
freq to provide sinewave
Mechanical Resonant Frequency

54 Hz
53 Hz

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52 Hz
Vibration

51 Hz
50 Hz

Frequency
Mechanical Harmonics
300 3

290
2.5
280

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270
2
260

250 1.5

240
1
230

220
0.5
210

200 0
4-Nov 9-Nov 14-Nov 19-Nov 24-Nov 29-Nov 4-Dec

At Resonance Other Frequency

Example of Resonant Frequency

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57 G Kappelhoff
The Solution…
A specially designed output filter is incorporated into
the traditional pulse width modulated Variable
Speed Drive. The result is a voltage similar to a

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rotating generator output voltage.

PWM VSD @ 60Hz SWD VSD @ 60Hz

Before Filter After Filter

 Quality of the VSD will Impact Run Life
All other VSD Types PWM VSD w/output filter

25
20
20
No. ESP failure

16 17 16
15 12 12
11 10

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9
10
6
5

0
1 2 3 4 5
Year

• Generated for an offshore field with 44 wells, all w/VSDs – 22 SWD

• Graph shows number of units to be pulled in the next five years:
 Using SWD – total: 55 pulls
 Using all other VSD types – total: 74 pulls (34.5% MORE)
 VSD Waveform Evolution
Six Step Waveform PWM Waveform Sinewave
ICS VSD GCS & SS2K VSD Waveform
SpeedStar SWD
VSD

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Voltage

Voltage

Voltage
Current
Current

Current
Load filter

• Installed at output of VSD.

• Purpose: reduce/eliminate
harmonics generated in the VSD

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going downhole.
• Harmonics severely increase
electrical stresses on dowhole ESP
electrical system, decreasing
runlife.
• Has to be tuned prior to every
installation (application specific set-
up).
Harmonic Line filter

• Installed at input of VSD.

• Purpose: reduce/eliminate
harmonics generated in the

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VSD reflected back to power
source, which could generate
damage on other power users
(even shut down the grid on
occasions).
• Designed-specific for every
application, after conducting
harmonics power study.
 Low Voltage VSD
Power
50/60 Hz

High V

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33 KV Junction
Box
13.8 KV (2200 V
60 amp) 200 V
11 KV

Low V
380
415 2000 V

460 60 amp
 Medium Voltage VSD
Power Input Output
50/60 Hz
Power Power
50/60 Hz Variable
High V
Hz

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High V
33 KV Junction
Voltage Box
3.0 KV
13.8 KV (2200 V
1800 V 60 amp) 200 V
11 KV
to
6.9 KV
4160 V
Low V
380
415 2000 V

460 60 amp
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Why use a VSD?
 Reda Single Stage Pump Performance Curve

Feet

70

60
Head (ft)

50

40

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30

20

10

3.00
HP

2.00
60 Hz
55 Hz
1.00

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500
Capacity - Barrels per Day
Flow Rate for a Pump is affected as follows:

Q2 Hz 2
= Q = 60/50 x 3500 = 4200 BPD
Q1 Hz 1
350

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300

250
Flow Rate

4200
200
3500
150

100

50

0
0 20 40 60 80 100

Frequency (hertz)
Horse Power in the Motor is affected as follows:

HP 2 Hz 2
= HP = 60/50 x 170 = 204 HP
HP1 Hz 1
350

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300
Motor Horsepower

250

200

150

100

50

0
0 20 40 60 80 100

Frequency (hertz)
Affinity Laws for a Pump on a VSD:

HZ
Flow HZ = Flow 60 x

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60

2
HZ
Head HZ = Head 60 x
60

3
x HZ
BHP HZ = BHP60
60
The BHP required by the pump increases with
the cube of the hertz ratio. Graphically it would
look like:
500

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400

300
Pump BHP

200

100

0
0 20 40 60 80

Frequency (hertz)
Putting the two graphs together we can see the
design consideration

500

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400
HP required
by Pump
Horse Power

300

200

HP delivered
100 by Motor

0
0 20 40 60 80

Frequency (hertz)
Power Study
• Schlumberger EPC’s Power System Department
specializes in the design, analysis, training, and computer
simulation of power systems.

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• System analysis that can be done:
 Conceptual Design and Engineering

 Load Flow Studies

 Short-Circuit Studies

 Motor Starting Studies

 Transient Stability Studies

 Harmonic Studies and Mitigation

 Protective Equipment Coordination

 Equipment Evaluation

 Load Filter Analysis

Power System Packaging

•Schlumberger can provide engineering

support and manufacturing capability to

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design & build :
 Skids combining VSD’s with
transformers.
 Skids for Switchboards with
transformers.
 Custom designed control rooms.
 Full distribution switchgear layouts.
Schlumberger Private
QUESTIONS ?