Materials System Specification

55-SAMSS-002 1 September 2012

ESP Controllers
Document Responsibility: Electric Submersible Pump Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................ 2
2 Conflicts and Deviations................................ 2
3 References.................................................... 2
4 Definitions...................................................... 3
5 General.......................................................... 4
6 Service Conditions......................................... 4
7 Technical Features........................................ 5
8 Construction Features................................. 11

Previous Issue: 26 January 2011 Next Planned Update: 26 January 2016

Revised paragraphs are indicated in the right margin Page 1 of 15
Primary contact: Cox, Robert Lee on 966-3-8733341

Copyright©Saudi Aramco 2012. All rights reserved.

Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

1 Scope

This specification defines the mandatory requirements for electrical controllers for
Electrical Submersible Pumps (ESPs) in crude oil service. The controllers shall be
installed indoors or outdoors, in an offshore or onshore environment.

2 Conflicts and Deviations

2.1 If there are any conflicts between this specification and associated purchasing,
project or engineering documents, this specification shall take precedence.

2.2 Direct all requests to deviate from this specification in writing to the Company
or Buyer Representative, who shall follow internal company waiver procedure.

2.3 The designation “Commentary” is used to label a sub-paragraph that contains

comments that are explanatory or advisory. These comments are not mandatory,
except to the extent that they explain mandatory requirements contained in this
specification.

3 References

The following is a summary of all the documents which have been mentioned within
this specification. Full compliance to these documents is not necessarily required.
Whether the entire document or specific part(s) of these documents are applicable have
been identified throughout this specification.

3.1 Saudi Aramco References

Saudi Aramco Materials System Specification

55-SAMSS-004 Modular Building for ESP Equipment Industry
Codes and Standards

3.2 Industry Codes and Standards

International Code Council (ICC)

ICC IBC International Building Code

American Society of Civil Engineers (ASCE)

ASCE 7 Minimum Design Loads for Buildings and Other
Structures

International Electrotechnical Committee

IEC 60529 Degrees of Protection Provided by Enclosures

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

National Electrical Manufacturers Association

NEMA 250 Enclosures for Electrical Equipment

4 Definitions

AFD: Adjustable Frequency Drive.

Severely Corrosive Environment: Offshore, or onshore within 5 kM of coastline.

Mildly Corrosive Enviroment: Anywhere beyond the 5 km of the coastline.

Crude Oil Service: Directly producing crude oil or producing water in support of
crude oil production.

Disconnector: Manually operated device that will physically open the main circuit,
provide padlocking provisions in the open position and visual indication that the circuit
poles are open.

ESP: Electric Submersible Pump.

ESD: Emergency Shutdown system.

FVC: Full Voltage Controller.

Indoors: Inside building designed per 55-SAMSS-004.

Main circuit: All the conductive parts of an assembly included in a circuit which is
intended to transfer electrical energy to the connected load.

Offshore: Overwater.

Onshore: On-land.

RTU: Remote Terminal Unit.

RVC: Reduced Voltage Controller.

SD Transformer: Step-down transformer. Transformer used to match the voltage

input of the electrical service to the voltage and phasing requirements of the ESP
controller. This transformer can be dedicated to an individual ESP or can serve
multiple ESPs.

Specification: The main body of this document. Does not include the information
contained within the Appendices.

Stainless steel: Either 316 series or 317 series stainless steel material.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

5 General

5.1 Words in bold font are defined in Section 4.

5.2 Whenever this specification requires compliance to a third party document

(e.g., API, UL, IEC, etc.), this document shall be the edition which was in effect
on the date of the Quotation Request.

5.3 This specification shall take precedence over any referenced third party
document.

5.5 All documentation shall be in English.

5.6 All temperatures are in Celsius units (unless specified otherwise).

5.8 The specific location(s) and environment in which the controllers will be
installed shall be specified within the purchasing documents.

6 Service Conditions

The controllers shall be designed to operate continuously under the following conditions:

6.1 Ambient Air Temperature

6.1.1 Minimum: 0 degrees.

6.1.2 Maximum:

6.1.2.1 Outdoor controllers: Onshore: 55 degrees, Offshore: 55 degrees

6.1.2.2 Indoor controllers: 40 degrees

6.1.3 Average, over one month:

6.1.3.1 Outdoor controllers: Onshore: 40 degrees,

Offshore : 35 degrees.

6.1.3.2 Indoor controllers: 35 degrees

6.1.4 Manufacturer shall consider internal temperature rise of his equipment

and confirm that it will operate under all load conditions in the
environments indicated in Paragraph(s) 6.1.2 and/or 6.1.3.

6.1.5 The temperature of metal surfaces exposed to direct solar radiation can
reach 75°C. The interiors of unventilated metal cabinets (exclusive of
internal heat-producing sources) can reach 56°C. The transformer and

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

its accessories, including cabinets and junction boxes, shall be designed

accordingly.

6.2 Relative Humidity (Condensing)

6.2.1 24 hour average: 95%.

6.2.2 1 month average: 90%.

6.2.3 Maximum (for outdoor controllers): 100%

6.3 Earthquakes: None. Site Class D per IBC or ASCE 7

6.4 Electrical Area Classification: Unclassified

6.5 Sand and dust storms, fog, airborne contaminants (for outdoor controllers):

6.5.1 NaCl to 300 ppm. MgCl to 50 ppm.

6.5.2 Dust concentrations of 1 mg/m³. 95% of dust particles are less than
20 micrometers in diameter. 50% of dust particles are less than
1.5 micrometers in diameter. Compound in dust include sodium,
magnesium, silicon and aluminum.

6.5.3 Pollutants (worst case): H2S-5 ppm, SO2-10 ppm, CO-100 ppm,
NOx-5 ppm and hydrocarbons-150 ppm.

6.5.4 For offshore installations, accumulation of wetted salt (NaCl) and wind
borne seawater salt spray.

6.6 Wind – Maximum (for Outdoor Controllers)

6.6.1 Two second gust: 32.6 m/sec (73 mph)

6.6.2 One minute withstand: 28.3 m/sec (63 mph).

6.7 Rain: Minimal. Occasional heavy rainstorms (for outdoor controllers).

6.8 Directly exposed to sun (for outdoor controllers).

Exception 6.8:

Unless indicated otherwise in purchasing documents.

6.9 Altitude: Less than 1000 meters.

6.10 Corrosive Environment.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

Exception to 6.10:

Unless indicated otherwise in purchasing documents.

7 Technical Features

7.1 General

7.1.1 The controller shall be fully operational with only the power source from
the SD transformer.

7.1.2 If specified in the purchasing documents, outdoor controllers shall be

equipped with transient voltage surge suppression device(s) that shall
protect phase-to-phase, phase-to-ground, phase-to-neutral and neutral-to-
ground for all three phases. The device shall function in the following
manner:

7.1.2.1 Shall have a response time of <= 1.0 nS and have a UL life
cycle rating of > 16,000 impulses (as tested at 20 kV, 10 kA
impulses).

7.1.2.2 Shall clamp at no more than 20% above the rated voltage.

7.1.2.3 Shall have a minimum of two (2) years experience used in

conjunction with ESP controllers.

7.1.3 Control voltage shall be a maximum of 120 VAC and/or 48 VDC.

7.1.4 Control voltage shall be derived downstream of the disconnector.

7.1.5 Indicating lights shall be LED (Light Emitting Diode) type.

7.1.6 Communication Interface

7.1.6.1 Communication with the controller shall be via a Saudi

Aramco RTU with the following characteristics:

7.1.6.1.1 Communication protocol shall be Serial Modbus

RTU or Modbus TCP/IP as specified in the
purchasing documents.

7.1.6.1.2 Data acquisition will be via Serial RS485 port or

Ethernet as specified in the purchasing documents.

7.1.6.1.3 For applications where multiple controllers are in

close proximity such as an offshore platform or drill

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

site, the data link from the RTU to the ESP

controllers will be a multi-drop RS-485.

7.1.6.1.4 Data will be stored in a contiguous Modbus register.

7.1.6.2 The controller shall shutdown on receipt of a remote digital

STOP command, or a local or remote emergency shutdown
(ESD) command. This contact will be normally open,
maintained closed contact (open on ESD).

7.1.6.3 For START and STOP, a momentary close contact will be

furnished for the start (normally open) and a momentary open
contact for the stop (normally closed. A tripped ESP shall
require manual local re-set prior to allowing remote control.
A provision for remote start function shall be made.

7.1.6.4 Pumps shall remain operational if communication to the RTU

fails.

7.1.6.5 Controller shall be capable of providing the following

information via the Saudi Aramco RTU:

7.1.6.5.1 Motor run/stop status (Digital Input).

7.1.6.5.2 Motor Amps.

7.1.6.5.3 ESP Start/Stop Command (Digital Output).

7.1.6.5.4 Overload Amps Setting.

7.1.6.5.5 Output voltage.

7.1.6.5.6 Outdoor controllers shall provide the following

additional information:

7.1.6.5.6.1 Suction Pressure.

7.1.6.5.6.2 Discharge Pressure.

7.1.6.5.6.3 Motor Temperature.

7.1.6.5.6.4 Current Leakage.

7.1.6.5.6.5 Fluid Intake Temperature.

7.1.6.5.6.6 Pump Vibration.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

7.1.6.5.6.7 Down Hole Fluid Flow (Calculated).

7.2 Adjustable Frequency Drives (AFD)

7.2.1 The AFD shall function to convert the incoming power from the SD
transformer to an adjustable frequency and voltage for controlling the
speed of the ESP motor.

7.2.2 Voltage/Frequency Rating: At AFD input; as specified on purchasing

documents.

7.2.3 Power Rating: Continuous operation at 100% of nameplate rating.

120% nameplate rating for 1 minute.

7.2.4 Rectifier pulses: Minimum shall be 18 (referenced to the AFD DC

bus).

7.2.5 Efficiency: 95% minimum at rated load and frequency.

7.2.6 Power Factor: 98% minimum (at rectifier input) over entire power and
speed range.

7.2.7 Frequency Range: Minimum 20 Hz to 90 Hz.

7.2.8 Voltage Tolerance (based upon AFD input rating):

7.2.8.1 Continuous operation at nameplate power rating

7.2.8.1.1 Voltage level: -5% or +10%.

7.2.8.1.2 Frequency: ±2%.

7.2.8.1.3 Phase Unbalance: ±2%.

7.2.8.2 Continuous operation but at reduced output power/torque:

Voltage level: -5% to -10%.

7.2.8.3 For up to 200 ms, at reduced power/torque:

Voltage level: -10% to -55%.

7.2.9 Shall be equipped with an auto-restart feature that functions as follows:

7.2.9.1 Shall trip the AFD based upon excursions from select
programmable settings (e.g. overload, underload,
undervoltage, etc.).

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
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7.2.9.2 Shall automatically restart the ESP when the excursions that
caused the trip are back within tolerance.

7.2.9.3 Shall be capable of restarting the ESP when the motor is

rotating.

7.2.9.4 Shall be disabled with the receipt of a remote or local STOP

or ESD command.

7.2.9.5 Shall be manually activated or de-activated local to the AFD.

7.2.10 As a minimum, the following drive protection functions shall be

provided:

7.2.10.1 Overcurrent.

7.2.10.2 Overvoltage.

7.2.10.3 Undervoltage.

7.2.10.4 Load short circuit.

7.2.10.5 Load ground fault.

7.2.10.6 AFD overload.

7.2.10.7 ESP motor overload.

7.2.10.8 Output phase loss.

7.2.10.9 AFD temperature.

7.2.11.10 ESP high pump pressure differential.

7.2.11 Communication Interface

7.2.11.1 The AFD shall be capable of receiving a remote analog

signal via the RTU to adjust the speed of the ESP.

7.2.11.2 Loss of speed control signal shall leave the ESP running at
the last set speed.

7.2.11.3 In addition to the information in Section 7.1, the AFD shall

be capable of providing the following additional
information via the Saudi Aramco RTU:

7.2.11.3.1 Frequency Setting.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
Issue Date: 1 September 2012
Next Planned Update: 26 January 2016 ESP Co ntro ll ers

7.2.11.3.1 AFD cabinet temperature.

7.2.11.3.1 AFD cabinet high temperature shutdown.

7.2.11.3.1 Frequency Signal (Analog Output).

7.2.11.3.1 AFD Output Voltage.

7.2.12 SD transformers that are integral to the AFD shall be equipped with
tap changers with the following characteristics:

7.2.12.1 Be externally, manually operated rated for de-energized

operation.

7.2.12.2 Be capable of being pad lockable in each position.

7.2.12.3 Have positive visual and tactile position indication.

7.2.12.4 Be designed so that positioning the tap changer between taps

is not possible.

7.2.12.5 Be provided with a minimum of six (6) tap settings on the

high voltage side of the transformer; four (4) to decrease and
two (2) to increase the transformation ratio.

7.2.12.6 Voltage variance between tap positions shall be

approximately 2.5%.

7.3 Full Voltage Controllers (FVC)

7.3.1 The FVC shall function to directly connect the incoming power to the
ESP motor via a main circuit contactor. This contactor shall have the
following characteristics:

7.3.1.1 Be 3-pole.

7.3.1.2 Have a field replaceable operating coil.

7.3.1.3 If rated 200 A or greater, interrupter poles shall be vacuum.

7.3.2 The following electrical protective functions shall be provided with

each FVC:

7.3.2.1 Short circuit.

7.3.2.2 ESP motor overload (trip).

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
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7.3.2.3 Phase loss/imbalance (trip).

7.3.2.4 ESP motor undercurrent (trip).

7.3.2.5 ESP motor backspin (start inhibit).

7.3.2.6 ESP motor phase reversal (start inhibit).

7.3.3 If specified in the purchasing documents, shall be equipped with an

auto-restart feature that functions as follows:

7.3.3.1 Shall trip the FVC based upon excursions from select
programmable settings (e.g., overload, underload,
undervoltage, etc.).

7.3.3.2 Shall automatically restart the ESP when the excursions that
caused the trip are back within tolerance.

7.3.3.3 Shall be disabled with the receipt of a remote or local STOP

or ESD command.

7.3.3.4 Shall be manually activated or de-activated local to the FVC.

7.4 Reduced Voltage Controllers (RVC)

7.4.1 The RVC shall function to connect the incoming power to the ESP
motor via a voltage reducing device and main circuit contactor(s).
The contactors shall have the same characteristics as for the FVC
controllers:

7.4.2 The RVC shall have the following characteristics:

7.4.2.1 Shall have a minimum of four (4) selectable starting output

voltage levels between 25% and 100% of rated input voltage.

7.4.2.2 Time spent at each voltage step shall be manually selectable.

7.4.2.3 The minimum number of automatic voltage step changes (in

the case of transformer/reactor based designs) or the ramp
pattern/rate range (in the case of electronic based designs)
during the starting sequence, shall be specified in the
purchasing documents.

7.4.2.4 The minimum electrical protective functions shall be the

same as with the FVC.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
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7.4.3 If specified in the purchasing documents, shall be equipped with an

auto-restart feature that functions the same as the described for a FVC.

8 Construction Features

8.1 General

8.1.1 Device nameplates shall be in the English language according to

American usage.

8.1.2 Each controller shall be labeled with the following:

8.1.2.1 Purchase order number.

8.1.2.2 Manufacturer’s serial number.

8.1.2.3 Manufacturer’s shop order number, date, and catalog

designation.

8.1.2.4 Horsepower rating of motor.

8.1.2.5 Maximum full load amperes.

8.1.2.6 Nominal voltage range.

8.1.3 Barriers to be installed to separate personnel from energized

components.

8.1.4 Stainless steel surfaces shall not be painted or coated.

8.1.5 Where dissimilar metals are in contact, the contact points shall be
suitably protected to prevent corrosion due to galvanic action.

8.2 Outdoor

8.2.1 Adhesives shall not be used to control, restrict or prevent movement

(e.g., attachment of nameplates, wire straps, wireways, gaskets, etc.)
and shall not be used to maintain a seal (e.g., interconnection of gasket
surfaces).

8.2.2 Enclosures shall have the following characteristics:

8.2.2.1 Controllers shall be enclosed with sheet steel.

8.2.2.2 Continuous seal welding shall be used to seal all exterior

seams.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
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8.2.2.3 If installed in a severely corrosive environment:

8.2.2.3.1 Meet the equivalent performance requirements of

a NEMA 250 Type 4X or IP6X per IEC 60529
with ‘X’ being a numeral between ‘4’ and ‘8’.

8.2.2.3.2 Enclosure material and external hardware such as

fasteners (bolts, screws), hinges and locking
devices shall be stainless steel.

8.2.2.4 If installed in a mildly corrosive environment:

8.2.2.4.1 Meet the equivalent performance requirements of

a NEMA 250 Type 4 or IP6X per IEC 60529 with
‘X’ being a numeral between ‘4’ and ‘8’.

8.2.2.4.2 Box material shall be Manufacturer’s standard and

external hardware such as fasteners (bolts, crews),
hinges and locking devices shall be of similar
metal to the enclosure to avoid galvanic corrosion.

8.2.2.5 No field assembly of the enclosure is permitted.

8.2.2.6 Hinged doors shall be provided for compartments housing

routinely serviceable equipment and shall have the following
characteristics:

8.2.2.6.1 The door seal design shall assure a dust-tight door

edge seam with only the operation of the 3-point
latching mechanism described below.

8.2.2.6.2 Hinge shall be heavy-gauge, continuous and full

height.

8.2.2.6.3 Opening and closure of door shall be via a

3-point latching mechanism operated by a handle.
Latching rods that secure the door to the stationary
structure shall have rollers on the ends.

8.2.2.6.4 Shall be electrically bonded to the stationary

enclosure.

8.2.2.6.5 Each hinged door unit shall be a maximum of

900 mm wide.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
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8.2.2.7 Hinged doors and externally removable panels shall be fitted

with a continuous, molded, replaceable gasket. Attachment of
the gasket, or integrity of the seal, shall not be dependent upon
adhesives (e.g., continuous lip mounted seal).

8.2.2.8 All compartment doors, when fully open, shall not impede
access to any of the components in any of the compartments.

8.2.3 Devices on the exterior of the compartment door which require manual
operation or viewing (e.g., switches, pushbuttons, displays, etc.) shall
be mounted a maximum of 1700 mm from the base of the enclosure.

8.2.4 The power, grounding, control, and communication cabling shall

enter/exit via the bottom of the controller enclosure.

8.2.5 Space heater(s) shall be installed within the enclosure for the purposes
of eliminating condensation within the controller prior to equipment
being put into full operation. Design shall allow the space heater(s) to
be energized with an external power supply with all the controller
doors and covers in their closed position.

8.2.6 A disconnector shall be provided for each controller and shall have the
following characteristics:

8.2.6.1 Manually operable only with the controller door in the closed,
secured position. Note that this is conditional upon the
mechanical interlocking described below.

8.2.6.2 The operating handle shall be mechanically connected

directly to the disconnector irrespective of the position of the
compartment doors/covers.

8.2.6.3 The operating handle shall be padlockable in the OPEN

(switched off) position.

8.2.6.4 It shall not be necessary to remove the padlock(s) from the

operating handle to open or close the associated compartment
doors/covers.

8.2.6.5 There shall be external indication to show the operating

handle position (e.g., "ON" or "OFF", "CLOSED" or
"OPEN", "I" or "O").

8.2.6.6 When the operating handle is in the OPEN position and the
controller enclosure is open, it shall not be possible to contact
any voltage greater than 24 V.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-002
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8.2.7 Mechanical interlocks shall be provided to prevent:

8.2.7.1 The compartment door housing the disconnector from being

opened if the operating handle of the isolation device is in the
closed position. This interlock shall be defeatable with the
use of a tool (i.e., screw-driver, wrench, etc.) and two
separate operations.

8.2.7.2 The operating handle from being closed if the compartment

door is in the open position. This interlock shall be defeatable.

8.2.7.3 Interlocks shall be of substantial mechanical strength. Design

strength shall be sufficient to prevent an individual, without
the assistance of tools or leverage material, to force open the
compartment door.

8.3 Indoor

Disconnectors shall not be provided for indoor controllers.

Commentary Note 8.3:

Disconnectors will be provided at the electrical distribution panel feeding the

controller.

Revision Summary
26 January 2011 New Saudi Aramco Materials System Specification
1 September 2012 Minor revision to change max. ambient from 45°C to 55°C.

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