ESP System Technology

Overview

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ESP Downhole System
The basic ESP downhole system components are ...

The Pump

The Seal Chamber Section

The Motor

The Power Cable

The Monitoring System (optional)

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ESP Downhole System
The system …
 Should be set above the perforations of the well for unit cooling
 Must be sized to specific well data
 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 that either bolts on or is threaded
into the pump housing

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Pump Stage
 Consists of an impeller and diffuser
 The impellers rotate with the shaft and spin
at the RPM of the motor
 The diffusers turn the fluid into the next
impeller and do not rotate
 Pumps are assembled by stacking stages on
a shaft and compressing the stack in a
housing
 A stage will produce a given amount of flow
and lift (head) at the motor RPM

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Pump Performance
Pump stage performance has three measured parameters
which are…
 Flow Rate
 Lift (aka “Head”) or Discharge Pressure
 Brake Horsepower or Motor Load
 From the above, Hydraulic Efficiency may be calculated

The follow slide shows these parameters plotted on a

single stage performance curve

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Pump Curve

Single Stage Performance, 3500 RPM

Sg = 1.0, 60 Hertz
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 Pump Stage Hydraulic
Design
ESP Stage designs fall into one of
two hydraulic categories …

 Radial Flow - flow path is generally perpendicular

(radial) with respect to the pump shaft

 Mixed Flow - flow path has both axial and radial

direction with respect to the pump shaft

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Pump Stage Design
 Radial Flow stages are used for …
Pump Housing Diameter Approx. BEP Flow
3.38 inches (338 series) less than 1500 BPD
4.00 inches (400 series) less than 2000 BPD
5.13 (513 series) less than 3000 BPD

 Mixed Flow stages are used for flow rates greater than
those listed above for the same pump diameter

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Pump Product Range
Min. Casing OD. 60 Hz BEP Flows (min-max)
4 1/2 inch (338 series) 800 - 2500 BPD
5 1/2 inch (400 series) 300 - 6000 BPD
7 inch (513 - 562 series) 1200 - 20,000 BPD
8 5/8 inch (675 series) 7000 - 35,000 BPD
10 3/4 inch (875 - 900 series) 21,000 - 75,000 BPD
13 inch + (1025 - 1038 series) up to 127,000 BPD

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Impeller Terminology
Upthrust Washer Impeller Hub

Top Shroud

Impeller
Vane

Bottom Shroud
Downthrust Washer
Impeller Skirt
Impeller Eye

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 Pump Thrust Load
 Under normal operating conditions, fluid recirculation on the top and
bottom side of the impeller cause forces to be applied on the upper and
lower impeller shrouds
 When the recirculation forces are greater on the upper shroud, the impeller
is moved down which is termed “downthrust”
 When the recirculation forces are greater on the lower shroud, the impeller
is moved up which is termed “upthrust”
 The magnitude recirculation forces depends upon the flow rate going thru
the impeller vs. its hydraulic capacity, i.e., its operating range

SPH, p. 9

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Pump Stage Thrust Load
Fluid Recirculation
(causes Pressure)
Flow into
Next Diffuser

Impeller Flow Path

Fluid Recirculation
(causes Pressure) Flow from Diffuser

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Pump Stage Thrust Load
Fluid Recirculation on Top Shroud
Pressure x Area = Downthrust
(increases as flow decreases)

Fluid Recirculation on Bottom Shroud Pressure x Area = Upthrust

(increases as flow increases)

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Thrust vs. Flow Curve

Downthrust
THRUST LOAD

+ (positive)

0
Upthrust
-
(negative)

Shut In BEP Wide Open

Operating Range

STAGE FLOW RATE

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Upthrust & Downthrust

When operating in its recommended range, most stages are in
light to moderate downthrust

Downthrust increases as the flow through the stage decreases
(or on the left-hand side of the pump curve)

Upthrust increases as the flow through the stage increases (or
on the right-hand side of the pump curve)

Flow rates to the left of the operating range will increase wear
on the downthrust washers

Flows to the right of the operating range will cause wear on the
upthrust washers

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Variable Speed
Operation
ESPs may also be ran at variable speeds. Changing the speed or frequency
of an ESP system follows the “Affinity Laws” …
 New Flow Rate = Old Flow (New Hz/Old Hz)
 New Head = Old Head (New Hz/Old Hz)2
 New Brake HP = Old BHP (New Hz/Old Hz)3
 New Motor HP = Old MHP (New Hz/Old Hz)

As can be seen above, the pump load or brake HP changes at a greater rate
than the motor HP. This makes matching the motor and pump size at
maximum frequency critical to a good application and long run life
SPH, p. 52-54

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Variable Speed
Performance
 Using the Affinity Laws, a single stage performance curve
may be plotted using the 60 Hz fixed speed performance
data as a reference

 Head versus Flow is plotted resulting in a new operating

range for the recommended frequency limits (30 - 90 Hertz)

 The shape of the operating range is known as the

“Tornado”. Variable speed curves are sometimes called
“Tornado Curves”

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Variable Speed Pump
Curve

Head vs. Flow, Variable Speed (30-90 Hz),

Single Stage, Sg = 1.0
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The Gas Separator
 Takes the place of a standard pump intake
 Is used in applications where free gas causes
interference with pump performance
 Separates a portion of the free gas from the fluid
entering the intake to improve pump performance
 Gas separator types include:
– Reverse Flow
– Rotary

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Reverse Flow Gas
Separator
Reverse flow gas separators …
 Separate gas by changing the direction of flow of the gas-liquid mixture
 Are highly dependent on annular area, fluid velocity, and relative Sg of the
gas and liquid
 Can also be accomplished by a unit shroud in wells of sufficient diameter or
by setting below the well perforations with proper motor cooling
 Are good for low to moderately gassy wells

SPH, p. 64

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Rotary Gas Separator
 Utilizes a specially designed rotating chamber (rotor),
paddle wheel, or induced vortex to impart centrifugal
force on the fluid
 The rotor or induced vortex forces the heavier fluid to
the outside & allows the free gas to migrate to the center
of the chamber
 At the top, the two streams are physically separated
 The liquid rich stream is ported internally to the pump
inlet
 The gas rich stream is vented to the casing annulus
 Can be deployed as a tandem unit for additional
separation capability

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Gas Separator
Application
Use Gas Separators when …

Free gas % is greater than 10% with radial flow stages

Free gas % is greater than 15% with mixed flow stages

Application Notes & Cautions …


After separation, free gas going into the first stage should be less than
the above percentages

Very gassy wells may require a tandem separator

Sandy wells requiring a rotary gas separator should utilize specially
design abrasion resistant units or another form of gas handling
technology

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The Seal Chamber
Section
Is located between the pump and motor
 Transfers the motor torque to the pump shaft
 Equalizes the internal unit and wellbore pressure
 Provides area for motor oil expansion volume
 Isolates the well fluid from the clean motor oil
 Absorbs the pump shaft thrust load
 The Four “Shuns” - expansion, equalization,
isolation, & “absorbsion”
 aka “Equalizer”, “Protector”, or “Seal Section”
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Seal Section
Components
Major 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
(equivalent to 2917 RPM at 50 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

Housing

Stator Laminations

Epoxy Encapsulation

Rotor Kapton-Wrapped
Bearing with T-ring Magnet Wire

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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 Application
Motor 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
Components
2 4
1 - Conductor (Copper)
2 - Insulation (Polypropylene or EPDM)
3 - Jacket (Nitrile or EPDM) & Tape
4 - Armor (Galvanized, Stainless, or Monel) 3 1
 Benefits: Low profile to fit in tight
clearance installations

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Cable Types - Round
Components
1 - Conductor (Copper) 3 2

2 - Insulation (Polypropylene or EPDM)

4 1
3 - Jacket (Nitrile or EPDM) & Tape
4 - Armor (Galvanized, Stainless, or Monel)
 Benefits: Less current imbalance & runs
cooler than equivalent flat cable

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Cable Types - Motor Lead
Extension
Components
1 - Conductor (Copper)
2 - Insulation Film (Polyimide) 1 2 3

3 - Insulation (EPDM)
4 - Jacket / Tape & Braid or Lead Sheath
(Low Temp or Hi Temp)
5 - Armor (Low Profile Galv, SS, or Monel) 5 4

 Benefits: Tape and braid provides added

decompression resistance

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Cable Types - Extruded
Barrier
Components
1 - Conductor (Copper) 4 2
2 - Insulation (EPDM)
5 1
3 - Extruded Fluorobarrier (Low or Hi Temp)
4 - Jacket (Nitrile or EPDM)
5 - Armor (Galvanized, Stainless, or Monel)
3
 Benefits: Unlike tapes, the barrier blocks fluid,
aids decompression resistance, and improves
electrical properties

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Cable Types - Lead Sheath
Components
1 - Conductor (Copper)
2 5 4
2 - Insulation (Polypropylene or EPDM)
3 - Lead Sheath
4 - Tape or Braid (on EPDM product only)
5 - Armor (Galvanized, Stainless, or Monel) 3 1

Benefits: Lead sheath blocks gasses & protects
conductor from H2S attack

Available in round profile with EPDM jacket

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Cable Types - Capillary
Tube
Features & Benefits Capillary Tube

 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
Standard Power Cable
 Instrument wire can be inserted in some capillary
tube sizes
 An outer layer of armor is applied to protect the
capillary tubes

Capillary Tubes

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Power Cable Application
Proper application of ESP cable requires ...
 Limiting voltage drop to 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, hi gas, etc.

SPH, pp. 100-102

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Cable Temperature
Temperature Ratings of ESP Cables - insulation / covering / jacket (*denotes
limiting material)
 Polypropylene* / Nitrile 200o F (95o C)
 Polypropylene* / Lead 220o F (105o C)
 EPDM / Nitrile* (with or w/o Barrier) 280o F (140o C)
 EPDM / Low Temp Barrier* / EPDM 300o F (150o C)
 EPDM / EPDM (with or w/o hi temp Barrier) 400o F (205o C)
 EPDM* / Lead Sheath 450o F (230o C)
 Motor Lead Extension - Low Temp 250o F (120o C)
 Motor Lead Extension - High Temp 400o F (205o C)
 Motor Lead Extension - Lead Sheath 450o F (230o C)

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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 -- Fiberoptics

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The Surface Equipment
The surface equipment (beyond the wellhead)
consists of …
 The Motor Controller
 The Transformer(s)
 The Junction or “Vent” Box

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The Controller System
The 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

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The Switchboard
Features
 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

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The Motor Controller
The 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

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The Variable Speed
Controller
Features & 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

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Variable Speed Pump
Curve

Head vs. Flow, Variable Speed (30-90 Hz),

Single Stage, Sg = 1.0
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The VSC Control System
Features
 Is simple to operate,
parameters set on the key pad
 Some can be operated in
current limiting mode (I-limit)
 Can be controlled manually
&/or from a variety of external
controls

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The Transformer
The 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

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The Junction Box
The 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

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