ESP System Technology

Overview

1
 ESP Downhole System
The basic ESP downhole system components
are ...
 The Pump
The Seal Section
 The Motor
The Power Cable
The Monitoring System (optional)

2
Product Identification Key
 Equipment for 4.5 inch casing and larger
“300 Series”
Series Diameter model Type
338 3.375” D pump\seal
375 3.75” D motor
385 3.85” E pump

3
Product Identification Key
 Equipment for 5.5 inch casing and larger
“400 Series”
Series Diameter model Type
400 4.00” F pump/seal
400 4.00” 400P Centurion Pump
450 4.50” F motor

4
Product Identification Key
 Equipment for 7.0 inch casing and larger
“500 Series”
Series Diameter model Type
513 5.125” G pump/seal
538 5.375” 538P Centurion Pump
544 5.438” G motor
562 5.625” K motor

5
Product Identification Key
 Equipment for 8-5/8 inch casing and larger
Series Diameter model Type
675 6.75” H pump/seal
725 7.25” H motor

6
 Product Identification Key
 Pumps only
Series Diameter model Minimum Casing
875 8.75” I 10-3/4”
900 9.00” N 10-3/4”
1025 10.25” J 13-3/8”
1038 10.38” M 13-3/8”

7
 Product Identification Key
 Pump Stage Key
example 1: FC4300
F = 400 series, 4.00” pump
C = casting, S = synthetic impeller material
4300 BPD, best efficiency point (BEP) flow
except I and J pumps are in GPM
example 2: 538P17
538 = Series
P = Pump
17 = 17 hundred (1700) BPD @ BEP & 60 Hz

8
Product Identification Key
Model Designation Key
1st Letter - Series D, F, G, K, H, I, J

2nd Letter - Product Type

P - pump, RS - rotary separator
S - seal, M - motor

9
 Product Identification Key
3rd, 4th, … Letters - Options, some of the most popular are …
LT - lower tandem, MT –middle tandem,
AR - abrasion resistant (pump),
X - corrosion resistant metallurgy, C - labyrinth type (seal),
M - modular AR style, C - ‘compression’ fixed impeller type
(pump)
B - bag type (seal), G - high temperature option
B, C, E, F, H… in 3rd letter motor - rating ‘generation’

10
LT = Lower Tandem pump
( with built in intake )

The seal bolts on here

11
 If MT (middle tandem) or LT
(Lower Tandem) then a
flange face is the head of
the pump.
Shipping Cap

Head

LT/MT = Lower/Middle Tandem

pump
12
If FP type or Upper Tandem
(UT) then a discharge is
built into the pump.

Built in Discharge head

FP Pump

13
 UT or MT
pump

Middle Tandem pump Base

Shipping Cap

14
The Bolt on Head FPHVDIS

The Middle Tandem

or Lower Tandem
Pump Head

15
 UT or MT pump bolts on here.

Gas separator intake (cut away).

May be bolted on to the base of a
MT (Middle Tandem) or UT
(Upper Tandem) Pump

The Seal bolts on here.

16
ESP Downhole System
The system …
 Should be set above the perforations of
the well for unit cooling
 Must be sized to the well’s productivity
 Should be monitored for changes in well
and/or unit performance

17
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 and discharge that either bolts onto
or is threaded into the pump housing

18
Built in Discharge head Tubing screws in here

Pump Housing
Stationary Diffuser

Rotating Impeller

Pump Shaft Built in Intake

The Pump

Bolts to the Seal

19
 Cutaway of Pump

Stationary diffusers

Rotating (right to left) impellers

20
Impeller
21
Impeller

The impeller rotates

about the pump axis,
with the shaft

It provides the
centrifugal force
to the fluid - gives
it energy.

22
Impeller

Fluid enters the

impeller through the
‘eye’ near the shaft
and exits the impeller
on the outside.

23
Impeller - Cut Away 24
Impeller

Hub

Upper
Shroud

Vanes

Lower
Shroud

Skirt Eye
25
Diffuser
26
Diffuser

The diffuser does not

rotate, it turns the fluid
up into the next
impeller
It transforms the fluid
velocity, it’s energy,
into head

27
Diffuser - Cut Away 28
Impeller &
Diffuser
Diffuser redirects the fluid up
into the next impeller and turns
fluid energy into head

Impeller spins and gives

energy to fluid which exits
around the outside

Diffuser directs fluid into the

eye of the impeller

29
Impeller in Diffuser - A Pump ‘Stage’ 30
 31
Pump Stage - cut away
 Developing the
Pump Stage
Head – Capacity
Curve Pump Stage

Fluid Reservoir
32
 Developing the
Pump Stage
Head – Capacity
Curve
1

Head
(Lift)

Fluid Reservoir
33
The Seal Chamber Section

Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates (seals) the well fluid from the clean motor oil

Equalizes the internal unit and wellbore pressure

Provides area for motor oil expansion volume

Absorbs the pump shaft thrust load

The Four “Shuns” - expansion, equalization, isolation,
& “absorbsion”

aka “Equalizer”, “Protector”, or “Seal Section”

34
The Seal Chamber Section
 Is located between the pump and motor
 Transfers the motor torque to the pump shaft
 Isolates (seals) the well fluid from the clean motor
oil

35
Pump Motor

36
Pump

Motor

37
38
39
Pump

Motor
40
Pump

Seal

Motor
41
 The Seal Section
Located between the pump and motor
Transfers the motor torque to the pump shaft

C e n tr ilif t 42
Labyrinth
Chamber

43
Labyrinth
Chamber

44
45
Double
Labyrinth
Chamber

46
47
The Seal Section, purpose:

1. Isolation
Isolates (seals) the clean motor oil from the well fluid

48
 Isolation

Labyrinth Chamber

49
50
51
52
53
54
 Isolation

Mechanical Seals

Prevents fluid migration down the seal shaft r

55
 Pump

Labyrinth
Chamber

Motor
56
57
58
Pump

Bag
or
Bladder

Motor
59
Pump

Motor
60
61
 Isolation
Bag (or Bladder)

62
 Isolation -
Recap
1. Labyrinth Chamber
2. Mechanical Seals
3. Bag (or Bladder)

63
The Seal Chamber Section
 Is located between the pump and motor
 Transfers the motor torque to the pump shaft
 Isolates the well fluid from the clean motor oil
 Provides area for motor oil expansion volume

64
65
Labyrinth
Chamber

Motor Oil - Heated

66
Labyrinth
Chamber

Motor Oil - Cooling

67
Double Labyrinth Chamber

68
Motor
The Seal Section, purpose:

2. Expansion
Provides space for motor oil expansion

69
 Expansion

Labyrinth Chamber

70
Bag (or Bladder)

Motor Oil - Heated

Motor 71
Bag (or Bladder)

Motor Oil - Heated

Motor 72
 Check valve

Bag (or Bladder)

Motor Oil - Heated

Motor 73
74
75
 Check valve

Bag (or Bladder)

Motor Oil - Heated

Motor 76
 Check valve

Bag (or Bladder)

Motor Oil - Heated

Motor 77
 Check valve

Bag (or Bladder)

Motor Oil - Heated

Motor 78
 Motor Oil - Cooling

Motor 79
 Motor Oil - Cooling

Motor 80
Double Bags

Motor Oil - Heated

Motor 81
Double Bags

Motor Oil - Heated

Motor 82
Double Bags

Motor Oil - Heated

Motor 83
84
85
Parallel Bags

Motor Oil - Heated

Motor 86
Parallel Bags

Motor Oil - Heated

Motor 87
Expansion
Bag (or Bladder)

88
 Expansion -
Recap
1. Labyrinth Chamber
2. Bag (or Bladder)

89
The Seal Chamber Section
 Is located between the pump and motor
 Transfers the motor torque to the pump shaft
 Isolates the well fluid from the clean motor oil
 Provides area for motor oil expansion volume
 Equalizes the internal unit and wellbore pressure

90
Motor

91
 92
‘n’ thousand feet
93
94
95
 The Seal Section, purpose:

3. Equalization
Equals pressure between the outside casing
and inside the motor housing

96
 Equalization
1. Labyrinth Chamber
2. Bag (or Bladder)

97
The Seal Chamber Section
 Is located between the pump and motor
 Transfers the motor torque to the pump shaft
 Isolates the well fluid from the clean motor oil
 Equalizes the internal unit and wellbore pressure
 Provides area for motor oil expansion volume
 Absorbs the pump shaft thrust load

98
99
100
101
Compression, Fixed Impeller, Pumps

102
Compression, Fixed Impeller, Pumps

103
Pump

Seal

Motor
104
Seal (Lower Chamber)

105
Motor
Seal (Lower Chamber) Upthrust Ring
Thrust Runner
Thrust Runner
Thrust Bearing Area Carbon Face

Bearing
Heat Exchange Area Bearing Retainer

Screen Filter

106
Motor
Seal Unit
Base

107
Bearing Retainer

108
Oil Pump

109
Bearing

110
Carbon
Face

111
Thrust
Runner

112
Thrust Runner Carbon Face

Thrust Runner
113
Upthrust
Bearing

114
Upthrust Bearing

Bearing Runner
115
116
Bearing Assembly
Complete

117
118
The Seal Section, purpose:

4. Absorption
Absorbs the thrust of the pump

119
Absorption

Thrust Bearing

120
The Seal Chamber Section

Is located between the pump and motor

Transfers the motor torque to the pump shaft

Isolates the well fluid from the clean motor oil

Equalizes the internal unit and wellbore pressure

Provides area for motor oil expansion volume

Absorbs the pump shaft thrust load

The Four “Shuns” - isolation, equalization,
expansion, & “absorbsion”

Or “Equalizer”, “Protector”, or “Seal Section”

121
Seal Section Components - review
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)

122
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

123
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
 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

124
Motor Components

Housing

Stator Laminations

Epoxy Encapsulation

Rotor Kapton-Wrapped
Bearing with T-ring Magnet Wire

125
 Stator
Bearing with
T-Ring

rotor

126
Stator Laminations on a Mandrel

127
Stator Laminations pressed into
the motor housing

128
A wound Stator with Leads attached

129
Potted End
Turns

130
 Rotor Laminations
Rotor Copper End Ring
Rotor Spacers
Rotor Bearing
Rotor T ring

131
Rotor Bearing
Rotor

132
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

133
Motor Volts vs. Amps

Optimum Voltage

134
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

135
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

136
Cable Types - Flat
Components
1 - Conductor (Copper) 2 4

2 - Insulation (Polypropylene or EPDM)

(Ethylene Propylene Diene Monomer)
3 - Jacket (Nitrile or EPDM) & Tape
3 1
4 - Armor (Galvanized, Stainless, or Monel)
 Benefits: Low profile to fit in tight
clearance installations

137
Cable Types - Round
Components
1 - Conductor (Copper) 3 2

2 - Insulation Polypropylene or EPDM

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

138
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

139
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

140
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

141
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

Instrument wire can be inserted in some capillary Standard Power Cable
tube sizes
 An outer layer of armor is applied to protect the
capillary tubes

Capillary Tubes

142
Power Cable Application
Proper application of ESP cable requires ...
 Limiting voltage drop to no more than 30 volts per 1000’ and 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, high gas, etc.

SPH, pp. 100-102

143
Poly Cable KV Rating
4 KV 5 KV
3 KV

144
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 -- Fiber optics

145
The Surface Equipment
The surface equipment (beyond the wellhead)
consists of …
 The Motor Controller
 The Transformer(s)
 The Junction or “Vent” Box
 Wellhead
 Surface Cable

146
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

147
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

148
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

149
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

150
The VSC Graphic Control System
Graphic display Interface

151
 GCS Main Menu

The organization of parameters and information is common

for the 9 main menu options on all GCS products.
152
GCS Status Screen
153
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

154
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

155