Powerlift ESP Industry

ESP System Start-Up, Commissioning and

Operation
Commissioning and Start up procedure for ESP
 Tools box: which include tools for connecting, disconnecting the power cables
 Only approved PPE should be worn when working on the equipment
 Electrical Meters: which include the Fluke and Megger that used for
performing the Continuity Test and Insulation Test for the downhole Power
Cable and surface power Cable and test the functionality of the VSD parts.

 FRC & Hot Gloves: which should be worn by the Engineer to confirm the
Power Isolation

2 Day 2 | ESP System Start-Up, Commissioning and Operation

 Tool box meeting with personnel involved. Which will be documented in the TBT
Sheet.
 Make visual inspection of the ESP system surface equipment, ensure grounding of
the VSD and step-up transformer to the existing ground grid;
 Make sure the armor of the downhole cable at the X-mas is grounded (the armor
must be connected to the lower nut of the lowest flange of the X-mas) of the well;
 Check the VSD, step-up transformer, junction

box, tighten the bolted connections of the live

components and connections to the zero bus.

3 Day 2 | ESP System Start-Up, Commissioning and Operation

Lock Out and Tag Out (LOTO) :

Lock Out / Tag Out

is the procedure that notifies and limits access to unauthorized personnel to the
equipment. This is typically done with the gang locks and tags shown to the right.
When all work is done the locks can be removed by the qualified personnel to allow the
equipment to then be operated.(OAA)

OAA remove all the tags and then open all x-mass tree valves in order to Run the ESP

4 Day 2 | ESP System Start-Up, Commissioning and Operation

ESP Commissioning Steps:
 Perform downhole Cable Integrity & Continuity Test from Well Head
(Phase-Phase & Phase-Ground) :
A.Cable Integrity Test has to be performed using certified and
calibrated device.
B.Phase- Gnd. Test has to last for 10 min and the applied Voltage
should be 1000 V

 ESP commissioning recommendation

 VSD setup & configuration:
1. application engineer or client will give us primary VSD setting point like:
AMPS
motor nameplate Voltage
HP
Mim F
Frequency
Max F
Cable type and length CABLE AWG #1 and 120 ft (as example)

Downhole parameter set point (high Pd set, low Pd set, high Pi set, low Pi set, Ti set, Tm set, Vx
Vy,)
Going to calculation sheet to find :

2730 67 1 100 ft (Vdrop =120v)

45 65

415

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.
related to calculation sheet:

Find: Secondary volts @ max Hz 2730 + Cable Drop 120 = 2850 +/- 10%
In case we have VSD Filter we should use filter factor=1.067 (in BHI Case)

as know VSD Vout = 415 and transformer in put need V= 480 and this issue can solve
with Input power ratio

go to transformer nameplate to choose available tap voltage which is a require voltage

that motor need it to run correctly and we should know if the transformer with Dalta
connect or star so available tap is (3607)

Transformer nameplate show as below:

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it is important to find Xfmr (transformer ratio)

for first set up we will set :

Overload with 100% of motor current nameplate and when we run the ESP and get
stability condition we will re-set overload with operation condition
BHI company use (Xfmr*VSD current nameplate) and other company use
OL=motor current operation*1.15
Underload = 0 and then we run the ESP and get stability condition we will re-set
underload with operation condition
BHI use (0.8*motor running current) as other company

Overload trip (OLT) is intended to shutdown an electric motor when the operating
current exceeds a nominal current; the aim is to prevent overheating and
breakdown of the stator winding.

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Setting-up of voltage drop protection should be performed in order to
stabilize ESP system operation.

Protection setting for the maximum voltage (overvoltage):

Vmax setting = vnom.pwor.line * 1,1.

Protection setting for the minimum voltage (undervoltage):

Vmin setting = Vnom.pw.line * 0,9.

Actuation time delay should be set to 5 seconds.

11 Day 2 | ESP System Start-Up, Commissioning and Operation

Current unbalance protection
Current unbalance protection is necessary to ensure stable operation of electric
motor. Recommended distortion of current phases should not exceed 4%

Ph1= 200 Ph2= 201 Ph3= 200 balance

Ph1= 200 Ph2= 201 Ph3= 230 unbalance

Voltage unbalance protection

Voltage unbalance protection is necessary to ensure stable operation of electric
motor.

Voltage unbalance should not exceed 4%

Day 2 | ESP System Start-Up, Commissioning and Operation

 Backspin protection
• Backspin protection is intended to prevent ESP system starting during fluid bleeding
from tubing.
• The setting should be 5 Hz.
• Restart period should be set from 1 to 5 minutes.

 No-load test
Disconnect cables of Transformer, Downhole and
run the VSD with no-load to ensure there are no
issue with our VSD set up (run at F=30 Hz and
then increase it to 60 Hz).

 RTU communication
Confirm RTU communication
with client team.

Day 2 | ESP System Start-Up, Commissioning and Operation

 Confirm that all the X-tree and flow line valves are open

 Run ESP with first rotation

Example of A Commissioning Start
100 3500

ES P S ta rt
90

3000
80
Firs t Ind ica tio n Bo th P re s s ure s d e cre a s e
o f Flo w
70
2500

60
Ta ke No te o f S hut-In S uctio n
P re s s ure
50 2000
Co ntro lling P re s s ure
with Cho ke
40

1500
30

20
1000

10

0 500

14 Curre nt We llhe a d Te mp e ra ture We llhe a d P re s s ure Inta ke P re s s ure Dis cha rg e P re s s ure
with first rotation we should monitor value of Pd with Pi, as shown in pervious fig. we
noticed that Pd reduce to the value of Pi, which mean we are in wrong rotation.
after 10 min. we SD the ESP and then;

 Run the ESP with second rotation (right rotation)

we noticed that Pd start increase step by step more than Pi until stabilize, the main
Example of A Routine Start
we have differential pressure which help us to produce the oil.
100 3500
Normal Running Conditions

ESP Start
90

3000
80
First Indication of Flow

70
Check Pressure has Equalised 2500

60

50 2000
Controlling Pressure with Choke

40

1500
30 Min 30 Minute wait

20
1000

10

0 500
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 Send ESP parameters to Application engineer.
 Start optimization to ensure that ESP is running inside ROR. Set the VSD
alarms and downloaded the data log
 Perform Housekeeping to the Well Site and confirm that work site is safe,
clean and all equipment are arranged properly.

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