REDA ESP AnuiNc=D OPERATIONS COURSE INDEX REDA advanced ESP Operations Course Index Section 1 Introduction and Overview of REDA Systems 4.1 Available Ranges of REDA's Equipment 1.2. Types of REDA ESP Insiallations 42.1 Standard installations 4/22 installation with Fluid Shroud 1.2.3 Booster System 4.2.4 Bottom Intake System 1.25 Bottom Discharge Application 1.26 Inter-Zone injection System 1.27 Production - injection System 1.2.8 Cable-Deployed (COPS) and Coiled Tubing Deployed Pumping Systems (CTDPS) 4.2.9 Horizontal Pumping Systems 42.10 Progressing Cavity Submergible Pumping Systems (PCESP) Section 2 THE ESP SYSTEM AND ITS APPLICATIONS 2.1 Pumps 2.4.1 Pump Applications 2.2 Intake Sections 2.2.1 Application of Intakes and Gas Separators 2.3 Motors 2.3.1 Motor Applications 2.3.2 “Raling’ ESP Motors 2.4 Protectors 2.4.1. Protector Operation Cycles 2.4.2 Protector Applications, 2.5 Power Cable 2.5.1 Power Cable Applications 2.8 Pump Setting Depth Constraints Section 3 ESP OPERATIONS 3.1. ESP Equipment Handling 3.1.1. Handling of Used Equipment 3.2_Installation, Start-up and Pulling the ESP 3.2.1 Recommendations for Running the ESP 3.2.2 Starting the ESP 3.2.3 Recommencations for Fulling and Rerunning ESP Components 2.2.4 ESP Pull and Run Reports 3.3 Voltage Optimization of Underloaded ESP Motors 3.3.1 Effect of Reduced Voltage on Motor Amps 3.3.2 Effect of Reduced Voltage on Motor Torque end Speed 2.3.3 Effect of Reduced Voltage on Power Factor 3.3.4 Recommendations for Voltage Optimization 2.3.5 Voltage Optimization Procedures 3.3.8 Protection of Lightly Loaded ESP Motors 3.4 Switchboard vs. VSD Operation 3.5 Protection of the ESP from Electric Transients 3.6 Production of Abrasive Fluids 3.7 Production of Corrosive Fluids 3.8 Production of Fluids with Tendency to Form Seale 3.9. Production of Fluids with High G.O.R. @REDA 1096. All Righte Resoned,REDA Advanced Operations Course index 3.8.1 REDA's Advances Gas Handler (AGH) 3.10 Temperature Considerations 3.11 Amp Chart Analysis and Diagnosis 3.14.1 Normal Operations 3.11.2 Power Fluctuations 3.11.3 Gas Locking 3.41.4 Unloading Heavy Well Control (Kill) Fluid 3.11.5 Fluid Pump Off Condition with Gas Interference 3.11.6 Fluid Pump Off Condition without Gas interference 7 Fluid Pump Off Condition - Restart Failure .8 Excessive Cycling 9 Free Gas in Pump ‘10 Undercurrent Shutdown 3.11.12 Tank Lever Controller 3.11.13 Overload Conditions 3.11.14 Pump Handling Solids 3.11.15 Excessive Manual Restart Attempts 2.11.47 Erratic Loading Condition 2.11.18 Emulsion or Surface System Load Section 4 ESP MONITORING and “RUN-LIFE" 4.1 Monitoring Operation Parameters 4.2 Average Run-Life and Days in Service Section 5 ESP FAILURE ANALYSIS 5.1 Generel Procedures for Dismantle Inspection Analysis of ESP Components £2 Preliminary Inspection of Used ESP Components, 5.3. Pumps 5.3.1 Losses in Centrifugal Pumps 5.3.2 Wear Patterns in Pump Stages 5.3.3 Mechanical Inspection of Pumps 5.3.4 Performance Tests of Used Pumps 5.3.5 Dismantie Inspection of Pumps Intakes and Gas Separators Motors, 5.5.1 Preliminary Inspection 5.5.2 Electrical Inspection 5.5.3 Mechanical inspection 5.8 Proteciors 57 PS 5.8 Power Cable 5.8.1 Inspection 5.8.2_H/-POT Test 5.9 Wear Causes and Recommend BREDA 1996. AI Rigs Reserve, 422 123 125 127 128 129 130 431 432 133 134 135 136 137 438 130 140 441 142 143 153 153 473 175 175 17 17 79 184 187 180 191 131 191 192 196 198 198 198 198 200REDA ESP ADVANCED OPERATIONS COURSE Section 1 Introduction and Types of Installations of ESP Systems. 4.1 Introduction and Available Ranges of REDA’s Equipment. REDA was established in 1930 by Armais Arutunoff, the inventor of the submersible motor. REDA specializes in tne design, manufacture, application, marketing, installation, service and repair of + Electric Submergible Pumping System (ESP) Equipment + Submergible Power Cables + ESP Power Supply and Control Systems Today, over 14,000 REDA Submergible Pumping Systems are installed in 115 countries. These systems together lift approximately 1 of every 12 barrels of oil produced in the world. REDA is the world's leading supplier of Electric Submergible Pumping Systems for oll, water and industrial applications supported by a worldwide network of service and repair ‘@REDA, 1097. AI Rights ReservedREDA ‘Seqian 1) REDA systen Cverew facilities !ocated in all major oil production regions. Some of the products and services available from REDA service centers include Complete Submergible Pumping Systems REDA Power Cable Seles and Repair Pump and Motor Performance Testing Complete Line of Accessories & Equipment ‘Minor Equipment Repairs Well Testing ‘Teardown and Inspection Facilities Power System Analysis Authorized Field Service Personnel Application Engineering Services REDA offers a range of equipment for casings as small as 4.5" with production rates as low as 150 bpd, as well as flow rates up to 100,000 bpd in 13 3/8" casing. Figures 1.1 and 7.2 graphically show the range of head capacity for the most common casing sizes used in the industry, Maximum Head-Capacity tor REDA Pumps 20001 15000} 10000 7 4 Total Dynamic Head - Feet 0 10000 20000 30000 Flow Rate - BPD (60 Hz) 4.5" Casing 5.5"Casing (1 7" Casing Figure 1.1 Head Capacity of REDA's ESP in 4.5, §.5 and 7° casing ‘OREDA 1957. Al Richts ReservedREDA ESP ADVANCED OPERATIONS COURSE Maximum Head-Capacity for REDA Pumps wg 750 7 ] ° 2 Zan . le P 3 ee 3 : $ 5000; Z 7 a. E | £ 250( 1 5 a = 3 : = 2 oo a 0 50000 100000 Flow Rate - BPD (60 Hz) 11.75" Casing 13.375" Casing Figure 1.2 Head Capacity of REDA's ESP in 11.7, and 13.375" casing Depending on application conditions, REDA can offer a pumping system for bottom hole temperatures from 50 °F to 550 °F or more. REDA also offers the most extensive line of abrasion resistant pumping equipment in the world, as well as being the most reliable. REDA provides submergible motors from 7.5 HP in 375 Series to 1170HP in 582 Series at 60Hz. ‘REDS, 1987, Al Rights Reserved. 3REDA Sexto0 1. REDA Sysiem Overew 60 Hz Maximum Horsepower 8 8 5 456 540 562 738 Motor Series Figure 1.3, Maximum available motor Horsepower (60 HZ) REDA pumping equipment comes in three nominal thermal ratings depending on the bottom hole temperature. For geothermal, steam flood, or even low flow rate applications, HOTLINE™ is recommended, Standard Intermediate ) HOTLINE 250°F 300°F 500°F 4 @REDA 1957. Al Rights Reserved, ) JREDA ESP ADVANCED OPERATIONS COURSE 1.2. Types of REDA ESP Installations There are several types of installations that can be made by combining the basic components of the ESP to fit the most diverse operating requirements. In some types of installations it's necessary to introduce modifications to one or more of the stancarc ‘components in order to adjust them to the new disposition in the equipment string (°.9 inverted pumps). 41.2.1 Standard Installation In a typical installation, we always find ona or more of the following basic components: multi-stage centrifugal pump, intake or gas seperator, protector, and the electric motor ~ which is located in the very bottom of the string ~ providing the power to move the pump, All the components are connected together and hang from the tubing. We will have a motor flat cable extension, power cable and electric connectors as well In a typical installation, the pump is seated above the perforations in such a way that the well fluid moves upward around the motor housing, cooling the moter by dissipating the heat generated, oom Standard Installation =< Figure 1.4 Standard ESP installation @REDA, 1007 Al Right ReservedREDA ‘Secton 1; REDA Sysiem Grewwew 1.2.2 Installation with fluid shroud ‘A modification from the typical standard installation uses a shroud over the equipment that is bolted on the intake and covers the intake, protector and motor. The shroud directs the ‘wall fluids past the motor to increase its cooling. Shrouded installations are common in low flow rate installations, when the equipment is seated in or below the perforations, or in large diameter casing installations. Shrouded Installation la Centrifugal Pump I Intake or Gas Separatorti.) Protector + A Electric Motor Shroud -——__. __| Figure 1.5 Installation of the ESP with fluid shroud 6 @REDA 1007, All Righte ReservedREDA EP ADVANCED OPERATIONS COURSE 41.2.3 Booster System A submergible pumping system can be used to increase the inlet pressure to @ high pressure, for example adding pressure to Iong flow lines or increasing pressure to an injection system in waterficod projects. The low pressure fluid goes through the annulus and the high pressure fluid comes out through the tubing. These applications are usually installed in a shallow casing with just enough length to match the equipment length and one discharge tube, so that when the unit needs to be pulled out it can be done without the need of a workover nig. The booster application always will require a fluid shroud. Annular Liner (Can) Centrifugal Pump Electric Motor} Figure 1.6 ESP Booster Installation REDA, 1997. All Rotts Reserved, 7REDA Section) REDA System Ovevew 1.2.4 Bottom Intake System A variation on the ESP system is the bottom intake system, where the components are reversed and the intake is placed below the motor. This type requires the use of a downhole packer because the fluid is produced through the annulus. The fluid goes into the bottom intake and is discharged into the casing annulus, passing around the protector and motor to remove the heat generated on it's way to the surface. ‘The system is useful in dewatering applications or low NPSH applications where setting the intake as low as possible is desirable IL, Bottom Intake Intake Thrust Chamber Figure 1.7 Bottom Intake System 8 BREDA 1997. AI Righis ReservedREDA ESP ADVANCED OPERATIONS COURSE 4 Bottom Discharge Application This configuration offers the discharge on the very bottom for low or high pressure injection. In this application, the components of the pumping system are reversed, having the pump in the bottom of the string with its ends reversed. A downhole packer will also be required Injection fluid can enter either the casing annulus or the tubing (or both). If injection fluid enters through the tubing string, a perforated joint above the unit allows the fluid into the annulus just above the motor. G Bottom Discharae Electric Motor] Protector Figure 1.8 Bottom Discharge System PREDA, 1967. All Rights Resend 9REDA Seton! REDA System Oversew 4.2.6. Inter-Zone Injection System This is en application of the bottom discharge system that injects water produced in the upper zone into a lower injection zone of the same well, Using a different configuration, is also possible to produce from @ lower zone and inject into an upper zone. A packer is required in either case Since this and the production-injection systems are “closed systems’, they are very attractive for waterflood systems. The system does not require surface storage facilities, pumping, or chemical treatment for the produced water. Figure 1.9 Inter-Zone Injection System 10 SREDA 1987. Al Rights ReservedREDA ESP ADVANCED OPERATIONS COURSE 1.2.7. Production - Injection System With this “closed injection system’ i's possible to use a conventional Suomergible Pumping System to pump the water preduced in one wall and inject it into one or more injection wells, at the same time, even if they are in different zones, Figure 1.10 Production-Injection System OREDA, 1997, Al Ricts Reserved 4REDA ‘Section 1: REDA System Overnew 4.2.8 Cable Deployed (CDPS) and Coiled Tubing Deployed Pumping Systems (CTDPS) Cable Deployed and Coiled Tubing Deployed systems represent an option in applications where @ workover rig is either not available or is cost prohibitive, and to reduce downtime costs. With the Cable Depioyed System, the submergible pump is lowered into the well with @ tension cable and seated in a landing profile in either 5" or 7” production tubing The downhole components of the CDPS are inverted trom a typical submergible pump installaton. The motor is in the top of the string and the pump is in the bottom, The tension cable is @ torque-balanced wire rope similar to cable used in many wireline operations, In the CTDPS the equipment arrangement can be the typical ESP or inverted, as necessary. Figure 1.14 Coiled Tubing Deployed Pumping System 2 EREDA 1997 All Rights ReservedREDA ESP ADVANCED OPERATIONS COURSE 4.2.9 Horizontal Pumping Systems REDA pumps can also be used with a standard surface motor to provide high pressure boosting. This system offers very low noise and vibration, which is beneficial in populated areas, Repairs are as simple as lifting off the bad part and putting on a new one, which virtually eliminates the long down times associated with triplex or other PD pumps Figure 1.12 Horizontal Pumping System Paralleling pumps allows for much higher flow rates. Another advantage of parallel pumps is that if one fails, it can be isolated with valves in the manifold, allowing the other pumps to continue operating while the failed unit is being repaired. Butterfly Valve =F Blocking! Check Throttling —— ——— Valve Valve Se ae —= == Flanged | Discharge \| — Hose | cre ‘| \| @ LB oe = 3 _ | 2 \| )) $ For Additional Unit —— "= Figure 1.13 Multiple HPS Units in Parallel OREDA, 1967. All Rights Recanved, 13REDA Section 1) REDA Sysiem Oversow REDA also offers this system with a diesel engine drive system. All units come pre- mounted and aligned on the skid so installation is simple. Figure 1.14 Engine-Driven Horizontal Pumping System 4.2.40 Progressing Cavity Submergible Pumping Systems (PCESP) ‘A popular method of producing heavy oil in deviated and horizontal wells is using Progressing Cavity Pumps (PCP’s). The major problems associated with conventional PCP’s in deviated and horizontal wells nas been the tubing leaks caused by wear and failures of the sucker rod drive shaft. The new pumping system PCESP does not utilize rod string for the torque transmission but the downhole components are run on standard producing tubing. The PCESP uses REDA two- or fourpole motors, modular protectors, power cable and a flex drive gearbox to reduce the pump speed to operating RPM and drive a progressing cavity pump. We have the ability to monitor the downhole pressure and temperature of the PCESP. Figure 1.15 Bottom Drive Progressing Cavity Submergible Pumping System “4 @REDA 1997, AI Rights ReservedREDA ESP ADVANCED OPERATIONS COURSE Section 2 THE ESP SYSTEM AND ITS APPLICATIONS The basic downhole components of Submergible Pumping System are as follows: the pump(s), intake, protector(s), electric motor(s), power cable and motor flat cable extension Important options include a Pressure -Temperature sensor, and in gassy wells, 2 gas separator and/or advanced gas nandler. ‘Some accessories commonly used in ES? installations are check valves, bleeder valves, motor guides or centralizers, cable protectors, cable clamps, electric connectors and chemical injection systems. 24 Pumps REDA submergible pumps are multistage centrifugal pumps, The type or geometry of the stage controls the volume of fluid that can go through it, and the number of stages will determine the total head (TDH) generated. REDA pumps are manufactured in a wide range of capacities for applications in most common casing sizes. OREDA, 1997, Al Rights Reserved, 15REDA Section? The ESP Sysiem and ts Apocations ‘The stages are "named’ according to the "best efficiency point’ (BEP) flow rate in barrels per cay (at 60 Hz). For example, a pump stage type DN1750 is @ stage, which is most efficient at about 1750 BPD. The letter "N" in the pump name (ON1750) indicates the stage impeller is Ni-Resist, which is the standard material of impellers and diffusers. For special applications, such as highly corrosive environments, handling abrasives, asphaltenes or scale probiems, etc., REDA provides special coatings and alloys for stages, When It is required to pump fluids with very low lubricity, special graphalloy stage bearing systems are available. Absence of the letter “N" in the pump stage type indicates a plastic impeller. For example, an A1200 is a Ryton impeliat pump (plastic) designed to be most efficient at 1200 BPD The AN1200 is almost identical in performance but has a Ni-Resist metal impeller. The diffuser is Ni-Resist in both pumps. This nomenclature is valid for the A, D, G, S, H and J Series pumps but it breaks down on the larger pumps, The M520, M675, N1050, N1500 and P2000 pumps are all Ni-Resist even though some have no "N" in the name. Additionally, these pumps are not named in "BPD" but rather "GPM" (gallons per minute). For example, an M675 is designed to be most efficient around 675 GPM (60 Hz). A housing number such as "10," "40," etc. is simply a predetermined length of housing and this length is common to all pumps from “A” to “J” type pumps. Since different stage types have different stage lengths, each one will nave a different number of stages for a given housing number. Furthermore, even in the same stage type the number of stages contained in @ certain housing size could be different, depending on the pump construction type, such as Floater (FL), Compression Ring (CR), Abrasion-Resistant-Floater (ARZ FL), Enhanced Stabilized-Floater (ES FL), etc. Fixed housing sizes are used to allow common parts to be used (housings anc shafts) among all pumps. The “housing size" designation is different for pumps stages “M" type and larger, where the housing number is strictly the number of stages of the pump. 16 @REDA 1967 Al Rights ReservesREDA ESP ADVANCED OPERATIONS COURSE Pumps - 60 Hz - 3500 RPM Pump Monel Shaft Shaft Recommended Capacity @ 60 Hz [Series - 0.D. Type Max. BHP. Size { BPD) (Mid) 96 Series 0.0. 3.38 400 Series - 0.0. 4.00 513 Series 0.0.5.3 538 Series 0.0. 5.38 562 Series 0.0. 5.62 675 Series 0.0. 8.75 862 Series 0.0. 8.62 950 Series 0.0. 9.50 1000 Series 0.0. 40.00 (Sia tag 4g “sna san ss a) 1125 Series 0.0.11.25 EXD = a ae ‘@REDA, 1967, Al Rights Reserves 7REDA ‘Section 2: The ESP System and ts Appatons Depending on how the stage handies the thrust generated, we have three basic types of construction 1) "Floater" Construction - each impeller is free to move up and dow the shatt as it wants to so it is said to “float” on the shaft In floater type pumps, since each stage handles its own thrust generated in ne stage itself, the only thrust transmitted to the protector thrust bearing will be that which results from tne effect of the differential pressure generated by the pump acting on the top shaft cross area and the weight of the shaft (the force due to the weight of the shaft is not usually significant) 2) "BFL" (Bottom Floater) Construction. The upper stages are compression while the bottom are floaters. This is @ specel way of handling thrust so there is zero thrust on the protector bearing. 3) "Compression" Construction - every impelier is fixed to the shaft rigidly so that it cannot move without the shaft moving. All the impellers are "compressed" together to make one rigid body. Only thrust) due tothe gg oer Call ff tear Protectoy pressure oj — fhe top shaft area, here Floater Figure 2.1 Pump construction type as it relates to thrust angling in a compression pump, all the impeliers are rigidly fixed to the shaft so that if an impeller wants to move up or down, it will take the shaft with it. 18 @REDA 1987 AllRignts Reserved.REDA ESP ADVANCED OPERATIONS COURSE During assembly, the impeller is normally sitting on its lower diffuser due to gravity. There is a small amount of free play in the coupling such that the pump shaft can fall down to where the impellers ride directly on the lower diffusers or on the downthrust washers, if avaliable. O_o, — Impeller is in full down Be EZ positon Dorr nerere! Figure 2.2 Impeller position before shimming When we install a compression type pump it will be necessary to perform a process called the “Field Spacing Procedure”, where shims are installed in the pump-to-pump and pump-to-intake couplings. We will raise" the pump shaft so that the impelier is not allowed to touch the diffuser, or we will raise” the shaft enough to allow the impellers just to sit on the downthrust washer. In some cases, we will allow the shaft to “drop” after final assembly ~ all depending on the type of pump that we are installing. In this way we can insure that all the thrust will be transferred to the protector thrust bearing ‘©REDA, 1997. Al Rishi Reserved 19REDA ‘Secton 2: The ESP System and ms Appieatons \, When shimming 675 Series pumps and larger. which do not have down thrust washers, the shaft is lifted so that the impellers are lifted slightly off of the diffuser. Recommended shatt lift is 1/82 inch for 675 Series pumps and 1/16 inch for 862 and 950 Series pumps. This allows all thrust developed in the pump shaft to be transferred directly to the protector shaft, Impeller is lifted slightly off diffuser. Shims piaced in coupling to raise the shaft Figure 23 Shimming 675 Series and larger pumps. 562 Series pumps and smaller do have downthrust washers. When shimming, we do not need to lift the shaft. Engineering spacing requirements only require that we match flush (ust touch) shaft to shaft. “But when shimming abrasion-resistant-comoression ring pumps ARZ-CR with rulon thrust washers, we will allow the lowest pump shaft to “drop” by leaving a gap of 4/64 inch to 4/32 inch. All additional upper pump shaft(s) must be matched fiush to the lower pump. ‘The actual amount of lift or gap required will vary between 1/16 inch and 1/64 inch and must be defined for each type of pump. 20 ®REDA 1997. A Rights ReservedREDA ESP ADVANCED OPERATIONS COURSE Match the shafis flush, so that impelles just set on thrust washers. \ <= shims > - if required — are “qm. Placed in coupling to match the shaft Figure 2.4 Shimming 562 series and smaller pumps. 2.4.1. Pump Application In applications for very abrasive or corrosive fiuids, low lubricity fluids, scale problems, etc., REDA provides special coatings, bearing materials and metallurgies for stages providing extra protection For handling sand or abrasives, REDA offers a reliable and exclusive line of abrasion resistant pumping systems. REDA’s Abrasion Resistant Zirconia "ARZ” pumps, intakes and gas separators use a patented compliant bearing system. They have hardened Zirconia bearings in pump heads & bases and Zirconia bearings evenly distributed along the pump for radial support. This design greatly increases the in-service time in this kind of aggressive environment. ARZ pumps also incorporate thicker downthrust washers and some have pedestal type lower diffusers. REDA's ARZ pumps are available in two different pump constructions; floater. © and-~=—«scompression _designs. ‘@REDA, 1997. Al Rights Reserved 24REDA ‘Section 2: The ESP System and ts AppicawoNS For applications that expect to see extremely large quantities of abrasives, or intend to operate outside the recommended range, the ARZ compression ning design pump will normally be the best option. In order to accomplish this, the protector thrust bearing musi be properly selected REDA's patented compliant bearing system significantly reduces the impact loads and the chance of damage to the ceramics by using two o-rings between the outside diameter of the ceramic bushing and the inside bore of the bearing support Once in place, the o-nngs are compressed and keep the bushing from rotating. The o-ings also keep the bushing from coming into contact with the beanng support. The compliant bearing system will take more misalignment than a standard rigid bushing because the bushing can tilt slightly on the o-rings. The compliant bushing will line up with the shaft providing the best running position for the bearing. The o-ings dampen the impact loading caused by excessive vibration within the pump that might be seen when & pump is wearing cut due to erosion or corrosion damage. Zirconia Siooy Zirconia compliant bushing (Spacer | mei Figure 2.5. REDA's ARZ Compliant Bearing System 22 EREDA 1997 Al Rights ReservedREDA ‘Secton 2. The ESP System and ts Appieztons For applications that expect to see extremely large quantities of abrasives, or intend to operate outside the recommended range, the ARZ compression ring design oump will normally be the best option. In order to accomplish this, the protector thrust bearing must be properly selected. REDA’s patented compliant bearing system significantly reduces the impact loads and the chance of damage to the ceramics by using two o-ings between tne outside diameter of the ceramic bushing end the inside bore of the bearing support. Once in place, the o-nngs are compressed and koap the bushing from rotating. The o-rings also keep the bushing from coming into contact with the bearing support. The compliant bearing system will take more misalignment than a standard rigid bushing, because the bushing can tilt slightly on the o-rings. The compliant bushing will line up with the shaft providing the best running position for the bearing. The o-ings dampen the impact loading caused by excessive vibration within the pump that might be seen when a pump is wearing out due to erosion or corrosion damage. Zirconia Sleov Zirconia compliant bushing Zirconia compliant isleave rconia sleeve Retaining ring | — [o-ring] [Spacer —_— wes ii Q Figure 2.5. REDA's ARZ Compliant Bearing System 22 @REDA 1907. Al Rights Resarved,i REDA ESP ADVANCED OPERATIONS COURSE The number of zirconia bearings contained in an ARZ pump will depend on the pump housing size, but in general, they are evenly distributed in the pump length, in such a wey that we will have a bearing spacing of approximately 10 inches. ‘The ARZ bearings are located between the standard stage of the pump. The bearing Figure 2.5 Beanng spacing for improved radial support In applications where the full ARZ design is not required, the Enhanced Stability "ES" design is 2 very good option. The ES pump uses the same compliant bearing system as the ARZ pump, but only in the head and base, It does not have ARZ radial bearings between the stages. REDA’s ES design is available in either floater or compression construction, Figure 2.7 ARZ Head and Base @REDA, 1907, Al Rights Reserves. 23REDA Secton2. The ESP Sysem arc as Applications Practical recommendations for selecting the pump for your application: + Bigger diameter is almost always better. You should choose the largest diameter pump that can be run in the casing size Usually the larger diameter pump is less expensive and more efficient, and it will better perform in handling gassy or viscous fluids than one with a smaller diameter. * Choose the more efficient pump. Once the pump series has been defined, you should choose the most efficient pump for the operating conditions (not the lowest number of stages). * Put together the pump string with like pump housing sizes. After defining the number of stages required for the application, if possible, make your pump strings with pumps of the same housing sizes. Even though, in general, the actual pump string used in the application will be determined mainly based on the inventory stock. If the pump(s) required for your application is not a standard pump, ali deviations from the standard must be explicitly defined; for example, high strength shaft, monel trim, aflas elastomers, Redalloy, etc. + Avoid designing "FL" type pumps for operating in up-thrust. A floater pump operating in up-thrust looses efficiency because of the fiuid's ability to re-circulate from the high pressure to low pressure eye area. In addition to efficiency losses, this can promote diffuser erosion in abrasive fluids. + Check Protector thrust bearing capacity When sizing a compression type pump, it the downthrust generated by the selected number of stages at shut-in condition exceeds the HL protector thrust bearing limit, there are several options to consider. One option could be to use a surface pressure control. Another could be to use a BFL or FL type pump, if available. + Fluids with mild abrasives content Floater type pumps are very good at handling mild abrasives. The seal formed by the impeller anc downthrust washers on the lower diffuser prevents material from getting into the radial bearing area. An even better way to increase the reliability of the system ‘would be to use an enhanced stabilized “ES’ pump coupled to an ARZ intake. 24 @REDA 1997 All Rigs ReservedREDA ESP ADVANCED OPERATIONS COURSE * Fluids with sand and other abrasive content ARZ pumps and intakes should be used in applications where the pump is expected to handle 2 considerable amount of abrasives. Compression ARZ type pumps are preferable because the thrust is handled by the protector thrust bearing, wnich is immersed in a very clean oil environment. Always use ARZ intake sections in conjunction with ARZ pumps. «Unknown well productivity ‘The expanded operating range of the compression ring type pumps is the Dest choice in applications where the well productivity is unknown, or if the pump sizing has been done using an “assumed” well productivity. Compression ring pumps are available in standard, £S and ARZ construction. The protector thrust bearing selected must have enough load capacity * Free gas at the pump intake Gas occupies 2 lot of room in the pump stages, so a larger stage will be needed to maintain volumetric efficiency. Compression type pumps should perform better than floater types because the total volume that each stage will handle will be lower as the pressure increases, and, for this reason, the thrust in every stage will be different. = Special Applications For special applications dealing with extreme conditions of severe abrasion, corrosion. fluid with very low lubricty, etc., there are special pumps, with special stages, bearing materials and/or coatings available to reduce the accelerated wear. Consult REDA’s Application and Special Projects Engineering Department. 2.2 Intake Section ‘An aim when sizing when sizing an ESP system is to produce the maximum amount of oil with no compromising the performance of the ESP system. A factor that degrades the system performance is the presence of free gas in the pump stages. Depending on the amount of free gas expected at design conditions in the pump intake it is determined what type of intake section to use. It can be an intake (Figure 2.8) or a gas separator (Figure 2.9) Even though there are stil available standar intakes with metallic bearngs, are stil available, the use of ARZ construction is more common every day. REDA Engineering recommends that only ARZ Intakes and Gas Separators be used, because the reliability of the unit will be greatly enhanced by the durability of the compliant zirconia bearing system, (OREDA. 1997. Al Riohis Reserved 25REDA ‘Sexton 2 The ESP System and ns Apprsanens This is especially true if we take into consideration the fact that the protector seals will be protected from vibrations that might occur if using standard Intakes or Gas Separators, Figure 2.8 ARZ Intake 2.2.1 Application of Intakes and Gas Separators ‘A Gas Separator is still an intake, but with some special features designated to keep free gas from entering the pump. Gas separation and gas handing has been improving continuously. Static gas separators use reverse direction of fluid to cause more gas to move up the annulus allowing fiuid into pump. For this reason they are also called Reverse Flow gas separators. Since they do not deliver effective work to the fluid they are also known as Static gas separators. (figure 2.9.2.) 28 (©REDA 1997, AllRignts Reserved,ESP ADVANCED CPERATIONS COURSE (b) Dynamic KGS, GRS, GRS-ES (c) Dynamic Vortex Figure. 2.9 REDA Gas Separators Where the fluid enters the gas separator the direction of flow is inverted, diminishing the amount of gas pulled by the liquid that gets into the gas separator. Some bubles continue their path by the annulus and some enter the gas separator but break apart again and continue going upwards in the annulus between the housing and intemal shroud of the gas separator. Finally the gas which did not got separated to the pump with the liquid. (Figure 2.10) Figure. 2.10 Reverse flow Gas Separators GREDA, 1997 ARights Reserved 27REDA Section 2 The ESF Symem ands Appleations ‘As opposed to tne static gas separators, dynamic gas separator do deliver effective work to the fiuid in order to improve the gas separation in the gas Separator. To visualize the operation of a dynamic gas separetor we can distinguish three intemal sections: Pressure increase chamber, separation chamber and by pass. In the first section the inducer increases the mixture pressure. In the second section the phases are separated due to centnfugation, Being tne liquid phase heavier, it is expelled towards the internal wall of the gas separator while the Gas phase concentrates towards the shaft since itis lighter. On top of the gas separator the fluid are redirected by the crossover. Separation efficiency is not an easy number to predict due to the number of variables involved. Natural separation alone might vary from as low as 5% to as high as 70% depending on the fluic makeup. velocities, flow pattems, equipment dimensions, ete. Normally we would use rule-of-thumb estimates like the following based on experience: Separator Type | Separation | Gas Ingestion | Efficiency | Percentage | Standard intake 0-20% | 80-100 % rse Flow G.S. [25-50% | 50-75% Rotary G. 5-20 Rotary gas separators have a limitation in their application because the inducer is mounted in the middle of a large bearing span, in an area with a rotating mass of very high inertia, wnich may be radially unbalanced. This imbalance can be due to the inducer being filled with a non-homogeneous fiuic of vanable specific gravity. or it may be nor-uniformly eroded by abrasives with time, or because of a combined effect. In an effort to minimize this effect, REDA has developed the *RS-ES Gas Separator, which significantly reduces the mass of the rotating element, and decreases the radial bearing spacing maintaining the same separation efficiency as the old longer design. The *RS-ES and Vortex Gas Separators incorporates three ARZ compliant Dearings in its standard construction Follow some practical recommendations that could be useful when selecting the pump for your application. ‘Testing conducted at Tulsa University in Oklahoma indicated that all types of gas separators have definite flow ranges where they are effective and other flow ranges where they are not. The TU tests agree with REDA's recommendations. 28 @REDA 1907. Al Rigne ReservesREDA ESP ADVANCED OPERATIONS COURSE Permissible Flow Ranges {in bpd total fluids at 60 Hz) TYPE MAXIMUM FLOW | MAXIMUM FLOW —_| MINIMUM FLOW (EFFECTIVE) (PERMISSIBLE) ‘398 Series ARS (338 Series) | 2440 BPD 250 BPD 387/400 Series 65GS 7750 BPD 4300 BPD NA RF 2500 BPD 6000 BPD NA CRS, DRS-ES 4000 BPD 500 BPD 513 / 538 Series 74GS 3600 BPD 9000 BPD NA RF 4800 BPD 42000 BPD NA GRS, GRS-ES 7000 BPD 1000 BPD vcsa $20-90 __| 9000 BPD NA Recommendations for selecting the Intake section: * Always use ARZ type Intakes or Gas Separators. Remember that gas (vapor) is not a very good lubricant. 2 Check Gas Separator flowrate limits A gas separator shouldn't be picked just because it is of the same size (series) as the pumps(s). When choosing the gas separator, verify that the flowrate to be handled is inside the specific gas separators flowrate range. * Use a Rotary Gas Separator only if you need it. One intrinsic characteristic of a Rotary Gas Separator is that the inducer is mounted in the middie of a large bearing span. A Rotary Gas Separator tends to experience more bearing wear, probably more often, than any other single type of equipment. If the gas separation necessary to produce the well can be reached by using a reverse flow gas separator, the overall system reliability will be better. Note that @ redial flow type stage can handle up to approximately 10% free gas and @ mixed flow type stage can handle up to 20% free gas. Keep the system as simple as possible. If a Rotary Gas Separator is required, the power required to operate it must be considered when sizing the motor. Conservative horsepower velues to consider for *RS and *RS-ES gas separators at 3500 rpm follow: @REDA, 1997. All Rights Resend 29REDA ‘Sexton 2 The ESP System ara ts Appheations Rotary Separator [HP required @ 60 Hz Sees 338, ARS. 4.75 HP. Series 400, DRS. 1.25 HE ‘Senes 540, GRS [7.00 HP, Series 535, VGS $20-90__ | < 5.0 HP. 2.3. Motor The basic principles of design and operation of ESP motors ate the same 2s normal electric surface motors, ESP motors are two-pole, three-phase, squirrel cage induction type, which run at approximately 3500 rpm on 60 Hz frequency and 2917 rpm on 50 Hz frequency There are some differences in the way the REDA motor is designed and manufactured, because of the unique geometry required to fit inside a very small casing. The motors are filled with 2 highly refined mineral oil that provides dislectric strength, lubrication for bearings and good thermal conductivity to dissipate the heat generated to the motor housing. The heat is then transferred to the well fluid moving past the exterior surface of the motor. The thrust bearing of the motor is designed to carry only the load of the motors rotors and shat. The ESP motor can be used with AC current of 60 or 50 Hz. The only difference between 50 Hz and a 60 Hz motor is tne nameplate REDA motors are available in five different series: 375, 456, 840, 562 and 736 for applications in wells with casing ODs of 4.50", 5.50", 6.625", 7.00", 8.625" and larger, respectively. The motor performance (speed, power factor, efficiency, amperage) changes with tne actual percentage of motor load relative to the nominal horsepower. There are performance curves for each type of motor. 2.3.4 Motor application Different types of REDA motors are available to meet to the specific operating conditions for each application. The horsepower's range from 7.5 HP in 4.5" casing to 1170 HP in 7° casing and larger. When determining the motor HP to be used, there are some considerations that need to be done if the system will be operated with @ switchboard and if the workover procedure 30 @REDA 1997, AU Rights ReservesREDA ESP ADVANCED OPERATIONS GOURSE includes killing the well with high gravity fluid, If the well fluid has a low specific gravity, the operating horsepower may be much less than the horsepower required for unloading tne control fiuid. It may be necessary to up-size the motor to allow for unloading the well Pothead Cavity ‘<— Thrust Bearing Fill Vave Insulator Tube ans Rotor Rotor Besring San ane Prom Lavs Ke) Pree Winding Hollow Shaft Sain Motor Oil Fil Vave 2.9/8" EUEBOX Singe Motor (562) UT Motor (562) Figure 2.11 Cross section of a REDA ESP motor ‘After determining the horsepower required to operate the ESP (pump(s) + gas separator + AGH + protector), considering all the operation concitions, a motor with at least this power must be selected As it can be seen in the REDA catalogue on the following page, there are several motors that can be used for a required HP. (OREDA, 1997. Al Righs Reserved 31REDA ‘Ssoton 2: The ESP system end fs Appicatons REDA Motors range at 60 Hz et Gey eal acces BPs BEA ester ea) SK 30-127 (127 5 sx 30-127 127 5 Sk 425-150 475-300 300 2 Sx 12.5- 150 175-300 300 2 MK 10 - 720 140-240 © 240 2 Mx 40 - 120 140-240 © 240 2 PK 40 - 720 140-240 © 240 2 PX 40 - 120 440-240 © 240 2 SK 28 -250 300-750 750 3 sx 25 -250 300-750 750 3 MK 20 -200 240-600 600 3 Mx 20 -225 240-600 600 3 PK 20 -200 240-600 600 3 PX 20 -225 240-600 600 3 Dominator 30 - 450 300-750 1170 3 738E___200-340 400-998 ___9s9 3 NOTE: Contact REDA engineering for information about applications of 582 molors over TEOH>. Even though in certain field circumstances, the motor selection may be limited to picking a motor available from the warehouse stock, some considerations need to be made in the general process for selecting the appropriate motor for the application. ‘The process of selecting the motor is an iterative process which includes: * Motor Series, Motor Type, ‘© Motor contiguration, Voltage and Amperage ano special requirements Actual Motor performance & Operating Temperature. + Re-select motor, if necessary. 2 Motor Series In general, just as in pumps, select the largest motor diameter that will property fit in the hole. Larger diameter motors are less expensive. ‘The larger the motor diameter, the more horsepower per unit length can be developed. Larger motors can go to higher horsepower without the need for tandem connections ~ simpler systems are better. 32 BREDA 1997. Al Rights ReservedREDA ESP ADVANCED OPERATIONS COURSE Motor Type With the development and introduction of new types of REDA motors, the classic designation of REDA motors has been changed. Now there is a new nomenclature which provides the user with important information for the application of the motors, The motor type is designed with two letters: © The first letter is a code which provides information about the motor rating 'S = Standard (250°F BHT - fixed horsepower), N = Intermediate (300°F BHT - conservative fixed HP) H= Hotline (500 °F Internal Temperature - fixed HP) P= High Performance (250°F BHT - conservative fixed HP) R= Optimum (400 °F Internal Temperature - variable HP) REDA Motor Bottomhole Temperature Limits 20°F 225 °F 260 °F 275°F ——-300°F 375 SK, 458/540 SK, SX, PK, PX |4sers40 MK, NX 1562 Dominator 738 © The bottom hole temperature should be used only as a first approach in selecting the motor. All motor HP ratings are based on ‘1 foot per second minimum flow of water past the motor. Lower flow rates or fluids such as oil can lower the effective HP rating. There may be a motor running extremely hot in @ relatively cold well because of high load and/or low flow. Low velocity conditions cause very litle or no heat to be removed from the motor housing, Always use the actual motor temperature rather than BHT to verily if the motor is appropriate for the application. Software like Heatrise or SubPump™ model the actual moter operating conditions, providing a very useful value for the motor operating temperature under the specific operating conditions. @REDA, 1997. Al Rights Reserved 33REDA Secton 2: The ESP System and ts Appieatons @ The second letter is a code which provides informaticn about the insulation K = Conventional winding and varnish, X = New patented winding material, without varnish. The following table correlates the new and old motor designations: * Motor Configuration, Voltage and Amperage and Special Requirements Based on the horsepower required for the maximum anticipated load, the motor series and the motor type selected, we will know if it will be necessary to use a single section or tandem motors. Just as with pumps, we need to consider the motor metallurgy if we expect to have corrosives or continuos acidification treatments in the well Now we should look at the volts and amps. For any given HP there will be several voltages and amperages available. 6OHZ SOHZ Ratings Carbon Steel Redalloy cL Wt MK MK {HP Voit Amps Type (Ft) (Lb.) Part Number | | Part Number 700 a5 S157 1007 7089846 7090943 UT 158 4090216 4081313 2S 15.7 ‘1007 1089853 4090050 UT 158 sos0224 3091321 120 5 3S 185 1194 7089861 7090968 UT 185 4090292 +0913 | cT_ 188 1090372 1091479 | 35 S185 1198 1089879 7080876 UT 185 4080240 4081347 740 eS 21.2 1380 1080887 1090984 ur 212 1090257 41091354 | cT_ 215 1090380 1091487 | 685 S242 1080 1089085 080992 ur 212 1090285 1081362 | CT 215 1020398, 1091495 Ws S212 1260 1089303 1081006 UT 242 4090273 41094370 34 ‘OREDA 1987. Al Fights ReservedREDA ESP ADVANCED OPERATIONS COURSE For any particular horsepower, the product of the volts and amps will be essentially constant. For example, in a particular HP if we have @ 1000V, SOA motor, @ 2000V moter would be 25 amps and a S00V motor would be 100 amps. In other words, KVA is constant High voltage motors (single motors) are no more or less efficient than low voltage motors ‘The reason to have three or four motors of the same HP but different voltage is that lower voltage means higher current, which results in higher voltage drop in the power cable Even though the motor efficiency does not change, the overall system efficiency will decrease with higher amperage. if the amperage is too high, the motor may not be able to start due to excessive cable voltage drop. The voltages of submergible motors (1100, 1300, 2100, etc.) are aifferent than the standard surface voltages and have been chosen because ESP motors have to contend with a very long length of power cable, which surface motors do not in determining motor voltages, we are really limited by surface equipment. Motor control panels come in certain voltage ranges, such as 60OV, 1000V, 1500V, 240GV, etc. Motor voltages are selected assuming a lencth of cable such that the total voltage (motor plus cable loss) will fall just below one of the panel ratings. In general, the higher the voltage the better, but it cannot be so high that we exceed the control panel rating, Higher voltage motors require smalier gauge wire end very low HP motors simply cannot be wound at very high voltages because the wire would be too small to work with. In summary, it is generally preferable to select the motor with the highest voltage (low amperage), taking into consideration the power cable and surface equipment. If additional horsepower is required over what can be achieved in one section, a CT or LT motor can be added to @ UT motor. When putting mare than one motor together in tandem combinations, always keep the sections the same HP and voltage. For example, 2 300 HP ‘540 motor should be made of two 150 HP motors rather than something like e 200 HP and 2 100 HP. It is possible to mismatch motors if the wire size is the same in each winding, but this should be avoided and never done without consulting engineering When using two motors in tandem, we double the HP (add the two HP's together). We also double the voltage but the amperage remains the same. With three motors we triple the HP and voltage but the amperage still does not change. (@REDA, 1097. AllRignts Resenee, 38REDA Secton 2, The ESP system anc ts Appieatons For example, a 140 HP, 1299V, 69.5A UT motor coupled to a 140 HP, 1299V, 69.54 CT motor would give us @ 280 HP, 2598V, 69.5A motor. Always take care when adding motors together so that the total voltage does not exceed the system limits + Motor Performance & Operating Temperature. With the aid of software like SubPUMP™ we can get the actual motor performance, fiuid velocity and the motor operating temperature. Compare the operating temperature with the limits and, if we are exceeding the motor temperature limits, we may need to ra-select the motor. REDA’s DOMINATOR 562 motors have variable ratings and feature a new rotor and stator design. The 562 motor provides a broad operating range which allows the user to select how he wants to load the moter, Regardless of how the motor is loaded, there will be very litte change in motor performance. Operating at light loads will give very iow temperature nse which will ultimately translate into @ longer run life. Operating at very heavy loads will sacrifice some in ultimate run life but may be more economical for the end-user, depending on the performance objectives, This allows the Application Engineer to determine, on an individual basis, what the ‘optimum rating for the 562 motor for any given application will be, based on the customer's performance objectives, 2.3.2 “Ratin! of ESP Motors The motor performance curves show us how the performance of the motor will change as we vary from the full load rating If we look in the REDA catalog we will find several pages of motors which give the horsepower rating and break down the various sizes into several voltages and amperages. Let's take @ 100 HP moter MK type as an example. What makes a 100 HP motor a 100 HP motor? 36 EREDA 1997. All Rights ReservedREDA ESP AVENGED OPERATIONS COURSE REDA '540 Series Motors - MK Type BOHZ $OHZYRatings Carbon Steel Redalioy cw MK MK 2 Vor Amps Type (Ft) (Lb) Part Number | | Part Number 00 ES 1305 Ea STS Ste? 1007 T0884 yo30343 Ee or ise Tess | | toatsis_| 2313 aS 187 1007 7089853 7030850 ur 158 1090224 4081321 120 115 5 S185 119 71088861 "1090958 oes ut 185 1090232 1031339 | ct 188 4030372 3031479_| 2270 Bes S 185 1194 1089879 1090976 | ‘ = UT 185 1090240 3091347 740 mr eS 2iz 1960 1088887 030864 | UT 212 1090257 1091354 | 5 . cr__215 41030280 41091487 | 8 es S 212 1380 1039895 09082 | e ut 212 1030285 1091362 - ct 215 +1080388 1091485 Biot WS S212 1380 “1089802 091008 : ur 212 1090273 1091370 ‘OREDA, 1997, Al Rights Reserve, 37REDA ‘Section2:The ESP System ana ts Appeaieons 60 Hz Motor Performance Curves 540 Series MK & MX Type 3600 FL] 3550 Speed RPM 3500] 3450) apo) 90 80 70 60 Percent 50 Efficiency 40 30 20 10 90) 0} 70} Percent 5 1) Power Factor | 40 20) Percent Nameplate Power and Amperage wo 3 4 os 0 oO 8 90 100 Percent of Nameplate Load Figure 2.12 Motor performance curves 540 Senes MK & MX type 38 @REDA 1097. AURighte ReservedREDA ESP ADVANCED OPERATIONS COURSE In this industry, conventional rating systems give a nameplate horsepower to the motor based on some assumptions, which typically include bottom hole temperature and fluid fiow rate past the motor. In those applications where little is known about the well conditions, the motor rating must be selected assuming the “worst-case” conditions. It gives a "safe" rating for the motor, In reality, a motor does not usually deliver the exact horsepower shown on the namepiate. Either the pump horsepower does not exactly match the nameplate or the surface conditions may not allow for ideal nameplate conditions. ‘The motor will put out exactly as much horsepower as the pump requires — no more and no less! What happens to the motor if it is not operating at the exact nameplate horsepower? A little or a lot, depending on how far away from nameplate conditions it settles. Motors are designed to be "most efficient’ and have an acceptable speed and power factor at the “design point". This point is where thay are typically rated. Straying from the design point will usually sacrifice efficiency or speed, ‘As long as the motor does not exceed its physical capabilities, there is no real harm, In fact, it is common practice in the industry to “overload” a motor, or otherwise say that there is 10% additional horsepower available in very cool wells, Even with conventional ratings, a "fixed" horsepower is not really enforced in practice Sometimes it's necessary to underioad (DE-RATING) the motor in hot well applications and sometimes we can use more horsepower than stated in the nameplate (RE-RATING) What happens when we place additional load on the motor? In order to generate the additional HP it will slow down. 260 2664 Speed RPM 20 34st 3404 wo 0 3 4 6 6 70 @ 99 100 Percent of Nameplate Load Figure 2.13 Motor Speed-load curve 540 Senes MK & MX type ‘OREDA, 1967. Rights Reserves 39REDA Section 2 The ESP Sysem ard ts Applications {twill also build up adcitional intemal heat and run hotter. Since the motor is not 100% efficient, some of the horsepower input is lost to heal. Let's say, for example, we have a 100 HP motor with an efficiency of 87% driving a 100 HP pump, The power delivered to the motor will be: HPocrpur _ 100 HP host = Efficiency 0.87 ~ 1'SHP In this case, the well fluid will have to remove 15 HP (115 - 100HP) of eneray (heat) in order to cool the motor. If the same motor were loaded with a 125 HP pump, assuming that the efficiency will femain constant at 85%, the HP delivered to the motor would be: HPourur _ 125 HP eur = Efficiency ~ O87 = 144HP This means that the motor must dissipate 19 HP (144 - 125HP) in the form of heat to the fluid passing over the housing. Higher horsepower output means higher heat generated, which means that the motor must dissipate that extra heat in the same size space. The higher loaded motor will have to dissipate an additional 4 HP in the form of heat. Since the motor cannot increase its surface area, the only way to Gissipate more neat is to nave @ higher temperature differential. Since the well fluid temperature cannot go down, the motor temperature must goup. In a standard application, the surface voltage is fixed and the amperage changes as the load on the motor changes. We use this information in the form of an amp chart to see what is happening with the motor downhole. We can very easily anticipate this relationship by simply looking at the equation for motor horsepower. _ Volts * Amps *1732 *Eff."P.F. HBr ag Note that, if everything else is fixed, the amps will have to increase if the horsepower does and this should be @ “linear” relationship. In realty, this reletionship is not linear since power factor and efficiency are not truly constant and the more they vary — the greater will be the change in amperage. (One problem with increasing the amperage too much is that higher amperage will give us greater copper losses in the motor winding which is not good for efficiency. We can 40 [@REDA 1997. All Rights ReservesREDA ES? ADVANCED |ATIONS COURSE conclude that @ way to keep the rise in amperage in check, is by increasing the voltage with increasing horsepower, But as in every thing, there will be a practical limit to how far this can continue. We can look at the laminations to understand the basics of this concept, The figure 2.13(a) snows an example of what the flux lines might look like for one phase winding based on a moderate loading of the motor, ee oh SS Se ee Figure 2.14 Flux ines for one phase winding with moderate and heavily load If we place more load on the same motor, we get many more flux lines (figure 2.13(a)) required to generate the necessary horsepower, i.e., we increase the flux density induced in the laminations. But if we keep raising the voltage and amperage, we will eventually reach a point where we have all the flux lines we can handle — this is called SATURATION. Any more horsepower beyond this point will severely overheat our motor. Another practical consideration on rating a motor is the motor speed, We know that the motor will slow down with load, If the motor speed is too low, we will lose Pump pertormance so we must set the HP at a point where the speed is acceptable. REDA 1097 AlIRohts Reserved aREDA Becton 2: The ESP System ard Applications Torque 0 20% «= 40% = 60% 80% — 100% == 120% Speed (% of No-Load Speed) Figure 2.18 Speed - Torque of typical REDA Motor ‘One of the most important considerations in rating the motor is temperature. During motor ‘operation, heat is generated in the windings which must be dissipated by the fluid flowing past the outside of the motor. The maximum intemal temperature of the motor will be partly determined by the physical components such as insulation, solders, oil, etc. The standard REDA motor is limited to an internal motor temperature of less than 400°F. In normel operations there are some common factors that can cause the motor temperature to exceed the motor temparature limit, and must be avoided, These factors are: well pump off, pump gas locking, locked pumps, loss of heat transfer cue to ‘Gepositions on tne motor housing, tubing leaks, fluid recirculation, loss of flow due to a closed valve and motor overloading. Another limiting factor will be the temperature differential. As the motor heats up, the ‘components expand at different rates because not all the matenals are the same. Even If the motor were all one matenal, expansion would vary since the intemal temperature changes within the motor itself, as you can see in figure 2.15. The motor is designed with certain tolerances to allow this thermal expansion, If too much expansion occurs (such as with overheating), tolerances might be exceeded and could result in bearing failures or other damage 42 (CREDA 1967, All Rights ReservesREDA ESP ADVANCED OPERATIONS COURSE Casing |.D. Potential Hot Spot Motor Housing Stator Winding Th sete ‘ot spor'temperature and may or may not be in cemer ct shaft Tw nthe winding ompersture Ts is ne moter shin temperature Too. tsthe bulk hud temperature Figure 2.16 ‘Typical temperature profile in a submergible motor Al of these factors go into setting the ratings for motors. The 540 senes SK motor and PK type (formerly 90-O and 91 type respectively) motors are physically identical. The only difference is the HP per rotor rating. The SK is based on 42.5 HP per rotor and the PK type is 10.0 HP per rotor. The PK type is more efficient and runs cooler but takes more motor to do the same job. (OREDA, 1007. Al Rights Recon. 43REDA Secton 2: The ESP systemang ts Appleatons 2.4 Protectors ‘The protector serves as a vital link in the entire assembly. If itis not properly applied, it can reduce the overall running life of the system. Histoncally REDA has offered different types of protectors in many different configurations to meet various application requirements. The labynnth type 66L. protectors, and the positive seal protectors PFSB (pre-filled single bag) and PFDB (pre-filled double bag) nave been used successfully around the world for decades; they and combined configurations of them, are still widely used today. The use of the new REDA "Modular’ protector system is becoming more common, The purpose of the modular system is to give the customer the ultimate in flexibility in applying protectors while maintaining all the advantages of adcitional seals, etc., without duplicating unnecessary parts. The system is actually very simple. It consists of a head, base, shaft, seal section (either labyrinth or bag type] and a “seal body" which, with the repositioning of a few valves and plugs, aliows the protector to be assembled in any one of dozens of possible configurations. Fig 2.16 shows some of the possible combinations. Regardless of wnat configuration is chosen, the protector function is essentially the same ‘The naming convention for modular protectors is simple and easily shows how a protector is designed, In naming, always start from the top and move downward, ‘The protector is named for the type(s) of seal chambers used and how those chambers are connected (ie., in “series” or “parallel’), ‘The "L" is for labyrinth chamber and the "B" is for the bag type chamber. As for the connection type, "P" means PARALLEL and "S" means SERIES. In some cases, there will be an "HL" on the end of the name. This simply means that this is a "high load” protector which employs a high capacity thrust bearing in the base. Given this convention, for example: A BSBSL-HL protector is a three chamber design with a bag cn top connected in series to another bag which is then connacted in senes to a labyrinth chamber. Also, it has a high load thrust beanng a EREDA 1997 All Rights ReservedREDA ESP ADVANCED OPERATIONS COURSE Head Chamber m2 Seal Body BSBSL_LSLSB_BPBSLSL Thrust Only Figure 2.17 ‘The REDA modular protector system. Moduier protectors are available in 400 Series (4.00 "), 540 Senes (5.13 ") and 562 Series (6.62"). Both the 540 and 562 series have the same top and bottom flange and can either be run on a 540 or 562 motor without adapters, The 400 Series is designed to be run on the 456 Series motor without an adapter. The protector has three primary functions: ‘= To keep well fluid out of the motor. = To cany the downthrust developed in the pump. «To couple the torque developed in the motor to the pump via the protecior shat, ‘@REDA, 1007. Al Rights Resend. 45REDA Sector 2 The ESP System and ts Apaioavens ‘One of the main functions of the protector is to keep well fluids out of the motor where they could potentially do harm. It works by simply keeping the pressure on the inside of the unit the same as the pressure on the outside of the unit, regardless of what the extemal pressure is. Since the bottom of the protector is open to the motor, the motor pressure remains the same as that in the well annulus around it. By maintaining a negligible pressure difference, there is no tendency for the well uid to penetrate into the moter. To accomplish this, the protector must aliow “communication” with the well fluid in some fashion. There are several Protector designs which allow the well fluid and motor fluid to transfer pressure to each other without any actual mixing of the two fluids. One such protector type is the "Labyrinth" type. Top of unit is in contact with well fluid via the pump intake The fluid level can rise and The heavier gravity well fluid is sep- arated by gravity. A"U-tube” design keeps the heavy well fiuid from going | lower into the unit fall as keeping the thrust needed to | bearing and motor balance the | full of clean oil, pressure. Bottom of unit is in direct contact with motor head Figure 2.18 Labyrinth type protector The labynnth design uses the difference in specific gravity of the well fluid and the motor oil to keep them apart, even though they are in direct contact. With this design, the motor oil and well fluid are in direct contact because the protecior is open at the top. The labyrinth 48 (@REDA 1997, AlRights ReservecREDA ESP ADVANCED OPERATIONS COURSE chamber is isolated from the shaft rotation by the shaft tube so that no mixing will occur by the shaft rotation. There will be cases where a labyrinth type chamber will simply not work. In cases where the wall fluid is lighter gravity than the motor oil (Le.. approximately 0.85), the motor oll will go to the bottom of the chamber rather than the top, causing the motor fluid to be displaced bby well fiuid pretty quickly. If the well fluid is about the same or lighter gravity than the motor fluid, this type of protector should not be used. Figure 2.18 Labyrinth type protector with well fluid lighter than motor oil Labyrinth protectors also will not work in horizontal or highly deviated wells. The gravity separation design requires the unit to be mostly upnght. This protector can operate in some amount of deviation but the expansion volume is somewhat recuced. Many times the labyrinth protector is "checked" in the field to determine if water got into the bottom of the unit. If this is cone, aways do it bafore the unit is laid down on its side. Once on its side, water initialy in the bottom of the chamber may redistribute itself since the U-tube restriction is effectively removed. Figure 2.20 Contamination of a labyrinth protector in horizontal position (©REDA, 1967. Al Rights Record 47REDA ‘System anc ts Appleatons For applications where the well fluid and motor oil gravities are similar, or where a well is highly deviated, a different protector design uses a "positive seal" or “bag” chamber to physically separate the two fluids The bag is made of a high temperature / high performance elastomer which can withstand the harsh downhole environments typically encountered. ‘The bag keeps the well fluid on the outside and the clean motor oll on the inside. When the motor oil expands or contracts, the bag simply flexes to accommodate the necessary volume change The bag is free to change volume as necessary and yet keeps the two fluids physically seperated at all s| times. Figure 2.24 Positive seal or “bag” type protector ‘The positive seal protector offers a great deal of flexibility and is useful in a wide variety of applications. One area where care needs to be taken with this type of protector is with harsh well chemicals as may be experienced with a treatment program. As with any oil field elastomer, care must be taken to ensure that the rubber will not be damaged by anything it will encounter in the well. If the positive seal is breached, the motor can easily be contaminated with well fluid. Another function of the protector is to absorb the thrust generated by the pump. The protector thrust bearing gives a very large surtace over which to absorb thrust. In addition, it does so in a nice clean oll environment which greatly prolongs the ESP unit life ‘Take care to select a protector series which has a thrust bearing rating greater than the maximum thrust the pump will generate 48 ‘SREDA 1007. Al Rich ReservedREDA ESP ADVANCED OPERATIONS COURSE Upthrust bearing Thrust Runner Downthrust bearing Figure 2.22 Protector Thrust Bearing section ‘One other function which the protector carries out is transmission of the motor torque to the pump, since it is physically located between the two. Although this may seem trivial, in the selection process we need to be certain that the protector shaft is capable of delivering the full torque required without exceeding its yield strength, which could result in a broken shaft A series connection is simply one inline after the other, just like series resistors in an electrical circuit. For well fluid to enter the lower chamber, it must completely displace all the oil in the upper chamber first. Having two bags in senes means the lower bag is 2 fecundant seal to tne upper bag and is there as “insurance” in case the upper bag faiis for some reason. “Series” systems provide no additional expansion capacity. ‘Two bags in parallel, on the other hand, do double the available expansion volume. This is useful in higher horsepower applications (larger motors hold more cil) where the natural expansion and contraction might exceed the capacity of one bag. If only one bag is used and the capactty is exceeded, the unit will allow well fluid penetration. Two bags eliminates this possibility. While there are many possible permutations, it is never possible to connect two labyrinth chambers in parallel (LPL). Nor can a bag be connected in parallel to a labyrinth chamber (LPB or SPL} The allowable combinations are: LSL, LSB, BSL, 8SB and BPB OREDA, 1967. All Rights Reserved 49REDA Secton2; The ESP System and ts Appbcatons 2.4.1, Protector Operation Cycles With this basic understanding of how the protectors are put together and how bath the labyrinth and positive seal (bag) sections operate, we will now look at the operation cycle, which consists of the following steps: 2.4.1.1. Servicing the Protector Prior to installation. All modular protectors come "pre-filled" with clean motor oil from the factory or repair center. Dunng field assembly, the Field Service Technician will add oil to “top off” the protector to replace any oil lost during the assembly process. Because of the complex design of the protector system, the filing procedure is exacting and should only be done by qualified personnel. If proper procedures are not followed it is possible to trap air inside the protector which can potentially cause a shaft seal failure dunng operation. This, in tum, may damage the protactor and motor. Figure 2.22 illustrates the oil flow path during filling a LSB type modular protector. The vent plugs are replaced at intervals to ensure that any air that may still have been trapped inside is removed from the unit. Figure 2.23, Oil flow path during filing 2 LSB type protector Since the protector is serviced at the surface, the motor oll temperature will be the current Outside Ambient Temperature (OAT). 50 ‘GREDA 1967, All Rotts ReservedREDA ESP ADVANCED OPERATIONS COURSE 2.4.1.2, System Landing at Setting Depth, Oil Expands. |At this point the protector is lowered into the well and will gradually warm up to the Bottom Hole Temperature (BHT). Depending on the temperature rise, the motor oil in the system will begin to expand until the setting depth is reached. Let's say the volume expands 9%. Given that the system can only hold 100% volume, the system will dump the 8% overboard. This oil will never be recovered. 2.4.1.3, Motor Operates, Oil Expands More. When the system is started for the first time, the intemal heating of the motor will increase its temperature until the motor reaches its operating temperature (MOT). This will cause an additional expansion of cil, typically another 2-4%. But again, the system can only hold 100% volume, The 2.4% oll expanded will again be lost to tne well bore. 2.4.1.4. Motor Stops, Oil Contracts ‘The system will run for some time and then be switched off. Over the course of 2-4 hours, the motor cil will contract as it cools by the same amount it expanded when the motor was tumed on. Now the system is only 86 - 98% full of motor fluid so the protector will then have a small amount of well fluid in the first chamber making up the belance of the volume. If the chamber is a labyrinth, the well fluid will travel down a tube to the bottom of the chamber where it will stay due to the differential in specific gravity of the motor fluid and well fluids. This will be the first fluid expelled when the motor is switched on in the future. If the first chamber is a bag, the bag will be drawn inward by the collapsing motor fluic. The partial vacuum will draw well fiuid in around the outside of the bag where it will stay because of the positive barrier of the bag 2.4.1.5, Motor Operation Cycles. ‘As the unit cycles, the system can loose additional motor oil due to several reasons: « Intemal motor temperature can increase * Spectfic gravity fluctuations can increase the load on the motor, raising the temperature Gases can be cissoived into the motor oil and expand during low pressure cycles + Emulsions can form in the chambers, etc. PREDA 1997, Al Rights Reserve: 51iL REDA Secton 2: The ESP symem and ms Appieatons i All of this, added to the cycling, can cause additional motor fluid to be lost. If the system has a bag, the bag will not totally collapse until the system has expelled an equal amount of motor fluid that can be contained inside of the bag to start with 2.4.1.6. Unit is Pulled Out to Surface, Oil Contracts. When the unit is pulled, the motor oil will cool once again to surface temperature (OAT). Depending on the previous well cycling and BHT, the amount of oil shrink can exceed the capacity of a iabyrinth chamber or bag, causing evidence of bag tearing and well fluid in lower chambers. Most bag damage is caused during system removal from the well, not dunng down hole operation 110% 100% E 2 g 5 | 80% OAT BHT MOT Temperature Figure 2.24 Protector Operation Cycles Now we will look at three examples to see how the chambers work in conjunction with each other in the protector operation cycle’ 52 PREDA 1907, Al Righs ResarvesREDA ESP ADVANCED OPERATIONS COURSE LSB Modular Protector Motor operates and oil ‘expands 4 to} 100% 5 8 S © 80% + “OAT BHT MOT Temperature Figure 2.25 Operation cycles in a LSB type protector @REDA, 1097 All Rights Reserves 53REDA ‘Sexton 2; The ESP System and ts Applcatons . 2 o 2 a L Ss 5 3 o = a wn a i ae alee | Unt Motor operates Motor stops Motor cyces-on — Motorcycies- | | instaiiea and oil and oil anc oll oftand off | | inwell expands contracts ‘expands: contracts | | | 110% 3 8 se Oil volume 80% qo OAT BHT MOT Temperature Figure 2.26 Operation cycles in a BSB type protector 54 @REOA 1967, Al Rights ReservedREDA ESP ADVANCED OPERATIONS COURSE BPB Modular Protector Motor operates Motor stops and oil and oil expands contracts 11 0% 100% e Oil volum 80%| ee oe tN OAT BHT MOT Temperature Figure 2.27 Operation cycles in a BPS type protector OREDA 1967, ll Rights Resewes.REDA ‘Section 2: The ESP system and ts Appicatons 2.4.2. Protector Application With any series of Mocular protector, flexibility is the primary advantage. With the mocular system, itis possible to "custom fit" the protector to the appiication. ‘The following guidelines show some of the possible protector configurations and the areas where each has its strengths and weaknesses. This table should be used as reference only, the proper protector chamber configuration must be defined depending on the specific well fluid properties, equipment used and operating conditions. For example, if the well fluid has sand or if you expect to chemically treat the well, a labyrinth type chamer in the top is desirable, ASO Se (A) Applicability improves with correct elastomers for higher temperature service, usually Aflas for seal elastomers, o-rings, & bags (8) Those that detenorate specific elastomers used In addition to proper selection of the "seal chamber’ configuration, the selection of the materials used in the protector is also of prime importance. Metallurgy will also be a factor. Elastomers are used to some extent in every protector. Depending on the downhole environment, some elastomers may perform much better than others. Although REDA primarily uses either HSN or Aflas elastomers for the “low” and "high" temperature models respectively, many other elastomers are available for special applications 56 ©REDA 1907, Al Righis Recarvess REDA ES® ADVANCED OPERATIONS COURSE Protector Elastomer Selection REDA Elastomer Application Guidelines Neoprene | Nitrile | Carboxy-Nitrile | HSN | Viton | Afias 250 _275 300_| 350 | 400 Relative Chemical Resistance Properties Temp. Limit (Deg F)* Water/Oil Hydrogen Sulfide Amines Polar Chemicals Carbon Dioxide were ww “Temperature Limit above indicates maximum operating temperature for the specific REDA compound. An elastomeric component will operate at a ‘temperature higher than the well ambient temperature depending on its Jecation in the equipment. Contact REDA for specific applicaton assistance 4 = Excellent long term resistance (very low swell/maintains very high physical properties) 2.= Good long term resistance (moderate swellimaintains high physical properties) 3 = Fair- depends upon exposure time and temperature (good short term resistance) 4.= Poor - no resistance even in short term ‘Asa general rule, Aflas is used in all high temperature applications, Since one of the primary functions of the protector is to handle thrust generated by the pump, selection of the proper thrust bearing is also very important. ‘The following curves indicate the allowable thrust load on the 400 and 540 Series protector as a function of downhole temperature for 2817 RPM and 3500 RPM. it should bs noted that the protector will be hotter than the motor which is again hotter than ‘the well fluid, All this is factored in to these performance curves. GREDA, 1997. Al Rights Reserves 57REDA 58 Seston 2 The ESP Syatem and ts Appcatens Protector Load Ratings vs. Temperature for REDA 2 Oil REDA 540 Series protector thrust bearing | 12.600 Clie nt)! a [leronze (TB) a Load Rating (LEA) g ao fo Standard (STB) [ee e o T0080 Eo 7260 Fo Bottom Hole Temp (°F) (= ZSOO RPM and above. ——- 2577 RP Protector Load Ratings vs. Temperature for REDA 2 Oil REDA 400 Series protector thrust bearing 10.000 pag ete) Load Rating (Lo) o 8 7200 a) oF 3500 RPM and above. ———~ 2017 RPM OREDA 1097 AU Rights ReservecREDA ESP ADVANCED OPERATIONS COUR: When sizing @ protector for en application, it is sometimes necessary to consider the power used by the protector when sizing the motor. In larger diameter | higher thrust load applications, failure to do so could result in an overloaded motor. For smaller diameter and/or lower load conditions, the additional power consumption is usually insignificant, less than 2 HP, Protector Power Consumption for REDA 2 Oil Est. Power Consumed at 200 °F BHT 0 2000 ©4000 ©6000 ©8000 © 10000 12000 14000 ‘Thrust Load in Pounds Figure 2.28 Protector HP consumption 2.5 Power Cable The power cable is a major component of the ESP system which caries the electncal power from surface to the downhole motor, and carries pressure and temperature signals from the downhole monitoring sensor (PS! or DMT or DMST) to surface. All REDA cable uses annealed lead alloy coated copper conductors. Each phase is individually insulated and the insulation is physically bonded to the conductor with adhesive. These insulated conductors may then have a protective bamer andior braid applied over them. Then the cable is jacketed for mechanical and chemical protection and finally, itis usually armored for good mechanical protection. ‘Success or failure of the ESP system depends directly on the proper selection of the cable size, type and configuration for the application, In very deep or severe wells that requires special cable features, the cable can be the most expensive component of the system. ®REDA, 1987 All Rights Recorved 59REDA ‘Section 2: The ESP System and ts Appicatane REDA’s modular cable allows the user to customize the required cable for his specific well conditions. The modular cable is available in either round or fiat configuration and with stranded, compacted or solid conductors. ‘The following table shows the abbreviations used for the more common materials Component Abbreviation Material description Insulation 1) PPE, P Polypropylene copolymer QE EPDMcetnyene Prooyene Dene Memvene) rubber 3)K Kapton 4)T Sermi-conductive tape (REDASURFACE) Barrier ys PVDF (Polyvinylidiene fluonde) 2) TB Tedlar™ tape 3) F Teflon ™ FEP extrusion 4) 7B High temperature tape 5) L Lead Jacket 41) PE HDPE (High density polyethylene) 20 il-resistant nitrile rubber compound 3)E EPDM rubber compound Armor 1G Galvanized steel 2) HG Heavy Galvanized steel 3) DG Double Galvanized 4) Ss Stainless Steel 5)M Mone! Standard interlocking profile FP Flat profile For example, a 2/7 POTB G4F cable will be; = #2 AWG with 7 strends conductors = Polypropylene insulation = Olkresistant nitrile jacket Tape and braid Galvanized steel armor 4 KV rating Flat cable AAOZOVN Some of the most commonly used cable configurations have been grouped in tamily names like REDALENE, REDABLACK, REDAHOT and REDALEAD. REDALENE cables utilize Polypropylene insulation (P or PPE) and an oii-resistant nitrile jacket (0), The maximum conductor temperature is 205°F and minimum ambient 60 ‘@REDA 1007, Al Rights Reserve,