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operation
ESP Start-up
- setting depth;
- horsepower and type of the motor (kW) and required inflow;
- rated current of the motor, idle current;
- rated voltage of the motor; required voltage at the tap of the
step-up transformer;
- rated frequency of the electric motor;
- type and density of kill fluid.
If all the issues with the workover team are cleared, accept the
completed operations note of ESP from the workover team.
ESP Start-up
Before start-up:
- calculate the required voltage at the transformer output
using the formulas below and set the closest higher tapping
compared to the calculated:
a) for switchboards with direct and soft start:
U 2 (U dem U ) * (380 / U1 )
b) for VSDs for acynchronous motors:
U 2 (Udem * FM / 50) U
c) for VSD for PMM:
U 2 (UDEM * FM / Frated) U
PMM (permanent magnet electric motors) with rated shaft
rotational velocity of 3000 rpm may be operated at up to
4200 rpm
Voltage losses per 1000 meters of cable line:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
14,6 28 32 35 14,6 21 24 27 14,6 18 20 23 14,6 13 16 17
18 34 39 44 18 26 30 33 18 22 25 28 18 17 19 21
21 40 46 51 21 31 35 39 21 26 29 33 21 19 22 25
22 42 48 53 22 32 37 41 22 27 31 34 22 20 23 26
24 46 53 58 24 35 40 45 24 29 34 37 24 22 26 28
25 48 55 61 25 37 42 46 25 31 35 39 25 23 27 29
26 50 57 63 26 38 43 48 26 32 36 40 26 24 28 31
27 51 59 66 27 39 45 50 27 33 38 42 27 25 29 32
28 53 61 68 28 41 47 52 28 34 39 44 28 26 30 33
29 55 64 70 29 42 48 54 29 35 41 45 29 27 31 34
30 57 66 73 30 44 50 56 30 37 42 47 30 28 32 35
32 61 70 78 32 47 53 59 32 39 45 50 32 29 34 38
33 63 72 80 33 48 55 61 33 40 46 51 33 30 35 39
34 65 74 83 34 50 57 63 34 42 47 53 34 31 36 40
35 67 77 85 35 51 58 65 35 43 49 54 35 32 37 41
36 69 79 87 36 53 60 67 36 44 50 56 36 33 38 42
37 70 81 90 37 54 62 69 37 45 52 58 37 34 39 43
38 72 83 92 38 55 63 71 38 46 53 59 38 35 40 45
… … … … … … … … … … … … … … … …
40 76 88 97 40 58 67 74 40 49 56 62 40 37 43 47
Switchboard/VSD
settings and
protection
How to set overload protection
(OP)
Overload protection is intended to shutdown electric motor when
the operating current exceeds rated current; the aim is to prevent
overheating and short circuit of the stator winding. Adjustment of
the overload protection should be performed before ESP startup.
The adjustment procedure should comply with the Operation
Manual of the switchboard/VSD .
Setting value of overload protection for microprocessor controller
switchboards and insulation control protection is calculated by the
formula:
OP = 1.05 * Irated,
where: OP is the setting value of overload protection;
Irated is the motor rated current in amper (А).
Overload protection setting actuation time is 30 sec.
How to select step-up
transformer voltage (U tap)
Optimum voltage at the step-up transformer output
should be selected after pumping-out of the kill fluid and
putting ESP into stable operation. Voltage optimization
should be applied after changing ESP operating mode.
The selection should be done through step-by-step
voltage reduction, i.е. switch-over of the transformer taps
after approval of the required shutdowns. When reducing
the voltage, keep monitoring motor operating current. If
the current goes up, bring the tapping switch of step-up
transformer to the previous position.
How to set motor underload
protection
- Underload setting during start-up should be
15% less than motor operating current.
- Underload setting during commissioning of the
well should be set according to Table B.1 after
the optimal voltage is selected.
% of reduced Setting value for Trip on underload for
Load, %
value Iwork switchboard
70 and
15 (load) -15%
more
from 50 to
10 (load) -10%
70
Less than
5 (load) – 5%
50
Protection against voltage spikes
Voltage spikes protection is necessary for stable
ESP operation.
High-voltage protection setting: Umax = 420 V
(110%). Actuation time delay should be set to 5
seconds.
Low-voltage protection setting: Umin = 340 V
(90%). Actuation time delay should be set to 5
seconds.
Protection against current phase
misbalance
Protection against current phase
misbalance is necessary to ensure stable
operation of electric motor and maximum
run-life. Recommended misbalance of
current phases should not exceed 15%.
Percentage of current phase misbalance
should be calculated by the following
formula:
I max
I 100
Iav
Protection against voltage phase
misbalance
Protection against voltage phase
misbalance is necessary to ensure stable
operation of electric motor. Misbalance of
voltage phases should not exceed 5%.
Insulation resistance protection of
the ‘step-up transformer – cable –
electric motor’ assembly
Insulation resistance protection of the ‘step-up transformer – cable –
electric motor’ assembly is intended to prevent short circuit of
electrical components. Protection setting should not be less than 30
kohm.
During conversion from standard mode to operation without control
of insulation resistance):
Switch off insulation control device or function;
Actuation time of overload protection should be reduced to 5 sec.;
Automatic restart should be switched to ‘Lock’ position for overload
protection;
When necessary, disconnect zero point.
Backspin protection
V (R R )
1
2 2
2
(m3)
Calculation of inflow based on level recovery
in the production casing
Fluid inflow from formation after ESP system shutdown
should be determined after fluid discharge from the tubing
(in case of leaking or missing check valve).
Time of fluid discharge form the tubing (in case of leaking
check valve) can be determined by backspin rotation
which is determined at the switchboard.
Continuous monitoring of the inflow from formation during
ESP operation and shutdown for cooling allows to reduce
start-up and commissioning time and to avoid
unreasonable ESP startups and shutdowns which reduce
ESP run life.
Final stage of the procedure
f
P P50 - Effective power of the motor
50
For example: under 50 Hertz the pump consumes 55 kW, if the well is to
operate only under 50 Hertz, we select 63 kW motor.
If the pump is to operate under 60 Hertz, the results will be as follows:
under 50 Hertz the power consumption of the pump is 55 kW, under 60
Hertz it is: 3
F
Р pump 2 2 Р pump1
F1
3
60
Р pump 2 55 95kW
50
F 60
Рmot 2 2 Рmot 1 90 108kW
F1 50
Нsubmers
Рsens Рcons 10
fluid
Advantages of VSD compared to switchboard
during seizure troubleshooting
During ESP operation, VSD has a number of considerable
advantages compared to switchboard. These advantages
can be clearly demonstrated during ESP startup and
during wedging of seizure.
The main advantage of VSD over switchboard both in
normal ESP operation and during wedging of seizure is
that VSD allows soft start of the unit. With the switchboard
the motor during startup receives the voltage preset at the
transformer.
Firstly, in this case, there is a high probability of motor,
seal or pump shaft fracture, especially if during wedging
the voltage at the transformer is increased additionally.
The result failure due to lack of fluid flow. Secondly, if
motor shaft doesn’t move during start-up, all of the power
supplied from the surface intended to generate torque
goes to heating the motor winding and submersible cable.
After a number of trials within a short period, this becomes
the key reason for reduced insulation of ‘cable-motor’
assemble and hence, ‘R-0’ failure during seizure wedging.
VSD allows to perform starting from 0-10 Hertz, therefore,
the voltage supplied to the motor is also lower. As a
result , the motor and the cable experience less heating.
During startup of the unit the maximum torque is
generated in the first 0.1-1 second. If the seizure is not
wedging at this moment, the supplied power is used for
heating during the remaining time till overload protection
actuation.
Another advantage of VSD over switchboard is opportunity to
change rotation gradually without ESP shutdown (to avoid shaft fracture
and slips of seal shafts) and application of various ejective methods of
seizure troubleshooting. Rational application of these VSD functions
combined with methods of wedging seizure described above
considerably increases possibility of wedging ESP seizure.
A competent approach to seizure troubleshooting using a VSD
allows to avoid shaft fracture, motor and cable overheating and
increases possibility of wedging compared to ESPs wth switchboard.
Often, to wedging seizure we can use flushing (direct/(squeeze
treatment) and reverse) by crude oil with solids or by formation water
with scale. This causes deterioration of reservoir performance and killing
of the well. Preparation for flushing takes 1 to 5 hours. Application of
VSD allows to restart the unit without special tools, machines and no
waste of time. Wedging ESP seizure using a VSD should be performed
by competent personnel with enough knowledge, skills and experience to
use a VSD.
Checking ESP operation mode
3 days after ESP commissioning (not later than 7 days), an electrician and a
Customer’s representative check the operation mode of the ESP by
checking flow rate measurements, dynamic level, manifold, wellhead and
annulus pressure; when setting the automatic restart time take into account
the time required to discharge the fluid from the tubing (in case of the
leaking or missing check valve);
The electrician and a Customer’s representative perform adjustment of the
switchboard protections based on Нd, flow rate and operating current. The
electrician selects the optimum motor voltage by adjusting transformer taps
or changing the base frequency or base frequency voltage, and checks the
ESP insulation resistance.
After that, based on achieved operating current he adjusts the switchboard
protections. Minimum current is selected in order to ensure optimum load of
the motor and to reduce heat losses.
Settings and protections made are subject to approval by the Customer.
ESP shutdowns
during operation
Reasons for shutdown
ESP shutdown due to overload (OP) protection
ESP shutdown due to underload
ESP shutdown due to insulation control
protection
Reduced (no) flow
Electric power cut (scheduled and emergency
cases)
ESP shutdown by overload
protection