9 Surface Equipment

Surface Equipment
Schlumberger
Schlumberger
Confidential
Private
460
415
380
Low V
11 KV
13.8 KV
33 KV
High V
50/60 Hz
Power
Surface Equipment Options for ESPs
60 amp
2000 V
200 V
Schlumberger Private
Provides a connection point for the

surface cable from the motor control
panel to the power cable in the wellbore
coming from the wellhead .
Allows for any gas to vent that may
have migrated through to the power
cable.
Provides easy accessible test point for
electrically checking downhole
equipment.
Minimum required distance from
wellhead : 35 ft; minimum required
distance from switchboard: 15 ft.
Junction box / Vent Box
460
415
380
Low V
11 KV
13.8 KV
33 KV
High V
50/60 Hz
Power
4) Controller
3) VSD
2) Switchboard
1) Transformer
Components
Four Main
Junction
Box
(2200 V
60 amp)
60 amp
2000 V
200 V
Rates (BPD)
HP
kVA
Surface Equipment is measured in terms of:
Motors are measured in terms of:
TDH (feet)
Pumps are measured in terms of:
Size of Surface Equipment
460
415
380
Low V
11 KV
13.8 KV
33 KV
High V
50/60 Hz
Power
kVA = 229 kVA
1000
kVA = 2200 x 60 x 1.732
1000
kVA = Volts x Amps x 3

Junction
Box
(2200 V
60 amp)
60 amp
2000 V
200 V
The main function of the motor

controller is to protect the ESP motor
(primarily) by measuring the surface
current and voltage (overload and
underload)
Other parameters can be added to the
controller wellhead pressure, flow/no
flow, etc.
The controller also provides the
capability to monitor performance of
downhole electrical system (current,
voltage, frequency, etc).
Motor Controller
A transformer will not add power to a

system
A transformer will not change amperage

or frequency
A transformer will change voltage from

one value to another.
Transformer
Schlumberger
Schlumberger
Confidential
Private
the voltage.
and a different number wire windings on the other side to change
Normally there is an iron core that has wire windings one side
How does it work?
V = 11000V
1:1
VS = 11000V
Transformer with the same number of

windings:
V = 11000V
5:1
V = 2200V
Transformer with the different number of

windings:
Temperature
Paint
Spill Pans
kVA Size
Efficiency
Need to consider:
VSD Rated
Oil Filled
Dry Type (Air Cooled)
Transformer Types
Only if temperature is not a concern
Only if there are no losses in any of the

other surface components
229 KVA?
What Size Transformer is

Required for this system?
Schlumberger
Schlumberger
Confidential
Private
A switchboard will not add power to a

system
A switchboard will not change amperage

or frequency
A switchboard is basically an on/off

switch.
Switchboard
Schlumberger
Schlumberger
Confidential
Private
Motor
Main Contactor
Power Fuses
Main Disconnect
Switchboard Diagram
Disconnect Switch Mechanical, Fused
Power Fuses Short Circuit Protection
Vacuum Contactor Main Power Switching
Lightning Arrestors Voltage Surge Protection
Enclosure 12 Gauge Metal Construction,

NEMA 3
Major components
FixStar MCP Switchboards
Main Disconnect switch/circuit breaker, Vacuum

(air break) contactor & lightning arrestor
Separate high & low voltage compartments
UniConn + UniConn CT Module & Burden
Module
3 instrument potential transformer & A095
Backspin Shunt full spec system
Bristol Ampchart recorder

Red/Green/Amber status lights, H-O-A switch
Not included as standard:
Standard features:
FixStar -Features
UniConn Comm.Card
Battery Enclosure
SCB Back Panel
Antenna
Internal SCB
FixStar Switchboard Options
Motor Controller
Pilot Devices: indicator lights and switches
Protection : primary transformer fuses, secondary

circuit breakers
Backspin Shunt Backspin Detection
Current Transformers Current Monitoring
Instrument Potential Transformers Voltage

Monitoring
Control Power Transformer
Auxiliary Equipment Motor Control
FixStar MCP Switchboards
Cable Pack
UniConn Memory Module
UniConn Phoenix Interface Card
Choke
Phoenix Surface Kit
FixStar Switchboard Options
460
415
380
Low V
11 KV
13.8 KV
33 KV
High V
50/60 Hz
Power
Junction
Box
(2200 V
60 amp)
60 amp
2000 V
200 V
460
415
380
Low V
11 KV
13.8 KV
33 KV
High V
f
Tr
a
ns
50/60 Hz
2200
V
S
w
itc
er
or
m
rd
h
b
oa
Power
Junction
Box
(2200 V
60 amp)
Medium Voltage Switchboard
60 amp
2000 V
200 V
460
415
380
Low V
11 KV
13.8 KV
33 KV
f
Tr
a
ns
High V
480V
S
w
itc
er
or
m
rd
h
b
oa
50/60 Hz
480V
T
r
an
er
rm
s fo
Power
Junction
Box
(2200 V
60 amp)
2200
V
Low Voltage Switchboard
60 amp
2000 V
200 V
A VSD will not add power to a

system
A VSD will not change amperage
A VSD can turn an ESP on and off and

control the frequency
VSD
Schlumberger
Schlumberger
Confidential
Private
Time, or "period" = 1 second
20 cycles = 20 Hertz
60 cycles = 60 Hertz
Alternating Current
New technology has allowed medium voltage

VSDs to be become affordable and will likely
be the standard in the future.
However, most VSDs in the oil industry are

low voltages.
VSDs also come in a low and medium

voltage design.
460
415
380
Low V
11 KV
13.8 KV
33 KV
f
Tr
a
ns
High V
er
or
m
50/60 Hz
480V
480V
T
r
an
er
rm
s fo
Power
Junction
Box
(2200 V
60 amp)
2200
V
Low Voltage VSD
60 amp
2000 V
200 V
VS
D
Capacitor
(DC Bus)
Control Logic
IGBT
(Inverter)
MOTOR
IGBT (Insulated Gate Bipolar Transistor): to invert DC

power into a varying AC power
Capacitors: to help smooth DC output
Diode: to convert AC power to DC power
Diode
(Converter)
VSD Operation
D e f D is k : In te r na l
1
V
-1
0s
0Hz
Hz
X : 3 9. 0 62 5 m s
X:60
Y:7 4 7 .4 7 3 m V
Y:4 5 2 .1 3 2 m V r m s
100ms
1 .6 kH z
Poor Current wave form

caused excessive heating and
vibrations, therefore reduced
motor run life
/d iv
200
mV
C H 2 T im e
R eal
B:
V rm s
50
m Vrms
/d iv
500
m Vrms
C H 2 L in S p e c
L in M a g
A:
D a te : 0 1 -2 0 -9 7 T im e : 0 8 :5 3 :0 0 A M
S ave / R e c
Standard Six Step

Current
1
V
-1
V
0s
0 Hz
X:5 1.269 5 ms
Hz
Y:74 4.68 mV
Y:28 2.229 mVr ms
1 24.87 79ms
3.2k Hz
Better current wave form

near to a Sine wave
/div
200
mV
C H1 T ime
Rea l
B:
V rms
40
m Vrm s
/div
C H1 L in S pec
400
m Vrm s
LinM ag
A:
X:6 4
D ef Disk: In ter nal
Date : 01- 23-97 Tim e: 09:33:00 AM
Save/R ec
SWD Current
Output Wave Shapes
Back
into the
power
system
Down to
the ESP
VSD Cause Harmonics to go both ways
Proportion surviving
1.0
0.8
0.6
0.4
0.2
0.0
1000
Runlife
PWM or
6 Step VSD
2000
4000
Installed days
LRT: p=0 CPH: p=0
3000
5000
6000
7000
Traditional VSDs (> 20% THD)
SpeedStar SWD/MVD (< 20% THD)
Steadily increasing run-life over 15 year sample period. Proportion surviving

is not representative of present run-life experience
Runlife
SineWave VSD
Assumptions & Notes

SWB
Switchboard statistics are relevant for all sine wave applications.
Unknown/VSD
VSD statistics are relevant for all VSD types.
Statistical sample of 20,000+ ESP System applications collated over a 15
year period.
All failure types (surface and down-hole related) and non-failure pulls
included in statistical sample.
CPH-survival
curves
for paneltype
ESP System Survival
Sine Wave
vs Unfiltered
VSD Output Waveform
17
12
11
Year
16
12
10
Using SWD total: 55 pulls
Using all other VSD types total: 74 pulls (34.5% MORE)
Graph shows number of units to be pulled in the next five years:
16
20
PWM VSD w/output filter
Generated for an offshore field with 44 wells, all w/VSDs 22 SWD
10
15
20
25
All other VSD Types
No. ESP failure
Field Performance Impact - Example
Installed at output of VSD.

Purpose: reduce/eliminate
harmonics generated in the VSD
going downhole.
Harmonics severely increase
electrical stresses on dowhole ESP
electrical system, decreasing
runlife.
Has to be tuned prior to every
installation (application specific setup).
Load filter
Installed at input of VSD.

Purpose: reduce/eliminate
harmonics generated in the
VSD reflected back to power
source, which could generate
damage on other power users
(even shut down the grid on
occasions).
Designed-specific for every
application, after conducting
harmonics power study.
Harmonic Line filter
460
415
380
Low V
11 KV
13.8 KV
33 KV
f
T
r
an
s
High V
er
or
m
50/60 Hz
Low Voltage VSD
T
r
an
er
rm
s fo
Power
Li
ne
F
ilt e r
ne
F
ilt e r
Li
Junction
Box
(2200 V
60 amp)
60 amp
2000 V
200 V
Loa
d
F
ilter
VS
D
460
415
380
Low V
11 KV
13.8 KV
33 KV
High V
50/60 Hz
Power
6.9 KV
3.0 KV
High V
50/60 Hz
Power
Input
VS
D
4160 V
to
1800 V
Voltage
Variable
Hz
Power
Output
Junction
Box
(2200 V
60 amp)
Medium Voltage VSD
60 amp
2000 V
200 V
Why use a VSD?
Schlumberger
Schlumberger
Confidential
Private
Head (ft)
HP
1.00
2.00
3.00
10
20
30
40
50
60
70
Feet
Capa
50 Hz
Hz
Hz
70
70 Hz
65 Hz
60 Hz
55 Hz
50
H
55
60
H
65
Capacity - Barrels per Day
city
Hz
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500
ly Load
Pump On
Head
Reda Single Stage Pump Performance Curve
Flow Rate
50
100
150
3500
3818
200
250
300
350
Q2
Q1
20
Hz 2
=
Hz 1
60
Frequency (hertz)
40
80
100
Q = 60/50 x 3500 = 3818 BPD
Flow Rate for a Pump is affected as follows:
Motor Horsepower
50
100
150
200
250
300
350
HP 2
HP1
20
Hz 2
=
Hz 1
60
Frequency (hertz)
40
80
100
HP = 60/50 x 170 = 204 HP
Horse Power in the Motor is affected as follows:
HZ
60
HZ
60
= Head 60 x
BHP HZ = BHP60
Head HZ
Flow HZ = Flow 60
HZ
60
Affinity Laws for a Pump on a VSD:
Pump BHP
100
200
300
400
500
20
60
Frequency (hertz)
40
80
The BHP required by the pump increases with

the cube of the hertz ratio. Graphically it would
look like:
Horse Power
100
200
300
400
500
20
40
60
Frequency (hertz)
HP delivered
by Motor
80
HP required
by Pump
Putting the two graphs together we can see the

design consideration
SLBs objective is NOT only to sell various

surface equipment pieces.
Our objective is to ensure that the OVERALL
ESP surface equipment PACKAGE deployed
would be able to function as designed and serve
all intended purposes
Responsibility / Objectives
System analysis that can be done:

Conceptual Design and Engineering
Load Flow Studies
Short-Circuit Studies
Motor Starting Studies
Transient Stability Studies
Harmonic Studies and Mitigation
Protective Equipment Coordination
Equipment Evaluation
Load Filter Analysis
simulation of power systems.
Schlumberger EPCs Power System Department

specializes in the design, analysis, training, and computer
Power Study
Custom designed control rooms.
Full distribution switchgear layouts.
Skids for Switchboards with

transformers.
Skids combining VSDs with

transformers.
support and manufacturing capability to

design & build :
Schlumberger can provide engineering
Power System Packaging
QUESTIONS ?

9 Surface Equipment

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Surface Equipment

Surface Equipment Options for ESPs

Provides a connection point for the

Junction box / Vent Box

Surface Equipment Options for ESPs

Surface Equipment is measured in terms of:

Motors are measured in terms of:

Pumps are measured in terms of:

Size of Surface Equipment

kVA = 229 kVA

kVA = 2200 x 60 x 1.732

kVA = Volts x Amps x 3

Surface Equipment Options for ESPs

The main function of the motor

A transformer will not add power to a

A transformer will not change amperage

A transformer will change voltage from

and a different number wire windings on the other side to change

How does it work?

Transformer with the same number of

Transformer with the different number of

Dry Type (Air Cooled)

Only if temperature is not a concern

Only if there are no losses in any of the

What Size Transformer is

A switchboard will not add power to a

A switchboard will not change amperage

A switchboard is basically an on/off

Disconnect Switch Mechanical, Fused

Power Fuses Short Circuit Protection

Vacuum Contactor Main Power Switching

Lightning Arrestors Voltage Surge Protection

Enclosure 12 Gauge Metal Construction,

FixStar MCP Switchboards

Main Disconnect switch/circuit breaker, Vacuum

Bristol Ampchart recorder

Not included as standard:

SCB Back Panel

FixStar Switchboard Options

Pilot Devices: indicator lights and switches

Protection : primary transformer fuses, secondary

Backspin Shunt Backspin Detection

Current Transformers Current Monitoring

Instrument Potential Transformers Voltage

Control Power Transformer

Auxiliary Equipment Motor Control

FixStar MCP Switchboards

UniConn Memory Module

UniConn Phoenix Interface Card

Phoenix Surface Kit

FixStar Switchboard Options

Surface Equipment Options for ESPs

Medium Voltage Switchboard

Low Voltage Switchboard

A VSD will not add power to a

A VSD will not change amperage

A VSD can turn an ESP on and off and

Time, or "period" = 1 second

New technology has allowed medium voltage

However, most VSDs in the oil industry are

VSDs also come in a low and medium

Low Voltage VSD

IGBT (Insulated Gate Bipolar Transistor): to invert DC

Capacitors: to help smooth DC output