Esp System Start Up Commissioning and Operation Last

ESP System Start-Up,
Commissioning and Operation
© NOVOMET |WWW.NOVOMET.RU/ENG | 2017

Start-up procedure of ESP system
The number of personnel on startup of the well should

be written in the contract for each oil company
and corresponds to the internal rules of the oil company
and generally accepted safety rules.
2 Day 2 | ESP System Start-Up, Commissioning and Operation

NOT JUST ANOTHER ESP PROVIDER © NOVOMET |WWW.NOVOMET.RU/ENG | 2017
Start-up procedure of ESP system
During startup the following people should be present

on the well:
representatives of ESP company (produce startup and configure
equipment);
representatives of oil company (provide opportunities for startup
and coordinate all actions on the well);
drilling company representatives.
3
Prior to the start-up proceed as follows:
Make visual inspection of the ESP system

surface equipment, ensure grounding of the
VSD and step-up transformer to the existing
ground grid;
Make sure the armor of the downhole cable
at the X-mas is grounded (the armor must
be connected to the lower nut of the lowest
flange of the X-mas) of the well;
Check the VSD, step-up transformer,
junction box, tighten the bolted connections
of the live components and connections to
the zero bus;
Check the correct phase sequence in the
terminal box by a high-voltage phase
indicator.

Attention!
For VSD for PMM motors it is prohibited to perform check of

correspondence of voltage with transformer tap voltage because
VSD for PMM cannot be started in idle mode with disconnected
PMM motor (except VSD Novomet in U/F – mode).
For VSD for PMM it is prohibited to check correct phase sequence

with high-voltage phase indicator. Phasing should be performed
with ohmmeter (digital multimeter).
When running VSD Elekton for PMM do not use output filter
between the VSD and step-up transformer, since it will cause pulse
distortion of the output voltage of VSD for PMM, and hence,
impossibility to find position of the rotor.

Person in charge of the startup and commissioning
should know the following information:
Capacity, head and
composition of the unit in the
hole, its recommended
operating range;
Diameter of the casing

(interior volume of the string
without the tubing and the
volume of 1 line meter/feet of
the annulus), tubing and
pump setting depth;

Person in charge of the startup and commissioning
should know the following information:
Power and type of electric motor (kW) and minimal reservoir flow for
cooling the motor;
Nominal current of the electric motor, idling current (in catalog or unit
certificate)
Nominal voltage of electric motor and needed tap of the step-up
transformer;
Nominal frequency of the electric motor;
Type of kill fluid and its density.
Example:
N460PM 200 3870V 6000RPM SGL
Novomet
406 series
Permanent Magnet motor
Power, 200 hp (at rated rotation frequency)
Rated voltage, 3870V (at rated rotation
frequency)
Rated rotation frequency, 6000 rpm
Single motor
7
Startup of ESP system (1/3)
Before startup it is necessary to calculate the required

voltage at the transformer output using equations and to
choose next higher tap if compared to the rated one:
a) for Switchboard without VSD and Switchboard with soft start:
U SUT .nom
U 2  (U nom.motor  U cable.line )  ( )
where:
U1
U1 — actual voltage at step-up transformer primary winding, V;
U2 — tap voltage at SUT secondary winding, V;
Unom.motor — motor nominal voltage (at power line nominal frequency – (50Hz or 60Hz), V;
USUT.nom — nominal voltage at SUT primary winding (380V or 480V), V;
ΔUcable.line - voltage losses in cable line, V;

b) for VSD for AM and PMM (except VSD Novomet) :
Fmax
U 2  (U nom.motor  )  U cable.line
Fnom
where:
U2 — tap voltage at SUT secondary winding, V;

Fnom — motor nominal frequency (for AM - 50Hz or 60Hz; for PMM – 100Hz or 200Hz), Hz;
Unom.motor — motor nominal voltage (at motor nominal frequency), V;
Fmax — maximum expected operating frequency of ESP, Hz;

c) for VSD Novomet (VSD can calculate it automatically):
Fmax
U motor  (U nom.motor  )
Fnom
Umotor — motor voltage at Fmax, V;
Fnom — motor nominal frequency (for AM - 50Hz or 60Hz; for PMM – 100Hz or 200Hz), Hz;
Unom.motor — motor nominal voltage (at motor nominal frequency), V;
Fmax — maximum expected operating frequency of ESP, Hz;

Calculation of tap voltage in SU transformer
U 2  U SUT.nom.  Ktr.2
USUT.nom. - nominal primary voltage of SUT, (380V or 480V), V;
U2 — tap voltage at SUT secondary winding, V.
U motor U cable.line

K tr.2 
U fc U swf
Ktr.2 - accurate transformation ratio for SUT, including voltage losses in output
sine-wave filter;
For VSD Novomet it is recommended to insert
Ufc = 320 V…360 V (VSD for 380 V);

Ufc = 420 V…460 V (VSD for 480 V…500 V).
It is necessary to ensure a stable output signal if there is a fluctuation of the input
voltage.
Calculation of tap voltage in SU transformer
U swf  2    Lswf  Fmax  I motor.nom  K tr.1  0,001

ΔUswf - voltage losses in output filter, V;
Lswf - inductance of output sine-wave filter, mH;
Imotor.nom - motor nominal current, A;
Ktr.1 - transformation ratio for SUT;
U motor U cable.line
K tr.1  ( )
U fc
Ufc – maximum output voltage of VSD according to U/F-curve, V;
Ktr.1 - transformation ratio for SUT;
12
Attention!
During VSD selection operator should be guided

by VSD current.
During VSD selection margin should be taken into

account of VSD current 40…60%

Calculation of voltage losses in cable line:
Calculation by equation
38.7  I motor .nom  Ltotal .cab
U cable.line 
S cable1000
Imotor.nom - motor nominal current, A;
Ltotal.cab - submersible cable length, m;
Scable - cable section, mm2
38,7 - temperature coefficient.
Calculation according to table
table value  Ltotal.cab

U cable.line 
1000
table value - losses per 1000 meters (3 281 ft ), V;
Voltage losses in cable with copper Voltage losses in cable with copper Voltage losses in cable with copper Voltage losses in cable with copper
conductors, AWG#5 (size 3x16 mm2), conductors, AWG#4 (size 3x21 mm2), conductors, AWG#3 (size 3x25 mm2), V conductors, AWG#2 (size 3x33 mm2),
V (per 1000 meters/3281 ft) V (per 1000 meters/3281 ft) (per 1000 meters/3281 ft) V (per 1000 meters/3281 ft)
Reservoir temperature, Reservoir temperature, Reservoir temperature, Reservoir temperature,

0F/0С 0F/0C 0F/0C 0F/0C
Imotor
Imotor nom., Imotor nom., Imotor nom.,
nom.,
A 104-147 149-194 >194 A 104-147 149-194 >194 104-147 149-194 >194 A 104-147 149-194 >194
A
40-64 65-90 > 90 40-60 70-90 >90 40-60 70-90 >90 40-60 70-90 >90
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
15
Attention!
Check with voltmeter if voltage in Junction box

corresponds to voltage of transformer tap.
For VSD for PMM motors it is prohibited to perform
check of correspondence of voltage with transformer tap
voltage because VSD for PMM cannot be started in idle
mode when PMM is disconnected (except VSD Novomet
in U/F – mode).

Settings and protection
of VSD

Selection of step-up transformer voltage
Should be selected after pumping-out of the

kill fluid and ESP operation is stabilized.
The selection should be done through step-

by-step voltage reduction, i.е. switch-over of
the transformer taps upon approval of the
required shutdowns.
While reducing the voltage necessarily keep

on monitoring the operating current of electric
motor, if current goes up, bring the tapping
switch of step-up transformer to the previous
position.

Overload trip
Overload trip (OLT) is intended to

shutdown an electric motor when the
operating current exceeds a nominal
current;
The aim is to prevent overheating and
electrical breakdown of the stator winding.
Adjustment of the overload protection
should be performed before ESP system
startup.
OLT = 1.05 * Imotor.nom

OLT - the setting value of overload trip, A;
Imotor.nom - nominal current of the motor, А.

No-load trip of submersible motor
No-load trip (NLT) during startup (setting

to stable operation) should be set 15%
less than the operating current of the
electric motor.
NLT during confirmation of well set to

stabilized operation (verification check)
should be set with the motor load level
included after the optimal voltage is
selected
% of reduced Setting value for No-load Trip
Load, %
value Iwork for VSD
70 and more 15 (load) -15%
from 50 to 70 10 (load) -10%
Less than 50 5 (load) – 5%
Setting-up mains voltage drop protection
Setting-up of voltage drop protection should be performed

in order to stabilize ESP system operation.
Protection setting for the maximum voltage (over voltage):
Umax setting = Unom.pw.line * 1,1. (110%)
Protection setting for the minimum voltage (under voltage):
Umin setting = Unom.pw.line * 0,9. (90%)
Actuation time delay should be set to 5 seconds.

Current unbalance protection
Current unbalance protection is necessary to ensure stable

operation of electric motor.
Recommended distortion of current phases should
not exceed 15%.
Current unbalance should be calculated by the following
equation:
I max
I  100
I average
ΔI — current unbalance (%),
ΔImax — maximum current variation from average value,
Iaverage — average value of current phases.
Voltage unbalance protection
Voltage unbalance protection is necessary to ensure stable

operation of electric motor.
Voltage unbalance should not exceed 5%.

Insulation resistance protection
Insulation resistance protection is intended to
prevent electric breakdown of energized
components of the system.
Setting of low insulation resistance of the
assembly ‘step-up transformer – cable – electric
motor’ should not be less than 30 kOhm.
During conversion from operation characterized
by ‘fast-response’ overload protection
(i.е. without control for insulation resistance):
• Deactivate insulation control unit or
function for control of insulation resistance;
• Actuation time of overload protection
should be reduced to 1 sec.;
• Automatic restart switch should be put to
‘Blocked’ position after the overload
tripping;
• Turn off zero (Y-connection) wire if
necessary.
Backspin protection
Backspin protection is intended to prevent ESP system

starting during fluid bleeding from tubing.
The setting should be 5 Hz.
Restart period should be set from 1 to 5 minutes.

Determine correct rotation direction of the ESP
system shaft and leak-tightness of tubing
After ESP startup it is necessary to determine

if the electric motor shaft is rotating in proper
direction through the following methods:
а) using current and load of electric motor: check
load and current of the electric motor with direct and
reverse rotation (the correct rotation will demonstrate
higher current and load of electric motor);
b) pressure test of the X-mas: while the unit is in

operation gradually close the line valve, keep on
checking the pressure growth rate and pressure value
at the buffer pressure gage, make this operation for
direct and reverse rotation (with the correct rotation
the pressure growth rate and pressure value will be
higher).
Bringing well to stable operation
Continuous operation of ESP without the inflow

from reservoir is prohibited due to lack of fluid motion
along the submersible motor.
Submersible electric motor series Continuous operation duration
ESP system with a submersible motor

not more than 2 hours
up to 32 kW inclusive

not more than 1 hour
from 32 kW to 45 kW inclusive

not more than 30 minutes
exceeding 45 kW

Methods for determination of reservoir inflow
Calculation of inflow based on production rate
Qinf  Qggs  Qann , ( m 3

)
day
Qinf 60
 Qggs  ( Н din.2  Н din.1 )  S  24  ( ), ( m 3
)
T day
S   ( R12  R22 ), m2
Qggs — well flow rate measured by gaging battery for the period Т,
recalculated per day, m3/day;
Qann — well flow rate measured by change of fluid level in annulus, m3/day;
Hdin — well fluid dinamic level, m;
S —annulus space area, m2;
R1 — casing radius, (m);
R2 — tubing radius, (m);
T — measuring time, (min);
Methods for determination of reservoir inflow
Calculation of inflow based on production rate
Qinf  Qggs  Qann , (bpd )
Qinf  Qggs  5,614  ( Н din.2  Н din.1 )  S  24  ( 60 ), (bpd )

T
S   ( R12  R22 ), ft 2
Qggs — well flow rate measured by gaging battery for the period Т, recalculated per day, bpd;
Qann — well flow rate measured by change of fluid level in annulus, bpd;
Hdin — well fluid dinamic level, ft;
S —annulus space area, ft2;
R1 — casing radius, (ft);
R2 — tubing radius, (ft);
T — measuring time, (min);

Calculation of inflow based on recovery
of level in the production string
Fluid inflow from reservoir after ESP system shutdown
should be determined after fluid outflow from tubing
is completed (if check valve is leaking or there
is no valve).
Duration of fluid outflow form tubing (if check valve

is leaking) can be determined by backspin rotation
which is determined at the switchboard.

Final stage of the procedure
The well shall be deemed to be at the stabilized

operation mode when the flow rate is stable, dynamic
level is stable for 6 hours.
This time value may vary in different well conditions,

series of the unit, completeness set of the unit, harsh
conditions in the course of startup etc.
Another criterion to assume the well is set to stable

operation is the equal annulus pressure and line
pressure (Рann = Рlin), which is applicable for most of
the wells.

Features of ESP commissioning
with VSD

Features of ESP commissioning with VSD
 f2 
Q  Q f    - Capacity of pump
f
2
1
 f1 
 f2 
2
H  H f1    - Head of pump
f
2  f1 
3
 f2 
W  W f1    - Power consumed by the pump
f
2  f1 
 f2 
P  P f1    - Effective power of the motor
f
2  f1 
Features of ESP commissioning with VSD
For example: at 50 Hz the pump consumes 55 kW, if the well

is assumed to be operating only under 50 Hz, then we select motor of
63 kW.
If the pump is assumed to be operating under 60 Hz,
then the results will be as follows: under 50 Hz the power consumption
of the pump is 55 kW, then under 60 Hz it is:
3
 F2  if you plan to operate ESP
W pump2    W pump1
 F1  on frequency of 60 Hz, then
3 the same pump will need
 60  a higher power of 90 kW.
W pump2    55  95kW
 50 
 F2   60 
Рmot2  
   Рmot1   90  108kW
 F1   50 

Features of startup and commissioning ESP
with downhole sensor system
With Рann – 0 atm, it is difficult to find Нstat and change
of Нdyn after the ESP system startup.
If we have pressure data at pump intake we can calculate
Нstat and Нdyn changing. Pressure at pump intake can be
converted to meters of fluid column by the equation:
Н dyn( stat)  H psd  Н submers
Downhole sensor
Н submers 
 Рsensor  Рannulus  10
(m, atm, g/cm3 )
 fluid
 fluid - reservoir oil density
Н submers 
 Рsensor  Рannulus   2,23
  API  131,5 (ft, psi, API )
141,5
During startup with switchboard
There is a high probability for motor shaft
breakdown, gas separator shaft or protector
shaft, especially during unlocking stuck pump
the voltage at the transformer is increased
additionally, the result is ‘no flow’ failure;
If there is no movement from a standstill and

speeding up of the motor shaft with such
startup, then all of the power supplied from the
surface intended to generate torque goes to
heating of the motor windings and submersible
cable.
After a number of trials within a short period

this becomes the root cause of reduced
insulation of ‘cable-motor’ system and hence,
‘R-0’ failure reason during unlocking.
Advantages of VSD if compared to DOL
switchboard during unlocking stuck pump
In the course of ESP system operation
VSD has a number of undoubted
advantages if compared to DOL
switchboard.
These advantages can be clearly

demonstrated during ESP system startup
and during unlocking stuck pump.
The main advantage of VSD when

unlocking stuck pump
is the fact that VSD enables soft start of
the unit.

VSD advantages
1. VSD allows to perform starting from

frequency 0-10 Hz, meanwhile when we
supply less frequency to the motor, the
voltage supplied is also less, hence, the
motor and the cable experience less heating.
2. Another advantage of VSD if compared to

switchboard is the possibility to use gradual
shift-over of ESP system shafts rotation
speed without a shutdown (avoiding shaft
breakdown and slips of protector shafts) and
application of various jog methods of
unlocking.
VSD advantages
3. Quite often unlocking stuck pump includes flushing

(direct and reverse) by crude oil with mechanical impurities
or by Reservoir salt water as a flushing fluid. This causes
colmatage of pay zone and killing the well. Moreover
preparatory operations for flushing take 1 to 5 hours. We can
use advantages of VSD and try to restart the unit with no
special tools, machines and no waste of time. Unlocking stuck
pump with VSD should be performed by competent personnel
having the knowledge, skills and experience to use VSD.
Confirmation of the ESP system operation
mode (1/2)
3 days after the well with the ESP system is brought to
a stable operation mode (but not more than 7 days), an
electrician with a Customer’s representative attendance
confirms the operation mode of the ESP system through
control measurements of flow rate, fluid dynamic level,
line pressure, wellhead pressure and annulus pressure;
when setting the restart time one should bear in mind
the time needed to bleed the fluid from tubing (in case
of non-tight check valve);

Confirmation of the ESP system operation
mode (2/2)
The electrician with a Customer’s representative
perform fine-tuning of the VSD protections
proceeding from the achieved fluid dynamic level,
flow rate and operating current. He selects the
optimum voltage for the electric motor by adjustment
of the transformer voltage stages or changing the
basic frequency or voltage of the basic frequency, and
checks the ESP system insulation resistance.
After that proceeding from the minimum achieved
operating current he adjusts the VSD protections.
Minimum current is selected in order to ensure
optimum load of the motor and to reduce heat losses.
Settings and protections introduced are subject to
approval by the Customer.

Thank you!
42

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ESP System Start-Up,

Commissioning and Operation

© NOVOMET |WWW.NOVOMET.RU/ENG | 2017

The number of personnel on startup of the well should

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

During startup the following people should be present

Make visual inspection of the ESP system

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

For VSD for PMM motors it is prohibited to perform check of

For VSD for PMM it is prohibited to check correct phase sequence

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

Diameter of the casing

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

Before startup it is necessary to calculate the required

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

b) for VSD for AM and PMM (except VSD Novomet) :

U2 — tap voltage at SUT secondary winding, V;

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

c) for VSD Novomet (VSD can calculate it automatically):

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

U motor U cable.line

Ufc = 320 V…360 V (VSD for 380 V);

U swf  2    Lswf  Fmax  I motor.nom  K tr.1  0,001

During VSD selection operator should be guided

During VSD selection margin should be taken into

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

Calculation according to table

table value  Ltotal.cab

Reservoir temperature, Reservoir temperature, Reservoir temperature, Reservoir temperature,

Check with voltmeter if voltage in Junction box

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

NOT JUST ANOTHER ESP PROVIDER © NOVOMET |WWW.NOVOMET.RU/ENG | 2017

Should be selected after pumping-out of the

The selection should be done through step-

While reducing the voltage necessarily keep

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

Overload trip (OLT) is intended to

OLT = 1.05 * Imotor.nom

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

No-load trip (NLT) during startup (setting

NLT during confirmation of well set to

Setting-up of voltage drop protection should be performed

Umax setting = Unom.pw.line * 1,1. (110%)

Protection setting for the minimum voltage (under voltage):

Umin setting = Unom.pw.line * 0,9. (90%)

Actuation time delay should be set to 5 seconds.

Current unbalance protection is necessary to ensure stable

Voltage unbalance protection is necessary to ensure stable

Voltage unbalance should not exceed 5%.

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

Backspin protection is intended to prevent ESP system

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

After ESP startup it is necessary to determine

b) pressure test of the X-mas: while the unit is in

Continuous operation of ESP without the inflow

ESP system with a submersible motor

ESP system with a submersible motor

ESP system with a submersible motor