Motors

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 Objectives

To Understand the Theory of Operation of a Motor

To Describe the key components of a Motor

Identify Motor Rating considerations

To Describe the effects of Frequency vs Horsepower

To Discuss Motor Selection and Configurations

To Understand Motor Performance Curves

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 Motor Construction

The Downhole Electric Motor:

»3 phase

»Squirrel cage

»2 pole

»Induction Motor.

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 Motor Construction

Because the structure resembles the cage used to

exercise squirrels, rotors of this type are called
“Squirrel-Cage” rotors.

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 Motor Construction (Stator)

Because of the way the

stator is wound, the three
phase power establishes a
two pole magnetic field
within the stator.

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 Stator
Laminations
Housing
Shaft

Rotor bar

+ + + Flux Lines
Winding

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 Motor Construction (Stator)
The stator is the core or electrical field of the motor. Housing

Stator
The stator is composed of the
housing material for a desired
Stator
diameter, the stator core, and the Core
stator windings

The stator core is composed of

Stator
laminations stacked under Windings
pressure to insure a permanently
tight core.

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 Motor Construction (Stator)

Laminations are thin sheets of die-

punched steel or bronze material.

Laminations
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 Motor Construction (Stator)

The stator is hand

wound by experienced
craftsmen. Each
stator is wound in
three phases with the
determined amperage
and voltage for each
order placement.

Windings
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 Motor Construction (Stator)

The windings are made from

either Polyimid or PEEK
material, for primary
magnetizing winding wound
through the die-punched
slots in the stator core.

Windings

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 Motor Construction (Rotor)
The rotor is a device that rotates inside of the
stator core.

The rotor is made up of rotor laminations that

are smaller in diameter from the stator
laminations and these creates the iron core.
Inside each slot are copper bars with
supporting copper end rings. Rotor

The bars are shorted together at each end by

a rotor “end ring”. Depending on the motor,
the end ring is either braided or brazed to the
rotor bars.

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Motor Construction (Rotor)

540 562

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 Motor Construction (Rotor Bearings)
The Bearing Material is Babbitt-lined steel Its main purpose is to provide the axial and
and machined after processing. There are radial thrust capabilities.
fluid holes to insure oil circulation and
wide angle oil grooves on the OD to
distribute lubrication evenly over the entire
length of the bearing surface.

The bearing sleeve is a bronze material for

the sleeve construction of the bearing. This
part is keyed to the shaft and the hole on the
sleeve is aligned with the hole on the shaft to
insure proper cooling and lubrication.

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 Motor Construction (Thrust Bearing)
The motor thrust bearing is
installed at the top of the rotor
string. It is designed to hold the
weight of the entire rotor assembly.

The thrust bearing limits on the

system will indicate the type of load
required for the selected bearing
material.

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 Motor Construction (Thrust Bearing)

REDA currently uses four types of

motor thrust bearings.
Babbitt
Glacier (Peak coated tilting pad)
Bronze pads
REDA Bronze

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 Motor Construction (Thrust Bearing)

A special note about thrust bearings here:

– The standard REDA bearing is "bi-directional" -- that is

the motor can be run in either direction with no loss in
bearing capacity.

– The Hi-Ex Glacier thrust bearing is uni-directional and

can only be operated in one direction. Reverse
operation may lead to bearing failure.

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 Motor Construction

Although the 562 motor head

is designed to mate to a 540
protector, the 562 UMB and DME
units must be used on the
bottom end. Both of these parts
are designed with the same
reservoir and filter system as
the 562 single motor with no loss
in features and benefits.

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 Motor Construction (Pothead)
REDA production system uses mainly
tape-in potheads versus plug-in type for
motor lead connection to the pothead.

Historically tie in potheads have

been more reliable than plug in
ones.

The disadvantage is the time

taken for connections

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 To Summarize the Motor

The stator takes electrical energy (KVA) from the surface and
converts this to magnetic energy in the stator laminations.

The magnetic field of the stator induces current (electrical energy)

flow in the rotor.

This electrical energy in the rotor induces a secondary magnetic field

in the rotor laminations.

The magnetic poles of the rotor will be attracted to (and repelled

by) the magnetic poles in the stator.

As the stator magnetic field moves, the rotor will move to try to
follow it.

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Motor Rating

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 Motor Rating

In standard applications, the surface voltage is fixed and

the amperage changes as the load on the motor changes.

In fact we use this information in the form of an amp chart

to see what is happening downhole with the motor.

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 Motor Rating

We can very easily anticipate this relationship by simply

looking at the equation for motor horsepower:

Motor HP = Volts x Amps x 1.732 x Eff x P.F

746

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 Motor Rating

In reality this relationship 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 current too much will give
us greater copper losses in the motor winding; which is not
good for efficiency.

By increasing the voltage with increasing horsepower,
we can keep the rise of amperage in control

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Motor Rating

This shows an example of

what the flux lines might
look like for one phase
winding based on a
moderate loading of the
motor.

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 Motor Rating
If we place more
load on the same
motor, we get
many more
flux lines
required to Moderate Load

generated the
necessary
horsepower.

Heavy Load
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 Speed - Torque of Typical REDA Motor

Normal
area of
operation

Torque

m p
u
g er P
Starting Torque Lar
To rque
Pump
0 20% 40% 60% 80% 100% 120%
Speed (% of No-Load Speed)
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Typical temperature profile in a Motor
Casing I.D.

Th Potential
Hot Spot
Tw

Ts
Flow
Tf
Motor
Housing

Stator Winding

Th is the "hot spot" temperature

Tw is the winding temperature
Ts is the motor skin
Tf is the bulk fluid temperature Schlumberger
 Motor Rating
Another limiting factor will be temperature differential. As the motor
heats up, the components expand and they expand at different rates
since not all the materials are the same.

Even if the motor were all one material, expansion would vary since
the internal temperature changes within the motor itself.

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 we could have bearing failures or
other damage.

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Motor Types, 60 & 50HZ
Combinations

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Motor Types, 60 & 50Hz Power supply

A 60 Hz motor can run on 60 Hz or 50Hz power.

Inductive resistance of stator winding is lower

at 50 Hz and we have to decrease voltage if the
motor runs at 50 Hz. The ratio of 60Hz and 50 Hz
voltage will be the same : 60/50

It also means that the same motor will deliver

less horsepower at 50 Hz than at 60Hz.

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 Frequency

For example, a 456 series 60Hz motor 120 HP - 2480V - 30.5

amp would have a 50 Hz rating of 100 HP - 2066V - 30.5 amp

The amperage does not change.

2480 Volts x 5/6 = 2066 Volts

120 HP x 5/6 = 100 HP
BUT
Current remains constant

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Motor Types, 60 & 50HZ Combinations

Say we have a 50 Hz pump application which requires 157

horsepower

but we only have a 60 Hz motor catalogue page available.

We want to use a 540 intermediate motor but don't know

which one. What do we do?

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Motor Types, 60 & 50HZ Combinations

We can easily determine an

equivalent 60 Hz horsepower
as follows:
60

Now we can go look for a 157 Hp x = 188.4 Hp
50
motor larger than 188.4 HP.
It looks like we will need a
200 HP. Let's take the 2194
volt, 55.5 amp motor. What
will be the 50 Hz rating?

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Motor Types, 60 & 50HZ Combinations

The 50 Hz rating will be:

50
200 Hp x = 167 Hp
60

50
2194 volts x = 1828 volts
60

55.5 amps = 55.5 amps

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 Motor Types, 60 & 50HZ Combinations

This will apply no matter what frequency the motor is

operating on.

It does not only apply to 50 Hz and 60 Hz.

What if we have this same motor operating on a generator

set and the generator is actually running at 65 Hz.

What would be the rating of the motor?

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Motor Types, 60 & 50HZ Combinations

The 65 Hz rating will be:

65
200 Hp x = 217 Hp
60

65
2194 volts x = 2377 volts
60

55.5 amps = 55.5 amps

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Motor Types, 60 & 50HZ Combinations

At 65 Hz, the motor is capable of more horsepower. If our

pump load is still only 157 Hp (it would not be, but that is
not the point), we would be under loading the motor.

We know this is not a problem and that motors will even be

more reliable under lower loads (lower internal heating).

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Motor Selection &
Application

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 Steps in Selection
Consider :

I. Motor Series

II. Motor Type

III. Motor configuration, Voltage and Amperage

IV. Actual motor performance & Operating
Temperature and compare against maximum
temperature of the well

V. Re-select motor if necessary

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 Motor Series

In general, just as in pumps, the bigger the better.

Larger diameter motors are less expensive to purchase.

as they can also go to higher horsepower without the need for tandem
connections which will enhance reliability — simple systems are better.

The only exception in this is the 738 motor.

The 738 motor is often more expensive than the 540 due to the lower
usage and higher cost of inventory, handling and storing.

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Motor Type - Ratings

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Motor Type – Insulation Rating

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Motor Oil Selection

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 Upper Tandem Motor

The motors can be

connected together to
create more horsepower
— to a limit.

Two motors connected

together are called tandem
Leads for
units. connection to
other motor or
DMT unit.

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 Tandem Motor Configuration
When putting more than one motor together in tandem
combinations, recommended to keep the sections the same
HP and voltage with similar amperage.
For example a 300 HP, 540 motor should be made of two
150 HP motors rather than something like a 200 HP and a
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.

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 Tandem Motor Configuration

With two motors 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.
For example, a 140 HP, 1299V, 69.5A UT
motor coupled to a 140 HP, 1299V, 69.5 CT motor
would give us a 280 HP, 2598V, 69.5A motor.

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 Tandem Motor Configuration

Always take care when adding motors together so that the

total voltage does not exceed the system limits -- i.e. do not
try to put 3500 volts on a 3 kV cable.

Surface controllers, transformers, wellhead feedthrough

mandrels (Penetrator, BIW Connector), etc. will all have
voltage limits we need to be concerned with.

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Motor De-Rating

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375 Conventional

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456 Dominator

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540 Conventional

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562 Dominator

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562 Maximus

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 Motor De - Rating
Example:
» Motor HP (nameplate)…………… 236HP
» Motor Voltage (nameplate)……… 2550 Volts
» Motor Amps (nameplate)………… 50Amps
» Expected Pump Load (AE Pad)….190HP

» %Load = Pump HP x 100

Motor HP

» Running Amps = %Load x NPA

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 Motor De - Rating

%Load = 190 HP x 100 ⇒ 80%

236 HP

Lets now analyze motor performance curve (562 Maximus)

Running Amps = %85 x 50 Amps ⇒ 42.5 Amps

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562 Maximus
Eff 88%

PF 80%

Amps 85%

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 Motor De - Rating
Therefore:
Motor HP = Volts x Amps x 1.732 x Eff x P.F
746

190 HP = Volts x 40 x 1.732

746

Hence De-rated Voltage : 2058volts

Not recommended to de-rate less than 50%

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 Summary - Construction

Describe the Function of the Stator?

Describe the purpose of the Rotor?

What is the main purpose of Motor Thrust Bearing?

What is the main purpose of Motor Thrust Bearing?

What is the purpose of the laminations in both Stator and Rotor?

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 Summary - Rating

What is Motor Saturation?

Describe the term Copper losses and how can this be minimized?

Explain the Torque vs Speed curve for the following:

» Pump Size
» RPM
» Shaft

Explain the effects of flow and fluid properties on motor temperature

performance?

What is the effect of frequency changes in terms of :

» Horsepower?
» Inductance?
» Generators?
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 Summary - Configuration

What precautions need to be considered with Tandem motors?

With Tandem motor configurations (ie: 300HP/1800V/50A):
» New HP?
» New Voltage?
» New Amperage?

Define Terminal Voltage?

De-Rate the following :

» 100GN7000
» TDH 3000 feet
» 2 X 150HP/2450V/54A Tandem Motors (562 Dominator)

Hint
» Calc Pump HP
» Calc %Load
» Calc Running Amps
» Calc New Voltage

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