Electrical Submersible Pump: Design, Installation, Commissioning and Maintenance

Course Code: EEC 131

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Electrical Engineering

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Introduction

Training course introducion / brief

Electric Submersible Pumps (ESPs) are used in most of global oil production operations. This training course is a complete package of topics that cover all aspects in relation to ESP; fundamental knowledge, equipment selection, installation, commissioning, operation monitoring, control and maintenance from the Electrical point of view. In addition, this training course will familiarize the user with the ESP system and its application by; detailed description of components and design features analysis. Recent innovations in ESP technology will also be presented and discussed so that the delegates are updated with current developments in ESP industry.

Overview the (ESP) systems main basic components of Electric Submersible Pumps.
Optimize well productivity using ESP systems
Identify the function of each component of the ESP system, and to select optional components and add-ons
Optimize system power efficiency
Monitor system performance using the different types of sensors available
Description of every component comprising the electrical submersible system
Installation considerations and important best practices to apply
Learn about the different types of ESP systems and its specific applications
Understand the components and equipment used with ESP
Be aware of the innovations in ESP pump technology
Selection of proper ESPs for specific purposes
Carry out ESP performance calculations
List the advantages and limitations of various ESP drive systems
Outline the power supply requirements of ESP installations
Maintain and troubleshoot ESP systems

Electrical power system configuration & components
Power system parameters and engineering criteria
Introduction to ESP technology and artificial lifting
Types of Oil lifting (Oil Production Methods )
Natural lifting.
Artificial lifting
Artificial lifting Types
Reciprocating displacement rod lift systems
Progressing Cavity Pumping systems (PCP)
Hydraulic lift systems
Gas lift systems
Electric Submersible Pumping Systems (ESP)
Practical ESP component
Submersible Electric motor.
Motor seal section (protector).
Intake or gas separator.
Centrifugal pump.
Power cable.
Electric power supply (power transformer).
Junction box.
Circuit breaker for operation and protection.
Variable Speed Drive (VSD).
Down-hole monitoring (sensor).

Introduction to AC Machine operation
Ac Motor Types
Idea of Operation AC Motor
AC motor construction & component
Stator
Rotor
Bearing
Mechanical basics
Developing a rotating magnetic field
Ac motor Problem of starting
Ac motor normal operation control
ESP Motor Parameter (Technical specs)
Motors speed torque characteristics
Methods of electric motor speed control
Electric motors breaking methods
ESP Motors speed / Torque characteristics
Starting torque
Pull-up torque
Breakdown torque
Full load torque
Starting values of current
Motor NEMA design
Practical Motors Troubleshooting
ESP Motor enclosures
Practical Permanent Magnet Motors (PMG)
AC Induction Motors vs. Permanent Magnet Synchronous Motors

Practical Motor starting methods
Direct-on-line (DOL)
Star-delta starters
Primary resistance starters
Electronic soft starters
ESP Motor sizing and selection
Electrical supply considerations
Load Curve
Motor efficiency
Pump low efficiency.
Pump gas locking.
Locked pumps.
Tubing leaks.
Fluid recirculation.
Loss of flow due to a closed valve.
Motor overloading.
ESP Motor Spin
Overload
Vibration
Misalignment
Friction
Stray oil
ESP Power Cable.
Characteristics of copper IEC 60228
Introduction of IEC 60502
Cables conductors’ types
Cables insulation
Cable components.
Motor connection.
Selection The insulation of the cables.
Voltage drops in the (ESP) cable.
Cables splices.
Steps of fault location finding of the cables.
Cables megger testing and burners.
Insulation test methods
Cables grounding during the test

Power Transformers design and operation
Transformer operation and construction
Power Transformers construction Testing & Inspection
ESP Transformers accessory Testing & Inspection
Electrical transformer protection Testing & Inspection
Mechanical and Electrical Testing & Inspection
Practical Determine Power Required by Pump
Practical Determine Total Power Required by Pump
Practical Power Required by Protector
Practical Determine Total System Power Required
Practical Determine Motor Current Required
Practical power cable losses
Practical Pump performance curve for single stage at 60hz
Practical Motor composite curve
Practical Generic protector loading curve
Practical Chart to determine 3 phase voltage drop in a power cable at 77°F
ESP various type of controllers
ESP Digital and analogue signals
Microcontrollers technology
HMI
Communications systems in ESP
Microprocessor RAM and ROM
Data transmission (wire and wireless) technologies
Alarms / Events / Notifications

Introduction to power electronics
Types of electronics switches and converters
Difference between various types of VFDs
Practical VFD components
Rectifier
DC link
Inverter
Practical VFD types
VFD effect of Motor Operation
Disassembly of an AC Drive
Component Identification
Various Designs of Drives
Hands-On Programming and Operation of an AC Drive and Motor
Adjust Minimum and Maximum Speed
Reset Drive to Factory Defaults
Adjusting Torque Output
General Drive Programming
Variable Frequency drives parameter programming and applications
Methods of Speed and Torque Control
VFD Rectifier Parts
Diode
Practical Rectifier Configuration
Practical VFD Rectifier pulses
6 pulse
12 pulse
18 pulse
24 pulse
VFD DC Link Parts
Coil and capacitor configuration
Effect of DC link
Operations of DC link energy and inverters, regeneration or dynamic slowdown, dynamic breaking, plugging
Sizing of capacitor effect
Configuration of DC link
VFD Inverter Parts
Thyristor (SCR), IGBT, MOSFET, GTO operation concept
Thyristor (SCR), IGBT, MOSFET, GTO configuration
Thyristor (SCR), IGBT, MOSFET, GTO types
Practical Inverter configuration
Pulse Width Modulation PWM concept
Control of frequency
Control of voltage
V/F ratio control
General discussion

Boost certificate of completion

BOOST's Professional Attendance Certificate “BPAC” is always given to the delegates after completing the training course, and depends on their attendance of the program at a rate of no less than 80%, besides their active participation and engagement during the program sessions.

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Shareable Certificate

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COURSE METHODOLOGY

Our Training programs are implemented by combining the participants' academic knowledge and practical practice (30% theoretical / 70% practical activities).

At The end of the training program, Participants are involved in practical workshop to show their skills in applying what they were trained for. A detailed report is submitted to each participant and the training department in the organization on the results of the participant's performance and the return on training. Our programs focus on exercises, case studies, and individual and group presentations.

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TRAINING COURSE: Electrical Submersible Pump: Design, Installation, Commissioning and Maintenance