Chapter - 08 Switchboard and VSD

Electric Submersible Pumps Mohamed Dewidar 2013
Chapter 8

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Switchboard and Variable Speed Drive
Table of Content
Section Content Page
1 Switchboard 2
1.1 Standard feature 2
1.2 Basic components 3
1.3 Theory of operation 6
2 Variable Speed Drive (VSD) 7
2.1 Introduction 7
2.2 Components 8
2.3 Theory of operation 10
2.4 VSD effect on ESP components 10
2.5 Benefits of VSD 13
2.6 Harmonics 15
2.7 VSD Example 1 19
2.8 VSD Example 2 32

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Switchboard and Variable Speed Drive
8.1. Switchboard
Switchboard is an electro-mechanical controller provides:
1. Manual disconnect switch.
2. Magnetically operated motor controller.
3. Over-current relays.
4. Undercurrent relay for pump off and gas lock protection.
5. An automatic time delay relay (used to restart the pump
after a predetermined shutdown time).
6. A Bristol recording ammeter, with mechanical clock, records
running time, down time and amount of current being used
during operation.

Fig (8.1) Switchboard
8.1.1. Standard Features
1. Enclosures are NEMA-3R/12, suitable for outdoor
application.
2. "Hand-Off Auto" selection switch "start" push button and
disconnect switches.
3. Recording ammeter with a combination 24 hour, 7 day clock.
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4. Automatic restart feature provides for restarting after
expiration of a preset time interval after shutdown due to
underload or power failure.
5. Switchboards are suitable for use with external control
devices.
6. Three current-limiting fuses are provided for heavy fault
current protection.
7. Vacuum contactors.
8. Lightning arrestors are provided.
9. Modifications required for use with downhole monitoring
system.
10. Full protection is provided by Electro-Mechanical or Solid
State Protection systems.
8.1.2. Basic components
Potential Transformers (PTs)
The main function of potential transformers is to reduce
voltage and current to safe operating levels for use by the
control circuit.
Potential transformers have a low voltage rating of 120 volts
(secondary), and variable high voltage ratings (Primary).
The accuracy and ratios of these transformers on each tap are
tested to a tolerance of + 2%.
The rated secondary voltage is 126 volts at a no load
condition. (Note: Not 120 volts. Fully loaded, there is a 5%
to 7% secondary voltage loss through the transformer.
Therefore, the voltage ratio should be obtained by using 126
volts instead of 120 volts initially).
Current Transformers
Electronic and mechanical measuring devices monitor the
amperage in the switchboard. To monitor the motor current, it
must be reduced to a level that is easier to measure. If the
amperage drawn by the motor was not reduced, measuring devices
would have to be large and cumbersome in order to house
components capable of withstanding high currents. Most ESP
measuring devices (motor controllers) are designed to operate
from 0 to 5 amps. To reduce or scale-down the actual current
in the switchboard to an acceptable level, current
transformers (CTs) are used.
CT Ratio's
The CTs should be sized such that under normal operating
conditions, secondary control amp levels are between 2.5 and
3.5 amps. This is done to obtain the best motor controller
performance and to have the pen track along the center of the
recording ammeter chart.
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The CT ranges used in the controllers have a TR of 100:5,
200:5 and 150:5, 200:5, 300:5.
Example 1
If 180 A is flowing through the conductor and the TR is 200:5,
what will the current on the secondary side of the CT?
200:5 ratio is 40 = (200/5)
Secondary Amps = 180/40 = 4.5 A

If one pass of the wire results in a control circuit current
greater than 5 amps, the C.T. ratio must be increased by going
to one with a higher turns ratio.
Control Circuit amperage can also be doubled by looping the
wire for two passes or increased by three passes.

Example 2
Take a motor load of 90 amps and the only current transformers
available are 300:5. What current would the ammeter see in
each of the situations below?
Motor load 90 amps, current transformer ratio 300:5 (=60)
90/(300/1:5) 90/(300/2:5) 90/(300/3:5)
1.5 Amps 3 Amps 4.5 Amps

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Example 3
59 amps goes through the switchboard, which is the best CT
ratio to use?
Motor Controllers work best between 2.5 - 3.5 Amps. This has
the amp chart pen tracking the center of the chart.
200:5 ratio 59 / (200 / 5) = 1.48 Amps
150:5 ratio 59 / (150 / 5) = 1.97 Amps
100:5 ratio 59 / (100 / 5) = 2.95 Amps
Example 4
59 amps goes through the switchboard what is the best CT ratio
to use?
A short cut is to simply multiply the current by 1.6 to get
the nearest ratio.
59 x 1.6 is 94.4 the nearest ratio is 100:5
In example 2, we examined 90 amps, what would the ratio be
using this quick method?
Motor load 90 amps, current transformer ratio 300:5 (=60)
90 x 1.6 = 144 the nearest ratio is 150/5 = 30: 90/30= 3 A
Power Circuit
Incoming power to the controller is applied to the disconnect
switch which is manually operated, i.e., on or off.
A lightning arrestor can be attached below this switch to
provide some measure of protection to the control and motor
from lightning strikes.
The motor current carrying power wires pass through three
current transformers. These transformers step down the power
circuit current to an amp level usable by the various load
sensing devices in the control circuit.
A potential transformer is used to step down the incoming high
voltage to provide 120 volts for the control circuit.
Vacuum contactors utilize three sets of normally open
contacts.
When energized, power is transmitted directly to the downhole
motor. Vacuum contactors utilize 3 vacuum bottles to switch
the power circuit.
The Control Circuit
Each of the current transformers in the power circuit
transmits current to one of the three overload relay coils.
The recording ammeter and underload relay are in series with
two of these overload relays to allow underload sensing and
recording of the running current.
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Each overload relay has a normally closed contact. These three
contacts are in series with one side of the 120 volt control
circuit.
If an overload occurs in any one of the power circuit phases,
the corresponding contact opens, turns off the control circuit
and shuts down the motor.
The underload relay has a normally closed contact which is
open when the motor is running normally. This contact closes
on underload condition.
Under Current Relays
The under current relay is a safety feature, installed in the
electro-mechanical switchboard control circuit.
In case of pump off condition, pump intake plugging off, pump
gas lock or a broken shaft, and if the under current relay is
set correctly, it will sense the low current and shut the unit
down.
8.1.2. Theory of operation
Switchboards provide full voltage and current when the
contactors are engaged. As previously stated, the power
(voltage, current, and frequency) applied to the switchboard
is also the output voltage, current, and frequency. Step-up or
step-down transformers may be used in line with the
switchboard to change the voltage to a level suitable for the
ESP electrical components (motor and cable).
When starting an ESP system with a switchboard, the frequency
and voltage are the same at the input and output terminals.
This results in a fixed speed operation. When started, the
motor will ramp up to its rated speed within a fraction of a
second. During starting, a motor can draw 5 to 8 times its
rated current. This high starting current allows the motor to
deliver several times its rated torque. This can cause
excessive electrical and mechanical stress on the ESP
equipment, especially in shallow set applications.
Generally, an ESP is placed into operation at a depth that
requires several thousand feet of power cable. During start-up
operations, this piece of cable causes a voltage drop to the
motor. This reduced voltage start decreases the initial
starting current and torque.
Time delayed underload protection and automatic protection
against voltage or current imbalance on all three phases is
offered in most solid state controllers, underload, or some
type of pump off protection, is necessary since low flow past
the motor will not give adequate cooling. Circuits designed
for automatic restart after shut down are normally included.
External control devices should be interfaced with the
controller as recommended and/or approved by the pump
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manufacturer to give dependable and trouble free operation.
All external control devices are connected to a time delay
which activates or deactivates the controller after a short
time delay. Usual external control devices are tank hi-lo
level controls or line pressure switches.
8.2. Variable Speed Drive
8.2.1. Introduction
Variable speed drives (VSD) allow operators to vary ESP
performance by controlling the speed of the motor.
Controlling motor speed can
Lower motor temperature.
Improve ESP gas handling capabilities
Control well drawdown
Adjust ESPs to changing well conditions
Decrease system stress at start-up
Maximize the benefits of downhole monitoring, and improve
system harmonics.
Variable speed drives are also used to control the pump speed
and protect the pumping system. VSD shut down the system if
conditions develop that could potentially damage the ESP.
If operating parameters go outside a set point, but are still
within a critical limit range, the VSD will slowly make step
changes to return to the initial set point. The unit also
provides up to 200% starting torque to overcome hard start
situations.
Electrical Submersible Pumps (ESP) are fairly inflexible when
operated at a fixed speed. The ESP is limited to a fixed range
of production rates and a fixed head output at each rate. The
VSD has gained acceptance as the ESP controller to alleviate
these restrictions. By allowing the pump speed to be varied,
the rate and/or head can be adjusted (depending on the
application) with no modification of the downhole unit.
8.2.2. Components
Converter (Rectifier)
The rectifier in a VFD is used to convert incoming ac power
into direct current (dc) power. One rectifier will allow power
to pass through only when the voltage is positive. A second
rectifier will allow power to pass through only when the
voltage is negative. Two rectifiers are required for each
phase of power. Since most large power supplies are three
phase, there will be a minimum of 6 rectifiers used.
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The term 6 pulse is used to describe a drive with 6
rectifiers. A VFD may have multiple rectifier sections, with 6
rectifiers per section, enabling a VFD to be 12 pulse,
18 pulse, or 24 pulse.
Rectifiers may utilize diodes, silicon controlled rectifiers
(SCR), or transistors to rectify power.
Diodes are the simplest device and allow power to flow any
time voltage is of the proper polarity.
Silicon controlled rectifiers include a gate circuit that
enables a microprocessor to control when the power may begin
to flow, making this type of rectifier useful for solid-state
starters as well.
Transistors include a gate circuit that enables a
microprocessor to open or close at any time, making the
transistor the most useful device of the three.
In the diagram below, diodes (D1 through D6) allow current to
flow only in one direction when enabled by the gate signal.
In this diagram, the AC power on L1 goes into Diodes D1 and
D2. Because of the position of these diodes, current flow can
only go up. The D1 diode conducts when the AC is positive and
D2 conducts when the AC goes negative.
This drives the top line (+) more positive and the bottom
line (-) more negative. Diodes D3 and D4 convert L2 power to
DC and Diodes D5 and D6 convert L3.
A volt ohmmeter or VOM can be used to measure this DC voltage.
In this type of circuit, the DC voltage is 1.414 times the AC
line voltage.
If 240 Vac is coming in, 339 Vdc is generated.
If 380 Vac is coming in, 537 Vdc is generated.
If 460 Vac is the line voltage, 650 Vdc is generated.

Fig (8.2) VSD converter (6 pulse)
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DC Bus
After the power flows through the rectifiers it is stored
on a dc bus. The dc bus contains capacitors to accept
power from the rectifier, store it, and later deliver
that power through the inverter section.
The dc bus may also contain inductors, dc links, chokes,
or similar items that add inductance, thereby smoothing
the incoming power supply to the dc bus.
Inverter
The final section of the VSD is referred to as an inverter.
The inverter contains transistors that deliver power to the
motor.
The Insulated Gate Bipolar Transistor (IGBT) is a common
choice in modern VSDs.
The IGBT can switch on and off several thousand times per
second and precisely control the power delivered to the motor.
The IGBT uses a method named pulse width modulation (PWM) to
simulate a current sine wave at the desired frequency to the
motor.

Fig (8.2) VSD components
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System Control
The control system motor controller provides protection,
monitoring, and control for electrical submersible pumps.
Use of the latest digital electronics and graphic display
technology allows for an intuitive, human interface that
delivers ease of set-up, operation and diagnostics.
When combined with available sensors, the controller is
configurable for use in many types of programmable motor
control applications. The controller provides additional
flexibility with system expansion and customization.
The display unit is common to all modules of the control
system family, providing a familiar interface for a variety of
control and measurement products.
8.2.3. Theory of operation
The basic operation of the VSD is to convert the incoming 3
phase AC power, typically at 480 volts or 380 volts, to a
single DC power supply.
Then using power semiconductors as solid state switches, it
sequentially inverts the DC supply to regenerate three AC
output phases of pseudo-sine wave power. The frequency and
voltage of the output wave are controllable.
Although pumping flexibility is typically the original purpose
of applying a VSD, there are additional benefits to the
operator. Particularly, the VSD extends downhole equipment
life, provides soft start capabilities, controls wellbore
drawdown, automatically controls speed, provide line-transient
suppression and may eliminate the need for surface chokes.
The VSD also helps prevent electrical failures, VSD
controllers do this by isolating the load from incoming
switching and lightning transients, balancing output volts to
reduce motor heating, ignoring frequency instability from
generator supplies, compensating for brownouts, and minimizing
starting stresses.
In addition, VSDs can improve overall system efficiency,
reduce the required generator size, obviate the need for a
choke, reduce downhole unit size and provide intelligent
control functions to maximize production.
The best combination of drive features and benefits must be
selected and combined based on the application.
8.2.4. VSD effects on ESP components
Effects on Centrifugal Pumps
The performance of the centrifugal pump is described by a
curve of head versus rate for a given speed. Changes in speed
generate a new curve.
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The head values are larger if the speed is increased and
smaller if the speed is decreased. As the operating frequency
of a three-phase induction motor varies, the pumps speed
changes in direct proportion to the frequency.
Thus, the speed of the pump and its hydraulic output can be
controlled simply by varying the power supply frequency. This
remains true provided that voltage and motor loading limits
are properly observed.
The technique of combining the performance characteristics of
the centrifugal pump and the three-phase induction motor,
allows a multiple frequency performance curve to be developed
(Figure 8.3). The following equations were derived based on
these conditions (Derived from Affinity Laws)

Fig (8.3) Variable speed pump curve
Chapter 8

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Effects on Motor
A fixed frequency motor of a particular frame size has a
specified maximum output torque for the specified voltage that
is supplied to its terminals. This same torque can be achieved
at other speeds by varying the voltage in proportion to the
frequency. This allows the magnetizing current and flux
density to remain constant and so the available torque will
also be constant (at nominal slip rpm).
As a result, power rating is obtained by multiplying rated
torque by speed. Power output rating is directly proportional
to speed.
It should be noted that this rerating of motors increases the
maximum horsepower available to fit a particular size casing.

Matching Motor, Pump and VSD
Normally the pump is chosen to deliver a certain hydraulic
output at a particular speed.
A motor is chosen so that the capacity matches the pump when
operating at the maximum anticipated speed. Any frequency
above that speed will overload the motor due to the cubic
nature of the pump load. Similarly, the motor will operate in
underload at lower frequencies. This relationship is reflected
in the current drawn by the motor as the motor nameplate amps
will only be drawn at the chosen speed.
The surface kVA requirement is calculated to include the
resistive loss in the power cable and motor requirements at
maximum frequency since this represents the peak requirement
of the system. A VSD unit is selected if its rated kVA
capacity matches or exceeds the requirements.
The linear characteristic of the motor HP capability
intersects the cubic pump BHP characteristic at the design
maximum frequency. Higher operating frequencies would generate
a motor overload situation (Figure 8.4). These principles lay
out the theory, but in practice, there are several additional
details that also need to be considered when designing a full
VSD system.
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Fig (8.3) HP versus BHP chart
8.2.5. Benefits of VSD
Low Inrush Motor Starting (low motor starting current)
It is common for AC induction motors to draw 6 to 8 times
their full load amps when they are started across the line.
When large amounts of current are drawn on the transformers, a
voltage drop can occur

affecting other equipment on the same
electrical system. Some voltage sensitive applications may
even trip off line. For this reason, many engineers specify a
means of reducing the starting current of large AC induction
motors.
A VSD is the ideal soft starter since it provides the
lowest inrush of any starter type. The VSD can use frequency
to limit the power and current delivered to the motor. The VSD
will start the motor by delivering power at a low frequency.
At this low frequency, the motor does not require a high level
of current. The VSD incrementally increases the frequency and
motor speed until the desired speed is reached.
High Power Factor
Power converted to motion, heat, sound, etc. is called real
power and is measured in kilowatts (kW).
Power that charges capacitors or builds magnetic fields is
called reactive power and is measured in Kilovolts Amps
Reactive (kVAR).
The vector sum of the kW and the kVAR is the Total Power
(energy) and is measured in Kilovolt Amperes (KVA).
Chapter 8

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Power factor is the ratio of kW/KVA
Motors draw reactive current to support their magnetic fields
in order to cause rotation. Excessive reactive current is
undesirable because it creates additional resistance losses
and can require the use of larger transformers and wires. In
addition, utilities often penalize owners for low power
factor.
Decreasing reactive current will increase power factor.
Typical AC motors may have a full load power factor ranging
from 0.84 to 0.88. As the motor load is reduced, the power
factor becomes lower.
Power factor correction capacitors can be added to reduce the
reactive current measured upstream of the capacitors and
increase the measured power factor. In most cases, this
results in maximum corrected values of 0.90 to 0.95.
The VFDs include capacitors in the DC Bus that perform the
same function and maintain high power factor on the line side
of the VFD.
This eliminates the need to add power factor correction
equipment to the motor or use expensive capacitor banks. In
addition, VFDs often result in higher line side power factor
values than constant speed motors equipped with correction
capacitors.
Low Full Load KVA
Total Power (KVA) is often the limiting factor in the amount
of energy that can be transmitted through an electrical device
or system. If the KVA required by equipment can be reduced
during periods of peak demand, it will help decreasing the
voltage sags. Higher in power factor has significantly lower
KVA.
-------------------------------------------------------------
Input Kw PF Amps Volts KVA
-------------------------------------------------------------
350.4 0.84 502 480 417
350.4 0.99 426 480 354
Note:
KVA = Volts x Amps x 1.732
Backup generators are typically sized to closely match the
load. Lowering KVA can reduce the size of the generator
required.
When VSDs are used, the generator size can approach an ideal
1:1 ratio of kW/KVA because the power factor is near unity
(1.0) and the harmonics (will be discussed late) produced by
the VFD are extremely low.
Chapter 8

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Lower KVA also benefits utilities. When the power factor is
higher, more power (kW) can be delivered through the same
transmission equipment.
8.2.6. Harmonics
Harmonics are integral multiples of some fundamental
frequency that, when added together, result in a distorted
waveform.
Power system harmonics:
Currents or voltages with frequencies that are integer
multiples (h=0,1,2,N) of the fundamental power frequency
1
st
harmonic: 60Hz
2
nd
harmonic: 120Hz
3
rd
harmonic: 180Hz
Single phase 3
rd
, 6
th
, etc (triples) can cause transformer
neutral conductor overheating
Three phase 5
th
, 7
th
, 11
th
, 13
th
, etc can cause equipment
malfunctions.
The following are some harmonics examples:

5
th
harmonics
Chapter 8

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7
th
Harmonics

11
th
Harmonics
Chapter 8

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13
th
Harmonics

Result of af 5
th
, 7
th
, 11
th
, and 13
th
harmonics
Negative Effects of Harmonics
Overheating and premature failure of distribution
transformers.
Increasing iron and copper losses or eddy currents
Overheating and mechanical oscillations in the motor
load system
Chapter 8

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Producing rotating magnitude field, which is opposite to
the fundamental magnitude field.
Overheating and damage of neutral ground conductors
Trouble sustained type Harmonics: 3
rd
, 9
th
, 15
th

A 3-phase 4-wire system: single phase harmonic will add
rather than cancel on the neutral conductor
Power factor correction capacitor failure.
Reactance of a capacitor bank decreases as the frequency
increases.
Attenuation of Harmonics
Active filters
Inject equal an opposite harmonics onto the power system
to cancel those generated by other equipment.
12 Pulse rectifier
Two separate rectifier bridges supply a single DC bus.
The two bridges are fed from phase-shifted supplies.
(Very effective in the elimination of 5
th
and 7
th
harmonics
18-pulse Rectifier
An integral phase-shift transformer and rectifier Input
which draws an almost purely sinusoidal waveform from
the source. (Attenuates all harmonics up to the 35th and
Stops harmonics at the source.

Sinusoidal waveform of different pulse converter
Chapter 8

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8.2.7. VSD design example 1
Suppose we have an application where we want to produce a range
of 2000 BPD to 5500 BPD in a 7 casing well. The fluid gravity
is 1.048 and we have previously calculated that we will need
4900 feet of TDH at the 5500 BPD flow.
The first thing to do is choose a pump.
Which pump is most likely to be the best selection for the
job?
There is not always a clear cut answer as to what is the
"right pump". Let's take a look at the GN4000 of Reda.

Although the curves do not extend down to 2000 BPD, we can
estimate by extrapolation that we could probably get there
with about 40 Hz.
In sizing the VSD application, the high end is more important.
The upper end will determine the size of the pump required
since we need more TDH at this point and the pump puts out
less head per stage at higher flow rates for any given
frequency.
So where should we operate our GN4000 pump? That is, what
frequency should we choose for the 5500 BPD flow rate?

Chapter 8

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It looks like we can operate at 70 Hz and still be
comfortably within the recommended operating range.
At 70 Hz and 5500 BPD, the pump puts out about 37 feet of
head per stage.
So how many stages will we need?
No of stages = 4900 feet TDH 37.0 feet/stage
= 132 stages
How much horsepower will this pump require to do the job?
Just to be safe, let's take the maximum point on the curve.
We can either take the BHP per stage we read on the 60 Hz
curve of 1.47 and correct it for frequency as:
HP @60 HZ=1.47*132*1.048=203 HP
BHP
70
= 1.47 x (70 60)
3
= 2.33
or we can simply read the 70 Hz BHP curve directly from the
graph.
Either way we should get the same answer of 2.33.

Chapter 8

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Chapter 8

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So our total pump Hp requirement at our maximum frequency
will be:
BHP
70
= 2.33 x 132 x 1.048 = 322 hp
What size motor should we use (60 Hz rating)?
Since the motor HP output varies directly with hertz, we can
easily calculate the 60 Hz equivalent requirement.
MHP = 322 x (60 70) = 276 hp
We are ignoring the HP requirement for gas separator and
protector for this example
Let's select a 540 series PK type motor. Which one should
we select to do the job?

From the catalog, we will be using two 140 Hp's in tandem
for a total of 280 Hp, 2598 Volts and 69.5 Amps (60 Hz
Rating)
Let's use a tandem motor with 140 Hp in each section for a
total of 280 Hp. This is more than the 276 Hp we actually
need so it will be adequate. The next size smaller would
only give us 260 Hp which is not enough.
We have three choices of winding for this size motor. Why
did we select one with low voltage?
If we had chosen the 2101 volt motor, this would be a
combined voltage of 4202 volts (at 60 Hz The maximum
allowable motor voltage is 4160, so we would exceed the
motor rating even operating at 60 Hz or less.
An even better reason is that it was not available in a CT.
We could not have done it if we had tried.
By the way, what is the maximum frequency we can operate
this unit without overloading the motor?
Remember that we can easily check this with our equation:
Chapter 8

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We do not have much more speed to play with but we have
enough to do the job.
We sized the motor based on our anticipated production fluid
of 1.048 gravity.
What would happen if we were to have to unload a heavier
kill fluid used to workover the well?
We would expect the gravity to be higher and therefore the
load on the motor.
Should we size a larger motor to handle the overload caused
by the kill fluid?
That is certainly one way to handle the problem.
Another solution might simply be to start up the well at a
lower frequency and bring the speed up to 70 Hz after the
well was unloaded.
An even better solution would be to operate the VSD on
"current mode". This also works very well in viscous
applications.
In "current mode", we ask the drive to try to maintain a
constant downhole current and adjust the frequency as
necessary to achieve this.
In general, we know that motor amperage will increase with
frequency. This relationship is approximately quadratic.

We know that at the maximum limiting frequency, the motor
will reach full load, or nameplate, amperage. Higher than
this frequency, it will continue to rise, overheating the
motor.
Chapter 8

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In current mode, we have to define the maximum and minimum
desired currents as well as maximum and minimum frequencies.

As drawn, the unit will hit its current limit before it hits
its frequency limit. This means that variations in motor
load will cause the frequency to change (within the window)
to try to maintain the current constant.

At this point we have sized the pump and motor and we know
we want to use a VSD.
The question now becomes what size VSD do we use?
Chapter 8

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VSD's are sized in terms of KVA capability. So we need to
know how much KVA we have to supply.
In order to do this, we need to look at only the highest
frequency we plan to operate as this is where we will be
doing the most work.
The motor we will use is 280 Hp, 2598 V and 69.5 A at 60 Hz.
What will be the rated KVA at 70 Hz?
The motor voltage at 70 Hz will be:
V
70
= 2598 x (7060) = 3031 v
What will the 70 Hz amperage be?
The amperage will still be nominally 69.5 A. We only expect
the voltage to change with frequency.
So the motor KVA at 70 Hz will be:
KVA = (3031 x 69.5 x 1.732) 1000 = 364
We need to remember the voltage drop in the cable.
In this case, assume we are using #2 AWG.
What will our voltage drop in the cable be if the cable is
5000 feet long?

It looks like the voltage drop is about 21 volt per 1000' so
our total voltage drop will be:
Voltage drop = 5000 x 21 1000 = 105 volts
So we can add this to our 3031 motor voltage to get a
surface voltage of 3136 volts.
In other words we need the VSD to output 3136 volts at 70 Hz
to properly supply our motor for the task at hand.
The KVA required will be:
KVA = (3136 x 69.5 x 1.732) 1000 = 378
Chapter 8

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This is pretty close to 390 KVA.
Could we use a 390 KVA VSD?
SPEEDSTAR 2000 NEMA 3
KVA Output Amperage
66 79
83 100
111 133
130 156
163 196
200 241
260 313
325 391
390 469
454 546
518 624
600 722
700 843
815 981
932 1122
1000 1203
1200 1445
No, we could not --- for a couple of reasons:
First, remember we just said that we needed the VSD to
output 3136 volts at 70 Hz. The only problem is that the
maximum voltage the VSD can possibly put out is 480 V.
This means we need a "Step-up" transformer between the VSD
and the motor. Transformers are not 100% efficient so we
need to add a couple of percent to the KVA the transformer
must supply the motor to come up with a KVA size for the
transformer.
If we add 4% to the 378 KVA demand, this gives us about 394
KVA. The 4% is just estimated, it is usually 2 - 4%.
Different transformers have different efficiencies and the
actual efficiency, if known, should be used.

We should pick a VSD and step up transformer with at least
394 KVA capacity.
Well our 394 KVA is still within a couple of percent of the
390 KVA drive size -- could we still use it?
No, the most important thing to remember about a VSD is that
it can never be overloaded for any reason, it will simply
blow fuses.
The VSD Step-down transformer should have some special
considerations.
High impedance to reduce harmonic distortion on the power
Chapter 8

- 27 -

system.
10% oversized to reduce harmonic heating.
The Step-up transformer, however, must always be made
specifically for a VSD application.
We need the VSD to output 394 KVA and fortunately VSD's are
rated by output KVA rather than by input.
VSD's are not 100% efficient either. Let's assume we will
only be about 98% efficient in power conversion. This means
we will need to input 402 KVA to the VSD to get 394 KVA out
so we will need at least a 402 KVA transformer.
If you plan to operate in the deserts of the Middle East, it
might not be wise as the drive may get too hot. Derating
may be helpful in prolonging life.
Another thing to consider is that a VSD is not always
capable of delivering its maximum KVA.
Unbalanced voltage or weak power systems may prevent optimum
usage of the VSD.
In general terms, for this case it looks like we need a 454
KVA (60 Hz rating) drive.
Remember we plan to operate from 40 to 70 Hz on this drive
so we need to know this information when the drive is being
set up by the service engineer.
The VSD can operate over a wide frequency range but the
maximum voltage output will be 480 V.
What we want to do is set the drive up so that it outputs
480 V at our maximum frequency of 70 Hz.
This way we are getting the maximum output KVA capability of
the drive.

Chapter 8

- 28 -

What happens if we set the drive up with 60 Hz as the base
frequency?
This means that the drive can never go higher than 60 Hz and
we know we need to get up to 70 Hz.
What would happen if we set the drive up with 90 Hz as the
base frequency?
If 90 Hz is our "base" operating frequency, the VSD will
only output about 373 volts at our 70 Hz design point.

Well we have selected a 454 VSD for our application and we
are still using our 280 Hp motor. We know that the pump
will draw 322 Hp at 70 Hz.
Where should we set our overloads and underloads to properly
protect the motor?
Assume we will set them 15% above and 20% below nominal
amperage.
We know that our motor is 69.5 A so we should set the U/L as
69.5 x 80% or 56 amps.
We should set the O/L as 69.5 x 115% or 80 amps.
Remember that the motor will not draw 69.5 amps simply
because it says so on the nameplate.
The current draw will depend on the load placed on the
motor.
What we need to do is determine the load on the motor.
The pump BHP at 70 Hz is 322 Hp.
A 280 (60 Hz rating) motor is capable of delivering 327 Hp
at 70 Hz so the load on the motor will be:
Chapter 8

- 29 -

Percent Full Load = 322 327 = 98.5%
Now compare this to the motor curve.

From the curve we can see that the motor should draw about
99% N.P. amps or 68.8 amps.
The correct U/L would then be 55 amps and the O/L should be
set at 79 amps.
This is not too far off the nameplate calculations we did
before so we probably did not need to go to such extremes.
What would happen if we decided to operate our unit at 50 Hz
for a short period?
What is the Pump BHP requirement at 50 Hz?
HP
50
= 1.47 x 1.048 x 132 x (50 60)
3
= 118 hp
What is the motor output horsepower at 50 Hz?
MHP = 280 x (50 60) = 233 hp
% N.P. Load = 118 233 = 50%
Let us look at motor curve again

Chapter 8

- 30 -

From the curve we can see that the motor should draw about
55% N.P. amps or 38 amps.
Obviously we would need to reset the underload so that the
unit will not shut off automatically. We also need to reset
the overload -- otherwise the unit could pull almost 200% of
running amps before shutting off which could easily damage
the downhole equipment.
Since our nominal running amperage should be 38 amps.
The correct U/L would then be 30 amps and the O/L should be
set at 43 amps.
Note that when we run at 70 Hz, we expect the motor to draw
69 amps and when operating at 50 Hz we expect only 38 amps.

The change in frequency does not have any direct bearing on
the motor running current.
The reason the amperage is lowered is only because we are
reducing the load on the motor at slower speeds.
So a VSD application is not a constant amperage operation.
We know that the VSD puts out a constant volts-to-hertz
ratio. This is a requirement of the design.
What happens to the motor?
Remember that we have 5000 feet of #2 cable running between
the drive and the motor. We also tapped the step-up
transformer to give us 3136 volts at our 70 Hz design point.
This means that if the frequency is reduced to 50 Hz, the
output from the transformer will be:
Surface voltage = 3136 x (50 70) = 2240 volts
Let's look at our voltage drop in the cable at 50 Hz since
we will only draw 38 amps.

Chapter 8

- 31 -

At 50 Hz, we will only have about 12 volts lost per 1000
feet or a total voltage drop in the cable of only 60 volts.
Since the surface voltage from the drive is 2240 V that must
mean that the motor is getting 2180 volts.
Well a 2598 (60 Hz rating) motor at 50 Hz should get 5/6ths
of that or 2165 volts. We are not too far off in this case.
The point to remember here is that even though a VSD is
designed to give us a constant volts-to-hertz ratio, in
practice we can never achieve this if power cable is
involved.
The reason is that the current does vary with the change in
speed due to changing pump BHP requirements and this changes
the amount of load we place on the motor which, in turn,
affects the voltage drop in the cable.

If the cable is very long or is undersized, this may become
significant. It may be necessary to re-tap the transformer
to a lower voltage if operation at the lower frequency will
be for an extended period of time.
VSD's come in a Nema 1 configuration which is the smallest
unit for any particular size. They are not weatherproof and
must be placed inside a protective structure such as a
control room on an offshore platform.
The Nema 3R version is in a weatherproof enclosure and can
be placed on a pad at the well site. Even though it is
weather proof, an additional sun shade or some type of
screen is helpful in extremely hot environments.
Drives can even be provided in a sealed walk-in enclosure
with air conditioning.
Chapter 8

- 32 -

These are useful in harsh environments such as the desert or
jungles. One advantage of this type of drive is that it can
be worked on even if it is raining outside.
8.2.8. VSD design example 2
Say we have a well which is producing 50% oil (total
fluid gravity is 0.95) and we want to use a VSD because we are
expecting the water cut to increase over the next couple of
years.
Our objective is to stay within the operating range of whatever
pump we select.
We will have 50 Hz 380V primary power and 4500 feet of #4 AWG
cable.
We are told we need to design for 4600 feet of TDH at 6000 bpd
and that we may want to produce as low as 3000 bpd and the TDH
at 3000 will be 2900 feet.
What should we do?
The first thing to do is select a likely pump. Choosing a
pump for a VSD application is not as direct as sizing one
for a single speed application but, with a little practice,
we can get pretty good at guessing.
In this case, we should try out two pumps -- first let's
size a GN4000 and then we will size a GN5600 to compare the
two.
So what do we do with the GN4000?

Chapter 8

- 33 -

It looks like we will not fall in the operating range
anywhere.
What if we increase the frequency above 70 Hz?
Just by extrapolation, it looks like we can get there at
about 75 Hz so let's try that as our design point.
What will be the head per stage at 6000 bpd and 75 Hz?
We first need to start from some point we know. We need to
correct 6000 bpd back to our 50 Hz curve to get the
equivalent 50 Hz flow (we could actually convert back to any
one of the drawn curves).
We can now read the head per stage at 4000 bpd.
Flow
50
= 6000 x (50 75) = 4000 bpd

It looks like the head per stage is about 18.4 feet and we
are just inside the operating range which was our objective.
We now need to correct this head back to 75 Hz.
Head
75
= 18.4 x (75 50)
2
= 41.4 ft/stg

Since the TDH is 4600 feet, we need 111 stages.
No. of stages = 4600 41.4 = 111 stgs
Sizing the pump was pretty easy, now we need to size the
motor. In order to do this we first need to determine the
BHP of the pump. Since we already know the BHP per stage at
60 Hz, let's just use that value again.
What size motor will we need?
Chapter 8

- 34 -

BHP
75
= 1.45 x 0.95 x 111 x (75 60)
3
= 299 hp
The motor must output 299 Hp at 75 Hz but we need to convert
this back to a 50 Hz nameplate rating.
MHP
50
= 299 X (50 75) = 200 hp
So we need a motor with at least 200 Hp 50 Hz rating.

From the catalog, we will be using two 100 Hp's in tandem
for a total of 200 Hp, 2250 Volts and 58.5 Amps (50 Hz
Rating)
This will be 200 Hp, 2250V, 58.5 A. Remember that we need
to add the voltages for tandem motors.
We now need to determine the KVA at the maximum frequency of
75 Hz.
We need to calculate the motor voltage at the 75 Hz speed.
volts
75
= 2250 x (75 50) = 3375 volts
The motor terminal voltage will be 3375 volts.
From the voltage drop chart, we should get a value of about
27V/1000' loss. This will give us a total voltage drop of
about 124 volts.

Chapter 8

- 35 -

Voltage drop = 27x 4.7 = 124 volts
Surface voltage = 3375 + 124 = 3499 volts
What will be the "wellhead" KVA?
KVA at the wellhead will be:
KVA = 3499 x 58.5 x 1.732 1000 = 354
Choose a VSD of 390 KVA.
SPEEDSTAR 2000 NEMA 3
KVA Output Amperage
66 79
83 100
111 133
130 156
163 196
200 241
260 313
325 391
390 469
454 546
518 624
600 722
700 843
815 981
932 1122
1000 1203
1200 1445
Unfortunately in our excitement we forgot about transformer
losses. If we add 4% for the transformer we would need a
transformer of at least 368 KVA.
This is still OK -- can we use the 390 KVA
We can never forget that the 390 KVA is a 480 Volt rating.
A VSD is limited by the maximum amount of voltage which can
pass through it as well as the maximum amount of current.
The product of the voltage and the current gives the KVA
rating.
The 390 KVA rating is based on 480V input/output and 469 A
maximum amperage.
When we go down to 50 Hz, the I/O of the drive is 380V but
the maximum amperage does not change.
This means that we must "de-rate" the drive for 380 V
operation so a 390 drive now becomes a 309 KVA drive
(390*380/480).
In order to be able to use 390 KVA VSD and meet our 368 KVA
requirement we will need to provide 480 V input to the VSD
Chapter 8

- 36 -

instead 380 V, even using 50 Hz frequency or use a 480 V
gen-set.
So we will pick the 390 KVA, assuming that we will be able
to get 480 V input VSD for our application.
Where should we set the O/L and U/L for the 75 Hz operation?
(assume in this case that the O/L will be set at 115% and
the U/L will be at 80%).
The correct O/L would be 67.3 Amps and the U/L should be set
at 46.8 Amps.
O/L = 58.5 x 1.15 = 67.3 Amps
U/L = 58.5 x 0.8 = 46.8 Amps
What about our lower flow rate point? Where will it occur
and what will the O/L and U/L be and what will be our KVA at
that point?
Our low flow point was 3000 BPD and the TDH was 2900 feet.
What frequency will we need to set the VSD to in order to
achieve this target?
If the TDH is 2900 feet and we are using 111 stages, this
would give us 26 feet per stage at that point.
We can look at the pump curve to determine the frequency.
Head per stage = 2900 111 = 26 feet/ stg

Chapter 8

- 37 -

Lining up the head per stage and the flow, it looks like
this will match at about 50 Hz.
What is the BHP at 50 Hz?
The total brake horsepower will be about 88 Hp.
BHP
50
= 1.45 x 0.95 x 111 x (50 60)
3
= 88 hp
We already know our motor is 200 Hp because that is the 50
Hz nameplate rating.
This gives us 44% of nameplate load. From the motor
performance curve, we estimate that the motor will draw
about 50% of nameplate amps (58.5) at this point so our
current will be 29.3 Amps.
% Load = 88 200 = 44 %
Running Amps = 58.5 x 0.5 = 29.3 Amps
Our surface voltage will simply be 3499 x (50/75) or 2333
volts so the KVA at the wellhead is 118 (2333 x 29.3 x 1.732
= 118).
Why did we use the surface voltage at 75 Hz and convert
directly to 50 Hz by the ratio rather than calculate the
surface voltage from the motor voltage at 50 Hz and adding
cable loss based on our new running amps like we did before?
This has assumed that the drive was running at 75 Hz and the
frequency was turned down to 50 Hz.
Since the drive maintains a constant volts-to-hertz ratio on
its output, the step-up transformer will also maintain a
constant volts-to-hertz ratio. If it was putting out 3499
volts at 75 Hz, then it will output 50/75 ths of that at 50
Hz or 2333 Volts.
Where should we set the O/L and U/L?
The correct O/L at this point is 33.7 Amps
O/L = 29.3 x 1.15 = 33.7 Amps
U/L = 29.3 x 0.8 = 23.4 Amps
The U/L should be set to 23.4 Amps.
Now that we have sized the GN4000, let's size the GN5600 the
same way. We need to pick an upper operating point.
From the curve it looks like we have quite a choice of
operating frequencies. We need to be a little careful
because as we go higher in frequency we are moving further
left on the operating range (for a constant flow).
If we are too far left at the top frequency, we may be well
out of the range at the lower flow/frequency point.

Chapter 8

- 38 -

This is what makes sizing VSD applications by computer so
convenient. You can do many variations in a short amount of
time to "optimize" the equipment configuration.
We can do the same thing by hand but it just takes a lot of
time. For this example, let's assume our maximum frequency
will be 60 Hz.
How many stages will we need?

Chapter 8

- 39 -

It looks like the head per stage is about 28.2 feet so we
would need 163 stages to meet the 4600 foot TDH requirement.
# Stages = 4600 28.2 = 163 stgs
How much BHP will this take?
Since we are using 60 Hz, it makes it pretty easy to just
read the BHP directly from the curve. It looks like it is
about 1.8 BHP per stage.
BHP
60
= 1.8 x .95 x 163 = 279 hp
What size motor will we need to give us 279 Hp at 60 Hz?
Remember the VSD is what is supplying the 60 Hz, we are
still using 50 Hz power.

We know we need 279 Hp so 280 Hp (60 Hz rating) will work.
We can use the ratings right out of the catalog. Two 140 Hp
motors at 60 Hz will give us 280 Hp.
So we will use the 117 Hp (50 Hz nameplate rating) motors.
We will pick tandem 117 Hp's with a 1083V, 69.5 A winding.
The motor will be 233 Hp (117 Hp per section) 2166V, 69.5 A.
Remember that since this is a 50 Hz application, we will
have a 50 Hz nameplate.
What will our KVA be?
The motor voltage will be 2600 V at 60 Hz and we would
expect about 30V/1000' loss in the cable. This gives us a
surface voltage of 2738 for a wellhead KVA of 330.
Surface voltage = 2600 + (30*4.6) = 2738 volts
KVA = (2738 x 69.5 x 1.732) 1000 = 330
If we add 4% for the transformer, we would end up with a 343
KVA requirement.
Chapter 8

- 40 -

Do not forget to de-rate the drive. A 390 KVA drive will not
work for this 343 KVA with the standard voltage for 50Hz
(380V) requirement because the 390 KVA rating is based on 60
Hz, 480 V power.
If we want to use the 390 KVA, again we will need to provide
480V input to the VSD. Also we need make sure the tap in the
VSD is in the 480V input position if we use 480V.
What will the proper O/L (115%) and U/L (80%) be in this
case?
Again we are very close to full load on the motor so we can
assume nameplate current draw.
This would give us an O/L of 79.9 Amps and an U/L of 55.6
Amps.
O/L = 69.5 x 1.15 = 79.9 Amps
U/L = 69.5 x 0.8 = 55.6 Amps
Let's compare our two sizings for the moment
Pump
Type
# of
stages
Motor hp @ 50hz Maximum
KVA
GN4000 1 11 11 1 2 20 00 0 3 37 79 9
GN5600 1 16 63 3 2 23 33 3 3 34 43 3
Why does the GN4000 take more KVA?
Well obviously it should because we are running at a higher
frequency.
Actually frequency has nothing to do with it. In the
greater scheme of things, the well does not care what kind
of electricity it is getting.
The reason the GN5600 takes less KVA is because it is simply
a more efficient pump at 6000 bpd and 60 Hz than is the
GN4000 at 75 Hz.
Remember the GN4000 was to the far right of the operating
range at that point and the GN5600 was almost in the middle.

Chapter 8

- 41 -

The difference in KVA is more or less coincidental. The
lesson to be learned here is that sizing the pump, at
whatever frequency, near the middle of the operating range
will reduce the KVA requirement and the electric bill
because the pump efficiency is greatest here.
Let's look at the equipment size itself.
Notice the unit running at 75 Hz is much smaller (number of
pump stages and motor horsepower) than the 60 Hz unit.
Pump
Type
# of
stages
Motor hp @ 50hz Maximum
KVA
GN4000 1 11 11 1 2 20 00 0 3 37 79 9
GN5600 1 16 63 3 2 23 33 3 3 34 43 3
In general, the higher the maximum frequency of the design,
the smaller the unit. This makes the purchase price of the
equipment much lower. There is a direct financial benefit
to designing for very high frequencies.
The only possible exception to this would be if two
different size units under consideration happened to fall
near a KVA rating of a drive.
For example, say a slightly larger pump and motor required
374 KVA (due to better pump efficiency at the design point)
and the smaller unit required 398 KVA.
The smaller unit would require a 454 KVA drive which is more
expensive so the increased cost of the drive may more than
offset the savings on the downhole unit.
These are simply things which must be evaluated when
considering cost.
Remember that our tendency to reduce cost by using a smaller
unit and running it faster will result in a shorter run life
due to increased motor heating.
Additionally, faster pump speed may be very detrimental in
an abrasive environment since the sand will impact the
impellers with much more energy causing faster erosion.
Just for the fun of it, what will be the lower frequency
operating point for the GN5600?
We have a 163 stage pump and we need 2900 feet of TDH at
3000 bpd.
This comes out to 17.8 feet per stage.
Head per stage = 2900 163 = 17.8 feet/stg
Let's look at this point on the curve.
The problem is that it is not on the curve. So what
frequency will we have to turn the pump with to get to this
point?
Chapter 8

- 42 -

We will just have to guess. Take a look at the curve and
estimate the frequency.
It looks like it is around 43 or 44 hertz.
Let's calculate to be sure.
What is the first thing we need to do?
The first thing is to get back to something we know. We need
to refer back to a known curve.
We will try a first guess of 43 hertz and correct back to
the 50 Hz curve.
Flow
50
= 3000 x (50/43) = 3488 bpd
The head per stage on the 50 Hz curve at 3488 bpd is about
23 feet per stage. We can now correct this known head back
to 43 Hz.
We are just a little low of our 17.8 foot mark. Let's try
44 hertz:
Head
43
= 23 x (43/50)
2
= 17 ft
Correcting for 44 Hz we get a 50 Hz flow of 3409 bpd.
Flow50 = 3000 x (50/44) = 3409 bpd
The head per stage on the 50 Hz curve at 3409 bpd is about
23.5 feet per stage. We can now correct this known head
back to 44 Hz.
Chapter 8

- 43 -

Head
44
= 23.5 x (44/50)
2
= 18.2 ft
This is slightly high. We made a pretty good guess after
all.
This pump will meet our lower flow and TDH requirements
somewhere between 43 and 44 hertz.
Getting back to our sizings -- have we made any mistakes?
Quite possibly we have.
Remember in our original problem statement we were using a
50% oil gravity of 0.95 but we were told that the water cut
would increase.
In both cases we sized the motors at very near 100% load.
If the water cut does increase, we will overload these
motors forcing us to reduce the frequency and lose
production.
In reality increasing water cut may increase our TDH
requirement and we might need to consider increasing the
pump size if the difference is too great.
As a bare minimum we would probably want to "oversize" the
motor. This would allow us to handle a higher gravity fluid.
It could also, depending on how much we oversized it, allow
us to raise the frequency further to increase the TDH output
of the pump to meet the well's increasing requirements over
time.
By the way, it might be a good idea to check to see that we
do not exceed the shaft horsepower limit. Let's look at the
GN4000 since it is designed to operate at 75 Hz.
We previously calculated that the BHP at 75 Hz would be 299.
If we look in the technical data on the pump catalog page,
we can see that a standard shaft is good for 313 Hp.
Well our 299 is getting pretty close -- or is it? Look at
the technical data for this pump on the 60 Hz page. The
shaft horsepower limit is 375 Hp instead of 313 Hp.
Remember that the shaft hp limit changes with the speed.
Higher speeds will increase the horsepower limit.
The shaft horsepower at any speed (frequency) can be easily
calculated.
HP Limit
HZ
= HP Limit
50
x (HZ 50)
or, in this case:
HP Limit
50
= 313 x (75 50) = 391 hp
Well we are clearly below the horsepower limit so we should
be okay. We were able to calculate the maximum frequency
Chapter 8

- 44 -

allowable by the motor -- can we also calculate the maximum
frequency the pump shaft will take?
Yes we can and the calculation is very much like that for
the motor.
SHP means shaft horsepower limit. We are interested in
knowing exactly where:
SHP
HZ
= BHP
HZ

So we can use the following equations and simply set them
equal.
SHP
HZ
= SHP
50
X (HZ 50)
BHP
HZ
= BHP
50
X (HZ 50)
3

We know the shaft limit at 50 Hz is 313 Hp and that the pump
BHP at 50 Hz will be 88 Hp so we need to solve for
frequency.
SHP
50
=BHP
50
x (HZ 50)
2

Rearranging gives:

If we plug in our values, we can see that we would not
exceed the shaft horsepower below 94 hertz.

Chapter - 08 Switchboard and VSD

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Chapter - 08 Switchboard and VSD

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Electric Submersible Pumps Mohamed Dewidar 2013

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