1、1InitialsSubmersible Pump Cable Overview 2InitialsINTRODUCTION TO ESP CABLEModular design many options3InitialsREDA Production Systems-LAWRENCERPS Lawrence is part of the Schlumberger GroupLocated in Lawrence Kansas since 1976Manufacturer of electric power cable and rubber molded components for ESPs
2、Producer of more ESP cable than any other manufacturerCertified to ISO 9001 Includes All aspects of Cable Manufacturing4InitialsElectrical Submersible CablePower is supplied to the electric motor by electric cable.Power Cable5InitialsCable SelectionElectrical PropertiesPhysical DimensionsEnvironment
3、al ResistanceMechanical StrengthTemperatureHandling Conditions6InitialsCable SelectionThe proper cable size is governed by the amperage,voltage drop,and space available between the tubing collar and casing.7InitialsCable SelectionA range of conductor sizes are available to meet application.requireme
4、nts.8InitialsCable SelectionCables are available in either flat or round configurations.FLATROUND9InitialsCables can be installed in wells where bottom hole temperature is excess of 300 degrees Fahrenheit.Cable Selection10 InitialsCONDUCTORINSULATIONBARRIER INJECTION TUBE(optional)JACKETARMORCable C
5、omponents11 InitialsSIZEDAMAGE RESISTANCEFLEXIBILITYCOSTConductor SelectionCompacted ConductorSolidRound12 InitialsADHESION&STRAND BLOCKING-Downhole Performance-Gas transmission-Gas entrapment/corrosion-Corona dischargeCoating/AdhesiveCopperAlloy coatingAdhesiveStrand blockALLOY COATING-Chemical res
6、istance13 InitialsAll these calculations are based on extensive research and Finite Element Analysis(FEA)of downhole cable system modelsConductor Size SelectionTemperature Equivalency(F)457451446441435430424419414408CasingTubingAnnular FluidProduced Fluid14 InitialsTEMPERATUREPRESSURE CHANGESGAS TO
7、OIL RATIO(GOR)CARBON DIOXIDE ATTACKOIL ATTACKInsulation SelectionInsulation15 InitialsDefinite melt pointLimited by temperatureEase of processingSimple formulationsThermal failure is often dramaticTHERMOPLASTIC vs.THERMOSETNo melting pointOften higher temperature ratingMore difficult to processCompl
8、ex formulationsThermal failure is generally gradualPolymer ChainsCrosslinked Polymer ChainsPolyproylene CoploymerTHERMOPLASTICEthylene Propylene Diene MethyleneTHERMOSET16 InitialsExcellent electrical propertiesLow costAvailable in three different colorsPOLYPROPYLENE ADVANTAGES Excellent resistance
9、to well fluids17 InitialsUpper temperature range,softens at 205F(96C)Subject to crazing in certain environmentsPOLYPROPYLENEDISADVANTAGES205F/96CBOOM!BOOM!18 InitialsExcellent electrical properties,although higher power losses(DLA)than polypropyleneAvailable in three different colorsEPDMADVANTAGES E
10、xcellent high-temperature stability,has been used at up to 550F(288C)in geothermal wells19 InitialsSusceptible to mechanical damage at elevated temperaturesEPDMDISADVANTAGESLimited well fluid resistance,oil swells EPDM compounds20 Initials3 kV:tested at 20 kV DC,7 kV AC4 kV:tested at 30 kV DC,10 kV
11、AC5 kV:tested at 35 kV DC,13 kV ACVoltage Rating and Selection CriteriaOPERATING VOLTAGEVOLTAGE SPIKES/TRANSIENTSMECHANICAL DAMAGE21 InitialsSurface Voltage is higher than motor Voltage(Voltage drop)Energy is required to push current through a cableOhms law;V=I(R+XL)=IrL/A+IXLVoltage Dropx,000 ftVsu
12、rfaceVmotor22 InitialsCurrent(A)0204060801001201400102030405060Voltage Drop(V,per 1,000 ft)#1/0 AWG#1 AWG#2 AWG#4 AWG#6 AWGVoltage Drop Graph23 InitialsTEMPERATURECHEMICAL ENVIRONMENTGASHANDLINGBarrier SelectionBarrier24 InitialsBarrier TypesTEDLAR TAPE-300F(150C)TEFLON FEP EXTRUSION-350F(175C)PROPR
13、IETARY HIGH TEMPERATURE TAPE-400F(205C)LEAD-550F(288C)POLYVINYLEDINE FLUORIDE EXTRUSION-300F(150C)25 InitialsSUPERIOR HOOP STRENGTHHIGHER TEMPERATURETAPE vs.EXTRUDED BARRIERTAPE ADVANTAGEEXTRUDED BARRIER ADVANTAGES FASTER TO PROCESS26 InitialsTEMPERATURECHEMICAL ENVIRONMENTGASHANDLING CONDITIONSJack
14、et SelectionJacket27 Initials185F(85C),HIGH DENSITY POLYETHYLENE(HDPE)250F(121C),NITRILE 1275F(135C),NITRILE 2350F(176C),NITRILE 3350F(176C),EPDMJacket Types HDPE Nitrile 1 Nitrile 2 Nitrile 3 EPDM28 InitialsEPDM Rubber+Oil=EXCELLENT HIGH TEMPERATURE STABILITYPOOR RESISTANCE TO OIL29 InitialsGOOD PH
15、YSICAL PROPERTIESPOOR ELECTRICAL PROPERTIESPOOR RESISTANCE TO WATERNITRILE Rubber+Water=EXCELLENT RESISTANCE TO OILHARDENS AT TEMPERATURES ABOVE 275F(135C)SLOW DECOMPRESSION RATE30 InitialsEPDM&NITRILE Jackets Offer Different AdvantagesNitrile(NBR)EPDMPhysical propertiesGoodPoor to fairOil resistanc
16、eGoodPoor to fairWater resistancePoor to fairGoodDamage resistanceGoodPoorH2S resistanceFairGoodAmine resistanceFairGoodHeat resistanceFairGoodService temperatureup to*275F/135CGreater than350F/176C*HSN available up to 350F/176C31 InitialsDAMAGE RESISTANCEDECOMPRESSION CONTAINMENTCORROSION RESISTANC
17、EArmor SelectionArmor32 InitialsHEAVY GALVANIZED STEEL(0.034/0.86mm thick)HEAVY COATING CLASS II GALVANIZED STEELDOUBLE ARMOR(two layers)STAINLESS STEELMONELTWO DIFFERENT ARMOR PROFILES Armor TypesSTANDARD GALVANIZED STEEL(CLASS I)(GSA,0.020/0.51mm&0.025/0.64mm thick)33 InitialsArmor Profile TypesFl
18、at profile interlockedFlat profileStandard crown profile interlocked34 InitialsREDA Production SystemsCable OptionsCONDUCTORS:SOLIDCOMPACTEDSTRANDEDINSULATION:PPE COPOLYMEREPDM 1EPDM 2EPDM 3EPDM 4BARRIERS:TEDLARTAPESOLEFEXTRUSIONFEPEXTRUSIONHIGH-TEMPTAPELEADJACKET:HDPELOW-TEMPNITRILESTANDARDNITRILEH
19、IGH-TEMPNITRILEEPDMARMOR:GALVANIZEDSTEELHEAVYGALVANIZEDDOUBLEGALVANIZEDSTAINLESSSTEELMONEL35 InitialsPPEPE POLYETHYLENE:185F (85C)REDA Production SystemsCable Families REDALENE:205F (96C)POTBPPEO36 InitialsREDA Production SystemsCable FamiliesETBO REDAHOT:250-350F (121-177C)REDABLACK:300-400F(149-20
20、4C)EERETBEF37 InitialsELBE REDALEAD:400-450F (203-232C)ELBKELBREDA Production SystemsCable Families MOTORLEADS:250-450F(121-232C)38 InitialsFLAT CABLE EXTENSIONS(FCE)(Motorlead Pothead)MOTORLEAD-Typically smaller conductor than power cable,thus runs hotter.-KEOTB-250F(121C)-KELB-450F(232C)-KELTB-450
21、F(232C)Motor Connection Options39 InitialsPOTHEADS-Tape-In Pothead-Tape wrapped around individual connector leads inside motor.-Plug-In Pothead-mating block mounted in motor.-Direct Connect Pothead-Power cable attached directly to the Pothead.(Plug-In Type)Motor Connection Options40 InitialsTape-In
22、Pothead vs Plug-In PotheadREDA Tape-In DesignAdvantages:Most Reliable Highest breakdown strength in industryDisadvantages Longer installation time on rig floor Advantages:Ease of installationDisadvantages Lower breakdown strength Not as reliable as Tape-In41 InitialsWhat does#4/1 KEOTB 0.015M5F represent?#4/1#4 AWG Solid conductorK Polyimide(Kapton)primary insulationE EPDM secondary insulationO Nitrile jacketTB Tape(probably Tedlar)&braid0.015 Armor thickness(inches)M Monel armor5 5 kV Voltage rating F Flat cableCable Nomenclature
