Saudi Aramco Engineering Standard...Saudi Aramco Materials System Specifications 55-SAMSS-001 ESP Controller Skid – Outdoors 55-SAMSS-002 ESP Controllers 55-SAMSS-003 ESP Transformers

Previous Issue: 1 February 2011 Next Planned Update: 1 February 2016

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Primary contact: Cox, Robert L. on 966-3-8733341

Copyright©Saudi Aramco 2010. All rights reserved.

Engineering Standard

SAES-I-002 21 May 2012

ESP System – Supplier Integration

Document Responsibility: Electric Submersible Pump Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................ 2

2 Conflicts and Deviations................................ 2

3 References.................................................... 2

4 Definitions...................................................... 3

5 General.......................................................... 4

6 System Design.............................................. 4

7 Controllers................................................... 10

8 Transformers............................................... 10

9 Building........................................................ 11

10 Downhole Equipment.................................. 12

11 Shipping....................................................... 26

Document Responsibility: Electric Submersible Pump Standards Committee SAES-I-002

Issue Date: 21 May 2012

Next Planned Update: 1 February 2016 ESP System - Supplier Integration

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1 Scope

1.1 This standard is intended to be used by the ESP system supplier (ESPSS) and

presents the mandatory requirements for the design, application and integration

of the complete ESP package.

1.2 It is acceptable that this document be included with purchase orders.

2 Conflicts and Deviations

2.1 If there are any conflicts between this standard and associated purchasing,

project or engineering documents, this specification shall take precedence.

2.2 Direct all requests to deviate from this standard in writing to the Company or

Buyer Representative, who shall follow internal company waiver procedure.

2.3 The designation “Commentary” is used to label a sub-paragraph that contains

comments that are explanatory or advisory. These comments are not mandatory,

except to the extent that they explain mandatory requirements contained in this

standard.

3 References

The following is a summary of all the documents which have been mentioned within

this standard. Full compliance to these documents is not necessarily required.

Whether the entire document or specific part(s) of these documents are applicable, have

been identified throughout this standard.

3.1 Saudi Aramco References

Saudi Aramco Materials System Specifications

55-SAMSS-001 ESP Controller Skid – Outdoors

55-SAMSS-002 ESP Controllers

55-SAMSS-003 ESP Transformers – Outdoors

55-SAMSS-004 Modular Building for ESP Equipment

3.2 Industry Codes and Standards

International Code Council (ICC)

ICC IBC International Building Code

https://standards.aramco.com.sa/public/StandardDocInfo.aspx?AbbCode=55-SAMSS-001







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American Petroleum Institute (API)

API RP 11S8 Recommended Practice on Electric Submersible

Pump Vibrations

Institute of Electrical and Electronic Engineers (IEEE)

IEEE 519 IEEE Recommended Practices and Requirements

for Harmonic Control in Electrical Power

Systems

4 Definitions

AFD: Adjustable Frequency Drive

Approval: Written approval from the Chairman of the Saudi Aramco Electric

Submersible Pump Committee

BEP: Best Efficiency Point

Controller: Either AFD, FVC or RVC

Severely Corrosive Environment: Offshore, or onshore within 5 kM of coastline

Mildly Corrosive Enviroment: Anywhere beyond the 5 km of the coastline.

Crude Oil Service: Direct crude oil production or producing water in support of crude

oil production.

ESD: Emergency Shutdown System

ESP: Electric Submersible Pump.

ESPSS: ESP System Supplier. The contractor responsible to supply the material,

service and installation required to meet the performance requirements defined within

the purchasing documents.

FVC: Full Voltage Controller

High Voltage: Voltages greater than 1 kV.

Indoors: Inside building designed per 55-SAMSS-004

Loop Distribution: Characterized by equipment having two incoming power

connections and multiple outgoing power feeds, but only one source of power.

The incoming connection that is not the power source is used to route the power to

another loop distribution device.





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Low Voltage: Less than 1000 V.

Offshore: Overwater or onshore within 5 kM of the coastline

Onshore: On-land

RTU: Remote Terminal Unit

RVC: Reduced Voltage Controller

SD Transformer: Step-down transformer. Transformer used to match the voltage input

of the electrical service to the voltage and phasing requirements of the ESP controller.

This transformer can be dedicated to an individual ESP or can serve multiple ESPs.

SU Transformer: Step-up transformer. Transformer used to match the voltage output

of the ESP controller to the voltage rating of the ESP motor.

Standard: The main body of this document. Does not include the information

contained within the Appendices.

Stainless steel: Either 316 series or 317 series stainless steel material.

5 General

5.1 Terms in bold font are defined within Section 4.

5.2 Whenever this standard requires compliance to a third party document

(e.g., ANSI, API, IEC, etc.), this document shall be the edition which was in

effect on the date of the Quotation Request.

5.3 This standard shall take precedence over any referenced third party document.

5.4 All documentation shall be in English.

5.5 All temperatures are in Celsius units (unless specified otherwise).

5.6 Oil-filled equipment (e.g., transformers, switches) shall not be installed indoors.

6 System Design

6.1 General

6.1.1 Surface equipment system shall be specified as suitable for either a

severely corrosive or mildly-corrosive environment.

6.1.2 If specified by Saudi Aramco that a loop distribution configuration will

be used to feed the SD transformers, these transformers shall be




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specified with integral loop-feed switches.

6.1.3 SD transformers that are feeding multiple ESPs shall be specified with

a distribution panel.

6.1.4 Design and packaging of surface electrical equipment shall assume that

the equipment may be ‘mothballed’ for up to one year before use.

6.1.5 Each ESP shall have a separate controller, SD transformer and SU

transformer (if applicable). This equipment shall be contained on an

individual skid constructed per 55-SAMSS-001.

Exception 6.1.5:

Where multiple wells are fed from one drill site or platform, the SD transformer may be installed separately, to reduce footprint and weight requirements.

6.1.6 Individual skids are not required if the ESP equipment is installed

indoors.

6.1.7 Wellhead junction boxes that are not mounted on the controller skid

shall have the following characteristics:

6.1.7.1 Be equipped with either:

6.1.7.1.1 A breather and drain mechanism.

6.1.7.1.2 For sheet metal enclosures, the above or a 5 mm

hole drilled in the bottom of the enclosure.

6.1.7.2 Be certified and labeled by a third-party certification

organization as meeting the below NEMA or IP criteria.

6.1.7.3 If installed in a severely corrosive environment:

6.1.7.3.1 Be NEMA 250 Type 4X or IP6X per IEC 60529

with ‘X’ being a numeral between ‘4’ and ‘8’.

6.1.7.3.2 Box material and external hardware such as

fasteners (bolts, screws), hinges and locking devices

shall be stainless steel.

6.1.7.4 If installed in a mildly corrosive environment:

6.1.7.4.1 Be NEMA 250 Type 4 or IP6X per IEC 60529 with

‘X’ being a numeral between ‘4’ and ‘8’.





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6.1.7.4.2 Box material shall be Manufacturer’s standard and

external hardware such as fasteners (bolts, screws),

hinges and locking devices shall be of similar metal

to the enclosure to avoid galvanic corrosion.

6.1.8 For offshore locations a deck drawing has been provided with the

purchasing documents. The surface equipment shall be arranged based

upon the criteria and the layout submitted with the quotation.

6.1.9 Horizontal spacing from the edge of the platform or support column to

the outside edge/wall of the controller skid, transformer or controller

building shall be a minimum of 1 meter.

6.1.10 The wellhead junction box that interfaces the controller to the wellhead

shall be sized to accommodate the termination of 5 kV rated armored

cable and stress cones type terminations.

6.2 Service Conditions

6.2.1 ESP system shall operate under the following electrical conditions:

6.2.1.1 Continuous at rated capacity:

6.2.1.1.1 Input voltage level: - 5% or + 10%

6.2.1.1.2 Input frequency: ± 2%

6.2.1.1.3 Phase Unbalance: ± 2%

6.2.1.2 Continuous but at reduced output power/torque:

Input voltage level: -5% to – 10%

6.2.1.3 For up to 200 ms, at reduced power/torque:

Input voltage level: - 10% to – 55%

6.2.2 ESP system shall operate under the following environmental conditions:

6.2.2.1 Ambient Air Temperature

6.2.2.1.1 Minimum: 0 degrees.

6.2.2.1.2 Maximum:

6.2.2.1.2.1 Outdoor: Onshore; 55 degrees,

Offshore; 55 degrees




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6.2.2.1.2.2 Indoor: 40 degrees

6.2.2.1.3 Average, over one month:

6.2.2.1.3.1 Outdoor: Onshore; 40 degrees,

Offshore; 35 degrees.

6.2.2.1.3.2 Indoor: 35 degrees

6.2.2.2 Manufacturer shall consider internal temperature rise of his

equipment and confirm that it will operate under all load

conditions in the environments indicated in Paragraph 6.2.2.1.

The temperature of metal surfaces exposed to direct solar

radiation can reach 75°C. The interiors of unventilated metal

cabinets (exclusive of internal heat-producing sources) can reach

56°C. The transformer and its accessories, including cabinets and

junction boxes, shall be designed accordingly. Sun shields shall

not be fitted, unless specified

6.2.2.3 Relative Humidity (Condensing)

6.2.2.3.1 24 hour average: 95%.

6.2.2.3.2 1 month average: 90%.

6.2.2.3.3 Maximum (outdoor): 100%

6.2.2.4 Earthquakes: None. Site Class D per IBC or ASCE 7

6.2.2.5 Electrical Area Classification: Unclassified

6.2.2.6 Sand and dust storms, fog, airborne contaminants (outdoor):

6.2.2.6.1 NaCl to 300 ppm. MgCl to 50 ppm.

6.2.2.6.2 Dust concentrations of 1 mg/m³. 95% of dust

particles are less than 20 micrometers in diameter.

50% of dust particles are less than 1.5 micrometers

in diameter. Compound in dust include sodium,

magnesium, silicon and aluminum.

6.2.2.6.3 Pollutants (worst case): H2S-5ppm, SO2-10 ppm,

CO-100 ppm, NOx-5 ppm and hydrocarbons-

150ppm.




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6.2.2.6.4 For offshore installations, accumulation of wetted

salt (NaCl) and windborne seawater salt spray.

6.2.2.7 Wind – maximum (outdoors):

6.2.2.7.1 Two second gust: 32.6 m/sec (73 mph)

6.2.2.7.2 One minute withstand: 28.3 m/sec (63 mph).

6.2.2.8 Rain: Minimal. Occasional heavy rainstorms (outdoors).

6.2.2.9 Directly exposed to sun (outdoors).

Exception 6.2.2.9:

Unless indicated otherwise in purchasing documents.

6.2.2.10 Altitude: Less than 1000 meters.

Commentary 6.2.1, 6.2.2:

The above service conditions are contained within the material specifications for the specific ESP surface electrical equipment.

6.3 Monitoring/Communications

6.3.1 Saudi Aramco shall provide an RTU connection to the controller

system. The following information shall be provided for transmission to

this RTU:

6.3.1.1 Suction Pressure

6.3.1.2 Discharge Pressure

6.3.1.3 Motor run/stop status (Digital Input)

6.3.1.4 Motor Temperature

6.3.1.5 Motor Amps

6.3.1.6 Current Leakage

6.3.1.7 Frequency Setting

6.3.1.8 AFD cabinet temperature

6.3.1.9 AFD cabinet high temperature shutdown

6.3.1.10 Fluid Intake Temperature




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6.3.1.11 Pump Vibration

6.3.1.12 Down Hole Fluid Flow (Calculated)

6.3.1.13 ESP Start/Stop Command (Digital Output)

6.3.1.14 Frequency Signal (Analog Output)

6.3.1.15 AFD Output Voltage

6.3.1.16 Overload Amps Setting

6.3.2 Other data streams that are provided as standard equipment shall be

provided for Saudi Aramco’s approval.

6.3.3 The data format to the RTU shall be defined and provided to Saudi

Aramco within 4 weeks after receipt of order.

6.3.4 For AFDs, the pump speed will be adjusted from the Saudi Aramco

remote control room via the RTU.

6.4 Emergency Shutdown System (ESD)

6.4.1 A local or remote ESD by Saudi Aramco shuts in wells and switches off

power to the wellsite. ESP equipment shall be configured such that a

loss of power due to ESD or other power interruption does not lose

accumulated data or set points.

6.4.2 ESD signal will be fail-safe.

6.4.3 Saudi Aramco shall supply equipment, if any, required to de-energize the

wellsite upon receipt of an ESD signal from Saudi Aramco’s RTU.

6.4.4 ESP equipment shall be designed so there is no damage to the equipment

after an ESD.

6.5 Power Quality

6.5.1 ESP system shall be designed so that for all connection combinations of

Saudi Aramco’s power system and all energization and loading

combinations of the controllers, the voltage and current distortion at the

point of connection to the Saudi Aramco’s power source (i.e., high

voltage connection at primary winding of SD transformer) shall meet

the following criteria with input harmonic filters (if required):

6.5.1.1 The voltage Total Harmonic Distortion (THD) shall not exceed

5% and individual harmonic voltage distortion shall not exceed




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3% as measured at primary voltage side of the step-down

transformer(s) at any wellsite location.

6.5.1.2 Current distortion limits shall not exceed the values presented

within IEEE 519 for General Distribution Systems.

6.5.1.3 The maximum commutation notch depth shall be 20%.

6.5.1.4 The maximum notch area shall be 22,800 volt-microseconds.

6.5.1.5 The values above are based upon 480 V systems. Values must

be adjusted for actual system voltage.

6.5.2 ESPSS shall perform a computer-simulated harmonic analysis and

supply any equipment needed to ensure that these performance criteria

are met. The analysis results shall be provided to Saudi Aramco for

review prior to the installation of the surface electrical equipment.

6.5.3 ESPSS shall identify what Saudi Aramco electrical system information

is required to perform the analysis. Saudi Aramco shall be allowed a

minimum of four (4) weeks to provide this information.

6.5.4 The analysis shall give consideration to the cable capacitance of shielded

power cables connected to the Saudi Aramco’s system. The analysis

shall be performed including all harmonics through the 33rd

, as a

minimum.

6.5.5 The ESPSS shall be responsible to perform any testing or obtain any

measurement of the electrical system that is necessary for the analysis.

6.5.6 The ESPSS shall provide information for electrical load and short circuit

system studies to be performed by Saudi Aramco, for the transformers,

controllers, pumps, motors and cables.

7 Controllers

7.1 ESP electrical controllers shall meet the requirements of 55-SAMSS-002.

Exception to 7.1:

With an existing AFD installation which are fed from a common SD transformer, the addition of a new AFD may require that the new AFD match the technical characteristics of the existing units. With approval, specific AFD design characteristics may be altered to match the existing AFDs.





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7.2 If controllers are located outdoors and the controllers, or SD transformer is

fed by an overhead power line, the controllers shall be specified with transient

voltage surge suppression device(s).

7.3 The AFD shall meet the above detailed harmonic system performance criteria in

the without the use of any filtration. No special filtration shall be considered as

a technically acceptable alternative due to the varying anticipated system loads

over the life of the project.

7.4 The controller rating, in addition to the previous calculation, must include any

losses expected from the SU transformer (if required) and any required thermal

de-rating of the controller.

8 Transformers

8.1 Transformers associated with ESPs shall meet the requirements of

55-SAMSS-003.

8.2 For offshore applications, a maximum of five(5) ESPs shall be fed with one SD

transformer.

8.3 For onshore applications each ESP shall have a dedicated SD transformer.

8.4 SU or SD transformers shall not be installed indoors.

Exception to 8.4:

Non-oil filled SD transformer that is integrated into the AFD by the AFD manufacturer.

8.5 KVA sizing of transformers shall be as follows:

8.5.1 Each transformer shall be sized based on expected total operating load

with its corresponding ESP at any time during the production periods of

the well.

8.5.2 If the transformer must be de-rated for ambient temperature, only the de-

rated KVA capacity shall be considered and the original KVA and de-

rated values must be clearly stated in the proposal.

8.5.3 Detailed calculations shall be provided showing how the KVA ratings

were derived. No “rule-of-thumb” calculations will be accepted.

8.5.4 The maximum KVA determined by the calculation method described in

this section shall be used as the basis for determining the applicable

pricing schedule as outlined in the purchasing documents.





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8.5.5 KVA sizing of SU transformer shall be as follows:

8.5.5.1 Use the motor nameplate horsepower selected that was used to

size the pump based on the highest water cut and lowest

reservoir pressure prediction (i.e., worst case scenario) for each

well and assume that the motor is fully loaded and operating at

70 Hz.

8.5.5.2 Include motor power factor, cable losses, and any harmonic.

8.5.6 KVA sizing of SD transformer shall be as follows:

Include any losses introduced by the controller and any harmonic

content resulting from any non-sinusoidal waveforms which could cause

additional heating of this transformer.

9 Building

Buildings housing ESP power/control equipment shall meet the requirements of

55-SAMSS-004.

10 Downhole Equipment

10.1 Cable

10.1.1 Motor feeder downhole cable shall be suitable for downhole service

environmental conditions as described in the purchasing documents.

10.1.2 Conductors shall be solid copper with lead-tin coating. Plain or bare

copper conductors are not allowed.

10.1.3 The cable primary insulation shall be positively bonded individually to

each coated conductor.

10.1.4 Power cable conductors shall be #4 AWG (or equivalent) or larger and

must be selected to consider startup losses to ensure the ESP motor is

capable of starting. Conductor sizes smaller than #4 AWG will not be

permitted under any circumstances. Appropriate conductor size shall

be considered when developing the pricing schedules in the purchasing

documents.

10.1.5 Power cable shall be round configuration to minimize voltage

imbalance except where space restrictions require the use of parallel

cable.





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10.1.6 The motor lead extension cable primary insulation shall be either

Kapton or PEEK with an EPDM secondary insulation. All motor lead

cables shall be lead jacketed and come with Monel protective armor.

Pothead termination insulation shall be epoxy or other similar material.

The use of lead (Pb) backfill in the pothead is not permitted.

10.1.7 Downhole cable information shall be provided including type of cable,

flat or round cable configuration, type of armor, size of the conductors,

ampacity charts, length of cables, characteristics of cables (such as

resistance {RDC, RAC}, temperature compensation, initial

temperature, running temperature, reactance, capacitance).

10.1.8 Cable information data sheets contained with the purchasing

documentation shall be completed and submitted to Saudi Aramco.

10.1.9 Cable shall be supplied on a reel suitable for use on the ESPSS

supplied Cable Spooler.

10.1.10 Appropriate banding materials shall be provided. If necessary, cross

coupling cable protectors as means of fixing and protecting cable on

down-hole production tubing, packer, pump and protector, shall be

provided.

10.1.11 The electric cable between the packer and motor must resist corrosion

and gas permeation. This section of cable must also be resistant to

hydrochloric acid (15%) in the event that an acid squeeze is performed.

10.2 Packer Penetrator

10.2.1 Penetrator design shall minimize the number of infield connections.

Ideally splices will be located above the packer.

10.2.2 The penetrator shall have a mechanism to account for space out/length

adjustment.

10.2.3 The penetrator shall feature a proven sealing mechanism.

10.2.4 The penetrator shall be compatible with the proposed production

packer, it is envisaged that the packer penetrator design will make up

to a 1.9” 10 round API tubing connection.

10.2.5 Pressure, temperature and power rating of the penetrator shall be

provided.

10.2.6 All flow wetted parts must be resistant to corrosion assuming the

water, gas and oil compositions indicated in the purchasing documents.




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10.3 Production Packer

10.3.1 Packer shall be retrievable.

10.3.2 Packer shall be compatible with penetrator systems proposed by the

ESPSS.

10.3.3 Packer elements and elastomers shall be compatible with well

conditions and completion fluids indicated in the purchasing

documents.

10.3.4 All flow wetted parts must be resistant to corrosion assuming the

water, gas and oil compositions indicated in the purchasing documents.

10.3.5 Packer shall be sized for the appropriate casing size and weight. Refer

to purchasing documents.

10.3.6 Packer shall be field redressable.

10.3.7 Detailed & dimensional drawings shall be included in technical

proposal.

10.3.8 Load to unseat packer shall be submitted (e.g. 50,000 lbs over pull).

10.3.9 Packer shall not have any differential movement as it sets and unsets.

10.3.10 Threads top and bottom are to be new VAM unless otherwise indicated

in the purchasing documents. Mandrel length shall allow for at least

one re-cut at each end.

10.4 Free Flow Device

Completions may include a free flow device that meets the following

requirements:

10.4.1 Automatically opens to direct fluid and solids up the tubing when the

pump is started.

10.4.2 Automatically closes to prevent fluid and solids fall back through the

pump when the pump is stopped.

10.4.3 Automatically allows fluid and solids to bypass the pump assembly

when flowing the well with the pump not running.

10.4.4 All flow wetted parts must be resistant to corrosion and erosion

assuming the water, gas and oil compositions indicated in the




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purchasing documents. Preferred design is moving dart (sliding

sleeve) design over flapper.

10.4.5 A detailed, dimensional drawing shall be submitted. Drawing shall be

submitted for 2 3/8”, 2-7/8”, 3-1/2” and 4-1/2” tubing. The free flow

device shall screw directly into pump discharge/sensor sub.

10.4.6 The integrity of the free flow device shall be guaranteed by the

manufacturers. ESPSS must provide 2 years case history and contact

numbers for operator personnel.

10.4.7 Include redress/rebuild kit price with Free Flow Device equipment

table quote.

10.5 By-Pass System

(Y-Tool) for 9-5/8” Casing Completions or Larger shall be provided with the

following characteristics:

10.5.1 The By-pass system shall allow wireline, logging or coil tubing access

below the ESP completion.

10.5.2 The By-pass system shall be installed in 9-5/8” casing with 40 or 44#

weight.

10.5.3 Materials shall be compatible with the well bore fluids as indicated in

the purchasing documents.

10.5.4 Properly designed clamps above and below shall be provided: Pump,

Seal, Motor and Downhole multi-sensor to clamp to the 2-7/8” Flush

Joint bypass.

10.5.5 A blanking plug shall be provided. The blanking plug latches into the

bypass and shall prevent ESP pumped fluid from re-circulating back

down the bypass tubing.

10.5.6 A re-entry guide on the end of the 2-7/8” tubing, shall be provided.

10.5.7 A Slick-Line plug shall be provided. This plug latches into the bypass

and provides a hydraulic seal during slick-line operations (0.108 &

0.125” wire).

10.5.8 A Coil Tubing plug shall be provided. This plug latches into the

bypass and provides a hydraulic seal during coil tubing operations

(1.5 & 1.75” CT).




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10.5.9 A Logging plug. This plug latches into the bypass and provides a

hydraulic seal during logging operations (0.219, 0.25 & 0.469” cable).

10.5.10 An Isolation plug shall be provided. This plug latches into the bypass

and shall be used during surface bull-heading operations to pump fluid

down the flush joint tubing only.

10.5.11 2-7/8” flush joint tubing for the Bypass shall be provided. The length

of this tubing will be as required to extend to the bottom of the ESP

assembly plus an additional 10 feet to extend below. If, for any reason,

the completion will require additional length to the bypass tubing to

satisfy any completion requirements, this additional length of tubing

will be supplied by Saudi Aramco.

10.5.12 Complete prices in the contract catalog detailing all component prices,

shall be provided. Prices shall be listed separately to allow ordering of

individual components as needed by Saudi Aramco.

10.5.13 ESPSS shall be responsible for rebuilding, repair or redressing the

latch-in tools. Redress/ repair charges in the contract catalog, shall be

provided. Also, provide the cost of a rebuild kit where Saudi Aramco

purchases the kit and rebuilds the tools themselves.

10.5.14 A complete bypass assembly system for every 9-5/8” completion

including only the blanking latch-in tool, shall be provided.

The remaining latch-in tools: Slick-line, Coil Tubing, Isolation and

Logging Plugs four(4) complete sets shall be required as well service

tool spares. By-pass assembly shall be compatible with the ESP

equipment specified for the well.

10.5.15 The latch-in plug/tools shall be provided to Saudi Aramco Wireline /

Field Services. Wireline / Field Services shall decide the final storage

point for these tools. All tools shall be listed on the well completion /

installation paper work for inventory/ invoice purposes.

10.6 Pump

10.6.1 The design flow rates shall take into consideration any anticipated

changes in reservoir performance for three years of operation and be

designed to achieve the target date under any such conditions.

10.6.2 Pumps shall be selected to operate at equal to or greater than the BEP

shown on the 60 Hz pump curve from the ESPSS’s catalog but no

more than half way between the BEP flow rate and the maximum

recommended operating rate at 60 Hz. In different wording, the pump




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type selected must produce the design flow rate between 50% and 75%

inclusive of the ESPSS’s recommended operating range as published

in the catalog while operating at 60 Hz.

10.6.3 The number of pump stages selected shall be based on the worst case

conditions that could be encountered during the first three years of

production while still operating at 60 Hz. The “worst case” condition

shall be defined as the highest expected water cut and the lowest

anticipated reservoir pressure even if they do not happen to fall within

the same year. For example, given a particular well is expected to have

reservoir pressures for the first three years of 3012 psi, 2816, psi and

2940 psi respectively and, during that same three year period, the

anticipated water cuts will be 12%, 26% and 43% respectively, the

“worst case” condition would be 2816 psi (year 2) and 43% water cut

(year 3).

10.6.4 All calculations and selections shall be performed with the latest

version of SubPump currently released and the results of these

calculations shall be included as supporting information for the

technical proposal. No software other than SubPump will be allowed

or technically accepted.

10.6.5 A combination of standard housings that contains a number of stages

equal to the required number of stages shall be used if possible. A

combination of standard housings that contains a number of stages

closest to the required number, but larger than the required number,

shall be used if the combination does not match the required number of

stages. All housings shall contain the full number of stages. No

“destaging” of pump housings is permitted.

10.6.6 Wellbore data shall be provided during final detailed design.

10.6.7 Setting Depth shall be as indicated in the purchasing documents.

ESPSS shall ensure that the setting depth for each well allows the ESP

to be landed in a favorable operating location that will not place any

unnecessary stress on the operating ESP.

10.6.8 The following information shall be provided to the ESPSS during final

detailed design:

10.6.8.1 Flowing (pumping) wellhead pressure

10.6.8.2 Static bottomhole pressure

10.6.8.3 Water cut




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10.6.8.4 Proposed or actual directional survey

10.6.8.5 Inflow performance

10.6.9 Fluid properties shall be as indicated in the purchasing documents.

10.6.10 All exposed materials must be resistant to corrosion assuming the

water, gas, and oil compositions shown in the purchasing documents.

10.6.11 The wellheads will be equipped with a variable choke.

10.6.12 The ESP downhole equipment shall be designed for two alternatives.

The first alternative shall be STANDARD SPECIFICATION

equipment and the second alternative shall be HIGH SPECIFICATION

equipment. The details of these two specifications shall be as indicated

in the purchasing documents. These details shall be the minimum

requirements. If the ESPSS feels additional enhancements are required

over and above these minimum requirements, the ESPSS is

encouraged to offer these enhancements if they are likely to improve

runlife performance. For example, although stainless equipment may

not be clearly specified in the purchasing documents, if the ESPSS

believes it is warranted based on the fluid analysis provided in the

purchasing documents, he should clearly state this in his technical

proposal as his proposed alternative.

10.6.13 Pump testing prior to installation shall be in accordance with the latest

API RP 11S Series as appropriate and as amended per purchasing

documents.

10.7 Motor

10.7.1 Motor shall be three phase, squirrel cage induction type, designed to

operate continuously at any speed within the control range of the

controller.

10.7.2 ESPSS shall ensure that the winding temperature sensor (prefer

thermocouple inserted into the motor winding) in the motor is

compatible with the downhole sensor package.

10.7.3 ESPSS shall submit the motor coating design to Saudi Aramco for

approval. The same system shall be used on pump, protector and

motor. In place of coating, corrosion resistant materials may be

substituted.

10.7.4 Motor shall be filled with the ESPSS’s high dielectric oil to provide

bearing lubrication and assist in heat transfer. The oil selected will take




Page 19 of 26

into account the expected motor operating temperatures under normal

operating conditions.

10.7.5 Selection of specific motor shall include pump load requirements

throughout the anticipated operating range plus the additional loading

for accessory items that absorb motor torque (seal sections, thrust

bearings, etc.).

10.7.6 ESPSS shall clearly indicate HP per unit length of motor used in his

designs at 60 HZ base freq.

10.7.7 The motor will be the standard sized motor, or combination of motors,

that is required to produce the pump selected above at the highest

water cut and at an operating frequency of 70 Hz regardless of the

actual design frequency chosen to select the pump.

10.7.8 The motor, or combination of motors, shall be larger than the required

horsepower at maximum operating frequency but closest to the

required horsepower.

10.7.9 The ESPSS should verify that the motor has sufficient HP capacity for

unloading the well of killfluid.

10.7.10 In the event that the motor selected to operate up to 70 Hz will be

operating in a severely underloaded condition at nominal conditions,

the motor frame selected may be smaller in order to improve the

loading as long as the motor is capable of achieving all possible

operating conditions requested and this is demonstrated to be based on

sound engineering judgment. For the purpose of selection, a severe

underload is defined as anything below 50% of nameplate rating.

10.7.11 It should be kept in mind that, especially for AFD operated units, field

rerating of motors will be allowed to improve motor loading at lower

nominal operating conditions and this may be considered in the motor

selection. For example, if a motor selected to operate up to 70 Hz

would give a nominal loading less than 50% for base conditions but

that motor could be safely field rerated to improve the load in excess of

50% for that operating condition, the motor would still be considered

the best choice.

10.7.12 As a minimum, the following motor tests shall be performed:

10.7.12.1 Winding analysis surge test per ESPSS’s QC standard test.

A copy of the surge curve shall be submitted with the test

documentation.




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10.7.12.2 High potential test on the stator.

10.7.12.3 Insulation resistance test.

10.7.12.4 Measurement of the winding resistance.

10.7.12.5 Measurement of no-load current (each phase).

10.7.12.6 Measurement of nominal no-load speed.

10.7.12.7 Polarization index test/Surge test.

10.7.12.8 Coast test

10.7.12.9 Motor load test

10.7.12.10 Vibration test as per requirements in “String Testing”

section of this standard. The written test procedure shall

be submitted for approval prior to manufacture of any

motor. In all cases, the pass/fail criteria for each test shall

be clearly identified.

10.8 Bottom Hole Assembly (BHA) Configuration

10.8.1 The ESP may be conventionally deployed on jointed tubing, coiled

tubing or be a “cable internal” Coiled Tubing Deployed ESP

(CTDESP). Refer to the purchasing documents for the sketch that

shows the bottom hole assembly. ESPSS will provide equipment as

indicated in purchasing documents.

10.8.2 Conventionally deployed ESPs shall be per the following:

10.8.2.1 No downhole bleeder valve will be installed.

10.8.2.2 The base design is to include double bag / double labyrinth

protectors (i.e., four chambers) or equivalent. Series bag

sections shall be the standard and parallel bags should only

be used where the motor size requires its application.

10.8.2.3 A downhole sensor package is to be provided with the

following data points as a minimum:

10.8.2.3.1 Suction Pressure

10.8.2.3.2 Discharge Pressure

10.8.2.3.3 Motor Winding Temperature




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10.8.2.3.4 Downhole temperature (at fluid intake)

10.8.2.3.5 Current leakage

10.8.2.3.6 Vibration

10.8.2.4 Downhole sensor is to be compatible with surface

monitoring equipment package.

10.8.2.5 Saudi Aramco will provide 2-3/8”, 2-7/8”, 3-1/2”, 4-1/2”

and 5-1/2” tubing for wells completed with 4-½”, 5”, 7” and

9-5/8” casings/liners. Final tubing size & type shall be

confirmed by Saudi Aramco prior to ESPSS ordering

downhole materials.

10.8.2.6 ESPSS may be required to provide a free flow device

(see 10.10) installed above the pump that will automatically

open when the pump is running, automatically close when

the pump is off, and automatically allow flow to by-pass the

pump. This requirement shall be detailed in Exhibit 1 of

this Attachment II of Schedule B.

10.8.2.7 The packer is to be hydraulic type. Saudi Aramco will

supply a seating nipple as shown on Exhibit 4 of this

Attachment II of Schedule B. Packer setting depth will be

determined after contract award but, in general, will be

approximately 200 feet above the pump setting depth.

10.8.2.8 For packer force calculations, use the following average

tubing string temperatures: ESPSS shall submit tube

movement/packer calculations for approval.

10.8.2.8.1 140F for stabilized shut-in conditions

10.8.2.8.2 170F for stabilized producing conditions

10.8.2.8.3 120F for worst-case contraction case

(squeezing or circulating annular fluid)

10.8.2.8.4 Tubing hydrotest pressure is 3000 psi

10.8.2.8.5 Wellhead/annulus testing pressure is 3000 psi

10.8.3 Coiled Tubing Deployed ESP (CTDESP)




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10.8.3.1 In addition to the downhole ESP completion, ESPSS may

be required to supply the coiled tubing with the power cable

internally installed. Although this type of system could

conceivably be run in any well, it is ideally suited to

SmartWell completions where the ESP would be run inside

a 7” production liner. Cable assemble shall be as follows:

10.8.3.1.1 Power Cable size shall be # 2 or # 1 AWG, to

be deployed in a 2” or 2-3/8” coiled tubing.

The yield strength rating and wall thickness of

the CT shall be determined based on the

following:

10.8.3.1.1.1 Maximum length to run.

10.8.3.1.1.2 Combined weight of cable, flat

pack (if required) & the oil

filling the CT.

10.8.3.1.1.3 Weight of ESP completion.

10.8.3.1.1.4 Corrosion rate.

10.8.3.1.2 The cable shall be supported inside the CT by

some mechanical means such that there will be

no slippage of the cable in relation to the CT

either while running in hole or normal

operation. The mechanical retention may be

accomplished by internal clamping or simple

friction in addition to any buoyancy fluid that

might be used to fill the inside of the CT. If a

Flat Pack [control line and/or TEC (Tubing

Encapsulated Conductor)] is required to be

installed inside the CT, a heavy fluid may be

selected to provide additional buoyancy.

10.8.3.2 The lower electrical connector shall be a 2 piece design.

The top half is the slip connector that crimps onto the coiled

tubing. The lower half, bolted to the upper half, is to be

bolted to the center tandem motor. It should have an anti-

torque pins with a yield rating in excess of any potential

transient load that might be encountered.

10.8.3.3 The power cable shall be connected to the lower connector

through a field attachable connector (5000 PSI, 5 KV, 125




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amp, 300F rating) with all reservoir fluid exposed parts of

the lower connector to be made of 416 stainless steel

material or higher specification. It shall have a good fishing

profile to pull the string. It shall also incorporate a

constraint not to allow for the power cable to come out of

the coiled tubing.

10.8.3.4 The motor shall be a center tandem design. Motor rating

shall be selected considering the motor winding temperature

not to exceed the lower connector rating (300F).

The motor shall either have an internal mechanism to

prevent any upward movement of the shaft/rotor assembly

or may incorporate a separate upthrust prevention chamber

to be bolted between the motor and the lower connector.

10.8.3.5 The Universal Motor Base-Bottom Intake type is to provide

a Y-point and allow for the shaft running through the UMB.

It shall also provide the termination of the sensor wires to

the motor.

10.8.3.6 Protector or Seal Section shall be a Bottom Intake design

and installed below the motor and an Expansion Chamber

(if required) located above the motor. The BI Protector

shaft shall be designed to be rigidly locked to the pump

shaft. The BI protector shall be capable of withstanding

any and all upthrust and/or downthrust conditions

developed within the ESP system.

10.8.3.7 The Bottom Intake protector must support the pump shaft

and pump thrust from above. The protector design is to

include double bag /double labyrinth (i.e., four chambers)

or equivalent.

10.8.3.8 Expansion chamber (Shaft less Protector) as an additional

section may be added above the motor if this is the

ESPSS’s preferred design. Expansion chamber base design

can include double bag/single labyrinth (i.e., three

chambers). Additional parallel bags should be added to

account for tandem motor applications.

10.8.3.9 The pump discharge head shall be a non-locking type and to

allow the pump and protector shafts to be rigidly coupled

together. The discharge head should be manufactured from

full duplex stainless steel and be designed without any

sharp radii to avoid the creation of stress concentrations.




Page 24 of 26

10.8.3.10 The pump intake shall be designed to deliver the produced

fluid from the tailpipe directly into the pump without the

need for any shroud or lower thrust section to be installed

below the pump. A “shrouded” pump will generally not

meet Saudi Aramco’s completion or production

requirements due to the OD constraint placed on the pump

housing by a shroud.

10.8.3.11 The downhole sensor system shall be capable of delivering

the same information as indicated above with a

conventionally deployed ESP.

10.8.3.12 The ESPSS shall provide the stinger to mate to the pump

intake and shall be compatible with the lower completion

assembly.

10.8.3.13 If required, the ESPSS shall provide the lower completion

to provide a seal between the pump intake and discharge.

In this event, a permanent seal bore packer with the

accessories (i.e., latching device, expansion joint, and

anchor) shall be installed. The packer can be set with coil

tubing. Seal bore packer shall have the following

characteristics.

10.8.3.13.1 The Seal bore packer shall be retrievable and

can be reset using CT without the need for

milling.

10.8.3.13.2 The Seal bore packer can be set at the

optimum pump setting depth independent of

the lower completion design constraints. In

different wording, if the ESP stinger gets too

long, the packer can be pulled and replaced

with a new length or pull the upper packer and

replace it deeper in the well to accommodate

the longer CTDESP string and maximize the

drawdown at the pump intake.

10.8.4 Encapsulated ESP System (Pod ESP)

10.8.4.1 As an alternative completion, the ESPSS shall quote an

encapsulated ESP system for use in both 9 5/8” and 7”

cased holes. This Pod ESP may either be for single string

use where there is a need for casing protection or tandem

use where the desire is to provide a redundant system to




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increase the time between well interventions to increase

useful operating life. For the purpose of pricing in this

contract, please refer to the Exhibits of this Attachment II to

Schedule B to determine whether this contract will be for

single or redundant systems. Pod ESP systems shall not

consider the need for Y-tools. In addition to the ESP string,

the Pod ESP system shall, as a minimum, consist of:

10.8.4.1.1 Tubing (Saudi Aramco provided) to pup joint

crossover.

10.8.4.1.2 Pup joint to suit the shroud hanger assembly

10.8.4.1.3 Shroud hanger assembly

10.8.4.1.4 Electrical penetrator for shroud assembly

10.8.4.1.5 Lower pup joint

10.8.4.1.6 Adjustable union

10.8.4.1.7 Offset sub and lower pup joint

10.8.4.1.8 Crossover pup joint (if required)

10.8.4.1.9 Additional pup joints as required for spaceout

10.8.4.1.10 Auto-diverter valve

10.8.4.1.11 Adapter into pump discharge or pump

discharge pressure adapter

10.8.4.1.12 ESP centralizer

10.8.4.1.13 Crossover from shroud assembly to shroud

casing

10.8.4.1.14 Shroud casing as required to encapsulate the

ESP string

10.8.4.1.15 Lower shroud to tubing crossover

10.8.4.1.16 Shroud stinger (no more than 20 feet shall be

quoted – if additional length is required, this

will be provided by Saudi Aramco)




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10.8.4.1.17 Tubing adapter to match Saudi Aramco

provided stinger tubing (if required)

10.8.4.1.18 Tubing nipple (sealbore)

10.8.4.1.19 Assembly and pressure testing is required with

certification to be provided to Saudi Aramco

prior to equipment acceptance.

10.8.4.1.20 The diameter of the shroud will be on the

advice of the ESPSS. The diameter should

take into account the ESP landing location

including running through any dogleg, flow

velocity across the motor and pressure loss

across the ESP string prior to the pump intake.

All these calculations will be performed and

agreed to prior to running in hole.

10.9 String Testing

Mechanical vibration testing shall be performed per API RP 11S8. The

maximum allowable vibration for any piece of equipment will be 0.10 in/sec and

shall be measured in two perpendicular planes at the locations specified under

API RP 11S8. If the purchasing documents require a full string vibration test be

performed, the maximum allowable vibration at any point of the string shall not

exceed 0.10 in/sec.

11 Shipping

Shipping containers for surface electrical equipment shall be suitable for storage in an

outdoor tropical location for up to one year before use. The container shall have a

provision for access to connections for space heaters.

Revision Summary

1 February 2011 New Saudi Aramco Engineering Standard. 21 May 2012 Changed primary contact, removed downhole equipment to separate specification.

Documents

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