Selecting downhole power cable size for a 140 kW ESP motor

[kondands]

Good day. Guys, how do I pick cable size? I have ESP motor 140, I nom 45.5 A.

Original topic

Добрый день! Парни подскажите, как выбрать сечение кабеля, у меня пэд 140 Iном 45,5а.

[Sheppard]

Good day.

Best is to ask the cable-line OEM for the TU. It should have "tables of allowable current ratings at various well-fluid and gas-air temperatures" - in plain words, max current per size vs ambient temperature.

If you cannot get the TU, use the tables in the attachment, but remember those tables are for polypropylene insulation. A different insulation material will give different numbers.

For fluid temperature 100 C and ESP motor rated current 45.5 A, I would recommend KIPpBP-125 - 3x16, 16 mm2.

Scan / image text translation (original scan kept as attachment below):

Page 1 title: Table of allowable current ratings at various gas-air ambient temperatures.

Columns: cable type; operating ambient temperature of the cable, C; continuous allowable load current, A, not more than; by nominal conductor size, mm2: 7 / 8 / 10 / 13.3 / 16 / 21.15 / 25 / 35.

Code: Select all

+----------------+-----+------+------+------+-------+------+--------+------+------+
| Cable type     | T C | 7    | 8    | 10   | 13.3  | 16   | 21.15  | 25   | 35   |
+----------------+-----+------+------+------+-------+------+--------+------+------+
| KPpBP-120      |  20 | 64.0 | 69.0 | 78.5 |  92.6 |  103 |    122 |  135 |  165 |
|                |  30 | 60.7 | 65.5 | 74.5 |  87.9 | 98.0 |    116 |  128 |  157 |
|                |  40 | 57.4 | 61.9 | 70.3 |  83.0 | 92.5 |    109 |  121 |  148 |
|                |  50 | 53.7 | 58.0 | 65.9 |  77.8 | 86.7 |    102 |  113 |  139 |
|                |  60 | 49.9 | 53.8 | 61.2 |  72.2 | 80.5 |   95.0 |  105 |  129 |
|                |  70 | 45.7 | 49.3 | 56.0 |  66.1 | 73.7 |   87.0 | 96.2 |  118 |
|                |  80 | 41.0 | 44.3 | 50.3 |  59.4 | 66.2 |   78.2 | 86.4 |  106 |
|                |  90 | 35.8 | 38.7 | 43.9 |  51.9 | 57.8 |   68.2 | 75.4 | 92.6 |
|                | 100 | 29.7 | 32.1 | 36.4 |  43.0 | 47.9 |   56.6 | 62.6 | 76.8 |
|                | 110 | 20.9 | 23.7 | 26.9 |  31.8 | 35.4 |   41.8 | 46.2 | 56.7 |
|                |120* | 8.96 | 9.66 | 11.0 |  13.0 | 14.5 |   17.1 | 18.9 | 23.1 |
+----------------+-----+------+------+------+-------+------+--------+------+------+
| KIPpBP-125     |  20 | 65.1 | 70.2 | 79.8 |  94.2 |  105 |    124 |  137 |  168 |
|                |  30 | 61.9 | 66.8 | 76.0 |  89.7 | 99.9 |    118 |  130 |  160 |
|                |  40 | 58.7 | 63.3 | 72.0 |  84.9 | 94.7 |    112 |  124 |  152 |
|                |  50 | 55.2 | 59.6 | 67.7 |  79.9 | 89.0 |    105 |  116 |  143 |
|                |  60 | 51.5 | 55.6 | 63.1 |  74.5 | 83.1 |   98.0 |  108 |  133 |
|                |  70 | 47.5 | 51.2 | 58.2 |  68.7 | 76.6 |   90.4 |  100 |  123 |
|                |  80 | 43.0 | 46.5 | 52.9 |  62.4 | 69.6 |   82.1 | 90.8 |  111 |
|                |  90 | 38.3 | 41.3 | 46.9 |  55.4 | 61.7 |   72.9 | 80.6 | 98.9 |
|                | 100 | 32.7 | 35.3 | 40.1 |  47.3 | 52.7 |   62.2 | 68.8 | 84.5 |
|                | 110 | 25.9 | 28.0 | 31.8 |  37.5 | 41.8 |   49.4 | 54.6 | 67.0 |
|                | 120 | 16.6 | 18.0 | 20.4 |  24.1 | 26.8 |   31.7 | 35.0 | 43.0 |
|                |125* | 8.89 | 9.60 | 10.9 |  12.9 | 14.4 |   16.9 | 18.7 | 23.0 |
+----------------+-----+------+------+------+-------+------+--------+------+------+
| KPpBP-130      |  20 | 66.1 | 71.3 | 81.1 |  95.7 |  107 |    126 |  139 |  171 |
|                |  30 | 63.1 | 68.1 | 77.4 |  91.3 |  102 |    120 |  133 |  163 |
|                |  40 | 59.9 | 64.6 | 73.5 |  86.7 | 96.7 |    114 |  126 |  155 |
|                |  50 | 56.6 | 61.0 | 69.4 |  81.9 | 91.3 |    108 |  119 |  146 |
|                |  60 | 53.0 | 57.2 | 65.0 |  76.7 | 85.5 |    101 |  112 |  137 |
|                |  70 | 49.2 | 53.1 | 60.3 |  71.2 | 79.4 |   93.7 |  104 |  127 |
|                |  80 | 45.0 | 48.6 | 55.2 |  65.2 | 72.7 |   85.8 | 94.9 |  116 |
|                |  90 | 40.5 | 43.7 | 49.7 |  58.6 | 65.3 |   77.1 | 85.2 |  105 |
|                | 100 | 35.3 | 38.1 | 43.3 |  51.1 | 57.0 |   67.3 | 74.4 | 91.3 |
|                | 110 | 29.3 | 31.6 | 35.9 |  42.4 | 47.3 |   55.8 | 61.7 | 75.7 |
|                | 120 | 21.6 | 23.3 | 26.5 |  31.3 | 34.9 |   41.2 | 45.6 | 55.9 |
|                | 130 | 8.83 | 9.53 | 10.8 |  12.8 | 14.3 |   16.8 | 18.6 | 22.8 |
+----------------+-----+------+------+------+-------+------+--------+------+------+

Page 2 title: Table of allowable current ratings at various well-fluid temperatures.

Same column layout. Cable types KPpBP-120, KIPpBP-125, KPpBP-130.

Code: Select all

+----------------+-----+------+------+------+-------+------+--------+------+------+
| Cable type     | T C | 7    | 8    | 10   | 13.3  | 16   | 21.15  | 25   | 35   |
+----------------+-----+------+------+------+-------+------+--------+------+------+
| KPpBP-120      |  20 | 78.3 | 84.3 | 96.1 | 113.0 |126.0 |  149.0 |165.0 |202.0 |
|                |  30 | 74.4 | 80.3 | 91.3 | 108.0 |120.0 |  142.0 |157.0 |192.0 |
|                |  40 | 70.2 | 75.8 | 86.2 | 102.0 |113.0 |  134.0 |148.0 |182.0 |
|                |  50 | 65.8 | 71.0 | 80.7 |  95.3 |106.0 |  125.0 |139.0 |170.0 |
|                |  60 | 61.1 | 65.9 | 74.9 |  88.4 | 98.5 |  116.0 |129.0 |158.0 |
|                |  70 | 55.9 | 60.4 | 68.6 |  81.0 | 90.3 |  107.0 |118.0 |145.0 |
|                |  80 | 50.3 | 54.2 | 61.7 |  72.8 | 81.1 |   95.7 |106.0 |130.0 |
|                |  90 | 43.9 | 47.3 | 53.8 |  63.5 | 70.8 |   83.6 | 92.4 |113.0 |
|                | 100 | 36.4 | 39.3 | 44.6 |  52.7 | 58.7 |   69.3 | 76.6 | 94.0 |
|                | 110 | 26.9 | 29.0 | 33.0 |  38.9 | 43.4 |   51.2 | 56.6 | 69.4 |
|                |120* | 11.0 | 11.8 | 13.5 |  15.9 | 17.7 |   20.9 | 23.1 | 28.3 |
+----------------+-----+------+------+------+-------+------+--------+------+------+
| KIPpBP-125     |  20 | 79.7 | 86.0 | 97.7 | 115.0 |129.0 |  152.0 |168.0 |206.0 |
|                |  30 | 75.9 | 81.9 | 93.0 | 110.0 |122.0 |  144.0 |160.0 |196.0 |
|                |  40 | 71.8 | 77.5 | 88.1 | 104.0 |116.0 |  137.0 |151.0 |186.0 |
|                |  50 | 67.6 | 72.9 | 82.9 |  97.8 |109.0 |  129.0 |142.0 |175.0 |
|                |  60 | 63.1 | 68.0 | 77.3 |  91.3 |102.0 |  120.0 |133.0 |163.0 |
|                |  70 | 58.2 | 62.8 | 71.3 |  84.2 | 93.8 |  111.0 |122.0 |150.0 |
|                |  80 | 52.8 | 57.0 | 64.8 |  76.4 | 85.2 |  101.0 |111.0 |136.0 |
|                |  90 | 46.9 | 50.6 | 57.5 |  67.8 | 75.6 |   89.2 | 98.7 |121.0 |
|                | 100 | 40.0 | 43.2 | 49.1 |  57.9 | 64.6 |   76.2 | 84.3 |103.0 |
|                | 110 | 31.8 | 34.3 | 39.0 |  46.0 | 51.2 |   60.5 | 66.9 | 82.1 |
|                | 120 | 20.4 | 22.0 | 25.0 |  29.5 | 32.9 |   38.8 | 42.9 | 52.7 |
|                |125* | 10.9 | 11.8 | 13.4 |  15.8 | 17.6 |   20.7 | 22.9 | 28.2 |
+----------------+-----+------+------+------+-------+------+--------+------+------+
| KPpBP-130      |  20 | 82.9 | 89.5 |102.0 | 120.0 |134.0 |  158.0 |175.0 |214.0 |
|                |  30 | 79.2 | 85.4 | 97.1 | 115.0 |128.0 |  151.0 |167.0 |205.0 |
|                |  40 | 75.2 | 81.1 | 92.2 | 109.0 |121.0 |  143.0 |158.0 |194.0 |
|                |  50 | 71.0 | 76.6 | 87.0 | 103.0 |115.0 |  135.0 |149.0 |183.0 |
|                |  60 | 66.5 | 71.8 | 81.6 |  96.3 |107.0 |  127.0 |140.0 |172.0 |
|                |  70 | 61.7 | 66.6 | 75.7 |  89.3 | 99.6 |  118.0 |130.0 |159.0 |
|                |  80 | 56.5 | 61.0 | 69.3 |  81.8 | 91.2 |  108.0 |119.0 |146.0 |
|                |  90 | 50.8 | 54.8 | 62.3 |  73.5 | 82.0 |   96.7 |107.0 |131.0 |
|                | 100 | 44.3 | 47.8 | 54.4 |  64.2 | 71.5 |   84.4 | 93.4 |115.0 |
|                | 110 | 36.8 | 39.7 | 45.1 |  53.2 | 59.3 |   70.0 | 77.4 | 95.0 |
|                | 120 | 27.2 | 29.3 | 33.3 |  39.3 | 43.8 |   51.7 | 57.2 | 70.2 |
|                | 130 | 11.1 | 12.0 | 13.6 |  16.0 | 17.9 |   21.1 | 23.3 | 28.6 |
+----------------+-----+------+------+------+-------+------+--------+------+------+

Asterisks on 120 C / 125 C mark the cable type's rated ceiling, where allowable current drops sharply.

Page 3 heading: Affinity laws.

ESP pump rate changes linearly (directly proportional to frequency):

Q = Q50 * (Fp / Fn)

where Q is calculated rate; Q50 is rate at 50 Hz; Fp is calculated frequency; Fn is rated frequency.

ESP pump head changes with the square of frequency:

H = H50 * (Fp / Fn)^2

where H is calculated head; H50 is head at 50 Hz.

ESP pump power changes with the cube of frequency:

N = N50 * (Fp / Fn)^3

where N is calculated power; N50 is power at 50 Hz.

ESP motor power changes linearly (directly proportional to frequency).

Maximum allowable run time on current overload:

Code: Select all

+----------------------------------+------+------+------+------+------+
| ESP motor overload vs nameplate  |  1.1 |  1.2 |  1.3 |  1.4 |  1.5 |
+----------------------------------+------+------+------+------+------+
| Allowable run time, min          |   60 |   10 |    5 |    2 |    1 |
+----------------------------------+------+------+------+------+------+

Dynamic fluid level in the annulus from the downhole monitoring system (TMS):

H_sub = L_set - (P_sensor - P_annulus) * 10 / rho_oil

Page 4 title: Conductor sizes of electrical wires.

Code: Select all

+-------+---------+----------+
| AWG   | D, mm   | S, mm2   |
+-------+---------+----------+
| 4/0   | 11.6840 | 107.2193 |
| 3/0   | 10.4038 |  85.0114 |
| 2/0   |  9.2659 |  67.4322 |
| 1/0   |  8.2525 |  53.4881 |
| 1     |  7.3482 |  42.4086 |
| 2     |  6.5430 |  33.6240 |
| 3     |  5.8268 |  26.6652 |
| 4     |  5.1892 |  21.1492 |
| 5     |  4.6203 |  16.7657 |
| 6     |  4.1148 |  13.2980 |
| 7     |  3.6652 |  10.5509 |
| 8     |  3.2639 |   8.3669 |
| 9     |  2.9058 |   6.6315 |
| 10    |  2.5883 |   5.2615 |
| 11    |  2.3038 |   4.1684 |
| 12    |  2.0523 |   3.3081 |
| 13    |  1.8288 |   2.6268 |
| 14    |  1.6281 |   2.0820 |
| 15    |  1.4503 |   1.6521 |
| 16    |  1.2903 |   1.3076 |
| 17    |  1.1506 |   1.0398 |
| 18    |  1.0236 |   0.8229 |
| 19    |  0.9119 |   0.6530 |
| 20    |  0.8128 |   0.5189 |
+-------+---------+----------+

Allowable current ratings for copper downhole cables.pdf

Original reply

Добрый день!

Лучший вариант запросить у завода-изготовителя кабельной линии ТУ на кабель, там должны быть указаны "таблицы допустимых токовых нагрузок при различных температурах скважинной жидкости и газовоздушной смеси", говоря по простому максимальные токи под каждое сечение в зависимости от температуры окружающей среды.

Если возможности получить ТУ нету, воспользуйтесь таблицами во вложении, но учитывайте один тот момент, что эти таблицы под кабель с полипропиленовой изоляцией, если изоляционный материал будет другой, то и значения будут отличаться.

А вообще под температуру жидкости 100 градусов Цельсия, при номинальном токе ПЭД 45.5 А, порекомендовал бы кабель кабель КИПпБП-125 - 3х16, сечением 16 мм[sup]2[/sup]

Allowable current ratings for copper downhole cables.pdf

[Serden]

In plain words: we use KPpBP-120S. Up to ESP motor 160 we take 16 mm2, above that 25 mm2, or take current density 4 A per mm2 and you will not go wrong. In your case 45.5 A / 4 A ~ 11.4 mm2, so 16 mm2 with margin.

Original reply

Если по простому: У нас используется КПпБП-120С, до ПЭДН-160 берём 16мм2, свыше - 25мм2 или бери плотность тока 4А на мм2, никогда не ошибёшься, в твоём случае 45,5А/4А~11,4мм2, получается тебе 16мм2 с запасом.