Electric

Submersible
Pumps

1
Advanced Thinking – Down to Earth
Service
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Advanced Thinking – Down to Earth
Service
By bringing together a highly experienced team with and gas industry. Located in the heart of Canada’s
state-of-the-art manufacturing and a deep commitment energy sector, our focus is on Electric Submersible
to customer service, Canadian Advanced is able to Pump Systems for Artificial Lift applications, Horizontal
deliver superior high pressure pump applications and Pump Systems for a variety of high pressure
leading variable speed drive systems to the global oil applications, and innovative Variable Speed Drive
Systems.

Engineered Operating sophisticated production processes in challenging

conditions, extreme climates and remote locations requires reliable pumping systems.
Canadian Advanced pumping systems are the industry choice, producing more
flow, more head, greater efficiency and wider operating ranges than most
competitor’s offerings.

Canadian Advanced creates high quality, innovative, safe and environmentally

sound solutions by applying advanced state-of-the-art technologies, strict quality
management and superior engineering capabilities. Our detailed process and
application knowledge has allowed us to develop several patented engineering
solutions as well as custom design systems when required.

Quality All Canadian Advanced operations are certified to ISO 9001:2000

standards to ensure the highest quality products with the greatest value for
customers worldwide. Quality assurance begins with a contract review and
continues throughout the entire process. All products are inspected and
performance tested in line with relevant API and other specification criteria
before leaving the factory.
CAI Electric Submersible Pumping
System
The CAI Electric Submersible Pump System consists of several components that are
carefully selected to combine into the most economical and efficient solution for each set
of well conditions.

Surface Equipment (1) Above ground a system controller

combined with a variable frequency drive and related transformer or the patented
CAI Variable Frequency Generator provide controlled power supply to the ESP.

1
Power Cable (2), Motor Lead Extension (3),
The electrical main cable and the flat cable motor lead extension with pot-
head connect the surface equipment with the ESP motor and well monitoring
device.
2
Pump (4) The pumping unit itself consists of the multi-stage centrifugal
pump housed in a pressure sleeve with the capability of producing capacities up
to 50.000 BPD from depths of up to 13.900 ft.

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Gas Seperator/Intake (5) lmmediately under the pump is the
intake combined with a gas separator if required. The gas separator
allows for troublefree operation in well conditions with free gas contents of more
than 10%. 9

Motor (6) The high quality electrical motor (6) for well casings 41/2" and
larger is a squirrel cage, two pole, three phase induction motor. The motor turns 4
at a speed of approximately 3500 RPM at 60 Hz and 2900 RPM at 50 Hz power
source.
5
Sensor (7) The down hole sensor is located below the motor and transmits
important well and system data via the main power cable to the surface.
8
Protector (8) Located between motor and pump intake is the protector.
The protector isolates the motor from the well fluid and contains the high
capacity thrust bearing. 3

Check Valve (9), Drain Valve (10) Other protective

devices are located above the pump discharge: The check valve that 6
closes o n shut d o w n of the unit and prevents back spinning and the
drain valve that allows for pulling the ESP without a wet tubing string.

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Expert Advice The correct application of technology is the critical
success factor for any down hole pumping solution. You can count on Canadian
Advanced’s professional engineers to design an Electric Submersible Pumping
System that provides optimum performance in each of your well applications.
 Pump
The pump is a multi-stage centrifugal design. Each stage consists of an impeller
(1), a diffuser (2) and a bearing (3).

Impeller with
GFR Diffuser
Phenolic
Resin Washer

Impeller and Diffuser The impeller is the rotating element and

adds velocity to the pumpage; the stationary diffuser converts this velocity
1 into
pressure energy and redirects the pumpage to the entrance of the next stage
2 impeller.
The impeller/diffuser design combinations are available in a variety of Ns
(Specific Speed) designs – from axial to mixed flow – to provide optimum
3 efficiencies for any given well condition. The hydraulic designs are such that a
positive downward thrust is generated throughout the operating range to
assure stable hydraulic operation and to prevent thrust reversal. The standard
hydraulics can handle 1 0 % to 1 5 % of free gas.

The CAI standard material for both impellers and diffusers is a stable austenitic
cast material of Ni-Resist which provides sufficient corrosion and erosion
4 resistance in most well applications. Other materials such as Super Duplex SS
or Boronized Ni-Resist are available to allow for additional protection in
extremely corrosive or abrasive services.

Bearings In each stage of the standard configuration the impeller

shroud and the diffuser act as bearing surfaces, in addition the upper and
lower journal bearing of each pump section are supplied in Tungsten Carbide
5 for added protection against abrasion and vibration. Optional stage bearing
designs are available to handle well conditions with high content of abrasives.

Compression Pump

1) Impeller 2) Diffuser
3) Bearing 4) Housing
5) Shaft
Housing The pump stages are housed in a pressure sleeve (housing)
(4) made of high grade alloy steel. The inside diameter of the housing is
isolated from the pumpage; the outside surface may be treated with a
special coating as an added protection from hostile fluid in the well
casing.

Shaft Standard pump shafts (5) are machined from Monel K-500 matrial
which provides excellent mechanical strength in normal conditions.
Special extra high strength shafting material (Inconel) is available for
special applications.

This modular construction concept provides for the optimal selection of

hydraulic flow and head combinations to suit any range of well
requirements and can produce fluids from depths of up to 13.000 ft (3.960
m)

CAI Compression Pump Design

1
2
In this design the impellers are fixed to the pump shaft with lock rings. The
full hydraulic down thrust of impellers and shaft and the weight of the
CAI Floating Impeller Pump Design
3 rotating element is carried by the tilting pad thrust bearings in the
4
protector.
This designThis
usesdesign is commonly
a sliding used in higher
impeller whereby rated pumps
the impeller, driven(675
by aSeries
key,
and above).
can slide freely in axial direction on the shaft. The hydraulic thrust of each
individual stage is carried by three GFR phenolic resin thrust washers,
embedded in the impellers, that run against the stationary diffuser. With
this design no hydraulic thrust is transmitted from the impellers to the
shaft. The weight of the shaft plus the d o w n thrust created at the top end 5
of the shaft are carried by a tilting pad bearing in the protector assembly
below the pump. Optional stage bearing designs are available to handle
well conditions with high abrasive content.

Floating Impeller Pump

1) Impeller 2) Diffuser
3) Bearing 4) Housing 5) Shaft
1
Submersible
2 Motor
The design of the CAI Electric Submersible Motor is guided
environmental conditions found in most oil well applications.
by the harsh

3 The motors are AC two pole, three phase squirrel cage induction type designs. All
4 motors are filled with highly refined mineral oil. The oil is specifically selected to
provide optimum dielectric strength, sufficient thermal conductiviity to secure
proper motor cooling and ample lubrication for the thrust (1) and journal bearings
(7) in the motor and protector assembly. A n internal thrust bearing carries the
thrust load generated by the rotor element.

Depending on motor size and cable length, the operating voltage of the motor
5 can range between 380 and 5000 Volts. The horse power ranges from 8 to 1000
HP in single, tandem and TUT configurations ( tandem-upper-tandem, creates
1000 Hp and larger motor systems with standard motor sections coupled
mechanically but not electrically – request separate leaflet for TUT technology).
6 Standard design operating temperatures can be as high as 190ºC (375ºF).

The motor shaft (8) is rifle drilled to allow for sufficient oil circulation for all
journal bearings and the motor thrust bearing. Shafts are available in high
7 strength materials for high torque / high horsepower applications.

The rotor (6) and stator (5) designs are optimized to provide high electric
efficiency and uncompromised performance under all operating conditions.

8 The flat Motor Lead Extension (2) is connected to the motor by means of a
taped-in pothead connector (4).

A downhole sensor can be attached to the motor base (10) to transmit critical
information such as intake pressure, intake temperature, motor temperature,
motor vibration etc. via the main power cable to the surface controls.

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1) Thrust Bearing 2) Motor Lead Extension 3) Drain and Fill Plug

4) Pothead Connection 5) Wound Stator 6) Squirrel Cage Rotor
7) Journal Bearings 8) Rifle Drilled Shaft 9) Motor Casing
10) Motor Base
Submersible Motor
 Protecto
2
r
The Protector is located between the pump and the
motor. The Protector is a key element in providing 2
efficient trouble free operation and extended
longevity to the entire ESP system; the primary
5
functions of the Protector are:
• To act as physical barrier between the well fluid
and the motor oil under all conditions.
• To carry the (residual) hydraulic downthrust
generated by the centrifugal pumping action as
well as the weight and thrust generated by the
rotating element of the ESP.
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• To equalize the pressure inside the motor to the
pressure conditions in the well bore.
• To maintain a minimum pressure differential
across the seals. Specially designed mechanical
seals exclude well bore fluid from entering the
motor.
• To provide a flexible chamber (Viton bags) that
allows the motor oil to expand and contract as a
function of changing well and motor tempera-
tures during installation, motor start-up and shut-
down. The specially designed labyrinth and a
check valve allows movement of the expanding
3
motor oil into the well bore and blocks the entry
of well bore fluid during the contraction of the
motor oil.
1
The CAI standard protector configuration consists of
a labyrinth section and a bladder section. This 2
configuration combines ample volume to allow for
sufficient thermal expansion with extensive
protection against well fluid entering the motor and
thrust bearing cavities

2
1

4
1) Thrust Bearing 2) Mechanical Seal
3) Elastomer Expansion Bag 4) Fill Plug
5) Check Valve
Double Labryrinth
Double Bag Section Section
 Gas
Separator
In wells with high Gas to Liquid Ratio (GLR) the free gas has to be separated
from the liquid to prevent the ESP system from cycling, cavitation and gas
locking which would reduce production and the run life of the ESP system.

The gas handling parameters of each well and ESP combination are affected by a
6 large number of variables such as specific speed of pump stage design (axial,
mixed or radial flow), fluid properties, well geometry and completion details etc.
5
Two principal separator designs are commonly used either separate or in
combination or as tandem setups for severe gas handling requirements:

4 • Reverse Flow Separator

(moderate separation efficiency)
• Rotary Gas Separator
(high separation efficiency)

In the Reverse Flow Separator the entering well fluid is forced to change
3 direction; the lighter free gas continues to rise and vents to the annulus, the
heavier liquid stream turns in a downward direction and is then lead to the
first pump stage.

2
In contrast, the Rotary Gas Separator (RGS) uses centrifugal force to separate
the gas and liquid streams. The mixture of gas and liquid enters through the
intake screen (1) into the inducer section (2). The inducer increases the
pressure of the liquid stream and moves the mixture through the guide
vanes (3) into the centrifugal rotor chamber (4) where the heavier liquid
stream is forced to the outer area of the chamber whereas the lighter gas
stream concentrates in the centre of the chamber. Through the separation
chamber (5) the liquid stream is directed towards the pump intake stage and
the gas stream is vented into the annulus. Radial bearings (6) and an
oversized shaft provide dynamic stability to the Separator.
6
Canadian Advanced provides two RGS options: The Open Rotor Design RGS
(medium gas content) and the Closed Rotor Design RGS (high gas content). CAI
1 application engineers will help you to find the best solution for each
particular well situation.

Rotary Gas Seperator

1) Intake Screen 2) Inducer

3) Guide Vanes 4) Rotor
5) Divider 6) Bearing

Open Rotor Design Closed Rotor Design

Surface
Equipment &
Power Cable
The electrical Surface Equipment and Power Cable are an essential part of a
complete Electric Submersible Pumping System. Canadian Advanced is using
leading brand quality components engineered to offer optimum efficiency and
maximum run life. Approvals from different Certification Authorites are available.

Switchboards Switchboards are normally used for fixed speed

ESP applications. A large variety of options exist to meet the specific
requirements of each application.

Motor Controls The Motor Controller monitors and provides

information such as motor load, power supply, down hole sensor data.
The controller also protects the motor against unsafe operation and
start-ups. SCADA connections allow operation and control from remote
control centers.

Variable Speed Drives Variable Speed Drives (VSD) allow

for variable speed operation of the ESP unit. State-of-the-art
technology will be applied to reduce the damaging effect of system
inherent harmonics on insulation and mechanical components. Harmonic
filters are commonly used to reduce this effect.

Transformers Specialized three phase transformers are required

in various system configurations in the step-down and step-up function.
Our transformers are designed to work in the rugged oil field environment
and feature a wide range of taps to allow for optimum voltage supply
to the ESP motor.

Variable Frequency Generator The Variable

Frequency Generator (VFG) is an innovative and patented Genset
technology
engineered by Canadian Advanced. The VFG generates a pure sine wave
output with no harmonics across its full variable speed and variable
power range. The VFG features additional production and high electrical
efficiency combined with an extended run life of ESP systems.

Power Cable Canadian Advanced features power cable in a wide

range of sizes and construction types from reputable manufacturers to
provide its customers with the most economical and efficient solution.
Operating Range Charts
Typical operating ranges of Canadian Advanced Electric Submersible Pumps. For applications outside the shown
range please contact CAI Sales Engineering. Top chart shows 50 Hz hydraulics, bottom chart shows 60 Hz hydraulics.

(m 3 /h) .66
6.6 66 660

(ft) (m)

14,000 4,267

50Hz HYD R A UL IC
3,657
12,000 S
PUMP 338 562 875
SERIES 513 675 1025
400
10,000 538 3,048

8,000 2,438

6,000 1,828

4,000 1,219

2,000 610

0 0
100 1,000 10,000 100,000

FLOW RATE (BDP)

(gal/min ) 2.92
29.2 292 2920

(m 3 /h) .66
6.6 66 660

(ft) (m)

14,000 4,267

60Hz HYD R A UL IC
12,000 SPUMP 338 513 562 875
3,657
SERIES 400 538 675 1025

10,000 3,048

8,000 2,438

6,000 1,828

4,000 1,219

2,000 610

0 0
100 1,000 10,000 100,000
FLOW RATE (BDP)

(gal/min ) 2.92
29.2 292 2920
Customer Support
Service
The long-term success of any pumping system Canadian Advanced prides itself on providing
depends upon the quality and availability of fast and efficient response to any situation,
customer support services. without compromising quality.

Fast Response Our field technicians will install, start and monitor the pumping system to
ensure successful operation. The crews are equipped with state-of-the-art tooling and modern truck-
mounted spooling units for all cable spooling and banding needs. Canadian Advanced service centres,
strategically located across the globe, offer our customers easy access to a full range of repair and
maintenance services including unit installation, troubleshooting and preventive maintenance.

Servicing All Markets In addition to supplying parts and services for all of our
equipment, Canadian Advanced’s in-house re-engineering specialists will design, deliver and fit high
integrity components for other manufacturer’s machinery – including upgrading and retrofitting
existing pump installations. Using root-cause failure analysis, system investigation and material
assessment, Canadian Advanced can modify existing installations to meet new duty conditions,
improve operating efficiencies and increase MTBF.

Canadian Advanced also provides all the accessories needed during installation and overhaul of
Electric Submersible Pumps and Horizontal Pump Systems including bleeder valves, check valves,
banding materials, MONEL bolting and couplings, as well as flat cable extensions for most designs
used in the industry.

Commitment At Canadian Advanced, we constantly strive to improve our customer

service performance and deliver the highest possible life cycle value in the industry.
Canadian Advanced provides a
broad range of pumping
systems.
Variable Frequency Generators (VFG) Rebuilding of ESP’s
Canadian Advanced has developed and manufactures Canadian Advanced rebuild used ESP’s of most known
a unique power supply system that eliminates the need manufacturers into “as new” condition. Systems are
for variable speed drives, harmonic filters and step-up completely tested and certified before leaving the
transformers. It provides a pure sine wave and significantly factory.
extends your MTBF and production rates. Combined with
an improved electrical efficiency the VFG reduces both, Speciality Engineering & Testing
your capital and operating costs.
In addition to our standard product ranges Canadian
Advanced specializes in Custom Product Engineering. Our
Horizontal Pumping Systems (HPS)
modern and extensive testing facilities guarantee you
Canadian Advanced manufactures a range of HPS for low thorough testing of each engineered solution before the
flow/high head applications like crude oil transfer, pipeline product is shipped to the field.
booster, water injection and reverse osmosis. The HPS
technology distinguishes itself as a cost effective alternative ConsumabIes
to other designs like multi-stage barrel, split case and
segmental pumps. The HPS technology is based on the Canadian Advanced offers all of the materials and
proven multi-stage centrifugal pump design that is used accessories needed for the installation and overhaul
in our ESP product range. of Electrical Submersible Pumps and Horizontal
Pump Systems.

Contact Canadian Advanced Inc. – Head Office

5307 - 72 A Avenue, Edmonton, Alberta Canada, T6B 2J1

Tel: + 1-780-469-0770 Fax: + 1-780-450-4592
Toll Free: 1-888-480-7867
sales@canadianadvanced.com

www.canadianadvanced.com

Advanced Thinking – Down to Earth

Service