Issue Date: 10/26/2000

Rev. Date: 07/15/2003

Revision: # / 03

Author: Bill Pelton

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Content ID: 2034163

START ESP WITH SS2K

Oct. 26, 2000
Rev. 2, 19 June 2002
Rev. 3, 15 July 2003 (updates shown in bold)
Bill Pelton
Subject:

2034163 Starting ESPs with the SpeedStar 2000 VSD

Based on HMI software 2.03 (only difference with 2.06 is noted)

Introduction

The SS2K has 16 menu items that affect normal starting and four more that affect a special
rocking start feature. Additionally the tap setting on the step up transformer and the capacitance
setting of the load filter (if used) also affect starting performance.

Motor Voltage
Low voltage motors in deep wells can be difficult to start on a VSD. ESP applications
where the cable voltage drop exceeds 10% of the total wellhead voltage should be avoided
by using higher voltage motors or larger cable.

Base Frequency, Transformer Saturation and Voltage Boost

The base frequency (HMI menu 204) is the frequency at which the VSD outputs its maximum
voltage. The maximum practical output voltage is about 5% less than the input voltage. One of
the oldest tricks to solve a hard starting problem is to reduce the base frequency. The reason for
this is that reducing the base frequency requires a corresponding reduction in the tap setting of
the transformer. This reduces the ratio of VSD amps to motor amps, giving the VSD more starting
muscle. The standard VSD rated step up transformers built for Reda by Southwest
Southwest require
that the volts/Hz ratio not exceed the design volts/Hz ratio of the primary winding by more
than 10%. The normal ratio is 480 volts at 60 Hz giving a normal ratio of 8. As long as the
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Do not disclose, use, or reproduce without written approval from Schlumberger

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The SpeedStar 2000 VSD (SS2K) offers a great deal of flexibility for starting ESPs. Because of the
differences of different ESP installations, no one approach to solving starting problems will
always be the solution. The purpose of this document is to impart an understanding of the issues
to field personnel so that they will better understand what to look for and what changes to make
in their particular installation.

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voltage at the base frequency divided by the base frequency

frequency does not exceed 8.8 the
transformer should be okay.
Voltage boost (459) is used to increase the Volts/Hz ratio during starting. If too much voltage
boost is used, transformer saturation can result. The maximum amount allowable varies with
base frequency. With 480 volt power and a base frequency of 60 Hz. a voltage boost of 30% or
less would not saturate the transformer. With 480 volt power and a base frequency of 55 Hz., the
maximum voltage boost should not exceed 20%.
20% Since use of voltage boost requires trial and
error, the best approach is to set it at 1% (the original Toshiba default) and set the V/Hz pattern
control selection (460) to one of the modes such as Auto
Auto Boost
Boost that automatically sets voltage
boost.
It has recently been learned that
tha t Auto Boost requires over sizing the VSD and use of an
R992 load filter. The now preferred V/Hz profile is CONSTANT; however this will require the
use of the VBOOST program (3037793) to establish the voltage boost percentage required
by menu 459.

The meanings of the parameter selections are listed in Table 1.

Table 1
Menu 460
Selection

Meaning

Constant

VSD varies its output voltage linearly with its output Hertz change (at
30 Hz, output voltage is approximately half fo what it is at 60 Hz.).
VSD varies its output voltage as the square of its output Hertz change
(at 30 Hz., output voltage is approximately of of what it is at 60 Hz.).
VSD increases its output voltage at low output Hz. to increase motor
starting torque. VSD must have a sine wave load filter and be
oversized by at least 15%.
Same as Auto Boost, but VSD lowers output voltage during lightly
loaded periods (reduces idle amps). VSD must have a sine wave
load filter and be oversized by at least 15%.
VSD maximizes torque developed by motor and compensates for
motor slip. (462) and (850) must be set. VSD must have a sine wave
load filter and be oversized by at least 15%.
Same as Vector Control, but VSD lowers output voltage during lightly
loaded periods (reduces idle amps). (462) and (850) must be set. VSD
must have a sine wave load filter and be oversized by at least 15%.

Variable
Auto Boost

Auto Boost ES

Vector Control

Vector Control ES

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and not to be disclosed, used, or reproduced without written approval from Schlumberger.

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Volts per Hertz Pattern Control Selection (460)

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The present default (version 2.03 HMI software) of (460) is Constant. There are known cases
where an installation that was tripping off on inverter overcurrent with the Constant setting
worked okay with the Variable setting.
The recommended setting for (460) is Constant.
Constant

Startup Frequency (458)

Since starting frequencies of less than 5 Hz. will theoretically interfere with downhole monitoring
operation (ie. Surveyor) a good practice would be to set (458) to be 6 Hz. for normal operations. In
a hard starting situation, a higher start frequency such as 9 Hz. might produce better results.
Finding the best start frequency for any given application is a trial and error process; however, a
new program called VBOOST (3037793) does a reasonable job of estimating a good start
frequency and voltage boost ssetting
etting.
etting

Starting Acceleration Rate (470) Hz per (471) seconds

The starting acceleration rate recommended by Toshiba is 10 Hz per second or less. For this rate
set (470) to 10 and (471) to 1. Faster rates could significantly increase the portion of the load due
to acceleration and may prevent a successful start. One advantage of a fast acceleration rate is
that if the start frequency selected turns out to be a poor choice, a fast acceleration will quickly
accelerate to a more acceptable start frequency. Since the VSD can put out over 100% of rated
current for short periods of time, it is important that the VSD quickly get the motor to start turning.
Basically starting acceleration rates that are too fast or too slow are both problems. Some where
in the middle is best. 10 Hz per second is the recommended startup acceleration rate.

Minimum to Target Acceleration Rate (472) Hz per (473) seconds

This acceleration rate would not normally be associated with a starting problem. If you knew that
the trip off were occurring after the VSD had reached the minimum speed, then this rate should
be examined. 4 Hz per second is the recommended default for this acceleration rate. Set (472) to
4 and (473) to 1.

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and not to be disclosed, used, or reproduced without written approval from Schlumberger.

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If the voltage boost percentage were fixed, then the starting torque will increase as the startup
frequency increases; however, the starting current will also increase. If the starting current is
more than the VSD can deliver, further increases in start up frequency would not help and a
lower startup frequency would be better.

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Transformer Tap
Even if you are not changing the base frequency, changing the transformer tap either up or down
may improve starting performance. Once again it is trial and error.
If the motor is not fully loaded and the VSD is small relative to the size of the motor, tapping down
is more likely to produce the best results.
If the VSD is large relative to the motor size and the motor is fully loaded, tapping up is more likely
to produce the best results.
In order to verify that a tap setting produces the correct voltage, the V/Hz profile (menu
460) must be set to CONSTANT before taking a measurement. After taking the voltage
measurement the V/Hz profile can be changed to another V/Hz profile if that is desired..

Sometimes an excessive start current is due to the capacitive load filter. Usually an increased
amount of capacitance solves the problem. In some cases where there was 15% unused VSD
capacity, the carrier frequency (450) was increased from 2.2 kHz to 3.0 kHz and this solved the
problem.

G3 Reset Problem FSB 136

The procedure detailed by FSB 136 must be performed or alternatively a Toshiba keypad can be
used to set G3 parameter 161 (OL Selection) to 3 (Soft stall On, Motor OL trip off).
FSB 136 is not required on the new 2.06 software.

Rocking Start
A procedure known as a rocking start can be used to free a stuck pump. This process is detailed
in FSB 126.

Catch a Spinning Motor

The catch a spinning motor feature (menu 454) has sometimes caused starting problems with the
R992 filter. If at all possible, menu 454 should be set to OFF when using an R992 filter.
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and not to be disclosed, used, or reproduced without written approval from Schlumberger.

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Capacitive Load FFilter

ilter Capacitance Setting