VSD Affinity Laws and Applications

Artificial Lift
AE ESP 1 Training, Course 15 04-Sep-2006 to 29-Sep-2006 04- Sep29- SepDay 5

VSD Affinity Laws Application of Affinity Laws VSD Applications
VSD Affinity Laws

At the end of this section, you will be able to Use the VSD affinity laws to calculate new performance parameters for the following equipment. Understand the affinity laws as they apply to pump properties:
Flow Head Power Efficiency Shaft Power Limit
And Motors
Nameplate Voltage Amperage Rating Power Rating
AE ESP 15 slide 2
VSD Affinity Laws for Pumps RPM Flow

RPM 2
Flow RPM 1
2 1
RPM RPM Head RPM 1
2
2 1
Head RPM 2
RPM RPM
2
BHPRPM 2 SBHL 2 RPM
= BHPRPM 1
RPM RPM RPM
1 2
SBHL 1 RPM
AE ESP 15 slide 3
VSD Affinity Laws for Pumps Flow Head Power Efficiency Shaft Limit
Q1 = Q0
1 0
Independent
2
h1 ( Q1 ) = h0 ( Q0 ) 1 0
PREQ1 ( Q1 , SGX ) = PREQ 0 ( Q0 , SGX ) 1 0
1 ( Q1 ) = 0 ( Q0 )
SBHL1 = SBHL0
AE ESP 15 slide 4
1 0
Pump Laws, Graphical Representation

Assuming 10% increase in Frequency
AE ESP 15 slide 5
MultiPump Laws, Multi-Hz Head Curve

REDA Production Systems
Rev. A
Reda Pump Performance Curve GN4000 540 Series * - 1 Stage(s)

Fluid Specific Gravity 1.00
Feet
70
60
70 Hz
50
40
60 Hz 55 Hz
30
50 Hz 45 Hz 40 Hz 30 Hz
20
10
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
Capacity - Barrels per Day
AE ESP 15 slide 6
MultiPump Laws, Multi-Hz Power Curve
AE ESP 15 slide 7
VSD Affinity Laws for Motors, Conventional Volt 2

=
Volt1
HZ HZ
A2
A1 HZ HZ
HP 2
HP
AE ESP 15 slide 8
VSD Affinity RULES for ALL Motors Conventional and Dominator Nameplae Voltage Amperage Rating Power Rating
V1 = V0
A1 = A0
1 0
Ratings PAVAIL1 = PAVAIL 0

AE ESP 15 slide 9
1 0
Motor Laws, Graphically

Graphically it would look like this for a 200 HP, 60 Hz motor:
350 300
Motor Horsepower
250 200 150 100 50 0
20
40
60
80
100
Frequency (hertz)
AE ESP 15 slide 10
OLD VSD Affinity Laws for Motors, Dominator

For All Frequencies
Voltage
0, 1 60-Hz
V1 = V0
1 0
1 > 60-Hz
Amperage Power
A1 = A0 PAVAIL1 = PAVAIL 0
1 0
60 A1 = A60 1 PAVAIL1 = PAVAIL 60 Special
Like Conventional
AE ESP 15 slide 11
Old Dom. Motor Power, Graphically
350 300
Motor Horsepower
250 200 150 100 50 0
20
40
60
80
100
Frequency (hertz)
AE ESP 15 slide 12
Old Dom. Amperage Rating, Graphically
175
Motor Amperage Rating
150 125 100 75 50 25 0
20
40
60
80
100
Frequency (hertz)
AE ESP 15 slide 13
Exercise 2.08
90-Minutes Work together if you need We will go over the answers together afterward. Every single participant is expected to be able to answer any single question
Application of VSD Affinity Laws

Upon completion of this section, you should be able to:
Combine multiple affinity laws to consider advanced issues Maximum Safe VSD Speed as limited by
Motor Power Shaft Power Housing Pressure Limit
Motor Performance as a function of speed

Motor Load Expected Amperage
Expected flow from a well

Pump curve intersection with System curve
AE ESP 15 slide 15
Maximum Safe Speed: Pump Power Req

What determines the pump power requirement at a given frequency?
D725N 50 Hz / 2917 RPM Pump Performance Curve
46 - 123 4.00 0.625 0.307 5.500 m3/d inches inches in inches
400 Series - 176 Stage(s) - Sp. Gr. 1.00

Standard High Strength Standard Buttress Welded 78 Hp 125 Hp 5000 psi 6000 psi 6000 psi

Rev. -
Optimum Operating Range Nominal Housing Diameter Shaft Diameter Shaft Cross Sectional Area Minimum Casing Size
Shaft Brake Horsepower Limit Housing Burst Pressure Limit
Meters
1,250
B.E.P. Q = 95 H = 876.82 P = 21.08 E = 60.25
Hp Eff
50 50%
1,000
40 40%
750
30 30%
500
20 20%
250
10 10%
25
50
75
100
125
150
Capacity - Cubic Meters per Day
What can change when we change the frequency?

AE ESP 15 slide 16
Maximum Safe Speed: Pump vs. Motor

350 300
PAVAIL1 = PREQ1 PAVAIL0
250
Power
200
150
100
PREQ0
50
0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 17
1 0

Therefore, were looking for 1 such that:
PREQ1 ( MAX , SG X ) = PAVAIL1 PAVAIL1 = PAVAIL 0 1 0 3 1 PREQ1 ( MAX , SG X ) = PREQ 0 ( MAX , SG X ) 0
We know from our affinity laws that
Substituting
PREQ 0 ( MAX , SG X ) 1 = PAVAIL 0 1 0 0
3
Solving for 1
1 = 0
PAVAIL 0 PREQ 0 ( MAX , SG X )
AE ESP 15 slide 18
Valid for any reference frequency 0

350
Works going down, too!

300 250
PREQ0
Power
200
PAVAIL1 = PREQ1
150
100
PAVAIL0
50
0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 19
0 1
Maximum Safe Speed: Effect of Density

350 300
PAVAIL1 = PREQ1 PAVAIL0
250
Power
200
150
100
PREQ0
50
0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 20
1 0
10
Maximum Safe Speed: Old Dominator

350 300
PAVAIL1 = PREQ1 (> 60) PAVAIL0 > PREQ0 PAVAIL0 < PREQ0
250
Power
200
PAVAIL1 = PREQ1 (< 60)

150
100
PREQ0
50
0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 21
1 0
Motor Limit Old Dominator Laws

The process to determine the maximum safe speed for a dominator is the same: Equate PAVAIL1 to PREQ1 Substitute in appropriate affinity law Solve for 1 Because the affinity law for motor power rating changes at 60-Hz, the formulas will change:
0, 1 60-Hz
1 > 60-Hz
PAVAIL1 = PAVAIL 0 1 0
PAVAIL1 = PAVAIL 60
3 PAVAIL 60 1 = 60 PREQ 60 ( MAX , SG X )
Special
AE ESP 15 slide 22
1 = 0
PAVAIL 0 PREQ 0 ( MAX , SG X )

Same as normal
11
Motor Limit Old Dominator Rule vs. Normal

350 300
Standard 250 200 Motor Horsepower 150

100 50 0 0 20 40 60 80 100
Frequency (hertz)
350 300
Dominator 250 Motor 200 Horsepower 150

100 50 0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 23
Shaft Limit
350
SBHL1 = PREQ1
300
SBHL0
250
Power
200
150
100
PREQ0
50
0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 24
1 0
12
Maximum Safe Speed: Shaft Rating vs. Power Req

PREQ1 ( MAX , SG X ) = SBHL1
SBHL1 = SBHL0 1 0 3 1 PREQ1 ( MAX , SG X ) = PREQ 0 ( MAX , SG X ) 0
Substituting
PREQ 0 ( MAX , SG X ) 1 = SBHL0 1 0 0
3
Solving for 1
1 = 0
SBHL0 PREQ 0 ( MAX , SG X )
AE ESP 15 slide 25
Housing Pressure Limit

7000 6000
PH,MAX
P(Q=0)1 = PH,MAX
5000
Pressure
4000
P(Q=0)0
3000
2000
1000
0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 26
1 0
13
Maximum Safe Speed: Housing Pressure

P(Q = 0)1 = PH , MAX

P (Q = 0)1 = P (Q = 0) 0 1 0
2
Substituting
P (Q = 0) 0 1 = PH ,MAX 0
2
Solving for 1
1 = 0
PH , MAX P (Q = 0) 0
AE ESP 15 slide 27
Overall Speed Limit

For a given system (pump, motor), we need to consider all possible limits:
Motor Shaft Housing Pressure
The limit with the lowest safe speed is the maximum safe speed.
AE ESP 15 slide 28
14
Comparing Limits, graphically

SBHL1 = PREQ1
350 7000 300
PAVAIL1 = PREQ1 PAVAIL0 SBHL0
6000
250
5000
PH,MAX
Power
200
P(Q=0)0
150
P(Q=0)1 = PH,MAX
4000
3000
100
PREQ0
2000
50
1000
0 0 20 40 60 80 100
Frequency (hertz)
AE ESP 15 slide 29
1 0
Overall Speed Limit: Example

Consider the following example:
Pump: GN2100X135 Ref. Frequency (0) = 60-Hz Avg. SG = 1.04 PREQ0(Max, 1.04) = 150-HP P(Q=0)0 = 3370-psi SBHL0 = 256-HP (standard shaft) PH,MAX = 5000-psi (V-thread) PAVAIL0 = 200-HP
AE ESP 15 slide 30
15
Overall Speed Limit: Example

Max. Speed according to motor:
1 ( Motor ) = 0
PAVAIL 0 200 = (60) = 69.2 Hz PREQ 0 ( MAX , SG X ) 150 SBHL0 256 = 60 = 78.3 Hz PREQ 0 ( MAX , SG X ) 150 PH , MAX P (Q = 0) 0 5000 = 73.0 Hz 3370
Max. Speed according to shaft:

1 ( Shaft ) = 0
Max. Speed according to housing:

1 ( Hous) = 0
= 60
Overall Max. Safe Speed: 69.2-Hz Limit for Safe Speed: Motor (these values approximate the graphical example)
AE ESP 15 slide 31
Motor Performance: Load

Consider that
Load = PREQ PAVAIL
At 0 we can specify:
Load 0 = PREQ 0 PAVAIL 0
And at 1 we can specify:

Load1 = PREQ1 PAVAIL1
AE ESP 15 slide 32
16
Motor Performance: Load

But we can substitute in for PREQ1 and PAVAIL1 using the pump and motor affinity laws
PREQ 0 1 0 Load1 = PAVAIL0 1 0
3
140 120 100
Load0
Load
80 60 40 20 0 0 20 40 60 80 100
Load1 = Load 0 1 0
This is not accurate enough for real calculations, but is an acceptable approximation
Frequency (hertz)
AE ESP 15 slide 33
Motor Amperage
If we assume that actual running amperage is proportional to load, then we can write:
I Load
And then we can conclude that:

I1 = I 0 1 0
2
1.4 1.2 1.0
I0/A
This is a very bad assumption for detailed calculations and should only be used as an approximation
I/A
0.8 0.6 0.4 0.2 0 0 20 40 60
True Approx.
80 100
Frequency (hertz)
AE ESP 15 slide 34
17
Flow rate and Frequency

We understand the relationship between pump characteristics and frequency: What about expected flow rate?
AE ESP 15 slide 35
Exercise 2.09
18
VSD Applications
Upon completion of this section, you should be able to:
Solve for frequency with a known pump and a target well condition Size a motor to work at an abnormal frequency Design a Pump to work appropriately for a range of flow rates with given well performance Design a Pump to cover potentially changing conditions from a well over time. Design a Pump to cover a large range of potential operating conditions with uncertain well performance
AE ESP 15 slide 37
Solving for design frequency

For our pump designs so far, we followed a rigid procedure:
Establish target conditions Select Appropriate Pump Select the required number of stages to achieve the target conditions
AE ESP 15 slide 38
19
Solving for design frequency

But what if we cant design a custom pump?
Need to work with whats in inventory The number of desired stages isnt available
This is when a VSD is very useful: We can change the pump curve to match our requirements by changing the operating frequency
Wrong Pump, But close Right pump, too many stages
AE ESP 15 slide 39
Solving For Frequency

So how are we going to find our frequency to make our pump work in our target conditions? You cant solve for it using formulas. Using PAD
Change the frequency or RPM until the head curve matches your requirement. Using frequency you can only go to nearest 1-Hz.
5656-Hz
AE ESP 15 slide 40
6060-Hz
20
Solving For Frequency

Using PAD
If you have NO IDEA, you can use the multi-Hz plot:
Rev. A
Reda Pump Performance Curve SN3600 538 Series - 172 Stage(s)

Minimum Casing Size 7.000 OD Check Clearances
Feet
12,500
65 Hz 60 Hz
10,000
55 Hz
7,500
50 Hz 45 Hz
5,000
2,500
1,000
2,000
3,000
4,000
5,000
6,000
But Make sure you go back and double-check after!

AE ESP 15 slide 41
VSD Applications Motor Sizing

Now that your pump is sized, you need to select your motor. Determine your power requirement at your design frequency. Use the MOTOR POWER RATING affinity law to correct this power to a reference frequency (60-Hz, 50-Hz) Select the smallest motor with a power rating larger than your power requirement at reference frequency Use the MOTOR POWER RATING affinity law to correct your motor power back to design frequency. Calculate motor load.
Power
Hz
AE ESP 15 slide 43
21
Example Finding Frequency
AE ESP 15 slide 44
Exercise 2.10
22
Flow Rate Range

The second typical application for a pump with a VSD is to consider a flow rate range for a well with established productivity. For example
My client gives me her well data that determines inflow and says that it is very accurate. But shes not sure what flow rate she wants from the well. But she does know that she wants to produce anywhere from some minimum flow rate to some maximum flow rate without changing the pump.
So what do we do?
AE ESP 15 slide 46
Flow Rate Range

Lets start by considering the system curve. And then lets establish some goals:
Reasonable efficiency for the whole flow range. Reasonable flow rates (relative to ROR) for whole flow range. Reasonable frequencies for whole flow range.
TDHMAJ TDHMIN
QMIN
AE ESP 15 slide 47
QMAJ
23
Flow Rate Range

And lets consider the implications of the relative position of our two points:
The higher flow-rate point will have a higher design frequency The higher flow-rate point will have a higher power requirement
TDHMAJ TDHMIN
Our QMAJ, therefore, is much more important from a design standpoint.
QMIN
AE ESP 15 slide 48
QMAJ
Flow Rate Range

So that gives us some guidance:
Choose an operating frequency for the major flow point. Design a pump like normal emphasizing high efficiency and near BEP (remember, we can customize frequency!) Then were going to solve for minimum frequency just like in our first VSD application And we will review our operating point at QMIN to see if were happy. If not, we tweak the design (stages and frequency)
Rev. A

Feet
12,500
65 Hz 60 Hz
10,000
55 Hz
7,500
50 Hz 45 Hz
5,000
2,500
1,000
2,000
3,000
4,000
5,000
6,000
AE ESP 15 slide 49
24
Flow Rate Range

Some notes on variable rate applications
A dead well system curve cuts across the multi-frequency head plot from left to right at increasing Q/BEP ratios. The lower flow rate, therefore, will nearly always be further left from BEP than the higher flow rate. For very large flow rate ranges, it may not be possible to keep your lower rate within the ROR. Make sure you calculate all relevant information at each operating point.
Rev. A

Feet
12,500
65 Hz 60 Hz
10,000
55 Hz
7,500
50 Hz 45 Hz
5,000
2,500
1,000
2,000
3,000
4,000
5,000
6,000
AE ESP 15 slide 50
Example Flow Rate Range
AE ESP 15 slide 51
25
Exercise 2.11
Changing Conditions
Another application for a VSD is for a well where the ESP is will last a long time. In such a well, we will need to take into consideration the expected change in well conditions over the life of the ESP. Things that will definitely change over time:
Reservoir Pressure Well Productivity Average Fluid Density
To figure out what to do, as always, we start with
AE ESP 15 slide 53
26
Changing Conditions on System Curve

Consider the following example for a well with a target PWF. We expect the following significant changes in our well from now until the expected run life
Decreased Static Pressure Decreased Productivity Increased Water cut (and therefore avg. Density)
PR0 PR1
Target PWF
QMAX1
QMAX0
AE ESP 15 slide 54
Changing Conditions
After that, the process is basically the same as the flow rate range application
Pick one of the two points and design a pump Solve for the operating frequency for the second point Adjust your design if youre not happy
Rev. A

Feet
12,500
65 Hz 60 Hz
10,000
55 Hz
7,500
50 Hz 45 Hz
5,000
2,500
Things to Remember Harder to pick starting point Higher Flow rate may not mean higher frequency Optimizing present production is usually more important than future production
1,000
2,000
3,000
4,000
5,000
6,000
AE ESP 15 slide 55
27
Example Changing Conditions
AE ESP 15 slide 56
Exercise 2.12
28
Unknown Productivity
Our last VSD application is to use a VSD to cover a range of potential conditions when the exact well performance is unknown. This application is surprisingly common:
New well drilled in a mature formation
Re-perforated well After workover or stimulation
First time installing an ESP in the well Big increase in drawdown and uncertain expectations on results
So where do we start?
AE ESP 15 slide 58
Though the wells productivity may be unknown, we can usually get an estimate or range of potential productivity:
Net-pay comparison from wells in the same reservoir Skin range combined with theoretical well performance High tolerance based on limited well drawdown to this point.
QMAX/MIN QMAX/MAX
AE ESP 15 slide 59
PR
29
Once we have established a range on potential inflow conditions, we can establish some PWF targets:
Optimize production Formation Limits
PR
And though our Inflow is uncertain, our outflow is well defined by well conditions
QMAX/MIN
QMAX/MAX
AE ESP 15 slide 60
So now we combine our variable inflow with our outflow to establish a system range for our pump:
PR
QMAX/MIN
AE ESP 15 slide 61
QMAX/MAX
30
From there, our procedure is the same as before:
Our maximum point is the most important for efficiency and power requirement, so we use that as a starting point. Then we solve for the operating frequency of the other points. And we review the intersection of our potential operating range with our pump multi-frequency curve. If were not happy
We need to tweak our design until we are satisfied.

Adjust pump style, # stages, frequency
Once we have decided on our pump, then we size our motor on our max flow point.
AE ESP 15 slide 62
Reviewing on the Multi-Hz plot:
Rev. A

Feet
12,500
65 Hz 60 Hz
10,000
55 Hz
7,500
50 Hz 45 Hz
5,000
2,500
1,000
2,000
3,000
AE ESP 15 slide 63
4,000
5,000
6,000
31
Example Unknown Productivity
AE ESP 15 slide 64
Exercise 2.13
32

VSD Affinity Laws and Applications

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Artificial Lift

AE ESP 1 Training, Course 15 04-Sep-2006 to 29-Sep-2006 04- Sep29- SepDay 5

VSD Affinity Laws

VSD Affinity Laws for Pumps RPM Flow

RPM RPM Head RPM 1

BHPRPM 2 SBHL 2 RPM

RPM RPM RPM

PREQ1 ( Q1 , SGX ) = PREQ 0 ( Q0 , SGX ) 1 0

Pump Laws, Graphical Representation

MultiPump Laws, Multi-Hz Head Curve

Reda Pump Performance Curve GN4000 540 Series * - 1 Stage(s)

Capacity - Barrels per Day

MultiPump Laws, Multi-Hz Power Curve

VSD Affinity Laws for Motors, Conventional Volt 2

Ratings PAVAIL1 = PAVAIL 0

Motor Laws, Graphically

250 200 150 100 50 0

OLD VSD Affinity Laws for Motors, Dominator

60 A1 = A60 1 PAVAIL1 = PAVAIL 60 Special

Old Dom. Motor Power, Graphically

250 200 150 100 50 0

Old Dom. Amperage Rating, Graphically

Motor Amperage Rating

150 125 100 75 50 25 0

Application of VSD Affinity Laws

Motor Performance as a function of speed

Expected flow from a well

Maximum Safe Speed: Pump Power Req

400 Series - 176 Stage(s) - Sp. Gr. 1.00

REDA Production Systems

Shaft Brake Horsepower Limit Housing Burst Pressure Limit

B.E.P. Q = 95 H = 876.82 P = 21.08 E = 60.25

Capacity - Cubic Meters per Day

What can change when we change the frequency?

Maximum Safe Speed: Pump vs. Motor

PAVAIL1 = PREQ1 PAVAIL0

Maximum Safe Speed: Pump vs. Motor

We know from our affinity laws that

Valid for any reference frequency 0

Maximum Safe Speed: Pump vs. Motor

Works going down, too!

Maximum Safe Speed: Effect of Density

PAVAIL1 = PREQ1 PAVAIL0

Maximum Safe Speed: Old Dominator

PAVAIL1 = PREQ1 (< 60)

Motor Limit Old Dominator Laws

PAVAIL 0 PREQ 0 ( MAX , SG X )

Motor Limit Old Dominator Rule vs. Normal

Standard 250 200 Motor Horsepower 150

Dominator 250 Motor 200 Horsepower 150

Maximum Safe Speed: Shaft Rating vs. Power Req

SBHL1 = SBHL0 1 0 3 1 PREQ1 ( MAX , SG X ) = PREQ 0 ( MAX , SG X ) 0

We know from our affinity laws that

Valid for any reference frequency 0

Housing Pressure Limit

Maximum Safe Speed: Housing Pressure

We know from our affinity laws that

Valid for any reference frequency 0

Overall Speed Limit

Comparing Limits, graphically

PAVAIL1 = PREQ1 PAVAIL0 SBHL0

Overall Speed Limit: Example

Overall Speed Limit: Example