CHAPTER II

BASIC THEORY

2.1 Introduction

Electrical Submersible Pump (ESP) is a subsurface centrifugal pump

with a multistage (impeller) driven by an electric motor. Electric power

supplied from the transformer through the switchboard, and the power will

be forwarded from the switchboard to Electrical Submersible Pump (ESP)

motor through a power cable that is attached along the tubing. In the

Electrical Submersible Pump (ESP) motors, electric power will be

converted into mechanical power. Shaft of Electrical Submersible Pump

(ESP) will rotate at the same time, the impeller spins and push the fluid

towards the surface through a pump intake or gas separator. In the design of

Artificial Lift data is needed regarding IPR or Inflow Performance

Relationship and Productivity Index (PI) which will indicate the magnitude

of the potential production from the reservoir and its influence on the

working fluid level during production. Artificial Lift is a mechanism to lift

hydrocarbons from the reservoir to the surface, because the reservoir

pressure is not enough to push oil up to the surface and uneconomical if

flow naturally. Artificial Lift consists of two groups of components, namely

surface facilities and down hole facilities.

2.2 Down Hole Facilities

2.2.1 Pump

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Pumps installed hanging on the tubing using the tubing

hanger. Pump used is a multistage centrifugal pump types, the stage

consists of an impeller and a diffuser. Impeller is locked on the axis

of the pump (shaft), while the diffuser pressed on the pump housing

with compression sub number of stages mounted on each pump will

be directly correlated with the capacity of hea head capacity of the

pump.

Fig 2.1 Centrifugal Pump

2.2.2 Intake (Gas Separator)

Mounted below the pump, where the connecting axis

coupling wear. Intake is designed to reduce the volume of gas that

goes into a gas pump separator.

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Fig 2.2 Intake

2.2.3 Protector
Protector (reda) is often referred to as the seal section

(centilif) or equalizer. Protector is filled with oil that has a high

resistance value because if the resistance value is low, will deliver

electricity and will cause terhubungannya between phase to ground

(body), so it will burn the motor.

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Fig 2.3 Protector

2.2.4 Motor
The type of motor Electrical Submersible Pump (ESP) is a

two pole electric motors, threephase special lubricating oil in the

content that has electric strength. Motor mounted at the bottom on

the circuit and the motor is driven by an electric current is sent

through a cable from the surface.

Fig 2.4 Motor

2.2.5 Electric Cable

Electric wires used are of the three conductors. There are two

types, namely flat cable and round cable type. Wires serve as a

conductor of electric current from the switchboard to the motor

Electrical Submersible Pump (ESP) in the well.

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Fig 2.5 Flat Cable

Fig 2.6 Round Cable

2.2.6 Pressure Sensing Instrument Unit

Pressure sensing instrument or PSI Unit has two main

components, namely:
1. Pressure sensing instrument Down Hole Unit
Installed under the motor type upper or center tendem

because it is connected to the wire connection of the electric

motor as if part of the motor.

2. Pressure sensing instrument Surface Hole Unit
Is part of the system that controls the work down hole and

is a unit of information in the capture of the down hole unit.

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2.3 Surface Facilities

2.3.1 Well Head
Well head is seating hang tubing in the well. Well head used

for the installation of Electrical Submersible Pump (ESP) is not the

same as the well head to the well gushes nature but adapted to the

needs.
2.3.2 Junction Box
Junction box placed between the wellhead and the switch

board for security reasons. Junction box usually placed 15 feet

from the wellhead and is normally 2 to 3 feet above the ground.

Fig 2.7 Junction Box

2.3.3 Switchboard or Motor Controller

Switchboard is a control panel work surface when the pump

is working, equipped with a motor controller, overload and underload

protection is also ampere meter record flow chart that serves the

motor is running.

2.3.4 Transformer
Electrical Submersible Pump (ESP) motors have capacities

horse power, amperage, and voltage is varied. The voltage required

to operate Electrical Submersible Pump (ESP) motors ranging

between 7,200 to 13,800 volts.

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Fig 2.8 Transformer

Fig 2.9 Electric Submersible Pump (ESP)

2.4 Performance Characteristics of Electrical Submersible Pump (ESP)

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Electric motors rotating at a relatively constant rate, rotate the pump

(impeller) passes the shaft which is connected with the part protector. Power

is channeled to the equipment below the surface via the electrical conductor

wires affixed to the tubing, fluid enters the pump in operation. The behavior

of the pump is at the highest efficiency rates when only liquids produced.

The high volume of free gas causing inefficient pump operation. System

Electric Submersible Pump (ESP) usually can only deal with the free gas

between 10% to 20% before the pump performance decreases and occurred

Gas Lock.

2.5 Working Conditions Optimum of Electrical Submersible Pump (ESP)

Electric Submersible Pump (ESP) has properties like multilevel

centrifugal pump. Each level (stage) consists of impeller and diffuser. In

operation, fluid is directed to the base of the impeller with a vertical

direction. Rotary motion is given to the liquid by the blades of the impeller.

The centrifugal force causes the fluid so that the fluid leaving the radial flow

impeller at high speed impeller and directed back to the next by a diffuser.

The process continues until it reaches the impeller at the last stage.

Production fluid will pass through the impeller are arranged sequentially

and each level will increase the pressure (head). Total head occur is the sum

total of each head formed on each impeller.

2.6 Causes of Failure in Operations Electrical Submersible Pump (ESP)

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In this study the system reservoir, Electric Submersible Pump (ESP)

well, and surface facilities is assumed to operate properly and does not take

into account factors that can disrupt the operation. However, the following

are the things that can cause the time range operation Electric Submersible

Pump (ESP) shorter than it should be. These things include:

a. Design of Electric Submersible Pump (ESP) are not appropriate.

b. Poor quality on the Electric Submersible Pump (ESP) equipment.
c. Corrosion of pump equipment and the motor housing.
d. Pengendapan scale pada motor dan stage pompa.
e. Scale.
f. High reservoir temperature.
g. Gas into the pump.

2.7 Basis Calculation of Electrical Submersible Pump (ESP)

In principle, the planning or design of a submerged electric pump

unit for wells with high water cut is the same as planning regular electric

pump unit, where the desired maximum production rate also maximum

water production Control by calculating the critical rate where the desired

rate of oil production is greater than the critical rate, causing water coning.

The production must continues because they have economic value and the

occurrence of water coning is fair to old wells that have water cut greater

than 90%.
Parameter stating the productivity of the formation is the

Productivity Index (PI) and Inflow Performance Relationship (IPR).

Productivity Index (PI) is an index used to express the ability of a

formation to produce at a pressure difference specified or the ratio of the

production rate of the resulting formation of productive drawdown which is

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different bottomhole pressure when conditions are static (Ps) and the current

flow occurs ( PWF). The equation of Productivity Index (PI):

q
PI = J = ( Ps P wf ) STB/Day/Psi

.......................................(Equation 2.1)

If the fluid in the formation is two phases condition, then the form

of the equation used is as follows:

Pb
Pwf Pwf 2
10,2
Pb( )
0,8(
Pb
)

PI = Pr
Pr +
1,8

Q

.....(Equation 2.2)

Inflow Performance Relationship is the well's ability to drain the

reservoir of oil production. Inflow Performance Relationship or known by

the name of IPR is given in the form of a graph is the relationship between

the pressure flowing bottomhole upfront formation (Pwf) to the flow rate of

fluid (Q), which consists of the flow of oil and water (single phase), as well

as oil, water and gas (two-phase).

Curve Inflow Performance Relationship (IPR) is used to determine

how much ability wells to drain the fluid reservoir (Gross). From the curve

Inflow Performance Relationship (IPR) can be planned accordingly so

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Artificial Lift resulting in the optimum flow rate of the well. The procedure

of making Inflow Performance Relationship (IPR):

1. Calculating Fluid Gradient (Gf)

Gf = [(1 - Wc) x Sgo + (Wc x Sgw)] x 0.433.(Equation 2.3)

2. Calculating Static Pressure (Ps)

..(Equation 2.4)
SFL = Dmid perf
Pr( =Pr[(Dmid
Pc
+ ) perf SFL) x Gf] + Pc
Gf Gf ..(Equation 2.5)

3. Calculating Pwf
..(Equation 2.6)
Pwf = [(Dmid perf DFL) x Gf] + Pc
4. Value of Qmax

Qmax =
..(Equation 2.7)
5. Make IPR with some Pwf assumptions
IPR curve created by the method of vogel to assume some value

Pwf Plot Q with Pwf assumptions.

2.8 Optimation Parameters of Time Range Operations Electrical

Submersible Pump (ESP)

Design of Electrical Submersible Pump (ESP) the right will set the

pump to operate at its optimum flow rate range, where the flow rate is

adjusted to the ability of the reservoir. Design of Electrical Submersible

Pump (ESP) requires accurate data, including reservoir pressure, the well

productivity index, the data reservoir fluid, and others. Considered the

parameters in the optimization of the time range operation Electrical

Submersible Pump (ESP):

a. Speed production rate of 1 ft / sec.
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b. Depth of Electrical Submersible Pump (ESP).

Production optimization calculation step by Electrical Submersible

Pump (ESP):

1. Q design Determination
....(Equation 2.8)
2. Pwf design Determination
Qdesign = 80% x Qmax
....(Equation 2.9)
Pwf design
3. Specific = 0.125
Gravity x Pr
Mix (-1 +Determination
Fluid
a. Specific gravity water

8180 (Q
Qmax
b. Oil Specific gravity
)
....(Equation 2.10)
SG Water = Water cut x SG
....(Equation 2.11)
Air
c. Mix Fluid Specific gravity
SG oil = Oil Cut x SG Oil
....(Equation 2.12)
d. Fluid Gradient (SG)
SG Mix Fluid = SG Water + SG
Minyak
Gf = SG Mix Fluid ....(Equation
x 0.433 psi/ft 2.13)

e. Working Fluid Level (WFL) Determination

WFL = MidPerfo

( Pwf Gfdesain ) ....(Equation 2.14)

4. Pump Setting Depth Determination
5. Pump Intake Pressure (PIP) Determination
a. Depth Difference = Mid Perforasi Pump Setting Depth (PSD)
b. Pressure Difference = Depth Difference x Gf
c. Pump Intake Pressure = Pwf Pressure Difference
6. Total Dynamic Head (TDH) Determination
a. Fluid Over Pump (FOP) Determining

FOP = ....(Equation 2.15)

PIP
b. Vertical
Gf Lift (HD) Determining
....(Equation 2.16)
HD = TVD
c. Tubing - FOP
Friction Loss (HF) Determining

100
C
....(Equation 2.17)

HF = Friction Loss x PSD
Friction Loss = 100 1.85
1.85( )
C
2.083

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....(Equation 2.18)

d. Tubing Head (HT) Determining

Tubing Pressure
....(Equation 2.19)
HT =Dynamic Head
e. Total Gf (TDH) Determining
....(Equation 2.20)
7. Pump Selection
TDH = HD + Number
a. Counting the
HF + HT of Stage

....(Equation 2.21)
b. Determining Motor CapacityTDH
Number of Stage = ( )
Head per Stage + 10
....(Equation 2.22)
HP
BHP = Stage x
c. Surface Voltage Determining of Switchboard
i. Cable Selection
ii. Determining Cable Length

Length Cable = PSD TVD + 100 ft

....(Equation 2.23)

iii. Cable Voltage Drop

iv. Surface Voltage Counting

Surface Voltage = Motor Voltage + [

( Available Frek
Frek min )
....(Equation 2.24)

2.9 Economic Analysis Electrical Submersible Pump (ESP) Well

In increase the rate of well productivity index marked by increasing

productivity and production rate. The final result is expected to increase the

production rate of the wells after pump replacement and gain increased

profit for the company. In increasing the production rate can increase greater

profits for the company after the economic analysis.

After designing the pump, it will be the economic analysis for the

well X. The economic analysis is performed by calculating the advantage of

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the number of production wells X were reduced by all of the cost of renting

pumps. Costs that need to be calculated, that is:

a. Pump rent cost
b. Engine rent cost
c. Cost of produced water injection services
....(Equation 2.25)
d. Cost
TotalofCost
treating chemical
= Gross x WCproduction
x Cost per services
Barrel
....(Equation 2.26)
e. Cost of treating chemical injection services
Gross
Total Cost = 1000 bbl x Treatment
....(Equation 2.27)
f. Cost of rent transfer pump
Gross
Total Cost = 1000 bbl x WC x Treatment
....(Equation 2.28)
After doing all the calculations of the costs, then we can find out the
Total Cost = Nett x Rent Cost
total cost of the rent Electric Submersible Pump (ESP) by summing all

costs. And the benefits can be determined by counting the number of

production wells advantage of X are reduced by all of the cost of pump rent.