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This article walks through the suggested nine step procedure for selecting and designing an electric
submersible pump. This nine step procedure for ESP design is a basic hand-design of simple water and light
crude oil. For more complicated well conditions, such as high GOR, viscous oil, high-temperature wells, etc. a
number of computer programs are available to automate this process.
In this example, a high water cut well is considered. This is the simplest type of well for sizing submersible
equipment.
Well Profile:
Vertical Well
Casing: 7” 26#
Bottomhole Temperature: 90 °C
Wellhead Temperature: 50 °C
Inflow performance:
Present production rate: 2500 bfpd @ Pump Intake Pressure = 1160 psi
Power sources:
Possible problems?
The pump intake pressure (1160 psi) is greater than bubble point pressure (964 psi). So that, the Productivity Index
(PI) inflow performance method will most probably give satisfactory results.
PI=Q/(Pr-Pwf)
Firstly, we need to calculate the flowing bottomhole pressure (Pwf). Pwf is calculated from the pump intake
pressure (PIP), hydrostatic pressure and friction loss in the casing annulus between the pump setting depth and the
datum point. In the given example, as the pump is set 290m above the perforations, the friction loss, because of
flow of fluid through the annulus from perforations to pump setting depth, is small, as compared to the flowing
pressure, and can be neglected.
Pwf is calculated from the pump intake pressure (PIP), hydrostatic pressure and friction loss in the casing
annulus between the pump setting depth and the datum point. In the given example, as the pump is set 290m
above the perforations, the friction loss, because of flow of fluid through the annulus from perforations to pump
setting depth, is small, as compared to the flowing pressure, and can be neglected.
Therefore:
Pwf = PIP + hydrostatic pressure from pump intake depth to the datum.
Because there is both water and oil in the produced fluids, it is necessary to calculate a composite SG of the
produced fluids. SG is calculated from oil SG and water SG.
SG(oil) = 0.845
WC= 90%
SG = 0.9935
PI = 3.33 bpd/psi.
At a liquid rate of 3500 bfpd, the PIP is a bit smaller than the bubble point pressure (964 psi). Therefore, the
Productivity Index (PI) inflow performance method will most probably give satisfactory results.
In this third step, one must determine The total fluid volume (Vt) of oil, water, and gas at the pump intake. For this
example, Standing’s correlation was used (Standing is the oldest, simplest and most commonly used correlation).
Where:
To determine the solution GOR (Rs) at the pump-intake pressure, we need to substitute the pump-intake pressure
for the pressure (P) in Standing’s equation. For this example, motor temperature is 70 °C (158 °F).
Rs = 190.3 scf/stb
Using the following Standing’s equation, determine the oil formation volume factor (Bo):
Bo = 0.972 + 0.000147 × [190.3 × (0.8/0.845)^0.5 + 1.25 × 158]^1.175
Bg the volume, in barrels, that one thousand Standard. cubic feet of gas would occupy at some specific pressure
and temperature. It indicates how much the gas volumetrically compresses when taken from Standard conditions
(60 ºF, 1 atm) to any other specific conditions.
Now, these three variables: Rs, Bo, and Bg are known. So that, the volumes of oil, water, and free gas can be
determined and percentages of each calculated.
Solution Gas Volume = (Solution GOR @ PIP x Oil rate) = (Rs x Oil rate)
Solution Gas Volume = 190.3 × 3500 × (1-0.9) = 66710 scf = 66.71 Mscf
Vo = Bo × BOPD
Vo = 395.9 bopd
Vg = Free Gas x Bg
Vg = 3.29 × 3.085 = 10.15 bgpd
Vg = 10.15 bgpd
Vw = 3150 bwpd
Vt = 3556,1 bfpd
This is a negligible amount of gas, it is expected that pump performance will not be affected by gas, so no need for
a gas separator (for more details, refer to the post: ” ESP: Pump Intake “).
TMPF = [(BOPD × SGo) + (BWPD × SGw)] × 5.6146 × 62.4 + (GOR × BOPD × SGg × 0.0752)
TMPF = [3500 × (1-0.9) × 0.845) + (3500 × 0.9 × 1.01)] × 5.6146 × 62.4 + (200 × 3500 × (1-0.9) × 0.8 × 0.0752)
SGcomp = 0.997
Now, we know the total volume of fluid entering the first pump stage (3556,1 bfpd) as well as the composite
SG (0.997). we can continue to the next step of the ESP system design.
HL = 2859.68 ft
The ESP industry has traditionally used the Hazen-Williams formula to calculate these friction losses (in terms of
head, not pressure).
The Hazen-Williams formula is an empirical equation developed for municipal water distribution systems. It works
reasonably well when water is the flowing medium. However, it should not be used to calculate friction losses in
viscous or gassy fluids.
Hazen-Williams Equation:
Q = 3556,1 bfpd
F= 38.83 ft /1000ft
Ft = 218.26 ft
From the input data, the desired wellhead pressure is 87 psi. Calcultate the corresponding head at wellhead using
the composite SG:
TDH = 3357.19 ft
NB: The TDH required is based on normal pumping conditions. If the well is killed with a heavier-gravity fluid, a
higher head is required to pump the fluid out, until the well is stabilized on its normal production. Therefore, more
horsepower is required to lift the heavier kill fluid. This should be considered when selecting the motor rating for
the application.
Obviously, the pump ID (series) must fit the 7” 26# casing (ID = 7.276″).
Select the 538 series G31 pump.
NB: When two or more pump types have similar efficiencies at the desired production rate, refer to the post titled
“ESP design – Step 5: Pump Type” to get recommendations on the most adaptable pump to be considered.
From the selected pump performance curve, The head in meters for one stage at 565 m3/d (3556 bfpd) is 8.6 m
(28.2 ft). The BHP per stage is 1.875 hp.
To determine the total number of stages required, divide the TDH by the head/stage:
From manufacturer’s information for the Series 538 G31 pump. The housing no. 17 can house a maximum of 117
stages, 124 stages for a housing no. 18.
Either housing no. 17 or 18 should be adequate. In our case, housing no. 18 is selected.
Pump BHP required:
Once the required number of pump stages is decided, calculate the Pump BHP required:
As calculated in the “Step 3: Gas Calculations” in this post, the percentage of free gas was negligible (0.29% of the
total volume of fluids at the pump intake). So that, no need for a gas separator.
Seal:
It is preferable to select a Seal series the same as that of the pump and the motor. Otherwise, an adaptor is
required to connect the units together.
From the manufacturer’s catalog, the 513 series GSB3 DB HL (double-bag, high load thrust bearing) [3 chambers,
Bag/Bag/Labyrinth] seal section is selected for this well MF1.
Seal HP required:
The HP required for the seal depends on the TDH produced by the pump and has to be added to the HP required
for the pump. The following Horsepower vs. TDH curve shows a requirement of 2.95 hp for the 513 Series seal
operating against a TDH of 3357.19 ft.
Therefore:
Motor:
When selecting a motor, consideration should be given to choosing as large motor as possible for the casing to
optimize the initial cost, motor efficiency, operating cost and ensure better motor cooling (higher fluid velocity).
As mentioned in Step 1: Input Data, MF1 experienced frequent starts and stops. This is why, from the
manufacturer’s catalog, we selected an XP motor which is suggested for wells with frequent starts and stops. Select
the 333-hp 562 Series motor from the catalog.
The motor voltage can be selected on the basis of considerations discussed in the post “ESP design – Step 6:
Optimum Size of Compounds”. For this example, (333 hp; 2321 V; 88 amps) seems to be a good choice.
Check the manufacturer’s catalog and equipment information to assure that all operating parameters are well
within their recommended ranges (e.g. shaft HP, housing burst pressure, and fluid velocity).
Typically, the motor is selected to operate in the range from 70 to 100% of its rating. Generally speaking, the
maximum motor load should not exceed 110%, in the other hand selecting a motor with minimum operating load
(e.g. 10% or 20%) nullifies the protection monitoring of the motor.
Refer to the manufacturer’s cable catalog to determine if the size selected can be used within the proposed tubing
and casing sizes. Cable diameter plus tubing-collar diameter will need to be less than the inside diameter of the
casing. In our case, all cable sizes can be used.
The cable size is selected based on its current carrying capability. Using the motor amps (88) and the following
cable voltage drop chart, select a cable size with a voltage drop of less than 30 volts per 1,000 ft.
Conductor sizes #1 and #2 fall in this category. Cables #1 and #2 have voltage drop of 26 volts/1,000 ft and 20
volt/1000 ft @ 25°C (77°F) respectively. Calculate their voltage drop at the downhole temperature (158°F in our
case).
For cables operating at a different temperature, the voltage drop can be determined by multiplying it by
Temperature Correction Factor (TCF) as indicated in the formula below or by using the table below:
TCF = 1 + 0.00214 × (T – 77)
Therefore:
Cable Type:
As per the input data, the downhole conditions of this well aren’t considered severe (no risk of corrosion, no sour
gases, downhole temperature not high..). So that a standard cable type is selected (with galvanized steel armor).
Cable Length:
The pump setting depth is 5620 ft (1713 m). With 100 ft (30.5 m) of cable for surface connections, the total cable
length should be 5720 ft (1743.5 m).
Cable Bands:
Install three bands per section from the motor pothead to the first splice in the power cable (don’t install bands on
a cable splice). Place a band above and below the splice approximately 4 inches.
The minimum banding recommendation is two bands per tubing joint, with one band in the middle of the joint and
the other band 2 to 3 ft above the collar.
Cross-Coupling Cable Protectors are used to protect and support ESP cable. Install a cross-coupling protector every
10 joints.
Select these accessories on the basis of required ODs and type of threads.
The motor-controller selection is based on its voltage, amperage, and KVA rating. Therefore, before selecting the
controller, one must first determine the motor controller voltage.
The surface voltage (SV) is the sum of the motor voltage and the total voltage loss in the cable. Taps on the
transformer have to be adjusted to closely achieve this value.
NB: Surface voltage is less than standard 3 KV cable. 3 kV or higher cable construction can be selected. For this
example, a 4 kV power cable is selected.
The motor amperage is 88 amps; the KVA can now be calculated.
Where:
KVA = 374
The 380V motor controller: model: 4500-VT (411 KVA / 624 A) suits these requirements.
Transformers:
The transformer selection is based on the available primary power supply (418 V), the secondary voltage
requirement (2455 V) and the KVA requirement (374 KVA).
Surface cable:
Since a submersible pump motor is an induction motor, its speed is proportional to the frequency of the electrical
power supply. This relationship between variables involved in pump performance (such as head, flow rate, shaft
speed) and power is known as “Affinity Laws” (also called “Pump Laws”).
According to the affinity laws, the following relationships exist between the actual speed of the centrifugal pump
and its most important performance parameters:
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