The Optimum Selection of Power Cable

for ESP System

By Emad Ebsis.Faraj
MSc Petroleum and Gas Engineering

Falcon_1979m@yahoo.com

Mobile phone: 0914196382

References and i1lustrations at end of paper. 1

 Emad E. Faraj

Abstract

This paper discusses the method of power cable design for electrical submersible
pumps, a method which can result in a more optimal design that means solving the
problem of short operating life and more economically efficient ESP system. A
procedure is developed for estimating the maximum expected operating temperature
of the conductor for each cable size. Cable length, type and size selection was done
with the aim of minimizing the operating cost along with accomplishing the optimum
performance. An accurate selection of power cable insulation type can be made for
each cable size based upon the maximum operating conductor temperature. Total
cable investment cost can then be determined for each cable size. Power loss
calculations are also provided to predict the power cost of the cable. The final cable
selection can be determined by economic analysis.

Introduction
Electric submersible pump system is a major form of artificial lift in secondary
recovery operations. The optimum production conditions must be provided for an ESP
well to produce at its greatest potential and achieve a successful run life; therefore
ESP downhole and surface equipment must be designated and operated properly.

The ESP power cable is responsible for transmitting the required power to the motor
in the downhole. The ESP power cable is an important part of the system and its right
selection is vital technically and economically. The cable length, type and size must
be considered when designing ESP system.

It has been the practice to choose the smallest conductor size possible, in this manner
reducing the initial cost for the installation. This practice, in many cases, led to
incorrect economic judgement which costs the operator of the equipment a great deal
as well as reducing the life of the selected system.

Once the factors effecting the proper cable selection are recognized, then a computer
program can be effectively used to calculate and to print necessary data for optimum
power cable size.

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 Emad E. Faraj

The length of the power cable

The cable length is determined by adding about 100ft to the pump depth to ensure
sufficient connection to the surface equipment. The cable should reach the top of the
ESP pump from where MLE is connected to the terminal of the motor (the pothead).

The selected power cable length is shorter which will have an effect on the total
operating cost .The total monthly cost will be reduced to approximately 50% for the
new cable as shown in table 6.

The type of the power cable

The cable type selection is based on the well conditions of temperature, gas content
and the well fluid corrosiveness. Based on the down-hole temperature, the selected
power cable is round 4KV, with 350oF maximum temperature. More specifications
for power cable are illustrated in figure A-2 in appendix A.

The selection of cable size depends on technical and economic considerations. The
technical approach is mainly the physical dimensions (the cable fits in the annulus
between the casing string and the ESP unit), the motor current and the voltage drop
along the length of the cable.

 The choice of cable size must be based on that the total voltage drop is less
than 30V/1000 ft of cable (rule of thumb).
 And on the cable of total voltage drop less than 5% of the nameplate voltage of
the motor.
The voltage drop along the cable can be obtained from:

At motor current of 61.7 and the voltage drop value per 1000ft from chart in figure A-2
in appendix A is equal to:

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 Emad E. Faraj

is beyond the recommended voltage drop limit.

AWG#1 , AWG#2 and AWG#4 total voltage drop are 8% ,10 % and 15%
respectively of the nameplate voltage of the motor (891 V). AWG#1 and AWG#2
which are closer to the standard value.

AWG#6 will be excluded as its total voltage drop at the motor nameplate current is
beyond the voltage drop limit of 30V/1000ft.

The economics of power cable

The selection of optimum size of power cable should also involve economic
considerations which are mainly the total cost per month over the expected life of the
power cable. Although the smaller diameter power cable has low capital cost, it has
the higher operating cost. On the other hand, bigger size of conductor has lower
operating cost, but with higher capital investment.

The calculations of the cost for selecting the optimum size of ESP cable are described
in the following part. An assumption which is illustrated in table 1 was made in order
to perform the cost calculations for selecting the power cable.

Table 1: Assumption Made to Calculate the Total Cost of the Cable

Cable Expected
60
life (Months)
Prime Interest Rate
12
%/year
Electricity Cost
5
C/KWh

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Different power cables conductors specifications and prices are shown in table 3.
Table 2: Properties of Different Cable Sizes

Cable Resistance
Cable Size Price per length $/ft
Ohms/1000ft
AWG 1 0.139 11.92
AWG 2 0.170 10.46
AWG 4 0.271 8.71

 The Monthly Payback Period(PB) :

Where: CI= capital investment $

n= the expected life of the cable in months

Mint= monthly interest rate

Where: = is the prime interest rate, % per year.

The monthly operating cost is equal to the power consumed along the cable length per
month.

 Cable total resistance (RT) in Ohms at the bottom-hole temperature

Where: L= Length of the power cable ft

R= cable resistance at 77 oF, ohms/1000ft

BHT= bottom-hole temperature oF

 The power loss (Pl) along the power cable in KW

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 Emad E. Faraj

Where: I= the required motor current in amps

 The monthly cost Cpl power loss $/month

Where: Ce= the cost of the electricity C/KWH

Table 3 contains results of calculation of cable size cost.

Table 3: Cost Calculations of Cable size

Monthly Cost of Total
Capital Total Power
payback power monthly
Cable size investment Resistance loss
period loss cost
($) (Ohm/1000ft) (KW)
($/month) ($/month) ($/month)
AWG# 1 48,872 1085 0.744 6.8 245 1330
AWG #2 42,886 952 0.910 8.3 299 1251
AWG #4 35,711 793 1.451 13.17 474 1267

It is obvious from the table above that AWG# 2 is the best choice in term of cost, but
additional factor should be considered before taking final decision about the size of
the cable, which is the motor start-up voltage check.

Motor start up equation

Motor start-up voltage check which is the ratio of start-up voltage to nameplate
voltage, is another important factor in determining the optimum size of the cable.

Where: Vst = start up voltage`

Vnp= motor nameplate voltage in volt

I= motor required current in amps

RT= total cable resistance in Ohms

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 Emad E. Faraj

The ratio of start-up voltage to motor nameplate voltage should be greater than 50%
of the nameplate voltage at the motor terminal to avoid possible start-up problems.
The ratios of start-up voltage to motor nameplate voltage for several cable conductors
are shown in table 4.

Table 4: Motor Voltage Check at Start-up

Motor Nameplate Motor Required
Vst/Vnp %
voltage (volt) current (Amp)
AWG #1 82
891 55 AWG #2 78
AWG# 4 64

Based on the table above AWG#1, 2 and 4 provide sufficient voltage to the motor
terminal for successful start-up.

Since the main factor in selecting the power cable size is based on the total monthly
cost AWG# 2 is selected as it gives the most economical solution.

Table 5 shows the selected power cable characteristics.

Table 5: Proposed Cable Characteristics

Design Round
Size 2- Copper
Length 4100 ft
Power Rating 4 KV
Voltage Drop 91 V
Max. Down-hole
350 oF
Temperature

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Table 6: Cable Cost Comparison Calculations

Existing Cable New Cable

Size AWG#1 AWG#2
Length (ft) 6000 4100
Capital Cost
71,520 42,886
($)
Monthly Payback
1587 952
($/month)
Total Resistance
1.089 0.910
(Ohm/1000ft)
Power loss (KW)
24 8.3
Cost of power loss
864 299
($/month)
Total monthly cost
2451 1251
($/month)

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Table 7 presents a summary to the result of proposed ESP cable parameters obtained
both by simple calculations and Software simulation.

Table 7: Comparison of Results between Hand Calculations and Software Simulation

Hand Calculations Soft Ware Simulation

Power frequency Hz 60 60
Np Voltage 891 825
Np Current amp 61.7 46
Np Horse Power 88 62
Cable Round Round
Length (ft) 4100 4100
Size 2 2
Surface Voltage 961 921.36
Voltage Drop 91 96.3

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Conclusions
The challenge for any ESP system is to increase the profitability as well as reduce the
operating cost which is mainly the electricity bill and the workover operations.

Several types and sizes of cables may be acceptable in a certain well from a material
viewpoint. However, the final decision of which cable is the optimum choice should
be an economic one established on investment costs against operating costs.

The Outcome revealed that no much difference between the results obtained from
software simulation and hand calculations.

The proposed power cable is shorter than the existing one due to that the setting of the
proposed pump is at 4000ft instead of 5900ft this will reduce the power cable length
and the monthly cost from 2451$ to 1251 $ consequently, there will be an amount of
72,000$ saved over the expected life of the cable. Minimising the pump setting will
result in reducing the number of pump stages required to lift the liquid to the surface
and in turn less motor horse power. Also less voltage drop will result from decreasing
the cable length.

Acknowledgement
The author wishes to thank the many members of the Division of ESP in Gailo 59E
field who helped make this paper possible.

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 Emad E. Faraj

Nomenclature

AWG = American Wire Gauge

A = Amperage
ESP = Electric Submersible Pump
F = Degree Fahrenheit
KV = Kilovolt
KVA = Kilowatts- Volts- Amperage
L = Cable Length ft
Mint = Monthly Interest Rate
MLE = Motor Lead Extension
n = Expected Life for Cable
PB = Monthly Pay Back
Pint = Prime Interest Rate
PL = Power Loss in the Cable
PSI = Pound per Square Inch
RT = Total Cable Resistance
V = Voltage

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References

1. ESP power cable. (2015).Petrowiki. Retrieved 18 January, 2015, from

http://petrowiki.org/ESP_power_cable
2. Maston L. Powers.: "Economic Considerations for Sizing Tubing and Power Cable
for Electric Submersible Pumps", SPE.
3. API RP 11S4, API Recommended Practice for Sizing and Selection of
Electric Submersible Pump Installations, first edition, API (May 1, 1993).
4. R.E. Schultz, B.T. MacKenzie, l and K. Marefat, "ESP Cable Insulation: Selection
for performance", SPE #14690.

5. Takas, G. 2009. Electric Submersible Pumps manual: design, operating, and

maintenance. Retrieved 25 January, 2015, from
http://app.knovel.com/web/toc.v/cid:kpESPMDOM1/viewerType:toc/root_slug:electrica
l-submersible/url_slug:electrical-submersible/?

6. Vandevier, J. E.: "Optimum Power Cable Sizing for Electric Submersible Pumps",
SPE 1#16195.

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Appendix

Figure A-1: Redahot Round Cable ampacity chart (amperage carrying capacity)

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Figure A-2: Cable Current and Voltage Drop in Conductors Chart

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ESP Design Report created on Fri Apr 08 23:33:35 2016

Design Data
===========

Design Production Rate = 3500.00 STB/d

Design Outlet Pressure = 105.00 psia
Static Reservoir Pressure = 2540.00 psia
Water Cut = 86.00 %
GOR = 300.00 scf/STB
Pump Depth = 4000.00 ft
Casing ID = 7.00 inches
Design Frequency = 60.00 hz
Head Factor = 1.00

Pump Data
=========
Pump Intake Liquid Rate = 3708.61 STB/d
Pump Intake Free Gas Fraction = 4.06 %
Selected Pump = Reda : SN3600
Number of Stages = 32
Pump Efficiency = 69.46 %
Pump Power = 55.79 hp
Pump Intake Pressure = 998.97 psia
Pump Discharge Pressure = 1602.02 psia
Pump Head Required = 1496.97 ft
Liquid Density = 58.96 lb/ft3
Free Gas Fraction at Inlet = 0.04

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 Emad E. Faraj

Motor Data
==========
Selected Motor = Reda : 540_Series_S : Single
NP Power at 60 Hz = 62.50 hp
NP Voltage at 60 Hz = 825.00 volts
NP Current at 60 Hz = 46.00 amps
NP Power at Design Speed = 62.50 hp
NP Voltage at Design Speed = 825.00 volts
NP Current at Design Speed = 46.00 amps

Cable Data
==========
Cable Length = 4100.00 ft
Voltage Drop = 96.36 volts
Downhole Voltage = 825.00 volts
Surface Voltage = 921.36 volts
Total System KVA = 73.32

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