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 Example on ESP Design
Casing size: 7.0 inch
Perforation depth: 6800 ft.
Tubing sizes available: 3.5 inch OD EUE, 9.3 lb
Pump setting depth: 5500 ft
Static Bottom Hole Pressure: 3000 psi
Oil Cut: 25 %
Water S.G.: 1.085
Gas S.G: 0.70
Oil API Gravity: 32 (0.866)
GOR: 300 scf/bbl
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Productivity Index: 1.42 bpd/psi
Bottom Hole Temperature: 160 deg F
Wellhead Temperature: 100 deg F
Wellhead Pressure require: 100 psi
Desired Flow rate: 2300 STB/D
Viscosity of oil @ WHT: 15 cp
Viscosity of oil @ BHT: 5 cp
Viscosity of water @ WHT: 0.9 cp
Viscosity of water @ BHT: 0.6 cp
Hz: 50
Casing is unvented, i.e., string has unvented packer.
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1. Calculate the average specific gravity
𝐴𝑣𝑔 𝑆𝑃. 𝐺𝑟 = 𝛾𝑤 × 𝑊𝐶 × 𝛾𝑜 × 1 − 𝑊𝐶
𝐴𝑣𝑔 𝑆𝑃. 𝐺𝑟 = 1.085 × 0.75 × 0.866 × 1 − 0.75 = 1.03
2. Calculate the fluid gradient
Fluid Gradient = Water gradient x Avg SP.Gr
Fluid Gradient = 0.433 x 1.03 = 0.446 psi/ft
3. Calculate the static fluid level (SFL)
𝑆𝐵𝐻𝑃
𝑆𝐹𝐿 = 𝑀𝑖𝑑 𝑜𝑓 𝑃𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑖𝑜𝑛 𝑑𝑒𝑝𝑡𝑕 +
𝐹𝑙𝑢𝑖𝑑 𝐺𝑟𝑎𝑑𝑖𝑒𝑛𝑡

3000
𝑆𝐹𝐿 = 8630 + = 73 𝑓𝑡
0.446

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4. Calculate the bottom hole flowing pressure at mid of perforations.
𝑄
𝑃𝐼 =
Ps − 𝑃𝑤𝑓

𝑄 2300
𝑃𝑤𝑓 = Ps − = 3000 − = 1380 𝑝𝑠𝑖𝑎
𝑃𝐼 1.42

5. Calculate the bottom hole flowing pressure at the pump setting depth
(PSD) which is pump intake pressure (PIP).
𝑃𝐼𝑃 = 𝐵𝐻𝐹𝑃 − 𝑀𝑖𝑑 𝑜𝑓 𝑃𝑒𝑟𝑓. 𝐷𝑒𝑝𝑡𝑕 − 𝑃𝑢𝑚𝑝 𝑑𝑒𝑝𝑡𝑕 × 𝐹𝑙𝑢𝑖𝑑 𝐺𝑟𝑎𝑑𝑖𝑒𝑛𝑡
𝑃𝐼𝑃 = 1380 − 6800 − 5500 × 0.446 = 800 𝑝𝑠𝑖
6. Calculate the drawdown
𝑄 2300
𝐷𝑟𝑎𝑤𝑑𝑜𝑤𝑛 𝐷𝐷 = = = 1620 𝑝𝑠𝑖
𝑃𝐼 1.42

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7. Calculate dynamic fluid level DFL
DFL = SFL + DD = 73 + 3632 = 3705 ft
8. Calculate the fluid column above the pump
𝑃𝐼𝑃 800
fluid column above the pump = = = 1794 𝑓𝑡
𝐹𝑙𝑢𝑖𝑑 𝐺𝑟𝑎𝑑𝑖𝑒𝑛𝑡 0.446

9. Calculate Rs @ PIP

1.2048
𝑃𝐼𝑃 100.0125 𝑥 𝐴𝑃𝐼
𝑅𝑠 = 𝛾𝑔𝑠
18 100.00091 𝑥 𝐵𝐻𝑇

1.2048
800 100.0125 𝑥 32
𝑅𝑠 = 0.7 𝑥 = 137 𝑆𝐶𝐹/𝑆𝑇𝐵
18 100.00091 𝑥 160

10. Calculate the total produced gas QGT

QGT = GOR x (1-WC) x Q = 300 x (1 – 0.75) x 2300 / 1000 = 172.5 Mscf 7
12. Calculate the total gas in solution @ PIP (QGIS) in Mscf
QGIS @ PIP = Rs x (1 – WC) x Q /1000
QGIS = 137 x (1 – 0.75) x 2300 / 1000 = 78.8 MSCF
13. Calculate the total free gas @ PIP (QGF) in MSCF
QGF = QGT – QGIS = 172.5 – 78.8 = 94 MSCF (Casing is unvented)
14. Calculate Bg @ PIP or get it from PVT data of the reservoir
5.04 ×𝑍 ×(𝐵𝐻𝑇+460)
𝛽𝑔 =
𝑃𝐼𝑃

Where Z is the gas compressibility factor given (Z = 0.886)

5.04 ×0.886 ×(160+460) 𝑏𝑏
𝛽𝑔 = = 3.4
800+14.7 𝑀𝑠𝑐𝑓

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15. Calculate the volume of free gas under reservoir conditions (QGR),
this will enter the pump as the system in unvented
QGR = QGF x Bg = 94 x 3.4 = 319 bbl/day
16. Calculate Bo @ PIP
𝛽𝑜 = 0.972 + 0.000147 𝑥 𝐹1.175
If Rs < GOR then

𝛾𝑔 0.5
𝐹 = 𝑅𝑠 + 1.25 𝑥 𝐵𝐻𝑇
𝛾𝑜

If Rs > GOR then

𝛾𝑔 0.5
𝐹 = 𝐺𝑂𝑅 + 1.25 𝑥 𝐵𝐻𝑇
𝛾𝑜

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In this example, Rs < GOR; so

0.7 0.5
𝐹 = 137 𝑥 + 1.25 𝑥 160 = 323
0.866

𝛽𝑜 = 0.972 + 0.000147 𝑥 (323)1.175 = 1.1 𝐵𝐵𝐿/𝑆𝑇𝐵

17. Calculate the volume of oil at reservoir conditions (QOR)
QOR = Qo x Bo = Q x (1 – WC) x Bo
QOR = 2300 x (1 – 0.75) x 1.1 = 634 bbl/D
18. Calculate the water volume in the reservoir
QWR = WC x Q x Bw = 0.75 x 2300 x 1 = 1725 Bbl/D
19. Calculate the total volume of fluid entering the pump under
reservoir conditions (QRT)
QRT = QOR + QWR + QGR = 634 + 1725 + 319 = 2678 bbl/D 10
20. Calculate the free gas % at the pump intake
% of free gas = QGR/QRT x 100 = 319 / 2678 x 100 = 11.9%
21. In order to recalculate the real average specific gravity including
gas and real fluid gradient, we have to calculate the total weight of the
fluid.
Oil mass = Qo x OSG x 62.4 x 5.615
Oil mass = 2300 x 0.25 x 0.866 x 62.4 x 5.615 = 174,457 lbm
Water mass = Qw x WSG x 62.4 x 5.615
Water mass = 2300 x 0.75 x 1.085 x 62.4 x 5.615 = 655,726 lbm
Gas mass = Qo x GOR x GSG x 0.0752
Gas mass = 2300 x 0.25 x 300 x 0.7 x 0.0752 = 9080 lbm
Total mass = 174,457 + 655,726 + 9080 = 839,263 lbm 11
22. Calculate the density, specific gravity and gradient
Density = mass / volume = 839,263 / (2678 * 5.615) = 55.82 lb/cu.ft
S.G = Fluid density / water density = 55.82 / 62.4 = 0.8945
Gradient = S.G x 0.433 = 0.8945 x 0.433 = 0.3872 psi/ft
23. Calculate the TDH based on the new gradient
Dynamic fluid level = PSD – PIP / G = 5500 – 800/0.3872 = 3434 ft
Friction loss for a given tubing diameter can be estimated based on average
viscosity of 10 cp and rate of 2678 bbl/D as 166 ft
WHP in ft = WHP / Gradient = 100 / 0.3872 = 258 ft
TDH = 3434 + 166 + 258 = 3858 ft

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24. Select a pump suitable for installation in 7” casing and also capable
of production 2678 bbl/d
Select SN2600 of rada

From chart
Head per stage = 46 ft/stage

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25. Calculate the number of stages required for TDH and motor HP
Number of stages = TDH / ft per stage = 3858 / 46 = 84 stages
From pump SN2600 catalogue select the housing number 70 (88 stages)
HP required = No. of stages x HP per stage x fluid S.G
HP required = 88 x 1.32 x 0.8945 = 104 hp

From motors catalogue select series 540,

117 hp motor, 1751 v, 40.5 A.

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26. Check shaft loading and housing pressure limitations
Check pump shaft hp (Monel, 256 hp) with motor hp, if the motor hp is
more than pump shaft hp, ask for high strength shaft (Inconel, 410 hp)
Pump head at shut in conditions = 58 x 88 = 5104 ft
Pump discharge pressure at shut in = 5104 x 0.3872 = 1976 psi
Housing pressure rating = 5000 psi (From catalogue)
Therefore the housing is OK
27. Calculate protector thrust bearing load
Maximum in operating range = 1976 psi
Cross sectional area of pump shaft = 0.601 sq. in
TB load for floater pumps = 1976 x 0.601 = 1188 lb
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Select solid shoe bearing (Standard) rated at 2637 lbs (Information in
protector section of catalogue)
25. Cable size selection and voltage drop in cable
Motor is rated 120 hp, 60 Hz, 2270 v, 32.5 Amp and pump load is 104 hp
Motor operating current = (104/117) x 40.5 = 36 Amp
Choose a cable size with a volts drop < 30V/1000 ft
Choose AWG # 6 cable
Voltage drop at 36 amps = 25 volts / 1000 ft
Correct for temp. [(160 + 100)/2] = 130 °F
= 25 x 1.12 = 28 V
We have 5500 ft of cable allowing for 100 ft at surface
Voltage drop = 5.6 x 28 = 156.8 V 16
Calculate surface voltage
Surface voltage required = 1751 (motor) + 156.8 = 1907.8 v

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27. Calculate size of switchboard and transformer
Surface KVA = 1.732 x voltage x Amps / 1000
KVA = 1.732 x 2902 x 40.5 / 1000 = 134 KVA
Therefore, select SB1521, 182 KVA, 70A
Select transformer with minimum 200 KVA, 3 phse, and multi tapped
secondary.

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