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ESP Design - Hand Calculations: Step 1: Basic Data
ESP Design - Hand Calculations: Step 1: Basic Data
ESP Design - Hand Calculations: Step 1: Basic Data
production-technology.org/esp-design-hand-calculations/
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
1/16
Wellhead
Temperature: 50 °C
Wellhead Pressure:
87 psi
Casing-Head
Pressure: 15 psi
Inflow
performance:
Present production
rate: 2500 bfpd @
Pump Intake
Pressure = 1160 psi
Reservoir Pressure:
2320.6 psi
Pump Intake
Pressure: 1160 psi
Desired production
rate: 3500 bfpd.
Power
sources:
Available primary
voltage: 418 V
Desired frequency
range: 40Hz – 65Hz
Possible
problems?
2/16
The theory behind the production capacity calculations was detailed in the post ” ESP
design – Step 2: Production Capacity “. It consists on predicting the well inflow
performance.
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
3/16
PI = 3.33 bpd/psi.
From the Productivity Index equation, Pwf = Pr – Q/PI = 2320.6 – 3500/3.33 = 1269.5 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
4/16
The oil formation volume factor is defined as the ratio of the volume of oil (plus the gas in
solution) at any specified temperature and pressure to the volume of oil at standard
conditions.
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
5/16
Free Gas Volume:
The free gas equals the total gas minus the solution gas. The difference represents the
volume of free gas released from solution by the decrease in pressure from bubble point
pressure of 964 psi to the pump-intake pressure of 860 psi.
Vo = Bo × BOPD
Vo = 395.9 bopd
The volume of gas (Vg) at the pump intake equals the amount of free gas times gas
volume factor (Bg):
Vg = Free Gas x Bg
Vg = 10.15 bgpd
Vw = 3150 bwpd
Total fluid volume (Vt) of oil, water, and gas at the pump intake:
The total fluid volume (Vt) of oil, water and gas at the pump intake:
Vt = Vo + Vg + Vw
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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.
7/16
TDH = HL + Ft + Hwh
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).
Hazen-Williams Equation:
C = 120
Q = 3556,1 bfpd
8/16
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 = HL + Ft + Hwh
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″).
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.
9/16
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.
Once the required number of pump stages is decided, calculate the Pump BHP required:
10/16
Step 6: Optimum Size of Compounds:
The theory behind this step was detailed in the post “ESP design – Step 6: Optimum Size
of Compounds”. Actually, ESP downhole compounds have different sizes and can be
assembled in a variety of combinations. These combinations must be carefully selected to
operate the ESP within production requirement, downhole conditions, material strength,
and temperature limits, etc.
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.
11/16
Therefore:
Motor:
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
12/16
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).
13/16
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).
14/16
Motor Lead Extension (MLE):
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.
15/16
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:
The flow rate of a pump changes directly proportional to its operating speed.
The head developed by the pump changes proportionally to the square of the
speed.
The brake horsepower required to drive the pump changes proportionally to the
cube of the speed.
The efficiency of the pump does not change with speed changes.
16/16