ESP Application Engineering

Section 14a
Pump Sizing
Example 2

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Pump Sizing Procedure

(High Water cut well)

1. Collect data (well, production, fluid, electrical)

2. Determine the production capacity of the well
3. Calculate Total Dynamic Head (TDH) and determine
tubing size
4. Select pump stage type
5. Calculate the number of pump stages required
6. Check pump shaft loading and pump housing pressure.

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Pump Sizing Procedure

(High Water cut well)
7. Calculate motor horsepower requirements and select
a suitable motor
8. Calculate the protector thrust bearing load and select
a suitable protector
9. Determine the correct cable size and select a suitable
cable type.
10. Calculate the surface voltage and KVA requirements
and select a suitable switchboard and transformer

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1. Collect Data
 Casing size
 Perforation depth
 S.G. of produced fluid
 Tubing sizes available
 Pump setting depth
 Static Fluid Level
 Productivity Index
 Bottom Hole Temperature
 Wellhead Pressure required
 Desired Flowrate

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1. Collect Data

 Casing size 7.0 inch

 Perforation depth 5000 ft.
 S.G. of produced fluid 1.05
 Tubing sizes available 3.5 inch OD UVE, 9.3 LB.
 Pump setting depth ? ft
 Static Fluid Level 1820 ft
 Static Bottom Hole Pressure 2000 psi
 Water Cut 30 %
 Water S.G. 1.05
 Oil API Gravity 30

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1. Collect Data

 Productivity Index 0.9 BPD/psi

 Bottom Hole Temperature 250 deg F
 Wellhead Pressure reqd. 50 psi
 Desired Flowrate 6000 BPD

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We have an Oil and Water Mixture

 In this example we have a mixture of oil and water

 Therefore we need to calculate an average SG for the
fluid mixture.
 Ave S.G. = ((0.7 x 1.05) + (0.3 x 0.876))
= 0.735 + 0.263 = 0.998
 Fluid Gradient = 0.433

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We also have to Calculate the Static Fluid

Level

 What do we know to help us

1. Fluid Gradient = 0.433 as we have just calculated

2. SBHP — which has been given at the depth of 5000
ft.

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Calculating the Static Fluid Level

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2. Determine the Production Capacity of

the Well
 Flowing fluid level = Static fluid level + Drawdown
 Max Drawdown possible = 5000 ft — 381= 4619 ft.
 Max Drawdown (psi) = 4619 x 0.433 psi/ft = 2000 psi
(Gradient = 0.433x S.G.)
 Maximum possible flow (drawing fluid right down to
the perforations = 2000 psi x 3.5 BPD/psi = 7000 BPD

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3. Calculate TDH @ 1300 BPD

 Flowing Fluid Level @ 6000 BPD = SFL + DD

 Draw Down (psi) = 6000 BPD/ 3.5 BPD/psi = 1714 psi
 Draw Down (feet) = 1714 psi/ .433 psi/ft = 3958 ft.
 Flowing Fluid Level = 381 ft + 3958 ft = 4339 ft
 Friction Loss = 100 ft per 1 k ft x 4841 ft = 484 ft

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3. Calculate TDH @ 1300 BPD

 WHP = 50 psi /0.433 psi/ft = 115 ft.

 Total Dynamic Head = Static Lift + WHP + Friction

TDH = 4339 + 115 + 484 = 4938 Ft

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4. Select Pumps Stage type

 Select a pump suitable for installation in 7.00 inch

casing and also capable of producing 6000 BPD

SELECT a GN 5200

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5. Calculate the Number of Stages Required

 At 6000BPD the GN 5600 generates 28 ft per stage

(please review the GN 5600 curve in the catalog)
 Number of stages required = 4938 ft/ 28 ft per stage
= 176 stages

 Utilizing the next standard Housing sizes

 Select 2 x 68 housings and 1 x 41 = 177 stages

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6. Check Shaft Loading and Housing Pressure

Limitations
 Pump Hp = 1.8 HP/stage x 177 x 1.0 (SG) = 318.6 HP
 Maximum shaft HP rating = 375 HP (see curve)
 Therefore the standard shaft is O.K.

 Maximum head in operating range = 34 X 177 = 6018 ft.

 Maximum pressure in range = 6018 ft x .433 = 2605 psi
 Housing pressure rating = 5000 psi (see curve)
 Therefore the housing is O.K.

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7. Select Motor

 Motor HP required = pump HP = 318.6 HP

 Select a motor suitable for installation in 7.0 inch well
Therefore select a 540 series motor (5.43 inch O.D.)

 Select a 540 series 350 HP, 4400 volt, 48 amp

(Tandem motor made up of 1 x UT motor and 1 x CT
motor — each 2220 volt, 48 amp sections. A UMB is
required.

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8. Calculate Protector thrust Bearing Load

and Choose Protector Type
 Maximum pressure in operating range = 2605 psi
Cross sectional area of Pump shaft = 0.785 sq. in.
 TB load for floater pumps = 2605 psi x 0.785 sq. in
=2033 lbs
 Select standard Bronze bearing rated at 4000 lbs @
250 deg F (information in protector section of catalog)
 (Note Standard bearing not recommended @ > 250 deg
F)

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9. Determine Cable Size

 Motor is rated 350 HP, 60 HZ., 48 Amp

 Pump Load is 318.6 HP
 Motor operating current = 318.6/350 x 50 = 43.7amp.
 Choose a cable size with a volts drop, 30v/1000 ft
 Choose No 4 AWG cable

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Calculate Surface Voltage and Size

Switchboard and Transformer
 Voltage drop at 43.6mamps = 18.6 volts/1000 ft
 We have 4941 ft of cable allowing for 100 ft at surface
 Voltage drop = 4.94 x 18.6 = 71.8 volts
 Surface Voltage required = 4400 (motor) +72 = 4472 v.

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Calculate Surface Voltage and Size

Switchboard and Transformer

 Surface Voltage required = 4400 (motor) +72 = 4472 v.

 Therefore use a Non Standard volt rated Switchboard as
the 1512 is 3900 volts max.
 Surface KVA = 4472 (volts) x 43.6 (amps) x 1.73 = 337 KVA
1000
 Therefore use a 400 KVA 3 phase dual wound transformer –
with multi tapped secondary

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End of this
Section

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