Electric Submersible Pumps Mohamed Dewidar 2013

Chapter 9


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ESP Design Examples
10.1. Introduction
In order to design ESP system, the following
procedures have to be followed:
1. Collect data (well, production, fluid, electrical).
2. Determine the production capacity of the well.
3. Determine tubing size.
4. Calculate Total Dynamic Head (TDH).
5. Select pump stage type.
6. Calculate the number of pump stages required.
7. Check pump shaft loading and pump housing pressure.
8. Calculate motor horsepower requirements and select a
suitable motor.
9. Calculate the protector thrust bearing load and select a
suitable protector.
10. Determine the correct cable size and select a suitable
cable type.
11. Calculate the surface voltage and KVA requirements
and select a suitable switchboard and transformer.
In current stage, we will calculate only the number of
stages; the other calculations will be involved in the next
chapters.
To calculate the number of stages, we have to calculate
first the Total Dynamic Head (TDH) that the pump has to
deal with.
The TDH is the sum of three basic components:
1. The Net Vertical Lift or net distance which the fluid
must be lifted (Dynamic Fluid Level, DFL).
2. The friction loss in the tubing string.
3. The wellhead pressure which the unit must pump against.
See the drawings below.
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TDH = Net vertical lift in ft + friction loss in ft + WHP
in ft

Pump setting depth does not affect net vertical lift
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Direction angle of the well does not affect the net vertical
lift
10.2. Example 1: (water well)
Casing size: 5.5 inch
Perforation depth: 6000 ft.
S.G. of produced fluid: 1.0
Tubing sizes available: 2 3/8 inch
Pump setting depth: 5500 ft
Static Fluid Level: 1820 ft
Productivity Index: 0.9 bpd/psi
Bottom Hole Temperature: 260 deg F
Wellhead Pressure required: 100 psi
Desired Flow rate: 1300 bpd
Hz: 60
Viscosity: 1 cp
Solution:
1. Determine the production capacity of the well
Flowing fluid level (DFL) = Static fluid level +
Drawdown
Max Drawdown possible = 6000 ft 1820 = 4180 ft.
Max Drawdown (psi) = 4180 x 0.433 psi/ft = 1810 psi
Max possible flow (drawing fluid right down to the
perforations = 1810 psi x 0.9 BPD/psi = 1629 BPD
2. Calculate TDH @ 1300 bpd
Flowing Fluid Level @ 1300 BPD = SFL + DD
Draw Down (psi) = 1300 BPD/ 0.9 BPD/psi = 1444 psi
Draw Down (feet) = 1444 psi/ 0.433 psi/ft = 3335 ft.
Flowing Fluid Level = 1820 ft + 3335 ft = 5155 ft
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Friction Loss (refer to Chapter 2) = 171 ft
WHP = 100 psi / 0.433 psi/ft = 231 ft.
Total Dynamic Head = DFL + WHP + Friction loss
TDH = 5155 + 231 + 285 = 5671 Ft
3. Select pump stages type
Select a pump suitable for installation in 5.5 inch
casing and also capable of producing 1300 BPD, Select
for example Centrilift pump type FC1200 (from the
manufacturer catalogue)

4. Calculate the number of stsges
At 1300 bpd the FC1200 generates 22.5 ft per stage
Number of stages required = TDH / Head per stage
Number of stages required = 5671 ft/ 22.5 ft per stage
= 252 stages
From the table of the pump housings of the
manufacturer, see below; select the suitable housing/s
which contains number of stages greater than the
calculated ones.
Select either housing 15 (262 stages) or hosing 12 (209
stages) + housing 3 (51 stages) of total 260 stages.
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5. Check shaft loading and Housing Pressure limitations
Pump Hp = 0.36 HP/stage x 260 x 1.0 (SG) = 93.6 HP
Maximum shaft HP rating = 125 HP (see Catalog)
Therefore the standard shaft is O.K.
Maximum head in operating range =31.2 X 260 = 8112'.
Maximum pressure in range = 8112 ft x 0.433 = 3513 psi
Housing pressure rating = 5000 psi (see Catalogue)
Therefore the housing is O.K
6. Select Motor
Motor hp required = 94 hp
Select a motor suitable for installation in 5.5 inch
well. Therefore select a 450 series motor (4.50 inch
O.D.)
Select a 450 series 100 HP, 2080 volt, 31 amp
Note: Remember BHT = 260 deg F
7. Calculate Protector thrust bearing load and choose
protector type
Maximum pressure in operating range = 3513 psi
Cross sectional area of Pump shaft = 0.371 sq. in.
TB load for floater pumps = 3321 psi x 0.371 sq. in =
1232 lbs
Select Solid Shoe Bearing (standard) rated at 1427 lbs
(information in protector section of catalog)
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F FM MB B 4 45 50 0 S SE ER RI IE ES S M MO OT TO OR RS S
450 SERIES MOTOR MODEL FMB
4.50 INCH (114.3 MM) O.D.
SIZE HP VOLT/AMPS LENGTH* WEIGHT
60
HZ
50
HZ
60 HZ 50 HZ FT. M. LBS. KG.
60 50 735/51 612/51 17 5.2 843 383
60 50 840/44 700/44 17 5.2 843 383
60 50 945/40 787/40 17 5.2 843 383
60 50 1270/30 1058/30 17 5.2 843 383
75 62.5 644/77 537/77 21 6.3 1030 467
75 62.5 924/52 770/52 21 6.3 1030 467
75 62.5 1129/43 941/43 21 6.3 1030 467
85 71 1290/43 1075/43 23 7.1 1161 527
85 71 2080/27 1733/27 23 7.1 1161 527
100 83 1000/64 833/64 27 8.3 1353 614
100 83 1150/56 958/56 27 8.3 1353 614
100 83 2080/31 1733/31 27 8.3 1353 614
120 100 1200/64 1000/64 32 9.8 1605 728
120 100 2080/37 1733/37 32 9.8 1605 728
8. Determine Cable size and voltage drop in cable
Motor is rated 100 HP, 60 HZ. , 31 Amp
Pump Load is 87 HP
Motor operating current = 94/100 x 31= 29 amp.
Choose a cable size with a volts drop < 30v/1000 ft
Choose No 4 AWG cable

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Voltage drop at 29 amps = 13 volts/1000 ft
VD corrected @ 260 DF = 13 x 1.4 = 18.2 volts
We have 5600 ft of cable allowing for 100 ft at surface
Voltage drop = 5.6 x 18.2 = 102 volts
9. Calculate Surface voltage and size switchboard and
transformer
Surface Voltage required = 2080 (motor) +102 = 2182 v.
Switchboard
MODEL KVA VOLTS AMPS
1500-SSC 415 1500 160
2400-SSC 664 2400 160
3300-SSC 913 3300 160
4800-SSC 1660 4800 200
33MR-SSC 913 3300 160
Therefore use a 2400 volt rated Switchboard.

Therefore use a 125 KVA 3 phase dual wound transformer
with Multi tapped secondary
10.3. Example 2: (oil well)
Casing size: 7.0 inch
Perforation depth: 6800 ft.
Tubing sizes available: 3.5 inch OD EUE, 9.3 lb.
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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
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 STbfpd
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 paker.
Solution:
1. Calculate the average specific gravity

Ave S.G. = (0.75 x 1.085 + 0.25 x 0.866) = 1.03
2. Calculate the fluid gradient

Fluid Gradient = 0.433*1.03 = 0.446 psi/ft
3. Calculate the Static Fluid Level (SFL)
SFL = 6800-3000/0.446 = 73 ft
4. Calculate bottom hole flowing pressure at mid-
perforations


P
wf
@ Mid Perfs = 3000 2300 / 1.42 = 1380 psi
5. Calculate bottom hole flowing pressure at Pump Setting
Depth (PSD), which is pump intake pressure (PIP).
P
wf
@ PSD (PIP) = 1380 (6800-5500)*0.446 = 800 psi
6. Calculate the drawdown
Drawdown = 2300/1.42 = 1620 psi
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Drawdown in ft = 1620 / 0.446 = 3632 ft
7. Calculate Dynamic Fluid Level (DFL)
DFL = SFL +DD = 73 + 3632 = 3705 FT
Or Drawdown = 6800 1380 / 0.446 = 3705 ft
Fluid column above the pump = 800 / 0.446 = 1794 ft
8. Calculate R
s
@ PIP or get it from PVT data of the
reservoir

Where:
R
s
= Gas in solution
= Gas Specific gravity (0.7)
PIP = Pump Intake Pressure (800 psi)
BHT = Bottom Hole Temperature (160
O
F)
Rs = 0.7x[(800/18)*(10
0.0125*32
/10
0.00091*160
)]
1.2048
= 137
scf/bbl
9. Calculate the total produced gas (Q
GT
)
Q
GT
= GOR*(1-wc)* Q = 300*(1-0.75)*2300/1000 = 172.5 mscf
10. Calculate the total gas in solution @ PIP (Q
GIS
) in mscf
Q
GIS
@ PIP = 137*(1-0.75)*2300 /1000 = 78.8 mscf
11. Calculate Total free gas @ PIP (Q
GF
) in mscf
Q
GF
= Q
GT
- Q
GIS
= 172.578.8 = 94 mscf (Casing is
Unvented)
12. Calculate
g
(gas formation volume factor) @ PIP or get
it from PVT data of the reservoir:

Where Z is the gas compressibility factor
If Z is not available, it can be calculated from the
following equations:

g
= 5.04*0.886 *(160 +460)/(800+14.7)

= 3.4 bbl/mscf
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13. Calculate the volume of free gas under reservoir
condition (Q
RG
), this will enter the pump as the system
in unvented.
Q
RG
= Q
GF
x
g
= 94*3.4 = 319 bbl/day
14. Calculate
o
(oil formation volume factor) @ PIP or get
it from PVT data of the reservoir:



As Rs < GOR, so,
F = 137 x (0.7/0.866)
0.5
+ 1.25 x 160 = 323

o
= 0.972 + 0.000147 x (323)
1.175
= 1.1 Rbbl/STbbl
15. Calculate the volume of oil at reservoir condition
(Q
RO
).
Q
RO
= Q
O
x
o
= 1.1*(1-0.75)*2300 = 634 Rbblpd
Q
RW
= volume of water (
w
~1) = 0.75 * 2300 = 1725 Rbblpd
16. Calculate the total volume of fluid entering the pump
under reservoir condition (Q
RT
).
Q
RT
= Q
RO
+ Q
RW
+ Q
RG
= 634+1725+319 = 2678 Rbblpd
17. Calculate free gas % at the pump intake
% of free gas = 319 / 2678 *100 = 11.9 %
18. In order to recalculate the real average specific
gravity including gas and accordingly, the real fluid
gradient, we have to calculate the Total Weight of the
Fluid
Oil Mass = Q
o
x OSG x 62.4 #/cuft x 5.6146 cuft/bbl =
2300 x 0.25 x 0.866 x 62.4 x 5.6146 = 174,457 Lb
Water Mass = Q
w
x WSG x 62.4 #/cuft x 5.6146 cuft/bbl =
2300 x 0.75 x 1.085 x 62.4 x 5.6146 = 655,726 Lb
Gas Mass = Qo x GOR x GSG x 0.0752 #/cuft x 5.6146 cuft/
bbl = 2300 * 0.25 * 0.7 * 0.0752 = 9,080 Lb
Total Mass = 174,457 + 655,726 + 9,080 = 839263 Lb
19. Calculate the density, specific gravity and gradient
Density = Mass Lb/ volume cuft = 839263 / (2678 *
5.6146) = 55.82 lb / cuft
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S.G = 55.82 / 62.4 = 0.8945
Gradient (G) = 0.8945 * 0.433 = 0.3872 psi/ft
20. Recalculate the TDH based on the new gradient
Dynamic fluid level = PSDPIP/G = 5500800/0.3872 = 3434
ft
Friction loss in 3-1/2 Tubing based on average
viscosity of 10 cp and rate 2678 Rbpd (refer to section
2.20) = 166
WHP in ft = 100 / 0.3872 = 258 ft
TDH = 3434 + 166 + 258 = 3858 ft
21. Select a pump suitable for installation in 7 casing and
also capable of producing 3678 Rbfpd
Select SN2600 of Reda

Head per stage = 46 ft/stage
22. Calculate the number of stages required for TDH and
motor HP
# of stages = TDH /ft per stage = 3858/46 = 84 stages
From pump SN2600 catalog select Hsg # 70 (88 stages)
Note
The average viscosity of the fluid does not have serious
effect on either head or rate of the pump. That why we
do not take into consideration.
HP required = # of stages * hp per stage * fluid SG
HP required = 88 * 1.32 * 0.8945 = 104 hp
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From motors catalog select Series 540, 117 hp motor,
1751 V, 40.5 A

Series 540 Motors - MK Type
HP VOLTS
AMPS Type
60
HZ
50
HZ
60
HZ 50 HZ
80 67
1235 1029 40
S
UT
2241 1868 22
S
UT
100 83
1305 1088 51.5
S
UT
2313 1928 27
S
UT
120 100
1105 921 69.5
S
UT
CT
2270 1892 32.5
S
UT
140
117
1022 852 85
S
UT
CT
1299 1083 69.5
S
UT
CT
2101 1751 40.5
S
UT
CT
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23. 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 condition = 58 * 88 = 5104
Pump discharge pressure at shut in = 5104 * 0.3872 =
1976 psi
Housing pressure rating = 5000 psi (from catalog)
Therefore the housing is O.K
24. Calculate Protector thrust bearing load
Maximum pressure in operating range = 1976 psi
Cross sectional area of Pump shaft = 0.601 sq.in
TB load for floater pumps = 1976 * 0.601 = 1188 lb
Select Solid Shoe Bearing (standard) rated at 2637 lbs
(information in protector section of catalog)
25. Cable Size Selection and voltage drop in cable
Motor is rated 120 hp, 60 HZ. 2270 v, 32.5 Amp Pump Load
is 104 hp
Motor operating current = (104/ 117) * 40.5 = 36 amp.
Choose a cable size with a volts drop < 30v/1000 ft
Choose AWG #6 cable
Voltage drop at 40.5 amps = 24 volts/1000 ft
Correct for Temp. [(160+100)/2]= 130 Deg F) = 24 * 1.12
= 26.88 volts
We have 5500 ft of cable allowing for 100 ft at surface
Voltage drop = 5.6 * 26.88 = 151 volts
26. Calculate Surface voltage
Surface Voltage required = 1751(motor) +151= 1902 v.

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27. Calculate Size of Switchboard and Transformer
Surface KVA = (1.732 * Volt * Amps) / 1000
KVA = (1.732 * 2902 * 40.5) / 1000 = 134 KVA
Therefore Selecta SB 1512, 182 KVA, 70 A
Select Transformer with minimum 200 KVA, 3 , and multi
tapped secondary
MDFH 1500 V Maximum
Amp Load KVA
14 To 20 36 To 52
20 To 45 52 To 117
45 To 90 117 To 234
90 To 160 234 To 416
1512 3900 V Maximum, 1900 V Minimum
35 To 70 91 To 182
70 To 115 182 To 299
115 To 165 299 To 429
10.4. Example 3 (viscosity correction)
In this example will take the same data and some
results of example 2 except the average viscosity of the oil
is 140 cs @ average temperature (140
o
F).
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Average water viscosity = (0.9 + 0.6) / 2 = 0.75 CS
Average
fluid
= WC x
W
+ (1-WC) x
O

Average
fluid
= 0.25 x 0.75 + 300 x 0.75 = 105 cs
So, the required fluid rate is 2678 downhole bfpd (78.12 US
gpm) with viscosity 225 cs.
At Q
W
= 2678 bpd the head per stage H
W
= 46 ft (from pump
curve as water) and
W
= 68 %
Pseudocapacity (P)=1.95 x
0.5
x [0.04739 x H
0.25746
x Q
0.5
]
-0.5

P = 1.95*105^0.5*(0.04739*46^0.25746*78.12^0.5)^-0.5 = 18.86
C
H1Q
=1.0045-0.002664*18.86-0.00068292*18.86^2
+0.000049706*18.86^3-0.0000016522*18.86^4
+0.000000019172*18.86^5 = 0.8815
C
Q
=0.9873+0.009019*18.86-0.0016233*18.86^2
+0.000077233*18.86^3-0.0000020528*18.86^4
+0.000000021009*18.86^5 = 0.88851
C

=1.0522-0.03512*18.86-0.00090394*18.86^2
+0.00022218*18.86^3-0.000011986*18.86^4
+0.00000019895*18.86^5 = 0.517
H
Vis
= 46 x 0.8815 = 40.6 ft
Q
vis
= 2678 x 0.88851 = 2380 bfpd (downhole) = 69.4 gpm

vis
= 68%*0.517 = 35.2 %
BHP
vis
= 60 * 40.6 * 0.943 / (3960 x 0.352) = 1.65 hp/stg
(compared with 1.32 hp/stg of example 2)
The friction loss at 108 cs and 2380 bfpd = 236 ft
New TDH = 3434 + 166 + 236 = 3838 ft
Required No of stages = 3838 / 40.6 = 95 stages (compared
with 84 stgs of example 2)
Required HP = 95 x 1.65 = 157 hp (compared with 104 hp of
example 2)

t
= 2678/2300 = 1.164 (as per example 2)
New STBPD = 2380/1.164 = 2045 STBPD
Conclusion
In case if the viscosity of the oil becomes 140 cs:
Production rate will be 2045 bpd instead of 2300 bpd.
The number of stages will be 95 instead of 84 stages.
The horsepower required will be 157 hp instead of 104 hp.


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Chapter 9


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