9 Step

9
Variable Speed
Pumping System

8
Accessories and
Optional Equipment

7Electric
Cable

6Optimum
Size Of
Components
5 Pump
Type

4 Total
Dynamic
Head
3
Gas
Calculations

2
Production
Capacity

1
Basic
Data
THE 9 STEP

TABLE OF CONTENTS
PAGE NO.
Centrilift's Educational Development Center..................................... 1

Nine-Step Overview ............................................................. 2

Step 1 - Basic Data ............................................................... 3

Step 2 - Production Capacity ..................................................... 4

Step 3 - Gas Calculations ........................................................ 5

Step 4 - Total Dynamic Head .................................................... 7

Step 5 - Pump Type .............................................................. 8

Step 6 - Optimum Size of Components .......................................... 9

Step 7 - Electric Cable ........................................................... 10

Step 8 - Accessory & Optional Equipment ...................................... 11

Step 9 - Variable Speed Pumping System ....................................... 13

Design Example 60 Hertz ....................................................... 16

Design Example Variable Speed ................................................ 22

AutographPCTM..................................................................... 28
THE 9 STEP
CENTRILIFT'S EDUCATIONAL DEVELOPMENT CENTER
The Centrilift Educational Development Cen-
ter (EDC) offers high quality education and
training programs, both for Centrilift associates
who design, build and service our products, and
for our valued customers.
Our modern training facility includes full me-
dia-equipped classrooms, a shop training area,
and a media development center. In addition to
a permanent staff of professional, experienced
instructors, numerous members of the Centrilift
organization are on call in their areas of exper-
tise.
There are three standard programs that are of-
fered to our customer. All have a common
objective to improve the overall reliability of the
ESP system by understanding its strengths and
limitations. This includes improving the operat-
ing life and drastically reducing maintenance
and repair costs. The three standard programs
are:
The Electrical Submersible Pumping System
Applications
This is a five day course designed for those
personnel involved in production operations,
which use electrical submersible pumping sys-
tems (ESP's) for artificial lift. The course in-
cludes an introduction to the individual compo-
nents of an ESP system, including their perfor-
mance characteristics and limitations.
This program is an in-depth technical seminar
dealing with the sizing and application of ESP
equipment in harsh environments, which in-
clude high GOR, high viscosity and variable
speed operation.
3
The Variable Speed Controller Technology -
Operation-Maintenance
This is a five day program designed for those
personnel directly responsible for the day-to-
day operation of Centrilift VSC systems. Each
of the major circuits, as well as the logic circuits,
will be discussed in detail. Using simulators and
actual VSC systems, participants will demon-
strate the actual start-up of a VSC system and set
all the necessary operating parameters.
The Installation, Troubleshooting and Ap-
plication of ESP Equipment
This is a five day course designed to prepare oil
field personnel for the installation of electrical
submersible pumping equipment. The course
provides instructions of the proper installation
techniques, as well as servicing and pulling of
ESP equipment. The course introduces the
student to the major ESP components and pro-
vides a brief explanation of the steps required to
size a complete ESP system.
To satisfy individual requirements, customized
programs can be developed for specific topics
and can be administered at field locations. For
a complete description of the course contents,
schedule and tuition, contact you local Centrilift
representative.
Whether our programs are for product informa-
tion, technical skills, or skills for working to-
gether, the EDC is dedicated to the same goal as
all Centrilift associates and facilities. This goal
is the pursuit of excellence.
 THE 9 STEP
NINE-STEP OVERVIEW
Centrilift has established a nine step procedure to help you design the appropriate submersible pumping
system for your particular well. Each of the nine steps are explained in the sections that follow, including
gas calculations and variable speed operation. The nine steps are:

Step 1 - Basic Data

Collect and analyze all the well data that will be
used in the design.

Step 2 - Production Capacity

Determine the well productivity at the desired
pump setting depth, or determine the pump
setting depth at the desired production rate.

Step 3 - Gas Calculations

Calculate the fluid volumes, including gas, at the
pump intake conditions .

Step 4 - Total Dynamic Head

Determine the pump discharge requirement.

Step 5 - Pump Type

For a given capacity and head select the pump
type that will have the highest efficiency for the
desired flow rate.

Step 6 - Optimum Size of Components

Select the optimum size of pump, motor, and
seal section and check equipment limitations.

Step 7 - Electric Cable

Select the correct type and size of cable.

Step 8 - Accessory & Optional Equipment

Select the motor controller, transformer, tubing
head and optional equipment.

Step 9 - The Variable Speed Pumping System

For additional operational flexibility, select the
variable speed submersible pumping system. The Electrical Submersible Pumping System
4
THE 9 STEP
STEP 1 - BASIC DATA
The design of a submersible pumping unit, un- 2. Production Data
der most conditions, is not a difficult task, espe- a. Wellhead tubing pressure
cially if reliable data is available. Although, if b. Wellhead casing pressure
the information, especially that pertaining to the c. Present production rate
well’s capacity, is poor, the design will usually d. Producing fluid level and/or pump intake
be marginal. Bad data often results in a misap- pressure
plied pump and costly operation. A misapplied e. Static fluid level and/or static bottom-hole
pump may operate outside the recommended pressure
range, overload or underload the motor, or draw- f. Datum point
down the well at a rapid rate which may result in g. Bottom-hole temperature
formation damage. On the other extreme, the h. Desired production rate
pump may not be large enough to provide the i. Gas-oil ratio
desired production rate. j. Water cut

Too often data from other wells in the same field 3. Well Fluid Conditions
or in a nearby area is used, assuming that wells a. Specific gravity of water
from the same producing horizon will have b. Oil API or specific gravity
similar characteristics. Unfortunately for the c. Specific gravity of gas
engineer sizing the submersible installations, oil d. Bubble-point pressure of gas
wells are much like fingerprints, that is, no two e. Viscosity of oil
are quite alike. f. PVT data

The actual selection procedure can vary signifi- 4. Power Sources

cantly depending upon the well fluid properties. a. Available primary voltage
The three major types of ESP applications are: b. Frequency
1. High water-cut wells producing fresh water c. Power source capabilities
or brine.
2. Wells with multi-phase flow (high GOR). 5. Possible Problems
3. Wells producing highly viscous fluids. a. Sand
b. Deposition
Following is a list of data required: c. Corrosion
d. Paraffin
1. Well Data e. Emulsion
a. Casing or liner size and weight f. Gas
b. Tubing size, type and thread(condition) g. Temperature
c. Perforated or open hole interval
d. Pump setting depth (measured & verti-
cal)
5
 THE 9 STEP
STEP 2 - PRODUCTION CAPACITY

The following is a simplification of procedures Inflow Performance Relationship

for predicting well performance. This discus- If Pwf is less than Pb, resulting in multi-phase
sion assumes a flow efficiency of one. A dam- flow, the IPR method should be used. The
aged well or other factors will effect the flow relationship is given by the following equation:
efficiency and could change the well's produc- Qo
tivity. Qo max =
2
Pwf Pwf
Productivity Index 1 - 0.2 ( Pr
) (
- 0.8
Pr
)
When the well flowing pressure (Pwf) is greater
This relationship was first used by W.E. Gilbert1
than bubble -point pressure (Pb) the fluid flow is
and further developed by J.V. Vogel2. Vogel
similar to single phase flow, and the inflow
developed a dimensionless reference curve that
performance curve is a straight line with slope J,
can be used to determine the IPR curve for a
as given by the productivity index, PI:
particular well.
Q
Pr - Pwf
Bottom Hole Well Pressure (PWF/PR). Fraction of Reservoir Pressure

PI = J =

Where:

Q = the fluid test production rate.

Pwf = the well flowing pressure

@ test rate Q.

Pr = the well static pressure.

Note:
Pr and Pwf are terms which are
always referenced to the same
specific vertical depth.
0 Producing Rate (qo/(qo) max). Fraction of Maximum
0
INFLOW PERFORMANCE
REFERENCE CURVE

6
THE 9 STEP
STEP 3 - GAS CALCULATIONS
The presence of free gas at the pump intake and
in the discharge tubing makes the process of
equipment selection much more complicated
and voluminous. As the fluid (liquid and gas
mixture) flows through the pump stages from
intake to the discharge and through the dis-
charge tubing, the pressure and consequently,
fluid properties (such as volume, density, etc.)
continuously go on changing. Also, the pres-
ence of free gas in the discharge tubing may
create significant “gas-lift” effect and consider-
ably reduce the required discharge pressure.
The performance of a centrifugal pump is also
considerably affected by the gas. As long as the
gas remains in solution, the pump behaves nor-
mally as if pumping a liquid of low density.
However, the pump starts producing lower than
normal head as the gas-to-liquid ratio (at pump-
ing conditions) increases beyond a certain “criti-
cal” value (usually about 10 - 15%). It is mainly
due to separation of the liquid and gas phases in
the pump stage and due to a slippage between
these two phases. This phenomenon has not
been well studied and there is no general corre-
lation describing the effect of free gas on pump
performance. A submersible pump is usually
selected by assuming no slippage between the
two phases or by correcting stage performance
based on actual field test data and past experi-
ence.
Ideally, a well would be produced with a sub-
mergence pressure above the bubble point pres-
sure to keep any gases in solution at the pump
intake. This is typically not possible, so the
gases must be separated from the other fluids
prior to the pump intake to achieve maximum
system efficiency.
There are numerous combinations of equipment
configurations and wellbore completions which
are available for enhancing the performance of
ESP's in gassy applications. Many of these are
identified in the "Gas Handling Guideline". Spe-
cifically, Centrilift offers several optional com-
7
ponents used for separating gas from the fluid
going to the pump intake. These are listed
acccording to increasing efficiency. The first is
a reverse flow intake, which uses the natural
buoyancy of the fluids for separation. The sec-
ond is a vortex type intake, which uses the fluid
velocity to set-up a rotational flow to induce
radial separation of the gas. The last is a rotary
gas separator intake, which utilizes a mechani-
cal, rotating chamber to impart a high, centrifu-
gal force on the fluid to separate the gas.
It is essential to determine the effect of the gas on
the fluid volume in order to select the proper
pump and separator. The following calculations
yield the percent free gas by volume.
If the solution gas/oil ratio (Rs), the gas volume
factor (Bg), and the formation volume factor
(Bo) are not available from reservoir data, they
must be calculated, and there are a number of
multi-phase correlations to select from. The
correlation you select will affect your design, so
select the one that best matches your conditions.
The following are Standings3 correlations for
solution gas/oil ratio, and formation volume
factor:
Solution Gas/Oil Ratio
Rs = Yg ( Pb
18
x
0
100.0125 x API ) 1.2048
100.00091 x T( F)
0
Or in metric,
1.2048
( 0.0125 x API 0
Rs= 0.1342Yg Pb x 100.00091 x (1.8T( 0 C) + 32)
10
)
Where:Yg = Specific Gravity Gas
Pb = Bubble-Point Pressure, psi (kg/cm2)
T = Bottom-hole Temperature, 0 F ( 0C)
NOTE: Pump Intake Pressure (PIP) should be
substituted for Bubble Point Pressure when
calculating intake conditions.
 THE 9 STEP

Gas Volume Factor Total Volume of Fluids

When these three variables, Rs, B o and Bg are
Bg = 5.04 ZT or in metric, Bg = 0.00377 ZT known, the volumes of oil, water, and free gas
P P can be determined and percentages of each cal-
Where: Z = Gas compressibility factor culated. The total volume of gas ( both free and
(0.81 to 0.91) in solution ) can be determined as follows:
T = Bottom-hole temperature degrees Producing GOR x BOPD
Rankine (460 + 0 F), or in metric Total Gas = = MCF
1,000
Kelvin (273 +0 C)
P = Submergence pressure psi, or
or in metric,
(kg/cm2)
Total Gas = Producing GOR x M3PD = M3
The gas volume factor, Bg, is expressed in reser-
voir barrels/st'd mcf gas (m3/m3) The gas in solution at submergence pressure can
be determined as follows:
Formation Volume Factor
Rs x BOPD
The formation volume factor Bo, represents the Solution Gas = = MCF
1,000
increased volume a barrel of oil occupies in the
formation as compared to a stock barrel.
The Free Gas equals the Total Gas minus the
Solution Gas.
Bo = 0.972 + 0.000147F1.175

0.5 The volume of oil (Vo) at the pump intake equals

Yg
Where: F = Rs ( Yo
) + 1.25T
stock tank barrels times Bo, the formation vol-
ume factor.

T = Bottom-hole temperature,0 F The volume of gas (Vg) at the pump intake

or in metric, equals the amount of free gas times Bg, the gas
volume factor.
Bo = 0.972 + 0.000147 x
The volume of water (Vw) in the formation is the
Yg 0.5 1.175 same as stock tank barrels.
{ 5.61 Rs( )Yo
+ 1.25 (1.8t + 32) } Total fluid volume (Vt) can now be determined.
Where: Vt = Vo + Vg + Vw
Yg = Specific Gravity of Gas
The percentage of free gas to total volume of
Yo = Specific Gravity of Oil
fluids can now be calculated:
t = Bottom-hole Temperature, 0 C
Vg
% Free Gas =
Vt
8
THE 9 STEP

STEP 4 - TOTAL DYNAMIC HEAD

The next step is to determine the total dynamic METRIC
head required to pump the desired capacity. The kg/cm2 x 10.01 m/kg/cm2
total pump head refers to feet (meters) of liquid Pd =
being pumped and is calculated to be the sum of: Specific Gravity
1) Net well lift (dynamic lift); 2) well tubing or
friction loss; and 3) wellhead discharge pres-
kg/cm2
sure. The simplified equation is as follows: Pd =
0.0999 x Sp. Gr.
TDH = Hd + F t + Pd Total Dynamic Head = Hd + Ft + Pd

where: Pd

TDH = total dynamic head in feet (meters)

delivered by the pump when pumping the de-
sired volume.

Hd = vertical distance in feet (meters) between

the wellhead and the estimated producing fluid
level at the expected capacity.

Ft = the head required to overcome friction loss Hd

in tubing measured in feet (meters).
Dynamic
Fluid Level
Pd = the head required to overcome friction in the
surface pipe, valves and fittings, and to over-
come elevation changes between wellhead and
Tubing
tank battery. Normally, this is measured in
gauge pressure psi (kg/cm2) at the wellhead and Ft
can be converted to head, in feet (meters) as
follows:
Pump
U.S.
psi x 2.31 ft/psi
Pd =
specific gravity
Seal
or
psi
Pd =
0.433 psi/ft x sp. gr. Motor

9

STEP 5 - PUMP TYPE
Refer to the pump selection data table, in the
Engineering section of your Centrilift catalog,
for pump types and ranges. Pump performance
curves (60 Hz and 50 Hz) are included in the
"Pump Curve" section of the catalog. Based on
expected fluid production rate and casing size,
select the pump type which will, at the expected
producing rate, be operating within the pump's
operating range and nearest to the pump's peak
efficiency,
Where two or more pump types have similar
efficiencies at the desired volume, the following
conditions determine the pump choice:
1. Pump prices and corresponding motor sizes
and prices may differ somewhat. Normally,
the larger-diameter pump and motor are less
expensive and operate at higher efficiencies.
2. When the wells capacity is not known, or
cannot be closely estimated, a pump with a
"steep" characteristic curve should be cho-
sen. If the desired volume falls at a point
where two pump types have approximately
equal efficiency, choose the pump type
which requires the greatest number of
stages. Such a pump will produce a capacity
nearest the desired volume even if the well
lift is substantially more or less than
expected.
3. If gas is present in the produced fluid, a gas
separator may be required to achieve
efficient operation. Refer to Step 3 to
determine the effect of gas on the produced
volume. The adjusted volume affects pump
selection and the size of the other system
components.
10
THE 9 STEP
4. In wells where the fluid is quite viscous
and/or tends to emulsify, or in other ex-
traordinary circumstances, some pump cor-
rections may be necessary to ensure a more
efficient operation. In such cases, contact a
Centrilift sales engineer for recommenda-
tions.
The VSSP System and Pump Selection
Under the above, or other pumping conditions,
also consider the Variable Speed Submersible
Pumping (VSSP) system. For instance, in item
2 above, if a well is not accurately known, a
VSSP system is ideal. An Electrospeed vari-
able speed controller effectively converts a
single pump into a family of pumps. So, a pump
can be selected for an estimated range and
adjusted for the desired production level, once
more data is collected.
The VSSP system with the Electrospeed im-
proves pump operation under other conditions
as well, including gassy wells, abrasive wells,
low volume wells, etc. It provides soft starts,
eliminates intermittent operation, breaks gas
locks, isolates equipment from power tran-
sients, minimizes downhole heating, and more.
Review Step 9when considering the VSSP sys-
tem. Variable frequency performance curves
are included in the "Pump Curve" section of the
Centrilift catalog. The VSSP System with
Electrospeed may provide additional econo-
mies of capital expenditure and operating
expenses, and should be considered in Step 6,
"Optimum Size of Components." The
Electrospeed variable speed controller and trans-
formers for the VSSP system are discussed in
Steps 8 and 9.
THE 9 STEP

STEP 6 - OPTIMUM SIZE OF COMPONENTS

Centrilift components are built in a number of
sizes and can be assembled in a variety of Total Dynamic Head
Total Stages =
combinations. These combinations must be Head/Stage
carefully determined to operate the submersible
Separator
pumping system within production requirements,
Refer to your catalog for gas separator informa-
material strength and temperature limits. While
tion. Make the necessary adjustments in horse-
sizing components, refer to the Engineering
power requirements and housing length.
section of your catalog for each of the following
tables and charts:
Motor
To select the proper motor size for a predeter-
Equipment Combinations in Various Casings
mined pump size, you must first determine the
Maximum Loading Limits
brake horsepower required by the pump. The
Maximum Diameter of Units
horsepower per stage is obtained by again refer-
Velocity of a Fluid Passing a Motor
ring to the performance curve for the selected
Shaft HP Limitations at Various Frequencies
pump and reading the value of the right scale.
The brake horsepower required to drive a given
A fluid velocity of 1 foot per second (0.305
pump is easily calculated by the following for-
meters per second) is recommended to ensure
mula:
adequate motor cooling. In cases where this
velocity is not achieved, a motor jacket may be
BHP = Total Stages x BHP/Stage x Sp. Gr.
required to increase the velocity. Contact your
sales engineer under such conditions.
Refer to your catalog for motor specifications.
Pump
Seal Section
Refer to the Centrilift performance curve of the
Refer to your catalog for selection of the proper
selected pump type and determine the number of
seal section. Series 338 seals are recommended
stages required to produce the anticipated ca-
for 338 series pumps using 375 series motors.
pacity against the previously calculated total
Series 400 seals are recommended for 400 series
dynamic head. Performance curves for 60 Hz,
pumps using 450 series motors. When 544 or
50 Hz and variable frequency performance are
562 series motors are used with a 513 series
located in the catalog. Note that the pump
pump, the 513 series seal is required. A 513-400
characteristic curves are single stage perfor-
series adapter is required whenever a 513 series
mance curves based on water with (specific
seal section is run with a 400 series pump.
gravity of 1.00) . At the intersection of the
desired production rate (bottom scale) and the
head-capacity curve (vertical scale), read the
head value on the left scale. Divide this value
into the total dynamic head to determine the
number of stages.

11

STEP 7 - ELECTRIC CABLE
Centrilift electric cables are normally available
from stock in conductor sizes 1, 2, 4, and 6.
These sizes are offered in both round and flat
configurations as shown in your catalog price
section under Centriline Power Cable.
Several types of armor and insulation are avail-
able for protection against corrosive fluids and
severe environments.
Cable selection involves the determination of:
1) cable size;
2) cable type;
3) cable length.
Cable Size
The proper cable size is dependent on combined
factors of voltage drop, amperage and available
space between tubing collars and casing.
Refer to the Cable Voltage Drop curve (see
engineering section) for voltage drop in cable.
At the selected motor amperage and the given
downhole temperature, the selection of a cable
size that will give a voltage drop of less than 30
volts per 1,000 ft. (305 meters) or less than 15%
of motor nameplate volts is recommended. This
curve will also enable you to determine the
necessary surface voltage (motor voltage plus
voltage drop in the cable) required to operate the
motor.
Finally, refer to the Equipment Combination
table (see engineering section) to determine if
the size selected can be used with the proposed
tubing and well casing sizes. Cable diameter
plus tubing collar diameter will need to be less
than the inside diameter (I.D.) of the casing.
12
THE 9 STEP
In determining the optimum cable size, consider
future equipment requirements that may require
the use of a lager size cable.
If power cost is a major concern, the Kilowatt-
Hour Loss Curve (see Engineering section) can
be used to justify the cable selection. Although
power rates vary widely, this data is valuable in
determining the economics of various cable
sizes.
Cable Type
Selection of the cable type is primarily based on
fluid conditions, bottom-hole temperature and
space limitations within the casing annulus. Refer
to your catalog price pages for cable specifica-
tions.
Where there is not sufficient space to run round
cable, use electric cable of flat configuration.
See Equipment Combinations table in Engi-
neering section of your catalog for round cable
limitations based on various casing and tubing
sizes. Consult your Centrilift representative
when temperature or gas is a critical factor.
Cable Length
The total cable length should be at least 100 ft.
(30M) longer than the measured pump setting
depth in order to make surface connections a
safe distance from the wellhead. Refer to curve
on Recommended Maximum Cable Length (see
Engineering section) to avoid the possibility of
low voltage starts.
Cable Venting
In all wells, it is necessary to vent gases from the
cable prior to the motor controller to avoid
explosive conditions. A cable venting box is
available to protect the motor controller from
such gases.
THE 9 STEP
STEP 8 - ACCESSORY& OPTIONAL EQUIPMENT
1. DOWN HOLE ACCESSORY
EQUIPMENT
Flat cable (motor lead extension):
Select a length at least 6 ft. (1.8m) longer than
pump, intake (standard or gas separator) and
seal section for the motor series chosen. Refer to
your catalog for dimensions.
Flat cable guard:
Choose the required number of 6 ft. (1.8m)
guard sections to at least equal the flat cable
length. Do not use guards for installation of 400
series pump and seal section in 5-1/2" O.D., 20-
pound casing and for installation of 513 series
pump and seal section in 6 5/8" O.D., 26-pound
casing.
Cable bands:
Use one 30 in. (76 cm) cable band every 2 ft. (60
cm) for clamping flat cable to pump. The 22 in.
(56 cm) length can be used for all tubing-cable
combinations through 3-1/2" O.D. tubing. For
4- 1/2" and 5-1/2" O.D. tubing use 30 in. (76 cm)
bands. One band is required for each 15 ft. (5 m)
of setting depth. Refer to your catalog for
dimensions.
Swaged nipple, check valve, and drain valve:
Select these accessories on basis of required
outside diameters and type of threads.
2. MOTOR CONTROLLERS
The VortexTM is a state-of-the-art digital control
consisting of two components:
• System Unit
This unit performs all the shutdown and
restart operations. It is mounted in the low-
voltage compartment of the control panel.
13
• Display Unit (Optional)
This unit displays readings, setpoints and
alarms. It is normally mounted in the amp
chart enclosure for easy access.
It provides all the basic functions, such as
underload, overload, phase imbalance, phase
rotation, etc. and over 90 other parameters
including password and communication
protocols.
3. SINGLE-PHASE AND THREE-PHASE
TRANSFORMERS
The type of transformer selected depends on the
size of the primary power system and the required
secondary voltage. Three-phase isolation step-
up transformers are generally selected for
increasing voltage from a low voltage system,
while a bank of three single-phase transformers
is usually selected for reducing a high-voltage
primary power source to the required surface
voltage.
On existing systems, some of Centrilift units
will operate without the use of an additional
transformer. For new installation of units with
higher voltages, it is usually less expensive to
install three single-phase transformers, connected
wye, to eliminate the auto-transformer.
 THE 9 STEP

In choosing the size of a step-up transformer or 6. SERVICING EQUIPMENT

a bank of three single-phase transformers the Cable reels, reel supports and cable guides:
following equation is used to calculate total Select size of cable reel required to handle
KVA required: previously selected cable size. Select set of
cable reel supports based on cable reel size.
Vs x Am x 1.73 Cable guides are designed to handle cable sizes
KVA = 1 through 6.
1,000
Normally, customers retain one cable reel, one
where: set of reel supports, and one cable guide wheel
KVA = Kilo-Volt-Amp or 1,000 Volt-Amp for future use.
Vs = Surface Voltage
Shipping Cases:
Am = Motor nameplate current in amps
Select type and length of case required to ac-
commodate previously selected motor, pump,
4. SURFACE CABLE
gas separator and seal.
Choose approximate length required for con-
necting controller to primary power system or to
7. OPTIONAL EQUIPMENT
transformer. Two pieces are generally required
Bottom-hole pressure (PHD) sensing device:
for installations using an auto-transformer. Size
The PHD provides continuous measurement of
should equal the well cable size except in the
bottom-hole pressures.
case of step-up or auto-transformer, where the
primary and secondary currents are not the same.
Automatic well monitoring:
Motor controllers are available for continuous
5. WELLHEADS AND ACCESSORIES
monitoring of pump operation from a central
Select the wellhead on the basis of casing size,
location. Contact your Centrilift representative
tubing size, maximum recommended load, sur-
for details.
face pressure, and maximum setting depth. Elec-
tric cable passes through the wellhead where
pressure fittings are not required.

Electric Feed Through (EFT) mandrels are also

available. The electric cable is spliced to pig-
tails. The EFT wellheads seal against downhole
pressure and prevent gas leaks at the surface.
Refer to your catalog for specifications.

14
THE 9 STEP

STEP 9 - VARIABLE SPEED SUBMERSIBLE PUMPING SYSTEM

The ESP system can be modified to include an New Frequency
Electrospeed variable frequency controller so New Rate = x 60 Hz rate
60 Hz
that it operates over a much broader range of
capacity, head, and efficiency. Since a submers- 2
ible pump motor is an induction motor, its speed
is proportional to the frequency of the electrical
New Head = ( New Frequency
60 Hz
) x 60 Hz head

power supply. By adjusting the frequency, the

variable speed submersible pump (VSSP) sys- 3
tem offers extraordinary potential for boosting New BHP = (
New Frequency
60 Hz
) x 60 Hz BHP
production, reducing downtime, and increasing
profits. The VSSP can be used to boost effi- where BHP = Brake Horsepower
ciency in many cases, including highly viscous
wells, waterflood wells etc. It extends the range New Efficiency = 60 Hz efficiency (there is
of submersible artificial lift to less than 100 BPD negligible loss)
(16 M3PD) and up to 100,000 BPD (16,000
M3PD). A set of curves can be developed for an arbitrary
series of frequencies with these equations, as
It is necessary to understand the effects of vary- shown in the variable frequency performance
ing the speed of a submersible pump, in order to curves at the end of this step (figure 1). Each
apply the VSSP system. The VSSP system can curve represents a series of points derived from
be analyzed in terms of varying frequency or in the 60 Hz curve for flow and corresponding head
terms of maintaining constant head. Sales engi- points, transformed using the equations above.
neers have computerized pump selection pro-
grams to assist you in VSSP system selection; Suppose we are given the following data at a
what follows is a basic explanation of the prin- frequency of 60 Hz:
ciples involved.
Rate = 1,200 BPD
Variable Frequency
The effects of varying frequency can be seen by Head = 24.5 ft. (from FC-1200 curve @ 1,200
preparing new head-capacity curves for the de- BPD)
sired frequencies, based on the pump's known
60 Hz performance curve data. The Electro- BHP = 0.34 BHP (from FC-1200 curve @ 1,200
speed controller is commonly used to generate BPD)
any frequency between 30 and 90 Hz.
If a new frequency of 50 Hz is chosen:
Curves for frequencies other than 60 Hz can be
generated by using the centrifugal pump affinity
laws. The equations derived from these laws
New Rate = ( ) 50
60
x 1200 BPD = 1000 BPD

2
are:
New Head = ( ) 50
60
x 24.5' =17'

15
 THE 9 STEP

3 50 Hz
New BHP = ( ) 50
60 x 0.34 BHP = 0.20 BHP
X1 Rate (BPD) 0 792 1000 1292
1563
By performing these calculations at other pro-
duction rates, a new curve for 50 Hz operation
can be plotted. Start by locating the existing Y1 Head (Feet) 22.2' 19.9' 17' 10.4' 0'
points on the one-stage 60 Hz curve:
Efficiency (%) 0 63.5 64 49 0
60 Hz
Plotting these coordinates gives the one-stage
X1 Rate (BPD) 0 950 1200 1550 1875 FC-1200 head-capacity performance curve for
operation at 50 Hz. Similar calculations will
Y1 Head (Feet) 32' 28.6' 24.5' 15' 0' provide coordinates for curves at other frequen-
cies, as seen below in the FC-1200 variable
Efficiency (%) 0 63.5 64 49 0 speed performance curve. The vortex shaped
window is the recommended operating range for
Following the above equations, calculate the the pump. As long as your hydraulic require-
corresponding values at 50 Hz: ment falls within this range, you are within the
recommended operating range of the pump.

Figure 1
16
 THE 9 STEP

NAME DESIGN EXAMPLE DATE NOV. 20, 1991

COMPANY
ADDRESS
WELL NO. AND FIELD NAME
WELL LOCATION (COUNTY, STATE, OTHER)
INSTALLATION: NEW ( X ) OR REDESIGN ( ) PRIMARY POWER SUPPLY: 12,470 VOLTS THREE
PHASE 60 HZ
PRODUCING FORMATION
FORMATION TYPE (SANDSTONE, LIMESTONE, OTHER) SANDSTONE

WELL DATA

API CASING 7 IN. O.D. 32 #/FT. 0 FT. TO 6,900 FT. M. TO M.

LINER NONE IN. O.D. #/FT. FT. TO FT. M. TO M.
OPEN HOLE FT. TO FT. M. TO M.
TOTAL DEPTH FT. M.
PERFORATION INTERVALS 6,750 FT. TO 6,850 FT. M. TO M.
FT. TO FT. M. TO M.
FT. TO FT. M. TO M.
API TUBING 2 - 7/8 IN. O.D. EUE 8 RD THREADS

RESERVOIR DATA (FROM TEST AND PRODUCTION DATA)

3
PRESENT PRODUCTION 850 BFPD. M PD PUMPING ( X ), SWABBING ( ), FLOWING (
) 3

BOTTOM HOLE STATIC PRESSURE 3,200 PSI G@ 6,800 FT. Kg/Sq. Cm. @ 3 M.
BOTTOM HOLE FLOWING PRESSURE 300 2,600 PSIG @ 850 BFPD 3 3
Kg/Sq. Cm. @ M PD
PSIG @ BFPD Kg/Sq. Cm. @ M PD
PRODUCING GOR 0
S.C.F./S.T.B. M /M
WATER CUT 75 %
OIL API GRAVITY 32
BOTTOM HOLE TEMPERATURE 160 °F °C
WATER SPECIFIC GRAVITY 1.085
GAS SPECIFIC GRAVITY 0.7
OIL VISCOSITY (1) CP. OR SSU@ °F °C
(2) CP. OR SSU@ °F °C
PVT DATA SOLUTION GOR FVF. PSIG Kg/Sq. Cm.
SOLUTION GOR FVF. PSIG Kg/Sq. Cm.
SOLUTION GOR FVF. PSIG Kg/Sq. Cm.
SOLUTION GOR FVF. PSIG Kg/Sq. Cm.
BUBBLE-POINT PRESSURE 1,500 PSIG Kg/Sq. Cm.
3 3
CENTRILIFT SPECIFICATIONS

DESIRED PRODUCTION 2,300 BFPD. OR BOPD FLUID M PD, OR OIL M PD

DESIRED PUMP (INTAKE) VERTICAL SETTING DEPTH 100 FT.
5,500 M.
DESIRED PUMP (INTAKE) PRESSURE PSIG Kg/Sq. Cm.
REQUIRED WELL HEAD PRESSURE PSIG Kg/Sq. Cm.
GOR THROUGH PUMP %
CASING VENTED TO ATMOSPHERE ( ) TO PIPELINE ( X ) NONE ( )
ELECTRIC POWER VOLTS CYCLES
DESIRED PUMP SERIES
DESIRED PUMP TYPE
CASING PRESSURE PSIG Kg/Sq. Cm.
SPECIAL PROBLEMS SAND( ), SCALE( ), CORROSION( ), PARAFFIN( ), H2S( ), POWER SUPPLY( )

17
 THE 9 STEP

DESIGN EXAMPLE
Step 1 - Basic Data The pump intake pressure can be determined by
See Centrilift well data sheet on previous page correcting the flowing bottom-hole pressure for
for well data. the difference in pump setting depth and the
datum point and by considering the friction loss
Step 2 - Production Capacity in the casing annulus. In the given example, as
Determine the well productivity at the test pres- the pump is set 1,300 feet above the perfora-
sure and production. In this case, the desired tions, the friction loss due to flow of fluid
production rate and pump setting depth are through the annulus from perforations to pump
given. The pump intake pressure at the desired setting depth will be small as compared to the
production rate can be calculated from the present flowing pressure and can be neglected.
production conditions.
Because there is both water and oil in the pro-
Since the well flowing pressure (2,600 psi) is duced fluids it is necessary to calculate a com-
greater than bubble-point pressure (1,500 psi) posite specific gravity of the produced fluids.
the constant PI method will most probably give To find the composite specific gravity;
satisfactory results. First, we can determine the
PI using the test data. Water cut is 75%;
0.75 x 1.085 = 0.8138
Q
PI = Oil is 25%;
Pr - Pwf 0.25 x 0.865 = 0.2163
850 bpd
PI = = 1.42 bpd/psi The composite specific gravity is the sum of the
3,200 psi - 2,600 psi weighted percentages:

Next, we can determine the new well flowing Composite Sp. Gr. = 0.8138 + 0.2163 = 1.03
pressure (Pwf ) at the desired production rate
The pressure due to the difference in perforation
(Q d).
Qd depth and pump setting depth (6,800' - 5,500' =
1,300') can be determined as follows:
Pwf = Pr - ( )
PI
Head (FT) x Specific Gravity
Pwf = 3,200 psi - ( )
2,300 bpd
1.42 bpd/psi = 1,580 psi
PSI =
2.31 Ft/PSI

1,300 Ft x 1.03
PSI = = 580 PSI
The well flowing pressure of 1,580 psi is still 2.31 Ft/PSI
above the bubble-point pressure of 1,500 psi,
therefore, the PI approach should give good Therefore, the pump intake pressure will be1,580
results. psi - 580 psi = 1,000 psi.

18
THE 9 STEP

Step 3 - Gas Calculations

In this third step we need to determine the total 3. Determine the Gas Volume Factor (Bg) as
fluid mixture, inclusive of water, oil and free gas follows:
that will be ingested by the pump.
5.04 x Z x T
Bg =
P
1. Determine the Solution Gas/Oil Ratio (Rs ) at
the pump intake pressure with Standing's nomo- Assuming 0.85 Z factor;
graph (see figure 2 ), or by substituting the
pump intake pressure for the bubble point pres- 5.04 x 0.85 x (460 + 160)
Bg= = 2.62 bbl/mcf
sure (Pb) in Standing's equation; 1,014
4. Next, determine the total volume of fluids and the
1.2048
Rs = Yg ( Pb
18
x 100.0125 x API
0

100.00091 x T( F)
0 ) percentage of free gas released at the pump intake:
a. Using the producing GOR, and oil volume,
determine the total volume of gas (TG) ;
1.2048
Rs = 0.7 (
1000
18
x
100.0125 x 32
100.00091 x 160
) TG = BOPD x GOR
1,000
or
Rs = 180 scf/stb
TG = (2,300 x 0.25) x 300 = 172.5 mcf
2. Determine the Formation Volume Factor (Bo)
1,000
using the Rs from above and Standing's nomo-
graph (see figure 3) or use Standing's equation as b. Using the solution GOR (Rs), at the pump
follows: intake, determine the solution gas (SG);
Bo = 0.972 + 0.000147 F1.175
SG = BOPD x R
s
where; 1,000
or
0.5
Yg
F = Rs ( ) Yo
+ 1.25T SG =
(2,300 x 0.25) x 180
= 103.5 mcf
1,000
0.5
0.7
F = 180 ( 0.865 ) + 1.25 x 160 = 361.92
c. The difference represents the volume of free
gas (FG) released from solution by the de-
crease in pressure from bubble-point pressure
Therefore;
of 1,500 psi, to the pump intake pressure of
Bo = 0.972 + 0.000147 (361.92)1.175 1,000 psi.
Bo =1.12 reservoir bbl/stock tank bbl
FG =172.5 mcf - 103.5 mcf = 69 mcf

19
 THE 9 STEP

d. The volume of oil (Vo), at the pump intake:
Vo = BOPD x Formation Volume Factor Bo
Vo = 575 bopd x 1.12 = 644 bopd
e. The volume of free gas (Vg ), at the pump
intake:
Vg = Free Gas x Gas Volume Factor Bg
Vg = 69 mcf x 2.62 bbl/mcf = 181 bgpd
f. The volume of water (V w), at the pump
intake:
Vw = Total Fluid Volume x % Water
Vw = 2,300 BPD x 0.75 = 1,725 bwpd
g. The total volume (Vt) of oil, water, and gas,
at the pump intake, can now be determined:
Vt = Vo + Vg + Vw
Vt = 644 bopd + 181 bgpd + 1,725 bwpd
Vt = 2,550 BFPD
i. The composite specific gravity, including
gas, can be determined by first calculating
the total mass of produced fluid (TMPF)
from the original data given:
TMPF ={ (BOPD x Sp. Gr. oil+ BWPD x
Sp. Gr. water) x 62.4 x 5.6146} + (GOR x
BOPD x Sp. Gr. Gas x 0.0752)
or
TMPF = {(575 x 0.865 + 1,725 x 1.085) x
62.4 x 5.6146} + (300 x 575 x 0.7 x
0.0752) = 839,064 lbs/day
TMPF
Composite Sp. Gr. =
BFPD x 5.6146 x 62.4
Composite Sp. Gr. = 839,064 lbs/day
2,550 x 5.6146 x 62.4

h. The ratio, or percentage of free gas present Composite Sp. Gr. = 0.939
at the pump intake to the total volume of
fluid is: 5. Now that the total volume of fluid entering the
Vg first pump stage is known (2,550 BFPD) and the
% Free Gas = composite specific gravity has been determined
Vt we can continue to the next step of designing the
or ESP system.

181 BGPD
% Free Gas = x 100 = 7%
2,550 BFPD

As this value is less than 10% by volume,

it would have little effect on the pump
performance, therefore, a gas separator is
not required. Although, there is significant
gas to effect the well fluid composite spe-
cific gravity at the pump intake.

20
THE 9 STEP

Step 4 - Total Dynamic Head Step 5 - Pump Type Selection

Sufficient data is now available to determine the
total dynamic head required by the pump.
TDH = Hd + Ft + P d
Hd = The vertical distance in feet between the
estimated producing fluid level and the surface.
Hd = Pump depth - ( PIP x 2.31ft/psi
Specific Gravity
) BPD (405 M3PD) is 41.8 ft. (13 m). The brake
Refer to Pump Selection Table in Engineering
section of catalog . Select the pump type with
the highest efficiency at the calculated capacity,
2,550 BPD (405 M3PD) that will fit in the
casing. Select the 513 series GC2200 pump and
locate it's performance curve.
The head in feet (meters) for one stage at 2,550
horsepower (BHP) per stage is 1.16.

To determine the total number of stages re-

Hd = 5,500 ft. - ( 1,000 psi x 2.31 ft/psi
0.939
) quired, divide the total dynamic head by the
head/stage taken from the curve.
TDH
Hd = 3,040 ft (926.6m). Number stages =
Head/stage
Ft = Tubing friction loss. Refer to Friction Loss 3,556 ft.
Charts in the engineering section. Number of stages = = 85 Stages
41.8 ft.
Friction loss per 1,000 ft. of 2-7/8" tubing (new) Next, refer to your catalog for the GC2200
is 49 ft. per 1,000 ft. of depth at 2,550 BPD (405 pump. The housing number 9 can house a
M3PD), or 4.5 meters per 100 meters. Using the maximum of 84 stages, 93 stages for a housing
desired pump setting depth: 10. Because the 84 stage pump is only one stage
less than our requirement, it will be our selec-
5,500 ft. x 49 ft.
Ft = = 270 ft. (82.3m) tion.
1,000 ft.
Once you've decided on the maximum number
Pd = Discharge pressure head (desired wellhead of pump stages, calculate the total brake horse-
pressure). Using the composite specific gravity: power required as follows:

100 psi x 2.31 ft/psi BHP = BHP/Stage x No. Stages x Sp. Gr.
Pd = = 246 ft. (75 m)
0.939
BHP = 1.16 x 84 x 0.939 = 91.5 HP
TDH = 3,040 ft. + 270 ft. + 246 ft. = 3,556 ft.
Step 6 - Optimum Size of Components
or Gas Separator
If a gas separator was required, refer to your
TDH = 926.6 m + 82.3 m + 75 m = 1,084 m catalog to select the appropriate separator and
determine its horsepower requirement.

21

Seal Section
Normally the seal section series is the same as
that of the pump, although, there are exceptions
and special adapters are available to connect the
units together. We will select the 513 series
GSB seal section.
The horsepower requirement for the seal de-
pends upon the total dynamic head produced by
the pump. The Horsepower vs TDH curves in
the Engineering section show a requirement of
3.0 horsepower for the 513 series seal operating
against a TDH of 3,556 ft. Therefore, the total
horsepower requirement for this example is 91.5
HP for the pump, plus 3.0 HP for the seal, or 94.5
HP total.
Motor
A 500 series motor (544 or 562) should be used
with the 513 series pump. In this example we
will select the 100 HP 562 series motor from the
catalog. The motor voltage can be selected
based on the following considerations:
a. The high voltage, consequently low-cur-
rent, motors have lower cable losses and
require smaller conductor size cables.
High voltage motors have superior start-
ing characteristics: a feature that can be
extremely important if excessive voltage
losses are expected during starting.
b. Although, the higher the motor voltage,
the more expensive the motor controller
will be.
In some cases, the savings due to smaller cable
may be offset by the difference in motor control-
ler cost and it may be necessary to make an
economic analysis for the various voltage mo-
tors. However, for this example, we will select
the high-voltage motor (100 HP 2145 volts, 27
amps).
22
THE 9 STEP
Referring to the Engineering section, it can be
seen that all operating parameters are well within
their recommended ranges (e.g. thrust bearing,
shaft HP, housing burst pressure and fluid veloc-
ity.
Step 7 - Electric Cable
Determine Cable Size
The cable size is selected based on its current
carrying capability. Using the motor amps (27)
and the cable voltage drop chart in the catalog,
select a cable size with a voltage drop of less than
30 volts per 1,000 ft. All conductor sizes 1
through 6) fall in this category. The #6 cable has
a voltage drop of 18.5 x 1.201 = 22.2 volts/1,000
ft. (305 m) and is the least expensive. This will
be the cable size used in our example.
Cable Type
Due to the gassy conditions and the bottom-hole
temperature, the CPN cable should be used.
Check to be sure the cable diameter plus tubing
collar diameter is smaller than the casing I.D.
(see Engineering section ).
Cable Length
The pump setting depth is 5,500 ft. (1676.4 m).
With 100 ft. (30.5 m) of cable for surface
connections, the total cable length should be
5,600 ft. (1,707 m). You will also find that the
cable length is within the recommended maxi-
mum length (see Engineering section).
Cable Venting
A cable vent box must be installed between the
wellhead and the motor controller to prevent gas
migration to the controller.
THE 9 STEP

Step 8 - Accessory and Miscellaneous

Motor Controller
Equipment The motor controller selection is based on its
Flat Cable - Motor Lead Extension voltage, amperage, and KVA rating. Therefore,
Pump Length = 14.8 ft. (4.51 m) before selecting the controller we must first
Seal Length = 6.3 ft. (1.92 m) determine the motor controller voltage. We will
Plus 6 ft. = 6.0 ft. (1.83 m) assume the controller will be the same as the
= 27.1 ft. (8.26 m) surface voltage going down-hole. The surface
voltage (SV) is the sum of the motor voltage and
Select 35 ft. (10.7 m) 562 series flat cable. the total voltage loss in the cable.

Flat Guards
Cable guards are available in 6 ft. sections,
therefore, 6 sections will be sufficient.
SV = 2,145 volts + ( 1,000 Ft
)
22.2 volts x 5,600 ft.

Cable Bands Surface Voltage = 2,269 Volts

The pump and seal section are approximately 20
ft. (6 m) long. Twenty-two inch (56 cm) bands The motor amperage is 27 amps, the KVA can
will be required to clamp to the housing, with now be Calculated:
bands spaced at 2 ft. ( 61 cm) intervals (10
bands). KVA = SV x Motor Amps x 1.73
1,000
Above the pump, banding of the tubing plus 2,269 volts x 27 amps x 1.73
cable, the twenty- two bands can also be used. KVA =
1,000
The bands should be spaced at 15 ft. (4.5 m)
intervals. The setting depth of 5,500 ft. would
require 367 bands. KVA = 106

Downhole Accessory Equipment The 6H-CG motor controller suits these require-
Refer to your catalog for the following: ments.

Swaged Nipple Transformer

The pump outlet is 2-7/8 inches, as shown on The transformer selection is based on the avail-
table 5, so no swaged nipple is required for the able primary power supply (12,470 volts), the
2-7/8 inch tubing. secondary voltage requirement (2,269 volts),
and the KVA requirement( 106 KVA). Chose
Check Valve 3 37.5 KVA single phase transformers as shown
The 2-7/8 inch EUE 8 round thread check valve in your catalog.
will be required.
Surface Cable
Drain Valve Select 50 ft. (15.2 m) of #1 cable for surface
The 2-7/8 inch EUE 8 round thread drain valve connection to transformers.
will be required.
23
 THE 9 STEP
DESIGN EXAMPLE - Variable Speed Pumping System

We will now take the previous example and

design a new system using a Variable Speed Pwf = Pr - ( )Qd
PI
Controller. To help justify the use of a variable
speed controller, I have added two new condi-
tions. Those conditions are: Pwf = 3,200 psi - ( )
2,875 bpd
1.42 bpd/psi
= 1,175 psi

1. First, assume we need to maintain a con-

The new well flowing pressure of 1,175 psi is
stant oil production (575 BOPD), although,
slightly below the bubble point pressure of 1,500
reservoir data indicates we should see an
psi, therefore, the PI approach should still give
increase in water cut (75% to 80%) over
good results.
the next few months.
The pump intake pressure can be determined the
2. To satisfy our economic justification in
same as before, although, first we must calculate
using the variable speed controller, we
a new composite specific gravity.
need to reduce the initial cost and size of
the downhole assembly. Water cut is 80%;
0.80 x 1.085 = 0.868
In order to maintain oil production as the water Oil is 25%;
cut increases, we need to determine the maxi- 0.20 x 0.865 = 0.173
mum desired flow rate with 80% water.
The composite specific gravity is the sum of the
Maximum Flow Rate = BOPD x 100
weighted percentages:
% oil

575 BPD Composite Sp. Gr. = 0.868 + 0.173 = 1.04

Max. Flow = x 100 = 2,875 BPD
20%
The pressure due to the difference in perforation
depth and pump setting depth (6,800' - 5,500' =
Step 2 - Production Capacity 1,300') can be determined as follows:
We can now calculate the pump intake pressure
at the maximum rate of 2,875 BPD. First, we Head (FT) x Specific Gravity
will make the assumption that even though the PSI =
water cut changes, the well's PI will remain 2.31 Ft/PSI
constant. We can now determine the new well
flowing pressure (Pwf) at the maximum desired 1,300 Ft x 1.04
PSI = = 585 PSI
production rate (Qd). 2.31 Ft/PSI

Therefore, the pump intake pressure can now be

determined; 1,175 psi - 585 psi = 590 psi.

24
THE 9 STEP

Step 3 - Gas Calculations

Next, we need to determine the total fluid mix- 3. Determine the Gas Volume Factor (Bg) as
ture that will be ingested by the pump at the new follows:
maximum desired flow rate (2,875 BPD).
Bg = 5.04 x Z x T
P
1. Determine the Solution Gas/Oil Ratio (Rs ) at
..the pump intake pressure with Standing's nomo-
Assuming 0.85 Z factor;
graph (see engineering section ), or by substitut-
ing the pump intake pressure for the bubble 5.04 x 0.85 x (460 + 160)
Bg= = 4.40 bbl/mcf
point pressure (Pb) in Standing's equation; 604
4. Next, determine the total volume of fluids, and the
Pb 1.2048
( )
0

x 100.0125 x API percentage of free gas released at the pump intake:

Rs = Yg 18 a. Using the producing GOR, and oil volume,
100.00091 x T( F)
0

determine the total volume of gas (TG) ;

1.2048
Rs = 0.7 ( 585
18
x
100.0125 x 32
100.00091 x 160
) TG = BOPD x GOR
1,000
Rs = 94 scf/stb or
(2,875 x 0.20) x 300
2. Determine the Formation Volume Factor (Bo) TG = = 172.5 mcf
1,000
using the Rs from above and Standing's nomo-
graph (see Engineering section) or use Standing's
equation as follows: b. Using the solution GOR (Rs), at the pump intake,
determine the solution gas (SG);
Bo = 0.972 + 0.000147 F1.175
BOPD x Rs
SG =
where; 1,000
0.5 or
Yg
F = Rs ( ) Yo
+ 1.25T
SG =
(2875 x 0.20) x 94
= 54.05 mcf
1,000
0.5
c. The difference represents the volume of free gas
F = 94 ( 0.7
0.865 ) + 1.25 x 160 = 284.56 (FG) released from solution by the decrease in
pressure from the bubble point pressure of 1,500
Therefore;
psi, to the pump intake pressure of 1,000 psi.
Bo = 0.972 + 0.000147 (284.56)1.175
Bo =1.08 reservoir bbl/stock tank bbl FG =172.5 mcf - 54.05 mcf = 118.5 mcf

25
 THE 9 STEP

d. The volume of oil (Vo), at the pump intake: a. Percent of gas not separated is 10%:
Vo = BOPD x Formation Volume Factor Bo Vg = Volume of gas at PIP x % ingested
Vo = 575 bopd x 1.08 = 621 bopd Vg = 521 BPD x 0.1
Vg = 52 BPD
e. The volume of free gas (Vg ), at the pump
intake: b. Total volume of fluid mixture ingested
Vg = Free Gas x Gas Volume Factor Bg into pump is:
Vg = 118.5 mcf x 4.40 bbl/mcf = 521 bgpd Vo = 621 BPD
Vg = 52 BPD
f. The volume of water (V w), at the pump Vw = 2,300 BPD
intake: Vt = 2,973 BPD
Vw = Total Fluid Volume x % Water
Vw = 2,875 BPD x 0.80 = 2,300 bwpd c. The amount of free gas entering the first
pump stage as a percent of total fluid
g. The total volume (Vt) of oil, water, and gas, mixture is:
at the pump intake, can now be determined: Vg
Vt = Vo + Vg + Vw % Free Gas =
Vt
Vt = 621 bopd + 521 bgpd + 2,300 bwpd
Vt = 3,442 BFPD 52 BPD
% Free Gas = x 100 = 2%
2,973 BPD
h. The ratio, or percentage of free gas present As the free gas represents only 2% by
at the pump intake to the total volume of volume of fluid being pumped it has no
fluid is: significant effect of the well fluid compos-
Vg ite specific gravity and may be ignored for
% Free Gas = conservative motor sizing.
Vt
or
521 BGPD 6. Now that the total volume of fluid entering the
% Free Gas = x 100 = 15% first pump stage is known (2,973 BFPD) and the
3,442 BFPD
composite specific gravity has been determined
we can continue to the next step of designing the
5. As this value is greater than 10% by volume, ESP system.
there is significant free gas to affect pump per-
formance, therefore, it is recommended that a
gas separator be installed. Next, we will have to
assume a gas separator efficiency. At 15% free
gas, we will assume 90% efficiency of separa-
tion.

26
THE 9 STEP

Step 4 - Total Dynamic Head Step 5 - Pump Type Selection

Sufficient data is now available to determine the We have now determined both hydraulic re-
total dynamic head required at the maximum quirements for our variable speed pumping sys-
desired flow rate (2,973 BPD). The total dy- tem. Those requirements are:
namic head for the minimum desired flow rate
(2,550 BPD) was previously determined to be Minimum Hydraulic Requirement
3,556 ft. Flow Rate 2,550 BPD
TDH = Hd + Ft + P d Total Dynamic Head 3,556 ft.

Hd = The vertical distance in feet between the Maximum Hydraulic Requirement

Flow Rate 2,973 BPD
estimated producing fluid level and the surface.
Total Dynamic Head 4,746 ft.
Hd = Pump depth - ( PIP x 2.31ft/psi
Specific Gravity
) In our economic justification for using the vari-
able speed controller, we elected to reduce the
size on the down-hole unit. To accomplish this,
Hd = 5,500 ft. - ( 590 psi x 2.31 ft/psi
1.04
) we can follow these guidelines:

1. As the operating frequency increases, the

Hd = 4,190 ft (1,277m). number of stages required to generate the
required lift decreases.
Ft = Tubing friction loss. Refer to Friction Loss
Charts in the engineering section. 2. The closer you operate to the best effi-
ciency point, the lower the power require-
Friction loss per 1,000 ft. of 2-7/8" tubing (new) ment, and the power cost.
is 60 ft. per 1,000 ft. of depth at 2,973 BPD (405
M3PD), or 4.5 meters per 100 meters. Using the 3. A fixed frequency motor of a particular
desired pump setting depth: frame size has a maximum output torque,
provided that the specified voltage is sup-
5,500 ft. x 60 ft. plied to its terminals. The same torque can
Ft = = 330 ft. (100.6m)
1,000 ft. be achieved at other speeds by varying the
voltage in proportion to the frequency. This
Pd = Discharge pressure head (desired wellhead way the magnetizing current and flux den-
pressure). Using the composite specific gravity: sity will remain constant, and so the avail-
able torque will be constant (at no slip rpm).
100 psi x 2.31 ft/psi As a result, power output rating will be
Pd = = 226 ft. (68.9 m)
1.02 directly proportional to speed, since power
rating is obtained by multiplying rated torque
TDH = 4,190 ft. + 330 ft. + 226 ft. = 4,746 ft.
times speed.
or
TDH = 1277 m + 100.6 m + 68.9 m = 1,446.6 m

27

Using the variable speed performance curves,
select a pump that will fit in the casing, and the
maximum flow rate (2,973 BPD) falls at its best
efficiency point (BEP). The GC-2200 satisfies
these conditions at 81 Hz (see below).
Next, select the head per stage from the curve on
the vertical axis, should read 86 ft. With the
maximum total dynamic head requirement of
4,746 ft., we can determine the number of pump
stages required.
Maximum Total Dynamic Head
No. Stages =
Head/Stage
4,746 ft.
No. Stages = = 55 stages
86 ft.
28
THE 9 STEP
Referring to the pump selection tables in the
catalog, you will find that a housing number 6
will support 55 stages of the GC-2200 pump.
Therefore, this 55 stage GC-2200 meets our
maximum hydraulic requirement.
To determine if it meets our minimum hydraulic
requirement, divide the minimum total dynamic
head requirement by the number of stages.
3,556 ft.
Minimum Head/Stage = = 64.7 ft.
55 stgs.
Plotting the minimum head/stage (64.7 ft.) and
the minimum flow rate (2,550 BPD) on the
curve below indicates an operating frequency of
70 Hz. Note, the minimum hydraulic require-
ment is also near the pump's BEP.
THE 9 STEP

Next, using the VSC curve for the GC-2200 find
the BHP/stage at the 60 hertz BEP (1.12 HP). To
calculate the BHP at the maximum frequency:
BHP @ Max. Hz. =
3
Using the technical data provided in the engi-
neering section determine if any load limitations
were exceeded (e.g. shaft loading, thrust bearing
loading, housing burst pressure limitations, fluid
velocity passing the motor, etc.).

BHP/Stg. x No. Stgs. x (

Max. Hz.
60 Hz .
)
x Sp. Gr. Next, select the power cable and calculate the
cable voltage drop. Based on the motor current
or
3
(35 amps) and the temperature (160 o F), number
1.12 x 55 x ( )
81 Hz.
60 Hz.
x 1.04 = 157.6 HP
6 cable can be used. Adding 200' for surface
connections, the cable voltage drop is:
24 v x 1.201 x 5,700'
In this example we decided to use a rotary gas Cable Drop = =164 volts
1,000
separator, which is a centrifugal machine. The
HP requirement also changes by a cube func- We can now calculate the required surface volt-
tion. Referring to the catalog, the 513 series age (SV) at the maximum operating frequency
rotary gas separator requires 5 HP at 60 Hertz. as follows:

Separator HP = 5 x ( )
81 Hz.
3
SV = Motor Volts x (Max Hz.
)
60 Hz. + Voltage Drop
60 Hz. x 1.04= 12.8 HP

Total BHP for pump and separator = 170.4 HP SV = 2,145 x (81 Hz.
60 Hz. ) + 164 = 3,060 volts

To calculate the equivalent 60 Hertz BHP for

both the pump and gas separator:
60 Hz.
60 Hz. BHP = BHP @ Max. Hz. x
Max. Hz.
or
60 Hz.
60 Hz. BHP = 170.4 x = 126.2 HP
81 Hz.
Select the appropriate model seal section and
determine the horsepower requirement at the
maximum TDH requirement. Select a motor
which is capable of supplying total horsepower
requirements for the pump, gas separator and
seal. In this example, we will select a 562 series
motor, 130 HP 2,145 volt and 35 amps.
Note: Surface voltage is greater than standard
3KV cable. Should select 4KV or higher cable
construction.
Sufficient data is available to calculate KVA.
SV x Motor Amps x 1.73
KVA =
1,000
3.060 x 35 x 1.73
KVA = = 185 KVA
1,000
Referring to the price section of the catalog, we
will select the model 2200 - 3VT, 200 KVA,
NEMA 3 (outdoor enclosure) Electrospeed vari-
able speed controller. All other accessory equip-
ment would be selected as the previous example.

29
 THE 9 STEP

Conceived specifically for Centrilift sales engineers as an aid when sizing pumps,
AutographPC TM
is a computer software program that runs on IBM compatible
computers.

AutographPC TM
is useful for both fixed speed (50 or 60 Hz) and variable speed
applications, and makes it practical to produce a unique performance curve for each
sizing.

Understanding the basic theory of sizing submersible pumps is considered a prerequisite

to using the computer software; contact your Centrilift sales engineer for details.

The complexity associated with designing
Variable Speed Electrical Submersible Pumping
Systems, along with the introduction of numerous
multiphase flow correlations, has made them the
ideal candidate for microcomputer applications.
Each application is unique and detailed
information on well completion, production
history and reservoir conditions is extremely
important during the initial design phase.
AutographPC TM is a computer software program
that runs on IBM compatible PC's designed to
greatly simplify the ESP sizing process. The
program approaches the sizing by first creating
a pictorial representation of the well performance
based on specific hydraulic requirements. This
After the creation of the well model, the pro-
gram will allow you to integrate it with a pump
model to graphically represent the system per-
formance. This is accomplished on the Pump
Sizing Screen (see figure 4).
There are several additional screens available
that allow you to select the appropriate sizing
method, as well as, the selection of the individual
components that make up the ESP system.
This concludes theNine-Step Sizing Procedure.
1
Gilbert, W.E. "Flowing and Gas-Lift Well Performance."
API Drilling and Production Pratice. 1954, API, p. 143.

is accomplished on theWell Information Screen 2

(see figure 3), which is the input document for
all the critical well data.
Vogel, J.V. "Inflow Performance Relationship for Solution
Gas Drive Wells." J. Pet. Tech., Jan 1968, pp. 83-93.
3
Standing, M.B. "Volumetric and Phase Behavior of Oil
Field Hydrocarbon Systems", Reinhold Publishing Corp.,
New York (1952).

30
THE 9 STEP

Figure 3 - Well Information Screen

Figure 4 - Pump Sizing Screen

31