131

Chapter 16

ELECTRIC SUBMERGIBLE PUMPS

W.J. POWERS, CLARENCE DUNBAR, and GEORGE V. CHILINGARIAN

INTRODUCTION

The electric submergible pump (ESP) is perhaps the most versatile of the major
oil production artificial lift methods. The purpose of this chapter is to provide the
reader with a broad-based understanding of the key factors in selecting, installing,
and operating electric submergible pumps. The ESP topics covered here are: electric
submergible pump system, applications, electric submergible system components,
selection data and methods, handling, installation and operation, and troubleshoot-
ing.

ELECTRIC SUBMERGIBLE PUMP SYSTEM

The Electric Submergible Pump System (ESP) is usually comprised of a down-

hole pump, electric power cable and surface controls. In a typical application, the
downhole pump is suspended on a tubing string hung on the wellhead and is
submerged in the well fluid (see Fig. 16-1). The pump is close-coupled to a
submergible electric motor, which receives power through the power cable and
surface controls.
The ESP has the broadest producing range of any artificial lift method. The
standard 60 Hz producing range of the ESP is from a low of 100 bbl of total fluid
per day up to 90,000 bbl/day. Variable-speed drives can extend the producing range
beyond these rates. Although most operators tend to associate ESPs with “high-
volume” lift rates, the average ESP produces less than 1000 bbl of total fluid per
day.
The ESPs are used to produce a variety of fluids as well as the gas, chemicals,
and contaminants commonly found in these fluids. They are currently economically
operated in virtually every known environment found in the oilfields of the world.
The oil/water ratio is, in general, not significant in assessing an application.
Relatively high gas/fluid ratios can be handled using “tapered” design pumps and a
special gas separator pump intake. Aggressive fluids (those containing H,S, CO,, or
similar corrosives) can be produced utilizing special materials and coatings. Sand

The help extended by Marshall Behrens and W. Duane Anderson was indeed invaluable.
738

and similar abrasive contaminants can be produced with acceptable pump life using
specially modified pumps and operation procedures.
The ESPs usually do not require storage enclosures, foundation pads, or guard
fences. An ESP can be operated in a deviated or directionally drilled well, although
the recommended operating position is in a straight section of the well. Because the
ESP can be up to 200 ft long, operation in a bend or “dog leg” could seriously affect
the unit’s run-life and performance by causing hot spots where the motor rests
against the casing. The ESP can operate in a horizontal position. In this case,
run-life will be determined by the protectors ability to isolate well fluid from the
motor.
These pumps are currently operated in wells with bottomhole temperatures up to
350’F. Operation at elevated ambient temperatures requires special components in
the motor and power cable that are capable of sustained operation at a high
ambient temperature.
The ESPs can efficiently lift fluids in wells in excess of 12,000 ft deep, and can be
operated in casing as small as 4: in. O.D. Many studies indicate that ESPs represent
the most efficient lift method and the most economic on a cost per lifted barrel
basis. Overall system efficiency can be as high as 68%, depending upon fluid
volume, net lift. and pump type.
The major disadvantage of the ESP is that it has a narrow producing rate range
compared to other artificial lift forms. It does handle free gas well but the impact of
large volumes of gas can be destructive to the pump. The run-life can be adversely
affected by poor quality electric power, but this is not limited to the ESP.

APPLICATIONS

The ESP has historically been applied in lifting water or in low oil cut wells that
perform similar to water wells. Within t h s apparently narrow segment, however,
there are numerous types of installations and equipment configurations. The follow-
ing equipment applications and configurations are covered in this section:
(1) Typical Installation
( 2 ) Booster/Injection
(3) Bottom Intake/Discharge
(4) Cavern Storage/Shrouded
(5) Offshore Platforms

Typical installation

A typical ESP installation is shown in Fig. 16.1. The ESP system’s major surface
and downhole equipment is presented here. In this installation, the available surface
power is transformed to the downhole power requirements by three single-phase
transformers. The transformed power is supplied by a power cable to a switchboard
and then through a junction box and wellhead-tubing support. The power cable is
run in with the production tubing string and is banded to the tubing to prevent
 139

0
0
" 0

--

Fig. 6-1. Typical installation of an electric submergible pump system (ESP)

740

mechanical damage during installation and removal. The power cable is spliced to a
motor flat cable, whch is banded to the exterior of the pump-protector-motor unit.
The centrifugal pump is located at the tr>pof the downhole unit, and is hung on the
tubing string by the discharge head. Below the pump is a standard intake which
provides for fluid entry to the pump. The center component is the protector. The
protector both equalizes external and internal pressures and isolates the motor oil
from the well fluid. The lowest component is the motor which drives the centrifugal
pump. The downhole unit is landed above the perforations. This is necessary so that
fluid entering the well flows past the motor. This flow cools the motor which would
otherwise be likely to overheat and fail.

ELECTRIC SUBMERGIBLE SYSTEM COMPONENTS

Motor

The ESP system’s prime mover is the submergible motor (see Fig. 16-2). The
motor is a two-pole, three-phase, squirrel cage induction type. Motors run at a
nominal speed of 3500 rpm in 60 Hz operation, and are filled with a highly refined
mineral oil that provides dielectric strength, bearing lubrication, and thermal
conductivity. A standard motor is capable of operating in wells at temperatures up
to 250’F. Higher temperature capability motors for hotter wells are also manufac-
tured.
Heat generated by motor operation is transferred to the well fluid as it flows past
the motor housing. A minimum fluid velocity of one foot per second is recom-
mended to provide adequate cooling. Because the motor relies on the flow of well
fluid for cooling, a standard ESP should never be set at or below the well
perforations or producing zone unless the motor is shrouded.
Reda motors, for example, are manufactured in four different diameters (series):
3.75 in., 4.56 in., 5.43 in., and 7.38 in.. Thus motors can be utilized in casing as small
as 44 in. in diameter. Horsepower capabilities range from a low of 74 hp in 3.75-in.
series, to a high of 1000 hp in the 7.38-in. series. Motor construction may be a single
section or several sections in tandem bolted together to reach a specific horsepower.
Motors are selected on the basis of the maximum outside diameter that can be easily
run in a given casing size.
The standard motor housing material is a heavy-wall, seamless, low-carbon steel
tubing. The motor shaft material is carbon steel. The rotor(s) are supported by
sleeve bearings made of Nitralloy and bronze. The squirrel cage rotor is made of one
or more sections depending on motor horsepower and length. The motor stator is
wound as a single unit in a fixed housing length.
The standard motor thrust bearing is a fixed pad Kingsbury type. Its purpose is
to support the thrust load of the motor rotors, and to vertically align the rotor-shaft
assembly within the stators’ magnetic field while the motor is running. Axial
alignment to maintain the air gap between the stator and the rotors is maintained by
special rotor bearings.
 741

Center Tandem Motor

Motor Head Showing

Power Cable Connection

Fig. 16-2. Motor of ESP system. (Courtesy of Reda Pump Division, TRW Energy Products Group.)
742

Pump with Standard Intake

Fig. 16-3.Example of a multistage centrifugal type electric submergible pump. (Courtesy of Reda Pump
Division, TRW Energy Products Group.)
 143

Pump

The electric submergible pump is a multistage centrifugal type (see Fig. 16-3).
The type of stage used determines the design volume rate of fluid production. The
number of stages determines the total design head generated and the motor
horsepower required.
The materials used in manufacturing impellers include Ni-Resist, Ryton, and
bronze. Diffusers are universally manufactured of Ni-Resist. The standard shaft
material is K-monel. Optional, high-strength shaft materials are used in deep setting
applications where conventional shaft material horsepower limits are exceeded.
“Bolt-on” design makes it possible to vary the capacity and total head of a pump by
using more than one pump section. Large-capacity pumps, however, typically have
integral heads and bases.
The housing of the pump contains the impellers and diffusers and supports the
weight of the complete unit. Housings are seamless, heavy-walled, low-carbon steel
tubing. The housing is capable of containing the normal operating pressure of the
pump with an adequate safety factor. The nominal outside pump diameter ranges
from 3.38 in. to 11.25 in.

Protector

The protector’s primary purpose is to isolate the motor oil from the well fluid
while balancing bottomhole pressure and the motor’s internal pressure. There are
two types of protector design: the positive seal (Fig. 16-4) and the labyrinth path
(Fig. 16-5). The “positive seal” design relies on an elastomer fluid barrier bag to
allow for the thermal expansion of motor fluid in operation, and yet still isolate the
well fluid from the motor oil. The “labyrinth path” design utilizes differential
specific gravity of the well fluid and motor oil to prevent the well fluid from
entering the motor. T h s is accomplished by allowing the well fluid and motor oil to
communicate through tube paths connecting segregated chambers.
The protector performs four basic functions: (1)connects the pump to the motor
by connecting both the housing and drive shafts, (2) houses a thrust bearing to
absorb pump shaft axial thrust, (3) isolates motor oil from well fluid while allowing
wellbore-motor pressure equalization, and (4) allows thermal expansion of motor
oil due to operating heat rise and thermal contraction of the motor oil after
shutdown. The standard protector housing material is the same carbon steel
material as is used in motors and pumps. The drive shaft is also K-monel.

Pump intake

Two types of intakes are used to allow fluid to enter the pump. These are the
standard intake shown in Fig. 16-3 and the gas separator intake shown in Figs. 16-6
and 16-7. A gas separator intake is used when the vapor/liquid ratio is greater than
that which can be handled by the pump. If the gas remains in solution, the pump
 Positive Seal Protector

Fig. 16-4. Positive-seal protector. (Courtesy of Reda Pump Division, TRW Energy Products Group.)
 745

Labyrinth Path Protector

Fig. 16-5. Labyrinth-path protector. (Courtesy of Reda Pump Division, TRW Energy Products Group.)
746

Static Type
Gas Separator

-
Fig. 16-6. Static type gas separator intake. (Courtesy of Reda Pump Division, TRW Energy Products
Group.)
 141

Fig. 16-7. Rotary gas separator intake. (Courtesy of Reda Pump Division, TRW Energy Products Group.)
748

will perform normally. Once the gas/liquid ratio exceeds a value of about 0.1,
however, the pump may produce a head lower than normal. As the vapor/liquid
ratio increases above 0.1 and free gas increases, the pump will eventually “gas lock”,
which usually drastically reduces fluid production and in extreme cases can damage
the pump. The pump, however, can tolerate progressively higher vapor/liquid ratio
at higher operating pressure.
There are two types of gas separator intakes: (1) the static type (Fig. 16-6) and
(2) the KGS rotary type (Fig. 16-7). The static type induces gas separation by
reversing the fluid flow direction. At the fluid entry ports, the reversal of fluid flow
direction creates lower pressure which allows the gas to separate. The separated gas
moves up the annulus and vents at the wellhead. The fluid, which still contains some
gas, enters the separator and moves downward into the standtube. The fluid is
picked up by the rotating pick-up impeller. The impeller creates a vortex which
forces dense, relatively gas-free fluid to the outside and allows additional gas
breakout along the shaft. This provides the first stage of the pump with a higher
density of fluid than if the gas broke out in the pump.
The Reda KGS rotary gas separator (Fig. 16-7) utilizes a rotary inducer-centri-
fuge to centrifugally separate the gas and produced liquids. The well fluid enters the
intake ports and moves into the inducer. The inducer increases the fluid pressure
discharging into the centrifuge. The centrifuge forces the denser fluid to the outside.
Gas rises from the center of the centrifuge through the flow divider into the
crossover section where gas vents to the annulus and fluid is directed into the first
stage of the pump.

Power cable

Electric power is supplied to the downhole motor by a special submergible cable.

There are two different cable configurations: (1)flat (or parallel) and ( 2 ) round (see
Fig. 16-8). Round construction is used except where casing-tubing clearance
requires flat constructions’ lower profile. The standard range of conductor sizes is
1/0-6 AWG (American Wire Gauge). This range meets virtually all motor amper-
age requirements. Almost all cable types use copper conductors. Although aluminum
conductors are sometimes used in high H,S concentration wells, mechanical protec-
tion is provided by armor made from galvanized steel or, in extremely corrosive
environments, from monel.
Cable is constructed with three individual conductors-one for each power
phase. Each conductor is enclosed by insulation and sheathing material. The
thckness and composition of the insulation and sheathing determines the conduc-
tors resistance to current leakage, maximum operating temperature capability, and
resistance to withstand permeation by well fluid and gas. For example, Reda electric
power cable is rated to operate up to 400°F at 1500 psi (see Table 16-1).
Round cable is also manufactured with an “I” wire. The “I” wire serves as an
electrical link between a downhole instrument and surface reading-processing
equipment.
 749

Round a n d Parallel P o w e r Cable

Fig. 16-8.Round and parallel power cable. (Courtesy of Reda Pump Division, TRW Energy Products
Group.)

Motor frat cable

The motor flat cable is in the lowest section of the power cable string. The motor
flat cable has a lower profile than standard flat power cable so that it can run the

TABLE 16-1
Reda cable types and applications

Cable type Configuration Maximum bottom- KVA rotary Armor

flat or round hole temperature (000)
( O F at 1500 psi)

Redalene F, R 205" 3-5 Galvanized

steel and monel
Redahot F,R 275' 3 Galvanized
steel and monel
Redalead F 350' 3-5 Galvanized
steel and monel
Redared R 400" 3-5 Galvanized
steel and monel
Polyethylene R 180" 3 None
750

Fig. 16-9. Switchboard with recording ammeter and RedalertTM motor controller. (Courtesy of Reda
Pump Division, TRW Energy Products Group.)

length of the pump and protector in limited clearance situations (see Fig. 16-1). The
motor flat cable is manufactured with a special terminal called a “pothead”. The
function of the pothead is to allow entry of electric power into the motor while
sealing the connection from well fluid entry.

Switchboard

The switchboard is basically a motor control device (see Fig. 16-9). Voltage
capability ranges from 600 V to 4900 V on a standard switchboard. All enclosures
are NEMA-3R (National Electrical Manufacturers Association), which is suitable
for virtually all outdoor applications. The switchboards range in complexity from a
 751

simple motor starter-disconnect switch to an extremely sophisticated

monitoring-control device.
There are two major construction types: electromechanical and solid state.
Electromechanical construction switchboards provide overcurrent-overload protec-
tion through three magnetic inverse time delay contact relays with pushbutton,
manual reset. Undercurrent protection is provided by Westinghouse SCR (Silicone
Controlled Rectifier) relays. These features provide protection against downhole
equipment damage caused by conditions such as pump-off, gas lock, tubing leaks,
and shutoff operation.
The solid state switchboards incorporate the highly sophisticated motor con-
troller. The purpose of the motor controller is to protect the downhole unit by
sensing abnormal power service and shutting down the power supply if current
exceeds or drops below preset limits. This is accomplished by monitoring each phase
of the input power cable to the downhole motor.
The monitoring function applies to both overload and underload conditions.
When a fault condition occurs, the controller shuts down the unit. It can be
programmed to automatically restart the downhole motor following a user selected
time delay if the fault condition is caused by an underload. The programmed time
delay can be from one minute up to twenty hours. Overload condition shutdown
must be manually restarted, but t h s should be done only after the fault condition
has been identified and corrected.

*
A valuable switchboard option is the recording ammeter. Its function is to
record, on a circular strip chart, the input amperage to the downhole motor. The

HAND HOLE ACCESSTOTAPCHANGER

12 500 UNITS 95 BIL HV BUSHINGS
2 h 5 0 UNITS I50 BIL HV B U S H I N G S 3 [
12GAUGETANK
EXTRA CREEP BUSHINGS
PAINT SYSTEM MEETS OR EXCEEDS
ASTM 5% SALT FOR 1519 HRS.

TAP CHANGER 2"O.D. (14 GA) COOLING TUBES

CORE a COIL BUSHING LEADS

HOLD DOWN SUPPORT
COIL BLOCK

COIL, ALL COPPER WINDING CORE, LOW LOSS MATERIAL

65°C INSULATING SYSTEM. GRAIN ORIENTED STEEL

HEAVY DUTY FRAME

CORE a COIL POSITION GUIDES

Fig. 16-10. Single-phase transformer. (Courtesy of Reda Pump Division, TRW Energy Products Group )
152

Hercules HHS Wellhead

Fig. 16-11. Hercules HHS wellhead, (Courtesy of Reda Pump Division, TRW Energy Products Group.)

ammeter chart record can show if the downhole unit is performing as designed or if
abnormal operating conditions exist. Abnormal conditions can result when a well’s
inflow performance is not correctly matched with pump capability or when electric
power is of poor quality. Abnormal conditions that are indicated on the ammeter
chart record are primary line voltage fluctuations, low current (A), high current, and
erratic current.

Transformer

The ESP system utilizes three different transformer configurations: (1) three
single-phase transformers (Fig. 16-10), (2) one three-phase standard transformer, or
(3) one three-phase autotransformer. Transformers are generally required because
primary line voltage generally does not meet the downhole motor voltage require-
ment. Oil-immersed, self-cooled (OISC) transformers are used in land-based appli-
cations. Dry-type transformers are sometimes used in offshore applications, which
exclude oil-filled transformers.

Wellhead

The wellhead or tubing support may be used as a limited pressure seal (see Fig.
16-11). The wellhead provides a pressure-light pack-off around the tubing and
power cable. High-pressure wellheads-up to 3000 psi-use an electrical power
feed-through mandrel to prevent gas migration through the cable. Wellheads are
manufactured to fit standard casing sizes from 4 i to 134 in.
 153

SWITCHBOA
-5OMlNlMUM-

15 FEET MINIMUM

JUNCTION B O X

Fig. 16-12. Junction box. (Courtesy of Reda Pump Division, TRW Energy Products Group )

Junction box

A junction box connects the power cable from the switchboard to the well power
cable (see Fig. 16-12). It is necessary to vent, to the atmosphere, any gas that may
migrate up the power cable from the well. This prevents accumulation of gas in the
switchboard, which can result in an explosive and unsafe operating condition. A
junction box is required on all ESP installations.

Accessory options

The following covers two major accessory options: (a) the pressure-sensing
instrument and (b) a variable-speed drive.

Pressure-sensing instrument ( P S I )
The pressure-sensing instrument (PSI) provides the operator with precise down-
154

Fig. 16-13. Pressure and temperature sensing instrument. (Courtesy of Reda Pump Division, TRW
Energy Products Group.)

hole pressure and temperature data. The PSI has two components: (a) a downhole
transducer-sending unit and (b) a surface readout unit (see Fig. 16-13). The
downhole transducer-sending unit connects electrically and bolts to the base of the
motor. Both pressure and temperature data are transmitted from the transducer-
sending unit to the surface read-out through the motor windings and the power
cable on a DC carrier signal. The transducer receives operating power from the
motor’s neutral winding. This allows the operation of the PSI even when the motor
is not running.
The major use of the PSI unit is determination of the producing potential of a
well. This is accomplished by determining both static and dynamic reservoir
pressures. By correlating the change in pressure with a given producing rate, a well’s
inflow performance can be accurately quantified. This, in turn, will allow equipment
selection which optimizes well production.

Variable speed drive

The variable speed drive (VSD) is a highly sophisticated switchboard-motor
controller (see Fig. 16-14). A VSD performs three distinct functions: (a) varies the
capacity of the ESP by varying the motor speed, (b) protects downhole components
 755

Fig. 16-14. Variable-speed drive switchboard motor controller. (Courtesy of Reda Pump Division, TRW
Energy Products Group.)

from power transients, and (c) provides “soft start” capability. Each of these
functions is discussed in succeeding paragraphs.
A VSD changes the capacity of the ESP by varying the motor speed. By changing
the voltage frequency supplied to the motor and thus motor rpm, the capacity of the
pump is also changed in a linear relationship. Thus, well production can be
optimized by balancing inflow performance with pump performance. This applies to
756

both long-range reservoir changes as well as short-term transients, such as those

associated with high GOR wells. This may eliminate the need to change the capacity
of a pump to match changing well conditions or it may mean longer run-life by
preventing cycling problems. This capability is also useful in determining the
productivity of new wells by documenting pressure and production values over a
range of drawdown rates. The change in voltage frequency can be made manually or
automatically. The VSD can operate automatically in a “closed loop” mode with a
programmable controller and PSI instrument.
The VSD also protects the downhole motor from poor quality electric power. The
VSD is relatively insensitive to incoming power balance and regulation, while
providing closely regulated and balanced output. The VSD will not output electric
power transients to the downhole motor, but it can be shutdown or damaged by
such transients. Given the choice, most operators would prefer to repair surface
installation equipment rather than pull and run downhole equipment. Within limits,
the VSD upgrades poor quality electric power. The VSD takes a given frequency
and voltage AC input, converts the AC to DC, and then rebuilds the D C to an AC
waveform. The shape of the waveform is a six-step square wave.
The “soft start” capability of a VSD provides two major benefits. The first is that
it reduces the start-up drain on the power system. Secondly, the mechanical strain
on the pump shafts is significantly reduced when compared to a standard start. This
capability is valuable in gassy or sandy wells. In some cases, slowly ramping a pump
up to operating speed may avoid pump damage.
The VSDs are manufactured in sizes ranging from 125 to 1000 KVA. These units
are designed for sustained operation at maximum ratings when properly applied to
a given set of pump and well conditions.

SELECTION DATA AND METHODS

The data requirements and calculation procedures required for pump selection in
a typical ESP application are presented in this section. The single most important
factor in selection of an ESP is the input data. The data used in sizing an ESP must
be accurate and reliable to insure that the unit is properly matched to the well’s
inflow performance.
The data required for selection of an ESP are: (1) mechanical data, (2) produc-
tion data, (3) fluid data, and (4) power supply.

Mechanical data

The ESP well data form (Fig. 16-15) exemplifies a specific pump selection (Jones
Oil Company; Smith No. 1 well). The mechanical data includes:
(1) Casing size and weight: 5) in. O.D.; 17 lb/ft.
(2) Tubing size, weight and thread: 2$ in. O.D.; EUE.
(3) Well depth-both measured and true vertical: 7070 ft.
 151
Request For Information

Gt73

REDA P U M P COMPANY
Bartlesville, Oklahoma
GENTLEMEN:

Will you please send me complete information concerning a Reda unit for the following oil well:

J . c l ~ . ~ ~ % o i \ . . b ~ ) / Sm'ltk..b.1
DESCRIPTION:
Company Well Name &! No. ............
Field or Pool Name ..... ......................... County ............................................ State . ......................
Production Formation sand .... Sand or Lime ............................. Total Well Depth ..21.0.0 ...... Fr.
Caring: .5.&. . . . In. O.D. . 1.7..-. Lbs. per Ft. ................... Liner: .................. In. O.D. . . . . . . . Lbs per EL.
T o p of Liner at .... ... ft. Bottom of Liner at ...................... ft.
Perforations: ..?025. .. to ... 7add. ft. Open Hole: . . . . . . . . . . . . . . to fr.

PRESENT P R O D U C T I O N A N D P R O D U C T I V I T Y DATA:
Average Production Rate: ............... .-............. Bbl. Oil/Day wtrh dQ.0 Bbl. Water/Day.
. Cu. Ft./Day gar produced with ............. Bbl./Day total fluid using .................. method of arriiical I l f r
i!mo
.
with ...... ........... feet of ~..L./s. . . . . . . . In. O . D . E U E I M . Tubing.
Static Fluid Level .385f . . . . ft. from top. Static Bottom Hole Pressure ................ P.S.I. at . . ft
Producing Fluid Level ..... f t . from top while producing A..a.o.. ....... Bbl./Day total fluid.
Productivity index is ....... Bbl./Day per P.S.I. of draw-down or t 238/
Bbl./Day per foot of draw-down
Fluid gradient 1 s 7'763. P.S.I./Ft.
From all observations i t is estimated this well is capable of producing 500 ..... Bbl./Day total fluid from a
producing fluid level of .z?s/ . feet from the cop.

GENERAL INFORMATION:
Well has had a history of problems due to the following checked condmonr: 0 Sand Production, L! Severe Corrosmn,
0 Paraffin, 0 Other such as . . . . . . . . . .

P S.I. back pressure IS maintained on the caring annulus, which 1: nol (cross out o n e ) vented

Gravity of 011 . . "API Specific gravity of brine .../!I 1.

. Bottom Hole Temperature 0 'F 14
Viscosity of Oil: ...... SSU a t ............... "F a n d ........... SSU at the bottom hole temp. of . 'F
Electric Power Supply: 3 .... phase, .6.O..... cycle with secondary voltage of volts and primary Y O I C ~ R P
of fZ500
Calculations indicate a Reda unit designed to pump a desired capacity of 5
0 0 Bbl./Day ratal fluid (oil plus
warer) against a total dynamic head of b.gO6. feet would ftr this well's particular characteristics. T h e calculated
total dynamic head is based o n ( I ) a producing fluid level of .*.??../
feet plus ( 2 ) 35
. . feet of frmron loss in
7aoo feet of a..% .. In. O.D. E U E / o . b tubing plus ( 3 ) .a00
PSI tubmg discharge pressure
Other Information or Remarks: ................... ............. . . . .
. . . . . . . . . . . . .

Yours very truly.

Name

Company

Address

Date . . ... ...... City .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(If above rnformation is submitted as completely as possible, it will greatly facilitate a prompt reply 1
R-144 - Revised 1/20/65.

Fig. 16-15. Request for information form. (Courtesy of Reda Pump Division, TRW Energy Products
Group.)
758

(4) Perforations depth-both measured and true vertical: 7025-7050 ft.

(5) Unusual conditions such as tight spots, dog legs and deviation from true
vertical at desired setting depth.
The casing size and weight determine the maximum diameters of the motor,
pump, and protector components that will physically fit in the well. In general, the
most efficient installation is obtained when the pump having the largest possible
diameter, in the target flow range, is selected.
The depth of the well and the performance determine the maximum setting depth
of the ESP. If the motor is to be set below the perforations, a motor shroud must be
used to provide a flow of well fluid past the motor for cooling. In this example the
pump setting depth is 7000 ft.

Production data

The production data needed for correct pump sizing includes (Fig. 16-15):
(1) Present and desired production rate: 200 bbl/day and 500 bbl/day.
(2) Oil production rate: 0 bbl/day.
(3) Water production rate: 200 bbl/day.
(4) Gas/oil ratio (free gas and solution gas or gas bubble point): 0 cf/bbl.
(5) Static bottomhole pressure and fluid level: 1500 psig at 7000 ft; fluid
level = 3851 ft.
(6) Producing bottomhole pressure and stabilized fluid level: 1100 psig at 7000 ft;
fluid level = 4691 ft.

a
w - lift requirements -
I
3000 - I -
- I
I -
2000 -
I
I -
-
I
I -
I000 -
I
I -
- I
I
I
-

Fig. 16-16. Capacity curve for the example well

 159

(7) Bottomhole temperature: 160°F.

(8) System back pressure from flowlines, separator, and wellhead choke: 200 psig
at the wellhead.
The inflow performance of a well establishes the maximum economic and
efficient rate at which it can be produced. Liquid level data may be used as a
substitute for producing pressures and rates in water or low oil cut wells with no
gas. In this case, a straight-line productivity index ( J ) curve may be used as a
reasonable approximation of well capacity (see Fig. 16-16).
Figure 16-16 graphcally illustrates the J of the above example well. The static
fluid level is at 3851 ft. At a production rate of 200 bbl/day, the producing level is
at 4691 ft. To obtain the pumping fluid level at the 500 bbl/day production, the
curve is extended to 500 bbl/day point at which the pumping fluid level is
approximately 5951 ft.
Most oil wells do not exhibit a straight-line J curve because of interference
caused by gas. The Vogel (1968) technique yields a downward sloping curve that

INFLOW PERFORMANCE RELATIONSHIPS

FOR SOLUTION - G A S DRIVE WELLS

BY: J. V. VOGEL
From SPE Paper 1476
January 1968 JPT
Qo
[Z) MAX = 1 - 0.20 PR
- 0.80 (2;
P, = Static Reservoir Pressure at Producina Zone
PwF= Well Bore Pressure at Producing Zone
Oo = Producing Rate (BPDI at PwF
Q0 Max = Producing Rate at 100%Drawdown PwF= 0

Fig. 16-17. Inflow performance relationships for solution-gas-drive wells. (After Vogel, 1968; courtesy of
the Society of Petroleum Engineers of AIME.)
760

corrects for gas interference. The IPR curve (Fig. 16-17) applies when wellbore
pressure in the producing zone drops below the bubble point resulting in two-phase
flow as the gas breaks out of the fluid. It is extremely important to remember that
the data obtained for t h s approach in sizing an ESP must be both accurate and
reliable to insure proper equipment selection.

Fluid data

The fluid data includes:

(1) Oil API gravity, viscosity, pour point, paraffin content, sand content, and
emulsion tendency; currently, 100% water.
(2) Water specific gravity, chemical composition, corrosion potential, and scale-
forming tendency; specific gravity = 1.1.
(3) Gas specific gravity, composition, and corrosive potential; no gas present.
(4) Reservoir formation volume factor, bubble point pressure, and viscosity-tem-
perature curve; no gas present.
The specific gravity of the produced fluid is directly related to the horsepower
required to turn a given size pump. Although relatively few applications encounter
fluid viscosities high enough to affect pump performance, it is important to be
aware that capacity, head and horsepower correction factors may be required. In
wells with a water cut of 65% or higher, the fluid generally will not require viscosity
correction factors (except for emulsions).
The PVT data are required when gas is present. Various computer programs ( e g ,
COMPSEL, a Reda computer program) for pump selection (discussed later in this
section) contain a subroutine which utilizes Standing’s (1952, 1975) correlations in
approximating the PVT values when actual data are not available. In high GOR
applications, PVT data are very desirable because the three standard correlation
estimates of Standing (1952, 1975), Lasater (1958) and Vasquez and Beggs (1980)
yield large differences in calculated downhole gas volume.

Electric power supply

The electric power supply includes:

(1)Voltage available and frequency: 12,500 V; 60 Hz.
(2) Capacity of the service: adequate.
(3) Quality of service (spikes, sags, etc.): good quality.
The power data is important because it partially determines transformer and
switchboard requirements. Frequency affects pump rotation speed, capacity, and
head.

Selection process

Once the required data have been gathered and analyzed, the first ESP selection
step is to determine the well’s production capacity at a given pump setting depth.
 761

This involves analysis of the inflow performance data as well as desired production
rate. Two key factors that must be considered are the minimum pump intake
pressure (net positive suction head), which the well will permit without pump-off or
gas lock, and the producing rate, which draws the fluid level down to an optimum
level.
The next selection step is to determine the total dynamic head ( T D H ) . The TDH
is the sum of three variables: (a) the true vertical lift distance from the producing
fluid level to the surface, (b) friction loss in the tubing string, and (c) discharge
pressure head at the wellhead. The design T D H determines the number of stages
required in a pump.
In the above-described example, the J is calculated by taking the present
production rate of 200 bbl/day divided by 4691 ft pumping fluid level minus the
static fluid level of 3851 ft. Thus, J is equal to 0.2381 bbl/day/ft of drawdown.
Next, the pumping fluid level is calculated at the 500 bbl/day rate. Dividing 500
bbl/day by 0.2381, gives 2099.96 ft drawdown. On adding t h s 2099.96 f t of
drawdown to the 3851 ft of static fluid level, a pumping fluid level of 5950.96 f t is
obtained.
The total head that must be developed by the pump will consist of the lift, the
tubing friction loss, and the wellhead pressure. The 200 psi wellhead pressure is
converted to feet of head by first calculating a pressure gradient for the 1.1 specific
gravity brine. The latter is multiplied by 0.433 psi/ft gradient for fresh water to
obtain 0.4763 psi/ft fluid gradient for the 1.1 specific gravity brine. On dividing the
200 psi wellhead pressure by the salt water gradient of 0.4763 psi/ft, the head of
419.9 ft is obtained.
The tubing friction loss can be calculated from Fig. 16-18. The figures for the old
tubing are used in order to be on the conservative side. In this particular example,
the tubing friction loss at 500 bbl/day is 5 ft per thousand feet and with 7000 ft of
tubing a total tubing loss is 35 ft: (7000/1000) X 5 = 35. To obtain the total
dynamic head requirements, the 5950.96 f t is added to the 35 ft of tubing friction
loss and 419.9 ft wellhead pressure (which in this example represents 200 psi
pressure at the surface). Thus, total head requirement is equal to 6405.86 ft.
Selection of a specific pump involves identifying a pump of the largest possible
diameter whch can be run in the well. The pump should have the target capacity
within its recommended operating range and close to its peak efficiency. The initial
pump capacity selection can be made from Table 16-11, for example, which lists all
Reda pumps grouped by series for various casing sizes. The first group is the “A”
series pumps which will go inside 4i-in. O.D. casing. The next group is the “400”
series pumps that will go into 5;-in. O.D. casing. In the recommended range
column, it is necessary to identify the pump that is in the 500 bbl/day range in
5:-in. casing. It is the D-550 pump that will fit this particular set of conditions.
The individual pump curve should then be reviewed to determine the optimum
producing range and the proximity of the design producing rate to the pump’s peak
efficiency (see Fig. 16-19 for a typical pump performance curve). It is very
important to choose a producing rate which is in the recommended capacity range
 LOSS OF HEAD DUE TO FRICTION
FRICTION OF WATER I N P I P E AS LISTED
LOSS PER BASED ON WILLIAM & HAZEN TABLES
I uuu
NEW - SCHEDULE 40 NEW P I P E
1

1 2 3 . 4 5 678910 2 3 4 5 678910 2 3 4 5 67a910

BPD X 100 BPD X 1000 BPD X 10,000
3 5 10 15 20 30 50 100 150 200 300 500 1000 1500 2000 3000
GALLONS PER MINUTE

Fig. 16-18. Determination of friction loss in tubing. (Courtesy of Reda Pump Division, TRW Energy Products croup.)
 763

TABLE 16-11
Engineering tables for the initial pump capacity selection (pumps 60 Hz/3500 rpm) (Courtesy of Reda
Pump Division, TRW Energy Products Group)

Series Outside Pump Max BHP a Capacity range

diameter type rating for recommended limits
(inches) pump shaft
(BPD) (m3/D)
338 3.38 A400 94 280-500 45 - 80
AN550 94 425-700 68-111
AN900 94 660-1 100 105-175
A1200 94 875-1575 139-250
A1500 125 1100- 1900 175-302
400 4.00 DN280 44 100-450 16-72
D400 94 280-550 45-81
DN450 94 320-575 51-91
D550 94 375-650 60-103
D700 94 500-900 80- 143
D950 125 600-1150 95-183
DNlOOO 125 760-1250 121-199
DN1300 125 975-1650 155-262
D1350 125 950-1800 151-286
DN1750 125 1200-2050 191-326
D2000 125 1400-2450 223-390
DN3000 256 2 100- 3700 334-588
DN4000 256 3400-5000 540-795
450 4.62 EN1250 160 950-1600 151-254
El450 160 1050-1800 167-286
EN3600 256 2800-4500 445-715
540 5.13 G2000 256 1500-2500 238-397
GN2500 256 2000-3 100 318-493
G2700 256 2100-3400 334-541
G3100 256 2200-3700 350-588
DN4000 375
GN5200 375 4200-6600 668- 1049
G5600 375 4500-7250 715-1153
GN7000 375 5500-8500 874-1351
GNlOOOO 637 8000-12000 1272-1908
562 5.62 HN13000 375 9200-16400 1463-2607
650 6.62 IN7500 637 6000-9500 954-1510
IN10000 637 8000-12250 1272-1948
675 6.75 JN16000 637 12800- 19500 -
2035 3100
JN21000 637 16000-25000 2544,3795
862 8.62 M520 631 12000-24000 1908-3816
M675 637 19000-32500 3021-5167
950 9.50 N1050 1000 24000-47500 3816-7552
1000 10.00 N1500 1000 35000-59000 5564-9380
1125 11.25 P2o00 lo00 53600-95800 8521- 15240

aFor additional shaft horsepower capability contact a TRW Reda company. Note: Larger capacity
pumps of larger horsepower are available upon request.
 164
0
m
8
s
0
N
m

Fig. 16-19. Typical pump performance curves.

-a
.-a
i-"

P
s
m
 765

of the specific pump. When a pump is operated outside this range, premature failure
can result. The recommended operating range for 60 Hz is defined by vertical lines.
The D-550 pump has an operating range of 380-650 bbl/day, and the 500 bbl/day
rate falls near the peak efficiency range of the pump. By intersecting the head
capacity curve at the 500 bbl/day rate, one can determine that the D-550 pump
develops approximately 22.40 ft of head per stage (2240/100 stages = 22.40 ft per
stage). The horsepower motor load curve is used similarly. Each stage will require
approximately 0.175 horsepower per stage.
Once a pump is chosen, the number of stages required can be calculated using the
lift (ft) per stage data from the performance curve:

TDH (ft)
Number of stages = (16-1)
Lift/stage( ft)

The horsepower required by the pump design can then be calculated. To accomplish
this, the horsepower required per stage is read from the specific pump performance
curve. The required motor horsepower is determined by multiplying the horsepower
required per stage by the number of design stages. The performance curve horse-
power data applies only to liquids with a specific gravity of 1.0. For liquids having
other specific gravities, the water horsepower must also be multiplied by the specific
gravity of the fluid pumped. Thus, the following equation can be used for the
horsepower calculation:

HP = (HP/stage) x (Number of design stages) X (sp. gr.) (16-2)

In the present example, the total head required is 6405.86 ft and the rate is 500
bbl/day of 1.1 specific gravity water. To determine the number of stages required,
the total head of 6405.86 ft must be divided by 22.40 ft/stage. T h s equals 285.98,
which rounds off to 286 stages. To determine the horsepower required to drive the
286-stage pump, the horsepower per stage of 0.175 is multiplied by the 286 stages
and then by the 1.1 sp. gr. to get a horsepower requirement of 55.06, whch may be
rounded off to 55 horsepower.
Once the design motor horsepower is determined, specific motor selection is
based on setting depth, casing size and motor voltage. Although the cost of the
motor is generally unrelated to voltage, overall ESP system cost may be lowered by
utilizing higher voltage motors in deep applications. This lower cost can sometimes
occur because a higher voltage can lower the cable conductor size required. A
smaller conductor size (lower-cost cable), can more than offset the increased cost of
a higher-voltage switchboard. Setting depth is a major variable in motor selection
because of starting and voltage drop losses, which are a function of the motor
amperage and cable conductor size.
Table 16-111 lists the most common Reda motors and voltages. The 375-series
motors go in 44-in. O.D. casing. The 456-series motors will go in 54-in. O.D. casing,
766

TABLE 16-111
List of the most common Reda motors and voltages
Moms 60 Hz
375 Series 456 Serles 540 Series
13 75" 001 14 56" 001 1543" 001
HP Volrs AMP HP Volts AMP HP Vnlt? AMP
75 415 13 5 10 435 15
10 5 400 20 15 23
655 16
20 28 5
15 330 34 750
450 17
415 27 25 410 39
13 5 415 35 690 22
30 425 44 5
650 22 5 25 5
2; i 440 38 5 1260
750 150
750 22 5 35 385 57
675 33
22 E 650 29 5 785 28
7Rn 74 5 40 59
110
430 33
880 29
1340 19
675 47
Tandem Mo'ors 50 815 39
30 630 35 5 955 33
1390 23
39 575 51
640 59
60 745 52
45 660 51 5 810 41
51 740 51 970 39
1330 29
1000 37 540 82 5
1250 31 10 750 60
58 5 860 51 945 47
1135 39
67 5 990 51 5 80 635 80
76 5 1110 51 860 60
1085 46
90 1320 51 5 1310 39
102 1480 51 710 81
1125 1650 51 5 90 960 59
1135 50
1275 1850 51 1220 46
1460 39
1960 29
100 80
920 70
738 S e w 1075 59
1355 46
2205 28 5
110 1190 60

220 1325 110 '" 945

1125
1295
81
70
59
Tandem Motors
240 2275 70 2245 35 1710 88
240 2060 73
260 2280 76 2590 59
340 2235 101 Tandem Motors
1850 88
1 80 a2 5 260 2250 67
14@ 1:oo 60 300 2150 87
1890 47
2270 39 320 1650 122
160 1270 80 2230 88 5
Tandem Motors
1720 60 360 1890 120
400 2300 115 2',70 46 2250 89
440 2050 142 2620 39 400 2200 115
480 2230 143 180 1420 81 450 2270 127
1920 59 480 2415 122
520 2420 143 2270 50 3345 88 5
600 3450 115 2440 46 540 2835 120
2920 39
680 3170 142 200 1580 ao 600 3300 115
720 3345 143 1840 70
2150 59
2710 46
220 2380 60
,890 a1
240 2250 70
2590 59
 161

540-series motors will go in 64-in. O.D. casing, and the 738-series motors will go
into 84-h. O.D. or larger casing.
In the 456-series motors, a 60-HP motor is the closest size to the requirement of
55 HP. There are several voltages listed for this motor horsepower. The reason is
that with a very shallow setting, one could use a lower-voltage motor resulting in a
less expensive switchboard. In this particular case, with a 7000-ft setting, it is
desirable to maintain a reasonably high motor voltage to keep the amperage down
to a low level whch will allow the use of a smaller size cable. Thus, one can select
the 60-HP, 970-V, 39-A motor.
Cable selection variables are amperage, voltage drop, annulus clearance, ambient
well temperature, and corrosion conditions. The recommended maximum voltage
drop should be limited to 30 V per thousand feet. If voltage drop exceeds this value,
a larger conductor size should be used. Round cable is normally used unless tubing
collar-annulus clearance dictates flat or parallel construction. The maximum oper-
ating temperature of a cable in relation to the specific well's ambient temperature
determines the specific type of cable. Armor and lead sheathing may be recom-
mended in a well with mechanical or clearance problems or in the presence of
corrosive gas such as H,S.
For the present example, Fig. 16-20, which shows cable voltage drop losses, can
be used to determine the size of a cable that is appropriate for a 35.75-A motor [ ( 5 5
HP/60 HP) X 39 A].
In this particular installation, size No. 4 cable can be selected. Referring to Fig.
16-20 at 35.75 A, in the case of the size No. 4 cable there is less than 3% loss per
thousand feet. With 7000 f t of cable, voltage drop loss is 147 V from the surface to
the motor: [(7000/1000) x 211. In order to determine the required surface voltage,
the 970 V requirement of the motor is added to the 147 V loss in the cable. Thus, a
total of 1117 V is required.
The surface electrical equipment (switchboard and transformer(s)) selection is
based on the required motor horsepower, voltage, amperage, voltage loss, and cable
size. The surface voltage is the sum of the downhole motor no-load voltage plus the
voltage losses due to cable size and other component losses. Voltage losses associ-
ated with transformers range from 2.5 to 6% depending on the manufacturer.
Additional impedance is associated with VSD transformer sizing. Transformers
must also be selected based on the primary voltage available and the required
hookup method: Delta Delta, Y Delta, or Delta Y.
To obtain the KVA requirement for the transformer bank, the total voltage
required is multiplied by the current (A) and by the square root of 3 for three-phase
power and' then divided by 1000: (1117 V X 35.75 A X 1.73): 1000 = 69.084 KVA.
The transformer banks are normally made in sizes of 25 KVA, 37f KVA, 50 KVA,
75 KVA, etc. A bank of three 25-KVA transformers gives a total KVA of 75, which
will be more than adequate for the 69.084 KVA needed in this installation.
The next step is the switchboard selection for this particular installation. There
are several types of switchboards available starting with the DFH-2 switchboard for
a 440-V installation. The MFH switchboard is for voltages up to 1000 V and the
 u
4

0 1
U
m
W e
-I0
mc
mu
06
r
a
U
I-

768
Fig. 16-20. Voltage drop chart. (Courtesy of Reda Pump Division, TRW Energy Products Group.)
 769

MDFH switchboard is for voltages up to 1500 V. Larger switchboards are for 2400-
and 5000-V installations. In this example, a size 3 MDFH switchboard is selected.
Size 3 would give a maximum current of 100 A and a voltage capability of up to
1500 V.
The protector selection variables are motor and pump series, motor horsepower,
and well temperature. Normally the protector is of the same series as the pump and
motor. Large horsepower motors (150 HP and larger) may require a larger oil
capacity. For large horsepower motors, one can use, for example, a Positive Seal
Double Bag model or a tandem “Labyrinth Path” model (Reda motors). An
ambient well temperature of 250°F or higher generally requires the use of the
“Labyrinth Path” protector.
Figure 16-21 lists the flat cable extensions for various motor sizes. In the present
example, inasmuch as the bottomhole temperature is 160”F, one can select the
standard flat cable material, which is described as 3KV KEOTB. If the bottomhole
temperature was, for example, 180”F, one could use a lead-covered flat cable
extension, which is described as 3KV KELB. The length of the flat cable should be
at least 5 f t greater than the length of the protector and the pump, so that the flat to
power cable splice is well above the pump discharge for clearance.
Thus, the major components of the installation have been selected: motor, pump,
protector, flat cable extension, the round cable going to the surface and the
switchboard. The remaining items to complete the installation are the check valve,
the bleeder valve, the tubing head, and the junction box at the surface. The purpose
of the check valve is to prevent fluid from running back to the pump when the unit
is shut down and causing the unit to spin in reverse rotation. It also eliminates the
necessity of filling the tubing each time the pump starts up. The check valve is
normally run 300-500 ft above the pump in a well where gas production is
anticipated. By setting the check valve 300-500 ft above the pump, in the event of
gas lock and pump shut-down, the gas has an opportunity to work out of the pump
and be replaced by liquid fluid for the subsequent startup.
The bleeder valve is normally run one joint above the check valve. It enables
drainage of the fluid from the tubing so that the tubing will not have to be pulled
“wet”. The wellhead is designed to support the tubing string and to enable the
packoff around the cable.
The ESP equipment selection in high water cut, low GOR wells are relatively
straightforward. Equipment selection in high GOR or viscous crude wells, however,
can be very complicated. Reda, for example, has developed a sophsticated com-
puter program called COMPSEL to comprehensively analyze alternative equipment
selections in such situations. COMPSEL can be used to select equipment or to
evaluate previously selected equipment. This capability means that, over time, the
engineer can evaluate the fit of a pump as oil well conditions change. If well inflow
performance changes significantly, the downhole equipment may need resizing both
to optimize production and prevent premature failure.
Pump performance is directly affected by parameters such as the formation
volume factor, GOR, viscosity, volume of free gas in the pump, and water cut.
770

Cable
Flat Cable Extensions
Type Dimensions Weights length
Size Description Series Armor Inches lbs. Ft.
6 3 KV KELTB l t P l 375 Monel 0 420 x 1 050 34 40 0
6 3 KV KELTB l t P l 375 Monel 0 420 x 1 050 47 55 0
6 3 KV KELTB l t P l 375 Monel 0 420 x 1 050 59 70 0
Price Adder Per Foot
6 3 KV KEOTB 456 Gab 0 484 x 1 142 29 40 0
6 3 KV KEOTB 456 Galv 0 484 x 1 142 39 55 0
6 3 KV KEOTB 456 Galv 0 484 x 1 142 49 70 0
Price Adder Per Foot
6 3 KV KEOTB 456 Monel 0 484 x 1 142 27 40 0
6 3 KV KEOTB 456 Monel 0 484 x 1 142 37 55 0
6 3 KV KEOTB 456 Monel 0 484 x 1 142 47 70 0
Price Adder Per Foot
6 3 KV KELB 456 Galv 0 485 x 1 150 44 40 0
6 3 KV KELB 456 Galv 0 485 x 1 150 60 55 0
6 3 KV KELB 456 Galv 0 485 x 1 150 77 70 0
Price Adder Per Foot
6 3 KV KELB 456 Monel 0 485 x 1 150 42 40 0
6 3 KV KELB 456 Monel 0 485 x 1 150 58 55 0
6 3 KV KELB 456 Monel 0 485 x 1 150 74 70 0
Price Adder Per Foot
4 3 KV KEOTB 540 Galv 0 531 x 1 280 36 40 0
4 3 KV KEOTB 540 Galv 0 531 x 1 280 50 55 0
4 3 KV KEOTB 540 Galv 0 531 x 1 280 63 70 0
Price Adder Per Foot
4 3 KV KEOTB 540 Monel 0 531 x 1 280 35 40 0
4 3 KV KEOTB 540 Monel 0 531 x 1 280 48 55 0
4 3 KV KEOTB 540 Monel 0 531 x 1280 61 70 0
Price Adder Per Faor
4 3 KV KELB 540 Gab 0 520 x 1 245 54 40 0
4 3 KV KELB 540 Galv 0 520 x 1 245 74 55 0
4 3 KV KELB 540 Galv 0 520 x 1 245 94 70 0
Price Adder Per Foot
4 3 KV KELB 540 Monel 0 520 x 1 245 52 40 0
4 3 KV KELB 540 Monel 0 520 x 1 245 72 55 0
4 3 KV KELB 540 Monel 0 520 x 1 245 91 70 0
Price Adder Per Foot
4 3 KV KEOTB 738 Galv 0 531 x 1 280 36 40 0
4 3 KV KEOTB 738 Galv 0 531 x 1 280 50 55 0
4 3 KV KEOTB 738 Galv 0 531 x 1 280 63 70 0
Price Adder Per Foot

Fig 16-21 Flat cable extensions for various motor sizes (Courtesy of Reda Pump Division, TRW Energy
Products Group )
 771

These factors result in greater intake volume than realized at stocktank conditions.
Under routine conditions of high water cuts, no produced gas, low viscosities, etc.,
the previously described selection technique is sufficient. If, however, the free
produced gas or fluid viscosity is of sufficient magnitude to influence “normal”
pump performance, a COMPSEL study using the best available productivity and
PVT data should be used to accommodate the complexities of these factors.
The COMPSEL program contains analytic models for pump performance, re-
servoir response and fluid characteristics. It utilizes the Chew and Connally (1959)
correlations for live fluid viscosity based on the quantity of gas in solution. Another
option uses Orkiszewski’s (1967) two-phase vertical flow model to compute pump
discharge pressure and horsepower required. Standing’s (1952) correlations are used
to provide surrogate PVT data when actual values are not available.
The fluid intake volume (oil, water and free gas) can be fixed by inputting the
surface production and intake pressure, or the program can utilize a subroutine to
calculate drawdown, flowing bottomhole pressure, etc., using the straightline J
method. This calculation can be refined, when producing conditions are below the
bubble point of the oil, by using the subroutine incorporating the Vogel (1968)
technique (IPR method). If PVT data (oil formation volume factor and solution
GOR versus pressure) are not available for use in the COMPSEL calculations, the
subroutine incorporating Standing’s correlations is automatically utilized in the
program.
Basically, COMPSEL has two semi-independent logical functions: selection and
simulation modes. In selection mode, the program takes a set of inpu‘t data,
including well, fluid, and reservoir characteristics, and selects an optimal submersi-
ble pump configuration based on a non-overlapping set of optimal flow limits.
Conceptually, the program does nothing which could not be done by hand; but the
time required to accurately compute manually the pressure, temperature, and fluid
conditions between every stage during a pump selection would make pump analysis
tedious and difficult.
In a selection case, all data of pump intake are calculated first, an initial stage is
then selected, and the performance for that first stage is computed. A new pressure,
at the top of that stage, is estimated by adding the pressure developed by the first
stage to the suction pressure. At this new pressure, a new total fluid flow is
calculated and a new stage selected. In this manner, as shown in Sample Problem
16-1, the pump is built up from the bottom. The key to the selection case lies in the
program’s ability to calculate a new pressure and, consequently, a new flow and
pressure gradient between each stage of the pump. The new flow rate is significant
because the total flow determines the next stage selection. The flow changes from
stage to stage because, as pressure and temperature increase, gas compressibility and
solubility change as do the water and oil viscosities (and the dissolved gas effect on
formation volume factor). The pressure gradient (density) change is significant
because, in general, the pressure developed by a stage is the gradient times the head
in feet, corrected for viscosity. Thus, the selection mode in COMPSEL monitors and
updates each of these variables at each stage in the pump selection.
772

In simulation mode, COMPSEL allows the user to input a pump configuration

and production environment and then computes for the user the expected flow rate
under the input conditions. T h s technique determines the overall efficiency of the
system and points out conditions that may dictate resizing the pump to avoid
excessive pump wear or performance deterioration due to a stage acting as a choke.

HANDLING, INSTALLATION AND OPERATION

This section provides recommended practice on the handling, installation and

operation of an ESP system. Because both safety and economic run-life are
dependent on correct procedures, the importance of following the recommended
practice cannot be overemphasized.

Handling

The downhole components, i.e., motor, pump, protector, and intake, are shipped
in a metal shipping box (see Fig. 16-22). The shipping boxes are painted red on one
end which should be placed toward the wellhead when the equipment is delivered to

Fig. 16-22. Shipping boxes positioned at the wellhead.

 113

0‘

Fig. 16-23. Cable handling procedures

the wellsite. The shpping boxes should be lifted with a spreader chain or bridled
with a sling at each end. Severe equipment damage can result from dropping,
dragging, or bouncing the boxes. The shipping boxes should never be lifted by the
middle of the box only.
The cable reel should be lifted using an axle and a spreader bar (see Fig. 16-23).
If a fork lift is used, the forks should be long enough to support both reel rims when
the reel is picked up from an end. The ends of the cable should be covered or sealed
to protect against corrosion.
Transformers and switchboards are provided with lifting hooks. To avoid damage,
the recommended practice is to lift with a spreader bar in order to maintain a
vertical position. Variable-speed drives are normally skid mounted with fork lift
slots and lifting eyes. Some VSD models are manufactured with pull bars.
Additional information on ESP handling and installation procedures is available
in the American Petroleum Institute publication entitled “API Recommended
Practice for Electric Submersible Pump Installations” (American Petroleum In-
stitute, 1980).

Installation

There are three steps to every ESP installation: (a) well preparation, (b) site
layout, and (c) running equipment in the well and start-up. The well preparation
procedure involves determining the downhole clearance conditions. Site layout
prescribes equipment and rig locations as well as size and capacity. Running
equipment in the well and start-up procedures include equipment handling, testing,
and responsibility of the rig crew and servicemen.
Prior to beginning installation of the ESP equipment, the well must be cleared of
any tubing, rods, packers, etc., that would prevent the downhole equipment from
114

reaching target setting depth. The casing flange and wellhead should be examined
for burrs or sharp edges. T l s is very important in small-diameter casing, because
cable damage can be caused by burrs or edges catching cable bands.
A gauge ring should be run in (particularly in 44-in. and smaller casing) to below
the setting depth of the downhole equipment. If gauging indicates tight spots, a
scraper or reamer should be used to remove the obstruction (scale, paraffin, burrs,
or partially collapsed casing). This will ensure adequate clearance for the ESP
downhole equipment as it is run into the well.
The BOP (if used) should be checked for adequate clearance as well as burrs and
sharp edges. Cut-out rams are available for most tubing and cable sizes. They
should be installed in the BOP for well control in the event of a “kick” during
equipment installation.
The pulling unit should be centered over the well as closely as possible. A guide
wheel-cable sheave should be safely secured to the rig mast no higher than 30-45 ft
above the wellhead. The guide wheel should be at least 54 in. in diameter.
The cable reel or spooling truck should be positioned about 100 ft from the
wellhead in direct line of sight of the rig operator. One person should be responsible
for the cable operation. The responsibilities of this person are to insure: (a) that
there is a minimum tension on the cable-the cable should be run at the same speed
as the tubing, (b) that the cable is kept clear of power tongs during tubing make-up
or break, and (c) that no one stands in front of the cable reel-spooler.
The cable junction box must be located at least 15 f t from the wellhead (see Fig.
16-16). The switchboard must be located a minimum of 50 ft from the wellhead and
a minimum of 35 ft from the junction box. The junction box is normally located 2-4
ft above ground level to insure adequate air circulation and easy access. The
junction box must never be located inside a building.
The pump manufacturer’s field representative checks all equipment prior to
installation. During installation, his responsibility is to supervise the pulling and/or
running of the downhole equipment. All equipment delivered to the wellsite is
checked to determine that all components necessary to complete the installation
have arrived and are not damaged.
Once the equipment, cable, and verification procedures are completed, the
assembly and run-in of downhole equipment can begin. The manufacturer’s field
representative directs the assembly and checks equipment as it is being run-in. Once
the run-in procedures are completed and final electrical tests are made, the manu-
facturer’s representative will complete the electrical connections. The switchboard
underload and overload adjustments are set according to the conditions expected
for each well. The pump is then started. Fluid pump-up time and load and no-load
voltage and amperage on each phase are recorded. Phase rotation should be
carefully checked to insure that the pump is rotating in the correct direction.
The quantity of production of oil, gas, and water should be monitored on
start-up and then regularly for the time required to achieve stability. A careful study
should be made on a pump installation that does not produce as designed. As much
information as possible should be gathered to aid in specific identification of the
 775

problem and appropriate remedial action. This will insure that subsequent installa-
tions will provide satisfactory run-life.
Pulling equipment out of a well involves essentially the reverse process of run-in.
The equipment and cable should be handled with the same care as when new
because it is still valuable. Cable damage and missing bands should be recorded at
the depth they occurred to aid in subsequent repair and evaluation. If the equipment
failure is judged to be premature, the condition of cable, flat cable, pump rotation,
and motor-protector fluid may be useful in determination of the cause of the
failure.

TROUBLESHOOTING

The purpose of this section is to outline a recommendation for identification and

solution of typical ESP problems. The only way a failure can be analyzed, and a
solution reached as to its cause, is by data collection. When a problem occurs, one
should have as much information as possible.
Data which should be routinely compiled on each ESP well is:
(1) Production:
(a) Water, oil, and gas.
(b) Run-life.
(c) Unit starts and stops.
(d) Dynamic and static fluid levels.
(e) Pump setting and perforation depths.
(2) Ammeter charts.
(3) Well conditions (presence and amounts of abrasives and corrosives, e.g., H,S).
(4) Electric power quality (surges, sags, balance, negative sequence voltages, etc.).
(5) Visual observations of equipment and cable condition on prior pulls.
(6) Reasons for equipment pull (failure, workover, size change, etc.).
(7) Bottomhole temperature (BHT).
When an ESP well is first put on production, data should be collected daily for
the first week, weekly for the first month, and a minimum of monthly after the first
month. Production data during the first month is very important, because it will
indicate if the pump is performing as designed. If a downhole pressure instrument is
installed, operating bottorrihole pressure (BHP) is equally important.
The major source of information when troubleshooting an ESP installation is the
recording ammeter. The recording ammeter is a circular strip chart accessory
mounted in the switchboard, which records the amperage drawn by the ESP motor
(see Fig. 16-24). A number of changes in operating conditions can be diagnosed by
interpreting ammeter records.
Ammeter chart “reading” identifying typical problem situations is .described
below.
Normal operation
A normal chart (Fig. 16-24) is smooth with amperage being at or near motor
nameplate amperage draw. Actual operation may be either slightly above or below
116

Fig. 16-24. Normal ammeter chart. (Courtesy of Reda Pump Division, TRW Energy Products Group.)

nameplate amperage. As long as the curve is symmetric and consistent over time,
however, operation is considered normal.

Normal start-up

A normal start-up will produce a chart similar to that shown in Fig. 16-25. The
start-up “spike” is due to the inrush surge as the pump comes up to the operating
speed. The subsequent amperage draw is high but trends toward a normal level.
This is principally due to the fluid level being drawn down to the design TDH,
resulting in a high but declining amperage draw.
 777

Fig. 16-25. Normal start-up ammeter chart. (Courtesy of Reda Pump Division, TRW Energy Products
Group.)

Power fluctuations

Operating ESP amperage will vary inversely with voltage. If system voltage
fluctuates, the ESP amperage will inversely fluctuate to maintain a constant load
(Fig. 16-26). The most common cause of this type of fluctuation is a periodic heavy
load on the primary power system. This load usually occurs when starting-up
another ESP or other large electric motor. Simultaneous start-up of several motors
should be avoided to minimize the impact on the primary power system. Ammeter
spikes can also occur during a thunderstorm accompanied by lightning strikes.
778

Fig. 16-26. Chart showing ammeter spikes (power fluctuations). (Courtesy of Reda Pump Division, TRW
Energy Products Group.)

Gas locking

Gas locking occurs as fluid level drawdown approaches the pump intake and
intake pressure is lower than the bubble point pressure. This situation is shown in
Fig. 16-27. This ammeter chart shows a normal start-up and amperage decline as the
fluid level is drawn down. The chart shows erratic fluctuations, however, as gas
breaks out near the pump beginning at approximately 6:15 a.m. As the fluid level
continues to draw down, cyclic loading of both free gas and fluid slugs leads to
increasingly wider amperage fluctuations, ultimately resulting in shutdown at ap-
proximately 7:15 a.m. due to undercurrent loading.
 119

Fig. 16-27. Ammeter chart showing gas locking. (Courtesy of Reda Pump Division, TRW Energy
Products Group.)

There are three possible remedies for gas locking: (a) installation of a gas
separator intake and/or a motor shroud; (b) lowering of the setting depth of the
pump (but not lower than the perforations unless the motor is shrouded); and (c)
reducing the production rate of the pump by using a surface choke (but insuring
that the production rate remains within the recommended range for that pump). If
the above solutions are not satisfactory, the pump should be replaced with a pump
that does not drawdown the fluid level, or the intake pressure must be reduced
below the bubble point pressure.
Another possible solution is to add a variable-speed drive (VSD) to the existing
system. The VSD controls the speed of the pump which, in turn, controls the pump
780

Fig. 16-28. Ammeter chart illustrating fluid pump-off. (Courtesy of Reda Pump Division, TRW Energy
Products Group.)

capacity. Thus, the pump output can be fine-tuned to protect against pump-off and
gas lock while contributing to improved pump life.

Fluid pump-off

Fluid pump-off occurs typically when an ESP is too large in relation to the inflow
capacity of the well. This condition is illustrated in Fig. 16-28. This chart shows a
normal start-up at 7:OO a.m. and normal operation until approximately 1O:OO a.m.
Then amperage draw begins to slowly fall until the underload setting is reached and
 781

the pump is shut-down about 2:15 p.m. Subsequent automatic restarts at 4:15 p.m.
and 8:15 p.m. produce similar results.
The remedial actions are much the same as those listed for gas lock and, in
addition, a well stimulation treatment may increase the well’s productivity closer to
a match with the pump.
In general, cycling an ESP is not conducive to optimum run-life. As a temporary
measure, the amount of time delay before automatic restart can be increased if the
switchboard is equipped with a Redalert motor controller, for example. This may
allow the fluid volume to build up to prevent as high a frequency of shutdown

Fig. 16-29. Ammeter chart showing excessive cycling. (Courtesy of Reda Pump Division, TRW Energy
Products Group.)
782

occurrence. Nevertheless, the pump and well are not compatible and the pump
should be checked as to size on the next changeout, or the well must be worked over
to improve productivity.
A form of frequent, short-duration cycling is shown in Fig. 16-29. This shows an
extreme pump-off condition. Although the initial reaction is to suspect a badly
oversized pump, there may be another cause. If a fluid level sounding, taken
immediately after pump shutdown, indicates fluid over the pump, the problem may
be a tubing leak or a restricted valve or discharge line. A tubing leak is typically
accompanied by somewhat low discharge pressure and low surface production rate.

Fig. 16-30. Ammeter chart illustrating gassy conditions. (Courtesy of Reda Pump Division. TRW Energy
Products Group.)
 783

If shutdown is due to a plugged valve or discharge line, tubing pressure should be

abnormally high.

Gassy conditions-emulsion

An ammeter chart of gassy but normal producing well is shown in Fig. 16-30.
The continuous amperage fluctuations result from alternating free gas and heavy
fluid pumping. Generally, this condition results in a reduction of stocktank barrels
in relation to pump design rate. This figure is also typical of an emulsion. The

Fig. 16-31. Ammeter chart illustrating presence of solids and debris. (Courtesy of Reda Pump Division,
TRW Energy Products Group.)
784

amperage fluctuations are caused by the frequent, temporary blockage of the pump
intake. If it is an emulsion block, spikes are normally lower or below the normal
amperage line.

Solids-debris

When debris or solids are found in a well, the amperage will display fluctuations
immediately after start-up. This condition is shown in Fig. 16-31. Typically, when
solids such as sand and scale, or weighted mud are found in a well, special care must

Fig. 16-32. Ammeter chart showing overload condition. (Courtesy of Reda Pump Division, TRW Energy
Products Group.)
 185

be taken on start-up to avoid pump damage. It may be necessary to put back

pressure on the well to prevent excess amperage until the kill fluid is removed
and/or sand production begins to decline to a safe volume.

Overload shutdown

A pump will also automatically shutdown in an overload condition. This condi-

tion is shown in Fig. 16-32. When an overload condition shutdown occurs, however,
the unit must not be restarted until the cause of the overload has been identified and
corrected. Some motor controller overload detection circuits contain a built-in time
delay, ranging from 1-5 sec at 500% of the set point to 2-30 secs at 200% of the set
point; they will not automatically restart the unit on an overload condition. A
restart attempt in an overload condition can destroy the downhole equipment if the
cause of the overload is not first identified and corrected.
The most common causes of an overload condition are increased fluid specific
gravity, presence of sand, emulsion, and of scale, electric power supply problems,
worn equipment, and lightning damage.

EXAMPLE PROBLEM 16-1-PUMP SELECTION ON A WELL WITH A HIGH PRODUCING

GOR

Given :
Casing size and weight: St-in.; 17 lb/ft
Tubing size, weight and thread: 2;-in.; 8rd EUE
Well depth (measured and true vertical): 7200 ft
Perforations depth: 7025-7050 ft
Present and desired production rate: 500 bbl/day
Oil production rate: 250 bbl/day
Water production rate: 250 bbl/day
Gas/oil ratio: 500 scf/bbl
Static bottomhole pressure: unknown
Producing bottomhole pressure and fluid level: 500 psi at 7000 ft
Bottomhole temperature: 160'F
Wellhead temperature: 120°F
System back pressure (flowlines, separator, and wellhead): 200 psi at wellhead
Oil gravity (API): 35" API; viscosity; pour point; paraffin content; sand and
emulsion tendency.
Water specific gravity: sp. gr. = 1.1; chemical content; corrosion potential; and
scale tendency.
Gas specific gravity: 0.65 with respect to air
Reservoir formation volume factor: FVF = B = 1.077; bubble point; and
viscosity- temperature curve.
In t h s example, it is assumed, that the gas ingestion percentage ( G I P ) is 50%,
i.e., that 50% of the free gas is produced through the pump and the remaining 50% is
786

2 ,33%,:7f,D6,39? k3tR75°/*G'P
3 500 STBPD 500 GOR 100%GIP
3200 50% OIL, 50% W A T E ~
4 500 STBPD, A L L WATER

-
2800

i,
2400-
a
-
g 2000-
3
Y) -
$ 1600-
n. -
-
1200-

-
800
-
400 -
I 2 3

'0 200 400 600 800 I000 1200 1400

CAPACITY, bbl/day

Fig. 16-33. Capacity curves for example problem 16-1. BHT = 160 O F .

produced up the annulus. The first step is to determine the pump discharge pressure
required in this well. This can be done using any one of several multiphase flow
correlations. The most commonly used methods are those of Hagedorn and Brown
(1965), Orkiszewski (1967), Duns and Ros (1963), Beggs and Brill (1973), and
Poettmann and Carpenter (1952).
Figure 16-33 shows four different oil, water, and gas combinations producing 500
stocktank barrels:
(1) 100% water
(2) 50% water; 50% oil; 50% GIP; GOR = 500 scf/bbl
(3) 50% water; 50% oil; 75% GIP; GOR = 500 scf/bbl
(4) 50% water; 50% oil; 100% GIP, GOR = 500 scf/bbl
As a higher percent of free gas is produced through the pumps (GIP), discharge
pressure decreases. The intake volume at the pump, however, increases dramatically.
In t h s example, the Hagedorn and Brown (1965) correlations are utilized. The
vertical flowing pressure gradients are presented in Fig. 16-34. In order to utilize
tlus correlation, the gas/liquid ratio (GLR)must be calculated first. Then the pump
discharge pressure is determined.

R, = ( R - R , intake) GIP + R , = (500 - 80) X 0.5 + 80 = 290 scf/bbl

and

GLR through the pump = R , X GIP = 290 X 0.5 = 145 scf/bbl,

 787

a 4 8 12 16 20 28

Fig. 16-34. Vertical flowing pressure gradients for various gas/liquid ratios (50% water and 50% oil).
(Courtesy of Reda Pump Division, TRW Energy Products Group, and PennWell Publishing Company:
Brown, 1980, p. 454.)

where R, = cumulative produced gas/oil ratio, scf/bbl, R = total producing gas oil
ratio, scf/bbl; R , = solubility of gas in oil at 500 psi (gas in solution), scf/bbl;
GIP = gas ingestion, percent; and GLR = gas/liquid ratio, scf/bbl.
Using Fig. 16-34, the 200 psi wellhead pressure is equal to 1500 ft of head. Thus,
+
the total head at 7000 f t is equal to: 7000 1500 = 8500 ft. Given 8500 f t head and
788

a GLR of 145 scf/bbl, from Fig. 16-34 the pressure required to flow is 2630 psig at
the pump discharge.
Next, the volume at the pump intake and successive stages is computed given the
bottomhole temperature and pressure:

Volume intake = (oil + dissolved gas) + (water) + (gas)

Y n = qo(1- 4)'0 + qO(W,)Bw + qo(1- K > ( R- Rs)(Bg)(GIP)
where qo = total fluid; Wc= percent water cut; B, = formation volume factor (FVF)
for oil; B, = formation volume factor of water; Bg= formation volume factor of
gas; R,= solubility of gas in oil, scf/bbl; R = total gas/oil producing ratio,
scf/bbl; and GIP = gas ingestion percent.
Standing's correlations are used here to determine the solution gas/oil ratio at
various pressures and the formation volume factor of oil. Refer to Figs. 16-35 and
16-36.
(a) Determine how many scf of gas are dissolved in a barrel of oil at 500 psi
intake pressure using Fig. 16-35:
At a pressure of 500 psi, 80 cu ft of gas are dissolved in a barrel of oil at 160°F
BHT.
(b) From Fig. 16-36, at 80 scf/bbl, formation volume factor of oil ( B , ) is equal
to 1.077.
As fluid moves through the pump, pressure increases and volume decreases.
These charts enable the determination of the gas in solution and the B, at each
incremental step in the pump calculation.
V,, = 500(1 - 0.5)1.077 + 500(1 - 0.5) X 500(1 - 0.5) X (500 - 80)0.5(0.00577) =
+
269.25(oil) + 250(water) 302.93(gas) = 822.18 bbl
where 0.00577 = Bg = 0.00504ZT/p = 0.00504 x 0.95 x 620/514.7 (bottomhole
conditions), 2 = 0.95 (compressibility factor obtained from Fig. 16-37; T = 620"R;
and p = 514.7 psia (submergence pressure).
The same method of calculating V,, is used to determine the volume at succes-
sively higher pressures until the discharge pressure of 2630 psi is reached. The
COMPSEL program performs this calculation in one-stage increments. In t h s
example, 50-psi increments are used to shorten the calculation process. On succes-
sive calculations, the value for GZP is 100% and, consequently, R becomes equal to
R,, where: R , = ( R - Rs)GZP+ R,; ( R - R,) = gas going up the casing; and
R , = (500-80)0.5 + 80 = 290 scf/bbl. Gas/liquid ratio through the pump = total
fluid X oil cut = 290 X 0.5 = 145 scf/bbl.
Thus the equation becomes:
in' = q(1- wc>[Bo+ (Wc/' - Wc) + ('p - Rs)Bgl.
For 550 psi:
+ +
V,, = 500(0.5)[1.08 + 1 (290 - 88)0.00539] = 250[1.08 + 1 1.091 = 792.5.
For 600 psi:
V,, = 250(1.084 + 1 + [(290 - 100)0.00480]) = 749 bbl/day.
 -1
W
Fig. 16-35. Determination of bubble point pressure for crude oils from California. (After Standing, 1952; courtesy of Chevron Research Company.) W
 790
EXAMPLE

ffEQUIffED:
Formation vo/ume at POO'F of a
bubble point fiquid having a gar-oil
ratio of 350 CFB, a g a s g r ~ v i t yof 0.75,
a n d a h n k o,/ g r a v i t y o f 30 .AP/.

PRO c E o u a E :
Starting at the / r f t side of the chart,
proceed horizonta//y d u n 9 t h e 350 CFB
/inr to a gas gravgty of 0. 7 5 . From this
point d r o p vwtica//y fo the 30%P/ /in=
Proceed horrzontaNy from fie tank oil
gravity scde to the 200'F h e . The
requirrd formation volume is rbund to be
f.22 barrel ner bar-/ of t a n k od.

-~ ~

FORMATION VOLUME of BUBBLE POINT LIQUID -

Fig. 16-36. Oil formation volume factor of California natural hydrocarbon mixtures of gas and liquid at bubble point. (After Standing. 1952; courtesy of
Chevron Research Company.)
 791

Fig. 16-37. Compressibility factors for a 0.65 gravity natural gas. (After Brown and Beggs, 1977, fig. 2.17,
p. 86; courtesy of PennWell Publishing Company.)

For 650 psi:

+ +
V, = 250(1.093 1 [(290 - 117)0.00441]) = 714 bbl/day.
For 700 psi:
F, +
= 250(1.095 + 1 [(290 - 119)0.00410])= 699 bbl/day.
For 750 psi:
F, + +
= 250(1.097 1 [(290 - 130)0.00380])= 676 bbl/day.
For 800 psi:
+
F, = 250(1.102 1 + [(290 - 138)0.0035])= 658 bbl/day.
For 850 psi:
F, +
= 250(1.109 1 + [(290 - 152)0.0033])= 641 bbl/day.
792

For 900 psi:

+
V,, = 250(1.112 1 + [(290 - 160)0.0031])= 629 bbl/day.
For 950 psi:
+
V,, = 250(1.115 1 + [(290 - 171)0.0030])= 618 bbl/day.
For 1000 psi:
V,, = 250(1.119 + 1 + [(290 - 180)0.0028])= 607 bbl/day.
For 1200 psi:
+
V,, = 250(1.136 + 1 [(290 - 255)0.0023]) = 554 bbl/day.
For 1400 psi:
+
V,, = 250(1.164 + 1 [(290 - 275)0.0019]) = 548 bbl/day.
For 1600 psi:
V,, = 250(1.18 + 1 + [(290 - 310)0.0019]) = 536 bbl/day.
At high pressures, R , increases to become equal to or to exceed the value of R ,
(specifically, above 1600 psi). When this occurs, there is no free gas. In Figs. 16-35
and 16-36, R , = R,, and at 290 scf the pressure is equal to 1535 psia; at a pressure
of 1535 psia, B, = 1.175. At pressures of 1535 psi through 2630 psi, the volume is
equal to:
V,, = 250(1.175 + 1 + [290 - 29010.0019) = 544 bbl/day.
The specific weight (y,) of gas moving through the pump can be calculated using
the following equation:

28.97 X SG, X p
Y, = ZR T

where SG, = specific gravity of gas, with respect to air; p = pressure of 1 atmo-
sphere; 2 = compressibility factor; R = gas constant; and T = temperature, OR.
At standard conditions:

28.97 X SG, X p
= 0.0496 lb/cu ft.
= 1 X 10.73 X 520

The weight of the gas is equal to:

y, x GLR = 0.0496 X 500 = 24.8 lb/bbl.
The specific weight of oil, yo, is equal to:
yo = SG, x 350 lb/bbl = 0.8489 X 350 = 297 lb/bbl.
The specific weight of water, y,, is equal to:
yw = SG, x 350 lb/bbl = 1.1X 350 lb/bbl.
+
Thus, the weight of one stocktank barrel = W, W, + W, = (24.8 X 0.5) + (297 X
+
0.5) (385 x 0.5) = 353.4 lb/bbl.
The net weight W, is equal to:
W, = 353.4 - 5.21(gas up casing) = 348.19 lb/bbl.
The weight rate of flow of 500 stocktank barrels per day = 500 X 348.19 = 174,095
lb/day. The weight of the pump fluid intake = 822 X 350 lb/bbl (at SG = 1.0) =
 793

287,700 lb/day. Thus, specific gravity is equal to:

174,095/287,700 = 0.61
and pressure gradient = 0.61 X 0.433 psi/ft = 0.264 psi/ft. The pressure gradients at
various pressures are presented below:
Pressure Flow Specific gravity Pressure gradient
(Psi) (bbl/day) SG (PSi/ft)
500 822 0.610 0.264
550 792 0.628 0.272
600 749 0.664 0.288
650 714 0.697 0.302
700 699 0.712 0.308
750 676 0.736 0.319
800 658 0.753 0.326
850 641 0.776 0.336
900 629 0.791 0.342
950 618 0.805 0.349
lo00 607 0.819 0.355
1200 554 0.871 0.377
1535 544 0.914 0.396

The pump selection for the pump intake rate of 822 bbl/day through the pump
discharge rate of 544 bbl/day would initially utilize the DN-750 pump (see Fig.
16-38). The initial rate of 822 bbl/day is very close to the peak efficiency of the
DN-750 pump. At pressures of 500 and 550 psi, the average volumetric rate of flow
is equal to: [(822 + 792)/2] = 807 bbl/day; the average specific gravity is 0.62; and
the pressure gradient is 0.268 psi/ft. The DN-750 pump develops about 22.7
ft/stage at the 807 bbl/day rate; thus:

pressure in psi per stage = pressure gradient X ft/stage = 0.268 X 22.7 = 6.08.

The number of stages is equal to:

total pressure/(pressure/stage) = 50/6.08 = 8.22.
Horsepower per stage at 807 bbl/day is 0.235. Thus, after correction for specific
gravity, the horsepower required for 8.22 stages is equal to:
8.22 x 0.235 x 0.62 = 1.19 HP.
For additional ranges:

Pressure Average flow Number of Horsepower

range rate stages
(Psi) (bbl/day)
500-550 807 8.22 1.19
550-600 770 7.60 1.14
600-650 731 6.92 1.06
- -
22.74 3.39
794
 795

main
S t o p -. P r o g r a m t e r m i n a t e d .
DATE - 3/21/1984 TIME - 12:36:54 pm
NEW C A S E

C O R R E C T I N G F'LIMP FERFORMANCE F O R V I S C O S I T Y
G I F OVER ONE. WILL. D l V l D E B Y 100.
COOPER 1.0 3.0
WRFIDE
.
1 l:ll:l~:ll:~
1. 1
.1
5 0 0 . I;I~:I~>~:I
PRESSLIRE 2 BARRELS F R E E
1 .9886 30. 0445
2 .
.
7021:) 7. 4507
-, 9'7 44 3.7'1.57
4 .9465 2.3677
5 .95e7 1.6527
6 95 10 . 1 .:'I I0
'7 .Y4.16 .
Y 11.14
8
Y .
c,921
I

-,
:'j 2 4
.
4ASb
1 1:)
11
12
i3
14
15 7'78.2

GR
.2 h 10
.2095
. t9r.19
.31R7

I 3650
.:.ti44

Fig. 16-39. Computer printout of Sample problem 16-1.

796

.
F i 4 I hh
541.M

TOTAL DYNAMIC HEAD 5Z9CI. 971)C)

MINIMCIM FUMF DISCHARGE PRESS!JRE 2 5 2 8 . .3:)l:)l:l
PRESSURE DHUP ACROSS F'IJMF 2 128. 3l:~l:ll:l

**** RESERVOIR DATA AND PUMP SEL.ECTION R E S U L T S *++*

WELL NAME E X A M F L F F'R0BLk.M # 1 60 CYCLE POWER

FLUID C H A R A C T E K I S T I C S WELLBOFE: CONDI T I O N 9

GOR
O I L GRAVITY &- ..
5ol:l. I:Kl SCF/BBL.
ClO DEti RP I
ME: AS1.IRE.I) DEP T t i
SIBHP
.
;:,a.
GAS G R A V I T Y hS INTAYE' F'RESSURE
c.
WATER CUT . ~ l , >00
. PERCENT WELL..HEAD PRESSURE
VISCOSITY 8.00 CP A T 11:)o.oO F: PERFORATIONS
VISCOSITY 2.415 CP A T 200.00 F ROTTOM HOLE TEMP
MEAN TEMPERATLIRE 140.10 DEE F FREE G A S A T I N T A K E
F I 1 . l-)l:) BF'D/I;'ST 'TLIBINO S I Z E
VERT PUMP DEPTH
WELLIiEAD TEMF

Fuw C r m F I GUHAT I or4 FUMF' FERFURMANCE

I NTAI.: E VOLUME 822.38 BFD

D I SCHARGE VOLCIME 541.66 HPD
DISCHARGE PKESSUFiE 2628.30 PSI
DR A w Do w IN 501:i.oo FSI
FBHF' 5":l . 1:10 PS I
STAGES TYPE D E S I R E D FLOW 500.00 BPD
82 DN-.7St:) HOF(sjEp:mOWER cc
ad. 85
264 D--5513

DATE .- ;/2i/i9a4 TIMF - 1:2:47:25 pm

Fig. 16-39 continued.

Using the same approach, the DN-750 stage is utilized followed by the D550,until
reaching the target rate of 544 bbl/day and 2630 psi discharge pressure.
The COMPSEL selection for this problem was 82 stages, DN-750,and 264
stages, D550. The horsepower requirements were 55.85 HP after the well is stabi-
lized at a design rate of 541.7 bbl/day. The design discharge pressure is 2628.3 psi.
An important point to remeber is that the COMPSEL designed pump is at a stable
producing rate. If the well was killed with a heavy fluid, additional stages and
 797

horsepower may be required to unload the well.

Figure 16-39 represents the computer printout of this problem.

SAMPLE PROBLEMS A N D QUESTIONS

(1) Determine the equipment series required, given the following information:
(a) Well total depth ( T D ) = 3900 ft
(b) 8;-in., 36-lb casing to a depth of 3000 ft
(c) 6;-in., 24-lb liner to TD; top at 2950 ft
(d) Depth of perforations = 3000-3450 ft
(e) Pump setting depth = 3250 ft
( f ) Flow rate: 2100 bbl/day STB-100 bbl/day of oil and 2000 bbl/day of water
(g) Tubing size: 2$-in., 8rd EUE
(h) Maximum fluid entry is below 3300 ft.
(2) Given the following information, design the pump, motor, cable string, and
transformer for an optimum ESP installation:
(a) Casing: 6i-in., 24-lb, I D = 5.921 in., drift = 5.796 in.
(b) Setting depth: 4000 ft vertical depth (VD), 4000 ft measured depth ( M D )
(c) Bottomhole temperature = 150 O F
(d) Tubing: 2$-in. EUE
(e) Surface pressure = 100 psi
( f ) Water cut = 90%; sp. gr. water = 1.0
(g) Voltage supply: 480 V
(h) Desired gross production rate: 1500 bbl/day
(i) PFL (lift) = 3800 f t
TDH = Net lift + Friction loss + System back pressure.
(3) Determine the expected production rate, given the following information:
(a) Gas absent
(b) Specific gravity = 1.1
(c) Lift: 5000 ft vertical; 7000 ft measured.
(d) Downhole pressure unit: 100 psi
(e) Tubing pressure = 150 psi
( f ) Installed pump: 230-stage, DN 750
(g) Motor length = 17.5 ft
(h) Protector length = 5.3 ft.
(4) Find (a) pump size (OD) from the manufacturer’s selection chart, and (b)
stage type (i.e., flow rate recommended range) using manufacturer’s selection chart,
given the following information:
(a) Casing: 7-in., 23-lb
(b) Tubing: 3-in., 8rd EUE
(c) Bottomhole temperature = 175O F
(d) Wellhead temperature = 130 O F
(e) Tubing pressure = 280 psi
798

( f ) GOR = 1290 cu ft/bbl

(g) Specific gravity of gas = 0.674 (air = 1.0)
(h) Oil gravity = 47 OAPI
(i) Water cut = 28.6%
0) Pump intake pressure = 1140 psi
(k) Gross production rate = 1900 bbl/day
(1) Gas separator efficiency = 50%
(m) PVT data:

Pressure
(Psi) 0 97 253 269 500 750 1000 1250
Rs
(cuft/bbl) 0 239 300 375 491 599 704 809
BO 1.08 1.29 1.34 1.40 1.47 1.54 1.59 1.65
ZatBHT 1 0.98 0.97 0.95 0.92 0.90 0.89 0.87

(5) Given the following data:

(a) 6850 No. 2 cable; maximum amp. = 70 A
(b) SBHP = 2500 psi at 7000 ft datum; 8241-1. casing
(c) FBHP = 1800 psi
(d) Tubing: 2H-in.
(e) Present total production = 525 bbl/day (75 bbl/day of oil)
( f ) ftube: 17 ft/lOOO f t
(g) GOR = 80 cu ft/bbl
(h) B H T = 160°F
(i) Perforations depth: 6900-7450 ft
0) Surface pressure = 100 psi
(k) Pump 17 = 60%
(1) Motor 17 = 90%
(m) Bo = 1.2
(n) PF = 0.9
(0)Fluid gravity data: sp. gr. oil = 0.904 (25OAPI), sp. gr. water = 1.02, sp. gr.
gas (air = 1)= 0.7.
(p) Pump setting depth = 6800 ft
(q) Pump intake desired pressure = 200 psi
Determine:
(a) Shut-in BHP at the pump
(b) Production capacity:
(i) using IPR curve, (ii) using J ( P I )
(c) Determine volumetric rate of flow (reservoir bbl) at intake
(d) Determine friction loss
(e) Determine TDH (total dynamic head) = Lift + Tubing friction loss + Wellhead
pressure - Intake pressure
 799

( f ) Determine hydraulic I-€'(H,)

(g) Determine motor Ep(H,,,)
(h) Calculate the minimum motor voltage
(6) What factors determine the maximum setting depth of the ESP? Why?
(7) Describe different types of pump intakes.
(8) What factors determine the maximum diameter of the pump, motor, and
protector? Why?

REFERENCES

American Petroleum Institute, 1980. API Recommended Practice for Electric Submersible Pump Installa-
tion. RP 11R. API, Dallas, Tex.
American Petroleum Institute, 1982. Recommended Practice for the Operation, Maintenance and Trouble
Shooting of Electric Submersible Pump Installations. API, Dallas, Tex.
Beggs, H.D. and Brill, J.P., 1973. A study of two-phase flow in inclined pipes. J. Pet. Tech., 25(5):
607-617.
Brown, K.E., 1980. The Technology of Artificial Lift Methob, Vol. 2a. PenWell, Tulsa, Okla., 720 pp.
Brown, K.E. and Beggs, H.D., 1977. The Technology of Artificial Lift Methods. Vol. 1. PennWell, Tulsa,
Okla., 487 pp.
Chew, J. and Connally Jr., C.A., 1959. A viscosity correlation for gas-saturated crude oils. Trans. A I M E ,
216: 23-25.
Duns, Jr., H. and Ros, N.C.J., 1963. Verticalflow of gas and liquid mixtures in wells. Proc. 6th World Pet.
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379-381.
Martin, J.W. and Vatalaro, F.J., 1979. Testing of Oil Well Power Cables Under Simulated Downhole
Conditions. TRW Reda Pump Div. Publ.
Mead, H., 1975. Oasis submersible lift operations. SPE 5287. Paper, presented at the Soc. Pet. Eng.
European Spring Meeting, London, April 14-15, 5 pp.
O'Neil, R.K., 1976. Application and selection of electrical submergible pumps. SPE 5907. Paper, presented
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Orkiszewski, J., 1967. Predicting two-phase pressure drops in vertical pipes. J. Pet. Tech., 6: 829-838.
Poettmann, F.H. and Carpenter, P.G., 1952. The multiphase flow of gas, oil and water through vertical
flow strings with application to the design of gas life installations. Drill. Prod. Prac., A P I : 257.
Standing, M.B., 1975. A pressure-volume-temperature correlation for mixtures of California oils and
gases. Drill. Prod. Prac., A P I : 275.
Standing, M.B., 1952. Volumetric and Phase Behavior of Oil Field Hydrocarbon Systems. Reinhold, New
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Schultz, H.F., 1973. Extraordinary application of electrical submergible centrifugal pump equipment. S P E
4723. Paper, presented at the South Plaine Prod. Tech. Symp., Lubbock, Tex., Nov. 1-2.
Swetnan, J.C. and Sackash, M.L., 1977. Performance review oftapered submergible pumps in the Three Bar
(Devonian) Field. SPE 6854. Paper, presented at the 52nd Annu. Fall Tech. Conf. and Exhibition,
Dallas, Tex., Oct. 9-12, 5 pp.
Vasquez, M. and Beggs, H.D., 1980. Correlations for fluid physical property predictions. J. Pet. Tech.,
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Vogel, J.V., 1968. Inflow performance relationships for solution-gas drive wells. J. Pet. Tech,, 20(1):
r~

83-92; Trans. A I M E , 243: 83-92.