Libya

Ministry of Higher Education

University of Ajdabiya

The Effect of Water Production on ESP

Design

By

Seif Aldin Khamis (04025)

Ahmed Abd Alrahman (04044)

Supervised By

Dr. Ghaith Hamed Bogfol

DEGREE OF BACHELOR IN PETROLEUM ENGINEERING

FACULITY OF ENGINEERING
2018

I
 ABSTRACT

This study aims to compare the results of two down hole ESP system designs by hand
calculations for the same well with the same input data but with different water cut
ratios to observe the effects of water cut on the ESP design known that we calibrated the
first design with the original water cut ratio with preexisting software (excel sheet)
results to confirm the error percent and we selected the same pump on purpose for
comparison reasons. The input data from the sarir oil field that is operated by the
Arabian gulf oil company (AGOCO) a subsidiary of the state owned national oil
corporations (NOC) the oil sarir field was discovered in 1996 by the British BP and is
consider to be the largest oil field in Libya at the depth of approximately 12000 ft and
was pumping around 300000 (bpd) before 2011 its pumped through a 500 kilometer
pipeline to the mersa El Hariga oil port.

II
 DEDICATION

We dedicate this project to our fathers and mothers who

supported us in thick and thin

We would like also to dedicate this project to our brothers and

sisters who were a major reason for our success

Also, we dedicate this project to our teachers, our colleagues,

who became our other families.

III
 ACKNOWLEDGEMENTS

We would like to take this opportunity first of all, submitting huge thank for God who
made all the things possible and gave us strength, patience and the ability to achieve this
project.

We would like to express our sincerely appreciation to our supervisor (Dr. Ghaith
Hamed Bogfol) for his guidance and constant supervision as well as for providing
necessary information regarding the project & also for his support to complete the
project.

Every project is successful due to the effort of a number of extraordinary souls who
have always given their golden advice or lent us a helping hand. We are sincerely
appreciating the inspiration , support and guidance of all those people who have been
instrumental in making this project a success.

Finally, we would like to express our gratitude towards our country & university for
their Contribution and encouragement, which help us in completion of this project.

Thanks for all you’ve done!

IV
 APPROVAL

This project report is submitted to the Faculty of Engineering, University of ajdabiya ,

and has been accepted as partial fulfillment of the requirement for the degree of

bachelor in petroleum Engineering. The members of the Examination Committee are as

follows:

________________________________________

Supervisor
Dr. GHAITH HAMED BOGFOL.
Department of petroleum Engineering.
Faculty of Engineering
University of Ajdabiya

____________________________________________

Examiner 1
---------------------------------------------
Department of petroleum Engineering
Faculty of Engineering
University of ajdabiya

____________________________________________
Examiner 2
-----------------------------------------------
Department of petroleum Engineering.
Faculty of Engineering.
University of ajdabiya.

V
 DECLARATION

We hereby declare that the project report is my original work except for quotations and

citations, which have been duly acknowledged. We also declare that it has not been

previously, and is not concurrently, submitted for any other degree at University of

ajdabiya or at any other institution.

___________________________________

SEIF ALDIN KHAMIS (04025)

AHMED ABD ALRAHMAN (04044)

Date:…………………………….

VI
 TABLE OF CONTENTS

ABSTRACT...................................................................................................................... II
DEDICATION .................................................................................................................III
ACKNOWLEDGMENTS .............................................................................................. IV
APPROVAL .................................................................................................................... V
DECLARATION ............................................................................................................ VI
TABLE OF CONTENT………………………………….……………………………VII
LIST OF FIGURES ...................................................................................................... VIII
LIST OF TABLE……...………………………………………………………….….….X
LIST OF ABBREVIATIONS ......................................................................................... XI
CHAPTER.1 INTRODUCTION ................................................................................... 1
1.1 NATURAL FLOW……………………………………….. …………………….…..1
1.2 TYPES OF DRIVING FORCEIN RESERVOIR……………..…………….………1
1.2.1 WATER DRIVE………………………………………………………...…....1
1.2.2 SOLUTION GAS DRIVE …………………………………………….…......2
1.2.3 GAS CAP DRIVE……… ……………………………………………….......2
1.2.4 GRAVITY DRAINGE….…………………………………………………....3
1.2.5 COMBINATION DRIVE……………………………………………….…...4
CHAPTER 2 ARITIFICIAL LIFT .............................................................................. 7
2.1 ARTIFICIAL LIFT ..................................................................................................... 7
2.2 TYPES OF ARTIFICIAL LIFT .............................................................................. 7
2.2.1 GAS LIFT .................................................................................................... ..7
2.2.1.1 CONTINOUS FLOW ......................................................................... …7
2.2.1.2 INTERMITTENT FLOW ................................................................. …..8
2.2. 1.3 ADVANTAGE OF GAS LIFT……………………………….…..……8
2.2.1.4 DISADVANTAGE OF GAS LIFT……………………………......……8
2.2.2 SUCKER ROD ............................................................................................ 9
2.2.2.1 COMPONENTS OF SUCKER ROD…………………………………..9
2.2.2.2 ADVANTAGE OF SUCKER ROD ………………………….………11
2.2.2.3 DISADVANTAGE OF SUCKER ROD………………………………11
2.2.3 ELECTRICAL SUBMERSIBLE PUMP..................................................... 11
2.2.3.1 DEFINATION OF ESP………………………………………………11
2.2.3.2 COMPONENTS OF ESP ..................................................................... 12
2.2.3.3 ADVANTAGE OF ESP ………………………………….………..…13
2.2.3.4 DISADVANTAGE OF ESP …………………………………………13
CHAPTER 3 ELECTRICAL SUBMERSIBLE PUMP………………………...….17
3.1 INTRODUCTION ................................................................................................ …17
3.2 COMPONENTS OF ESP……………………………………………………..……18
3.2.1 SURFACE COMPONENTS ............................................................................ 18
3.2.2 DOWN HOLE COMPONENTS ..................................................................... 23
3.3.3 ESP OPTIONAL COMPONENTS ...................................................................... 35
3.3 ADVANTAGES OF ESP PUMP ........................................................................ 39
3.4 DISADVANTAGES OF ESP PUMP .................................................................. 39
CHAPTER 4.4 DESIGN OF ESP ................................................................................ 42
4.1 DESIGN ESP BY HAND CALCULATION WITH WC 21 % ............................... 42
4.1.1 BASIC DATA ................................................................................................... 42
4.1.2 HAND CALCULATION ................................................................................. 43
4.1.3 RESULTS OF HAND CALCULATION .......................................................... 51
4.2 DESIGN ESP BY SOFTWARE ............................................................................... 52
VII
 4.2.1 RESULTS OF SOFTWARE............................................................................. 53
4.3 COMPARISON BETWEEN HAND AND SOFTWARE ....................................... 54
4.4 ESP DESIGN FOR THE SAME WELL WITH DIFFERENT WC 50 % ............... 55
4.4.1 BASIC DATA.................................................................................................... 55
4.4.2 HAND CALCULATION ................................................................................. 56
4.4.3 RESULTS OF HAND CALCULATION .......................................................... 63
4.5 COMPARISON OF THE SAME WELL WITH TWO DIFFERENT WC………..64
CHAPTER 5 CONCLUSIONS &RECOMMENDATIONS ................................... 65
5.1CONCLUSIONS ................................................................................................... 65
5.2RECOMMENDATIONS .................................................................................... 66
REFERENCES.............................................................................................................. 67

LIST OF FIGURES
FIGURE1.1 WATER DRIVE MECHANISM ................................................................ 1
FIGURE 1.2 SOLUTION GAS DRIVE ........................................................................... 2
FIGURE 1.3 GAS CAP DRIVE ...................................................................................... 3
FIGURE 1.4. GRAVITY DRAINGE DRIVE .................................................................. 4
FIGURE1.5 COMBINATION DRIVE ........................................................................... 5
FIGURE 2.1 COMPONENTS OF SUCKER ROD PUMP ............................................ 10
FIGURE 2.2 COMPONENTS OF ESP .......................................................................... 12
FIGURE2.3THE ARTIFICIAL LIFT TYPES ............................................................. 15
FIGURE3.1. ELECTRICAL SUBMERSIBLE PUMP .................................................. 17
FIGURE 3.2TRANSFORMER OF ESP ........................................................................ 19
FIGURE 3.3 JUNCKTION BOX .................................................................................. 19
FIGURE 3.4 COMPONENTS OF SWITCHBOARD .................................................. 21
FIGURE3.5WELLHEAD OF ESP ................................................................................ 22
FIGURE3.6 SURFACE COMPONENTS OF ESP ....................................................... 23
FIGURE 3.7 STATOR OF THE MOTOR ........................................................... ……..24
FIGURE 3.8 ROTAR OF THE MOTOR ...................................................................... 25
FIGURE 3.9 ROTAR BEARING .................................................................................. 25
FIGURE 3.10 MOTOR THRUST BEARING .............................................................. 26
FIGURE 3.11 POTHEAD OF THE MOTOR ............................................................... 26
FIGURE 3.12 MOTOR SEAL ....................................................................................... 27
FIGURE 3.13 PUMP INTAKE OF ESP ...................................................................... 28
FIGURE 3.14 CABLES OF ESP ................................................................................... 29
FIGURE 3.15 FLAT AND ROUND CABELS ............................................................. 29

VIII
FIGURE 3.16. THE COMPONENTS OF ESP CABLES ............................................. 31
FIGURE 3.17. IMPELLER AND DIFFUSER OF THE ESP PUMP ........................... 32
FIGURE 3.18. THE PUMP STAGE ………………...……………...…..………..…..33
FIGURE 3.19. THE IMPELLER OF THE PUMP……...…………..……...………… 33
FIGURE 3.20. THE PUMP DIFFUSER ………..……...……………...……………..34
FIGURE 3.21. THE CENTRALIZER… ………..……...……………...……………..36
FIGURE 3.22. THE CHECK VALVE… ………..……...……………...……………..37
FIGURE 3.23. THE MOTOR SHROUD ………..……...……………...……………..37
FIGURE 3.24. Y- TOOL / BYPASS… ………..……...…………….....……………...38
FIGURE 4.1. THE TUBING FRICTION LOSS.……...……………...………...……..44
FIGURE 4.2. THE PUMP PERFORMANCE CURVE ……………………...…...…..45
FIGURE 4.3. THE MAX STAGES OF THE PUMP. ...……………...………..……...46
FIGURE 4.5. THE TYPES OF THE PROTECTOR . ...……………...…………..…...47
FIGURE 4.5. THE TYPES OF PUMP INTAKE … . ...……………...…………...…..47
FIGURE 4.6. THE VOLT AND AMPERE OF THE PUMP . ………...………….…..48
FIGURE 4.7. THE TYPES OF THE CABLES……. . ...……………...………….…...49
FIGURE 4.8. THE CABLE VOLTAGE DROP…….. ...……………...……………...50
FIGURE 4.9. THE RESULTS of ESP DESGIN BY SOFTWARE. ..…………….…..52
FIGURE 4.10. TUBING FRICTION LOSS………………………. ..………………..57
FIGURE 4.11. THE PUMP PERFORMANCE CURVE………….. ..………………..58
FIGURE 4.12. MAX STAGES OF THE PUMP…………………... ..………………..59
FIGURE 4.13. THE TYPES OF PUMP INTAKES……………….. ..………………..59
FIGURE 4.14. THE TYPES OF PROTECTERS ……………………..………...…….60
FIGURE 4.15. VOLT AND AMPERE OF THE MOTORS………. ..………………..60
FIGURE 4.16. THE TYPES OF THE CABLE……………………. ..………………..61
FIGURE 4.17. VOLTAGE DROP OF THE CABLE……………... ..………………..62

IX
 LIST OF TABLE
TABLE 4.1 THE RESULTS OF HAND CALCULATION WITH W.C 21% ............. .51
TABLE 4.2. THE RESULTS OF SOFWARE …………………………………....…...53
TABLE 4.3 RESULTS OF COMPARSION OF SOFTWARE AND HAND………....54
TABLE 4.4 THE RESULTS OF HAND CALCULATION WITH W.C 50%……..….63
TABLE 4.5 RESULTS OF COMPARSION BETTWEEN TWO HAND DESGINS ...64

X
 ABBREVIATION

SYMBOL DISCRIPTION unit

OOIP ORGINAL OIL IN PLACE STB
GOR GAS–OIL–RATIO %
ESP ELECTRICAL SUBMERSIBLE PUMP -
BOPD BARREL OIL PER DAY BO/D
VSD VARIBLE SPEED DRIVE %
REDA RUSSIAN ELECTRICAL DYNAMO OF ARUTUNOFF %
KVA KILO VOLT AMPERE KV/A
AC ALTERNATING CURRENT AMPERE
CT CURRENT TRANSFORMER -
PT POTENTIAL CURRENT -
RPM REVOLUTION PER MINUTE R/MIN
OD OUTSIDE DIAMETER INCH
WG AMERICAN WIRE GAUGE -
TDH TOTAL DYNAMIC HEAD FEET
LE MOTOR LEAD EXTENSION -
RB RESERVOIR BARREL BARREL
STB/DAY
PI PRODUCTIVITY INDEX
/PSI
PWF FLOWING BOTTOM HOLE PRESSURE PSI
PS RESERVOIR PRESSURE PSI
D.F.L DYNAMIC FLUID LEVEL FEET
F FRICTION FEET
BPP BUBBLE POINT PRESSURE PSI
BFPD BARREL FLUID PER DAY B/D
HP HORS POWER hp
CU COPPER -
WC WATER CUT %

XI
CHAPTER I INTRODUCTION

CHAPTER 1
1. INTRODUCTION

1.1 Natural flow

A virgin reservoir may be under sufficient pressure to push hydrocarbons to the surface. As
the fluids are produced, the pressure will often decline, and production will falter artificial
drive methods may be necessary. (1)

1.2 The types of driving force in a reservoir

1.2.1 Water drive

In a water drive reservoir, the oil zone is in communication with an aquifer. As oil is produced,
the water in the aquifer expands and moves into the reservoir, displacing oil. In a water drive,
the reservoir pressure response to production decline depends on the size and permeability of
the aquifer and the rate at which the reservoir is produced. If the reservoir is produced at a low
rate, the aquifer is able to replace the fluid volumes produced and reservoir pressure remains
fairly constant. At high production rates, the aquifer is unable to keep up with withdrawals and
reservoir pressure drops. If the rate is then reduced to a low level, reservoir pressure will rise ,
Oil recovery from water drive reservoirs typically ranges from 35 to 75% of the original oil in
place. (2)

Fig (1.1) shown water drive mechanism

1
CHAPTER I INTRODUCTION

1.2.2 Solution gas drive

Crude oil under high pressure contains large amounts of dissolved gas. The more gas there
is in solution, the more compressible the oil. In oil reservoirs with little or no water drive,
reservoir energy to drive the oil toward the wellbore can be supplied by expansion of the
oil due to gas expanding in solution. This is a solution gas (or dissolved gas or depletion)
drive. When pressure drops below the bubble point in the reservoir, small, disconnected
gas bubbles form in pores, also pushing the oil toward the wellbore.
Oil recovery from solution gas drive reservoirs is usually low, ranging from 5 to 30% of
(OOIP).(2)

Fig (1.2) shown solution gas drive

1.2.3 Gas cap drive

In a gas cap drive reservoir, the primary source of reservoir energy is an initial gas cap,
which expands as the reservoir pressure drops Gas cap expansion causes reservoir pressure
to fall more slowly in a gas cap drive reservoir than in one producing in a solution gas
drive. The rate of pressure decline is closely tied to the relative size of the gas cap, with
larger gas caps resulting in a more gradual pressure decline as oil is produced. Early in the
life of a gas cap drive reservoir, the GOR rises slowly because the higher reservoir pressure

2
CHAPTER I INTRODUCTION

keeps more gas in solution in the oil. Later, the GOR increases dramatically as the
expanding gas cap reach the highest wells on structure. Oil recovery from gas cap drive
reservoirs typically ranges from 20 to 40% of the original oil in place. (2)
.

Fig (1.3) shown gas cap drive

1.2.4 Gravity drainage

Gravity drainage, or gravity segregation, is the tendency of oil, gas, and water to segregate
in a reservoir during production due to their differing densities. As a secondary drive
mechanism, gravity drainage occurs only in combination with one or more of the primary oil
reservoir drive mechanisms. The rate of oil gravity drainage in the reservoir is usually low
compared to field production rates. Over time, however, gravity drainage can be extremely
(2)
efficient and recoveries higher than any of the primary drive mechanisms are possible.

3
CHAPTER I INTRODUCTION

Fig (1.4) shown gravity drainage drive

1.2.5 Combination drive

Most oil reservoirs produce under the influence of two or more reservoir drive
mechanisms, referred to collectively as a combination drive. A common example is an oil
reservoir with an initial gas cap and an active water drive. The ultimate recovery obtained
from a combination drive reservoir is a function of the drive mechanisms active in the
reservoir. The recovery may be high or low depending on whether displacement or depletion
drive mechanisms dominate. Water drive and gas cap expansion are both displacement type
drive mechanisms and have relatively high recoveries. Solution gas drive is a depletion type
drive and is relatively inefficient. (2)

4
CHAPTER I INTRODUCTION

Fig (1.5) shown combination drive

5
Chapter 2

 Content:

 Artificial lift
 Types of artificial lift
 Gas lift
 Sucker rod
 ESP (electrical submersible pump)
CHAPTER II ARTIFICIAL LIFT

CHAPTER 2
2. ARTIFICIAL LIFT

2.1 Artificial lift

Artificial lift is a process used in oil wells to increase pressure within the reservoir and
encourage oil to the surface. When the natural drive energy of the reservoir is not strong
enough to push the oil to the surface, artificial lift is employed to recover more production.
While some wells contain enough pressure for oil to rise to the surface without stimulation,
most don't, requiring artificial lift. In fact, 96% of the oil wells in the US require artificial
lift from the very beginning. (3)

2.2 Types of artificial lift

1- Gas lift.
2 - Sucker rod.
3 - Esp. (electrical submersible pump).

2.2.1 Gas lift

Gas lift is a method of artificial lift that uses an external source of high-pressure gas for
supplementing formation gas to lift the well fluids. The principle of gas lift is that gas injected
into the tubing reduces the density of the fluids in the tubing; there are two basic types of gas
lift in use today:
1 - Continuous flow
2 - intermittent flow

2.2.1.1 Continuous flow

The vast majority of gas lift wells are produced by continuous flow, which is very similar to
natural flow .In continuous-flow gas lift, the formation gas is supplemented with additional
high-pressure gas from an outside source. Gas is injected continuously into the production
tubing at a maximum depth that depends upon the injection-gas pressure and well depth. The
injection gas mixes with the produced well fluid and decreases the density and, subsequently,

7
CHAPTER II ARTIFICIAL LIFT

the flowing pressure gradient of the mixture from the point of gas injection to the surface. The
decreased flowing pressure gradient reduces the flowing bottom hole pressure below the static
bottom hole pressure creating a pressure differential that allows the fluid to flow.(4)

2.2.1.2 intermittent flow

As the name implies, intermittent flow is the periodic displacement of liquid from the tubing by
the injection of high-pressure gas. The action is similar to that observed when a bullet is fired
from a gun. The liquid slug that has accumulated in the tubing represents the bullet. When the
trigger is pulled (gas lift valve opens), high-pressure injection gas enters the chamber (tubing)
and rapidly expands. This action forces the liquid slug from the tubing in the same way that
expanding gas forces the bullet from the gun. The disadvantage of intermittent-flow gas lift is
the "on/off" need for high-pressure gas , intermittent-flow gas lift is not capable of producing at
as high a rate as continuous-flow gas lift. Intermittent flow should not be considered unless the
flowing bottom hole pressure is low. (4)

2.2.1.3Advantage of gas lift

1- Subsurface gas lift equipment is relatively inexpensive
2- Most efficient in wells that produce sand and have high gas/liquid ratio
3-Flexible in meeting changing producing conditions
4- Adaptable in crooked hole
5- Capable of lifting large volumes of fluid
6- Most gas lift valves are simple devices with few moving parts
7- Gas lift valves may be wire line retrievable

2.2.1.4 Disadvantage of gas lift

1- Requires a continuous source of makeup gas
2- High operating cost if makeup gas in purchased
3- Safety hazards handling high pressure gas
4- High initial investment and High operating cost with corrosive gases
5- Frequent optimization is required
6 - Wet gases without proper dehydration will reduce the reliability of gas lift operations.

8
CHAPTER II ARTIFICIAL LIFT

2.2.2 Sucker rod

Beam pumping, or the sucker-rod lift method, is the oldest and most widely used type of
artificial lift for most wells. A sucker-rod pumping system is made up of several components,
some of which operate aboveground and other parts of which operate underground, down in the
well. The surface-pumping unit, which drives the underground pump, consists of a prime
mover (usually an electric motor) and, normally, a beam fixed to a pivotal post. The post is
called a Sampson post, and the beam is normally called a walking beam. The entire surface
system is run by a prime mover, V-belt drives, and a gearbox with a crank mechanism on it.
When this type of system is used, it is usually called a beam-pump installation. (5)

2.2.2.1 Components of sucker rod lift

A- Surface components
1) - The prime mover that provides the driving power to the system and can be an electric
motor or a gas engine.
2) - The gearbox reduces the high rotational speed of the prime mover to the required pumping
speed and, at the same time, increases the torque available at its slow speed shaft.
3) - The pumping unit, a mechanical linkage that transforms the rotary motion of the gear box
into the reciprocating motion required to operate the down hole pump. Its main element is the
walking beam, which works on the principle of a mechanical lever.
4) - The polished rod connects the walking beam to the sucker-rod string and ensures a sealing
surface at the wellhead to keep well fluids within the well.
5) - The wellhead assembly contains a stuffing box that seals on the polished rod and a
pumping tee to lead well fluids into the flow line. The casing-tubing annulus is usually
connected, through a check valve, to the flow line.

B - Down hole components

1) - The rod string composed of sucker rods, run inside the tubing string of the well. The rod
string provides the mechanical link between the surface drive and the subsurface pump.
2) -The pump plunger, the moving part of sucker-rod is directly connected to the rod string.

9
CHAPTER II ARTIFICIAL LIFT

\ Fig (2.1) shown components of sucker rod pump

10
CHAPTER II ARTIFICIAL LIFT

2.2.2.2 Advantage of sucker rod lift

1 - Relatively simple system design.
2 - Units easily changed to other wells with minimum cost.
3 - Efficient, simple, and easy for field people to operate.
4 - Applicable to slim holes and multiple completions.
5 - Can pump a well down to very low pressure (depth and rate dependent).
6 - System usually is naturally vented for gas separation and fluid level soundings.
7 - Flexible-can match displacement rate to well capability as well declines.
8 - Can lift high-temperature and viscous oils.
9 - Can use gas or electricity as power source.
10 - Corrosion and scale treatments easy to perform.
11 - Applicable to pump off control if electrified.
12 - Availability of different sizes.
13 - Hollow sucker rods are available for slim hole completions and ease of inhibitor treatment.
14 - Has pumps with double valves that pump on both upstroke and down stroke.

2.2.2.3 Disadvantage of sucker rod lift

1 - Crooked holes present a friction problem.
2- High solids production is troublesome.
3- Gassy wells usually lower volumetric efficiency.
4- Is depth limited, primarily because of rod capability.
5- Susceptible to paraffin problems.
6- Tubing cannot be internally coated for corrosion.
7- H2S limits depth at which a large-volume pump can be set.
8 -Limitation of down hole pump design in small diameter casing.

2.2.3 Electrical submersible pump

2.2.3.1 Definition of ESP
Electrical Submersible Pump (ESP) is an efficient and reliable pump used to artificially lift
moderate to high volume of crude oil and natural gas condensate from a wellbore. The volume
of fluids that can be lifted with the help of this pump ranges from 24 to 24600 m3/d. Generally
the pump is used when the volume is greater than 400 BOPD. If the pump is operated below
this volume, it usually tends to perform with low efficiency. (6)

11
CHAPTER II ARTIFICIAL LIFT

2.2.3.2 Components of ESP

A - Surface components
1 - Transformers
2 - Switchboard or variable speed drive (VSD)
3 - Junction box
4 - Well head
5 - Cable venting box

B - Down hole components

1- Cable
2- Cable guard
3 - Cable clamps
4 - Pumps
5 - Gas separator
6 - Motor
7 - Sensor- Data Acquisition Instrumentation
8 - Check valve
9 - Drain valve

Fig (2.2) shown the components of electrical submersible pump

12
CHAPTER II ARTIFICIAL LIFT

2.2.3.3Advantage of ESP pump

1) - Can lift a wide range of volumes from low volumes 400 B/D, to extremely high
volumes; (24600 m3/d) in shallow wells with large casing.

2) - Simple to operate.

3) - Easy to install down hole pressure sensor for telemetering pressure to surface by cable.

4) - Crooked holes present no problem.

5) - Applicable offshore.

6) - Corrosion and scale treatment easy to perform.

7) - Availability of different sizes.

8) - Lifting cost for high volumes generally very low.

2.2.3.4 Disadvantage of ESP pump

1) -Not applicable to multiple completions.

2) - Only applicable with electric power.

3) - High voltages (1,000 V) are necessary.

4) - Impractical in shallow, low volume wells.

5) - Expensive to change equipment to match declining well capability.

6) - Cable causes problems in handling tubular.

7) - Cables deteriorate in high temperatures.

8) - System is depth limited, 10,000 ft (3048.0 m), because of cable cost and inability to
install enough power down hole (depends on casing size).

13
CHAPTER II ARTIFICIAL LIFT

9) - Gas and solids production are troublesome.

10) - Not easily analyzable unless good engineering know-how.

11) - Lack of production rate flexibility.

12) - Casing size limitation.

13) - Cannot be set below fluid entry without a shroud to route fluid by the motor. also
allows corrosion inhibitor to protect outside of motor.

14) - More downtime when problems are encountered because of the entire unit being
down hole.

14
CHAPTER II ARTIFICIAL LIFT

Fig (2.3) shown the artificial lift types

15
Chapter 3

 Content:

 Introduction of Electrical submersible pump

 Definition of Electrical submersible pump
 Components of ESP system
 Advantage and disadvantage of ESP
CHAPTER III ESP

CHAPTER 3
3. ELECTRICAL SUBMERSIBLE PUMP

3.1 Introduction
Origin of ESP return to 1911, 18-year-old Russian engineer Armais Arutunoff invented the
first electric motor that operated in water. He added a drill and a centrifugal pump to the
motor, inventing what is now known as the electric submersible pump. Arutunoff
immigrated to the US, where he founded Russian Electrical Dynamo of Arutunoff, or
REDA. Electric submersible pumps are now operating in onshore and offshore fields
throughout the world. Electrical Submersible Pump (ESP) is an efficient and reliable pump
used to artificially lift moderate to high volume of crude oil and natural gas condensate
from a wellbore. The volume of fluids that can be lifted with the help of this pump ranges
from 24 to 24600 m3/d. Generally the pump is used when the volume is greater than 400
BOPD. If the pump is operated below this volume, it usually tends to perform with low
efficiency. (7)

Fig (3.1) shown electrical submersible pump

17
CHAPTER III ESP

3.2 Components of Electrical submersible pump

3.2.1.Surface components

A) –Transformers
the transformer is used to convert the incoming voltage at the location to the correct
voltage for the ESP. the selection of transformer is based on four parameters:
1- power rating in KVA (kilo volt ampere)
2- primary voltage
3- secondary voltage
4 - tap arrangement

power rating in KVA (kilo volt ampere)

The calculation of power rating in KVA for three phase transformer is based on winding
voltage and amperage information the simple formula to calculate the rating of three phase
transformer is KVA = (√3. V x I) /1000

Step up and Step down transformer

Transformers are composed of a magnetic path (iron core ring) wrapped in two coils. One
coil is connected to an AC input voltage and is called “the primary coil“. The other coil is
connected to an output circuit with a load resistance and is called “the secondary coil".
Transformers can either step-up or step-down a voltage. In Step-Down Transformer, The
number of turns in the primary coil is greater than the number of turns in the secondary
coil. In Step-Up Transformer, the number of turns in the secondary coil is greater than
the number of turns in the primary coil. (8)
Transformer transformation ratio
The ratio of the number of turns in the secondary winding to the number of turns in the primary
winding named Transformation Ratio (K). Transformation Ratio is also equal to the ratio of
secondary voltage to the primary voltage. If number of turns in primary coil greater than
secondary then it called setup down If number of turns in primary coil less than secondary
then it called setup up.

18
CHAPTER III ESP

Fig (3.2) shown transformer of ESP

B) – Junction box

The power cable coming from the well is connected to a surface electric cable leading to
the switchboard. As seen in the figure below, the two cables are joined in the junction box,
also called a “vent box”. The surface cable connects the junction box to the motor control
panel and the motor control panel to the secondary side of the transformers. (8)

Fig (3.3) shown junction box

19
 CHAPTER III ESP

It is a ventilated, weatherproof box performing the following three important

functions:

1) - Provides the electrical connection between the down hole and the surface electric cable.

2) -Vents any gas to the atmosphere which might reach this point due to migration of well
gases up the ESP power cable. The venting of gas eliminates the danger of fire or explosion
that could happen if gases travel in the cable to the switchboard.

3) - Acts as an easily accessible test point for electric checks of the down hole equipment.

C) –ESP Motor Switchboard

Switchboard provides the means for turning the pump motor on and off, and provides
electrical protection for the motor and cable. Switchboard consist of:

1) - Manual disconnect (switch)

this switch is used to disconnect the controller from the main power supply after the motor
has been stopped.

2) - Fuses
Connected below the disconnect switch and provide interrupting capability for short circuit
conditions that might develop in the motor or output wiring.

3) - Current transformers (CT’s) and the potential transformer (PT)

These devices allow special controls to monitor the amperage and voltage supplied to the
motor. Depending on the complexity of the controls,

4) - Contactor/Motor Starter

The contactor is located after the PT’s and CT’s and is the device that connects and
disconnects the motor from the power source. Connected to the contactor is the output cable
to the junction box and on to the wellhead and the motor. (8)

20
CHAPTER III ESP

5) - Low Voltage Control Section

This is what signals the power contactor to operate. It also responds to the manual inputs of
start and stop.

Finally, the switchboard will generally have a recording ammeter. This ammeter records
Motor Current versus Time. These amp charts are one of your best tools in solving pump
production problems. (8)

Fig (3.4) shown components of switchboard

21
CHAPTER III ESP

D) –Wellhead

Wellhead Equipment for ESP provides a tubing support and allows the power cable to
pass from the surface into the well bore. The wellhead is equipped with a wellhead feed
through mandrel or pack-off method. It provides a positive seal around the cable.
Wellheads and cable pack-offs are available in various pressure ratings and hanging load
capacities. The components of Wellhead is Wellhead feed through, penetrator, lower and
upper pigtails the tubing hanger holds a feed-through mandrel (also called: well
penetrator) equipped with the proper seals. Feed-through mandrel seals contain well
pressure and prevent gas leaks at the surface. Power cables are connected to the two ends
of this device via their three-phase connectors (also called: lower and upper pigtails). (8)

Fig (3.5) shown cable connection to the wellhead

22
CHAPTER III ESP

Fig (3.6) shown surface components of ESP

3.2.2 Down hole components

A) -ESP motor
ESP motor is installed below the motor seal and above the down hole sensor. In cases
where a down hole sensor is not installed, the motor is installed at the very bottom of ESP
string. ESP motor is an induction motor, two poles, three phases, squirrel cage type stator
winding filled with specific motor oil, high dielectric strength. The motor is rated for a
specific horsepower, voltage, & current. Its role is to drive the down hole pump and seal
section. The actual RPM is usually noted on the motor nameplate (example: 3500 RPM /
60 Hz – 2917 RPM / 50 Hz). ESP motor is close to the same design type as motors used on
beam pumping units. Of course, it must be small in diameter in order to fit inside oil well
casing sizes. (8)

23
CHAPTER III ESP

The ESP motor compounds

1) -The stator (the stationary part/static)

The stator is the core or electrical field of the motor. It is composed of the housing material
for the desired diameter, the stator core, and the stator windings. the housing material
Forms the cover for the motor and is threaded at both ends for head and base components.
The housing can be of different diameters and its material can be chosen for different
applications. The stator core is composed of laminations stacked under pressure to insure a
permanently tight core. Laminations are thin sheets of die-punched steel or bronze
material. The Stator windings are made from either Polyimide or PEEK material, for
primary magnetizing winding wound through the die-punched slots in the stator core. (8)

Fig (3.7) shown stator of the motor

24
CHAPTER III ESP

2) - The rotor (the moving part/rotate)

Is a device that rotates inside of the stator core? The rotor is made up of rotor laminations
that are smaller in diameter from the stator laminations and these create the iron core.
Inside each slot are copper bars with supporting copper end rings. Because the structure
resembles the cage used to exercise squirrels this type are called “Squirrel-Cage rotors”.

Fig (3.8) shown the rotor of motor

Rotor Bearings are one of the most vital parts of the motor. There are fluid holes to
insure oil circulation and wide angle oil grooves on the OD to distribute lubrication
evenly over the entire length of the bearing surface. (8)

Fig (3.9) shown rotor bearing

25
CHAPTER III ESP

3) -The Motor thrust bearing

The motor thrust bearing is installed at the top of the rotor string. It is designed to hold the
weight of the entire rotor string. There are several types of motor thrust bearings. The
thrust bearing limits indicate the type of load required for the selected bearing material.

Fig (3.10) shown motor thrust bearing

4) - The pothead
The pothead is a key part to connect the motor with the power cable; its mechanical and
end sealing ensure the long-term operation of the motor.

Fig (3.11) shown pothead of the motor

26
CHAPTER III ESP

B) – Motor seal (protector)

The Motor seal is installed below the intake and above the electric motor. It is also
named: Equalizer, balance chamber, or Protector.

Fig (3.12) shown the motor seal

The main Functions of protector:

1 - Equalizes the pressure in the wellbore with the pressure inside the motor.

2 -Provides area for motor oil expansion volume (induced by temperature changes in the
motor)
3- isolates the well fluid from the clean motor oil
4 - Absorbs the pump shaft thrust load

27
 CHAPTER III ESP

C) – ESP pump intake

“Pump Intake” is where the well fluid enters the Submersible Pumping System. Care
should be taken when designing a submersible pump intake because it is such a vital point
in the system that when not designed properly may create all kinds of problems. (8)

Fig (3.13) shown pump intake of ESP

There are three types of intake Sections:

1) Standard Intakes or BOI (bolt on intake).

2) Integral (manufactured as part of the pump).
3) Gas Separators (static and rotary gas separators).

28
 CHAPTER III ESP

D) ESP cable
The main cable consists of three conductor wires extending from the top of the motor flat
lead extension to the wellhead banded to the production tubing. The ESP cable carries
current (amperage) from the motor controller at the surface down to the motor. (8)

Fig (3.14) shown cables of ESP

Round and flat configurations are available in various materials and sizes

Fig (3.15) shown the flat and round cables

29
 CHAPTER III ESP

Power cable compounds

 Conductor
 Insulation
 Jacket
 Braids and covering
 Armor
 Injection Tube (optional)

1) - Cable conductor

The AC current is carried from the surface to the motor using cable conductor. It is generally
made of copper but some aluminum cable conductors exist. For ESP applications, four sizes
of conductors have been standardized: #1, #2, #4 and #6 AWG. The conductors may be
solid, stranded, or compact stranded.

2) - Cable insulation

Cable insulation isolates the electrical potential between conductors and other conducting
materials. Insulation also minimizes leakage current from the conductors.

3) - Cable jackets

Cable jackets are protective coverings used to mechanically shield the insulation from the
down hole environment.

4) - Braids and coverings

Supplementary layers of materials, named: braids and coverings, are used to guarantee a
specific mechanical performance characteristics. It could be either applied over the
insulation or on both sides of the jacket

5) - Cable armor

Cable armor is the outer covering of the cable which provides mechanical protection during
installation and removal of cables. In addition to the armor provides mechanical constraint
against swelling and expansion of underlying elastomeric materials in case of any exposure to

30
 CHAPTER III ESP

Well fluids. Cable is available in a range of conductor sizes, insulation types and construction to
accommodate well conditions, temperatures, etc. The cable manufacturer should be consulted for
specific recommendations when well conditions exist. The economic considerations are
governed by power cost, physical dimensions between the tubing and well casing, and the cost.

Fig (3.16) shown the components of ESP cable

E) - Centrifugal Pump (ESP Pump)

Pump Theory

The term “centrifugal pump” has been used to describe a wide variety of pumping applications
and designs throughout the years. A Centrifugal Pump is a machine that moves fluid by spinning
it with a rotating impeller in a diffuser that has a central inlet and a tangential outlet. The path of
the fluid is an increasing spiral from the inlet at the center to the outlet tangent to the diffuser.
The fluid rotational motion is the result of the concept of centrifugal forces. The pressure (head)
develops against the inside wall of the diffuser because of the curved wall forces fluid to move in
a circular path. (8)

31
 CHAPTER III ESP

Centrifugal Pump
The centrifugal pump is a multi-stage pump, containing a selected number of impellers
equipped with vanes, inside a closely fitted diffuser, located in series on an axial shaft,
driven by the electrical motor. It creates pressure by the rotation of a series of vanes in an
impeller. The impeller’s job is to transfer energy by rotation to the liquid passing through it,
thus raising the kinetic energy. The diffuser section then converts this energy to potential
energy, raising the discharge pressure. (8)

Pump Stage
A “Pump Stage” consists of an impeller, diffuser and thrust washers. The impellers rotate
with the shaft and spin at the RPM of the motor. The stationary diffusers turn the fluid into
the next impeller and do not rotate. Pumps are assembled by stacking stages on a shaft and
compressing the stack in housing. A stage will produce a given amount of flow and lift
(head) at the motor RPM. By stacking the Stages, the required head (TDH = Total Dynamic
Head) is obtained. (8)

Fig (3.17) shown the impeller and diffuser of ESP pump

32
 CHAPTER III ESP

Fig (3.18) shown the pump stage

Pump Impeller
The impeller is keyed to the shaft and rotates at the motor operating speed. The main impeller
compounds are:
Up thrust Washer, Top Shroud, Impeller Vane, down thrust Washer, Impeller Eye,
Impeller Skirt, Bottom Shroud and Impeller Hub.

Fig (3.19) shown the impeller of pump

33
 CHAPTER III ESP

Pump Diffuser
The diffuser is stationary and its function is to allow the fluid to flow efficiently from one
impeller to another. Also, it’s at the diffuser where the kinetic energy (velocity) is converted
into potential energy (pressure). Pump stages are placed onto a keyed shaft and then loaded
into a steel housing. When the threaded head and base are screwed into the housing, they
compress against the outside edge of the diffusers. This compression holds the diffusers
stationary. If, for any reason, this compression were lost, the diffusers would be free to
rotate. This rotation would cause the pump to lose almost all of its ability to produce any
(8)
head (or lift).

Fig (3.20) shown the pump diffuser

34
CHAPTER III ESP

3.2.3 ESP optional components

A) Down hole sensors

Sensors are available for mounting internally in the ESP components or externally as an
attachment to the system. The signals from these sensors are communicated to the surface
readout module by a separate instrument wire, "I"-wire, or by a signal imposed on one leg
of the ESP power cable. Typically, the standard ESP application only provides the
opportunity to monitor surface parameters, such as three-phase amps and volts, wellhead
(9)
pressure, and, to a limited extent, flow rate. Therefore, the protection and evaluation
possibilities are reduced. Today, there are sensor packages available that provide
measurement and monitoring of the following parameters:

1) Pump intake or casing annulus pressure

2) Internal motor temperature
3) Pump discharge pressure
4) Pump discharge temperature
5) Down hole flow rate
6) Equipment vibration

B) ESP packers
ESP packers are used when there is a requirement or a need for it to be set above the ESP
system their use normally prevents venting free gas up the annulus, unless a vented packer
is used. Packers can be shallow set or deep set. ESP packers have an electrical power cable
feed-through feature added to the normal wellbore packer functions. (9)

C) Centralizers/protectorilizers

Centralizers are sometimes used when the ESP is installed in a deviated wellbore. Its
function, when used in a deviated wellbore, is to be a contact point with the casing and
allow the ESP unit to have some standoff clearance. They are typically located at the
bottom of the ESP unit and, in some cases, at points along its length or at the discharge
tubing. They have to be constructed so as not to restrict the flow by the motor and to the
pump intake. (9)

35
CHAPTER III ESP

Fig (3.21) shown the Centralizers

Protectorilizers
Protectorilizers are used to protect the power cable, motor lead extension (MLE), and any
small hydraulic or electrical communication line from mechanical damage in deviated or
restricted-clearance casing, Along the ESP unit. (9)

D) Check/drain tubing valves

A check valve is used in the production tubing string, generally two to three joints above
the pump discharge, to maintain a full column of fluid above the pump. This may be
desired to eliminate the time it takes to raise the fluid from its static fluid level to the
surface ("pump-up time") or the protective shutdown time for fluid fallback. Normally,
each time an ESP cycles off, the fluid falls back from the surface to its static fluid level. On
restart, it again has to lift the fluid from its static point to the surface. Holding the fluid in
the tubing can eliminate this. Also, when the fluid is falling back, it causes the de-
energized pump to spin backwards. (9)

36
CHAPTER III ESP

Fig (3.22) shown the check valve

E) Motor shroud

The shroud assembly is made up of a jacket (a length of casing or pipe), a hanging clamp
and sealing retainer for the top, and a centralizer for the bottom. The shroud should extend
to below the bottom of the motor. The shroud inside diameter (ID) has to allow for the
insertion of the ESP with flow clearance to allow for proper cooling velocities without
choking or excessive pressure drop to the flow. The shroud outside diameter (OD) must
have sufficient clearance with the casing ID to assure reliable deployment and proper flow
from the well perforations to the pump intake. (9)

Fig (3.23) shown the motor shroud

37
CHAPTER III ESP

F) Screens and filters

Screens and filters are used with ESP systems to prohibit the flow of large solids into the
pump intake several cautions must be mentioned if screens or filters are used. The open
area of the screen must be several times larger than that of the open area of the pump
intake ports. This allows for proper flow without choking when, not if, the screen starts
building up debris and plugging. This is also the case with the filters. Also, remember that
the separated debris has to go somewhere and that is generally in the rat hole below the
ESP. The rat hole must be large enough to hold the amount of debris expected over a
period of time. This is because if it starts building up on the ESP, it can cause motor heat
problems, eventual complete plugging of the intake ports, and difficulty in pulling the unit.
Plugged screens and filters may cause severe pump and motor problems, if not designed
and applied correctly. (9)

G) Y-tool or bypass
The Y-tool and bypass system enables intervention or logging with wire line below an
ESP. It also provides a method to configure more than one ESP in a well to accomplish
production goals. The Y-tool is installed on the production tubing, providing two separate
conduits. One conduit is concentric with the production tubing and enables access to the
reservoir below the ESP. The second conduit is offset and used to support the ESP
system. (9)

Fig (3.24) shown Y-Tool / bypass

38
CHAPTER III ESP

3.3 Advantage of ESP pump

1) - Can lift a wide range of volumes from low volumes 400 B/D, to extremely high
volumes (26400 m3/d) in shallow wells with large casing.

2) - Unobtrusive in urban locations.

3) - Simple to operate.

4) - Easy to install down hole pressure sensor for telemetering pressure to surface by cable.

5) - Crooked holes present no problem.

6) - Applicable offshore.

7) - Corrosion and scale treatment easy to perform.

8) - Availability of different sizes.

9) - Lifting cost for high volumes generally very low.

3.4 Disadvantage of ESP pump

1) -Not applicable to multiple completions.

2) - Only applicable with electric power.

3) - High voltages (1,000 V) are necessary.

4) - Impractical in shallow, low volume wells.

5) - Expensive to change equipment to match declining well capability.

6) - Cable causes problems in handling tubular.

7) - Cables deteriorate in high temperatures.

8) - System is depth limited, 10,000 ft (3048.0 m), because of cable cost and inability to
install enough power down hole (depends on casing size).

9) - Gas and solids production are troublesome.

39
CHAPTER III ESP

10) - Not easily analyzable unless good engineering know-how.

11) - Lack of production rate flexibility.

12) - Casing size limitation.

13) - More downtime when problems are encountered because of the entire unit being
down hole.

40
Chapter 4

 Content:

 ESP design by hand calculation with Wc 21%

 ESP design by Software
 Comparison between software and hand calculation design
 ESP design by hand calculation with Wc 50%
 Comparison between the hand calculation designs with different
Wc %
CHAPTER IV ESP DESIGN

CHAPTER 4
4. DESIGNING OF ESP

4.1 ESP design by hand calculation with Wc 21%

4.1.1 Basic data

Field: Sarir field

Well no: L –31

[1] Well Data:

 Casing size = 7 inch

 Tubing size = 3 1/2 inch

 Top perforation = 8918 ft

 Deviation survey = vertical

 Datum depth = 8400 ft

[2] Production Data:

 Wellhead pressure = 220 psi

 Oil Production = 1100 STB/day (1254 BOPD)

 Water production = 300 STB/day (312 BWPD)

 Total production = 1400 STB/day (1566 BPD)

 Productivity index = 5 STP/ /day / Psi

 Static bottom hole pressure = 2825 psi

 Gas-oil ratio = 90 SCF/STB

 Water cut = 21%

42
CHAPTER IV ESP DESIGN

 Bottom hole Temperature = 200 F

[3] Fluid properties

 Bubble point pressure = 600 psi

 Oil formation volume factor = 1.14 RB/STB

 Water formation volume factor = 1.04 RB/STB

 Oil gradient = 0.32 psi/ft

 Water gradient = 0.48 psi/ft

4.1.2 Hand Calculation

First Step: Calculate Flowing bottom hole pressure

PI = (Q / (PS-PWF))
PWF = PS – (Q/PI)
PWF = 2825 – (1400/5) = 2545 Psi

Second Step: Calculate Liquid gradient

Liquid gradient = (Oil percentage * Oil gradient) + (Water percentage * water gradient)
Liquid gradient = (0.7857 * 0.32) + (0.21428 * 0.48) = 0.354285714 Psi/ft

Third Step: Calculate Dynamic fluid level

D.F.L = Datum depth – (PWF/ Liquid gradient)

D.F.L = 8400 – (2545/0.354285714) = 1216.532 Ft from the surface

43
CHAPTER IV ESP DESIGN

Fourth Step: Calculate Tubing friction loss

from the intersection 2.992" ID of old tubing and production rate 1566 bbl as shown in
the chart below , the tubing friction loss = 11.8 ft / 1000 ft

Fig (4.1) shown Tubing friction loss

Also, we calculated tubing friction loss by hazen williams equation

F = (2.083 × ((100 / C) ^ 1.852) × ((Q / 34.3) ^1.85)) / (ID ^ 4.8655)
F = (2.083 × (( 100 / 100) ^1.852) × ((1566 / 34.3) ^1.85)) / ( 2.992 ^ 4.8655)
F = 11.8 ft/ 1000 ft

Fifth Step: Calculate Minimum pump depth

Minimum pump depth = Datum depth – ((PWF – BP) / Liquid gradient)

Minimum pump depth = 8400 – ((2545-600) / 0.354285714) = 2910 ft
according to the minimum pump depth , we select actual pump depth
= ± 4500 ft

44
CHAPTER IV ESP DESIGN

\Sixth Step: Calculate Total dynamic head

TDH = Wellhead pressure + Dynamic fluid level + Tubing friction

TDH = (220/ /0.354285714) + 1216.53 + (11.8 /1000 × 4500) = 1890.59 ft

Seventh Step : we selected ESP Pump type from Schlumberger REDA catalog 2007
GN1600 , 50 HZ / 2917 RPM , 540 series by capacity 1566 BFPD (248.9 m3 /day ) and
casing size = 7"

Fig (4.2) shown the pump performance curve

Eighth Step : Calculate actual , minimum number of stages

We calculated Number of stages by intersection of capacity and down thrust curve from
fig (4.2) and the result = 26.69 ft / stage
Minimum number of stages = (TDH / number of stages)
Minimum number of stages = 1890.59 / 26.69 = 70.8 stage
We selected Actual number of stages from the table below = 75 stages , hsg = 50
Fl – CT Part number = 1019744

45
CHAPTER IV ESP DESIGN

Fig (4.3) shown max stages of the pump

Ninth Step : Calculate Horse power and efficiency

we calculate horse power by intersection of capacity and horsepower curve from fig (4.2)
Horse power = 0.52 hp / stage
Minimum Hp for all stages = Number of stages × (Hp / stage)
Minimum Hp for all stages = 75 * 0.52 = 39 Hp
we calculate efficiency by intersection of capacity and efficiency curve from fig (4.2)
the pump efficiency = 58 %

46
CHAPTER IV ESP DESIGN

Tenth Step : Select type of the pump intake

we selected ARZ – intake 540/540 (Standared) 540 series as shown in the figure below

Fig (4.4) shown the types of pump intake

Eleventh Step : Select type of the protector

we selected LSB type of the protector 540 series

Fig (4.5) shown the types of the protector

47
CHAPTER IV ESP DESIGN

Twelveth Step : Select type of the motor and specification

We selected Dk – type motor 50 HZ by 540 series and ID of the casing as shown in the
fig(4.6) below actual motor specification :
Hp = 42 hp
Ampere = 20.2 A
Volt = 1297 v

Fig (4.6) shown the volt and ampere of the motor

48
CHAPTER IV ESP DESIGN

Thirteenth Step : Choose type of the cable , voltage drop and surface voltage required

We selected Cable type = Redalene cable (POTP – G5F) - NO 2 CU compacted – flat

as shown in the figure below

Fig (4.7) shown the types of the cables

49
CHAPTER IV ESP DESIGN

Cable length = 4600 ft

The cable voltage drop as shown in the fig below = 6 volt / 1000 ft

Fig (4.8) shown the cable voltage drop

Tcf = 1 + 0.00214 * (T – 77)

Tcf = 1 + 0.00214 * (200 -77) = 1.26322
Actual voltage drop at 200F = 6 * 1.26322 = 7.57932 v / 1000 ft
Actual voltage drop for 4600 ft = (7.57932 /1000) × 4600 = 34.8648 v

Surface voltage required = voltage required at the motor + cable voltage drop
Surface voltage required = 1297 + 34.8648 = 1313.86 v

50
CHAPTER IV ESP DESIGN

4.1.3 The results of hand calculation

Table (4.1) shown the results of hand calculation with WC 21%

Name Results

D .F. L 1216.532 ft

Tubing friction 53.1 ft

T.D.H 1890.59 ft

Pump type GN – 1600 / 540 series

Actual stages 75 stage

Hp 42 hp

Volt 1297 v

Ampere 20.2 A

Pump efficiency 58 %

51
CHAPTER IV ESP DESIGN

4.2 Design ESP by Software

Fig (4.9) shown the results of ESP design by software

52
CHAPTER IV ESP DESIGN

4.2.1The results of software

Table (4.2) shown the results of Software

Name Result

D .F. L 1217 ft

Tubing friction 60 ft

T.D.H 1897 ft

Pump type GN - 1600

Actual stages 75 stage

Hp 58 hp

Volt 943 v

Ampere 23 A

Pump efficiency 58%

53
CHAPTER IV ESP DESIGN

4.3 Comparison between hand calculation and software

Table (4.3) shown the results of comparison between software and hand calculation

Name Hand calculation Software results Error %

D. F. L 1216.532 ft 1217 ft 0.03 %

Tubing friction 53.1 ft 60 ft 11.5 %

T.D.H 1890. 59 ft 1897 ft 0.3 %

Pump type GN- 1600 GN-1600 0%

Actual stages 75 stage 75 stage 0%

HP 42 hp 58 hp 27.5 %

Volt 1297 v 943 v ---

Ampere 20.2 A 23 A 12.17 %

Pump efficiency 58 % 58 % 0%

54
CHAPTER IV ESP DESIGN

4.4 ESP Design for the same well by hand calculation with increased Wt %

4.4.1 basic data

Field: Sarir field
Well no: L –31

[1] Well Data:

 Casing size = 7 inch

 Tubing size = 3 1/2 inch

 Top perforation = 8918 ft

 Deviation survey = vertical

 Datum depth = 8400 ft

[2] Production Data:

 Wellhead pressure = 220 psi

 Oil Production = 700 STB/day (798 BOPD)

 Water production = 700 STB/day (728 BWPD)

 Total production = 1400 STB/day (1526 BPD)

 Productivity index = 5 STP/ /day / Psi

 Static bottom hole pressure = 2825 psi

 Gas-oil ratio = 90 SCF/STB

 Water cut = 50 %

 Bottom hole Temperature = 200 F

55
 CHAPTER IV ESP DESIGN

[3] Fluid properties

 Bubble point pressure = 600 psi

 Oil formation volume factor = 1.14 RB/STB

 Water formation volume factor = 1.04 RB/STB

 Oil gradient = 0.32 psi/ft

 Water gradient = 0.48 psi/ft

4.4.2 Hand Calculation

First Step: Calculate Flowing bottom hole pressure

PI = (Q / (PS-PWF))
PWF = PS – (Q/PI)
PWF = 2825 – (1400 /5) = 2545 Psi

Second Step: Calculate Liquid gradient

Liquid gradient = (Oil percentage * Oil gradient) + (Water percentage * water gradient)
Liquid gradient = (0.5 * 0.32) + (0.5 * 0.48) = 0.4 Psi/ft

Third Step: Calculate Dynamic fluid level

D.F.L = Datum depth – (PWF/ Liquid gradient)

D.F.L = 8400 – (2545 /0.4) = 2037.5 Ft from the surface

56
 CHAPTER IV ESP DESIGN

Fourth Step: Calculate Tubing friction loss

from the intersection 2.992" ID of old tubing and production rate 1526 BBL as shown in
the chart below , the tubing friction loss = 11.27 ft / 1000 ft

Fig (4.10) shown Tubing friction loss

Also, we calculated tubing friction loss by hazen williams equation

F = (2.083 × ((100 / C) ^ 1.852) × ((Q / 34.3) ^1.85)) / (ID ^ 4.8655)
F = (2.083 × (( 100 / 100) ^1.852) × ((1526 / 34.3) ^1.85)) / ( 2.992 ^ 4.8655)
F = 11.27 ft/ 1000 ft

Fifth Step: Calculate Minimum pump depth

Minimum pump depth = Datum depth – ((PWF – PB) / Liquid gradient)

Minimum pump depth = 8400 – ((2545-600) / 0.4) = 3537.5 ft
according to the minimum pump depth , we select actual pump depth
= ± 4500 ft

57
 CHAPTER IV ESP DESIGN

Sixth Step: Calculate Total dynamic head

TDH = Wellhead pressure + Dynamic fluid level + Tubing friction

TDH = (220/ /0.4) + 2037.5+ (11.27 /1000 × 4500) = 2638.215 ft

Seventh Step : we selected ESP Pump type from Schlumberger REDA catalog 2007
GN1600 , 50 HZ / 2917 RPM , 540 series by capacity 1526 BFPD (243 m3 /day ) and
casing size = 7"

Fig (4.11) shown the pump performance curve

Eighth Step : Calculate actual , minimum number of stages

We calculated Number of stages by intersection of capacity and down thrust curve from
fig (4.11) and the result = 27.5591 ft / stage
Minimum number of stages = (TDH / number of stages)
Minimum number of stages = 2638.215 / 27.5591= 95.729 stage
We selected Actual number of stages from the fig below = 106 stages , hsg = 70
Fl – CT Part number = 1019751

58
CHAPTER IV ESP DESIGN

Fig (4.12) shown max stages of the pump

Ninth Step : Calculate Horse power and efficiency

we calculate horse power by intersection of capacity and horsepower curve from fig (4.11)
Horse power = 0.52 hp / stage
Minimum Hp for all stages = Number of stages * (Hp / stage)
Minimum Hp for all stages = 106 × 0.52 = 55.12 hp
we calculate efficiency by intersection of capacity and efficiency curve from fig (4.11)
the pump efficiency = 59 %

Tenth Step : Select type of the pump intake

we selected ARZ – intake 540/540 (Standared) 540 series as shown in the figure below

Fig (4.13) shown the types of pump intake

59
CHAPTER IV ESP DESIGN

Eleventh Step : Select type of the protector

we selected BSBSL type of the protector 540 series

Fig (4.14) shown the types of the protector

Twelveth Step : Select type of the motor and specification
We selected Dk – type motor 50 HZ by 540 series and ID of the casing as shown in the
fig( ) below actual motor specification :
Hp = 63 hp
Ampere = 36.6 A
Volt = 1073 v

Fig (4.15) shown the volt and ampere of the motor

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CHAPTER IV ESP DESIGN

Thirteenth Step : Choose type of the cable , voltage drop and surface voltage required

We selected Cable type = Redalene cable (POTP – G5F) - NO 2 CU compacted – flat

as shown in the figure below

Fig (4.16) shown the types of the cable

Cable length = 4600 ft

the cable voltage drop as shown in the fig below = 10.2 volt / 1000 ft

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CHAPTER IV ESP DESIGN

Fig (4.17) shown voltage drop of the cable

Tcf = 1 + 0.00214 * (T – 77)

Tcf = 1 + 0.00214 * (200 -77) = 1.26322
Actual voltage drop at 200F = 10.2 * 1.26322 = 12.8848 v / 1000 ft
Actual voltage drop for 4600 ft = (12.8848 /1000) × 4600 = 59.27 v

Surface voltage required = voltage required at the motor + cable voltage drop
Surface voltage required = 1073 + 59.27 = 1132.2 v

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CHAPTER IV ESP DESIGN

4.4.3 The results of hand calculation

Table (4.4) shown the results of hand calculation with WC 50%

Name Results

D.F.L 2037.5 ft

Tubing friction 50.715 ft

TDH 2638.215 ft

Pump type GN 1600 / 540 series

Actual stages 106 Stage

HP 63 hp

Volt 1073 v

Ampere 36.6 A

Pump efficiency 59 %

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CHAPTER IV ESP DESIGN

4.5 Comparison of the same well with two different Wc %

Table (4.5) shown the results of comparison between two hand calculation designs

NAME Wc = 21 % Wc = 50 %

D.F.L 1216.532 ft 2037.5 ft

Tubing friction 53.1 ft 50.715 ft

TDH 1890.59 ft 2638.215 ft

Pump type GN – 1600 / 540 series GN 1600 / 540 series

Actual stages 75 stage 106 Stage

HP 42 hp 63 hp

Volt 1297 v 1073 v

Ampere 20.2 A 36.6 A

Pump efficiency 58 % 59 %

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CHAPTER V CONCLUSION & RECOMMENDATION

CHAPTER 5
5. CONCLUSION AND RECOMMENDATION

5.1. CONCLUSION

1- Well no L- 31 from sarir field was selected to be the case study in this work.

2- From the input data we designed down hole ESP system with WC 21%

3- We compared our first design results to preexisting software (excel sheet) for calibration
Purposes and our results were close enough to the software.
4- We designed another down hole ESP system with the same data but with increasing of
WC to 50 %.
5- We compared first ESP design result to the second design result to observe the effect
Of increase in WC % on ESP design, note that we selected the same pump for comparison
purposes.
6- The effect of increase in WC % caused increase in TDH thus caused increase in the
Stages that required to lift the fluid to the surface, thereby requiring more horse power.
7- The variation of WC has no effect on our selection for intake and the cable but it has
On our selection of the protector.

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CHAPTER V CONCLUSION & RECOMMENDATION

5.2 RECOMMENDATION

1- before you design ESP system you have to familiar with the history of the well and
conduct regular tests at least every two weeks to get accurate reading.

2- You have to be careful with power supply source because the variation of power supply
causes pump problem.
3- You may need gas separator or advanced gas handler for your design if you have high
gas oil ratio.

4- You have to be well informed with down hole environment because it has significant
effect on ESP design such as sand, high temperature, corrosive gases etc.

5- When you designing ESP system by software you have to be accurate about your input
data.

6 - Troubleshoot the well before calling the work over rigs.

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 References

(1) Petroleum reservoir From Wikipedia, the free encyclopedia

https://en.wikipedia.org/wiki/Petroleum_reservoir

(2) Drive mechanisms and recovery from AAPG WIKI

http://wiki.aapg.org/Drive_mechanisms_and_recovery

(3) Rig zone website

https://www.rigzone.com/training/insight.asp?insight_id=315&c_id=

(4) Petrowiki
https://petrowiki.org/Gas_lift

(5) Petrowiki
https://petrowiki.org/Sucker-rod_lift

(6) Petropedia
https://www.petropedia.com/definition/8141/electrical-submersible-
PUMP-ESP
(7) https://www.slb.com/-/media/Files/resources/oilfield_
review/defining_series/Defining-ESP.pdf?la=en&hash
=CD7B3A0D52EE0AEC154FF643CD92A0B1F6834B39
(8) Production technology
https://production-technology.org

(9) Petrowiki
https://petrowiki.org/ESP_optional_components

67