ESP design project:

Introduction:
Electrical submersible pump:
Electrical submersible pump (ESPs) are easy to install and operate. They can
lift extremely high volumes form highly productive oil reservoir crooked/
deviated holes present no problem. ESPs are applicable to offshore
operations. lifting costs for high volumes are generally very low. Limitation to
ESP application include high voltage electricity availability, not applicable to
multiple completion, not suitable to deep and high temperature oil reservoirs,
gas and solids production is troublesome, and costly to install and repair. ESP
systems have higher horsepower, operate in hotter application, are used in
dual installations and as spare down -hole unit, and include down -hole oil and
water separation. Sand and gas problems have led to new products.
Automation of the systems includes monitoring, analysis and control. the ESP
is a relatively efficient artificial lift. ESP consists of subsurface and surface
components
d- subsurface components
- Pump
- Motor
- Seal electric cable
- Gas separator
c- surface components
- Motor controller
- Transformer
- Surface electric cable
The over all ESP system operate like any electric pump commonly used in
other industrial application. In ESP operations, electric energy transported to
the down hole electric motor via the electric cables. These electric cables are
on the of production tubing. the electric cable provides the electric energy
needed to actuate the down hole electric motor. the electric motor drives the
pump imparts the energy to the fluid in form of hydraulic power which lift
fluid to the surface.
 Literature review:
ESP System Operating Principle: -
The operating principle of ESP is based on installing a pump at the bottom of the
well increasing the pressure and allowing fluids to be produced
For this, a centrifugal pump is driven by an electrical submersible motor and
installed in the well
Electric energy to the motor is provided from the surface through an electrical
cable
Electrical Submersible Pumping:
Very complex system with a Mean Time Between Failures (MTBF) average
around 2 ½ year worldwide. However, MTBF is very dependent on working
conditions and there are many units operating for more than 10 years.
Can be applicable to a wide range of flowrates from 100 bpd up to 100,000 bpd.
Investment cost is directly related to the depth due to cable cost and motor
horsepower.
Efficiency increases with reduction in produced GLR either by reduction of GOR
or increase in WC.
Efficiency decreases with decrease in flowrate.
Casing size is not critical for high flowrates, although smaller casing allows for
installation of smaller less efficient pumps with smaller flow capacity.
Requires work-over to remove a conventional unit although cable and coil
deployed options are available.
Electrical systems require a stable source of electricity.
Electrical system (cable, motor and protector) are very sensitive to operating
temperature and fluids.
Can be very flexible with the use of a Variable Speed Drive (VSD) although this
will increase the investment costs.
Very delicate installation and a sometimes-high rate of “infant mortality” exist.
May have problems with scale, sand and wax although technological solutions
exist that may attenuate those problem
Lift Principle:
In order to produce flowrates higher than the natural equilibrium flowrate the
use of an artificial lift system is necessary
If an ESP is installed in the tubing string close to the perforations, the discharge
pressure of the pump is equal to the OPR pressure and the intake pressure of
the pump is equal to the IPR pressure
The difference between the OPR and IPR bottom hole flowing pressure for
flowrates bigger than the natural equilibrium flowrate defines the pressure
increment that the ESP must deliver
Pump performance:
The important information shown in the graph is the recommended
operating range
This is a region around the best efficiency point of the pump where the
manufacturer recommends the pump to be operated
Operating outside this range will damage the pump or the system
Pump performance catalog:
The catalog contains a summary of all the pumps manufactured
 Pump Performance Catalog Data (Cont.
The hydraulic horsepower and the motor load have the same unit
The hydraulic horsepower and the pump motor load are not the same
The hydraulic horsepower is the power transmitted to the fluids
The motor load is the required power at the pump shaft so that the pump
can work at the specified capacity delivering hydraulic horsepower to the
fluids therefore raising their pressure
Pump Performance Catalog Data (Cont.)
The maximum number of stages for each pump type is a function of the shaft
resistance (standard or high strength), the casing maximum pressure (standard
or high pressure) and the maximum load on the thrust bearing
As we increase the number of stages, the torque at the lower part of the shaft
increases. This can not be bigger than the shaft torque specifications
One of the common “accidents” with ESP is to start the system against a closed
valve. In this case the flowrate is zero and the stage develops its maximum head
(shut-off head). The pump casing has a bolted (or screwed) head and the pump
internal pressure can not exceed this connection limitation
Pumps will develop a thrust that must be supported by bearing located in the
seal or protector section.
The thrust is a combination of the force resulted from the fluids hitting the
impeller sat the pump intake trying to move them up (upthrust) and the force
resulting from the reaction of the impeller moving the fluids up on the discharge
which results on a force of the fluids trying to move the impeller down
(downthrust).
The result of those two effects is the net thrust of the impeller
If the number of stages is too high the thrust bearing limitations may be
exceeded
Types of Impeller Design:
The most obvious variable that affects pump performance is the size of the stage.
The effect of different pump diameters with same hydraulic design can be
estimated using the affinity laws
Bigger Pumps
More efficient
Less expensive
Better in handling gassy and viscous fluids
Handles higher HP
Develop Higher Thrust
A more complicate performance change has to do with the geometrical design of
the impeller itself. For the same pump size, same bep, efficiency will be a function
of the specific speed which is related with the pump hydraulic design.
Pump Selection
The selection of a pump for an application depends on several factors
Size of casing –determine the maximum size of pump
Frequency of electric power available –determine the rotational speed of the
motor
Flowrate desired –select pump with flowrate in optimum range for higher
efficiency
Pump Hydraulic design –Select the highest available efficiency pump for the same
size and bep.
Special conditions –gassy wells, viscous fluids, corrosive fluids, abrasive fluids –
may require special equipment
 Methodology:
The Total Dynamic Head Method
This method is only valid for single phase flow conditions
It assumes the liquid in the well is single phase
It neglects the friction losses in the casing
The pump must be set below the dynamic liquid level. A minimum pump
submergence is usually assumed to prevent the pump from running dry
The bottom hole flowing pressure is capable of lifting the fluids all the way to the
dynamic liquid level
The pump must provide a head sufficient to lift the fluids from the liquid level all
the way to the surface and to overcome the friction losses in the tubing
Result and discussion:
ESP design:

 A well 8000 ft deep, produces a mixture of oil and water with an specific
gravity of 0.95 and viscosity of 1 cp.
 The wellhead pressure is 140 psi and the minimum pump submergence
desired is 300 ft of fluid.

 The reservoir has an average reservoir pressure of 2070 psi and the
productivity index is 10 bpd/psi.
 Based on this information determine:
 The minimum pump setting depth
 The total dynamic head
 And the required hydraulic horsepower for a flowrate of 2200 bpd
for a tubing of 1.995” ID with a roughness of 0.00015 in
 The surface temperature is 65F and the temperature gradient is
15F/1000ft.
 The casing size is 6 5/8”.
 Electric current is at 60Hz and the protector will require 5 hp
 Determine the adequate pump to be installed in this well and the operating
param
Data
L res =8000 ft
Sg = 0.95
Viscu = 1 cp
Pwh = 140 psi
L sub = 300 ft
P = 2070 psi
J = 10 bpd/psi
Q= 2200 bpd
Dt = 1.995 id
Roughnes= 0.00015 in
Step 1
finding bottomhole pressure by using equation
2200
Pwf =p-q/j = 2070 – 10 = 1850 psi

finding dynamic liquid level using equation

step 2
finding dynamic liquid by equation
1850
8000- 0.433∗0.95 = 3503 ft

step 3:
finding pump setting depth by using equation

L pump = 3503+300 = 3803 ft

Step 4: finding require head

0.95∗2200
Re =92.2* 1∗1.995 = 96590

finding A by using equation

( (( )
16
1
[2.45∗ ln ]
) +(0.27∗( 0.00015
1.995 ) )
0.9
A= 7 = 1.2531*10^21
96590

Finding B by using equation

 16
37530
B =( ) = 2.69841*10^-7
96590

Finding friction by using equation

[ ]
1

( ) +(
12
8 1 ¿
12
8
F = 96590 3 = 0.018443
1.2531∗10 +2.69841∗10 )
21 −7 2

finding head required by using equation

−5 2
140 2.649210 ∗0.018443∗2200
Hreq = 0.433∗0.95 +3503+ 5
∗3803 = 4128 ft
1.995

Determine hydraulic horsepower

Hph =7.3710−6∗q∗Hreq∗sg
Hph = 7.3710−6∗2200∗4128∗0.95=64 hp
Step 5
Finding pump discharge by using equation

Pintake =0.433∗0.95(3803−3503) = 123 psi

Finding ΔP
ΔP=0.433∗sg∗Hreq = 0.433*0.95*4128 = 1698 psi
Pdischg = Pintake+ ΔPump = 123+1698 = 1821 psi
Step 6
Selecting pump based on
Q = 2200 bpd
Ldyn =3503 ft
Lpump = 3803 ft
Hreq = 4128 ft
Pumps use
TD 2200 1400---------2800 bpd
TD 3000 2000---------3700 bpd
TG 2000 1600-----------2700 bpd
TG 2500 1700----------3000 bpd
 Flowrate bpd Head ft Motor hp
2200 24.2 5
3000 15.5
2000 26
2500 23

Finding numbers of stages

Hreq 4128
1-N = Hstg = 24.2 =171

N = 171 stages
Hreq 4128
2-N= stage = 15.5 =266 stages

Hreq 4128
3-N= stages = 26 =159 stages

Hreq 4128
4-N= stages = 23 =179 stages
Conclusion: -
Head required.
The head that the pump must provide depends on the available intake pressure
and the required discharge pressure
To calculate those pressure, pressure drop models or correlations must be used.
Those correlations or models depend on the nature of the fluids being produced
Once the pump pressure increment is known we can determine the number of
stages based on the pump head performance and the fluids being produced
The pump head performance depends on the pumping conditions such as single
or multiphase flow, low or high viscosity
Single phase low viscosity fluids are usually very easy to design
Design for high viscosity and or multiphase conditions is possible, but they bring
added complications as well as uncertainties to the design
As a result, ESP applications can be grouped depending on the nature of the
problem
Bibliography:

1-petroleum production second addition

2-electrical submersible pump note