design of simple water and light crude oil. For more
high GOR, viscous oil, high-temperature wells, etc. a number of c
available to automate this process.
Step 1: Basic Data:
{As detailed in the article “Step 1: Basic data’, step 1 of the nine step design procedure is
the most important step because all the others design steps will depend on the basic data
selected in this step.
In this example, @ high water cut well is considered. This is the simplest type of welll for
sizing submersible equipment.
Well Profile: 13" 2/8 Casing 72H KSS @ 118m
37/2 Tubing Nuss 9.24
9°5/8 Casing K55 40% @ 1243m Water Cut: 90%
Water Gravity: 1,04 rel-H20
Gas Gravity: 0,8 rebair
Producing GOR: 200 sefist
Bubble Pressure: 964 psi
Bottomhole Temperature: 90 °C
Wellhead Temperature: 50 °C
Wellhead Pressure: 87 psi
Casing-Head Pressure: 15 psi
inflow performance:
Present production rate: 2500 bfpd @ Pump Intake Pressure = 1160. psi
Reservoir Pressure: 2320.6 psi
Datum point 2003m (top perforation).
Pump Intake Pressure: 1160 psi
Desired production rate: 3500 bipd.
Power sources;
Available primary voltage: 418 V
Desired frequency range: 40Hz — 65Hz
Possible problems?
No sand production, no scale deposit
‘No gas impurities (N2, H2S and Co2).
Production Capacit PI=Q/(Pr-Pwh)
Firstly, we need to calculate the flowing bottomhole pressure (Pw!). Pw is ¢
the pump intake pressure (PIP), hydrostatic pressure and friction loss in the c
annulus between the pump setting depth and the datum point. In the given example,
the pump is set 290m above the perforations, the friction loss, because of flow of fluid
through the annulus from perforations to pump setting depth, is small, as compared to the
flowing pressure, and can be neglected.
Pw is calculated from the pump intake pressure (PIP), hydrostatic pressure and friction }
loss in the casing annulus between the pump setting depth and the datum point. In the
given example, as the pump is set 290m above the perforations, the friction joss, because
of flow of fluid through the annulus from perforations to pump setting depth, is small, as
compared to the flowing pressure, and can be neglected.
Therefore:
Pwf= PIP + hydrostatic pressure from pump intake depth to the datum.
Pw = PIP + 0.433xSGx(2003-1703)x3.28
Because there is both water and oil in the produced fluids, it is necessary to calculate a
composite SG of the produced fluids. SG is calculated from oil SG and water SG.
SG(oil) = 141.5 / (AP I+131.5) = 141.5 / (35+131.5) = 0.845,
SG(oil) = 0.845
Water Gravity = 1.01.
WC= 90%
SG= 0,9%1,01+(1-0.9)*0.845= 0.9935.
‘8G= 0.9995 Pl = 3.33 bpdipsi.
Let's calculate, the Pwr at the desired production rate:
From the Productivity Index equation, Pwf = Pr — Q/PI = 2320.6 - 3500/3.33.
Pwf = 1269.5 psi
And PIP = 1269.5 — (1569.8-1160) = 860 psi.
PIP = 860 psi.
Ata liquid rate of 3500 bfpd, the PIP is a bit smaller than the bubble point pressure (964
psi). Therefore, the Productivity Index (PI) inflow performance method will most probably
give satisfactory results.
itis essential to determine the percentage of free gas by volume at the pumping
conditions in order to select the proper pump and gas handling device (if required). All
equations used in this section were detailed in the post "ESP design - Step 3: Gas
Calculations’.
In this third step, one must determine The total fluid volume (Vt) of oll, water, and gas at
the pump intake. For this example, Standing’s correlation was used (Standing is the
oldest, simplest and most commonly used correlation).
Solution GOR calculation:
ies: Px 1900125 <4? 1 2048R)
Rs: Solution gas-oil ratio (scf/stb) R, = 00057 =
18x10
‘API: Oil API gravity
SGg: Gas specific gravity (relative to air)
P: Pressure (psia)
T. Temperature (°F)
To determine the solution GOR (R,) at the pump-intake pressure, we need to substitute
the pump-intake pressure for the pressure (P) in Standing’s equation. For this example,
motor temperature is 70 °C (158 °F).
Rs = 0.8 * [ (860 * 10%(0.012535)) / (18 * 10*(0.00091 * 158) "1.20482
Rs = 190.3 scfistb
Oil Formation Volume Factor (Bo): Bo = 0.972 + 0.000147 x [190.3 * (0.8/0.845)"0.5 + 1.25 * 158.175
Bo = 1.131 bbl/stb @ 860 psi pump intake pressure.
Gas Formation Volume Factor (B,):
Bg the volume, in barrels, that one thousand Standard, cubie feet of gas would occupy at
some specific pressure and temperature. It indicates how much the gas volumetrically:
compresses when taken from Standard conditions (60 °F, 1 atm) to any other specific
conditions.
By assuming 0.85 Z factor, Determine the gas volume
factor (B,):
~ 305 Z» (T+ 460)
P
Bg = 5.05 « 0.85 x (158 + 460) }/ (860) ,
Bg = 3.085 bbl/Mscf @ 860 psi pump intake pressure. i
Now, these three variables: Rs, Bo, and Bg are known. So that, the volumes of oil, water,
and free gas can be determined and percentages of each calculated.
Total Gas Volum:
‘The total volume of gas (both free and in solution) can be determined as:
Total Gas Volume = (producing GOR x Oil rate)
[Oil rate}: stock tank barrels per day.
Total Gas = 200 x 3500 * (1-0.9) = 70000 scf = 70 Mscf free gas equals the total gas minus the solution gas.
volume of free gas released from solution by the decrease in p
pressure of 964 psi to the pump-intake pressure of 660 psi.
Free Gas Volume = Total Gas Volume — Solution Gas Volume
Free Gas Volume = 70 - 66.7 = 3.29 Mscf 3
Free Gas Volume = 3.29 Mscf
Volume of oil at the pump intake (Vo):
‘The volume of oil at the pump intake (Vo) equals stock tank barrels times oll formation
volume factor (Bo)
Vo = Bo x BOPD
Vo = 1.131 x 3500 * (1-0.9)= 395.9 bopd
Vo = 395.9 bopd
Volume of gas (Vg) at the pump intake:
The volume of gas (Vg) at the pump intake equals the amount of free gas times gas
volume factor (Bg):
Vg = Free Gas x Bg
Vg = 3.29 x 3,085 = 10.15 bgpd
Vg = 10.15 bgpd
Volume of water | (Vw) at the pump intake: +
The volume of water (Vwv) at the pump intake is the same as stock tank barrels:
Vw = Total fluid volume x Water Cut
Vw = 3500 x 0.9 = 3150 bwpd
Vw = 3150 bwpd % Free Gas = (Vg/ Vt) x 100
‘% Free Gas = (10.15/3556.1) x 100 = 0.20%
% Free Gas = 0,29%
This is a negligible amount of gas, it is expected that pump performance will not be Pe
affected by gas, so no need for @ gas separator (for more details, refer to the post: “ESP:
Pump Intake *).
Composite Specific Gravity (SG)comp:
‘To determine the composite specific gravity (SG)comp, the total mass of produced fluid
(including gas) needs to be calculated:
The Total Mass of Produced Fluid (TMPF) is:
TMPF = [(BOPD = SGo) + (BWPD x SGw)] x 5.6146 x 62.4 + (GOR x BOPD x SGg x
0.0752)
TMPF = [3600 * (1-0.9) * 0.845) + (3500 x 0.9 x 1.01)] x 5.6146 x 62.4 + (200 x 300 x
(1-0.9) = 0.8 x 0.0752)
‘TMPF = 1222469,4 Ibmid
The composite specific gravity (SG)comp is:
‘SGcomp = TMPF /(BFPD x 5.6146 x62,4)
‘SGcomp = 1222469,4 / (3500 x 5.6146 x62.4)
‘SGcomp = 0.997
Now, we know the total volume of fuid entering the first pump stage
8 the composite SG (0.997). we can continue to the next step of h
fe | TDHS H+ Fit Hen
Net Well Lift Calculation:
H.= Pump Depth — PIP (ft)
PIP( ft) = PIP / (0.433 psifft x SGcomp)
PIP (ft) = 860 / (0.433 = 0.997) = 3209.62 ft
NB: Giuseppe's comment on this article, is to be considered for the subsequent
calculation steps below.
H, = Pump Depth — PIP (ft) = 5620.08- 3209.84 = 2410.24 ft
H. = 2859.68 ft
Tubing Friction Le Loss Calculation | (Ft):
Many methods are available to calculate frictional pressure losses. They range from
simple empirical equations to rigorous mechanistic multiphase flow models.
The ESP industry has traditionally used the Hazen-Williams formula to calculate these
friction losses (in terms of head, not pressure).
The Hazen-Williams formula is an empirical equation developed for municipal water
distribution systems. It works reasonably well when water is the flowing medium.
However, it should not be used to calculate friction losses in viscous or gassy fluids.
Hazen-Wiliams Equation:
* F = Friction loss factor
(roo) ane ae Pe
* C=Correction Factor (100 for =F = “Ue (O-34.3)
x
old pipe, 140 for new pipe, 120 pie
for a typical value)
+ Q= Volumetric flow rate (bbl/d)
+ ID = Pipe inner diameter (in)
This can be simplified to the following equation:
C=120
= 3556,1 bfpd F= [15.11 « (Q/ CyM.852] / (104.8655)
F= 38.63 ft /1000f
Therefore, Ft = 38.83 x (5620.1/1000) = 218.26 ft
Ft= 218.26 ft
Wellhead Pressure Head (Hyn):
From the input data, the desired wellhead pressure is 87 psi. Calcultate the
‘corresponding head at wellhead using the composite SG:
Hyn ( f) = WHP / (0.433 psilft SGcomp)
Hye ( ) = 87 / (0.433 » 0,997)
Hw (2) = 279.26 ft
Total Dunamic Head (TDH) Calculation:
TDH = Hy + Fr Hun
TDH = 2859.68 + 218.26 + 279.26 = 3357.19 ft
TDH = 3357.19 ft
NB: The TDH required is based on normal pumping conditions. If the well is Killed with a
heavier-gravity fluid, a higher head is required to pump the fluid out, until the well is
stabilized on its normal production. Therefore, more horsepower is required to lift the
heavier kill fluid. This should be considered when selecting the motor rating for the
application
Step 5: Pump Type: E
From the manufacturer's catalog information, select the pump type which will be
operating within the recommended operating range and with the highest efficiency at the
calculated capacity 3556 bfpd (565 m*/d), The expected production profile of the well has
to be covered by the operating range of the pump during the expected ESP run life.
Obyiously, the pump ID (series) must fit the 7” 26# casing (ID = 7.276").
Select the 538 series G31 pump. G31 Pump 538 SERIES
| Stage Performance Curve
RPLI°2917 SpGr 1.0.
NB: When two or more pump types have similar efficiencies at the desired production
fate, refer to the post titled “ESP design — Step 5: Pump Type” to get recommendations
on the most adaptable pump to be considered.
Total number of stages required:
From the selected pump performance curve, The head in meters for one stage at 565
m®/d (3556 bipd) is 8.6 m (28.2 ft). The BHP per stage is 1.875 hp.
To determine the total number of stages required, divide the TDH by the head/stage
Total number of stages required = TDH/ ( head/stage )
Total number of stages required = (3357.19 /28.1) = 120 stages,
Stages required = 120 stages.
From manufacturer's information for the Series 538 G31 pump. The housing no. 17 can
house a maximum of 117 stages, 124 slages for a housing no. 18.
Either housing no. 17 or 18 should be adequate. In our case, housing no, 18 is selected.
ane Pump BHP required:
Once the required number of pump stages is decided, calculate the Pump BHP required:
Pump BHP required = BHP/stage x number of stages x SGcomp
Pump BHP required = 1.875 * 124 * 0.997 = 231.8 hp
Pump BHP required = 231.8 hp
Step 6; Optimum Size of Compounds: 4 _ ee
The theory behind this step was detailed in the post “ESP design ~ Step 6: Optimum Size
ef Compounds". Actually, ESP downhole compounds have different sizes and can be
assembled in a variety of combinations. These combinations must be carefully selected to
Operate the ESP within production requirement, downhole conditions, material strength,
and temperature limits, etc.
Gas Separator / Gas Handler:
‘As calculated in the “Step 3: Gas Calculations" in this post, the percentage of free gas
was negligible (0.29% of the total volume of fuids at the pump intake). So that, no need
for a gas separator,
Seal:
itis preferable to select a Seal series the same as that of ‘the pump and the motor.
Otherwise, an adaptor is required to connect the units together. ‘Seal HP required:
‘The HP required for the seal depends on the TTOH produced by the 1p ar
added to the HP required for the pump. The following Horsepower vs. TDH |
2 requirement of 2.96 hp for the 513 Series seal operating against a TDH of 3357.
Hor: ink.
ax. head with 513 Getva00 Pump
Max. Wood with 513;G
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