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Casing: 7” 26#
Wellhead Temperature: 50 °C
Inflow performance:
Present production rate: 2500 bfpd @ Pump Intake Pressure = 1160 psi
Power sources:
Possible problems?
....................(1)
and
....................(2)
Next, we can determine the new well flowing pressure (Pwf) at the estimated production rate (Qd).
....................(3)
and
....................(4)
The well flowing pressure of 1,580 psi is still above the bubblepoint pressure of 1,500 psi;
therefore, the PI approach should give good results. The pump-intake pressure can be
determined by correcting the flowing bottomhole pressure for the difference in the pump setting
depth and datum point, and by considering the friction-loss datum point and friction loss in the
casing annulus. In the given example, as the pump is set 1,300 ft 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.
Because there is both water and oil in the produced fluids, it is necessary to calculate a
composite SG of the produced fluids. To find the composite SG, water cut is 75%; therefore,
....................(5)
Oil is 25%; therefore,
....................(6)
The composite SG is the sum of the weighted percentages:
....................(7)
The pressure, because of the difference in perforation depth and pump setting depth (6,800 to
5,500 ft = 1,300 ft), can be determined as:
....................(8)
and
....................(9)
Therefore, the pump intake pressure is
....................(10)
....................(11)
and
....................(12)
Determine the formation volume factor (Bo) with Rs and the following Standing’s equation (can
also be found as a monograph).
....................(13)
where
....................(14)
Therefore,
....................(15)
and
....................(16)
Determine the gas volume factor (Bg) as
....................(17)
By assuming 0.85 Z factor (use actual PVT data if available),
....................(18)
Next, determine the total volume of fluids and the percentage of free gas released at the pump
intake. Using the producing GOR and oil volume, determine the total volume of gas (Vg).
....................(19)
Using the solution GOR (Rs) at the pump intake, determine the solution gas volume (VSG).
....................(20)
The difference represents the volume of free gas (VFG) released from solution by the decrease in
pressure from bubblepoint pressure of 1,500 psi to the pump-intake pressure of 1,000 psi.
....................(21)
The volume of oil (Vo) at the pump intake is
....................(22)
The volume of free gas at the pump intake (VIG) in barrels is
....................(23)
Next, is the equation for the volume of water (Vw) at the pump intake.
....................(24)
The total volume (Vt) of oil, water, and gas at the pump intake can now be determined by
....................(25)
The ratio or percentage of free gas present at the pump intake to the total volume of fluid is
....................(26)
As this value is less than 10% by volume, it has only a minor effect on the pump performance,
especially if most of the free gas is vented up the annulus. Use of a gas separation component is
not essential in this case.
The composite specific gravity (SG), including gas, is determined by first calculating the total
mass of produced fluid (TMPF) from the original data given.
....................(27)
and
....................(28)
Now that the total volume of fluid entering the first pump stage is known (2,550 BFPD) and the
composite SG has been determined, we can continue to the next step of designing the ESP
system.
....................(29)
and
....................(30)
The TDH required is based on the normal pumping conditions for the well application. 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. More HP is also required to lift the heavier kill fluid and
should be considered when selecting the motor rating for the application. Ft = tubing friction loss.
Refer to Fig. 1[2].
....................(31)
Hwh = desired head at wellhead (desired wellhead pressure). Using the composite SG,
....................(32)
and
....................(33)
....................(34)
and
....................(35)
....................(36)
The motor amperage is 27 amps; the KVA can now be calculated.
....................(37)
and
....................(38)
The 6H-CG motor controller suits these requirements.
Transformer. The transformer selection is based on the available primary power supply (12,470
V), the secondary voltage requirement (2,269 V) and the KVA requirement (106 KVA). Choose
three 313.5 KVA single-phase transformers as shown in the manufacturer’s catalog.
Surface cable. Select 50 ft (15.2 m) of no. 1 cable for surface connection to transformers.
Design example 2
Step one: variable-speed pumping system
Use the previous example, and design a new system using a VSC. To help justify the use of a
VSC, two new conditions were added. First, assume that we need to maintain a constant oil
production (575 BOPD), although, reservoir data indicate we should see an increase in water cut
(75 to 80%) over the next few months. Next, to satisfy our economic justification in using the
VSC, we must optimize the initial cost and size of the downhole assembly.
To maintain oil production as the water cut increases, we must determine the maximum desired
flow rate with 80% water.
....................(39)
and
....................(40)
....................(41)
and
....................(42)
The new well flowing pressure of 1,175 psi is slightly below the bubblepoint pressure of 1,500
psi; therefore, the PI approach should still give good results.
The pump-intake pressure can be determined the same as before, although, a new composite
specific gravity must be calculated.
....................(43)
....................(44)
The composite SG is the sum of the weighted percentages:
....................(45)
The pressure because of the difference in perforation depth and pump setting depth (6,800 +
5,500 ft = 12,300 ft) can be determined as
....................(46)
and
....................(47)
Therefore, the pump-intake pressure (PIP) can now be determined as
....................(48)
....................(49)
and
....................(50)
Determine the formation volume factor (Bo) with the Rs from Standing’s monograph or use
Standing’s equation[1]
....................(51)
where
....................(52)
and
....................(53)
Therefore,
....................(54)
Determine the gas volume factor (Bg) as
....................(55)
Assuming a 0.85 Z factor,
....................(56)
Next, determine the total volume of fluids, and the percentage of free gas released at the pump
intake. Using the producing GOR and oil volume, determine the total volume of gas (TG).
....................(57)
or
....................(58)
Using the solution GOR (Rs) at the pump intake, determine the solution gas volume (VSG).
....................(59)
The difference represents the volume of free gas (VFG) released from solution by the decrease in
pressure from the bubblepoint pressure of 1,500 psi to the pump intake pressure of 1,000 psi.
....................(60)
The volume of oil (Vo) at the pump intake is
....................(61)
and
....................(62)
The volume of free gas at the pump intake is
....................(63)
and
....................(64)
The volume of water (Vw) at the pump intake is
....................(65)
and
....................(66)
The total volume (Vt) or oil, water, and gas at the pump intake can now be determined
....................(67)
....................(68)
and
....................(69)
The ratio or percentage of free gas present at the pump intake to the total volume of fluid is
....................(70)
and
....................(71)
As this value is greater than 10% by volume, there is significant free gas to affect pump
performance; therefore, it is recommended that a gas separator be installed. Next, we must
assume the gas separator’s efficiency. At 15% free gas, a 90% efficiency of separation is used
on the basis of the manufacturer’s gas-separator performance information.
The percentage of gas not separated is 10%.
....................(72)
and
....................(73)
Total volume of fluid mixture ingested into the pump is
....................(74)
....................(75)
....................(76)
and
....................(77)
The amount of free gas entering the first pump stage as a percent of the total fluid mixture is
....................(78)
and
....................(79)
As the free gas represents only 2% by volume of fluid being pumped, it has little significant effect
on the well fluid composite SG and may be ignored for conservative motor sizing.
Now that the total volume of fluid entering the first pump stage is known (2,973 BFPD) and the
composite SG has been determined, we can continue to the next step of designing the ESP
system.
....................(80)
where HL = the vertical distance in feet between the estimated producing fluid level and the
surface, and
....................(81)
From Fig. 1 , friction loss per 1,000 ft of 2 7/8-in. tubing (new) is 60 ft/1,000 ft of depth at 2,973
B/D (405 m3 /d), or 4.5 m/100 m. Using the desired pump setting depth,
....................(82)
Hwh = the discharge pressure head (desired wellhead pressure). Using the composite SG,
....................(83)
and
....................(84)
or
....................(85)
....................(86)
and
....................(87)
Because a rotary gas separator was selected (which is a centrifugal machine using HP), it will
add additional load to the motor. The HP requirement also changes by the cube function.
Referring to the manufacturer’s information, the 513 series rotary gas separator requires 5 hp at
60 Hz.
....................(88)
Total BHP for the pump and separator = 157.6 + 12.8 = 170.4 hp. With Eqs. 89 and 90, the
equivalent 60-Hz BHP for both the pump and gas separator can be calculated:
....................(89)
or
....................(90)
Select the appropriate model seal section and determine the HP requirement at the maximum
TDH requirement. Select a motor that is capable of supplying total HP requirements of the pump,
gas separator, and seal. In this example, a 562 series motor with 130 hp; 2,145 volts; and 35
amps was selected.
Using the technical data provided by the manufacturer, determine if any load limitations were
exceeded (e.g., shaft loading, thrust bearing loading, housing burst pressure limitations, fluid
velocity passing the motor, etc.).
Next, select the power cable and calculate the cable voltage drop. On the basis of the motor
current (35 amps) and the temperature (160°F), no. 6 cable can be used. Adding 200 ft for
surface connections, the cable voltage drop is written as
....................(91)
We can now calculate the required surface voltage (SV) at the maximum operating frequency as
....................(92)
and
....................(93)
Note that the surface voltage is greater than standard 3KV cable. Therefore, 4KV or higher cable
construction should be selected. Sufficient data are available to calculate KVA.
....................(94)
and
....................(95)
Referring to the manufacturer’s catalog, select the model 2200-3VT, 200 KVA, NEMA3 (outdoor
enclosure) VSC. All other accessory equipment should be selected as in the previous example.
Nomenclature
Am = motor amperage, amps
Bg = gas volume factor, scf/bbl [m3/m3]
Bo = oil volume factor, bbl/STBO
constant = 3,960, where Q is in gal/min, and TDH is in ft [= 6,750, where Q is in m3/D,
C =
and TDH is in m]
D = diameter, in. [cm]
F = correlating function for Eq. 51
Ft = well-tubing friction loss
H = head, ft [m]
HL = net well lift
Hwh = wellhead pressure head, ft [m]
J = slope
N = rotating speed, rev/min
P = pressure, psi [kg/cm2]
Pb = bubblepoint pressure, psi [kg/cm2]
Pdischarge = pump-discharge pressure, psi [kg/cm2]
Pr = well static pressure, psi [kg/cm2]
Pwf = well flowing pressure, psi [kg/cm2]
Q = flow rate, B/D [m3/d]
Qd = estimated production rate
Qo = maximum production at Pwf = 0, B/D [m3/D]
Rs = solution gas/oil ratio, scf/bbl [m3/m3]
T = torque, ft-lbf
Tconductor = wellbore temperature at the ESP setting depth
TC = temperature, °C
TF = temperature, °F
TG = total volume of gas
TK = temperature, K
TR = temperature, °R
V = voltage, volts
VFG = volume of free gas
Vg = volume of gas
VIG = volume of free gas at the pump intake
Vo = volume of oil, bbl [m3]
Vs = surface voltage, volts
VSG = solution gas volume
Vt = total volume
Vw = volume of water
Z = gas-compressibility factor (typically 0.50 to 1.00)
ηm = motor efficiency
ηp = pump efficiency