Gas Lift valves

• GLVs are divided into two main categories: injection pressure

operated, IPO and production pressure operated, PPO. The operation
mechanism of both types is the same.
• The gas lift valve has a loading element, which is a spring, a nitrogen
charged bellows, or a combination of the two.
• The loading element provides the downward closing force in a gas lift
valve
 Injection Pressure or Casing (pressure)
operated valve IPO
• In this type of GLV, the casing pressure acting on the larger area of the bellows.
The casing pressure plays the main role in the valve operation. During the
unloading process, the drop in the casing pressure results in closing the valves in
order
 Production Pressure or Tubing (fluid )
operated valve PPO
• Unlike IPO GLVs, in the PPO GLVs, the tubing pressure acts on the larger area of
the bellows making the valve primarily sensitive to the tubing pressure. The drop
in the tubing pressure, as gas is being injected, is used to close the valve.
Apparatus used to apply energy to keep the valve closed are: (1) a metal
bellows charged with a pressurized gas, usually nitrogen; and/or (2) an
evacuated metal bellows and a spring in compression. The valve operating
pressure, in both cases, is adjusted at the surface before being run into the well.
All GLVs have check valves to prevent back flow.
• The regulator or valve remains closed until this set closing force is exceeded.
There are two main forces that open a GLV: (1) injected gas pressure in the
annulus and (2) produced fluid pressure in the tubing. As the gas being injected
through tubing, the tubing pressure starts dropping. Therefore, the valve will
close and stop gas flow from the annulus. In the case of a continuous flow
system, only the operating valve remains open.
• Most gas lift equipment manufacturers test-rack set valve opening pressures
are based on 60°F for nitrogen-charged gas lift valves. The valve is submerged
in a 60°F water bath to ensure a constant nitrogen temperature in the
bellows of each valve during the test-rack setting procedure.
• The test rack opening pressure is the pressure able to open the valve when
tubing pressure is equal to zero.
• This pressure is calcuted knowing:
The casing opening pressure at valve depth (from design)
The tubing pressure at valve depth (from design)
The size of the valve (calculated using the thronhill Craver equation for a designed
injected gas
The Temperature at valve to be able to convert the dome pressure at valve to dome
pressure at 60°F
• The test-rack closing pressure is obtained by bleeding the tester gas from the
downstream side of a gas lift valve.
• This theoretical closing pressure is noted when the downstream pressure
continues to decrease and the upstream pressures remain constant.
• The upstream and downstream pressures are equal momentarily at the instant
a gas lift valve closes.
• An accurate closing pressure is more difficult to observe than an initial opening
pressure and can be affected by the rate of decrease in the tester pressure
during bleedoff of the tester gas.
• The equations for initial valve opening pressure in a tester and in a well, and a
tester closing pressure are based on static force-balance equations.
• The spring-load effect replaces the bellows-charge pressure of the valve as the
closing force
• The determination of the test-rack opening pressure, Pvo, by flowing supply gas at
a low rate into a ring type tester with atmospheric pressure applied to the port
area:
Initial valve opening pressure in a tester at 60oF:
Closing force = opening force:

• Ab=total effective bellows area, in.2

• Pb=nitrogen-charged bellows pressure at 60°F, psig
• Ap=valve port area (ball/seat line contact area for sharp-edged seat), in.2
• The test-rack closing pressure, Pvct, is obtained by opening the gas lift valve,
closing the supply valve, and slowly bleeding off the encapsulating tester
pressure downstream of the port.
• Valve closing pressure in a tester at 60oF
Closing force = opening forces:

Pvct=test-rack valve closing pressure at 60°F if Ppft = Pot at instant valve closes, psig,
Pot=tester pressure upstream of gas lift valve port, psig
• The initial valve opening pressure in a well, PoD, is based on the injection-gas
and flowing-production pressures at valve depth. The injection-gas and
flowing-production pressures are interchanged for production-pressure-
operated (fluid-operated) gas lift valves.

PbvD=nitrogen-charged bellows pressure at valve temperature, psig

n=valve location designation (n = 1 for top valve),
PoD=initial gas lift valve opening pressure at valve depth, psig
pfD=flowing-production pressure at valve depth, psig,
ESP Motor Protector
The Motor seal is installed below the intake and above the electric motor. It is also
named: Equalizer, balance chamber, or Protector.

In addition to the main function of transferring the motor torque to the pump shaft,
the seal section performs four primary functions (Equalization, Expansion, Isolation,
and “Absorption”)
Equalizes the pressure in the wellbore with the pressure inside the motor,
Provides area for motor oil expansion volume (induced by temperature changes in the
motor),
Isolates the well fluid from the clean motor oil,
Absorbs the pump shaft thrust load (it houses the thrust bearing that carries the axial
thrust developed by the pump, it can either be upthrust or downthrust, depending on
the pumping conditions obviously for fixed impeller type only)
• The motor, pump and seal are often submerged below several thousand feet
of fluid. The seal section allows the pressure in the motor and the annulus to
equalize, so that there is very little pressure across the shaft seals or the
pothead connection.
• When selecting the protector, we need to be certain that the protector shaft is
capable of delivering the full torque required without exceeding its yield
strength which could result in a broken shaft.
• A protector consists of a head, base, shaft, seal chamber (either labyrinth or
bag type) and a seal body. With the repositioning of a few valves and plugs,
our modular design enables the protector to be assembled in dozens of
configurations.
 Seal Components:
• The main components of protectors are:
• Mechanical Seals: prevent the well fluid from traveling down along the shaft,
and into the next chamber. It is for this very reason the mechanical seal is often
called the heart of the seal section.
• Bag(s):  provides expansion volume and isolation for clean motor oil.
• Labyrinth Chamber(s):  provides expansion and isolation volume in vertical or
near vertical wells,
• Thrust Bearing: carries the thrust load of the pump shaft and stages (fixed
impeller type only). The biggest enemies of the thrust bearing are excessive
thrust, vibration, misalignment and foreign material or fluids (water).
 Seal Types:

There are two different types of seal sections:

Labyrinth path type protector:

Bag type protector (Positive Seal Protector)

 Labyrinth type protector:
Labyrinth type seal uses the difference in specific gravity of the well fluid and
the motor oil to keep them apart even though they are in direct contact.
Labyrinth-style protector creates a tortuous path of protection from well fluids.
The protector oil specific gravity is around 0,85. As long as well bore SG is
heavier, labyrinth path work to isolate motor fluid from well bore.
Excessive motor oil transferred to protector and then, spilled to annulus
 Labyrinth type protector:

• Limitations of Labyrinth Protectors:

• Labyrinth type protectors are not recommended to be installed in a deviated or
cycling well:
• Ineffective in well bore deviations > 40 degrees from vertical, (some Western ESP
manufacturers suggest it is not worth installing them even in wells with a deviation
of 20 degrees),
• Excessive cycling / frequent start-ups: well and motor fluids are in direct contact.
Each time the motor is stopped its oil cools, contracts, and a small amount of
mixing occurs. If there are many start-ups (e.g. intermittent producers) well fluids
can eventually reach the motor, especially in deviated wells.
• Also, when the well fluid is lighter gravity than the motor oil (i.e. about 0.85)
• LABYRINTH TYPE PROTECTOR IS NOT RECOMMENDED TO BE INSTALLED IN A
DEVIATED WELL
 Bag type protector

• Bag type seal is designed to physically separate the well fluid and motor oil
by the mean of elastomeric bags that function as a positive barrier.
• (By definition, an elastomer is a rubber-like material which can stretch
under low stress and return to its original shape when the stress is
removed. )
• Elastomer bag creates a positive barrier to well-bore.
• Bag expands and contracts to meet motor demand.
• Motor oil is not contaminated with well fluid as in the labyrinth protector
• Excessive motor oil is displaced from the bag through a check valve which
will automatically open as the pressure in the bag reaches 3-5 psi
 Bag type protector

• Elastomer must be selected carefully to match well temperature and fluid

properties. Unlike Labyrinth type seal, bag type can be installed at any well
deviation (even in horizontal wells). It offers a great deal of flexibility and is
useful in a wide variety of applications.
• One area where care needs to be taken with this type of seal is with harsh
well chemicals, as seal failure may be experienced (a bullheading acidizing
job for example). The durability of the bag material depends on the
temperature and the environment to which it is subjected.
ESP Nine Step Design Procedure
Step 1: Basic data
Step 1: Basic data
 Step 2: Production Capacity
• Once the first step “Collect basic data” is performed, we pass to the ” step 2:
Production Capacity. It consists on predicting the well inflow performance
which represents the relationship between pressure and flow rate at the well
face of an individual well and it is physically defined as the well flowing bottom-
hole pressure (Pwf) as a function of production rate. It describes the flow in the
reservoir.
• Many inflow performance relationships (IPR’s) are described in the literature. In
this article, we will briefly present three of the most widely used IPR’s to
describe the well performance:
Productivity Index IPR:
The PI model is derived from Darcy’s law and is applied when the
flowing bottomhole pressure (Pwf) is greater than the bubble point
pressure (Pb) (fluids flow similarly to single phase flow). The
productivity index (PI) is equal to the liquid flow rate divided by the
well drawdown (Pr-Pwf).
Q = PI (Pr – Pwf)
So that, the inflow performance curve is a straight line with a slope
equal to (-1/PI).
Pwf = (-1/PI) Q + Pr
Vogel’s IPR:
• Vogel’s IPR is an empirical relationship based on reservoir simulation results of pure oil in
solution gas-drive reservoir. Contrary to PI IPR, Vogel’s IPR could be used when the well’s
flowing bottomhole pressure (Pwf) is below the bubble point pressure (Pb) and if the
produced fluid is pure oil.
• By using dimensionless pressures and rates, Vogel found well productivity could be described
by:

Composite IPR:
• PI model is used for single phase flow (either water or oil/water mixture with Pwf>Pb). In the
other hand, Vogel’s model could be used when the well’s Pwf is below the Pb and the
produced fluid is pure oil.
• But what if the Pwf is below Pb and well’s produced fluids is a mixture of oil, water, and gas?
• In this case, the inflow performance could be described by the Composite IPR and IPR curve is
somewhere between the curve valid for pure oil (Vogel model) and the one valid for Pwf > Pb
(PI model).
 Step 3: Gas Calculations
• It is essential to determine the percentage of free gas by volume at the pumping
conditions in order select the proper pump and gas handling device (if
required).
• We start by determine the total volume of gas Vg:
• Total Gas = (producing GOR x Oil rate)
• The gas in solution at the pump intake can be determined as follows:
• Solution Gas = (Solution GOR @ PIP x Oil rate) = (Rs x Oil rate)

• PIP: Pump Intake Pressure

:The free gas equals the total gas minus the solution gas
Free Gas = Total Gas – Solution Gas
The volume of oil at the pump intake (Vo) equals stock tank barrels times oil
formation volume factor (Bo):
Vo = Bo x BOPD
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
• The volume of water (Vw) at the pump intake is the same as stock
tank barrels:
• Vw = Total fluid volume x Water Cut
• The total fluid volume (Vt) of oil, water and gas at the pump intake:
• Vt = Vo + Vg + Vw
• The percentage of free gas to total volume of fluids at the pump
intake can now be calculated:
• % Free Gas = Vg / Vt
 Step 4: Total Dynamic Head
• he step 4 of the ESP design consists on determining the total dynamic head
required to pump the desired capacity. It is common to simplify the
procedure by combining or summarizing the additional energy that the
pump must supply into a single term, Total Dynamic Head (TDH). TDH is a
summation of the net vertical distance fluid must be lifted from an
operating fluid level in the well, the frictional pressure drop in the
tubing and the desired wellhead pressure.
• TDH = HD + HF + HT
• TDH: total dynamic head in feet (meters) delivered by the pump when
pumping the desired volume.
• HD: vertical distance in feet (meters) between the wellhead and the
estimated producing fluid level at the expected capacity.
• HF: the head required to overcome friction loss in tubing measured in
feet (meters).
• HT: the head required to overcome friction loss in the surface pipe,
valves, and fittings, and to overcome elevation changes between
wellhead and tank battery.
HT is normally measured in gauge pressure at the wellhead. It can be converted to
head, In feet (meters) as follows: HT = (psi / (0.433 psi/ft x sp. gr.)
 Step 5: Pump Type
• In order to select the most suitable pump, Refer to the pump selection
data table in the manufacturer’s catalog for pump type, range and pump
performance curve. Based on expected fluid production rate and casing
size, select the pump type which will be operating within the
recommended operating range and nearest to the pump’s peak efficiency.
• When two or more pump types have similar efficiencies at the desired
production rate, the following recommendations should be considered to
select the most adaptable pump to the well conditions:
• The shape of the pump performance curve:
• The ability of a pump to adapt to changes in well performance depends
on the characteristic shape of the pump performance curve. A pump with a
steep characteristic (i.e. large change in head with respect to flow rate) is
less suited to a well with poorly defined inflow performance (IPR),
especially if it is intended to produce with a fixed drawdown. For such
pumps, a small loss in IPR translates to a large fall in pump intake
pressure and may result in gas locking. Conversely, the head produced by a
pump with a flatter characteristic will change less for a given change of flow
rate and can therefore be used over a wider variety of IPR’s with limited
changes in intake pressure.
• The number of pump stages:
• If two pump types have approximately equal efficiency at the desired
fluid production rate, select the pump type which requires the greatest
number of stages. Such a pump will produce a capacity nearest the
desired production rate even if the well productivity is substantially more
or less than expected. In the other hand, a greater number of stages
means longer pump which couldn’t be recommended in deviated wells
with high dogleg severity.
• The presence of gas at the pump intake:
• If gas is present in the produced fluid, a gas separator / gas handler may be
required to achieve efficient operations. Refer to the article “ESP: Intake & Gas
Separator” to review the different technologies of gas separator, as well as the
article “ESP: Gas handling device” to review the additional benefits of gas
handlers. The calculation of the percentage of free gas present at the pump
intake was detailed in Step 3 of the 9 Step Design Procedure
• Viscous fluid / Emulsion / Sand production…:
• If the produced fluid is quite viscous and/or trends to emulsify, the
reservoir trends to produce sand, or any other extraordinary
circumstances, some corrections to the pump design may be necessary
to ensure a more efficient operation. In such case, contact the
manufacturer for recommendations.
 Step 6: Optimum Size of Compounds
• ESP compounds have different sizes and can be assembled in a variety
of combinations. These combinations must be carefully determined to
operate the ESP with production requirement, downhole conditions,
material strength and temperature limits, etc. to select the optimum
size of compounds.
• Pump:
• To determine the required number of stages of the pump to produce the
anticipated capacity; just divide the Total Dynamic Head (TDH) by the
Head developed by Stage.
• The Head developed per stage is deducted from the published
performance curve which shows the discharge head developed by the
pump.
• Once calculated, divide the TDH by the Head developed per stage to get
the Total Number of Stages required to produce the anticipated capacity.
• Total Stages = TDH / [(Head / stage)]
• Gas Separator / Gas Handler:
• Gas separator is required if the percentage of free gas percentage at the pump
intake is greater than 10% with radial flow pump stages. In case of mixed flow
pump stages, gas separator is required if the free gas is greater than 15%. Refer
to the articles “ESP: Pump impeller types” and “ESP: Pump Stage” to review
the difference between radial flow and mixed flow stages.
• If the free gas percentage at the pump intake is above 15% we need to install
gas separator
• Seal:
• Refer to the manufacturer’s catalog to select the proper seal section. Make
sure that the seal series in the same as that of the motor and pump series,
otherwise a series adaptor is required to connect the units together. The HP
required for the seal depends on the TDH produced by the pump and has to be
added to the HP required for the pump.
• Motor:
• Large diameter vs. small diameter pump:
• When selecting a motor, consideration should be given to choose as large
motor as possible for the casing to optimize the initial cost, motor
efficiency, operating cost and ensure better motor cooling.
• More attention should be paid when selecting downhole equipment lengths and
diameters for deviated wells especially in case of high dogleg severity.
• To select the proper motor size for a predetermined pump size, you must
first determine the Brake Horse Power (BHP) required by the pump. The
BHP per stage represents the power required by a single stage of the
pump to produce the anticipated capacity. The BHP per stage is obtained
by referring to the published pump performance curve for the selected
pump and reading the value on the BHP axis of the right scale.
• The BHP required to drive the pump is calculated by the following formula:
• BHP = Total Stages x BHP/stage x SG
• Motor Load:
• Typically, the motor is selected to operate in the range from 70 to 100% of its
rating. Generally speaking the maximum motor load should not exceed 110%, in
the other hand selecting a motor with minimum operating load (e.g. 10% or
20%) nullifies the protection monitoring of the motor.
• (High voltage / low current) vs. (Low voltage / high current):
• The high voltage / low current motors have lower cable losses, therefore
require smaller size of cable conductor (consequently, lower initial cable cost).
In the other hand, high voltage motors have superior starting characteristic; a
feature that can be extremely important if excessive voltage losses are expected
during starting. Although, the higher the motor voltage the more expensive is
the motor.
• The horse-power required by the seal and the gas separator/gas handling
device (if any) has to be added to the BHP required to drive the pump. The HP
required for the seal, gas separator and gas handling device are obtained by
referring to the manufacturer’s catalog.

• All operating parameters have to be within their recommended ranges (e.g.

thrust bearing load, shafts load, housing burst pressure, and fluid velocity past
the motor). A particular attention should be paid when selecting equipment
metallurgy if corrosive and/or erosive downhole environment is expected.
 Step 7: Electric Cables
• The AC current is carried from the surface to the motor using either
copper or aluminum cable conductors. For ESP applications, four sizes of
conductors have been standardized: #1, #2, #4 and #6 AWG (AWG stands
for “American Wire Gauge”). Electric Cables are available in either flat or
round configurations.
• An electric submersible cable is mainly compounded by a cable
conductor, insulation, jacket, braid & covering and armor. These cable
compounds are for protection against corrosive fluids and severe
environments.
• Cable selection involves the determination of Cable Size, Type and Length.
• Cable Size:
• The proper cable size is dependent on combined factors of voltage drop,
amperage and available space between tubing collars and casing.
• Cable Voltage Drop:
• The following graph shows an example of Cable Voltage drop plot to determine the
voltage drop in cable. At the selected motor amperage and the given downhole
temperature, the selection of a cable size that will give a voltage drop of less than 30
volts per 1000 feet is recommended. This curve will also enable you to determine the
necessary surface voltage (motor voltage plus voltage drop in cable) required to operate
the motor.
• Cable Type:
• Selection of the cable type is primarily based on fluids conditions, bottom-hole
temperature and space limitation within the casing annulus. ESP cable is mainly
compounded by a cable conductor, insulation, jacket, braid & covering and armor. Types,
selection criteria, advantages and limitations of cable compounds were detailed in
previous articles. Refer to the following links for more details:
• Cable Conductors
• Cable Insulation
• Cable Jackets
• Braids and Coverings
• Cable Armor
• Where there is not sufficient space to run round cable, use electric cable of flat
configuration. The flat cable configuration induces a voltage imbalance. If it is significant,
a transition splice may be required. Verify this with the manufacturer.
• Cable Length:
• The total cable length should be about 100 ft (30 m) longer than the measured
pump setting depth in order to make surface connections a safe distance from
the wellhead. Check the voltage available at the motor terminal block to avoid
the possibility of low voltage starts. The available motor terminal voltage is the
surface supply voltage minus the cable voltage drop in cable.
 Step 8 – Downhole and Surface Accessory
Equipment
• to design an ESP with an efficient and cost-effective performance. The
required downhole and surface accessory equipment are discussed and
recommended practices are highlighted.
• Downhole Accessory Equipment:
• Motor Lead Extension (MLE):
• API RP 11S4 defines the Motor Lead Extension as a “special power cable extending
from the pothead on the motor to above the end of the pump where it connects
with the power cable. A low-profile cable (flat configuration) is usually needed in
this area due to limited clearance between the pump housing and the well
casing”. It is recommended to select a length at least 6 ft. (1.8 m) longer than the
upper end of the pump. The length of MLE has to be select in a way to avoid a splice
over a tubing collar. Doing so could allow the cable to catch on the wellbore casing
and damage the equipment.
• Banding Cable Protectors:
• Cable protectors are used to protect the Motor Lead Cables from damage
during installation, operation and pulling. The figures below show an example
of cable protectors.
• Cable Bands:
• Recommended practices related to cable bands and their use:
• Best practice is to install three bands per section from the motor pothead to
the first splice in the power cable.
• Do not install bands on a cable splice. Place a band above and below the
splice approximately 4 inches.
• The minimum banding recommendation is two bands per tubing joint, with
one band in the middle of the joint and the other band 2 to 3 ft above the
collar.
• When running through a dogleg or other tight spot in the well, consideration
should be given to installing more bands per joint.
• Any application with cable larger than number 4 cable or deeper than 7,000 ft
should use three bands per joint of tubing.
Cross Coupling Cable Protectors:
Cross Coupling Cable Protectors are used to protect and support ESP cable, control
lines and injection lines, as well to protect the power cable from damage during
installation, operation and pulling.
Check Valve:
A check valve is installed about two to three joints above the ESP pump to
maintain a full liquid column in the tubing string during equipment shut down
periods. 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.
In cases of high GOR wells where gas locking is a possibility, the check valve has to be
installed higher than normally, about five to six tubing joints above the ESP pump.
Actually, when the ESP shuts down, a gas cap can form under the check valve and be
held there by the fluid column above the check valve. If the gas cap volume is large
enough to extend down to or below the pump intake, the pump will be immediately gas
locked and unable to pump fluids.
• Surface Accessory Equipment:
• Switchboard / Variable Frequency Drive (VFD):
• Compared to conventional ESP installations with constant motor speeds (using a
switchboard device), installations running at variable frequencies (using a VFD) have
several advantages. The most important benefit is the wide flexibility of the variable
frequency ESP system that permits perfect matching of the lift capacity of the ESP
system and the well’s productivity.
 • At this phase of the design the motor has been selected. So that, nameplate voltage is known,
and the cable voltage drop has already been calculated.
• When specifying switchboards, Variable Frequency Drives and transformers, the most
important information is the maximum power of the ESP system required at the surface.
This can be found from the Necessary Surface Voltage and the motor current.
• Necessary Surface Voltage = Motor’s Nameplate Voltage + Cable Voltage Drop
• From the available models, a switchboard/VFD with a rated voltage above this value
(the necessary surface voltage) is selected (calculated at the maximum required
frequency when VFD is used). The power rating of the switchboard/VFD (in kVA units)
is found from the formula used to find three-phase electric power (the total KVA
required):

• Where:
• Vs is the required surface voltage, volts.
• A is the motor nameplate current, amps.
• Transformers:
• In the majority of cases, the available surface voltage is not compatible with
the required motor voltage. Therefore, transformers must be used to provide
the right voltage level on the surface.
• Type of transformers: Single-phase vs. Three-phase:
• The type of transformer selected depends on the size of the primary power
system and the required secondary voltage. Three-phase isolation step-up
transformers are generally selected for increasing voltage from low voltage
system, while a bank of three single-phase transformers is usually selected for
reducing a high-voltage primary power source to the required surface voltage.
• Transformers are selected on the basis of voltage levels and power ratings. The
required surface voltage heavily depends on the setting depth of the ESP
equipment since the voltage drop in the power cable increases with cable length.
This voltage drop plus the selected motor voltage give the necessary surface
voltage.
• The necessary three-phase step-up or step-down transformer should have the
same kVA rating as the switchboard.
• To select the size of a step-up transformer or a bank of three single-phase
transformers, the following equation is used to calculate the total KVA required:

• Where:
• Vs is the required surface voltage, volts.
• A is the motor nameplate current, amps.
• Wellhead Feedthrough, Penetrator, lower and upper pigtails:
• The electrical connection of surface and downhole power cables is detailed in
figures below. The tubing hanger holds a feed-through mandrel (also called:
well penetrator) equipped with the proper seals to contain well pressure and
prevent gas leaks at the surface. The power cables are connected to the two
ends of this device via their three-phase connectors (also called: lower and
upper pigtails).
• Junction Box:
• The power cable coming from the well should be 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”.

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

• Provides the electrical connection between the downhole and the surface electric cable.
• 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.
• Acts as an easily accessible test point for electric checks of the downhole equipment.
 Step 9 – Variable Speed Submersible Pumping System

• Compared to conventional ESP installations with constant motor

speeds, installations running at variable frequencies have several
advantages. The most important benefit of a Variable Speed
Submersible Pumping System is the wide flexibility of the variable
frequency ESP system that permits perfect matching of the lift
capacity of the ESP system and the well’s productivity. Therefore, it
operates over a much broader range of capacity, head, and efficiency.
Since a submersible pump motor is an induction motor, its speed is proportional to the
frequency of the electrical power supply. This relationship between variables involved in
pump performance (such as head, flow rate, shaft speed) and power is known as
“Affinity Laws” (also called “Pump Laws”).
• According to the affinity laws, the following relationships exist between the
actual speed of the centrifugal pump and its most important performance
parameters:
• The flow rate of a pump changes directly proportional to its operating speed.
• The head developed by the pump changes proportionally to the square of the speed.
• The brake horsepower required to drive the pump changes proportionally to the cube of
the speed.
• The efficiency of the pump does not change with speed changes.
• The above rules can be expressed by the following equations:
• N1 and N2 are pumping speeds (in RPM).
• Q1 and Q2 are pumping rates at pumping speeds N1 and N2 (in bpd).
• H1 and H2 are the developed heads at pumping speeds N1 and N2 (in ft).
• BHP1 and BHP2 are the required brake horsepower at pumping
speeds N1 and N2 (in hp)
• How can Affinity Laws be used to design the pump?
• Variable Speed Drives generate frequency goes from 30 to 90 Hz. Changing the operating
frequency will change the motor speed, the pumping speed will be changed, so that the
developed head and the required brake horsepower will change. Thus pump performance
curves for frequencies other than 60 Hz (or 50 Hz) can be generated.
• Each curve represents a series of points derived from the 60 Hz curve for flow and
corresponding head points, transformed using the Affinity Law Equations.
Gas lift optimisation
• understanding the pressure and rate of gas injection are crucial
in attaining the optimised production potential from the well.
• The optimal gas lift injection rate for a well, which is dependent
on many factors
• It is usually modelled for each well and on a field-wide basis.
• The comparison of hypothetical injection gas rate
scenarios and the original well condition - at any
time - becomes very valuable to determine the
impact on the production rate.
• Once this information is known, injection rates
and production rates can be plotted (Figure 3).
This is a very useful graph since its main objective
is to help identify the maximum rate, the technical
optimum injection rate, and the economic
optimum injection rate (the injection rate where
extra injection costs balance extra production
revenue).
• Because the gas lift has a small window to
operate efficiently, injecting more gas at some
point may end up in a lower production rate; this
behavior is typically observed after reaching the
maximum technical rate. The reason behind this
is the increment in friction due to a greater
volume flowing in the tubing which is faster than
the counterbalanced reduction in the hydrostatic
term in the pressure loss calculation.