ZONA DE ADIESTRAMIENTO .& CONSULTORES, S.A.ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. Cos a” THE 9 STEP TABLE OF CONTENTS PAGE NO. Centrilift's Training Center 1 Nine - Step Overview .. Step 1 - Basic Data . Step 2 - Production Capa Step 3 - Gas Caleulatio ® Step 4 - Total Dynamic Head Step 5 - Pump Type .. Step 6 - Optimum Size of Components Step 7 - Electric Cable «. 0 Step 8 - Accessory & Optional Equipment . Step 9 - Vanable Speed Pumping System ..... —— 1B Design Example 60 Hertz «..+00 fererers 16 Design Example Variable Speed 24 Autograph... etese 30THE 9 STEP ' ZONA DE ADIESTRAMIENTO.& CONSULTORES, S.A. otitas CENTRILIFT'S TRAINING CENTER The Centrilift Training Center offers high quality education and training programs, both for Centrilift associates who design, build andl service our produets, and for our valued custom- ers Ourmoderntraining facility includes full media- equipped classrooms, a shop training area, anda media development center. In addition to a permanent staff of professional, experienced instructors, numerous members of the Centrilift organization are on call in theie areas of exper: tise. ‘There are three standard programs that are of- fered to our customer. All have a common objective toimprove the overall reliability ofthe ESP system by understanding its strengths and limitations. This includes improving the oper- ating life and drastically reducing maintenance and repair costs. The three standard programs are: he Electrical Submersible Pumping System Applications This is a five day course designed for those personnel involved in production operations, which use electrical submersible pnmping sys- tems (ESP's) for artificial lift. The course in- cludes an introduction to the individual compo- nents of an ESP system, including their perfor- mance characteristics and limitations, This program is an in-depth technical seminar dealing with the sizing and application of ESP equipmentinharshenvironments, which include high GOR, high viscosity and variable speed operation. ‘The Variable Speed Controller ‘Technology-Operation-Maintenance This is a five day program designed for those personnel directly responsible for the day-to- day operation of Centrilift VSC systems. Each of the major cirenits, as well asthe logic circuits, will be discussed in detail. Using simulators and actual VSC systems, participants will demon- strate the actual start-up of a VSC system and set all the necessary operating parameters. ‘The Installation, Troubleshooting and ion of ESP Equipment This is five day conrse dasigned to prepare oil field personnel for the installation of electrical submersible pumping equipment. The course provides instructions of the proper installation ‘techniques, as well as servicing and pulling of, ESP equipment. The course introduces the student fo the major ESP components and pro- vides a brief explanation of the steps required to size a complete ESP system. To satisfy individual requirements, customized programs can be developed for specific topics and can be administered at field locations. Fora complete description of the course contents, schedule and tuition, contact you local Centrilift representative ‘Whether our programs are for product informa- tion, technical skills, or skills for working to- gether, the Training Center is dedicated to the same goal as all Centrilift associates and facili- ties. This goal is the pursuit of excellence.ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. cael THE 9 STEP e NINE-STEP OVERVIEW Centrilift has established a nine step procedure to help you design the appropriate submersible pumping system for your particular well, Each ofthe nine steps are explained in the sections that follow, including gas calculations and variable speed operation. The nine steps are: Step I - Basic Data Collect and analyze all the well data that will be used in the design, Step 2 - Production Capacity Determine the well productivity at the desired pump setting depth, or determine the pump set- ting depth at the desired production rate. Step 3 - Gas Calculations Calculate the fluid volumes, including gas, atthe pump intake conditions Step 4 - Total Dynamic Head Determine the pump discharge requirement. Step 5 - Pump Type Fora given capacity and head select the pump {ype that will have the highest efficiency for the desired flow rate Step 6 - Optimum Size of Components Select the optimum size of pump, motor, and seal section and check equipment limitations. Step 7 - Electrie Cable Select the correct type and size of cable. Step 8 - Accessory & Optional Equipment Select the motor controller, transformer, tubing hhead and optional equipment. Step 9- The Variable Speed Pumping System For additional operational flexibility, select the | === variable speed submersible pumping system, ‘The Electrical Submersible Pumping SystemZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. SEED THE 9 STEP so STEP 1 - BASIC DATA “The design ofa submersible pumping unit, un- | 2. Production Dass der most conditions, is not a difficult task, espe- a. Wellh cially if reliable data is available. Although, if . Welhes the information especially that pertaining to the e. Present wells capacity, is poor, the design will usually d. Producing be marginal. Bad data often results in a misap- pressure plied pump and costly operation. A misapplied e. Static ude ump may operate outside the recommended pressure range, overload or underioad the motor,or draw f. Datum point down the wel ata rapid rate which may result in g. Bottom-hole tempe formation damage. On the other extreme, the h, Desired product pump may not be large enough to provide the i. Gas-oil ratio desired production rate. 5. Water cut Too oftendatafrom other wellsin the samefield | 3, Well Fluid Conditions or in a nearby area is used, assuming that wells 4. Specific gravity of water o from the same producing horizon will have b. Oil APT or specific gravity similar characteristics. Unfortunately for the c. Specific gravity of gas engineer sizing te submersible installations ol 4. Bubble-point pressure of gas wells are much like fingerprints, thats, no two e. Viscosity of ol ae quite alike f£. PVT data The actual selection procedure can vary signifi. | 4, Power Sources cantly depending on the well fluid properties a. Available primary voltage ‘The three major types of ESP applications are: », Frequency 1. High water-cut wells producing fresh water ¢. Power source capabilities or bine. 2. Wells with multi-phase flow (high GOR), 5. Possible Problems 3. Wells producing highly viscous tus a. Sand b. Deposition Following is alist of data required: ©. Corrosion 4. Paraffin 1. Well Data . Emulsion a. Casing or liner size and weight £ Gas b. Tubing size, type and thread (condition) sg. Temperature - ¢. Perforated or open hole interval 4. Pamp setting depth (measured & vertical)end ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. THE 9 STEP STEP 2 - PRODUCTION CAPACITY ‘The following is a simplification of procedures forpredicting well performance. This discussion assumes a flow efficiency of one. A damaged well or other factors will effect the flow effi ciency and could change the well's productivity. Productivity Index ‘When the well flowing pressure (P,,) is greater than bubble -point pressure (P,) the fluid flow is similar to single phase flow, and the inflow performance curve is a straight line with slope J, as given by the productivity index, PI Inflow Performance Relationship If P,, is less than P, resulting in multi-phase flow, the IPR method should be used. The Q Put P, 1 on) an(22) ; This relationship was first used by W.E. Gilbert! and further developed by J.V. Vogel’. Vogel developed a dimensionless reference curve that can be used to determine the IPR curve for a particular well, 1.00 in Where ae Qs the fluid test production rate. 24, P,,=the well flowing pressure 2g @ test rate Q é he well static pressure. <0 Note: 2 B, andP,, are terms which are always referenced to the same in specific vertical depth 4 = 4 10 INFLOW P! 2 30 40 50 70809 Producing Rate (a,/(q,) max). Fraction of Maxizm /RFORMANCE REFERENC 1.00 “URVEZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. » THE 9 STEP Anarene ‘The presence of free ges at the pump intake and in the discharge tubing makes the process of equipment selection much more complicated and voluminous. As the fluid (liquid and gas mixture) flows through the pump stages from rake to the discharge and through the discharge tubing, the pressure and consequently, fluid properties (such as volume, density, ete.) con- tinuously go on changing. Also. thepresence of free gas in the discharge tubing may create significant “gas-lift” effect and considerably reduce the required discharge pressure, ‘The performan considerably affected by the gas. As long asthe gas remains in solution, the pump behaves nor- mally as if pamping a liquid of low density, However, the pump starts producing lower than normal head asthe gas-to-liquid ratio(at pumping conditions) increases beyonda certain “critical” value (usually about 10 - 15%). Itis mainly due to separation of the liguid and gas phases in the pump stage and due toa slippage between these two phases. This phenomenon has not been well studied and there is no general correlation de- scribing the effect of free gas on pump perfor- mance. A submersible pump isusually selected byassuming no slippage between the two phases or by comecting stage perfor actual field test data and past experience. of a centrifugal pump is also. nce based on a well would be produced with a ce pressure above the bubble point pressure to keep any gases in solution at the pump intake, This is typically not possible, so the gavesmust be separated from the other fluids prior to the pump intake to achieve maximum system efficiency ‘TEP 3 - GAS CALCULATIONS Centriliftofferstwotypes of gas separators, One isa reverse flow gas separator, which uses the natural buoyaney of the fluids forseparation and can handle free gas up to 10% by volume. The other is a rotary gas separator which separates the free gas by using centrifugal force. The rotary gas separator separates free gas with effi- ciency typically over 90%. Itis essential todetermine the effect of the gason the fluid volume in order to select the proper pump and separator, The following calculations Yield the percent free gas by volume. Ifthe solution gas/oil ratio (R,), the gas volume factor (B,), andthe formation Volumefactor (B,) are not available from reservoir data, they must be calculated, and there are a number of multi- phase correlations to select from. The correla- tion you select will affect your design, so select, the one that best matches your conditions. The following are Standings’ correlations for solu- tion gas/oil ratio, and formation volume factor: Solution Gas/Oil Ratio +(e =Y,Uig * jqoamrcth Or in metric, 10125 x “APE LORI AAT sey,(P, x Where:Y,, = Specific Gravity Gas P, = Bubble Point Pressure.psi (kg/cm?) T= Bottor'-hole Temperature, “F C)ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. y THE 9 STEP Gas Volume Factor B,=5.04 2 orin metric, B, = 0.00377 Where: Z ~ Gas compressibility factor (081 to 0.91) jottom-hole temperature degrees Rankine (460 + F), or in metric Kelvin (273 +°C) P= Submergence pressure psi, of (kg/em’) Ts ‘The gas volume factor, B,, is expressed in res: exvoir barrels/st'd mef gas (m'/m") Formation Volume Factor ‘The formation volume factor B.,, represents the increased volume a barrel of oil occupies in the formation as compared to a stock barrel B, = 0.972 + 0.000147F=""" a (=) s1ast y, Where: T= Bottom-hole temperature,” F or in metric, B, = 0.972 + 0.000147 x soin(2) + 1250803)" Y, Where: Y, = Specific Gravity of Gas Y, = Specific Gravity of Oil jottom-hole Temperature, °C Total Volume of Fluids ‘When these three variables, R,, B, and B, are known, the volumes of oil, water, and free gas ‘can be determined and percentages of each cal- culated. The total volume of zas ( both free and in solution ) can be determined as follows _ Producing GOR_x BOPD Total Gas = Soo MCF or in metre, Total Gas = Producing GOR x MPD = MP ‘The gas in solution at submergence pressure can be determined as follows: R, xBOPD =MCF 7,000 Solution Gas = ‘The Free Gas equals the Total Gas minus the Solution Gas ‘The volume of oil (V,) at the pump intake equals stock tank barrels times B,, the formation vol- ume factor. The volume of gas (V,)atthe pump intake equals the amount of free gas times B,, the gas volume factor. ‘The volume of water (V,)in the formation is the same as stock tank barrels. ‘Total fluid volume (V,) can now be determined V,+V,+Vy, ‘The percentage of free gas to total volume of fluids can now be calculated: % Free Gas = 2ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. eee THE 9 STEP eer” STEP 4- TOTAL DYNAMIC HEAD The next step is to determine the total dynamic head required to pump the desiredcapacity, The total pump head refers w feet (mevers) of liquid being pumped and iscalculated to be the sam of: 1) Net well lift (dynamic lift): 2) w: friction loss; and 3) wellhead disch: sure. ‘The simplified equation is sf tir 0.0999 x Sp.Gr. TDH =H, +F,+P. “Total Dynamic Head =Hg + Fy + Pq where: ® ‘TDH = total dynamic head in feet (meters) I delivered by the pump when pumpin; esired volume. H, = vertical distance in feet ( ) between wo the wellhead and the estimated producing fluid level atthe expected eapacin, LR F = thehead required toovers Reaeaneeees in tubing measured in feet (me Lee P,=thehead required toover Fwid Level] surface pipe. valves and : come elevation changes between wellhead and a tank battery. Normally. this is measured in a et gauge pressure psi (kg/cm ‘head and can be converted to head. in feet (meters) as follows: us. Ae psi_ x 2.31 fv Ler 4” “specific gravity AT sea eg —— 0.433 psi/fi x sp. g Mot SSCons ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. , THE 9 STEP STEP 5 - PUMP TYPE Refer to the pump selection data table, in the Engineering section of your Centrilift catalog, for pump types and ranges, Pump performance curves (60 Hz and 50 Hz) are included in the "Pump Curve" section of the catalog. Based on expected fluid production rate and casing size, select the pump type which will, at the expected producing rate, be operating within the pumps operating range and nearest to the pump’s peak efficiency, Where two or more pump types have similar efficiencies at the desired volume, the following. conditions determine the pump choice: 1, Pump prices and corresponding motor sizes and prices may differ somewhat. Normally. the larger- diameter pump aud anotor are less expensive and operate at higher efficiencies. 2. When the well's capacity is not known, or cannot be closely estimated, a pump with a "steep" characteristic curve should be cho- sen. If the desired volume falls at a point where two pump types have approximately equal efficiency, choose the pump type which requires the greatest number of stages. Such a pump will produce a capacity nearest the desired volume even if the well lift is substantially more or less than expected, 3, If gas is present in the produced fluid, « gas separator may be required to achieve effi cientoperation. Referto Step 3 todetermine the effect of gas on the produced volume. The adjusted volume affects pump selection ‘and the size of the other system components. 4, In wells where the fluid is quite viseous and/or tends to emulsify, or in other ex {raordinary circumstances, some pump.cor- rections may be necessary to ensure amore efficient operation. In such cases, contact a Centilift sales engineer for recommenda- tions. ‘The VSSP System and Pump Selection Under the above, or other pumping conditions, also consider the Variable Speed Submersible Pumping (VSSP) system. Forinstance, in item 2 above, if a well is not accurately known, a ‘SSP systemisideal. An Blectrospeed variable speed controller effectively converts a single pump into a family of pumps. So, a pump can be selected for an estimated range and adjusted for thedesited production level, once moredata is collected. The VSSP system with the Electrospeed im- proves pump operation under other conditions as well, including gassy wells, abrasive wells, low volume wells, etc. It provides soft starts, climinates intermittent operation, breaks gas locks, isolates equipment from powertransients, minimizes downhole heating, and more. Review Step 9 when considering the VSSP system, Variable frequency performance curves are included in the "Pump Curve" section of the Cenwrilift catalog. ‘The VSSP Systems with Electrospeed may provide additional economies of capital expenditure and operating expenses, and should be considered in Step 6, "Optimum Size of Components.” The Electrospeed vari- able speed controller and transformers for the SP system are discussed in Steps 8 and 9.THE 9 STEP ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. STEP 6 - OPTIMUM SIZE OF COMPONENTS Centtilift components are built in a number of sizes andcan be essembled in a variety of com- binations. These combinationsmust be carefully determined to operate the submersible pumping system within production requirements, mate- rial strength and temperature limits. While siz- ing components, referto the Engineering seetion of your catalog for each of the following tables and charts: Equipment Combinations in Various Casings Maximum Loading Limits Maximum Diameter of Units Velocity of a Fluid Passing a Motor ‘Shaft HP Limitations at Various Frequencies A fluid velocity of 1 foot per second (0. meters per second) is recommended to en: adequate motor cooling. In cases where this velocity is not achieved, a motor jacket may be required to inerease the velocity. Contact your sales engineer under such conditions, Pump Refer to the Centrilift performance curve of the selected pump type and determine the number of stages required toproducethe anticipated capac- ity againstthepreviously calculatedtotaldynamic head. Performance curves for60 Hz, $0 Hz and variable frequency performance are located in the catalog. Note that the pump characteristic ‘curvesare single stageperformance curves based on water with (specific gravity of 1.00). At the intersection of the desired production rate (bot- tom scale) and the heecl-capacity curve (vertical scale), read the head value on the left scale. Divide this value into the total dynamic head to determine the number of stages. Total Dyt Total Stages = HeadStage ic Head Separator Refer to yourcatalog for gas separator informa- tion, Make the necessary adjustments in horse- power requirements and housing length. Motor To select the proper motor size for a predeter: ‘mined pump size, you must first determine the brake horsepower required by the pump. The horsepower per siageis obtained by again refer- ring to the performance curve for the selected pump and reading the value of the right scale. ‘The brake horsepower required to drive a given pump is easily calculated by the following for- mule: BHP = Total Stages x BHP/Stage x Sp. Gr. Refer to your catalog for motor specifications. Seal Section Refer to yourcatalog for selection of the proper seal section, Series 338 seals are recommended for 338 series pumps using 375 series motors. Series 400 seals are recommended for 400 series pumps using 450 series motors. When 544 or 562 series motors are used with a S13 series pump, the 513 series seal is required. A513 series adapter is required whenever a 513 series seal section is run with a 400 series pump.ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. ) THE 9 STEP STEP 7 - ELECTRIC CABLE Centrilift electric cables are normally available from stock in conductor sizes 1, 2, 4, and 6. ‘These sizes are offered in both round and flat configurations as shown in your catalog price section under Centriline Power Cable. ‘Several types of armor and insulation are avail able for protection against corrosive fluids and severe environments, Cable selection involves the determination of 1) cable size: 2) cable type; 3) cable length, Cable Size ‘The proper cable size is dependent on combined factors of voltage drop, amperage and available space between tubing collars and casing. Refer to the Cable Voltage Drop curve (see engineering section) for 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 1,000. (305 meters) isrecommended This curve will also enable you to determine the necessary surface voltage (motor voltage plus voltage drop in the cable) required to operate the motor. Finally, refer to the Equipment Combination table (see engineering section) to determine if the size selected can be used with the proposed tubing and well casing sizes. Cable diameter plus tubing collar diameter will need to be less than the inside diameter (L.D.) of the casing In determining the optimum cable size, consider future equipment requirements that may require the use of a lager size cable. If power cost is a major concern, the Kilowatt- Hour Loss Curve (see Engineering section) can be used to justify the cable selection. Although power rates vary widely, this data is valuable in determining the economics of variouscablesizes. Cable Type Selection of the cable type is primarily based on fluid conditions, bottom-hole temperature and spacellimitations withinthe casingannulus. Refer to your catalog price pages for cable specifica- tions. Where there is not sufficient space to run round cable, use electric cable of flat configuration. ‘See Equipment Combinations table in Engi neering section of your catalog for round cable limitations based on various casing and tubing sizes, Consult your Centrilift representative when temperature or gas is a critical factor. Cable Length The total cable length should be at least 100 ft (OM) longer than the measured pump setting depth in order to make surface connections a safe distance from the wellhead. Referto curve on Recommended Maximum Cable Length (see Engineering section) to avoid the possibility of ow voltage starts. Cable Venting Inall wells, itis necessary to vent gases from the cable prior to the motor comtroller to avoid explosive conditions. A cable venting box is available to protect the motor controller from such gases,ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. THE 9 STEP - STEP 8 - ACCESSORY & OPTIONAL EQUIPMENT 1. DOWN HOLE ACCESSORY EQUIPMENT Flat cable (motor lead extension): Select a length at least 6 ft, (1.8) longer than pump, intake (standard or gas separator) and seal section for the motor series chosen. Refer to your catalog for dimensions. Flat cable guard: Choose the required number of 6 ft. (1.8m) guard sections to at least equal the flat cable Iength. Do not use guards for installation of 400 series pump and seal section in 5-1/2" O.D., 20- pound casing and for installation of 513 series pump and seal section in 6 5/8" O.D., 26-pound casing, Cable ban Use one 30;n. (76 cm) cable band every 2ft. (60 cm) for clamping flat cable to pump. The 22 in. (56 em) length can be used for all tubing combinations through 3-1/2" O.D. tubing 4-1/2" and 5-1/2" O.D. tubing use 30 in. (76cm) bands. One band is required for each 15 ft. (5m) of setting depth. Refer to your catalog for dimensions. Swaged nipple, check valve, and drain valv Select these accessories on basis of required outside diameters and type of threads. 2. MOTOR CONTROLLERS, ‘The Vortex™ isa state-of-the-art digital control consisting of two components: System Unit This unit performs all the shutdown and restart operations. It is mounted in the low- voltage compartment of the control panel. + Display Unit (Optional) This unit displays readings, setpoints alarms. It is normally mounted in the am chart enclosnre for easy access. It provides all the basic functions, such ss underload, overload, phase imbalance, p rotation, etc. and over 90 other paramete including password and communication protocols. INGLE-PHASE AND THRE] ‘TRANSFORMERS ‘The type of transformer selected depends on sizeof the primary power system andthe requ secondary voltage. Three-phase isolation ste up transformers are generally selected for increasing vullage from a low voltage sy while a bank of three single-phase transforme is usually selected for reducing a high-volta ptimary power source to the required su voltage. (On existing systems, some of Centrlift units will operate without the use of an addition transformer. For new installation of units with higher voltages, itis usually less expensive to install three single-phase transformers, connected ‘wye, to eliminate the auto-transformer.CENTRILIFT y THE Y STEP In choosing the size of a step-up transformer or a bank of three single-phase transformers the following equation is used to calculate total KVA required: V, x A,X 1.73 Wyse 7,000 lo-Volt-Amp or 1,000 Volt-Amp ce Voltage lotor nameplate current in amps 4. SURFACE CABLE Choose approximate length required for con- necting controller to primary powersystemorto transformer. Two pieces are generally required for installations usingan auto-transformer. Size should equal the well cable size except in the case of step-up or auto-transformer, where the primary and secondary currents arenotthe same. 5. WELLHEADS AND ACCESSORIES Select the wellhead on the basis of casing size, tubing size, maximum recommended load, sur. face pressure, and maximum setting depth Electric cable passes through the wellhead where ings are not required. pressure fi Electric Feed Through (EFT) mandrels are also available, The electric cable is spliced to pig tails. The FFT wellheads seal against downhole pressure and prevent gas leaks at the surface. Refer to your catalog for specifications. 6. SERVICING EQUIPMENT Cable reels, reel supports and cable guides: Select size of cable reel required to handle pre- viously selected cable size. Select set of cable reel supports based on cable reel size. Cable guides are designed to handle cable sizes 1 through 6. Normally, customers retain one cable reel, one set of reel supports, and one cable guide wheel for future use. Shipping Cases: Select type and lengthof case required to accom- modate previously selected motor, pump, gas separator and seal: 7. OPTIONAL EQUIPMENT Bottom-hole pressure (PHD) sensing device: ‘The PHD provides continuous measurement of bottom-hole pressures. Automatic well monitoring: Motor controllers are available for continuous monitoring of pump operation from a central location. Contact your Centrilift representative for details ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A.ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. as THE 9 STEP STEP 9 - VARIABLE SPEED SUBMERSIBLE PUMPING SYSTEM The ESP system can be modified to include an Electrospeed variable frequency controller so that it operates over a much broader range of capacity, head, and efficiency. Since asubmers: ible pump motor is an induction motor, its speed is proportional tothe frequency of the electrical power supply. By adjusting the frequency, the variable speed submersible pump (VSSP) sy: tem offers extraordinary potential for boosting production, reducing downtime, and increasing profits. The VSSP canbe usedto boostefficiency in many cases, including highly viscous wells, waterflood wells ete. It extends the range of submersible artificial lift to less than 100 BPD (16 M'PD) and up to 100,000 BPD (16,000 MPD). Itis necessary to understand the effects of vary- ing the speed of asubmersible pump, in order to apply the VSSP system. The VSSP system can be analyzed in terms of varying frequency or in terms of maintaining constanthead. Sales engi- rneers have computerized pump selection pro- grams to assist you in VSSP system selection; ‘what follows is a basic explanation of the prin. ciples involved. Variable Frequency The effects of varying frequency can be seen by preparing new head-capacity curves for the de~ sired frequencies, based on the pump's known 60 Hz performance curve data. The Electro speed controller is commonly used to generate any frequency between 30 and 90 Hz Curves for frequencies other than 60 Hz can be enerated by using the centrifugal pump affinity laws. ‘The equations derived from these laws are: New Frequency ewRae = x 60 He New Rae 60 Ke (exten) New Head = (EE) 5 60 Hz hens 2) x 6082 BHP where BHP = Brake Horsepower New Efficiency gible loss) 60 Hz efficiency (there is A set of curves can be developed for an arbitrary series of frequencies with these equations, as shown in the variable frequency performance curves at the end of this step (Figure 1). Each curve represents a series of points derived from the 60 Hzcurve for flow and correspondinghead points, transformed using the equations above. Suppose we are given the following data at a frequency of 60H: Rate = 1,200 BPD. Head BPD) 4.9 ft, (from FC-1200 curve @ 1,200 BHP=0.34 BHP (from F BPD) 1200 curve @ 1,200 Ifa new frequency of 50 Hz is chosen: New Ra OS 60 0Catag so) By performing these calculations at other pro- duction rates, a new curve for 50 He operation ‘ean be plotted. Start by locating the existing points on the one-stage 60 Hz carve: — 60 Hz — X, Rate (BPD) 0 950 1200 1550 1875 Y, Head (Feet) 32° 28.6 245' 15° 01 Efficiency (%) 0 635 64 49 0 Following the above equations, calculate the corresponding values at 50 Hz: THE 9 STEP — 50H, — X, Rate (BPD) 0 792 1000 1292 1563 Y, Head (Feet) 22.2" 19.9" 17° 10.4" Efficiency (%) 0 635 64 49 0 Plotting these coordinates gives the one-stage FC-1200 head-capacity performance curve for operation at 50 Hz. Similar calculations will provide coordinates for curves at other fre- ‘quencies, as seen below in the FC-1200 variable speed performance curve, The vortex shaped windowis the recommended operating range for the pump. As long as your hydraulic require- ment falls within this range, you are within the recommended operating range of the pump. eee {VARIABLE SPEED - ONE STAGE PUMP FERFORMANCE "too SERIES FC1200 ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A.ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. Cones THE 9 STEP eee NAME DESIGNEXAMPLE DATE NOV. 20, 1991 COMPANY ADDRES: WELL NO. AND FIELD NANE—__ WELL LOCATION (COUNTY. STATE. OTHER) —— INSTALLATION: NEW (CX ]OR REDESIGN (_) PRIMARY POWER SUPPLY: 12,47 PRODUCING FORMATION. = = —= — FORMATION TYPE (SANDSTONE, LMESTONE, 0 WELL DATA APLOASING 7 IN.OD, 92 #FT. _0 FIL 10_ 6.800 £1 ___ to LINER NONE —_IN.OD. oT FEO FT. uM mt (OPEN HOLE a = Fro Fr “ut —M TOTAL DEPTH SS eS a PEREORATION INIERVALS 6.750 F110 6.050 £1. To. M STO FT. —MT0 M. LTO. fal 7 APLTUBING 2-7/8 IN..D. EUE 8 ROTHREADS- RESERVOIR DATA (FROM TEST AND PRODUCTION DATA) PRESENT PRODUCTION ___850_BEPD. xP) __PUMPNG (x), SWABBING (), FLOWING) BOTTOM HOLE STATIC PRESSURE nS kgSy. Cn. 8 W. BOTTOM HOLE FLOWING PRESSURE 95a om © SPO KgSa.cm.@ MPD PRODUCING GOR, 30 SEKISe. —— er = “= WATER CUT_ 7% CL API GRAVITY 92" BOTTOM HOLE TEMPERATURE —7 : C WATER SPECIFIC GRAVITY 1.085 ___ssue oe = —ssue -__ PVT DATA, FF. PSIG VE — Psi SOLUTION GCF FVE_ PSIG ‘SOLUTION GOR, BUBBLE POINTPRESSURE 1,500 PSIG CENTRILIFT SPECIFICATIONS DESIRED PRODUCTION __ 2,900 BFPD. OR BOPD FuIDM"e0.0R___O1LMPD_ DESIRED PUMP (INTAKE) VERTICAL SETTING DEPTH 5500 F1 t DESIRED PUMP UNTAKE) PRESSURE = PSIG. ——kesa-6n. REQUIRED WELL HEAD PRESSURE 10 PSIG. 984° oR THROUGH PUP. ——— =a CASING VENTED TORTWOSPHEREC ) TO PIPELINE (X)__ NONE (_) ELECTRIC POWER, ~— worrs : CYCLES DESIRED PUMP SERIES DESIRED PUMP TYPE CASING PRESSURE PSIG Kaisa Gm, ‘SPECIAL PROBLEMS SAND( J, SGALE( ), CORROSION(), PARAFFIN ), He REMARKS POSSIBLE VSC APPLICATION DUE TO ANTICIPATED WATER CUT INCREASE _Carag ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. y THE 9 STEP DESIGN EXAMPLE Step 1 - Basie Data See Centrlift well data sheet on previous page for well data Step 2 - Production Capacity Determine the well productivity at the test pressureand production. In this case, the desired production rate and pump setting depth are given. The pump intake pressure at the desired pro- duction rate can be calculated from the present production conditions. e the well flowing pressure (2,600 psi) is reater than bubble point pressure (1,500 ps the constant PI method will most probably give satisfactory results. First, we can determine the PL using the test data, 850BPD —— - 2 BPD IPS 200 PSI - 2,600 PSI es Next, we can determine the new well flowing pressure(P, ,)atthe desired productionrate (Q,). G) 5 ( 300 BPD ‘00 psi - \ 1 42 BPDIPSL The well flowing pressure of 1,580 ps above the bubble point pressure of |, therefore, the PI approach should give good results, 16 ‘The pump intake pressure can be determined by correcting the flowing bottom-hole pressure for the difference in pump setting depth and the datum point and by considering the friction loss in the casing annulus. In the given example, as the pampis set 1,300 fect above the perforations, the friction loss due to flow of fluid through the annulus from perforations to pump setting depth will be small as compared to the flowing pres- sure and can be neglected Because there is both water and oil in the pro- duced fluids itis necessary to calculate a com- posite specific gravity ofthe produced fluids. To find the composite specific gravity; Water cut is 75%; 0.75 x 1.085 = 0.8138 Oil is 25%; 0.25 x 0,865 = 0.2163 The composite specific gravity is the sum of the weighted percentages: Composite Sp. Gr. = 0.8138 + 0.2163 = 1.03 The pressure due to the difference in perforation depth and pump setting depth (6,800' -5,500 1,300’) can be determined as follows: Head (Ft) x. Specific Gravity Sl 2.31 FYPSI 1,300 Ft x 1.03 =580 PSI 2.31 FUPSI ‘Therefore, the pump intake pressure will bel,580 psi -580 psi = 1,000 psiZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. THE 9 STEP nomen” Step 3 - Gas Calculations In this third step we need to determine the total fluid mixture, inclusive of water, oil and free gas that will be ingested by the pump. 1. Determine the Solution Gas/Oil Ratio (R, ) at the pump intake pressure with Standing's nomo- graph (see figure 2 ), orby substituting the pump intake pressure for the bubble point pressure (P,) equation; Py. goias earn ‘an s\Ts “ [gio@r Tee ) 208 1900125 x 32 [qn 2. Determine the Formation Volume Factor (B,) using the R, from above and Standing's nomo- graph (see figure 3)oruse Standing'sequationas follows: B,=09 0.000147 F'"* where; Gs). Fer, (yt) +1asr = 180 G&S) + 1.25 x 160 = 361.92 Therefore: 0.972 + 0.000147 (361.92)'""* 12 reservoir bbV/stock tank bbl 3. Determine the Gas Volume Factor (B,) as follows: Assuming 0.85 Z factor; 5.04 x 0.85 x (460 + 160) 1014 2.62 bbl/mef 4, Next, determine the total volume of fluids and the percentage of free gas released at the pump intake: a. Using the producing GOR, and oil volume, determine the total volume of gas (T.) BOPD x GOR 1,000 300 x 0.25) x 300_ 2. 9 = = 172.5 met a 1,000 b. Using the solution GOR (R,), at the pump intake, determine the solution gas (S,.): BOPD xR, 000) (2,300 x 0.25) x 180 7,000) c. The difference represents the volume of free gas (F.,) released from solution by the decrease in pressure from bubble point pressure of 1,500 psi, to the pump intake pressure of 1,000 psi =172.5 mef - 103.5 met = 69 mefZONAD: ADIESTRAMIENTO & CONSULTORES, S.A. Sohne THE 9 STEP AMASSAAd INIOA-ATAANA CINOITANY SVD AO SA LAV oF = Ssval y 1 = (LH) in L isd og = amnssaud yon dtung VIVO A TWVXA Ys pmo St for tuo “4,091 joatiezait 01 * pinbyy que pute $1040. 304.09 ‘oyeiut duind ayp 2124 9D PINS AAWVXA Figure 2 ‘CHART FOR CALCULATING BUBBLE-POLNT PRESSURE OR SOLUBILITY From API Publications RP 11U: Sizing and Selection of Electric Submersible Pump In W NOPYVIOUGAM TVYALYN AO SALLIEZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. onoitag THE 9 STEP —- FORMATION VOLUME OF BUBBLE-POINT LIQUIDS CHART FOR CALCULATING FORMATION VOLUME OF BUBBLE-POINT LIQUIDS, From API Publication RP 11U: Sizing and Selection of Electric Submersible Pump Installaions 19ZONA-DE ADIESTRAMIENTO & CONSULTORES, S.A. ‘DI re cum THE Y STEP 4. The volume of oil (V,), atthe pump intake: i. The composite specific gravity, including V, =BOPD x Formation Volume Factor B, 28, can be determined by first calculating the total mass of produced fluid (TMPF) V, =575 BOPD x 1.12 = 644 BOPD from the original data given: ce. The volume of fre as (V,), at the pump. 8 TMPF =| (BOPD x Sp. Gr. oil+ BWPD x ‘tales Sp. Gr. water) x 62.4 x 5.6146} + (GOR x V, = Free Gas x Gas Volume Factor B BOPD x Sp. Gr. Gas x 0.0752) V, =69 mef x 2.62 bbl/mef = 181 BGPD. The volume of water (V,), at the pump intake: TMPF = {(575 x 0.865 + 1,725 x 1.085) x V,, =Total Fluid Volume x 9 Water 62.4 x5.61.46) + 300x575x0.7 x0.0752) V,, =2.300 BPD 0.75 = 1,725 BWPD $59,064 tbstday TMPE Composite Sp. Gr, = ——_TMPF__ g. Thetotal volume (V,) of oil, water, and gas, BEPDxS.6140x 624 atthe pump intake, can now be determined: VeV,4V,4V, 839,064 Ibs/day V,=614 BOPD¢ 181 BGPD«1, Composite Sp. Gr = — 839.06 Poo ssc aeen! 2350 x 5.6146 x 624 h. The ratio, or percentage of free gas present Composite Sp. Gr, = 0.939 the pump intake to the total volume of fluid is: 5. Now thatthe total volume of fluid entering the i first pump stageis known (2.550 BFPD) and the % Free Gas = —£ composite specitic gravity has been determined y Wecan continue to the next step of desig or ‘SP system, 181 BGPD 44, 2,550 BFPD. % Free Ga As this value is less than 10% by volume it would have little effect on the pump performance, therefore, a gas separator is notrequired, Although, there i significant sas to effect the well fluid composite spe cific gravity at the pum 20 intake. SsZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. THE 9 STEP Step 4- Total Dynamic Head Sufficient data isnow available to determine the total dynamic head required by the pump. TDH=H,+F,+P, H, = The vertical distance in feet between the estimated producing fluid level and the surface, PIP x2.31fpsi H, 1,000 psi_x 0.939 Livpsi H, = 5,500 fi al 3,040 it (926.6m). Tubing friction loss. Refer to Friction Loss Charts in the engineering section. Friction loss per 1,000 ft. of 2-7/8" tubing (new) is 49ft, per 1,000 ft. of depth at 2,550 BPD (405 MPD), or 4.5 meters per 100meters. Using the desired pump setting depth: 5500 ft. x 49 ft 1,000 ft. =270 ft. (82.3m) P., =Discharge pressure head (desired wellhead the composite specific gravity: = 246 ft. (75m) ‘TDH = 3,040 fi. + 270 ft. + 246 ft 556 ft TDH = 926.6 m + 82.3 m+ 75 m= ,084 m Step 5 - Pump Type Selection Refer to Pump Selection Table in Engineering section of catalog . Select the pump type with the highest efficiency at the calculated capacity, 2,550 BPD (405 M’PD) that will fitinthe casing. Select the 513 series GC2200 pump and locate it's performance curve. ‘The head in feet (meters) for one stage at 2,550 BPD (405 M°PD) is 41.8 ft. (13 m). The brake horsepower (BHP) per stage is 1.16, ‘Todetermine the total number of stages required, divide the total dynamic head by the head/st taken fiom the curve. Number stages = 7 Number of stages = STF— = 85 Stages Next, refer to your catalog for the GC2200 pump. The housing number 9 can house a maximum of 84 stages, 93 stages for a housing 10.Because the 84 stage pump is only one stage less than our requirement, it will be our selec tion Once you've decided on the maximum number of pump stages, calculate the total brake horse power required as follow: BHP = BHP/Stage x No. Stages x Sp. Gr. BHP = 1.16 x 84 x 0.939 = 91.5 HP Step 6- Optimum Size of Components Gas Separator If a gas Separator was required, refer to your catalog to select the appropriate separator and determine its horsepower requirement.ZONADE ADIESTRAMIENTO & CONSULTORES, S.A. THE 9 STEP Seal Section Normally the seal section series is the same as that of the pump, although, there are exceptions and special adapters are available to connect the units together. We will select the 513 series GSB seal section, ‘The horsepower requirement for the seal de- pends upon the total dynamic head produced hy the pump. The Horsepower vs TDH curves in the Engineering section show a requirement of 3.0horsepower for the 513 series seal operating against a TDH of 3,556 ft. Therefore, the total horsepowerrequirement for this examples 91.5 HP forthe pump, plus3.0 HP forthe seal, or94.5 HP total Motor A500 series motor (5444 or 562) should be used with the 513 series pump. In this example we will select the 100 HP 562 series motor from the catalog. ‘The motor voltage can be selected based on the following considerations: a, The high voltage, consequently low-cur- rent, motors have lower cable losses and require smaller conductor size cables, High voltage motors have superior start- ature that ean be ing characteristics: a extremely important if losses are expected during starting. sive volt b. Although, the higher the motor voltage, the more expensive the motor controller will be. In some cases, the savings due to smaller cable may be offset by the dif costanditmay be necessary tomakean fence in motorcontroller conomic ‘sis for the various voltage motors. How- select the hig ever, for this example, we w voltage motor (100 HP 2145 volts, 27 amps). Referring to the Engineering section, it can be seen thatall operating parameters are well within their recommended ranges (e.g. thrust bearing shaft HP, housing burst pressure and fluid veloc ity Step 7 - Electric Cable Determine Cable Size The cable size is selected based on its current carrying capability. Using the motor amps (27) and the cable voltage drop chart in the catalog, selecta cable size witha voltage drop of lessthan 30 volts per 1,000 ft. All conductor sizes 1 6) all in this category. The #6 cable has 22.2 volts/1,000 ft. (305 m) and isthe least expensive. This will be the cable size used in our example. Cable Type Due to the gassy conditions and the bottom-hole temperature, the CPN cable should be used. Check to be sure the cable diameter plus tubing collar diameter is smaller than the easing LD. (see Engineering section ). Cable Length The pump setting depth is 5.500 ft. (1676.4 m) With 100 ft. (30.5 m) of cable for surface con- nections, the total cable length should be 5,600 ft. (1,707 m). You will also find that the cable ath is within the recommended maximum length (see Engineering section). Cable A cable vent box must be installed between the wellhead and the motor controller o prevent gas migration to the controller,ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. , THE 9 STEP —- Step 8 - Accessory and Miscellaneous Equipment Flat Cable - Motor Lead Extension Pump Length = 148 ft. (4.51 m) Seal Length 63 ft. (1.92 m) Plus 6 ft = 601 (83m 27.1 ft, (826m) Select 35 ft. (10.7 m) 562 series flat cable. Flat Guards Cable guards are available in 6 ft. sections, therefore, 6 sections will be sufficient Cable Bands The pump and seal section are approximately 20 fl. (6m) long. Twenty-two inch (56 em) bands will be required to clamp to the housing, with bands spaced at 2 ft. ( 61 cm) intervals (10 bands). Above the pump, banding of the tubing plus cable, the twenty- two inch bands can also be used, The bands should be spaced at 15 ft. (4.5 Is. The setting depth of 5,500 ft. would require 367 bands. Downhole Accessory Equipment Refer to your catalog for the following: Swaged Nipple ‘The pump outlet is 2-7/8 inches, as shown on. table5, sono swaged nipple is required forthe 2- 7/8 inch tubing. Check Valve ‘The 2-7/8 inch El will be required. S,ound thread check valve Drain Valve The 2-7/8 inch EUE 8 round thread drain valve will be required. Motor Controller The motor controller selection is based on its voltage, amperage, and KVA rating. Therefore, before selecting the controller we must first determine the motor controller voltage. We will assume the controller voltage will bethe same as the surface voltage going down-hole, The sur- face voltage (SV) isthesumof the motor voltage and the total voltage loss in the cable. 22.2 volts x 5,600 fi SV =2,145 volts + ( ae 1,000 ft. Surface Voltage 169 Volts ‘The motor amperage is 27 amps, the KYA can now be Calculated: KVA = SV. Motor Amps x 1.73 1,000 2,269 volts x 27 amps x 1.73 1,000 KVA KVA = 106 The 6H-CG moter controller suits these 1e- uirements ‘Transformer ‘The transformer selection is based on the avail- able primary power supply (12,470 volts), the secondary voltage requirement (2,269 volts), and the KYA requirement( 106 KVA). Chose 3 37.5 KVAsingle phase transformers as shownin, your catalog. Surface Cable Select 50 ft. (15.2 m) of #1 cable for surface connection to transformers.ZONADE, ADIESTRAMIENTO & CONSULTORES, S.A. . THE 9 STEP _ EXAMPLE Variable Speed Pumping System We will now take the previous example and design a new system using a Variable Speed Controller. To help justify the use ofa variable 2875 BPD ) 1175 ps1 speed controller, I have added two new condi- BPLIFSI tions. Those conditions are: The new well flowing pressure of 1,175 PSI is 1. First, assume we need to maintain acon | _ slightly below the bubble pointpressure of 1,500 stantoil production(575BOPD),although, | psi therefore, the PI approach should still give reservoir data indicates we should see an | good results increase in water cut (75% to 80%) over the next few months. ‘The pump intake pressure can be determined the same as before, although, first we must caleulate 2. To satisfy our economic justification in | 2 new composite specific gravity using the variable speed controlier, we | Water cutis 80%: need to reduce the initial cost and size of ede {bas — COGE the downhole assembly. ieee e 0.20 x 0.865 = 0.173 In order to maintain oil production as the water as cut eee ae Se = ‘The composite specific gravity is the sum of the ‘mur desired flow rate wit wi weighted percentages: BOPD Maximum Flow Rate = “2° x 100 Composite Sp. Gr. = 0.868 +0.173 = 1.04 575 BPD : ‘The pressure due to the difference in perforation Man OY epee Veet ies depth and pump setting depth (6,800'- 5,500° = 1,300) can be determined as follows: Step 2 - Production Capacity Weran now calculate the pumpintake pressure | poy _ Head (FT) x Specific Gravity at the maximum rate of 2,875 BPD. First, we 231 FuPST ‘will make the assumption that even though the water cut changes, the well's PI will remain Latte 10+ constant. We can now determine the new well PSI = ————_—_ = 585 PST flowing pressure (P,,) at the maximum desired 2 AL EMESL postiaetion rae 14 ‘Therefore, the pump intake pressure can now be determined; 1,175 psi - 585 psi = 590 psi ~~ m4ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. THE 9 STEP ee Step 3 - Gas Calculations Next, we need to determine the total fluid mix ture that will be ingested by the pump at the new maximum desired flow rate (2,875 BPD). 1. Determine the Solution Gas/Oil Ratio (R,) at the pump intake pressure with Standing’s nomo- ‘graph (see engineering section ), ory substitut- ing the pumpintake pressure for the bubble point pressure (P,) in Standing’s equation; @ ee ‘a R.=Y.Uqg * [marae 1208 (385 (® ) R,=94scfistb yop012s x 32 [paw 2, Determine the Formation Volume Factor (B,) using the R, from above and Standing's nomo- ‘graph (see Engineering section) oruse Standing’s equation as follows B, = 0.972 + 0.000147 FH” where; sy F w() + 1.25T 07 =94 (Gas ‘Therefore; ) 5125 160-284 56 B, = 0.972 + 0.000147 (284.56)! 08 reservoir bbl/stock tank bbl 25 3, Determine the Gas Volume Factor (B,) follows: SUxZxT P Assuming 0.85 Z factor; 04 x 0.85 x (450 +160) =4.40 bbl'mef 604 4. Next,detemninethetotal volameoffuids, and the percentage of free gas released atthe pump intake: ‘a, Using the producing GOR, and oil volume, determine te total volume of gas (1. BOPD x GOR Ts = [900 or 2,875 x 0.20) x 300 72.5 met 1,000 bb. Using the solution GOR (R,), atthe pump intake, determine the solution ges (S, BOPD xR, Glace 6 1,000 or 2875 x 0.20) x 94 So 7,000 = 54.05 mef c. The difference represeits the volume of free gas (F,) released from solution by the decrease in pressure from the bubble point pressure of 1,500 psi, to the pump intake pressure of 1,000 psi. 172.5 mef - 54.05 mef = 118.5 mefZONA.DE ADIESTRAMIENTO & CONSULTORES, S.A. , THE 9 STEP d. The volume of oil (V,), at the pump intake: V, =BOPD x Formation Volume FactorB, 621 bopd ¥i=57S bop x 10 €. The volume of free gas (V,), at the pump intake: V, = Free Gas x Gas Volume Factor B, V, =1185 mefx4.40dbl/mef=521 BGPD f. The volume of water (V,), at the pump intake: V,, = Total Fluid Volume x % Water 875 BPD x 0.80 =2,300 BWPD g. Thetotalvolume (V, of oil, water, and gas, atthe pump intake, can now be determined: V,=V,+V,+V, V,=621 bopd +521 BGPD+ 2,300BWPD V,=3.442 BFPD h. The ratio, or percentage of free gas present at the pump intake to the total volume of uid 521 BGPD "Free Gas = “79 BEPD x 100= 15% 5. Asthis value is greater than 10% by volume, there is significant free gas to affect pump per formance, therefore, itis recommended that a gas separator be installed. Next, we willhave to assume agas separator efficiency. At 15% free gas, we will assume 90% efficiency of separa. 26 a, Percent of gas not separated is 10%: V, = Volume of gas at PIP x 9 ingested V, =521 BPD Xx 0.1 V, =52 BPD b. Total volume of fluid mixture ingested into pump is: c. The amount of free gas entering the first pump stage as a percent of total fluid mixture is: ¥ % Free Gas = S2BPD 2.973 BPD As the free gas represents only 2% by volume of fluid being pumped it has no ignificant effect on the well fluid com- posite specific gravity and may be ignored for conservative motor sizing. % Free Gas x 100=2% 6.Now that thetotal volume of fluid entering the first pump stage is known (2,973 BFPD) and the ‘composite specific gravity has been determined ‘weean continue to the hext step of designing the ESP system,ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. eee THE 9 STEP Step 4 - Total Dynamic Head Sufficient data isnow available to determine the total dynamic head required at the maximum desired flow rate (2,973 BPD). The total dy- namic head for the minimum desired flow rate (2,550 BPD) was previously determined to be 3,556 fi DH estimated producing fluid level and the surface. PIP x 2.31fUpsi ) Specific Gravity si 1 fupsi ) 4,190 ft (1,277m). Pump depth ~ F,=Tubing friction loss, Refer to Friction Loss ‘Charts in the Engineering section Friction loss per 1,000 ft. of 2-7/8" tubing (new) is 60ft. per 1,000‘. of depth at 2,973 BPD (405 MPD), or 4.5 meters per 100meters. Using the desired pump setting depth: = 330 ft. (100.6m) ischarge pressure head (desired wellhead pressure), Using the composite specific gravity: 100 psi x 2.31 fu PORES = 226 ft. (689 m) TO? TDH = 4,190 ft. + 330 ft. + 226 f. = 4,746 ft. or TDH = 1277 m + 100.6 m+ 68.9 m= 1,446.6 m Step 5 - Pump Type Selection We have now determined both hydraulic re- quirements for our variable speed pumping system, ‘Those requirements. are finimum Hydraulic Requirement Flow Rate 2,550 BPD Total Dynamic Head 3,556 ft Maximum Hydraulic Requirement Flow Rate 2,973 BPD Total Dynamic Head 4,746 fi In our economic justification for using the variable speed controller, we elected to reduce the size on the down-hole unit. To accomplish this, we can follow these guidelines: 1. As the operating frequency increases, the number of stages required to generate the required lift decreases, 2, The closer you operate 0 the best effi- ciency point, the lover the power requ ment, and the power cost. 3. A fixed frequency moior of a particular frame size has a maximum output torque, provided that the specified voltage is sup- plied to its terminals. ‘The same torque can be achieved at other speeds by varying the voltage in proportionto the frequency. This way the magnetizing current and flux den- sity will remain constant, and so the avail- able torque will be constant (at no stip rpm). As a result, power output rating will be directly proportional to speed, since power rating is obtained by multiplying rated torque times speed.ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. tad THED STEP Using the variable speed performance curves, select a pump that will fit in the casing, and the ‘maximum flow rate (2,973 BPD) falls atits best efficiency point (BEP). ‘The GC-2200 satisfies these conditions at 81 Hz (see below). Next, select the head per stage fromthe curve on the vertical axis, should read 86 ft. With the maximum total dynamic head requirement of 4,746 ft, we can determine thenumber of pump stages required. Maximum Total Dynamic Head Referring to the pump selection tables in the catalog, you will find that a housing number 6 Will support 55 stages of the GC-2200 pump. ‘Therefore, this 55 stage GC-2200 meets our maximum hydraulic requirement, ‘To determine if it meets our minimum hydraulic, requirement. divide the minimum total dynamic head requirement by the number of stages. 3,556 ft. Minimum Head/Stage 64.7 f/stg, sigs No. Stages = = Plotting the minimum head/stage (64.7 ft.) and Hoad/Stigo the minimum flowrate(2,550BPD)on the curve 446: below indicates an operating frequency of 70 No. Stages= SFijyage = 55 stages Hz. Note, the minimum hydraulic requirement is also near the pump's BEP. = FEE cs . i I N j 28 VARIABLE SPEEO - ONE STAGE PUMP PERFORMANCE GENTRILET PUP FOR MiNIMUil7"0.D. WELL CASING ‘513 SERIES GC2200ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. eee THE 9 STEP Next, using the VSC curve for the GC-2200 find. the BHP/stage atthe 60 hertz BEP(1.12 HP). To calculate the BHP at the maximum frequency: BHP @ Max. Hz. Max, H: BHP/Sig. x No. Stgs. x CE x Sp. Gr 81 He. 112.x55 Gee x 1.04-= 157.6 HP In this example we decided to use a rotary ges separator, which is a centrifugal machine. The HP requirement also changesby acube function. Referring tothe catalog, the 513 seriesrotary gas Separator requires 5 HP at 60 Hertz, siz Separator HP = 5.x \ 60Hz,) x 1.04= 12.8 HP Total BHP for pump and separator = 170.4 HP. To calculate the equivalent 60 Hertz BHP for both the pump and gas separator: 60 Hz, BHP = BHP @ Max. Hz. x ©OH2 Max. Hz. oH. 60 Hz, BHP = 1704 1262 HP = ST Hz. Select the appropriste model seal section and determine the horsepower requirement at the maximum TDH requirement. Select a motor which is capable of supplying total horsepower requirements for the pump, gas separator and seal. Inthisexample, we will select a562 series motor, 130 HP 2,145 voit and 33 amps. Using the technical data provided in the Engi- neering section determine if any load limitations were exceeded (e.g. shaftloading, thrust bearing loading. housing burst pressure limitations, fluid velocity passing the motor, etc.) Next, select the power cable and calculate the cable voltage drop. Based on the motor current (35amps) and the temperature (160°F), number 6 eable can be used. Adding 200° for surface connections, the cable voltage drop is: 2Av x 1.201 x 5,700 7,000 Wecannowcalculate the required surface voltage (SV) at the maximum operating frequency as follows: 64 volts, Cable Drop ax HD SV=Motor Volts x (gaz) + Voltage Drop 81 Hz. sv =2145x (Go 447) + 164 = 3,060 volts Note: Surface voltage is greater than standard 3KV cable. Should select 4KV or higher cable ‘construction. Sufficient data is available to calculate KVA. kva = SVX Motor Amps x 1.73 =i 1,000 3,060 x35 x 1.73 BY 1,000 I8SKVA Referring to the price section of the catalog, we will select the model 2200 - 3VT, 200 KVA, NEMA3 (outdoorenclosure)Electrospeed vari- able speed controller, All other accessory equipment would be selected as the previous example,ZONADE ADIESTRAMIENTO & CONSULTORES, S.A. y THE 9 STEP Autograph ™ A computerized software aid to equipment selection, Conceived specifically for Centrilift sales engineers as an aid when sizing pumps, Autograph "is a computer sofiware program that runs on the Apple Macintosh ™ computer. Autograph '™ is useful for both fixed speed (50 or 60 Hz) and variable speed applications, and makes it practical to produce a unique performance curve for each sizing. ‘The program is based on a graphical approach to sizing and makes full use of the high resolution screen and printout capabilities of the Macintosh Understanding the basic theory of sizingsubmersible pumps isconsidered apre-requisite {0 using the computer software; contact your Centrilift sales engineer for details. ‘The complexity associated with designing Vari- able Speed Electrical Submersible Pumping Systems, along with the introductionof numerous multiphase flow correlations, has made them the ideal candidate for microcomputer applications. Eachapplication is uniqueand detailed informa- tion on well completion, production history and reservoirconditions is extremely important dur- ing the initial design phase Autograph™ is a computer software program that runs on the Apple Macintosh™ designed to greatly simplify the ESP sizing process. ‘The program approaches the sizing by first creating apictorial representation ofthe well performance based on specific hydraulic requirements. This is accomplished on the Model Well Seren (see figure 3). which is theinput document for all the critical well data, 30 Afterthe creation of the well model, the program will allow you to integrate it with a pump model tographically represent the system performance. ‘Thisisaccomplished on the Match Pump Screen (see figure 4), ‘There are several additional screens available that allow you to select the appropriate sizing method, as well as, the selection of the indi- vidual components that make up the ESPsystem, ‘This concludes the Nine-Step Sizing Proce- dure ‘Gi APL Inet, W.E, "Flowing and Gas- Lift Well Performance ling and Production Pratice 1954, AF, p. 143 2 Vogal, J.V. “Inflow Performance Relationship for Solution Gas Drive Wells."J. Pe Tec, Jan 1968, p. 83-93, standing, M.B. “Volunetic and Phase Behavior of Oil Feld Hydrocarbon Systems", Reintold Publishing Corp, New York (1952)ZONA DE ADIESTRAMIENTO & CONSULTORES, S.A. THE 9 STEP eereeeres a Dp. profile wan [ize] (QAP =|2200_j8PD Doints onli (Gmatie) Carger)) 5" 8" straight tine) op (oT w | 1550 64.0 2.87 > REEEELE a 1 Figure 4 - Autograph's Match Pump Screen 31