APPENDIX C - sb5d8e4489ff1fa7d.jimcontent.com · 675 6.75 8 5 /8 J7000N 4500–9000 ... in usual ESP cables. EXAMPLE PROBLEM ... Pump Performance Curve for a 1 Stage D400 at …

APPENDIX C

DESCRIPTION

Table C.1 contains dimensional data and recommended capacities for

REDA submersible centrifugal pumps.

Electrical Submersible Pumps Manual ISBN 978-1-85617-557-9# 2009 Elsevier Inc. All rights reserved.

365

Table

C.1

RecommendedcapacitiesofREDAsubmersible

centrifugalpumpsoperatingat60Hz@

3,500RPM

Nominal

Minim

um

Recommended

ShaftHP

Shaft

Pump

OD

casing

Pump

liquid

capacity

Std

High

diameter

series

(in.)

(in.)

designation

bpd

HP

HP

(in.)

338

3.38

4½

A400

200–500

94

150

0.625

AN550

400–700

94

150

0.625

AN900

700–1060

94

150

0.625

A1200

670–1380

78

125

0.625

AN1200

800–1650

94

150

0.625

A1500

1000–2000

125

200

0.687

AN1500

1000–2000

125

200

0.687

A2700N

1800–3400

125

200

0.687

400

45½

D400

200–550

94

150

0.625

D475N

200–625

94

150

0.625

DN525

300–625

94

150

0.625

D725N

350–925

94

150

0.625

D950

600–1150

125

200

0.688

DN1000

600–1350

125

200

0.688

366 Appendix C

D1400N

960–1700

125

200

0.688

DN1750

1200–2050

125

200

0.688

DN1800

1200–2400

125

200

0.688

DN2150

1300–2600

125

200

0.688

D2400N

1500–3200

162

245

0.688

DN3000

2100–3700

256

410

0.875

DN3100

2100–3900

256

410

0.875

D3500N

2400–4500

316

492

0.870

D4300N

3500–5400

256

410

0.875

D5800N

4400–7000

256

410

0.875

540

5.13

65 /8

GN1600

1000–2150

256

410

0.875

GN2100

1650–2700

256

410

0.875

G2700

2000–3400

256

410

0.875

GN3200

2200–4100

256

410

0.875

GN4000

3200–4800

375

600

1.000

GN5200

3900–6600

375

600

1.000

Continued

367Appendix C

Table

C.1

RecommendedcapacitiesofREDAsubmersible

centrifugalpumpsoperatingat60Hz@

3,500RPM—Cont'd

Nominal

Minim

um

Recommended

ShaftHP

Shaft

Pump

OD

casing

Pump

liquid

capacity

Std

High

diameter

series

(in.)

(in.)

designation

bpd

HP

HP

(in.)

GN5600

4000–7500

375

600

1.000

GN7000

5000–9000

375

600

1.000

GN10000

7000–12000

637

1019

1.188

538

5.38

7SN2600

1600–3200

256

410

0.875

SN3600

2400–4600

256

410

0.875

S5000N

4000–5400

375

600

1.000

S6000N

3500–7800

463

720

1.000

S8000N

3500–10500

463

720

1.000

SN8500

6000–11000

375

600

1.000

562

5.63

7HN13500

5000–18000

375

600

1.000

H15500N

11000–20000

637

1019

1.188

HN21000

17500–24000

637

1019

1.188

H28000N

28000–36000

637

1019

1.188

368 Appendix C

675

6.75

85 /8

J7000N

4500–9000

637

1019

1.188

J12000N

8000–18500

637

1019

1.188

JN16000

12800–19500

637

1019

1.188

JN21000

16000–25000

637

1019

1.188

725

7.25

95 /8

L16000N

11000–20000

637

1019

1.188

L43000N

36000–54000

1000

1600

1.500

862

8.63

103 /4

M520A

12000–24000

637

1019

1.188

M520B

12000–23000

637

1019

1.188

M520C

12000–22000

637

1019

1.188

M675A

19000–32500

637

1019

1.188

M675B

19000–29000

637

1019

1.188

M675C

19000–28000

637

1019

1.188

1000

10.00

113 /4

N1050

35000–64000

1500

2400

1.188

N1400NA

35000–64000

1500

2400

1.750

N1400NB

35000–60000

1500

2400

1.750

369Appendix C

APPENDIX D

DESCRIPTION

Tables D1 and D2 contain operational data of selected REDA electric

submersible motors operating at 60 Hz and 3,500 RPM.


Table D.1 Operational data of selected REDA electric submersible motors operating

at 60 Hz and 3,500 RPM

Nominal Motor MotorMotor OD type power Voltage Amperageseries (in.) – HP V A

456 4.56 Dominator 24 439 35.0

682 22.5

36 415 55.5

780 29.5

901 25.5

48 472 65.0

877 35.0

1039 29.5

1363 22.5

50 894 43.0

995 38.5

1097 35.0

Continued

371


at 60 Hz and 3,500 RPM—Cont'd


1198 32.0

1400 27.5

72 951 48.6

1437 32.0

2288 20.0

84 968 55.5

1252 43.0

1394 38.5

2102 25.5

96 945 65.0

1430 43.0

2402 25.5

108 881 78.5

1427 48.5

2520 27.5

120 1181 65.0

1586 48.5

2194 35.0

2598 29.5

132 1076 78.5

1299 65.0

2413 35.0

2635 32.0

372 Appendix D


at 60 Hz and 3,500 RPM—Cont'd


144 931 99.0

1174 78.5

2145 43.0

2389 38.5

2631 35.0

156 1272 78.5

1535 65.0

2588 38.5

168 1086 99.0

2503 43.0

180 2682 43.0

192 1890 65.0

2537 48.5

204 2008 65.0

2695 48.5

216 1397 99.0

1762 78.5

2125 65.0

2490 55.5

373Appendix D

Table D.2


562 5.62 Dominator 30 460 39.5

745 24.5

60 495 73.5

850 43.0

1205 30.0

90 850 64.0

1275 43.0

1380 39.5

1490 36.5

2125 35.5

120 850 85.5

990 73.5

1275 57.0

1415 51.5

2550 28.5

4160 17.0

150 885 102.5

1240 73.5

1415 64.0

2655 34.0

3190 28.5

4160 21.5

374 Appendix D

Table D.2—Cont'd


180 1275 85.5

2550 43.0

3190 34.0

210 1240 102.5

2490 51.5

3720 34.0

240 1415 102.5

2555 57.0

4250 34.0

270 1275 128.5

1595 102.5

2545 64.0

300 1235 147.5

1415 128.5

1775 102.5

2480 73.5

4250 43.0

330 1360 147.5

1560 128.5

1950 102.5

2725 73.5

3505 57.0

3895 51.5

Continued

375Appendix D

Table D.2—Cont'd


360 1700 129.0

2125 102.5

2550 85.5

3395 64.0

4250 51.5

390 1385 171.0

1840 129.0

2080 114.0

2300 102.5

2765 85.5

3685 64.0

420 2480 102.5

2975 85.5

3470 73.5

3965 64.0

450 1860 147.0

2125 128.0

2655 102.5

3720 73.5

4250 64.0

376 Appendix D

APPENDIX E

DESCRIPTION

Figure E.1 presents a widely used correlation to calculate the voltage drop

in usual ESP cables.

EXAMPLE PROBLEM

Find the three phase voltage drop in a 5,000 ft long AWG #2 size sub-

mersible cable with copper conductors if the motor current is 80 amps,

and the average cable temperature is 200 F.

SOLUTION

At a current of 80 amps and AWG #2 cable size the specific voltage drop

is read from the chart as:

DV=1; 000 ft ¼ 23 V=1; 000 ft

The total voltage drop at 77 F is found next:

DV ¼ 23 5; 000=1; 000 ¼ 115 volts

The correction factor for the actual cable temperature of 200 F is found

from the table on the chart as:

Correction ¼ 1:27

The total voltage drop across the cable at the operating temperature is

calculated as given in the following:

DVcorr ¼ 1:27 115 ¼ 146 amps


377

05

10

15

20

25

30

35

40

45

50

55

60

01

02

03

04

05

06

07

08

09

01

00

11

01

20

13

01

40

15

0

Cu

rre

nt,

Am

ps

Voltage Drop in Cable, V/1,000 ft

No. 6 C

u

No. 4 C

u

No. 2 C

u

No. 1 C

u

Thre

e P

hase V

oltage D

rop in E

SP

Cable

s

Cable

Tem

p =

77 F

Corr

ect V

alu

es f

or

Oth

er

Cable

Tem

pera

ture

s

Tem

pera

ture

Corr

ection F

acto

rs

Tem

p, F

F

acto

r 131 1

.12

149 1

.15

167 1

.19

185 1

.23

203 1

.27

221 1

.31

239 1

.35

257 1

.39

275 1

.42

293 1

.46

302 1

.48

30 V

/ 1

,000 ft R

ecom

mended V

oltage D

rop L

imit

Fig.E.1

Typ

icalvaluesofvoltagedropsin

copperconductors

378 Appendix E

CLASS PROBLEMS

ESP Design and Analysis Gabor Takacs, PhD

Instructor

CLASS PROBLEM ASSIGNMENT

Subject: Determination of a well’s CompositeIPR Curve

Class problem #1

Name of trainee: Date:

PROBLEM STATEMENT:

Develop the Composite IPR Curve for a well with the following para-

meters. The well was tested at 500 bpd at FBHP ¼ 1,500 psi, its SBHP

¼ 2,000 psi. The well produced with a water cut of 50%, the bubblepointpressure is 1,300 psi.

INSTRUCTIONS:

First, determine the relation between SBHP, FBHP and bubblepoint pres-

sure and accordingly calculate the PI, the rate at bubblepoint pressure, the

maximum oil rate, the slope, and the well’s maximum liquid rate.

Then calculate the FBHPs belonging to the rates given in the table,

using Eqs. 2.4 to 2.6 in your manual. Finally, plot the IPR curve on

the chart given.


379

SOLUTION:

Liquidrate

FBHP

bpd psi

0 2,000

1,300

0

0

500

1000

1500

2000

0 500 1000 1500

Liquid Rate, bpd

Flo

win

Bo

tto

mh

ole

Pre

ssu

re.

psi

380 Class Problems


Instructor


Subject: Tubing loss calculations Class problem #2


PROBLEM STATEMENT:

Find the head to be developed by an ESP pump operating at a depth of

7,000 ft and producing 1,500 bpd of SpGr ¼ 0.9 liquid. The liquid level

is at the pump, the wellhead pressure equals 350 psi, and the tubing is

23 8= in (new pipe).

INSTRUCTIONS:

First find the frictional head loss from Fig. A.1 in the Appendix, and cal-

culate the total loss. Then find the head to overcome the wellhead

pressure.

SOLUTION:

381Class Problems


Instructor


Subject: Use of the affinity laws Class problem #3


PROBLEM STATEMENT:

Based on the ESP pump performance curve (60 Hz, 3,500 RPM opera-

tion) attached, convert three points of the head, BHP, and efficiency

curves to 50 Hz operation, where the pump’s speed is 2,917 RPM. Take

the BEP point and the two limiting rates of the recommended operation

range. Plot your results on the chart provided.

INSTRUCTIONS:

Use the table given below.

SOLUTION:

Read from chart @ 60 Hz Calculated @ 50 Hz

Rate Head BHP Eff. Rate Head BHP Eff.

bpd ft HP % bpd ft HP %

Min

BEP

Max

382 Class Problems

00 100 200 300 400

BPD

ESP Design and Analysis Course Class Problems #3 & #4

500 600 700

5

10

15

20

25

30

Feet

Head-Capacity

BHP

Eff.

BHP % Eff.

60

40

20

00

.25

.5

Pump Performance Curve for a 1 Stage D400 at 3500 RPM; SpGr = 1

383Class Problems


Instructor


Subject: Viscosity correction of ESP pumpperformance

Class problem #4


PROBLEM STATEMENT:

Correct the pump performance curves provided to a liquid of SpGr ¼ 0.78and a viscosity of 88 cSt. Use the BEP point and the two limiting rates of

the recommended operation range. Plot your results on the chart

provided.

INSTRUCTIONS:

First convert the viscosity into SSU, and then find the correction factors

recommended in Table 4.1.

SOLUTION:

Read from chart Corrected for viscosity

Rate Head BHP Eff. Rate Head BHP Eff.

bpd ft HP % bpd bft HP %

Min

BEP

Max

384 Class Problems

00 100 200 300 400

BPD

ESP Design and Analysis Course Class Problems #3 & #4

500 600 700

5

10

15

20

25

30

Feet

Head-Capacity

BHP

Eff.

BHP % Eff.

60

40

20

00

.25

.5

Pump Performance Curve for a 1 Stage D400 at 3500 RPM; SpGr = 1

385Class Problems


Instructor


Subject: Free gas volume calculation at suctionconditions

Class problem #5


PROBLEM STATEMENT:

Using the Turpin correlation, find the severity of gas interference at the

ESP pump’s suction for the following data.

Oil API degree ¼ 40 PIP ¼ 500 psiGas Sp.Gr. ¼ 0.6 Oil rate ¼ 1,500 bpdSuction temp. ¼ 130!F Production GOR ¼ 250 scf/bbl

WOR ¼ 3

INSTRUCTIONS:

First, find the solution gas/oil ratio, then the volume factor of the gas, then

the free gas volume.

The oil volume factor is calculated next, then the liquid volumetric rate,

and finally the total fluid volume handled by the pump.

To find the severity of the gas interference, use the Turpin correlation

as given in Eq. 4.24.

Oil Sp:Gr: ¼ 141:5= 131:5þ APIð Þ

SOLUTION:

386 Class Problems


Instructor


Subject: ESP motor selection for VSD service Class problem #6


PROBLEM STATEMENT:

Select the proper ESP motor for 100-stage DN3000 pump running at 50

Hz and producing 2,400 bpd of a Sp.Gr. ¼ 0.85 oil. A rotary gas separatoris also used and takes 5 HP of power at 60 Hz operation. A one-stage per-

formance curve sheet (60 Hz operation) is attached.

INSTRUCTIONS:

First find the rate corresponding to 2,400 bpd @ 60 Hz operation, using

the affinity law. Then read the performance parameters at this rate from

the chart attached.

SOLUTION:

Q60 ¼ From perf. curves: BHP60/stage @ Q60 ¼

From affinity law: BHP50/stage ¼

BHP required for 100 stages: BHP50 ¼ BHP60 ¼

Rotary separator’s BHP requirement: BHPsep @ 50 Hz ¼

Total required BHP @ 50 Hz ¼

Motor power @ 60 Hz ¼

387Class Problems

Motor selected from Table D.2:

NPHP ¼Voltage ¼Amps ¼Check for max. allowed frequency: fmax ¼Calculated motor load: Load (%) ¼

Check pump shaft strength:

Allowed power @ 60 Hz from Table C.1:

Converted to 50 Hz ¼ OK OVERLOAD

Calculate required VSD voltage:

Voltage ¼

00 500 1000 1500 2000 2500

BPD

ESP Design and Analysis Course Class Problems #6

35003000 4000 4500 5000

5

10

15

20

25

30

Feet

Head-Capacity

BHP

Eff.

BHP % Eff.

75

50

25

00

.5

1

Pump Performance Curve for a 1 Stage DN3000 at 3500 RPM; SpGr = 1

388 Class Problems


Instructor


Subject: Determination of total dynamic head Class problem #7


PROBLEM STATEMENT:

The basic data for an ESP installation are as follows:

Pump setting depth ¼ 5,000 ft Depth of perforations ¼ 6,000 ftDesired pumping rate ¼ 4,500 bpd Liquid Sp.Gr. ¼ 0.95Tubing size ¼ 31 2= in (old pipe) Wellhead pressure ¼ 200 psi

Calculate the TDH for three different cases:

Case A: The dynamic liquid level is at 4,500 ftCase B: The static liquid level is at 1,000 ft

The well’s PI is 3 bpd/psiCase C: SBHP ¼ 2,200 psi

PI ¼ 2.8 bpd/psi

INSTRUCTIONS:

First calculate the dynamic liquid level then use Fig. A.1 in Appendix A

to find frictional losses.

SOLUTION:

389Class Problems


Instructor


Subject: Design of a conventional ESPinstallation

Class problem #8


PROBLEM STATEMENT:

Select the main components of an ESP installation running at 60 Hz in a

well with negligible gas production.

Pump settingD ¼ 4,500 ft

WHP ¼ 100 psi Sp.Gr. oil ¼ 0.85

Perforations @ 5,000ft

CHP ¼ 100 psi Sp.Gr. water ¼ 1.0

Tubing size 23 8=in new

Liquid rate ¼ 1,700STB/d

Sp.Gr. gas ¼ 0.60

Casing ID 6.09 in Static liquidlevel ¼ 1,820 ft

PI ¼ 2 bpd/psi

Bottomholetemp ¼ 200!F

Water cut ¼ 80% Frequency ¼ 60 Hz

INSTRUCTIONS:

Follow the steps outlined on the following sheets.

SOLUTION:

Inflow calculations:

Calculate liquid Sp.Gr. from water cut. Sp.Grl. ¼Calculate SBHP ¼ 0.433 (Lperf % Lstat) Sp.Grl. ¼ psi

Calculate FBHP ¼ SBHP % Q/PI ¼ psi

Calculate pump intake pressure

PIP ¼ FBHP % 0.433 (Lperf % Lpump) Sp.Grl. ¼ psi

Find dynamic liquid level from Eq. 5.6:

Ldyn ¼ ft

390 Class Problems

Find solution GOR from Eq. 5.3:

Oil API ¼ 141.5/Sp.Gr. oil % 131.5 ¼y ¼Rs ¼ scf/STB

Calculate oil volume factor @ PIP from Eq. 5.5:

F ¼Bo ¼

Calculate liquid rate at pump intake from Eq. 5.4:

Q ¼ bpd

Calculate TDH:

Find frictional head loss from Fig. A.1:

Dhfr (ft/1,000 ft) ¼DHfr ¼ Dhfr & Setting depth/1,000 ¼ ft

h0 ¼ 2.31 (WHP % CHP)/Sp.Gr. ¼ ft

TDH ¼ Ldyn þ DHfr þ h0 ¼ ft

Select pump type using Table C.1:

Series ¼ Pump type ¼

Performance parameters @ desired rate from attached performance

curve:

Head/stage ft/stage

BHP/stage HP/stage

Shut-in head/stage ft/stage

Allowed shaft power HP

Shaft diameter in.

Housing burst pressure psi

Calculate number of stages required:

No. of stages ¼ TDH/(ft/stage) ¼ stages

Pump housing # with stages (from the table attached)

Check pump for mechanical strength:

Pump BHP ¼ No. of stages & BHP/stage & SpGrl ¼ HP

Shaft checks OK not OK

391Class Problems

Max, internal housing pressure ¼ Shut-in

head/stage & stages & 0.433 & SpGrl ¼¼ psi

Housing checks OK not OK

Select protector:Downthrust from pump ¼ lb (Eq. 5.12)Series selected ¼Type selected ¼Load rating @ BHT ¼ lb OK not OKShaft power rating ¼ HP OK not OK

Select motor:

Motor series considered: Series _____

Check flow velocity around motor: (Eq. 5.13)

vl ¼ ft/s OK not OK

Required motor HP ¼ Pump BHP ¼ BHP

Select motor from Table D.1:Power ¼ HPVoltage ¼ VCurrent ¼ A

Motor loading ¼ %

Actual motor current ¼ AMotor efficiency ¼ %Motor power factor ¼ .

Select cable:

Cable current ¼ Actual motor amps ¼ A

Cable length ¼ Pump depth þ 100 ft ¼ ft

Cable type selected ¼Select cable size using program CABLES

When running the program, use the following parameters:

Cable life ¼ 60 months (5 years)

Power cost ¼ 5 c/kWh

Interest rate ¼ 12%

Selected cable size from program CABLES ¼ AWG #

Calculate voltage drop in cable, V/1,000 ft

Drop read from graph ¼ V/1,000 ft from App. E

392 Class Problems

Adjusted drop:

Vadj ¼ Vgraph (1 þ 0.00214 (BHT % 77)) ¼ V/1,000 ft

Voltage drop in cable: Vadj & Cable length/1,000 ¼¼ volts

Find power lost in cable:

Total resistance of cable:

Ohms/1,000 ft for AWG #6 ¼ ___

RT ¼ Length/1,000 ___ & (1 þ 0.00214 (BHT -77) ¼¼ ohms

Power loss ¼ 3 current2RT/1,000 ¼ kW

Calculate surface voltage, power:

Surface voltage ¼ Motor voltage þ Drop in cable ¼ volts

Surface kVA ¼ 1.732 & Surface voltage & Cable

current/1,000 ¼ kVA

Predicted power requirement ¼ kVA & Power factor ¼ kW

00 250 500 750 1000 1250

BPD

ESP Design and Analysis Course Class Problems #8

17501500 2000 2250 2500

10

20

30

40

50

60

Feet

Head-Capacity

BHP

Eff.

BHP % Eff.

60

40

20

00

.5

1

Pump Performance Curve for a 1 Stage GN1600 at 3500 RPM; SpGr = 1

393Class Problems

Available housings for GN1600 pumps:

Housing # Max. stages

10 12

20 28

30 43

40 59

50 75

60 90

70 106

80 122

90 137

ESP cable dimensional and pricing data:

AWG size OD, in. Weight, lb/ft Price, $/ft

1 1.357 1.69 11.30

2 1.280 1.44 9.69

4 1.091 1.00 6.46

6 1.000 0.75 5.11

ESP protector load rating data:

400 Series Protector

Lo

ad

(L

Bf)

BHT (F) 0 50 100 150 200 250 300

10,000

7,500

5,000

2,500

Bronze Bearing

Hi Ex Bearing

0

394 Class Problems

ESP protector shaft rating data:

Series Shaft diameter, in. Rated HP

375 0.875 256

400 0.875 256

540 1.187 637

562 1.187 637

ESP motor performance curves:

3600

3550

3500Speed

RPM

Percent

Efficiency

Percent

Power

Factor

Percent

Nameplate

Power

and

Amperage

Percent of Nameplate Load

3450

3400908070605040302010

85

75

65

55

45

35

100

80

60

40

20

10 20 30 40 50 60 70 80 90 100

395Class Problems


Instructor


Subject: Conventional installation design withmotor slip

Class problem #9


PROBLEM STATEMENT:

Using the data given in Class problem #8, select the components of an

ESP installation by including the effects of the ESP motor’s slip.

INSTRUCTIONS:

Most of the calculations are identical to those performed for solving Class

problem #8 and must not be repeated here. The only calculation steps to

be inserted after the motor selection are described in the following.

For your convenience, some of the calculated parameters to be used in

solving this problem are culled here from Class problem #8.

Liquid rate @PIP

1,728bpd

Pump BHP @ 3500RPM

93 HP

Selected motorpower

96 HP Selected motorcurrent

25.5 A

Calculated TDH 4,351 ft Number of pumpstages

106

396 Class Problems

SOLUTION:

Finding the actual motor speed:

To calculate the common speed of the ESP motor and the submersible

pump fill out the form until convergence is found.

Iteration step 1 2 3 4 5 6

Pump BHP

Motor loading, %

Motor RPM

Mod. pump BHP

BHP difference

Converged results:

Actual motor speed, RPM ¼Required motor HP ¼Motor loading ¼

Find the following parameters from motor performance curves provided

for Class problem #8 at the calculated motor loading:

Motor efficiency, %

Power factor

Percent amperage, %

Actual motor current from Eq. 5.26 ¼Find the pump head including the effects of motor slip:

Liquid rate @ 3500 SPM from Eq. 5.27 ¼Head/stage read from perf. curve @ 3500 RPM ¼Total pump head from Eq. 5.28, Hslip ¼Compare Hslip and TDH:

System can produce required rate YES NO

397Class Problems


Instructor


Subject: ESP installation design for a gassywell

Class problem #10


PROBLEM STATEMENT:

Select the main components of an ESP installation running at 60 Hz in a

well with considerable gas production.

Pump setting D ¼5,500 ft

WHP ¼ 100 psi Sp.Gr. oil ¼ 0.86

Perforations @ 6,000ft

Liquid rate ¼ 3,800STB/d

Sp.Gr. water ¼1.09

Tubing size 3½ in.new

Static BHP ¼ 2,000 psi Sp.Gr. gas ¼ 0.65

Casing ID 6.366 in. Water cut ¼ 50% PI ¼ 2.5 bpd/psiBottomhole temp ¼180F

Available frequency ¼60 Hz

GORprod ¼ 250scf/bbl

INSTRUCTIONS:

Follow the steps outlined on the following sheets.

SOLUTION:

Inflow calculations:

Find flowing BHP from PI equation:

FBHP ¼ psi

Calculate liquid Sp.Gr. from water cut. Sp.Grl. ¼Calculate pump intake pressure from Eq. 5.2:

PIP ¼ FBHP % 0.433 (Lperf % Lpump)Sp.Grl. ¼ psi ¼ psia

398 Class Problems

Gas separation calculations:

Find solution GOR from Eq. 5.3:

Oil API ¼ 141.5/SpGr Oil % 131.5 ¼ API deg

y ¼Rs ¼ scf/STB

Calculate gas volume factor:

Gas critical properties from Eqs. 4.27–4.28:

ppc ¼ psia

Tpc ¼ R

Reduced parameters:

ppr ¼Tpr ¼Deviation factor from Eq. 4.26:

Z ¼Gas volume factor from Eq. 5.30:

Bg ¼Free gas volumetric rate from Eq. 5.29:

qg0 ¼ bpd

Find liquid volumetric rate:

Calculate oil volume factor @ PIP from Eq. 5.5:

F ¼Bo ¼Liquid rate from Eq. 5.4:

ql0 ¼ bpd

Calculate Turpin F from Eq. 4.24:

F ¼ OK Gas separation needed

Use rotary gas separator with an efficiency of %

Gas volume ingested by pump from Eq. 5.32:

qing0 ¼ bpd

Calculate Turpin F from Eq. 4.24:

F ¼ OK Gas separation needed

Total fluid rate handled by pump from Eq. 5.33:

qfluid0 ¼ bpd

399Class Problems

Calculate TDH:

Find Sp.Gr. of flowing mixture from Eq. 5.34:

qo ¼ STBO/d

qw ¼ STBW/d

gm ¼Calculate dynamic liquid level from Eq. 5.35:

Ldyn ¼ ft

Find frictional head loss from Fig. A.1:

Dhfr (ft/1,000 ft) ¼DHfr ¼ Dhfr & Setting depth/1,000 ¼ ft

h0 ¼ 2.31 wellhead press/Sp.Grm. ¼ ft

TDH ¼ Ldyn þ hf þ h0 ¼ ft

Select pump type using Table C.1:Series ¼ Pump type ¼Performance parameters @ desired rate from attached performance

curve:

Head/stage ft/stage

BHP/stage HP/stage

Shut-in head/stage ft/stage

Allowed shaft power HP

Shaft diameter in

Housing burst pressure psi

Calculate number of stages required:

No. of stages ¼ TDH/(ft/stage) ¼ stages

Pump housing # with stages (from the table attached)

Check pump for mechanical strength:

Pump BHP ¼ No. of stages & BHP/stage & Sp.Grm. ¼ HP

Shaft checks OK not OK

Max internal housing pressure ¼ Shut-in head/Stage

& Stages & 0.433 & Sp.Grm. ¼¼ psi

Housing checks OK not OK

400 Class Problems

Select protector:

Downthrust from pump ¼ lb

Series selected ¼Type selected ¼Load rating @ BHT ¼ lb OK not OK

Shaft power rating ¼ HP OK not OK

Select motor:

Motor series considered: Series ___

Check flow velocity around motor:

vl ¼ ft/s OK not OK

Power required by rotary gas separator ¼ BHP

Required motor HP ¼ Pump BHP þ Separator BHP ¼ BHP

Select motor from Table D.1:Power ¼ HPVoltage ¼ VCurrent ¼ A

Motor loading ¼ %Actual motor current ¼ AMotor efficiency ¼ %Motor power factor ¼ .

Select cable:

Cable current ¼ Actual motor amps ¼ A

Cable length ¼ Pump depth þ 100 ft ¼ ft

Cable type selected ¼Select cable size using program CABLES

When running the program, use the following parameters:

Cable life ¼ 50 months (5 years)

Power cost ¼ 5 c/kWh

Interest rate ¼ 12%

Selected cable size from program CABLES ¼ AWG #

Calculate voltage drop in cable, V/1,000 ft

Drop read from graph ¼ V/1,000 ft App. E

Adjusted drop:

Vadj ¼ Vgraph (1 þ 0.00214 (BHT % 77)) ¼¼ V/1,000 ft

401Class Problems

Voltage drop in cable: Vadj & Cable length/1,000 ¼¼ volts

Find power lost in cable:

Total resistance of cable ohms/ft ¼ ______

RT ¼ Length/1,000 ohms/ft (1 þ 0.00214 (BHT % 77) ¼¼ ohms

Power loss ¼ 3 current2RT/1,000 ¼ kW

Calculate surface voltage, power:

Surface voltage ¼ Motor voltage þ Drop in cable ¼ volts

Surface kVA¼ 1.732& Surface voltage&Cable current/1,000¼ kVA

Predicted power requirement ¼ kVA & Power factor ¼ kW

0 1,000 2,000 3,000 4,000

Capacity - Barrels per Day

5,000 6,000 7,000

20

10

30

40

50

60

70

Feet Hp

7.00

6.00

5.00

4.00

3.00

2.00

1.00

Eff

70%

60%

50%

40%

30%

20%

10%

402 Class Problems

Available housings for S5000N pumps:

Housing # Max. stages

10 5

20 11

30 18

40 25

50 31

60 38

70 44

80 51

90 57

100 64

110 71

120 77

130 84

140 90

150 97

ESP cable dimensional and pricing data:

AWG size OD, in. Weight, lb/ft Price, $/ft

1 1.357 1.69 11.30

2 1.280 1.44 9.69

4 1.091 1.00 6.46

6 1.000 0.75 5.11

403Class Problems

ESP motor performance curves:

3600

3550

3500

Speed

RPM

(60 Hz)

Percent

Efficiency

Percent

Power

Factor

Percent

Nameplate

Voltage

and

Amperage

Percent of Nameplate Load

3450

3400908988878685848382

87

86

85

84

83

82

81

100

80Voltage

Amperage60

40

20

40 50 60 70 80 90 100

404 Class Problems


Instructor


Subject: NODAL analysis of ESPinstallations #1

Class problem #11


PROBLEM STATEMENT:

Determine the liquid production rate of an ESP system using a 100-stage

GN4000 pump. Well data are given as follows:


Static BHP ¼ 3,000 psi PI ¼ 4 bpd/psi

Perforations @ 6,000 ft Water cut ¼ 100%Tubing ID ¼ 2.992 in.old

Available frequency ¼ 60Hz

Assume wellhead pressures of 100, 200, and 300 psi.

INSTRUCTIONS:

Use the pump performance curve attached and plot the formation plus

pump performance curve on the same sheet.

1bpd ¼ 0:0292 gpm

405Class Problems

SOLUTION:

To plot the performance curve of the formation plus the pump, fill out the

following form.

Liquid FBHP Frict. Frict. Pump head reqd. at

rate head loss wellhead pressure

bpd psi ft/100 ft ft 100 200 300

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

Pump Performance Curve for a 1 Stage GN4000 at 3500 RPM SpGr = 1 BHP

5

2.5

0

%Eff.

75

50

25

0

Head-Capacity

BHP

0 1000 2000 3000

BPD

4000 5000 6000

Eff.

406 Class Problems


Instructor



Class problem #12


PROBLEM STATEMENT:

The well with the parameters given in the following is choked on the

wellhead to produce 3,200 bpd of water while an SN3600 pump with

120 stages is installed at 60 Hz operation. Investigate the use of a VSD unit

and find the required electrical frequency to produce the same liquid vol-

ume without choking the well. Calculate the energy wasted due to

choking.


Static BHP ¼ 2,500 psi WHP ¼ 100 psi

Perforations @ 7,000 ft Water cut ¼ 100%Tubing ID ¼ 2.992in old

PI ¼ 3 bpd/psi

INSTRUCTIONS:

The performance curve of the given pump is attached. Plot the perfor-

mance of the formation plus the ESP pump on the same diagram.

To find the wasted power, use Eq. 6.5.

1bpd ¼ 0:0292 gpm

407Class Problems

CALCULATIONS:

Liquid FBHP Frict. Frict. Reqd.

rate head loss head

bpd psi ft/100 ft ft ft

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

5,500

6,000

6,500

7,000

Required electrical frequency for 3,200 bpd ¼ Hz

Head drop across production choke ¼ ft

Power wasted due to choking: HP

408 Class Problems

Feet

20000

15000

10000

5000

00 1000

45 HZ

50 HZ

55 HZ

60 HZ

65 HZ

70 HZ

75 HZ

80 HZ

85 HZ

45

50

55

60

65

70

75

80

85

96

132

175

227

289

361

444

539

646

128

158

191

227

267

309

355

404

456

2000 3000 4000

BPD

5000 6000 7000 8000

Pump Performance Curve for a 120 Stage SN3600 at Multi-Hertz SpGr = 1

409Class Problems


Instructor



Class problem #13


PROBLEM STATEMENT:

Find the maximum liquid rate achievable from the well defined in the fol-

lowing for two cases: (1) at 60 Hz operation and (2) if the motor is run at

85 Hz. Investigate the effect of the flowline size on the rate and use flow-

line IDs of 2, 3, and 4 in. An ESP pump J12000N with 41 stages is used.


Static BHP ¼3,000 psi

Separator Pr. ¼ 200 psi

Perforations @ 3,400 ft Water cut ¼100%

Flowline length ¼2,000 ft

Tubing ID ¼ 2.992 in.new

PI ¼ 10 bpd/psi

INSTRUCTIONS:

Use the pump performance curve sheet supplied and plot the calculated

performance curve of the formation plus the pump on the sheet.

1bpd ¼ 0:0292 gpm

410 Class Problems

SOLUTION:

Fill out the following form to define the performance curve of the forma-

tion plus the ESP pump.

Flowline frict. gradient Flowline frict. head losses

Size(in.)

Size(in.)

Size(in.)

Size(in.)

Size(in.)

Size(in.)

Rate 2 3 4 2 3 4

bpd ft/100ft

ft/100ft

ft/100ft

ft ft ft

0

5,000

10,000

15,000

20,000

25,000

30,000

411Class Problems

TDH for flowline sizes

Tubing Tubing Size(in.)

Size(in.)

Size(in.)

Rate FBHP frict.grad

friction 2 3 4

bpd psi ft/100 ft ft ft ft ft

0

5,000

10,000

15,000

20,000

25,000

30,000

Feet

10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

00 5000

45 HZ

50 HZ

55 HZ

60 HZ

65 HZ

70 HZ

75 HZ

80 HZ

85 HZ

45 201

276

367

477

606

757

931

1130

1355

268

331

400

477

559

649

745

847

956

50

55

60

65

70

75

80

85

10000 15000 20000

BPD

25000 30000 35000

Pump Performance Curve for a 41 Stage J12000N at Multi-Hertz SpGr = 1

412 Class Problems


Instructor



Class problem #14


PROBLEM STATEMENT:

Inflow to a well produced by ESP equipment is known to follow the

Vogel IPR curve with SBHP ¼ 1,600 psi, and qmax ¼ 6,500 bpd. The

ESP pump has 60 stages, and pump performance is given at 60 Hz by

the following three points on the single-stage performance curve:

Min. recom. BEP Max. recom.

Q (bpd) 2,400 3,500 4,600

Head (ft) 59 51 33

Using the coordinate system of the IPR curve, find the liquid rate pro-

duced (1) at 60 Hz and (2) at 70 Hz operation.

Other relevant well data are listed as follows:


Perforations @ 4,000 ft WHP ¼ 100 psi

Tubing ID ¼ 2.441in old

Liquid Sp.Gr. ¼ 1.0

INSTRUCTIONS:

First, calculate the performance parameters at 70 Hz, using the affinity

laws. Then calculate and plot the performance curves of the ESP–well sub-

system for the given number of pump stages. Plot your results on the sheet

provided.

413Class Problems

SOLUTION:

Pump performance curve data for 60 stages.

Hz Min BEP Max

Rate Head Rate Head Rate Head

60 2,400 3,500 4,600

70

Calculate performance curves for the ESP–well subsysem.

Hz Rate Dhfr Dpfr FBHP

bpd ft/100 ft psi psi

60 2,400

60 3,500

60 4,600

70

70

70

Calculate well IPR data.

FBHP 0 160 320 480 640 800 960 1,120 1,280 1,440 1,600

Q 0

414 Class Problems

200

0

400

600

800

1,000

1,200

1,400

1,600

1,800

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000

Pumping Rate, bpd

Head D

evelo

ped, ft

415Class Problems


Instructor



Class problem #15


PROBLEM STATEMENT:

Using the data of Class problem #14, find the liquid rates received from

the installation for every 5 Hz increment in the frequency range 40 Hz to

75 Hz. Develop an Excel sheet for the solution and plot your results.

INSTRUCTIONS:

Follow the solution recommended in the previous Class problem.

416 Class Problems

INDEX

A

Abrasive solids

concentration, 157

damage, classification, 156

material hardness, 156–157

pump erosion, 158–159

radial bearings, 159

radial wear, reduction, 161–164

rubber, 160

sand damage, 158

sand production, 155

thrust washers, 159–160

Absolute open flow potential (AOFP),

11–12, 14

Affinity law, 234

Alhanati's approximate method, 220

Alternating current (AC)

circuits and power, 37–40

lagging, 39

line voltage, 37

Ohm's law, 38–39

three-phase supply, 36

Alternative deployed installations

cable suspended units, 350–351

coiled tubing (CT)

cable led inside/outside string, 353

inverted units, 353–354

versions, 352

American wire gauge (AWG)

calculation, 107

number, 105–106

voltage drop and energy waste,

109–110

Ammeter charts interpretation

electric power fluctuations, 325

erratic loading conditions, 337

failure restart, 328

free gas production, 330

frequent cycling, 329

gas interference, 326

normal operation, 323–324

operational problems, 323

overload condition, 334

pump-off condition, 327

restart attempts, 336

tank level control, 333

undercurrent failure, 332

undercurrent shutdown, 331

well cleanup, 335

Ampacity charts, 109–110

AOFP. See Absolute open flow potential

Artificial lifting

flowing wells, 1

gas lifting, 2

methods, comparison

lifting depth, 5

maximum liquid production rates vs.

lifting depth, 4

pumping

downhole pump, 2

jet, 4

rodless, 3

AWG. See American wire gauge

B

Bag-type protectors, 197

Best efficiency point (BEP), 56, 58, 122–124,

136–137, 169–170, 232

pumps, 26, 29

shock losses, 28

Bottomhole pressure, well inflow

performance

annular liquid gradients

flowing bottomhole pressure, 286, 289

gas-free liquid gradient, 287

gradient correction factor, 287–289

hydrostatic pressure, 285–286

static bottomhole pressure, 286

water/oil ratio (WOR), 286–287

annular liquid level, 284

pressure gradients, 285

surface casing pressure and well

sounding, 284

Brake horsepower (BHP), 58, 63, 77, 80–81

C

Cables

ampacity charts, 109–110

copper conductors, 106

electric, 43, 199

impedance, 107

materials, 102–104

operating conditions, 102

requirements, 101

round and flat, construction, 104–105

size, 105–106

suspended units, 350–351

temperature, 107–109

417

Cables (Continued)

voltage drop and power loss, 109

Capital recovery factor (CRF), 201, 302–303

Centrifugal pumps, 193

affinity laws

head and brake horsepower, 36

H–Q curves, different speed, 35

performance parameters, relationship,

34

axial thrust forces

balancing ring and holes, 33

groups in, 31

mixed flow impeller, 32

gas interference

head performance degradation, 137

impeller and diffuser, 137–138

phase segregation, 138

single-phase liquid, 136

hydraulic institute model

brake horsepower (BHP), 123

head and efficiency curves, 123–125

liquid rate, 122

water performance, conversion,

121–122

operational basics

balancing mechanisms, 26

components, 23

energy conversions, 24

impeller, 24–25

performance

curves, 30

head, 27

H–Q curve, derivation, 28

power conditions, 29

specific speed

impeller design, 27

radial and mixed flow stages, 26

stage, 23

Centrilift 400 series gas separators,

RGSs, 149

Coiled tubing (CT) installations, 6, 8

cable led inside/outside string, 353

inverted units, 353–354

versions, 352

Compression pumps

abrasion resistance, 162

fixed impeller, limitations, 62

Conventional design

actual motor speed, 214–215

downhole equipment, 204

motor and pump interaction

BHP, 213

comprehensive analysis, 212

iterative procedure, 212

motor/pump series-connected

system, 214

motor selection, 198–199

motor startup checking, 203

power cable

length and type, 200

size, 200–203

protector selection, 196–198

pump head, motor slip

pump brake horsepower, 217

pumping rate calculation, 215

total dynamic head calculation

(TDH), 216

pump selection stages, 194–195

pump series, 193

pump's mechanical strength checking,

195–196

pump type, 194

switchboard and transformer selection,

203–204

TDH calculations

frictional head loss, 192–193

true vertical depth (TVD), 192

well inflow calculations

flowing bottomhole pressure

(FBHP), 190

gas/oil ratio (GOR), 191

pump intake pressure (PIP), 190

Turpin correlation, 191

CRF. See Capital recovery factor

D

DHMs. See Downhole measurements

Diffuser, centrifugal pumps, 23

energy, conversion, 24

parts, nomenclature, 25

D1400N pump, 209

Downhole equipment, miscellaneous

cable bands, 110

centralizers, 112

check valve, 110–111

downhole instrumentation, 113

drain valve, 111

Y-tool, 112–113

418 Index

Downhole measurements, 314–316,

338–339

Dual zone installations, 347–350

E

Energy losses and efficiencies

electrical power losses

cable loss, 298

motor loss, 297–298

surface electrical loss, 298–299

hydraulic losses

backpressure loss, 296

gas separator, power loss, 297

pump loss, 296–297

tubing loss, 295–296

Ethylene propylene diene monomer

(EPDM), 167, 200

F

Floating impellers, 196–197

Flowing bottomhole pressure (FBHP), 11,

14, 17–20, 190, 340–341

Flowing wells, 1–2

Fluid flow velocity, 198

Fluid over pump (FOP), 192

Free gas handling ability, 154

G

Galvanized armor, 245

Gas/liquid ratio (GLR), 263, 265

Gas/oil ratio (GOR), 130, 191

Gas separator. See also Rotary gas separator

pump suction conditions, 99–100

reverse flow, 100–101

Gassy wells

free gas volume, 130–136

gas handlers, 153–154


impeller circulation, 152

inflow and free gas calculations

Alhanati's approximate method, 220

pressure distributions, 220

Turpin correlation, 220–221

kinetic energy, 128–129

natural gas separation, 140–145,

225–226

overstaged pumps, 151

pump performance degradation,

136–140

rotary gas separators (RGSs), 145–150

special pumps, 154

stage recirculation, 152

tapered pumps, 151–152

total dynamic head calculations,

221–222

Gate turn off thyristors (GTOs), 172

H

Hazen–Williams formula, 192

Head capacity curve (Q–H), 194

High well temperatures

motors, 166–167

submersible equipment, 166

Hydraulic fundamentals

head loss, 22

tubing flow calculations, 21–22

I

IGBTs. See Insulated gate bipolar transistors

Impeller

fixed

constructional stages, 59, 62

sand problem areas, 158

floating, 59

abrasive service, 162

construction, 61

thrust washers, 160

liquid flow path and vanes, 24

parts, nomenclature, 25

Induction motors

slip, 42–43

types, 41–42

Inflow performance relationship (IPR),

10, 13

composite curve, 15

FBHP calculation, 17

points calculation, 19–20

SBHP and test pressures, 18–19

schematic depiction, 16

Vogel's correlation

curve comparison, 15

dimensionless curve, 14

gas drive reservoirs, 13

In-situ liquid volumetric rate, 191

Installation methods

advantages and limitations, 7–8

alternative deployed type

cable suspended units, 350–351

419Index

Installation methods (Continued)

coiled tubing, 351–354

applications, 6–7

auxiliary pump, 141

conventional, 52

dip tube, 143

features, 53

gas separator, 143

inverted shroud, 144

shrouded, 142

surface arrangement, 115

tubing deployed type

dual zone type, 347–350

single zone production, 344–347

Insulated gate bipolar transistors

(IGBTs), 172

Integrated coiled tubing/electrical

submersible pumping (CT/ESP)

cable, 354

Inverted units, 353–354

IPR. See Inflow performance relationship

Isolation chambers, ESP protectors

bag / bladder-type

construction, 95

expansion /contraction capacity, 96

blocking fluids

oil flow, 93–94

usage, 94

labyrinth-type

annular-type, 92–93

breather tubes, 92

oil flow, 91

L

Laminations

rotor, 66

stator slots, 65

M

Measured depth (MD), 21

Metal armor, 200

MLE. See Motor lead extension

Mohs scale, mineral hardness, 156

Monitoring and troubleshooting

installations

ammeter charts interpretation, 323–337

techniques, 338–341

operations

acoustic surveys, 312–313

downhole measurements (DHMs),

314–316

levels, 310–312

parameters, 310

system failures

components, 320–323

conditions, 317–318

design installation, 317

electrical problems, 318

faulty equipment, 317

vibrations, 319–320

Motor lead extension (MLE), 353

ESP cable, 109–110

in motor, 67–68

splicing, 105–106

Motors

construction

electricity, 68

end rings, 66

insulation system, 65–66

pothead connector, 68

refined oil, 67

squirrel cage induction, 64

stator and rotor, 65

cooling effects, 76–77

heat transfer

annulus, average temperature, 83

convective coefficient, 80–81

electrical power input, 77

fluid, average temperature, 78–79

generated and absorbed, 78

steady-state skin temperature, 81–82

temperature distribution, 79

operational features

electric motors, 68

power supply, parallel connection, 69

voltage/current combination, 70

parts, 67

performance, 70–75

curves, 72–74

OD motors, 74

slip, 70

startup conditions, 74–75

testing types, 71–72

torque/speed, 71

voltage drop, 75

pump interaction

BHP, 213

comprehensive analysis, 212

420 Index

iterative procedure, 212

motor/pump series-connected

system, 214

shrouds, 344


well temperatures, 166–167

N

Natural gas separation, 220

Net positive suction head (NPSH)

inducers, 147, 150

pump stage geometry, 138

special pumps, 154

Nodal analysis, 44–45

gas rate, 251

oil well, production system, 250

PIP, 251

procedure, basic steps, 251–252

Q–H coordinate system

constant pumping speed, 254–256

flowing bottomhole pressure

(FBHP), 264

fluid gravity, 263

gas/liquid ratio (GLR), 263, 265

gas separation process, 264

liquid rate, 264–265

pressure distributions, 252–253, 261–262

pump discharge pressure, 253, 262

pump setting depth, 265

tubing string performance curve, 254

variable pumping speeds, 257–258

variable wellhead pressures, 259–261

rate/FBHP coordinate system

gas/liquid ratio (GLR), 276–277

pump discharge pressure, 272

pump performance curve, 273, 276–277

variable speed drive (VSD) unit, 272–273

Non-Newtonian fluids, 121

O

Operation monitoring methods

acoustic surveys, 312–313

downhole measurements

instruments and communications,

314–315

measured parameters, 315–316

levels, 310–312

parameters, 310

Operation optimization

CAPEX, 302

capital recovery factor (CRF), 302–303

installation design procedure, 301–302

monthly operating cost, 304

OPEX, 302

total monthly expenditure, 303

P

Parallel-connected installations, 344–345

PI. See Productivity index

PIP. See Pump intake pressure

Poseidon gas handler, 153

Power efficiency

electrical power losses

cable loss, 298

motor loss, 297–298

surface electrical loss, 298–299

hydraulic losses

backpressure loss, 296

gas separator, power loss, 297

pump loss, 296–297

tubing loss, 295–296

power flow

hydraulic power, 291

inductive reactance, 294

power factor, 293

surface power supply, 292

system efficiency, 299–301

Power factor (PF), 39

Pressure distributions, 219–220

Productivity index (PI), 190

Darcy's equation, 11

developement, 10

pressure vs. liquid flow rate, 11–12

Protector/seal section, 84

component parts, 86–87

functions, 85–86

isolation chambers, 91–96

load rating, 98

mechanical seal, construction, 96

oil transfer, 88

schematic drawing, 87

selection features, 97–98

shaft seals, 96–97

tandem, 98–99

thrust bearing, 88–91

Protector's thrust bearing, 197

Pulsed width modulation (PWM), 173–175

carrier frequency, 173

421Index

Pulsed width modulation (PWM)

(Continued)

modulation, 174

output, 174–175

Pump intake pressure (PIP), 130, 133–134,

138–140, 150, 190, 250–251, 265

Pumps

affinity laws, 34–36

axial thrust force, 31–34

axial thrust forces and operating

range, 59

cavitation, 30–31

centrifugal, 23–26

discharge pressure, 241–242

housing, 209

liquid producing capacity, 55

motor powers, 179

parts, 54

performance curves, 57–60

selection, 165

shafts, 195

specific speed, 26–27

suction pressure, 221


Q

Q–H coordinate system

constant pumping speed, 254–256

flowing bottomhole pressure (FBHP),

264

fluid gravity, 263

gas/liquid ratio (GLR), 263, 265

gas separation process, 264


pressure distributions, 252–253,

261–262

pump discharge pressure, 253, 262

pump setting depth, 265

tubing string performance curve, 254

variable pumping speeds, 257–258

variable wellhead pressures, 259–261

Q–H curve. See Head capacity curve

R

Radial flow, 155

Rate/FBHP coordinate system

gas/liquid ratio (GLR), 276–277

pump discharge pressure, 272

pump performance curve, 273, 276–277

variable speed drive (VSD) unit, 272–273

REDA. See Russian Electrical Dynamo of

Arutunoff

Resistive thermal devices (RTDs), 113

Rotary gas separation, 226–227

Rotary gas separators (RGSs), 158

available types

components, 147–148

inducer and paddle wheels, 148

paddle-wheel, 145–146

separation efficiency, 147–148

system types, 146

inducers, 150

natural separation process, 149–150

RTDs. See Resistive thermal devices

Russian Electrical Dynamo of Arutunoff

(REDA), 5

S

SCRs. See Silicone controlled rectifiers

Series-connected installations, 345–347

540 Series labyrinth-type protector,

243–244

Shrouded and horizontal well installations,

344

Silicone controlled rectifiers (SCRs), 172

Single zone production, 344–347

Six-step VSDs

voltage outputs, 173

waveforms, 174

SN3600, submersible pump

head performance curves, 169

pump efficiencies, 170

Solution node, 47

SSSVs. See Subsurface safety valves

Static bottomhole pressure (SBHPs), 12, 16

flowing bottomhole pressures

(FBHPs), 17

test pressures, 18–19

Submersible pumps

abrasion resistant, construction, 164

abrasive damage, 160

features, 53–57

operational principle, 53–54

stages, 55–56

thrust bearing, 55

floating vs. fixed impeller pumps, 61–62

compression pumps, 62

protector, selection, 61

422 Index

performance curves

data tolerance limits, 58

four-quadrant representation, 60

impeller pumps, 59

percentage slip, 57

up-and downthrust forces,

58–59

radial bearings

compliant, 163

pump stage, 162

resilient, construction, 161

tandem pumps, 55

temperature

fluids, 63–64

heat, 63

power, 62–63

Subsurface safety valves (SSSVs), 354

Sucker-rod pumping, 3

Surface casing pressure, 284

Surface equipments

junction box, 114–116

switchboard, 116–117

transformers, 117

wellheads, 113–114

Surface voltage, 203–204

Switchboard and transformers

frequency calculation, 234–235

galvanized armor, cable, 245

natural gas separation calculations,

239–240

pump operation, 243

pump selection, 242–243

rotary gas separation, 240–241

540 series labyrinth-type protector,

243–244

TDH calculations, 241–242

well inflow calculations, 236–238

System analysis

flowing oil well, 48

node points, 46

principles, 47–48

production system, 44–46

System failures

components

electric cable, 322–323

motors, 321–322

protector (seal) section, 322

pump, 321

rotary gas separators, 322

shafts, 320–321

conditions, 317–318

design installation, 317

electrical problems, 318

faulty equipment, 317

vibrations, 319–320

T

Tandem motors, 69–70

Tandem pumps, 55

Three-phase electric power, 204

Three-phase step-down transformer, 204

Three-phase step-up transformer, 204

Total dynamic head (TDH), 129, 345

Total harmonic distortion (THD),

176–177

Transformers

autotransformer, 40–41

step-up and step-down, 41

turn ratio, 40

Troubleshooting installations

ammeter charts interpretation

electric power fluctuations, 325

erratic loading conditions, 337

failure restart, 328

free gas production, 330

frequent cycling, 329


normal operation, 323–324

operational problems, 323

overload condition, 334

pump-off condition, 327

restart attempts, 336

tank level control, 333

undercurrent failure, 332

undercurrent shutdown, 331

well cleanup, 335

techniques

DHM unit, 338–339

flowing bottomhole pressure (FBHP)

calculation, 340–341

fuel consumption, 338

hydraulic and mechanical

components, 339

microprocessors, 338

True vertical depth (TVD), 21

Tubing deployed installations

dual zone type

commingled production, 347–349

423Index

Tubing deployed installations (Continued)

selective production, 349–350

single zone production

parallel-connected type, 344–345

series-connected type, 345–347

shrouded and horizontal well, 344

Turpin correlation, 191, 220–221

Turpin parameter, 239–240

V

Variable frequency, 167

AC supply, 168

head performance curves, 169

SN3600 pump, efficiency, 170

variable frequency generator (VFG),

177–178

variable speed drives (VSDs), 170–177

VSD/VFG, 178–184

Variable frequency generators (VFGs), 168,

183–184

components, 177

output waveform, 177–178

Variable speed drive (VSD), 6, 35, 120,

168, 170

available types

pulsed width modulation (PWM),

173–175

sine wave generator, 175–176

six-step, 173

components

DC control section, 172

inverter, 172–173

rectifier, 171–172

ESP well, electric power arrangement, 171

motor selection, 233–234

operational characteristics, 176–177

pump selection

checking pump operation, minimum

liquid rate, 233

driving frequency and the number of

stages, 232–233

quasi-sinusoidal waveforms, 166

rate/FBHP coordinate system, 272–273

switchboard and transformers

frequency calculation, 234–235

galvanized armor, cable, 245

natural gas separation calculations,

239–240

pump operation, 243

pump selection, 242–243

rotary gas separation, 240–241

540 series labyrinth-type protector,

243–244

TDH calculations, 241–242

well inflow calculations, 236–238

well inflow performance

best efficiency points (BEPs), 282

flowing bottomhole pressure, 282–283

inflow performance relationship (IPR)

curve, 282

main advantages, 283

production test, 282–283

well testing procedure, 283

Vent box, 114

Viscous liquids, pumping

brake horsepower and viscous

performance curves, 128

correction factors, 125–126

hydraulic institute model, 121–125

performance curves, 121, 125, 127

viscosity, increase in, 120

Vogel model, 190

Vogel's IPR correlation, 13–15

Voltage source inverters (VSIs), 171

VSD. See Variable speed drive

VSD/VFG interactions

frequency allowed, 180–181

motor and pump powers, 182–183

volts/frequency ratio, 178–179

W

Walking-beam pumping. See Sucker-rod

pumping

Water/oil ratio (WOR), 131–132, 134,

286–287

Well inflow performance, 9

artificial lift installation, 278

bottomhole pressures

annular liquid gradients, 285–290

annular liquid level, 284

pressure gradients, 285

surface casing pressure and well

sounding, 284

conventional method

actual bottomhole pressure, 279



curve, 280

424 Index


pressure gauge, 279

productivity index, 280

pump's shut-in head, 279–280

static bottomhole pressure, 280–281

wellhead pressure, 279–280

curved shape, 13

fluid particles, 10

gas/oil ratio (GOR), 191

productivity index (PI)concept, 10–12

pump intake pressure (PIP), 190

Turpin correlation, 191

Vogel's IPR correlation, 13–15

VSD drives

best efficiency points (BEPs), 282



curve, 282

main advantages, 283

production test, steps, 282–283

well testing procedure, 283

WOR. See Water/oil ratio

Z

Zirconia bearings, 163

425Index

Documents

APPENDIX C - sb5d8e4489ff1fa7d.jimcontent.com · 675 6.75 8 5 /8 J7000N 4500–9000 ... in usual ESP cables. EXAMPLE PROBLEM ... Pump Performance Curve for a 1 Stage D400 at …