Basic Data Production Capacity Gas Calculations Total Dynamic Head Pump Type Optimum Size of Components Electric Cable Accessories and Optional Equipment Variable Speed DriveTABLE OF CONTENTS PAGE NO. Nine-Step Overview .. 1 Step 1 - Basic Data .... peeese Step 2 - Production Capacity . 3 Step 3 - Gas Calculations .. 4 Step 4 - Total Dynamic Head . 6 Step 5 - Pump Type 7 Step 6 - Optimum Size of Components ... 8 Step 7 - Electric Cable «ss... 9 Step 8 - Accessory & Optional Equipment .. Step 9 - Variable 12 Design Example 60 Hz . a 15 Design Example Variable Speed . 24 AatagpaphPC! ., 7 CeTHE 2 STEP NINE-STEP OVERVIEW Centrilift has designed a nine step procedure to assist in the selection of the appropriate submersible pumping system for each particular well. Each of the nine steps, including gas calculations and vari- able speed operation, are explained in the sections that follow. The nine steps are: Step 1 - Basic Data Collect and analyze all well data to 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 fluid volumes, including gas, at the pump intake conditions. Step 4 - Total Dynamic Head Determine the pump discharge requirement Step 5- Pump Type Select the pump type that will have the highest efficiency for the desired flow rate for given capacity and head. Step 6 - Optimum Size of size of pump, motorand seal ‘omponents Select the opti section and check equipment limitations Step 7 - Electric Cable Select the correct type and size of cable. Step 8 - Accessory & Opti Select the motor controller, transformer, tubi head and optional equijiment 1 Equipment Step 9 - The Variable Speed Operation For additional operational Nexibility, select the variable speed submersible pump Variable Speed Drive ESP system with variable speed driveTHE 2 STEP EE conn @ STEP 1 - BASIC DATA Under most conditions, the design of a sub- ‘mersible pumping system is not a difficult task, especially if reliable data is available. If well ‘capacity or other information is poor, the design will usually be marginal. Inaccurate data often results in a misapplied pump and costly opera- tion. A misapplied pump may operate outside the recommended range, overload or underload the motor, or draw down the well at a rapid rate resulting in formation damage. On the other extreme, the pump may not be large enough to provide the desired production rate. Often data from other wells in the same field or in a nearby area is used under the assumption that wells from the same producing horizon will have similar characteristics. Unfortunately for theengineer sizing the submersible installations, oil wells are much like fingerprints, no two are just alike, The actual selection procedure can vary signifi- cantly depending upon well fluid properties. The three major types of ESP applications are: 1. High water-cut wells producing fresh water or brine. 2. Wells with multi-phase flow (high GOR). 3. Wells producing highly viscous fluids. Following is a list of required data Well Data a. Casing or liner size and weight b. Tubing size. type and thread (condition) c. Perforated or open hole interval «. Pump setting depth (measuted & vertical) 2. Production Data a, Wellhead tubing pressure b. Wellhead casing pressure . Present production rate 4. Producing fluid level and/or pump intake pressure . Static fluid level andior static bottomhole pressure £ Datum point g. Bottomhole temperature h. Desired production rate i. Gas-oil ratio j. Water cut 3. Well Fluid Conditions a. Specitic gravity of water b. Oil API or specific gravity . Specific gravity of gas 4. Bubblepoint pressure of gas e. Viscosity of oil f. PVT data 4. Power Sources a. Available primary voltage b. Prequeney . Power source capabilities 5. Possible Problems. a, Sand b. Deposition ©. Corrosion d. Paraffin ce. Emulsion f Gas TemperatureCentrilift STEP 2 - PRODUCTION CAPACITY The following is a simplification of the proce- dures required for predicting well performance. This discussion assumes a flow efficiency of ‘one. A damaged well or other factors will ef- fect the flow efficiency and could change well productivity. Productivity Index When the well flowing pressure (P,,) is greater than bubblepoint 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 rela~ tionship is given by the following equation: Q Pur Par y 1-02(—) -o8( > PR EF 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, Q, max = Q ~ 1.00 Peo Pas i 90 Where: ;. 40 Q= the fluid test production rate Zao P.,, = the well flowing pressure EZ 60 @ test rate Q é = so the well static pressure 5 a 40 g 20 Note: 3 2 B, and P., are terms always refers enced tothe flowing bottomholepres- = 10 sure/average flowing pressure at the § perforations. Reference Petroleum 3 Engineering Handbook, pages 32-4 a 1987, 3rd printi 10.20.30 40.50.60 .70 20 Producing Rate (q/(q,) max). Fraction of Maximum INFLOW PERFORMANCE REFERENCE CURVE, 50 1.0¢THE 2 STEP oe HUGHES: Centritift STEP 3 - GAS CALCULATIONS The presence of free gas atthe 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 intake tothe discharge and through the discharge tubing, the pressure fluid properties (suchas volume, density, etc.) continue to change. The presence of free gasin the discharge tubing may create significant “gas-lift” effects which could considerably reduce the required discharge pressure. The performance of a centrifugal pump is also affected by the gas. As long as the gas remains in solution, the pump behaves normally (as if pumping a liquid of low density). However, the pump starts producing lower than normal head as the gas-to-liquid ratio (at pumping conditions) increases beyond certain “critical” value (usually about 10 - 15%). This is mainly due to separation of the liquid and gas phases in the pump stage and slippage between these two phases. A submersible pump is usually selected by assuming noslippage between the two phases or by correcting stage performance based on actual field test data and past experience Ideally a well would be produced with a submergence pressure above the bubblepoint pressure tokeepany gases in solutionat the pump intake. This is usually not possible, so the gases must be either handled by the pump or separated from the other fluids prior to the pump intake to achieve maximum system efficiency ‘There are numerous combinations of equipment configurations and wellbore completions which are available for enhancing the performance of ESPs in gassy applications. Many of these identified in the "Gas Handling Guideline Specifically, Centrilift offers several optional components used for separating gas from the fluid going into the pump intake. These are listed according to increasing efficiency. The first is a reverse flow intake, which uses the natural buoyancy of the fluids for separation. Thesecond is a vortex type intake, which uses the fluid velocity to set-up a rotational flow that induces radial separation of the gas. The last is a rotary gas separator intake, which utilizesa mechanical, rotating chamber to impart a high, centrifugal force on the fluid to separate the gas. It is essential to determine the effect of the gas on the fluid volume in order to select the proper pump and separator. The following calculations yield the percent free gas by volume. If the solution gas/oil ratio (R,), the gas volume factor (B, ), and the formation volume factor(B,) are not available from reservoir data, they must be calculated, and there are a number of multi- phase correlations to select from. The selected correlation will affect your design. so select the one that best matches well conditions. The following are Standings’ correlations forsolution gas/oil ratio and formation volume factor: Solution Gas/Oil Ratio Py 2gnns » An yes TE [gn Or in metric, = 0.1342Y, (os yes Where: Y, = Specific Gravity Gas P, = Bubblepoint Pressure, psi (ke/em*) T= Bottom-hole Temperature. P(C) Horas » ru Jorma ee NOT substituted for Bubblepoint pressure when ealcu- lating intake conditions. Pump intake pressure (PIP) should be