ELECTRIC SUBMERSIBLE PUMP NEW DESIGN FOR ZUG-10

OFFSHORE NORTH WEST JAVA

Larasati Kris Sadewi
STEM Akamigas Cepu
ciciliaakrissa@gmail.com

Abstract
Offshore North West Java needed a new Electric Submersible Pump design for its
field well. The new Electric Submersible Pump design is needed to lift a new target rate
for one of their wells, ZUG-10. This well is deviated well and it has a high water cut. This
paper presents how to design Electric Submersible Pump and how to make selection for
each part of Electric Submersible Pump that match with the well conditions. There are
four parameters are needed for considering what types of pump are possible and
effective for the well, there are target rate, casing size, Total Dynamic Head (TDH) and
frequency. This paper shows the comparisson types of the possible pump for the well by
the pump performance curve. The paper also present how much pressure it takes to lift
the fluid into the surface by calculating Total Dynamic Head before selecting Electric
Submersible Pump. On the other hand, selecting every part of the Electric Submersible
Pump must be careful, due to the rate is close with minimum recommended operating
range it can be down thrust, and when the rate is close with maximum recommended
operating range it will be up thrust, and both of down thrust and up thrust can burning
the motor.

I. Introduction pump performance curve. Pump performance

In the early of an oil well live usually flow
naturally to the surface due to the high reservoir
pressure, it is called “Flowing Well”. As time
goes by, the reservoir pressure will decrease. In
this condition, the reservoir pressure can not lift
the fluid to the surface, and an artificial lift
method is necessary. On of the artificial lift
methods that mostly use in oil well is Electric
Submersible Pump. Electric Submersible Pump
(ESP) is an artificial lift method especially for
producing large volume fluid. It can produce 100
bfpd – 60,000 bfpd, also can be used for
directional well and vertical well until 15,000 ft
depth. The base to design an ESP is in its
curve is a technical data section of the ESP.
This curve contains every information necessary
to make the pump is suitable for an application.
The pump performance curve has two column.
The left column shows the recommended
operating range and physical parameters of the
pump, such as minimum diameter of the casing
and size of the shaft. The right column shows
important physical limitations of the pump, such
as shaft horsepower and housing burst pressure
limits. Recommended operating range in pump
performance curve must be considered when
selecting ESP because it shows the minimum
and maximum flow rate that can produced by
 the pump. From pump performance curve, "𝑃𝐼 = 𝑄/(𝑃𝑟) − 𝑃𝑤𝑓”
horsepower, head and pump efficiency can be
known. There is another important parameter for
PI = Productivity Index (barrel per day/psi)
selecting an ESP it is Best Efficiency Point
Q = Liquid rates (barrel fluid per day)
(BEP). BEP is optimum point for its pump, it
Pr = Reservoir Pressure (psi)
shows the optimum flow rate which the pump
Pwf = Well flowing pressure (psi)
can lift. Selecting every part of the ESP must
consider the efficiency cost that will take for
The equation states that liquid inflow a well is
running the ESP to the well.
directly proportional to pressure dradown. It plots
as a straight line on a pressure vs liquid flow rate
II. Proceedings
diagram. Since the fluid discharge by the ESP
Offshore North West Java needed a new
pump enters the tubing string, the discharge
Electric Submersible Pump design for its field
pressure of the pump should overcome the sum of
well. The new Electric Submersible Pump
pressure losses along the flow path at the fluid
design is needed to lift a new target rate for one
production rate. In designing ESP it is called Total
of their wells, ZUG-10. This well is deviated well
Dynamic Head (TDH). TDH is the important
and it has a high water cut. ZUG-10 produced
parameter for designing ESP. It is used to
1470 bfpd in 9th September 2017. The new
determine the required number of pump stages a
target rate is 1600 bfpd, with the new target rate
later phase of the design procedur, the total head
the well need the new ESP design that efficient
to be overcome by the ESP pump has to be
for the well. So, here is the steps to select every
determined. TDH is the sum of the following
part of ESP that match with the well conditions.
components, all expressed in length units:
• The wellhead pressure at the given liquid
Data and Methods
production rate (convert from psi to ft)
The proper design of artificial lift system
• The net hydrostatic pressure acting on the
requires a knowledge of the fluid rates that can
pump (Net Vertical Lift)
be produced from the reservoir and the
• The frictional pressure drop or pressure
performance of the well. There is two
friction loss that occurs in the tubing string
parameters to describe the fluid rates that can
at the given liquid rate
be produced from the reservoir and the
performance of the well. Those parameters
1. Wellhead Pressure
show the formation productivity or the capability
Wellhead pressure is the pressure at the
of the reservoir flowing the fluid to the surface.
discharge of the tubing from the well. It is the
There are Productivity Index (PI) and Inflow
resistance at the surface that the pump must
Performance Relationship (IPR). Productivity
overcome. The calculation for wellhead pressure
Index (PI) is index that will show the capability of
will convert from psi to ft because it can make
the reservoir to produce the fluid in barrel fluid
easier to calculate the number of stages.
per day at the differential of reservoir pressure
(Pr) and well flowing pressure (Pwf) and it is
WHP (psi)
called draw down. The method for this case will WHP (ft) =
O. 433 x SG𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑒
use Well Inflow Performance with The Constan
PI Concept. PI will be calculate in barrel per day
per psi. Here is the PI calculation:
WHP (psi) = Wellhead pressure at the be the final value for friction loss in 1000 ft
given liquid rate in psi depth.
SG composite = The sum from oil and water
spesific gravity 3. Net Vertical Lift
Net Vertical Lift is the vertical distance
2. Friction Loss from the static fluid level to the surface that
Friction loss is an energy loss caused which need to be calculated so that the
by the flowing fluid through the tubing fluid can be lifted to the surface.
string until the surface. There is a
relationship between the pipe diameter and Pwf
NVL = WFL = Perfo depth − ( )
the friction loss itself. 0.433 𝑥 1.04

NVL = Net Vertical Lif (ft)

fρ𝑣 2
∆P = Perfo depth = Perforation Depth (ft)
2g𝑐d
Pwf = Well flowing pressure (psi)

∆P = Pressure Loss (ft/1000ft)

⍴ = Fluid density (lb/ft3) All the components in the Net Vertical Lift

V = Fluid velocity (ft/sec) (NVL) calculation will be calculate in ft. So

Gc = Gravity constant the TDH calculation is the sum of NVL,

D = Pipe diameter (inch) Friction Loss and Wellhead Pressure.

From the formula there are two factors TDH = NVL + FL + WHP

wich explain the relationship between the

pipe diameter and the frictional pressure TDH = Total Dynamic Head (ft)

loss. When the pipe diameter increases, NVL = Net Vertical Lift (ft)

the velocity will decreases and the FL = Friction loss (ft)

frictional pressure loss will reduced WHP = Wellhead pressure in ft (convert

drastically by the square of the diameter from psi to ft)

changed. These two factors make an

increse in pipe diameter can reduce the ESP Slection

frictional pressure loss. There is another From the TDH it can be known the

formula for calculating pressure loss from every part of the ESP that will be selected

Hazen Williams Formula. from the catalog. There are steps for
selecting ESP pump. Before do the ESP

100 1.85 Q 1.85 selection, it must consider the well

2.083 ( ) x( )
F= C 34.3 conditions. So we can choose the best
ID4.8655
ESP for the well. Here is the ZUG-10 well
data:
F = Friction loss (Ft/1000 ft)
• Deviated well
C = 120 (constanta given)
• BHT = 169 F
Q = Liquid rates (bfpd)
• Pr = 700 psi
ID = ID Tubing
• Pwf = 90 psi
• SGwater = 1.05
After calculate the friction loss, multiply the
• °API = 17
friction loss with the depth of the well. It will
 • PIP from well test = 623 psi series of the pump. When selecting a
• New Target Rate = 1600 bfpd VGSA the series between VGSA and the
motor must be same or bigger, but it is not
• Liquid Rate from well test = 1470 bfpd allowed to choose the VGSA bigger than
• Water Cut = 90% the motor. In the VGSA catalog there are
• Step up tranformer = 1100 V- three columns that show different
2800 V information of the VGSA. There are,
• Casing size = 7” physical spesifications that shows such as
• Tubing size = 2 7/8” diameter, shaft size, make-up length and
• Frequency = 60 Hz weight. The other is the effective rates
column, it shows minimum and maximum
With the new target rate, ZUG-10 need a effective rates that overcome with the
new ESP design for its well. The well VGSA. And the last is an application
need an ESP which can produce 1600 guidlines column, it shows a shaft strength
bfpd in 7” of casing and 2 7/8” tubing. and power requirement of the VGSA.
There are some guidlines for selecting
every part of the ESP. 3. AGH Selection
It is quite same between choose
1. Pump Selection VGSA and AGH. But the information in the
The first step we need to do when AGH catalog is different. There are CR
designing an ESP is choosing the pump. Thrust, Head and Pressure information in
Before make a selection, target rate, the application guidlines column. The other
casing size, Total Dynamic Head (TDH) is there is an information column, it shows
and frequency must be considered. pump model and notes for each type of
There will be several pumps which AGH.
possible for the liquid rates. Consider
what type of pump which effective for the 4. Protector Selection
liquid rates that wanted to produce. After Protector is one of the important parts
get the most effective pump, review the in ESP. It is used for preventing the motor
pump curve for knowing the capability of from the well fluids. The motor can be
the pump, such as recommended burned whe it is contaminate with the well
operating range, the HP of the pump, the fluids. So the protector is necessary. There
Head which needed for lifting the fluid, are some options in the protector catalog
and the pump efficiency. When make a and it shows different conditions of the
pump selection, the number of stages it well. So choosing the protector must
take for lifting the fluid must be looking at the conditions of the well. In
determined by calculating the head of the protector, there are three types of protector
pump. chambers, labyrint, bag and bellow with
different model and different step of
2. VGSA Selection preventing the fluids. A protector will
VGSA is an intake of the pump. There always have multiple chambers. These
are some categories for choosing the chambers can be connected in series
proper intake for the pump. In the pump (designated with S) or paralel (designated
catalog there is column that shows the with P). Standard protector is use a three-
chambers protector and for extreme the ampacity graph and the motor
situation we can use four-chambers current.
protector.
Result and Discussion
5. Motor Selection The first step to design an ESP is do the
From the pump performance curve we TDH calculation. From the well data, the
have selected before, we know the HP first step that we can do is convert the
that are needed, we have known the HP Wellhead pressure from psi to ft.
of the VGSA, AGH and the protector.
Before make a selection for the motor, TDH Calculation
there is a calculation that needed to know
how much horsepower are needed for WHP (psi)
WHP (ft) =
the ESP to lift the fluid into the surface. O. 433 x SG𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑒

The motor series must be the same or

bigger with the series of the pump, the *Before do the WHP calculation, SG

VGSA and the AGH. The motor can be composite must be calculated first.

made up in single or tandem by looking Here is the SGcomposite formula:

at the catalog.
141.5
1. SGoil =
131.5+ °API
6. Cable Selection 141.5
SGoil =
Cable is one of the most important 131.5 + 17
parts in ESP. If we make the worst SGoil = 0,95

selection of the cable, it can burn the

motor. Before choose the right cable for 2. SGcomposite

the ESP, calculate the Cable Voltage SGcomposite = (fo x SGoil) + (fw x

Drop, Required Surface Voltage and KVA SGwater)

first. The well temperature is needed for SGcomposite = (0,1 x 0,95) + (0,9 x

choosing on of the types of the cable. We 1,05)

can get the best cable from the ampacity SGcomposite = 1,04

graph. There are some types of the cable

in the ampacity graph (#1AWG, #2AWG, 3. Wellhead pressure (ft)

#3AWG, #4AWG, and #6AWG) and each WHP (psi)

WHP (ft) =
O. 433 x SG𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑒
type of the cable has it own size. Plot the
90
temperature first on the graph and make WHP (ft) =
O. 433 x 1,04
a line up until it touches the first type of
WHP (ft) = 200 𝑓𝑡
the cable. After that make the line left
from that spot so we get the current at
From the calculation we get 200 ft for
the temperature and the type of the
Wellhead pressure.
cable. In the other hand, the important
The second calculation is Friction Loss
point in selecting a cable for an ESP is
Calculation.
make sure that the current is bigger than
the current of the motor, because if it too
100 1.85 Q 1.85
close from the motor current it can burn 2.083 ( ) x( )
F= C 34.3
ID 4.8655
the motor so determine the current from
 100 1.85 1600 1.85 The method will use in this case is IPR
2.083 ( ) x( )
F= 120 34.3
with PI constant. So, when we will
(2.441)4.8655
calculate the Pwf for the liquid rates
F = 23.64 𝑓𝑡/1000𝑓𝑡
target, the value of the PI is constant.
The next step is determine the Pwf at
We need to multiply the value with the depth
liquid rates target with PI formula.
of Pump Stting Depth (PSD) for getting the
friction loss in ft.
Q
PI =
Pr − Pwf
𝑓𝑡 1600
F=F ( ) x PSD 72 =
1000𝑓𝑡 700 − Pwf
𝑓𝑡 Pwf = 677,7 𝑝𝑠𝑖
F = 23.64 𝑥 2580 𝑓𝑡
1000𝑓𝑡
From the PI calculation we get the 677,7 psi for
F = 61.01 𝑓𝑡
Pwf at liquid rates target. The IPR Straight Line
Calculation is shown in Figure 1.
From the calculation we get 61.01 ft friction
loss through the pipe.
The next step is calculate the NVL

IPR Straight Line Calculation Pwf

The next calculation for getting the TDH NVL = WFL = Perfo depth − ( )
0.433 𝑥 1.04
is Net Vertical Lifft calculation (NVL). 677,7
NVL = WFL = 2713 − ( )
Before calculate the NVL, we need the 0.433 𝑥 1.04
NVL = 1210 𝑓𝑡
value of Pwf and PI of the well. Pwf in
liquid rates from the well test of ZUG-10
We get the NVL for this well. So we can
we can get with Pump Intake Pressure
calculate the TDH that is neede for the
(PIP) calculation. The value of PIP is given
ESP to lift the target rates to the surface.
from the welltest data.

TDH = NVL + FL + WHP

PIP = Pwf − (Middle perfo − PSD) x Gf
TDH = 1210 + 61.01 + 200
623 = Pwf − (2706 − 1580) x 0,45
TDH = 1471 𝑓𝑡
623 = Pwf − 56,7
Pwf = 679,7 𝑝𝑠𝑖
The pump needs 1417 ft to lift the target
rate to the surface.
In liquid rates from welltest data we get
Pump Selection
679,7 psi of Pwf. So, we can calculate
From the well data, the new target
the PI with the value of the Pwf at the
rate is 1600 bfpd. So we need to design a
liquid rates from welltest data.
pump with enough stages to produce

Q 1471 ft of head and 1600 bfpd for the

PI = target rate in 7” casing size. There are
Pr − Pwf
1470 several pumps that possible for the target
PI =
700 − 679,7 rate. But, after review the pump curves in
PI = 72 𝑏𝑓𝑝𝑑/𝑓𝑡
the catalog the closest pump is GN 1600 –
540 Series. From the GN1600 Pump
Performance Curve we get:
 GN1600 – 540 Series the well. ZUG-10 is well wich has high
HP : 0.9 hp / stages water cut, medium temperature, deviated
Head : 44 ft / stages well, and has 17 °API. Also there is no
Efficiency : 60% chemical issue. From the conditions we
ROR : 1000 – 2150 bfpd should choose the best protector for that
From the review we can calculate number conditions. In the catalog the protector
of stages that needed for the pump chamber wich match with the conditions is
TDH Labyrints and Bags. To avoid an extreme
Stages =
Head conditions of the well, the protector that will
1471 ft
Stages = choose is BPBLS. Why we need to put the
44 ft/stages
Labyrint next to the motor is to avoid a
Stages = 33 stages
possible vacuum for a bag that becomes
We also can calculate HP taht are
complety collapsed. And the Series of the
needed for one stage of the pump
protector is NTB 2550 lbf – 540 Series –
HP = HP x Stages
1HP – BPBSL.
HP = 0.9 x 33
HP = 30 HP
Motor Selection
The next is calculate available
Before choose the motor we need to
stages counting for the pump.
calculate total HP that will needed for the
From the catalog GN1600 will
motor. Total HP is the sum from Pump HP,
require one pump 1 EA 43
VGSA HP, AGH HP, and Protector HP.
stages – 4.9 ft long.
The pump performance curve GN1600 –
Total HP = Pump HP + VGSA HP + AGH HP
540 Series is shown in Figure 2.
+ Protector HP
Total HP = 30 + 6 + 37.5 + 1
VGSA Selection
Total HP = 74,5 HP
The series of the pump is 540 Series.
So, we would need the series of VGSA
To avoid the worst condition, there is a
that is bigger or the same series with the
safety factor for the motor.
pump. And after review the catalog, we
choose 540 Series – VGSA S20 – 90.6
Total HP
HP. Because the target rates is close with Required motor HP =
80%
the Effective Rates in VGSA Catalog (2000 74.5
Required motor HP =
bfpd – 9000 bfpd). 80%
AGH Selection Required motor HP = 93.125 HP
It is a little different between VGSA
Selection and AGH Selection. From the From Required Motor HP Calculation we
catalog the best AGH for the pump is 540 can choose the motor. So, from the catalog
Series AGH G20 – 80, 7.5 HP. With we choose 562 series maximus motor –
application ranges 2000 bfpd – 4000 bfpd. 113 HP – 2248 V – 30.6 A – S-GRB.

Protector Selection Cable Selection

When selecting protector for the When choosing the cable we need to
pump, we need to review the conditions of revie the well temperature. It is shown in
 Figure 3. From the graph we finally
choose Reda Max 400 Round - #4AWG –
140 A for the cable.

IPR Straight Line Figure 3. Ampacity Chart

800
600 From the chart we have 160°F as the well
Pwf

400 temperature and we get 140 A for the

200
0
current in #4AWG. We choose the #4AWG
0 500 1000 1500 2000 due to the temperature well will increase and
Q can burn the motor.

Figure 1. IPR Straight Line Pressure

0 500 1000 1500
0
The black line shows when the flow rate is Static Gradient
D 500
1470 bfpd we get 679.7 for the Pwf. And the Drawdown
e Perfo depth-PSD
green line shows with Pwf 677.7 psi and p 1000 TDH
1600 as the new target rater we get 1605 for t 1500
Q h
2000
maximum.
2500

3000

Figure 4. Pressure and Depth

Correlation

Figure 4. shows the pressure discharge

Figure 2. GN1600 Pump Performance Curve
pump that are needed for lifting the fluid to
the surface with Wellhead pressure 700
psi, we need 1282 ft of Pressure Discharge
Pump so we can produce the new target
rate.

Conclusion
With the new target rate for ZUG-10
we can coclude that:
- We choose an ESP new design with
GN1600 – 540 Series for the pump
- The pump required one pump 1 EA-
43 stages – 4.9 long
 - Choosing S20-90 – 540 Series – 6
HP for the VGSA
- AGH 540-80, 37.5 HP – 540 Series
for the AGH
- NTB 2550 lbf – 540 Series – 1HP –
BPBSL for the Protector
- 562 Series Maximus Motor – 113
HP – 2248 V, 30.6 A – S-GRB for
the Motor
- Reda Max 400 Round - #4AWG –
140 A for the cable
- The pump need 1282 ft as pump
discharge pressure to produce the
fluids to the surface
- From the IPR Straight Line we get
1605 bfpd for the maximum flow
rates

References
Gabor Takacs, Gulf Equipment Guides,
Electric Submersible Pumps Manual:
Design, Operations, and Maintenance,
1947.