Example 7

EX 7. 1

FloSystem User Course

ESP Design and Analysis

ESP Design and Analysis Modes

EX 7. 2

Design Mode Entering a Setting depth, max. OD, Op. frequency, Wear factors and Efficiency. A selection of the Pump/Motor is made Selection is made from a internal database of five manufacturers data Analysis Mode The Pump/Motor (ESP) has been selected Performance of the ESP can be analysed running sensitivities :
Pump variables e.g. Operating Frequency Reservoir parameters e.g. Water cut

ESP Design Mode

EX 7. 3

Open ESP.WFL - Review Reservoir, Deviation, and Equipment Data The completion string contains an ESP at the bottom of the tubing (i.e. 14632 ft) Select Data Preparation - ESP Data... Revise the Pump Environment box :
Note the Measured depth is the pump depth OD and ID are chosen considering the casing ID Operating frequency is a typical value Upstream temperature used only in manual mode calculations (leave as default)

ESP Data... : Design Mode only

EX 7. 4

ESP Data... : Design Mode only

EX 7. 5

Revise the values of Wear factors/Efficiency box

Note the wear factor are set to 1 for the pump and motor (i.e. no wear assumed) The efficiency of the gas separator is 100% i.e. no free gas through the pump

Revise the Calculations options box

The viscosity and gassiness are switched on

The Analysis equipment box can not be edited in this mode

ESP Design... :

EX 7. 6

ESP Design Rate : Liq. = 450 stb/day

EX 7. 7

Select Analysis - Operating Point... Select Calculate, Results and Plot Note Operating Pressure = 3547 psia and Liquid rate = 110 stb/day (very low for this well) Select Analysis - Pressure Drop
select Edit Rates... and set the design rate of 450 stb/day. Select calculate, results and plot note that the pressure at pump depth is 3226 psia

Select Analysis - ESP Design...

Note the Design liquid rate is set at 450 stb/day Verify with Choose ESP... that the list is empty Revise the Correlations... options

ESP Design... Box

EX 7. 8

Select Calculate and then Choose ESP...

ESP Design: Choose Pump

EX 7. 9

Revise the suitable list of Pump - Motor Choose Pump T4-500, motor T5 Series from manufacturer ESP Inc. and Cable #2 Select Plot to obtain the ESP performance

ESP Pump Performance

EX 7. 10

ESP Optimisation
Pump Performance

EX 7. 11

Select Optimise... to optimise the configuration in terms of

Frequency, Number of stages or Three performance criteria (minimum, maximum flowrate, or most efficient operating point) Cable size power losses will be included in the Electrical Power results

ESP Optimisation
Pump Performance

EX 7. 12

Frequency: design calculations repeated to obtain optimum number of stages and flowrate Number of Stages: the new operating frequency is estimated by reiteration (equations not shown) Performance: the operating frequency and number of stages are computed by iteration such that the operating rate (P and T from mid-point of pump depth) corresponds to the minimum, maximum or best efficiency value

ESP Optimisation
Pump Performance

EX 7. 13

As exercise optimise using the following parameters:

70 Hz reduce the number of stages to 103 change the performance to best efficiency

Review the impact of these changes on other design parameters

ESP Design
Install...

EX 7. 14

ESP Analysis Mode

EX 7. 15

Note that the switch Design mode only is switched off indicating that the Analysis mode is on The Analysis equipment box is now editable and displays the pump and motor parameters installed Select OK if satisfied with pump selected. Select Analysis - Operating Point (Edit rates -Fill)
Note that the new Operating Pressure is 3240 psia and the liquid rate is 451 stb/day.

Select Analysis - Pressure Drop

Note that the intake pressure is 2332 psia and the discharge pressure is 3240 psia at 14632 ft.

ESP Analysis
EX 7. 16

ESP Analysis: Sensitivity Studies

EX 7. 17

Once optimum parameters: Setting depth, Tubing size, FHTP and a Pump/Motor has been selected Check sensitivity to
Changing Reservoir Pressure Increasing watercut

Check Sensitivity to
Increase no of stages to increase flexibility if required Operating frequency

ESP Analysis: Op. Frequency (VFD)

EX 7. 18

Return to Analysis - Operating Point and select Sensitivities... Note that Sensitivity 2 is set to Operating frequency with values: 30, 45, 60, 75 and 90 Hz

ESP VFD Sensitivity

EX 7. 19

ESP VFD Sensitivity

minimum rate

EX 7. 20

best efficiency rate

maximum rate

ESP Analysis : WaterCut Sensitivity

EX 7. 21

Return to Analysis - Operating point and select Sensitivities... Note that sensitivity one is set to water cut with values : 0, 25, 50, 75, 99 %

ESP Analysis : WaterCut sensitivity

EX 7. 22

99% Water cut

0 % Water cut

ESP & Simulation VFP Tables

EX 7. 23

After all sensitivity runs have been done select Analysis - Export VFP file... to input VFP tables to a simulator. Following are typical requirements: Rate FTHP w.c. GOR Frequency b/d psia frac MSc/bbl Hz
100 200 300 500 750 1000 6 x 50 100 200 300 500 750 6 x 0.0 0.1 0.25 0.5 0.75 0.99 6 0.49 30 45 60 75 90 1 x 5 = 1080 runs

ESP Design: Manual Intervention EX 7. 24

Manual Calculations required for :
Packer Selection Protector Design Tubing Stresses Junction Box, transformers, switchboard