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SPS SIZE DESIGN FOR

WELL APPLICATION
AGENDA

 Background
 Objectives
 SPS Design
 Setting Pump Depth
 Pump Size
 Motor Design
 Accessories
 On VSD Case
 Troubleshooting
SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –

BACKGROUND
 79% of pump population in SLN is SPS Type.
 About $20 million of OPEX in 2003.
 Current OPEX running is about $1 million per
month.
 January 2003 findings:
 From all wells tested (37 wells) with MPFM, 21%
running with Improper design.
√ 80% due to under range capacity.
√ 20% due to insufficient stages
 Potential OPEX saving due to SPS about $1
million/year.
SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
OBJECTIVES

 Give a preview of SPS Size design process.


 Build awareness regarding SPS design with
VSD Application.
 Build awareness regarding current situation
and the impact of inappropriate design.

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN

Objectives in Designing:
 Maximize the incremental oil gain (not
necessarily the rate) or the NPV.
Influencing Factors:
 Pump availability.

 Reservoir capability.

 Surface capability (power, backpressure).

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN Typical SPS Installation
Fuse Switchboard Wellhead Cable Feed
4 Main components in Junction
through
Transform
designing: er
ESP
CONTROL
Box
Well Head

Pump set
Power Cable
Pump size

Stages Pump
Motor lead extension
and cable guard
Motor size
4100 ‘ Pump Intake
Perforation >
Protector

Motor

Casing shoe

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN

Consideration in designing:
 How much fluid?  Pump Size
 Where is the intake?  Pump set, Stages
 How much power required?  Motor size

 Gassy or not?  Accessories

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- PUMP SIZE

How much fluid that we want to produce?


 Reservoir consideration:
 Reservoir capability.
 Water Coning sensitivity.

 Producing gas condition.

Information : Swab test, Downhole Pressure, Fluid


Properties analysis, Rock properties
 Pump Availability
Information : Pump Table
SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- STAGES REQUIRED

Where do we want to install the pump/intake?


 Rule of thumb:
 100 ft above perforation  the motor is above the
perforation for cooling down.
 FOP ≥ 500 ft  anticipating fluid influx.
 Pump Stages
 How many stages required for the pump able to
“throw” the fluid up to GS?

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- STAGES REQUIRED
Well Head
Pressure
Factors to overcome:

TOTAL DYNAMIC HEAD (ft)


 “Distance”  WFL.
Working Fluid
Level  Discharge pressure
head  Pwh.
 Tubing Friction  Ft

Tubing Friction

TDH = Hd + Ft + Pd
TDH
Stages 
PUMP TABLE Head / Stages

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- IMPACT OF STAGES DESIGN
Well Head To Gathering Station
Pressure

Impact of proper design


pump stages

Impact of stages not accounted


for Backpressure or Well head

Impact of Stages
Lacking

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- MOTOR SIZE

How much power (Brake Horse Power) required


for the pump configuration?
 Power for Pump Stages:
BHP = No. Stages x HP/Stage (see Pump Table)
 Accessories:
 Gas Separator ~ 5 HP
 Protector ~ each 3 HP
Total BHP = BHP for Stages + BHP for Acc.

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- ON VSD APPLICATION WELL

 VSD or Variable Speed Drive is a tool to


change the frequency of the pump rotation.
 Current standard setting is 60 Hz or 2500
rotation per minute on pump rotation.
 VSD tool is installed at the surface and able to
control the rotation of the pump below.
 The benefits of this tool:
 Optimizing production (ex. Upsizing pilot).
 Drawdown test well (multi rate test).
SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- ON VSD APPLICATION WELL

Impact of changing pump rotation:


 Impact on production
NewFrequency
NewRate   Rate @ 60 Hz
60 Hz
 Impact on stages
2
 NewFrequency  Head
New Head   
Stages  60 Hz  Stages@ 60 Hz

 Impact on power
3
 NewFrequency 
NewBHP     BHP@ 60 Hz
 60 Hz 

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- ON VSD APPLICATION WELL

 Impact on production
Production
Liquid Trend
Production ofof
Trend BKS #111
BKS # 111
Found outout
Found running onon
running HzHz 62.5
60 60 HzHz 6565
62.5 HzHz 67.5
67.5HzHz
2500 reversed.Set
reversed.Set to to Normal
Normal
2500
rate, bbl bfpd

2000
2000
Production,

1500
1500

1000
1000
LiquidOil

500
500

0
01 40 79 118 157 196 235 274 313 352 391 430 469 508 547 586 625 664 703 742
1 39 77 115 153 191 229 267 305 343 381 419 457 495 533 571 609 647 685 723 761
Time
Time

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- ON VSD APPLICATION WELL

Impact on Pump Design:


 Pump Stages
Worst Case : change to lower frequency (50 Hz)
Ex. DN750 w/ 75 stages (from Table : 24.5 head/Stg)
Total Dynamic Head = 24.5 x 75 2
= 1838 ft
 NewFrequency  Head
New Head    DROP
Stages  60 Hz  Stages@ 60 Hz
561 ft
New Head/Stages = 17 head/Stages
New TDH = 17 x 75 = 1276 ft
SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- ON VSD APPLICATION WELL

Impact on Pump Design:


 Power Requirement
Worst Case : Change to higher frequency (70 Hz)
Ex. DN750/75/GS/1P w/ 30 HP (Table : 0.23 head/St)
Actual BHP = (75 x 0.23) + 5 + 3 = 25.25 HP
3
 NewFrequency  INCREASE
NewBHP     BHP@ 60 Hz
 60 Hz  14.85 HP

New Brake Horse Power = 40 HP


SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS DESIGN
- Current Practice in AMT

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS TROUBLESHOOTING
(Condition : Low Rate / Not Producing)

Category Indicators Cause Recommendation

Not Pumping • Pump load is low (need to calculate the Fluid Not Downsize /
(Can be re-start) normal load and then compare the actual Support Workover
The pump can still be load to the normal load). (FNS)
function • FOP is low (Rule of thumb, below 500 ft).
• The fluid rate is below pump capacity.
• Pump load is low. Broken Shaft Recondition
• FOP is high and stable.
• The load during reversed rotation = the load
during forward rotation.
• No build up pressure on the surface.
• On the Amp Chart trend, there is sudden
decrease of Amp Load.
• The rate is below the pump capacity or no Under Stages Recondition w/
rate at all. Add Stages
• The pump load is normal.
• The load during reversed rotation < The load
during forward rotation.
• FOP is high.
• Still building up pressure at surface.

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS TROUBLESHOOTING
(Condition : Low Rate / Not Producing)

Category Indicators Cause Recommendation

Not Pumping • Amp chart shows gassy trend. Gas Lock or Gas Recondition w/ GS
(Can be re-start) • The rate below pump capacity. Interference if Possible lower
The pump can still be • The pump load is not stable the pump set
function • The FOP can be uncertain (due to high
- Continued - gas).

• The load is normal. Tubing Leak Replace tubing


• The load during reverse rotation < the load
during forward rotation.
• The rate below pump capacity or no rate at
all.
• FOP is higher than usual.

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
SPS TROUBLESHOOTING
(Condition : Low Rate / Not Producing)

Category Indicators Cause Recommendation

Pump Failure • Hi Ampere. Pump Stucked • Check Amp Chart.


(Can not be re-started) • Check well history
The pump is not regarding sand.
function • DIFA for short run life.
- Continued - • Recondition.

• Low Reading. Leaked On: • Check Amp History.


Pothead • DIFA for short run life.
Cable • Recondition.
Motor Protection

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –
EXAMPLE OF SPS TABLE
(REDA TYPE)
Pump Cap. (BFPD) Head/stg HP/stg Stages
D400 280 - 550 23.6 0.143 73 92 110 129 148 165
DN450 350 - 550 18.5 0.128 94 113 188 207 266 282
TD450 350 - 550 18.1 0.130 50 100 150 200 250 300
DN750 550 - 950 24.5 0.230 75 94 113 133 152 169
TD850 550 - 1050 28.3 0.280 50 68 100 118 136 150
TD1200 800 - 1500 24.0 0.350 100 200 300 400 500 600
D1350 950 - 1800 21.4 0.330 72 91 109 128 147 163
GN2000 1650 - 2350 38.5 0.875 34 46 59 71 83 95
TG2000 1600 - 2700 38.0 0.980 100 200 300 400 500 600
GN3100 2500 - 3600 40.5 1.530 34 46 59 71 83 95
GN4000 3200 - 4500 35.0 1.480 19 25 39 46 52 75
GN5200 4400 - 6400 29.3 1.750 27 36 54 63 72 81
GN5600 5000 - 7250 26.5 1.820 27 36 54 63 72 81
GN7000 6000 - 8000 30.3 2.470 8 13 27 31 36 54
HN13000 9200 - 15200 45.0 6.380 15 30 41 45 60 71
M520 12000 - 24000 104.0 17.000 16 22 23 25 32 38
M675 19000 - 30000 117.0 27.000 14 15 28 29 30 42

SPS DESIGN
Duri, 13th October 2004 – SPS FORUM DISCUSSION –

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