DOWNHOLE PCP

SELECTION GUIDE LINES

Juillet 2006
0. CLIENT NEED :
“Why the client wants to run in hole a PCP or change its actual PCP ?”

Most of the time : GAINS OF PRODUCTION !

1st Step of PCP Selection : Identify Client Need.

• Reduce number of Work Over

• Produce the Well at maximum of its capacity (minimise submergence)

• Guarantee a Minimum Flow Rate

• Increase Production vs previous artificial lift

• Maintain Dynamic Level at a defined depth

• Produce Well at maximum without decreasing Downhole Pressure bellow bubble pt

• Maintain Flow Rate and Reduce Speed of PCP Equipment

• Maximize production in available completion (narrow casing and/or narrow tubing)

• Decrease PCP completion equipment cost

• etc …

Difficulty : Client require a flow rate without more details

Juillet 2006
1. Winpetro Approach :
1. Winpetro Design Flow Rate = Required Flow Rate + 20%
 80% max of PCP efficiency due to PCP Manufacturing Tolerance

2. Winpetro Design to Produce Well at Maximum of its capacity :

 Main Required Input Data :
PI, PCP Setting Depth
 Equipment selection and Operating point :
select PCP equipment and increase Flow Rate in order to reach the
minimum submergence of 100m.

3. Winpetro Design : Guarantee Flow Rate and Max PCP Operating Speed :
 Main Required Input Data :
Flow Rate required,
Head (PCP Setting Depth, Fluid Viscosity, Tbg Size, WHP)
 Equipment selection and Operating Point :
 produce required Flow Rate +20% @ 300rpm max
in Deep (MD > 1000m) and Deviated Well (Dog Leg > 4°/100ft).
 produce required Flow Rate +20% @ 350rpm max
in Deep (MD > 1000m) or Deviated Well (Dog Leg > 4°/100ft).
 produce required Flow Rate +20% @ 400rpm max
Juillet 2006 in Shallow (MD <1000m) and Vertical Well (Dog Leg < 4°/100ft)..
2. PCP Selection Check List :
 Operating Speed :
300rpm max in Deep Well (MD > 1000m) AND Deviated Well (Dog Leg > 4°/100ft).
350rpm max in Deep Well (MD > 1000m) OR Deviated Well (Dog Leg > 4°/100ft).
400rpm max in Shallow (MD <1000m) AND Vertical Well (Dog Leg < 4°/100ft).

Total Head : 70% Max of PCP Head Capability

 Dog Leg :
8°/100 ft Max, along Rod String
4°/100 ft Max, at PCP Setting depth

Hole Angle: 90° Max – horizontal (at PCP Depth)

Friction Losses in Tubing : 40% max of Total Head (if over 40%, upsize tubing or reduce max flow rate)

Gaz Liquid Ratio : 50% Max

 Temperature Downhole :
with 159 : Standard Nitrile : 120°C Max
with 199 : Nitrile with High ACN: 100°C Max
with 194/205 : “Soft” Nitrile: 60°C Max
with 198 : Hydrogenated Nitrile: 150°C Max
with 204 : Fluorocarboned Elastomer: 80°C Max

Elastomer / Fluid compatibility

H2S content : 5%

CO2 content : 5%

Sand content : 10%

Completion Equipment Dimensional Compatibility (Stator / Casing, Rotor / Tubing, Rod String / Tubing)

 Sucker Rod & Motor Sizing is matching with Recommended Drive Equipment Table.

Juillet 2006
3. MOTOR SIZING :

3.1 MOTOR OPERATING CONDITIONS :

A. MOTOR DIRECTLY COUPLED TO POWER SUPPLY

(0°C < Ambient Temperature < 40°C)

B. MOTOR DRIVEN BY VSD

(0°C < Ambient Temperature < 40°C)

C. MOTOR or MOTOR/VSD OPERATED WITH 40°C

< Ambient Temperature < 60°C

Juillet 2006
3. MOTOR SIZING :
3.2 REQUIRED DATAS :

 Winpetro Simulation Results “Worst Case Scenario”

(i.e. Lowest Submergence, and/or Highest Flow Rate
and/or Highest Speed, and/or Highest Head, etc.)

 PCP Operating Speed

 NOT Power at Shaft

 Hydraulic Torque
 Friction Torque

 Motor Speed (980rpm @50Hz) or Number of Pôles (4 or 6)

 Motor Protection (Explosion Proof, Non Sparkling or Standard)

 VSD Driven Motor or Not

 If VSD Driven : Range of required operating Frequency
(20 to 50 Hz or 10 to 60 Hz)

 Ambient Temperature

Juillet 2006
3. MOTOR SIZING :

3.3 MOTOR DIRECTLY COUPLED TO POWER SUPPLY :

(0°C < Ambient Temperature < 40°C)
 Calculation of Minimum Motor Torque Required :

Total Torque Absorbed by Pump = Hydraulic Torque + Friction Torque = 770,7 + 21,1 = 792 N.m

Required Torque at Pump = Total Torque Absorbed + 25% (safety factor) = 792 x 1,25 = 990 N.m

Required Motor Torque = Required Torque at Pump x PUMP Speed / MOTOR Speed = 990 x 348 / 980 = 351 N.m

 Motor Size Selection :

Motor Nominal Torque > Required Motor Torque

Motor Torque > (Hydraulic Torque + Friction Torque) x 1,25 x Pump Speed / Motor Speed

EXAMPLE :

 Datas :
a 200TP1800 @ 348 rpm is requiring :
Hydraulic Torque : 77,07 daN.m
Friction Torque : 2,11 daN.m
Motor : Explosion Proof, 6 poles
Ambient Temperature : 35°C

 Calculation :
Required Motor :
37 kW / 50 HP, EexdIIBT4, 6 Poles
with 361 N.m Nominal Torque @ 50 Hz
Juillet 2006
3. MOTOR SIZING :
MOTOR LOADABILITY WITH VSD

TORQUE available / TORQUE nominal (%)

110
3.4 MOTOR DRIVEN BY VSD :
(0°C < Ambient Temperature < 40°C) 100

90

80
• If 20 Hz < F < 50 Hz,
70
Motor Size should be derated of 10%
60
Required Motor Torque = 351,1 N.m * 1,1 = 387 N.m
50

• If 10 Hz < F < 60 Hz, 40

0
10

20

30

40

50

60

70

80

90
0
Motor Size should be derated of 20%

10
Frequency (Hz)

Required Motor Torque = 351,1 N.m * 1,2 = 421 N.m

EXAMPLE :

 Datas :
a 200TP1800 @ 348 rpm is requiring :
Hydraulic Torque : 77,07 daN.m
Friction Torque : 2,11 daN.m
Motor : Explosion Proof, 6 poles
Ambient Temperature : 35°C
With VSD

 Calculation :
Required Motor & VSD:
45 kW / 60 HP, EexdIIBT4, 6 Poles
with 441 N.m Nominal Torque @ 50 Hz

Juillet 2006
3. MOTOR SIZING :

3.5 MOTOR or MOTOR/VSD OPERATED

WITH 40°C < Ambient Temperature < 60°C

Derate Equipment of 1% for each °C over 40°C, in the limit of 60°C max.

1. Without VSD :
Required Motor Torque = 351,1 N.m + (58 – 40) x 1% = 414 N.m

2. With VSD :
Required Motor Torque = (351,1 N.m + (58 – 40) x 1%) x 1,2 = 497 N.m

EXAMPLE :

 Datas :
a 200TP1800 @ 348 rpm is requiring :
Hydraulic Torque : 77,07 daN.m
Friction Torque : 2,11 daN.m
Motor : Explosion Proof, 6 poles
Ambient Temperature : 58°C
Without or With VSD (10 to 60 Hz)

 Calculation :

1. Required Motor : 45 kW / 60 HP
2. Required Motor & VSD: 55 kW / 75 HP

Juillet 2006
3. MOTOR SIZING :

EXAMPLE :

 Datas :
a 200TP1800 @ 348 rpm is requiring :

Hydraulic Torque : 77,07 daN.m

Friction Torque : 2,11 daN.m

Motor : Explosion Proof, 6 poles

AMBIENT TEMPERATURE
 Calculation :

0°C < T < 40°C 58°C

Directly Connected to Power

37 kW / 45 HP 45 KW / 60 HP
Supply

MOTOR 20 Hz < F < 50 Hz 45 KW / 60 HP 55 KW / 75 HP

Driven by
VSD
10 Hz < F < 60 Hz 45 KW / 60 HP 55 KW / 75 HP

Juillet 2006
4. STATOR/ CASING Dimensional Compatibility :

3 STATOR CONSTRUCTION TYPES :

 STANDARD : Assembly of Elements by Collar

CROSS OVER

SLIM HOLE : Welded Assembly of Elements

PUP JOINT

 SLIM HOLE SPECIAL : Welded Assembly of Elements + Welded Accessories

COLLAR

STATOR / CASING compatibility :

CASING STATOR

STATOR
Radial Clearance = ( ID Casing – OD Stator) / 2

STOP BUSHING
RC
If RC > 10 mm : Stator can be run Safely into Casing

If 10 > RC > 5 mm : Limit of safe design : risk of Stator blocking during RIH.
TORQUE ANCHOR
Compatibility should be studied depending on specific Well / Reservoir /
Completion details (vertical/deviated well - shallow/deep well - Sandy well)

If RC < 5 mm : Impossible to RIH Stator in Casing

Juillet 2006
5. ROTOR / TUBING Dimensional Compatibility :

OD ROTOR = Max (OD ROTOR HEAD ; OD ROTOR CREST TO CREST)

Radial Clearance = ( ID Tubing – OD Rotor ) / 2

OD ROTOR HEAD
TUBING Rotor

OD ROTOR CREST TO CREST RC

If RC > 3 mm : Rotor can be run Safely into Tubing

If 3 > RC > 1 mm : Limit of safe design : risk of Rotor blocking or damage during RIH.
Compatibility should be studied depending on specific Well / Reservoir /
Completion details (vertical/deviated well - shallow/deep well - Sandy well)

If RC < 1 mm Impossible to RIH Rotor into Tubing

Juillet 2006
6. SUCKER ROD / TUBING Dimensional Compatibility :

3 DIAMETERS TO CONSIDER

OD Full Size Coupling Radial Clearance :

RC1 = (ID Tubing – OD Sucker Rod Body) / 2.

RC2 = (ID Tubing – OD Full Size Coupling) / 2.
OD Slim Hole Coupling RC3 = (ID Tubing – OD Slim Hole Coupling) / 2.
TUBING FULL SIZE COUPLING

SLIM HOLE COUPLING

OD Sucker Rod Body RC2

SUCKER ROD BODY

RC3 RC1
• For Sucker Rod Body :
If RC > 20 mm : Sucker Rod String can be operated safely into Tubing
If 20 > RC > 10 mm : Limit of safe design : risk of High Friction Losses and Eqpt. Damage.
Compatibility should be studied depending on specific Well / Reservoir /
Completion details (vertical/deviated well - shallow/deep well - Sandy well)
If RC < 10 mm : Impossible to operated Sucker Rod into Tubing or extreme risk of failure.

• For Sucker Rod Coupling :

If RC > 8 mm : Sucker Rods Couplings can spin safely into tubing
If 8 > RC > 4 mm : Limit of safe design : risk of tubing/coupling wear.
Compatibility should be studied depending on specific Well / Reservoir /
Completion details (vertical/deviated well - shallow/deep well - Sandy well)
If RC < 4 mm Impossible to RIH Sucker Rod Coupling into Tubing or
Extreme risk of quick failure
Juillet 2006
7. GAS SEPARATION RATIO :
It is important to estimate the repartition of quantity of gas produced by annulus
and by pump, in order to :
CASING PCP INTAKE
• determine if PCP might handle too much gas,
• size correctly PCP model, equipment and operating speed

3 COMPLETION CASES :

Anulus is closed or Packer is installed above PCP :

=> Gas Separation Ratio = 0 %

PCP is set BELLOW Perforations : AREA OF ANNULUS SECTION

=> Gas Separation Ratio = 90 %

 PCP is set ABOVE Perforations : Gas Separation Ratio depend on 2 factors :

> nature of oil (heavy, medium or light)
> size of completion equipments at PCP suction point

Gas Separation = Annulus sectional area / Total Casing sectional area at PCP Suction

CORRECTIVE FACTOR For Heavy, Medium and Light Oil :

Gas Separation = Annulus area / Total Casing area x CORRECTIVE FACTOR

 Heavy Oil, CR = 0,5

 Medium Oil, CR = 0,75
 Light Oil, CR = 1
Juillet 2006
8. PCP Drive Equipment – Recommended Design :

Selection of Recommended Drive Equipment was conducted for the following

operating conditions and for each PCP Model :

> @ Q = 2/3 x Q Max

> @ Head = 2/3 x Head Max

For each PCP Model :

A recommended Motor Size was selected for :

> direct connexion to Power Supply (not driven by VSD)
And
> with 0°C < Ambient Temperature < 40°C

(Derating of Motor Size should be considered if Motor is driven by VSD or

operated with 40°C < Ambient Temperature < 60°C)

Juillet 2006