Example 7

FloSystem User Course

ESP Design and Analysis


ESP Design and
Analysis Modes
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
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
ESP Data... :
Design Mode only
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... :
ESP Design Rate :
Liq. = 450 stb/day
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
Select Calculate and then Choose ESP...
ESP Design:
Choose Pump
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
ESP Optimisation Pump Performance
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
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
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...
ESP Analysis
Mode
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
ESP Analysis:
Sensitivity Studies
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)
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
ESP VFD Sensitivity
minimum rate
maximum rate
best efficiency
rate
ESP Analysis :
WaterCut
Sensitivity
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
0 % Water cut
99% Water cut
ESP & Simulation
VFP Tables
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 50 0.0 0.49 30
200 100 0.1 45
300 200 0.25 60
500 300 0.5 75
750 500 0.75 90
1000 750 0.99
6 x 6 x 6 x 1 x 5 = 1080 runs
ESP Design:
Manual Intervention
Manual Calculations required for :

Packer Selection
Protector Design
Tubing Stresses
Junction Box, transformers, switchboard