ELECTRIC SUBMERSIBLE PUMP (ESP)

DESIGN OF A VSD INSTALLATION

TUGAS AKHIR SEMESTER

Oleh :

Nama Mahasiswa : Larasati Kris Sadewi

Rahma Musyafia Muhammad
NIM : 15412012
15412024
Program Studi : Teknik Produksi Migas
Konsentrasi : Produksi
Diploma : III ( Tiga )

KEMENTERIAN ENERGI DAN SUMBER DAYA MINERAL

BADAN PENGEMBANGAN SUMBER DAYA MANUSIA ENERGI DAN SUMBER DAYA MINERAL
SEKOLAH TINGGI ENERGI DAN MINERAL Akamigas

Cepu, Desember 2017

 I. Data

Well Physical Data

Casing ID 6.331 in
Tubing ID 2.441 in
Tubing OD 2.875 in
Tubing New YES
Perforation Depth 6,500 ft
Pump Depth 6,000 ft

Well Performance Data

WHP @desired rates 100 psi

CHP @desired rates 20 psi
Min. desired liquid rate @a water 2,000 STB/d
cut of 50%
Max. desired liquid rate @a water 2,500 STB/d
cut of 60%
SBHP 2,200 psi
PI 1.5 bpd/psi
GOR produced 300 scf/STB
BHT 150 °F

Fluid Properties

Sp. Gr. of oil 0.86

Sp. Gr. of water 1.08
Sp. Gr. of gas 0.7
*Power supply data: Available surface voltage 4,500 volts

II. Solution

A. Well Inflow Calculation for The Minimum Rate

1. Flowing Bottom Hole Pressure (FBHP) at the minimum rate

Min . desired liquid rate

FBHP=SBHP−
PI
 2000
FBHP=2,200−
1.5

FBHP=867 psi

2. Pump Intake Pressure (PIP) Calculation

PIP=Pwf −¿

PIP=660 psi

3. Determine API gravity

141.5
° API = −131.5
SGo

141.5
° API = −131.5
0.86

° API =33

4. Determine varisble y

y= ( 0.00091 x T )−(0.01215 x ° API )

y= ( 0.00091 x 150 )−( 0.01215 x 33 )

y=−0.264

5. Determine Rs. From y calculation it can find Rs value

1.205
PIP
Rs=Sg gas
[(
18 x 10 y )]
1.205
660
Rs=0.7
[(
18 x 10−0.264 )]
Rs=116 scf /bbl

6. Ppc and Tpc Calculation

Ppc=709−58.7 x SG gas

Ppc=709−58.7 x 0.7

Ppc=668 psia

Tpc=170.5−307.3 x SG gas

Tpc=170.5−307.3 x 0.7

Tpc=386 R

7. Ppr and Tpr Calculation

PIP +14.7
Ppr=
Ppc

660+14.7
Ppr=
668

Ppr=1.01

T + 460
Tpr=
Tpr

150+460
Tpr=
386

Tpr=1.58

8. From Ppr and Tpr Calculation, variable Z can be known, here is how to
determine the variable Z

Tpr 1.58
Ppr ( Ppr ) 2
(
Z=1− A x
100.9813 ) ( + 0.274 x
100.8157 )
Tpr 1.58
Ppr ( Ppr ) 2
(
Z=1− 3.52 x
10 0.9813 ) ( + 0.274 x
100.8157 )
 Z=0.915

9. Now gas volume factor can be dtermined from the following calculation

T +460
Bg=0.0283 x Z x [ PIP+ 14.7 ]
150+ 460
Bg=0.0283 x 0.915 x [ 660+ 14.7 ]
Bg=0.023 ft 3 / scf

10. Volumetric rate of free gas is found from the following calculation

Qg' =Qo x ( GOR−Rs ) x Bg

Qg' =1000 x ( 300−116 ) x 0.023

Qg' =4,232 ft 3 /d

11. To find the liquid volumetric rate, the determination of the oil volume
factor can be found from the following calculation. Determine variable F

0.5
Sg gas
F ' =Rs x ( Sg oil ) +1.25 x T

0.5
0.7
F ' =116 x ( )
0.86
+1.25 x 150

F ' =292

Bo=0.972+0.000147 x F 1.175

Bo=0.972+0.000147 x 2921.175

Bo=1.088 bbl /STB

12. The liquid volumetric rate handled by the pump is found by the following

calculation and assuming Bw = 1

 Ql=( Qo x Bo ) +(Qw x Bw )

Ql=( 1,000 x 1.088 ) +(1,000 x 1)

Ql=2,088 bpd

B. Well Inflow Calculation for The Maximum Rate

1. Flowing Bottom Hole Pressure (FBHP) at the minimum rate

Min . desired liquid rate

FBHP=SBHP−
PI

2500
FBHP=2,200−
1.5

FBHP=533 psi

2. Pump Intake Pressure (PIP) Calculation

PIP=Pwf −¿

PIP=330 psi

3. Determine API gravity

141.5
° API = −131.5
SGo
141.5
° API = −131.5
0.86

° API =33

4. Determine varisble y

y= ( 0.00091 x T )−(0.01215 x ° API )

y= ( 0.00091 x 150 )−( 0.01215 x 33 )

y=−0.264

5. Determine Rs. From y calculation it can find Rs value

1.205
PIP
Rs=Sg gas
[(
18 x 10 y )]
1.205
330
Rs=0.7
[(
18 x 10−0.264 )]
Rs=50 scf /bbl

6. Ppc and Tpc Calculation

Ppc=709−58.7 x SG gas

Ppc=709−58.7 x 0.7

Ppc=668 psia

Tpc=170.5−307.3 x SG gas

Tpc=170.5−307.3 x 0.7

Tpc=386 R

7. Ppr and Tpr Calculation

PIP +14.7
Ppr=
Ppc

330+14.7
Ppr=
668

Ppr=0.516
 T + 460
Tpr=
Tpr

150+460
Tpr=
386

Tpr=1.58

8. From Ppr and Tpr Calculation, variable Z can be known, here is how to
determine the variable Z

Tpr 1.58
Ppr ( Ppr ) 2
(
Z=1− A x 0.9813
10 ) ( + 0.274 x 0.8157
10 )
Tpr 1.58
Ppr ( Ppr ) 2
(
Z=1− 3.52 x
10 0.9813 ) ( + 0.274 x
100.8157 )
Z=0.953

9. Now gas volume factor can be dtermined from the following calculation

T +460
Bg=0.0283 x Z x [ PIP+ 14.7 ]
150+ 460
Bg=0.0283 x 0.955 x [ 330+ 14.7 ]
Bg=0.048 ft 3 /scf

10. Volumetric rate of free gas is found from the following calculation

Qg' =Qo x ( GOR−Rs ) x Bg

Qg' =(2500 x 0.4)x ( 300−50 ) x 0.048

Qg' =12,000 ft 3 /d

11. To find the liquid volumetric rate, the determination of the oil volume
factor can be found from the following calculation. Determine variable F
 0.5
Sg gas
F ' =Rs x ( Sg oil ) +1.25 x T

0.5
0.7
F ' =50 x ( ) 0.86
+1.25 x 150

F ' =232

Bo=0.972+0.000147 x F 1.175

Bo=0.972+0.000147 x 2321.175

Bo=1.061 bbl/STB

12. The liquid volumetric rate handled by the pump is found by the following

calculation and assuming Bw = 1

Ql=( Qo x Bo ) +(Qw x Bw )

Ql=( 2,500 x 0.4 x 1.061 )+(2,500 x 0,6)

Ql=2,561 bpd

C. Natural Gas Separation Calculation for The Minimum Rate

1. Calculation of the cross-sectional area of the annulus

A=0.0055 x ( Casing ID 2−Tubing OD 2 )

A=0.0055 x ( 6.3312−2.8752 )

A=0.175 ft 2
2. The liquid superficial velocity in the annulus is calculated with WOR = 1
and Bw = 1 as:

Vsl=6.5 E−5 x ( QlA ) x ( Bo2 + 12 )

 2000
Vsl=6.5 E−5 x ( 0.175 ) x ( 1.088
2
1
+ )
2

Vsl=0.78 ft /sec

3. Calculation of density of gas phase at suction conditions

⍴ g=0.0764 x ( SGBggas )
0.7
⍴ g=0.0764 x ( 0.023 )
⍴ g=2.3 lb /ft 3

4. Calculation the density of liquid phase

⍴ 1=62.5 x ( Bo0.86x 2 )+( 1.082 )

0.86 1.08
⍴ 1=62.5 x ( 1.088 x2 ) ( 2 )
+

⍴ 1=58.5 lb/ft 3

5. Calculation for terminal rising velocity of the gas bubbles

1.4
1 ( 0.04 x 32 x ( ⍴1−⍴ g ) ]
Vb=2 {
2 [ ( ⍴ 1 )2 }
1.4
1 ( 0.04 x 32 x ( 58.5−2.3 )
Vb=2 {
2 [ ( 58.5 )2
]
}
Vb=0.539 ft / sec
6. The natural gas separation efficiency of the annulus is calculated using the
following calculation:

Vb
ηn= [ Vb+ Vsl ]
x 100

0.539
ηn= [ 0.539+0.78 ]
x 100

ηn=41 %

7. The amount of gas entering the pump can be found from the following
calculation

Qing= ( Qgas
5.61 )
x ( 1−ηn )

Qing= ( 4,232
5.61 )
x (1−0.41 )

Qing=454 bpd

8. The Turpin parameter Φ can be determined by the following calculation

Ql minimum desired x Qing

Φ=
3 x PIP x Ql

2000 x 454
Φ=
3 x 660 x 2,088

Φ=0.22<1

No gas separation is required

D. Natural gas separation calculation for the maximum rate

1. Calculation of the cross-sectional area of the annulus

A=0.0055 x ( Casing ID 2−Tubing OD 2 )

A=0.0055 x ( 6.3312−2.8752 )

A=0.175 ft 2
2. The liquid superficial velocity in the annulus is calculated with WOR = 1
and Bw = 1 as:

Vsl=6.5 E−5 x ( QlA ) x ( Bo2 + 12 )

2500
Vsl=6.5 E−5 x ( 0.175 ) x ( 1.061
2
+
1
2.5 )

Vsl=0.95 ft /sec

3. Calculation of density of gas phase at suction conditions

⍴ g=0.0764 x ( SGBggas )
0.7
⍴ g=0.0764 x ( 0.048 )
⍴ g=1.1 lb/ft 3

4. Calculation the density of liquid phase

⍴ 1=62.5 x ( Bo0.86x 2 )+( 1.082 )

⍴ 1=62.5 x ( 1.0610.86x 2.5 )+( 1.08
2.5 )

⍴ 1=60.8 lb /ft 3
5. Calculation for terminal rising velocity of the gas bubbles

1.4
1 ( 0.04 x 32 x ( ⍴1−⍴ g ) ]
Vb=2 {
2 [ ( ⍴ 1 )2 }
1.4
1 ( 0.04 x 32 x ( 60.8−1.1 )
Vb=2 {
2 [ ( 60.8 )2
]
}
Vb=0.536 ft / sec

6. The natural gas separation efficiency of the annulus is calculated using the
following calculation:

Vb
ηn= [ Vb+ Vsl ]
x 100

0.536
ηn= [ 0.536+0.95 ]
x 100

ηn=36 %

7. The amount of gas entering the pump can be found from the following
calculation

Qing= ( Qgas
5.61 )
x ( 1−ηn )

Qing= ( 12,000
5.61 )
x ( 1−0.36 )

Qing=1,368 bpd
8. The Turpin parameter Φ can be determined by the following calculation

Ql minimum desired x Qing

Φ=
3 x PIP x Ql

2000 x 1,368
Φ=
3 x 330 x 2,561

Φ=1,08>1

Gas separation is required

E. Rotary gas separation for the minimum rate

Let us assume that a properly selected rotary gas separator achieves a

separation efficiency of ηsep = 60%. The total combined volume of gas
integested by the pump is determined by the following calculation:

Qing= ( Qgas
5.61 )
x ( 1−ηn ) x (1−ηsep)

Qing= ( 4,232
5.61 )
x (1−0.41 ) x (1−0.60)

Qing=182bpd

The total in-situ fluid volume the ESP pump must handle is the sum of the
liquid and gas rates, so we can calculate the total Qliquid

Qliq=Ql+ Qing(new)

Qliq=2,088+182

Qliq=2,270 bpd
The Turpin parameter Φ can be calculated by the following calculation

Ql minimum desired x Qing (new)

Φ=
3 x PIP x Ql( new)

2000 x 182
Φ=
3 x 660 x 2,270

Φ=0.08<1

Operation of the pump is stable now.

F. Rotary gas separation for the maximum rate

If a rotary gas separator achieves a separation efficiency of ηsep = 60%, then

the total combined volume of gas ingested by the pump can be determined by
the following calculation

Qing= ( Qgas
5.61 )
x ( 1−ηn ) x (1−ηsep)

Qing= ( 12,000
5.61 )
x ( 1−0.36 ) x (1−0.60)

Qing=547 bpd

The total in-situ fluid volume the ESP pump must handle is the sum of the
liquid and gas rates, so we can calculate the total Qliquid

Qliq=Ql+ Qing(new)

Qliq=2,561+547

Qliq=3,108 bpd
The Turpin parameter Φ can be determined by the following calculation

Ql minimum desired x Qing (new)

Φ=
3 x PIP x Ql( new)

2,000 x 547
Φ=
3 x 330 x 3,108

Φ=0.36<1
Now the operation of the pump is stable.

The Turpin parameter Φ can be calculated by the following calculation

Ql minimum desired x Qing (new)

Φ=
3 x PIP x Ql( new)

2000 x 182
Φ=
3 x 660 x 2,270

Φ=0.08<1

G. TDH Calculation for the minimum rate

In order to find the pump’s required discharge pressure, Pd, vertical multi-

phase pressure drop calculations must be performed in the tubing string

from the wellhead to the pump setting depth. The gas/liquid ratio to be used

can be found by the following calculation

( 5.61 x 182 ) Rs x Qg
GLR= {[ Bg ][ +
Ql minimum desired ]}
( 5.61 x 182 ) 116 x 1,000
GLR= {[ 0.023 ][ +
2,000 ]}
GLR=80 scf /STB
The required pump discharge can be determined by the following calculation

Pd=FBHP−( Lperfo−Lset ) x (Gf + ΔPpump)

Pd=2,400 psi

The required TDH is now found from the pressure increase required and the
liquid’s density, so here is the calculation

Pd−PIP
TDH =144 x
⍴1

2,400−660
TDH =144 x
58.5

TDH =4,283 ft

H. TDH Calculation for the maximum rate

In order to find the pump’s required discharge pressure, Pd, vertical multi-

phase pressure drop calculations must be performed in the tubing string from

the wellhead to the pump setting depth. The gas/liquid ratio to be used can be

found by the following calculation

( 5.61 x 182 ) Rs x Qg
GLR= {[ Bg ][ +
Ql minimum desired ]}
( 5.61 x 547 ) 50 x 2,500 x 0.4
GLR= {[ 0.048 ][ +
2,500 ]}
GLR=46 scf /STB

The required pump discharge can be determined by the following calculation

 Pd=FBHP−( Lperfo−Lset ) x (Gf + ΔPpump)

Pd=2600 psi

The required TDH is now found from the pressure increase required and the
liquid’s density, so here is the calculation

Pd−PIP
TDH =144 x
⍴1

2,600−330
TDH =144 x
60.8

TDH =5,376 ft

I. Selection of The Pump for The Maximum Rate

Based on the casing, tubing size and the liquid rate, 540 Series GN33200 is
required for this well.

Required frequency 60Hz

Head/stage 41 Head/stage
HP/stage 1.5 HP/stage
BEP 3,200 bfpd
Range 2,200 bfpd – 4,100 bfpd

Stages
Head
Stages=
Head/stages
5,376
Stages=
41
Stages=132 stage s

Determine HP that are needed for one stage of the pump

HP=HP x stages

HP=1.5 x 132

HP=198 HP
*From GN3200 Catalog this pump willl require 2 EA stages. 1 EA 40
stages – 6.3 ft long and 1 EA 100 stages 14.7 ft long. This pump will be
made up in tandem.

Selecting Protector
With the well conditions, the best protector is BPBSL 540 Series-2550
NTB-1HP.

Selecting VGSA
It requires 540 Series, VGSA S20-90, 6HP

Selecting AGH
It requires 540 Series, AGH G20-40, 37.5HP

Motor Selection
Before choose the motor we need to calculate total HP that will needed for the
motor. Total HP is the sum from Pump HP, VGSA HP, AGH HP, and Protector HP

Total HP=Pump HP +VGSA HP + AGH HP + Protector

Total HP=198+ 6+37.5+1

Total HP=242.5 HP

To avoid the worst condition, there is a safety factor for the motor, as rule of
thumb it is devided by 80%.

Total HP
Required motor HP=
80 %

242.5
Required motor HP=
80 %

Required motor HP=303.2 HP

From Required Motor HP Calculation we can choose the motor. So, from
the catalog we choose 540 Series, 1 EA 63 HP-855 V-46A, 1 EA 250 HP-
1237V-127.1A

Cable Voltage Drop

Cable Voltage Drop=( PSD+100 ft ) x ( Voltage Drop per 1000 ft )

Cable Voltage Drop=( 6000+100 ft ) x ( 36 )

Cable Voltage Drop=219.6 V

Required Surface Voltage

Required Surface Voltage=Motor Voltage+Cable Voltage

Requir ed Surface Voltage=2,092+ 219.6

Requir ed Surface Voltage=2,331.6 V

KVA

Surface Voltage x Motor Ampre x 1.732

KVA=
1000

2,331.6 x 173.1 x 1.732

KVA=
1000

KVA=700 KVA