Pump Sizing

Example 1

Pump Sizing Procedure (High Water cut well)

1. Collect data (well, production, fluid, electrical) 2. Determine the production capacity of the well 3. Calculate Total Dynamic Head (TDH) and determine tubing size 4. Select pump stage type 5. Calculate the number of pump stages required 6. Check pump shaft loading and pump housing pressure

Pump Sizing Procedure (High Water cut well)

7. Calculate motor horsepower requirements and select a suitable motor

8.
9.

Calculate the protector thrust bearing load and select a suitable protector
Determine the correct cable size and select a suitable cable type.

10. Calculate the surface voltage and KVA requirements and select a suitable switchboard

1. Collect Data
Casing size Perforation depth S.G. of produced fluid Tubing sizes available Pump setting depth Static Fluid Level Productivity Index Bottom Hole Temperature Wellhead Pressure required Desired Flowrate

1. Collect Data
Casing size 5.5 inch Perforation depth 6000 ft. S.G. of produced fluid 1.0 Tubing sizes available 2 3/8 inch Pump setting depth 5500 ft Static Fluid Level 1820 ft Productivity Index 0.9 BPD/psi Bottom Hole Temperature 260 deg F Wellhead Pressure reqd. 100 psi Desired Flowrate 1300 BPD

2. Determine the production Capacity of the well

Flowing fluid level = Static fluid level + Drawdown Max Drawdown possible = 6000 ft 1820 = 4180 ft. Max Drawdown (psi) = 4180 x 0.433 psi/ft = 1810 psi (Gradient = 0.433x S.G.)

Maximum possible flow (drawing fluid right down to the perforations = 1810 psi x 0.9 BPD/psi =

3. Calculate TDH @ 1300 BPD

Flowing Fluid Level @ 1300 BPD = SFL + DD
Draw Down (psi) = 1300 BPD/ 0.9 BPD/psi = 1444 psi Draw Down (feet) = 1444 psi/ .433 psi/ft = 3335 ft. Flowing Fluid Level = 1820 ft + 3335 ft = 5155 ft

3. Calculate TDH @ 1300 BPD (cont.)

WHP = 100 psi / 0.433 psi/ft = 231 ft. Total Dynamic Head = Static Lift + WHP + Friction

TDH = 5155 + 231 + 171 = 5557 Ft

4. Select Pumps Stage type

Select a pump suitable for installation in 5.5 inch casing and also capable of producing 1300 BPD

Select a DN1300

5. Calculate the number of stages required

At 1300 BPD the DN 13000 generates 20.4 ft per stage (please review the DN1300 curve in the catalog)

Number of stages required = 5557 ft/ 20.4 ft per stage = 272 stages Utilising the next standard Housing size = 276 stages

6. Check shaft loading and Housing Pressure limitations

Pump Hp = .315 HP/stage x 276 x 1.0 (SG) = 87 HP Maximum shaft HP rating = 125 HP (see curve) Therefore the standard shaft is O.K. Maximum head in operating range =24 X 276 = 6624 ft. Maximum pressure in range = 6624 ft x .433 = 2868 psi Housing pressure rating = 5000 psi (see curve)

7. Select Motor
Motor HP required = pump HP = 87 HP Select a motor suitable for installation in 5.5 inch well Therefore select a 456 series motor (4.56 inch O.D.)

Select a 456 series 100 HP, 1350 volt, 50 amp Intermediate motor (Remember BHT = 260 deg F)

8. Calculate Protector thrust bearing load and choose protector type

Maximum pressure in operating range = 2868 psi Cross sectional area of Pump shaft = 0.371 sq. in. TB load for floater pumps = 2868 psi x .371 sq. in =1064 lbs

Select Bronze Bearing bearing rated at 3750 lbs @ 260 deg F (information in protector section of catalog)

9 Determine cable size

Motor is rated 100 HP, 60 HZ. , 50 Amp
Pump Load is 87 HP

Motor operating current = 87/100 x 50 = 43.5 amp. Choose a cable size with a volts drop < 30v/1000 ft

Calculate Surface voltage and size switchboard and transformer

Voltage drop at 43.5 amps = 18.6 volts/1000 ft We have 5600 ft of cable allowing for 100 ft at surface

Voltage drop = 5.6 x 18.6 = 104 volts

Surface Voltage required = 1350 (motor) +104 = 1454 v.

Calculate Surface voltage and size switchboard and transformer (cont.)

Surface Voltage required = 1350 (motor) +104 = 1454

Therefore use a 1500 volt rated Switchboard.

Surface KVA = 1454 (volts) x 43.5 (amps) x 1.73 = 1 KVA 1000 Therefore use a 125 KVA 3 phase dual wound transformer with Multi tapped secondary

Pump Sizing
Example 2

Pump Sizing Procedure (High Water cut well)

1. Collect data (well, production, fluid, electrical) 2. Determine the production capacity of the well 3. Calculate Total Dynamic Head (TDH) and determine tubing size 4. Select pump stage type 5. Calculate the number of pump stages required 6. Check pump shaft loading and pump housing pressure

Pump Sizing Procedure (High Water cut well)

7. Calculate motor horsepower requirements and select a suitable motor 8. Calculate the protector thrust bearing load and select a suitable protector 9. Determine the correct cable size and select a suitable cable type. 10. Calculate the surface voltage and KVA requirements and select a suitable switchboard and transformer

1. Collect Data
Casing size Perforation depth S.G. of produced fluid Tubing sizes available Pump setting depth Static Fluid Level Productivity Index Bottom Hole Temperature Wellhead Pressure required Desired Flowrate

1. Collect Data

Casing size 7.0 inch Perforation depth 5000 ft. S.G. of produced fluid ? Tubing sizes available 3.5 inch OD EUE, 9.3 LB. Pump setting depth ? ft Static Fluid Level ? Static Bottom Hole Pressure 2000 psi Oil Cut 30 % Water S.G. 1.05 Oil API Gravity 30

1. Collect Data
Productivity Index 3.5 BPD/psi Bottom Hole Temperature 250 deg F Wellhead Pressure reqd. 50 psi Desired Flowrate 6000 BPD

We have an Oil and Water mixture

In this example we have a mixture of oil and water Therefore we need to calculate an average SG for the fluid mixture. Ave S.G. = ((0.7 x 1.05) + (0.3 x 0.876)) = 0.735 + 0.263 = 0.998

We also have to calculate the Static Fluid Level

What do we know to help us

1. Fluid Gradient = 0.433 as we have just calculated 2. SBHP which has been given at the depth of 5000 ft.

Calculating the Static Fluid Level

Surface

381 ft Static Fluid level

2000 / 0.433 = 4619 ft

SBHP = 2000 psi

5000 ft

2. Determine the production Capacity of the well

Flowing fluid level = Static fluid level + Drawdown Max Drawdown possible = 5000 ft 381= 4619 ft. Max Drawdown (psi) = 4619 x 0.433 psi/ft = 2000 psi (Gradient = 0.433x S.G.)

Maximum possible flow (drawing fluid right down to the perforations = 2000 psi x 3.5 BPD/psi =

3. Calculate TDH @ 6000 BPD

Flowing Fluid Level @ 6000 BPD = SFL + DD
Draw Down (psi) = 6000 BPD/ 3.5 BPD/psi = 1714 psi Draw Down (feet) = 1714 psi/ .433 psi/ft = 3958 ft. Flowing Fluid Level = 381ft + 3958 ft = 4339 ft

3. Calculate TDH @ 6000 BPD (cont.)

WHP = 50 psi / 0.433 psi/ft = 115 ft. Total Dynamic Head = Static Lift + WHP + Friction

TDH = 4339 + 115 + 484 = 4938 Ft

4. Select Pumps Stage type

Select a pump suitable for installation in 7.00 inch casing and also capable of producing 600 BPD

Select a GN 5600

5. Calculate the number of stages required

At 6000BPD the GN 5600 generates 28 ft per stage (please review the GN 5600 curve in the catalog)

Number of stages required = 4938 ft/ 28 ft per stage = 176 stages Utilising the next standard Housing sizes Select 2 x 68 stg housings and 1 x 40 stg = 176

6. Check shaft loading and Housing Pressure limitations

Pump Hp = 1.8 HP/stage x 176 x 1.0 (SG) = 316.9 HP Maximum shaft HP rating = 375 HP (see curve) Therefore the standard shaft is O.K. Maximum head in operating range = 34 X 176 = 5984 ft. Maximum pressure in range = 5984 ft x .433 = 2591 psi Housing pressure rating = 5000 psi (see curve)

7. Select Motor
Motor HP required = pump HP = 316.8 HP Select a motor suitable for installation in 7.0 inch well Therefore select a 540 series motor (5.43 inch O.D.) (either a SX or SK (formerly 90-0) type desired depending upon insulation type required)) Select a 540 series 350 HP, 4400 volt, 48 amp Tandem motor made up of 1 x UT motor and 1 x CT motor each 2220 volt, 48 amp sections.

8. Calculate Protector thrust bearing load and choose protector type

Maximum pressure in operating range = 2591 psi Cross sectional area of Pump shaft = 0.785 sq. in. TB load for floater pumps = 2591 psi x 0.785 sq. in =2033 lbs

Select standard Bronze bearing rated at 9000 lbs @ 250 deg F (information in protector section of catalog)

9 Determine cable size

Motor is rated 350 HP, 60 HZ. 4400 v , 48 Amp
Pump Load is 316.8 HP

Motor operating current = 316.8/350 x 48 = 43.5amp. Choose a cable size with a volts drop < 30v/1000 ft

Calculate Surface voltage and size switchboard and transformer

Voltage drop at 43.5 amps = 18.6 volts/1000 ft We have 4941 ft of cable allowing for 100 ft at surface

Voltage drop = 4.94 x 18.6 = 71.8 volts

Surface Voltage required = 4400 (motor) +72 = 4472 v.

Calculate Surface voltage and size switchboard and transformer (cont.)

Surface Voltage required = 4400 (motor) +72 = 4472 v

Therefore use a Non Standard volt rated Switchboard The 1512 and the RPR2 boards are 3900 volts max.

Surface KVA = 4472 (volts) x 43.5 (amps) x 1.73 = 33 KVA 1000 Therefore use a 400 KVA 3 phase dual wound transformer - with multi tapped secondary

Something to think about with this sizing

As the motor selected resulted in us having to purchas a non standard switchboard and transformer, which may be very expensive we may wish to review the motor selection .

We could choose to use a tandem 175 HP, 1350 v 78. amp Motor , that is a 350 HP, 2700v, 78.5 amp motor instead,

If we did so we would have to reselect the cable, and