Artificial Lift

AE ESP 1 Training, Course 15 04-Sep-2006 to 29-Sep-2006 04- Sep29- SepDay 5

VSD Affinity Laws Application of Affinity Laws VSD Applications

VSD Affinity Laws

At the end of this section, you will be able to Use the VSD affinity laws to calculate new performance parameters for the following equipment. Understand the affinity laws as they apply to pump properties:
Flow Head Power Efficiency Shaft Power Limit

And Motors
Nameplate Voltage Amperage Rating Power Rating

AE ESP 15 slide 2

VSD Affinity Laws for Pumps RPM Flow

RPM 2

Flow RPM 1

2 1

RPM RPM Head RPM 1

2
2 1

Head RPM 2

RPM RPM
2

BHPRPM 2 SBHL 2 RPM

= BHPRPM 1

RPM RPM RPM

1 2

SBHL 1 RPM

AE ESP 15 slide 3

VSD Affinity Laws for Pumps Flow Head Power Efficiency Shaft Limit
Q1 = Q0

1 0

Independent
2

h1 ( Q1 ) = h0 ( Q0 ) 1 0

PREQ1 ( Q1 , SGX ) = PREQ 0 ( Q0 , SGX ) 1 0

1 ( Q1 ) = 0 ( Q0 )
SBHL1 = SBHL0
AE ESP 15 slide 4

1 0

Pump Laws, Graphical Representation

Assuming 10% increase in Frequency

AE ESP 15 slide 5

MultiPump Laws, Multi-Hz Head Curve

REDA Production Systems
Rev. A

Reda Pump Performance Curve GN4000 540 Series * - 1 Stage(s)

Fluid Specific Gravity 1.00

Feet
70

60

70 Hz
50

40

60 Hz 55 Hz

30

50 Hz 45 Hz 40 Hz 30 Hz

20

10

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

Capacity - Barrels per Day

AE ESP 15 slide 6

MultiPump Laws, Multi-Hz Power Curve

AE ESP 15 slide 7

VSD Affinity Laws for Motors, Conventional Volt 2

=

Volt1

HZ HZ

A2

A1 HZ HZ

HP 2

HP

AE ESP 15 slide 8

VSD Affinity RULES for ALL Motors Conventional and Dominator Nameplae Voltage Amperage Rating Power Rating

V1 = V0
A1 = A0

1 0

Ratings PAVAIL1 = PAVAIL 0

AE ESP 15 slide 9

1 0

Motor Laws, Graphically

Graphically it would look like this for a 200 HP, 60 Hz motor:
350 300

Motor Horsepower

250 200 150 100 50 0

20

40

60

80

100

Frequency (hertz)

AE ESP 15 slide 10

OLD VSD Affinity Laws for Motors, Dominator

For All Frequencies

Voltage
0, 1 60-Hz

V1 = V0

1 0
1 > 60-Hz

Amperage Power

A1 = A0 PAVAIL1 = PAVAIL 0

1 0

60 A1 = A60 1 PAVAIL1 = PAVAIL 60 Special

Like Conventional
AE ESP 15 slide 11

Old Dom. Motor Power, Graphically

350 300

Motor Horsepower

250 200 150 100 50 0

20

40

60

80

100

Frequency (hertz)

AE ESP 15 slide 12

Old Dom. Amperage Rating, Graphically

175

Motor Amperage Rating

150 125 100 75 50 25 0

20

40

60

80

100

Frequency (hertz)

AE ESP 15 slide 13

Exercise 2.08
90-Minutes Work together if you need We will go over the answers together afterward. Every single participant is expected to be able to answer any single question

Application of VSD Affinity Laws

Upon completion of this section, you should be able to:

Combine multiple affinity laws to consider advanced issues Maximum Safe VSD Speed as limited by
Motor Power Shaft Power Housing Pressure Limit

Motor Performance as a function of speed

Motor Load Expected Amperage

Expected flow from a well

Pump curve intersection with System curve

AE ESP 15 slide 15

Maximum Safe Speed: Pump Power Req

What determines the pump power requirement at a given frequency?
D725N 50 Hz / 2917 RPM Pump Performance Curve
46 - 123 4.00 0.625 0.307 5.500 m3/d inches inches in inches

400 Series - 176 Stage(s) - Sp. Gr. 1.00

Standard High Strength Standard Buttress Welded 78 Hp 125 Hp 5000 psi 6000 psi 6000 psi

REDA Production Systems

Rev. -

Optimum Operating Range Nominal Housing Diameter Shaft Diameter Shaft Cross Sectional Area Minimum Casing Size

Shaft Brake Horsepower Limit Housing Burst Pressure Limit

Meters

1,250

B.E.P. Q = 95 H = 876.82 P = 21.08 E = 60.25

Hp Eff

50 50%

1,000

40 40%

750

30 30%

500

20 20%

250

10 10%

25

50

75

100

125

150

Capacity - Cubic Meters per Day

What can change when we change the frequency?

AE ESP 15 slide 16

Maximum Safe Speed: Pump vs. Motor

350 300

PAVAIL1 = PREQ1 PAVAIL0

250

Power

200

150

100

PREQ0

50

0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 17

1 0

Maximum Safe Speed: Pump vs. Motor

Therefore, were looking for 1 such that:
PREQ1 ( MAX , SG X ) = PAVAIL1 PAVAIL1 = PAVAIL 0 1 0 3 1 PREQ1 ( MAX , SG X ) = PREQ 0 ( MAX , SG X ) 0

We know from our affinity laws that

Substituting
PREQ 0 ( MAX , SG X ) 1 = PAVAIL 0 1 0 0
3

Solving for 1
1 = 0
PAVAIL 0 PREQ 0 ( MAX , SG X )
AE ESP 15 slide 18

Valid for any reference frequency 0

Maximum Safe Speed: Pump vs. Motor

350

Works going down, too!

300 250

PREQ0

Power

200

PAVAIL1 = PREQ1
150

100

PAVAIL0

50

0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 19

0 1

Maximum Safe Speed: Effect of Density

350 300

PAVAIL1 = PREQ1 PAVAIL0

250

Power

200

150

100

PREQ0

50

0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 20

1 0

10

Maximum Safe Speed: Old Dominator

350 300

PAVAIL1 = PREQ1 (> 60) PAVAIL0 > PREQ0 PAVAIL0 < PREQ0

250

Power

200

PAVAIL1 = PREQ1 (< 60)

150

100

PREQ0

50

0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 21

1 0

Motor Limit Old Dominator Laws

The process to determine the maximum safe speed for a dominator is the same: Equate PAVAIL1 to PREQ1 Substitute in appropriate affinity law Solve for 1 Because the affinity law for motor power rating changes at 60-Hz, the formulas will change:

0, 1 60-Hz

1 > 60-Hz

PAVAIL1 = PAVAIL 0 1 0

PAVAIL1 = PAVAIL 60
3 PAVAIL 60 1 = 60 PREQ 60 ( MAX , SG X )
Special
AE ESP 15 slide 22

1 = 0

PAVAIL 0 PREQ 0 ( MAX , SG X )

Same as normal

11

Motor Limit Old Dominator Rule vs. Normal

350 300

Standard 250 200 Motor Horsepower 150

100 50 0 0 20 40 60 80 100

Frequency (hertz)
350 300

Dominator 250 Motor 200 Horsepower 150

100 50 0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 23

Shaft Limit
350

SBHL1 = PREQ1
300

SBHL0

250

Power

200

150

100

PREQ0

50

0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 24

1 0

12

Maximum Safe Speed: Shaft Rating vs. Power Req

Therefore, were looking for 1 such that:
PREQ1 ( MAX , SG X ) = SBHL1

SBHL1 = SBHL0 1 0 3 1 PREQ1 ( MAX , SG X ) = PREQ 0 ( MAX , SG X ) 0

We know from our affinity laws that

Substituting
PREQ 0 ( MAX , SG X ) 1 = SBHL0 1 0 0
3

Solving for 1
1 = 0
SBHL0 PREQ 0 ( MAX , SG X )
AE ESP 15 slide 25

Valid for any reference frequency 0

Housing Pressure Limit

7000 6000

PH,MAX

P(Q=0)1 = PH,MAX

5000

Pressure

4000

P(Q=0)0

3000

2000

1000

0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 26

1 0

13

Maximum Safe Speed: Housing Pressure

Therefore, were looking for 1 such that:
P(Q = 0)1 = PH , MAX

We know from our affinity laws that

P (Q = 0)1 = P (Q = 0) 0 1 0
2

Substituting
P (Q = 0) 0 1 = PH ,MAX 0
2

Solving for 1
1 = 0
PH , MAX P (Q = 0) 0
AE ESP 15 slide 27

Valid for any reference frequency 0

Overall Speed Limit

For a given system (pump, motor), we need to consider all possible limits:
Motor Shaft Housing Pressure

The limit with the lowest safe speed is the maximum safe speed.

AE ESP 15 slide 28

14

Comparing Limits, graphically

SBHL1 = PREQ1
350 7000 300

PAVAIL1 = PREQ1 PAVAIL0 SBHL0

6000

250

5000

PH,MAX

Power

200

P(Q=0)0
150

P(Q=0)1 = PH,MAX

4000

3000

100

PREQ0

2000

50

1000

0 0 20 40 60 80 100

Frequency (hertz)
AE ESP 15 slide 29

1 0

Overall Speed Limit: Example

Consider the following example:
Pump: GN2100X135 Ref. Frequency (0) = 60-Hz Avg. SG = 1.04 PREQ0(Max, 1.04) = 150-HP P(Q=0)0 = 3370-psi SBHL0 = 256-HP (standard shaft) PH,MAX = 5000-psi (V-thread) PAVAIL0 = 200-HP

AE ESP 15 slide 30

15

Overall Speed Limit: Example

Max. Speed according to motor:
1 ( Motor ) = 0
PAVAIL 0 200 = (60) = 69.2 Hz PREQ 0 ( MAX , SG X ) 150 SBHL0 256 = 60 = 78.3 Hz PREQ 0 ( MAX , SG X ) 150 PH , MAX P (Q = 0) 0 5000 = 73.0 Hz 3370

Max. Speed according to shaft:

1 ( Shaft ) = 0

Max. Speed according to housing:

1 ( Hous) = 0
= 60

Overall Max. Safe Speed: 69.2-Hz Limit for Safe Speed: Motor (these values approximate the graphical example)
AE ESP 15 slide 31

Motor Performance: Load

Consider that
Load = PREQ PAVAIL

At 0 we can specify:
Load 0 = PREQ 0 PAVAIL 0

And at 1 we can specify:

Load1 = PREQ1 PAVAIL1

AE ESP 15 slide 32

16

Motor Performance: Load

But we can substitute in for PREQ1 and PAVAIL1 using the pump and motor affinity laws
PREQ 0 1 0 Load1 = PAVAIL0 1 0
3
140 120 100

Load0

Load

80 60 40 20 0 0 20 40 60 80 100

Load1 = Load 0 1 0

This is not accurate enough for real calculations, but is an acceptable approximation

Frequency (hertz)

AE ESP 15 slide 33

Motor Amperage
If we assume that actual running amperage is proportional to load, then we can write:
I Load

And then we can conclude that:

I1 = I 0 1 0
2

1.4 1.2 1.0

I0/A

This is a very bad assumption for detailed calculations and should only be used as an approximation

I/A

0.8 0.6 0.4 0.2 0 0 20 40 60

True Approx.
80 100

Frequency (hertz)
AE ESP 15 slide 34

17

Flow rate and Frequency

We understand the relationship between pump characteristics and frequency: What about expected flow rate?

AE ESP 15 slide 35

Exercise 2.09
90-Minutes Work together if you need We will go over the answers together afterward. Every single participant is expected to be able to answer any single question

18

VSD Applications
Upon completion of this section, you should be able to:

Solve for frequency with a known pump and a target well condition Size a motor to work at an abnormal frequency Design a Pump to work appropriately for a range of flow rates with given well performance Design a Pump to cover potentially changing conditions from a well over time. Design a Pump to cover a large range of potential operating conditions with uncertain well performance

AE ESP 15 slide 37

Solving for design frequency

For our pump designs so far, we followed a rigid procedure:
Establish target conditions Select Appropriate Pump Select the required number of stages to achieve the target conditions

AE ESP 15 slide 38

19

Solving for design frequency

But what if we cant design a custom pump?
Need to work with whats in inventory The number of desired stages isnt available
This is when a VSD is very useful: We can change the pump curve to match our requirements by changing the operating frequency
Wrong Pump, But close Right pump, too many stages

AE ESP 15 slide 39

Solving For Frequency

So how are we going to find our frequency to make our pump work in our target conditions? You cant solve for it using formulas. Using PAD
Change the frequency or RPM until the head curve matches your requirement. Using frequency you can only go to nearest 1-Hz.

5656-Hz
AE ESP 15 slide 40

6060-Hz

20

Solving For Frequency

Using PAD
If you have NO IDEA, you can use the multi-Hz plot:
REDA Production Systems
Rev. A

Reda Pump Performance Curve SN3600 538 Series - 172 Stage(s)

Minimum Casing Size 7.000 OD Check Clearances

Fluid Specific Gravity 1.00

Feet
12,500

65 Hz 60 Hz

10,000

55 Hz
7,500

50 Hz 45 Hz

5,000

2,500

1,000

2,000

3,000

4,000

5,000

6,000

Capacity - Barrels per Day

But Make sure you go back and double-check after!

AE ESP 15 slide 41

VSD Applications Motor Sizing

Now that your pump is sized, you need to select your motor. Determine your power requirement at your design frequency. Use the MOTOR POWER RATING affinity law to correct this power to a reference frequency (60-Hz, 50-Hz) Select the smallest motor with a power rating larger than your power requirement at reference frequency Use the MOTOR POWER RATING affinity law to correct your motor power back to design frequency. Calculate motor load.

Power

Hz
AE ESP 15 slide 43

21

Example Finding Frequency

AE ESP 15 slide 44

Exercise 2.10
90-Minutes Work together if you need We will go over the answers together afterward. Every single participant is expected to be able to answer any single question

22

Flow Rate Range

The second typical application for a pump with a VSD is to consider a flow rate range for a well with established productivity. For example
My client gives me her well data that determines inflow and says that it is very accurate. But shes not sure what flow rate she wants from the well. But she does know that she wants to produce anywhere from some minimum flow rate to some maximum flow rate without changing the pump.

So what do we do?

AE ESP 15 slide 46

Flow Rate Range

Lets start by considering the system curve. And then lets establish some goals:
Reasonable efficiency for the whole flow range. Reasonable flow rates (relative to ROR) for whole flow range. Reasonable frequencies for whole flow range.
TDHMAJ TDHMIN

QMIN
AE ESP 15 slide 47

QMAJ

23

Flow Rate Range

And lets consider the implications of the relative position of our two points:
The higher flow-rate point will have a higher design frequency The higher flow-rate point will have a higher power requirement
TDHMAJ TDHMIN

Our QMAJ, therefore, is much more important from a design standpoint.

QMIN
AE ESP 15 slide 48

QMAJ

Flow Rate Range

So that gives us some guidance:
Choose an operating frequency for the major flow point. Design a pump like normal emphasizing high efficiency and near BEP (remember, we can customize frequency!) Then were going to solve for minimum frequency just like in our first VSD application And we will review our operating point at QMIN to see if were happy. If not, we tweak the design (stages and frequency)
REDA Production Systems
Rev. A

Reda Pump Performance Curve SN3600 538 Series - 172 Stage(s)

Minimum Casing Size 7.000 OD Check Clearances

Fluid Specific Gravity 1.00

Feet
12,500

65 Hz 60 Hz

10,000

55 Hz
7,500

50 Hz 45 Hz

5,000

2,500

1,000

2,000

3,000

4,000

5,000

6,000

Capacity - Barrels per Day

AE ESP 15 slide 49

24

Flow Rate Range

Some notes on variable rate applications
A dead well system curve cuts across the multi-frequency head plot from left to right at increasing Q/BEP ratios. The lower flow rate, therefore, will nearly always be further left from BEP than the higher flow rate. For very large flow rate ranges, it may not be possible to keep your lower rate within the ROR. Make sure you calculate all relevant information at each operating point.
REDA Production Systems
Rev. A

Reda Pump Performance Curve SN3600 538 Series - 172 Stage(s)

Minimum Casing Size 7.000 OD Check Clearances

Fluid Specific Gravity 1.00

Feet
12,500

65 Hz 60 Hz

10,000

55 Hz
7,500

50 Hz 45 Hz

5,000

2,500

1,000

2,000

3,000

4,000

5,000

6,000

Capacity - Barrels per Day

AE ESP 15 slide 50

Example Flow Rate Range

AE ESP 15 slide 51

25

Exercise 2.11
90-Minutes Work together if you need We will go over the answers together afterward. Every single participant is expected to be able to answer any single question

Changing Conditions
Another application for a VSD is for a well where the ESP is will last a long time. In such a well, we will need to take into consideration the expected change in well conditions over the life of the ESP. Things that will definitely change over time:
Reservoir Pressure Well Productivity Average Fluid Density

To figure out what to do, as always, we start with

AE ESP 15 slide 53

26

Changing Conditions on System Curve

Consider the following example for a well with a target PWF. We expect the following significant changes in our well from now until the expected run life
Decreased Static Pressure Decreased Productivity Increased Water cut (and therefore avg. Density)

PR0 PR1

Target PWF

QMAX1

QMAX0

AE ESP 15 slide 54

Changing Conditions
After that, the process is basically the same as the flow rate range application
Pick one of the two points and design a pump Solve for the operating frequency for the second point Adjust your design if youre not happy
REDA Production Systems
Rev. A

Reda Pump Performance Curve SN3600 538 Series - 172 Stage(s)

Minimum Casing Size 7.000 OD Check Clearances

Fluid Specific Gravity 1.00

Feet
12,500

65 Hz 60 Hz

10,000

55 Hz
7,500

50 Hz 45 Hz

5,000

2,500

Things to Remember Harder to pick starting point Higher Flow rate may not mean higher frequency Optimizing present production is usually more important than future production

1,000

2,000

3,000

4,000

5,000

6,000

Capacity - Barrels per Day

AE ESP 15 slide 55

27

Example Changing Conditions

AE ESP 15 slide 56

Exercise 2.12
90-Minutes Work together if you need We will go over the answers together afterward. Every single participant is expected to be able to answer any single question

28

Unknown Productivity
Our last VSD application is to use a VSD to cover a range of potential conditions when the exact well performance is unknown. This application is surprisingly common:
New well drilled in a mature formation
Re-perforated well After workover or stimulation

First time installing an ESP in the well Big increase in drawdown and uncertain expectations on results

So where do we start?

AE ESP 15 slide 58

Unknown Productivity
Though the wells productivity may be unknown, we can usually get an estimate or range of potential productivity:
Net-pay comparison from wells in the same reservoir Skin range combined with theoretical well performance High tolerance based on limited well drawdown to this point.
QMAX/MIN QMAX/MAX
AE ESP 15 slide 59

PR

29

Unknown Productivity
Once we have established a range on potential inflow conditions, we can establish some PWF targets:
Optimize production Formation Limits

PR

And though our Inflow is uncertain, our outflow is well defined by well conditions

QMAX/MIN

QMAX/MAX

AE ESP 15 slide 60

Unknown Productivity
So now we combine our variable inflow with our outflow to establish a system range for our pump:

PR

QMAX/MIN
AE ESP 15 slide 61

QMAX/MAX

30

Unknown Productivity
From there, our procedure is the same as before:
Our maximum point is the most important for efficiency and power requirement, so we use that as a starting point. Then we solve for the operating frequency of the other points. And we review the intersection of our potential operating range with our pump multi-frequency curve. If were not happy

We need to tweak our design until we are satisfied.

Adjust pump style, # stages, frequency

Once we have decided on our pump, then we size our motor on our max flow point.
AE ESP 15 slide 62

Unknown Productivity
Reviewing on the Multi-Hz plot:
REDA Production Systems
Rev. A

Reda Pump Performance Curve SN3600 538 Series - 172 Stage(s)

Minimum Casing Size 7.000 OD Check Clearances

Fluid Specific Gravity 1.00

Feet
12,500

65 Hz 60 Hz

10,000

55 Hz
7,500

50 Hz 45 Hz

5,000

2,500

1,000

2,000

3,000
AE ESP 15 slide 63

4,000

5,000

6,000

Capacity - Barrels per Day

31

Example Unknown Productivity

AE ESP 15 slide 64

Exercise 2.13
90-Minutes Work together if you need We will go over the answers together afterward. Every single participant is expected to be able to answer any single question

32