1993

American Petroleum Institute

RP 11S4
Recommended Practice for Sizing and Selection of Electric
Submersible Pump Installations

Recommended Practice for

Sizing and Selection of Electric
Submersible Pump Installations

API RECOMMENDED PRACTICE 11S4 (RP 11S4)

FIRST EDITION, MAY 1, 1993
(Formally API Recommended Practice 11U (RP 11U)
Second Edition
Reaffirmed and Reassigned, May 1, 1993)

American Petroleum Institute

1220 L Street, Northwest
Washington, DC 20005
‚

Issued by
AMERICAN PETROLEUM INSTITUTE
Production Department

FOR INFORMATION CONCERNING TECHNICAL CONTENTS OF THIS PUBLICATION CONTACT THE API
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COPIES OF THIS PUBLICATION.

Users of this publication should become familiar with its scope and content. This publication is intended to
supplement rather than replace individual engineering judgment.

OFFICIAL PUBLICATION
‚
REG. U.S. PATENT OFFICE

Copyright © 1993 American Petroleum Institute

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:11 2001)
 Note: This is the first edition of this API Recommended Practice. It supersedes API Recommended
Practice 11U (RP 11U) second edition, May 30, 1986 which was submitted to be renamed and reaffirmed at
the 1992 Standardization Conference as reported in Circ PS-1985, and subsequently approved by letter
ballot.

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Foreword

1. Jurisdiction: This Recommended Practice (RP) is under the jurisdiction of the American Petroleum
Institute (API) Committee on Standardization of Production Equipment (Committee 11).

2. Purpose: This document presents Recommended Practices for Sizing and Selection of Electric
Submersible Pump Installations and Related Equipment.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:11 2001)
3. Policy:

(1) American Petroleum Institute (API) Recommended Practices are published to facilitate the broad
availability of proven, sound, engineering and operating practices. These Recommended Practices are
not intended to obviate the need for applying sound judgment as to when and where these
Recommended Practices should be utilized.

(2) The formulation and publication of API Recommended Practices is not intended to, in any way, inhibit
anyone from using any other practices.

(3) Nothing contained in any API Recommended Practice is to be construed as granting any right, by
implication or otherwise, for the manufacture, sale, or use in connection with any method, apparatus, or
product covered by letters patent, nor as insuring anyone against liability for infringement of letters
patent.

(4) This Recommended Practice may be used by anyone desiring to do so, and a diligent effort has been
made by API to assure the accuracy and reliability of the data contained herein. However, the Institute
makes no representation, warranty or guarantee in connection with the publication of this Recommended
Practice and hereby expressly disclaims any liability or responsibility for loss or damage resulting from
its use, for any violation of any federal, state or municipal regulation with which an API recommendation
may conflict, or for the infringement of any patent resulting from the use of this publication.

SECTION 1 GENERAL

1.1 INTRODUCTION:

1.1.1

This RP is provided to meet the need for guidelines, procedures and recommendations covering Electric
Submersible Pumps and related equipment. These Recommended Practices are those generally
considered necessary for successful electric submersible pump operation. For installation see
API RP 11R, Recommended Practice for Electric Submersible Pump Installations.

1.2 SCOPE:

1.2.1

This Recommended Practice addresses the fundamental procedures for sizing and selecting electric
submersible pumps and related equipment for various well conditions.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:11 2001)
 1.2.2

This Recommended Practice is specifically prepared for installations in oil and/or water producing wells
where the equipment is installed on tubing.

SECTION 2 TERMS, DATA AND CHARTS

2.1 DEFINITION OF TERMS:

2.1.1 VD  Vertical Pump Intake Setting Depth (Ft.)

 is the true vertical pump setting depth measured from the surface.

2.1.2 MD  Measured Pump Intake Setting Depth (Ft.)

 actual pump setting depth measured along the well bore. Theoretically, in non-deviated wells, MD =
VD.

2.1.3 FOP  Fluid Over Pump (Ft.)

 calculated value

CAUTION: FOP calculated from a Sonic Fluid Level (FL) where FOP = VD - FL, can be very
misleading because of the actual fluid gradient (PSI/Ft.) of the fluid in the annulus. This Fluid Level
(FOP) may not give an equivalent Pump Intake Pressure.

2.1.4 HD  Vertical Lift (Ft.)

 Vertical Pump Setting Depth (VD) minus Fluid Over Pump (FOP). Therefore:
HD = VD − FOP

2.1.5 HF  Tubing Friction Loss (Ft.)

 Pressure Loss expressed in feet due to fluid flow through the tubing, and is a function of fluid velocity

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:12 2001)
 and viscosity.

2.1.6 HT  Producing Tubing Head (Ft.)

 Producing tubing pressure at wellhead converted to head in feet by using the specific gravity of the fluid
being pumped.

2.1.7 TDH  Total Dynamic Head (Ft.)

 is the head against which the pump is operating (discharging) expressed as feet of fluid being lifted.
TDH = HD + HF + HT

where:

HD = VD - FOP = Vertical Lift (Ft.)

HF = Tubing Friction Loss (Ft.)

HT = Producing Tubing Head (Ft.)

2.1.8 S.G.  Specific Gravity

 of oil, water and solution gas or any mixture thereof, at the pump intake.

2.1.9 Visc

 Viscosity (SSU)

2.1.10 BHT

 Bottom Hole Temperature (°F)

2.1.11 GOR

 Gas Oil Ratio (cu. ft./BBL)

2.1.12 STBO

 Stock Tank Barrels Oil (BBL)

2.1.13 CUT

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:13 2001)
  Water Cut (%)

2.1.14 PVF

 Pump Volume Factor

2.1.15 GLR

 Gas Liquid Ratio (cu. ft./BBL)

2.1.16 KVA

 Transformer Power Rating

2.1.17 Rs

 Volume of gas in solution at any pressure up to bubble point pressure (SCF/BBL). Bubble point
pressure is defined as the pressure above which all gas is in solution.

2.1.18 Bo

 Shrinkage Factor (formation volume factor). A multiplier applied to oil stock tank barrels to determine
volume occupied in formation. Can be calculated.

2.1.19 Bg or Formation Gas Volume Factor

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:13 2001)
  A multiplier applied to the volume of free gas existing at a given condition to determine the volume
occupied in the formation of free gas.

2.1.20

Vo = Volume of oil at PIP bbls.

2.1.21

Vg = Volume of free gas at PIP, bbls.

2.1.22

Vw = Volume of water at PIP, bbls.

2.1.23

Vt = Total volume of mixture (Vo + Vg + Vw) at PIP, bbls.

2.1.24

Vg/Vt  Gas volume to total volume ratio.

2.2 DATA AND CHARTS

2.2.1 Pump Performance Curves

(Fig. 1):

a. Show the Discharge Head, Brake Horsepower and Efficiency as a function of Flow Rate for one
stage of each pump type. Some curves may be set for 100 stages.

b. Are based on fresh water (S.G. = 1.0).

c. Give a Recommended Capacity Range for pump operation.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:14 2001)
 d. Are commonly available for both 50 Hertz (Hz) and 60 Hz motor operation.

2.2.2 Fluid Friction Chart

Fig. 2):

a. Shows fluid friction loss as a function of tubing size and flow rate.

b. Is shown for water for a pipe roughness of C = 120. If a viscous fluid is involved, proper corrections
must be made (see Section 2.2.3).

NOTE: A pipe roughness of C = 120 is used due to data availability and its universal use with
non-viscous fluids.

2.2.3 Tubing Friction & Viscosity Correction Charts

(Figs. 3 - 10):

a. It is recommended that viscosity correction be considered for pumped fluids with viscosity greater
than 50 SSU.

b. Fig. 3 may be used to determine viscosity (in centipoise) from gas free crude API gravity.

c. Figure 4 may be used to determine gas solution for a given API gravity crude oil at pump intake
pressure.

d. Figure 5 using gas in solution allows the determination of the correction crude oil viscosity
centipoise.

e. Figure 6 may be used to convert viscosity from centipoise to SSU.

f. Figure 7 provides the viscosity correction factor considering percent water cut and type of emulsion.
Where water is the primary phase it wets the wall of the tubing and the viscosity will be dependent
principally on the water properties.

g. Figures 8, 9 and 10 give the viscous flow head loss due to fluid friction in various tubing sizes, fluid
flow rates and fluid viscosities. (Pipe roughness C = 130).

NOTE: A pipe roughness of C = 130 is used due to data availability. Variance from a C = 120 is
insignificant.

2.2.4 Pump Performance Correction Chart

(Fig. 11):

a. It is recommended that viscosity correction should be considered to correct Pump Performance

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:14 2001)
 when the viscosity of pumped fluids is greater than 50 SSU.

b. Chart shown in Fig. 11 is to be used as general guideline only, since these values may change due
to specific pump design and pump size. Equipment manufacturer should be consulted for proper
correction factor.

2.2.5 Voltage Loss Chart

(Fig. 12):

a. This chart gives the voltage loss per 1000 ft. for various sizes of power cable at 68°F. A correction
factor should be used to determine the additional voltage loss at well operating temperature.

2.2.6 Well Temperature vs. Current Charts

(Figs. 13 - 16):

These charts are used to determine insulation temperatures when considering well temperature at
bottom and current through cable.

2.2.7 Pump Volume Factor

(Figs. 17 - 18):

a. These graphs allow calculation of the Pump Volume Factor (PVF) of a bubble point liquid knowing
amount of gas in solution at Pump Intake Pressure (PIP) (Fig. 4), gas gravity, API gravity of the crude
oil, and Bottom Hole Temperature (BHT).

b. These graphs assume that all free gas is produced through the casing annulus.

2.2.8 Motor Annular Fluid Velocity

(Fig. 19):

a. This chart allows the determination of fluid flow velocity by the motor for various casing sizes.

SECTION 3 ELECTRIC SUBMERSIBLE PUMP COMPONENT DESCRIPTION

3.1 Subsurface Equipment

(Fig. 20):

3.1.1 Motor

a. The motor is the driving force (prime mover) which turns the pump, and is a two pole, three-phase,
squirrel cage induction type that runs at a relatively constant speed of 3500 RPM at 60 Hertz

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:14 2001)
 frequency power.

b. The motor is filled with a highly refined mineral oil or synthetic oil that must provide dielectric
strength, lubrication for bearings, and good thermal conductivity. The nonconductive oil in the motor
housing lubricates the motor bearings and transfers heat generated in the motor to the motor
housing.

c. Heat from the motor housing is dissipated by the well fluids moving past the exterior surface of the
motor. Therefore, a pumping unit motor should never be set below the point of fluid entry unless some
means of directing the fluid by the motor is utilized. It is generally accepted practice to maintain a
minimum fluid velocity of one ft/second to insure proper motor cooling.

d. Tandem motors are single motors electrically and mechanically connected in series to provide larger
horsepower.

e. The motor is fitted with a thrust bearing which makes the motor suitable for rotation in one direction
only as designed by the manufacturer.

3.1.2 Motor Seal Chamber

The motor seal chamber (or motor protector) in general performs the following five basic functions:

a. To connect pump housing to the motor housing and to connect the drive shaft of the motor to the
pump shaft.

b. To house the pump thrust bearing to carry the axial thrust developed by the pump.

c. To prevent the entry of well fluid into the motor.

d. To equalize the pressure inside the motor with the well bore pressure and thus to eliminate the
pressure difference across shaft seals.

e. To compensate for the expansion and contraction of motor oil due to heating and cooling of motor
when the unit is running or shut down.

3.1.3 Intake Section or Gas Separator

The intake section plays the role of a suction manifold feeding the well fluid to the pump. Depending
on well conditions, it can be in the form of a simple adapter with inlet holes or in the form of a gas
separator. The gas separator is an aid in preventing gas lock and provides more efficient pumping of
gassy wells. Their effectiveness varies with each design and produced volumes.

3.1.4 Pump

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:15 2001)
 a. The submersible pump is a multi-staged centrifugal type. Each stage consists of a rotating impeller
and a stationary diffuser. The type and size of stage used determines the volume of fluid to be
produced. The number of stages determines the total head generated and when multiplied by the
horsepower per stage and specific gravity, the motor horsepower required can be determined.

b. Pumps are manufactured in a broad range of capacities.

c. Tandem pumps are two or more single pumps which are mechanically and hydraulically connected
in series to provide the total pump discharge head required for the application.

3.1.5 Motor Lead Extension

The motor lead extension is a special low profile (flat) power cable extending from the pothead on the
motor to above the end of the pump where it connects with the power cable. A low profile cable is
usually needed in this area due to limited clearance between the pump housing and the well casing.

3.1.6 Motor Lead Extension Guards

The guards provide mechanical protection for the motor lead extension.

3.1.7 Power Cable

The power cable is a special three conductor cable which extends from the top of the pump to the
wellhead, held to tubing by cable bands. It is available in a range of conductor sizes, insulation types
and construction to accommodate well conditions and temperatures. Economic consideration
governed by the cost of power and initial cost of cable must be evaluated.

3.1.8 Check Valves and Bleeder or Drain Valves

a. If a check valve is installed, it should be located a minimum of 6 to 8 joints above the pump to allow
gas to be purged from pump on start-up.

b. If a check valve is installed, a bleeder or drain valve should also be installed. It should be located
one joint above the check valve.

c. For larger horsepower units (above 250 HP) regardless of setting depth, and low capacity units (less
than 600 B/D) set deep (with static fluid level below 7000 feet), it is recommended that the tubing be
filled before start-up. This means these installations must be equipped with tubing Check Valves and
drain valves.

3.1.9 Cable Bands

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:15 2001)
 a. Cable bands are used to secure the Motor Lead Cable and Power Cable to the pump and tubing,
respectively.

b. Bands are available in carbon steel, stainless steel, and monel.

c. Bands are available in 22" to 42" lengths or as continuous banding material.

3.2 SURFACE EQUIPMENT

(Fig. 21):

3.2.1 Wellhead

a. The wellhead assembly provides a tubing support and allows the power cable to pass from the
surface into the well bore.

b. It must be provided with a wellhead feed through mandrel or pack-off method which provides a
positive seal around the cable.

c. Wellheads and cable pack-offs are available in various pressure ratings and hanging load capacities.
This must be considered when selection is made, including any local safety codes or other
requirements.

d. All valves exposed to pump pressure must be rated at or above full pump discharge pressure.

3.2.2 Junction Box (Vent Box)

a. A vented junction box provides a point to connect the surface cable from the motor control panel to
the power cable from the well and provides a vent to the atmosphere for any gas which migrates
through the power cable in oil wells.

3.2.3 Surface Cable

a. Surface cable connects the junction box to the motor control panel and the motor control panel to
the secondary side of the transformers.

3.2.4 Motor Control Panel

a. A motor control panel is a combination motor starter, overload-underload protective device and
recording instrument. Surge arrestors (Lightning Arrestors) should be included in the panel.

b. They are available in various voltage and amperage ratings with additional controls according to
power requirements.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:15 2001)
 3.2.5 Transformers

a. The purpose of the transformer is to provide correct surface voltage for proper motor operation by
changing electric power from a high voltage to a low voltage in the case of a step-down transformer or
low to high in case of step-up transformer.

b. Transformer selection is based on power rating in KVA, primary voltage, and tap arrangement.

SECTION 4 WELL DATA SHEET

(Fig. 22)

4.1

The proper selection of a particular pump type and size for a given application is very important and requires
detailed information on well completion, reservoir data and production data and history.

4.1.1 Required Data

a. The Well Data Sheet (Fig. 22) provides a form for collecting necessary data.

b. This form should be filled out as completely as possible, making certain that all data provided is
accurate, since this data will determine pump selection and sizing.

c. Data lines preceded with an asterisk (*) indicate data that must be provided to allow pump sizing
and selection.

SECTION 5 PUMP AND SYSTEM SIZING

5.1 Example Problem No. 1

 Water and Oil Production with no Gas. Problem nomenclature:

5.1.1

The following exhibit sheets provide data and information required for Example Problem No. 1.

a. Exhibit 1.1 Well Data Sheet

b. Exhibit 1.2 Pump Performance Curve

c. Exhibit 1.3 Pump Specifications

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:16 2001)
 d. Exhibit 1.4 Motor Specifications

e. Exhibit 1.5 Motor Seal Chamber Specifications

f. Exhibit 1.6 Motor Control Panel and Accessories Specifications

g. Exhibit 1.7 Transformer Specifications

h. Exhibit 1.8 Tubing Head Specification

i. Exhibit 1.9 Cable Specifications

j. Exhibit 1.10 Equipment and Cable Size Information

k. Exhibit 1.11 Flat Cable and Surface Cable Specifications

l. Exhibit 1.12 Downhole Equipment with Offset Tubing Head.

5.1.2

Unless otherwise specified, data used in sizing calculations comes from Well Data Sheet (Exhibit 1.1).

a. Well Fluid Composite Specific Gravity

1) - 3)

b. Well Fluid Composite Gradient

1)

c. Fluid Over Pump (FOP)

1)

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:16 2001)
 d. Vertical Lift HD

1)

e. Tubing Friction Loss - HF (Ref. Fig. 2)

1) - 2)

f. Producing Tubing Head - HT (Ft.)

1)

g. Pump Total Dynamic Head (Ft.)

h. Now Select Pump for 1100 B/D to Fit in 5½" Casing

1) A review of the performance (Head-capacity) curves results in a choice of pump type A (Exhibit
1.2), which shows maximum efficiency (66%) at required capacity (1100 B/D).

i. Determine Lift (Head) Per Stage

1) Referring to Exhibit 1.2 read vertically from 1100 B/D on the capacity scale to the head-capacity
curve intersection.

29.0 Ft./
2) From intersection read horizontally to left to head in feet per stage = (11).

j. Determine Horsepower Required Per Stages

1) Referring to Exhibit 1.2 read vertically from 1100 B/D on the capacity scale to the Brake

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:17 2001)
 Horsepower Curve intersection. NOTE: This curve is for a specific gravity of 1.0.

2) From intersection read horizontally to right to Brake Horsepower per stage of 0.35 H.P. While the
horsepower per stage at the required capacity (0.35 HP/Stage) at 1100 B/D can be used, it is
more common to use the maximum horsepower per stage factor. For the Type A pump stage =
0.38 HP/Stage /
(12)

CAUTION: Some performance curves are for single stages and others for 100 stages.

k. Number of Pump Stages Required

1)

2) Refer to Exhibit 1.3, Pump Specifications, to find closest number of stages in a standard pump
288 /
housing. For the Type A pump (14) stages would be selected. It is Housing No. 17T, is 29.2

feet long and weighs 863 pounds.

l. Motor Horsepower Required

1) Determine pump chamber horsepower.

2) Referring to motor seal section specifications (Exhibit 1.5) determine horsepower required by
motor seal chamber. It is 2.5 H.P.

3) Determine motor horsepower required by adding pump brake horsepower, motor seal section
horsepower and gas separator (if used) horsepower.
118.5 /
[116 + 2.5 + 0 = (15)]

120 /
4) Referring to Motor Rating Specifications (Exhibit 1.4) the closest motor size is (16) H.P. It is

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:18 2001)
 29.5 feet long and weighs 1430 pounds.

5) Check fluid flow velocity for motor cooling (Fig. 19). Since this is a 4½" O.D. motor in 5½" casing,
the velocity at 1100 B/D is well above the 1.0 ft./sec. minimum recommended velocity.

6) A choice of two motors is available:

a) 1150 V. and 67 A.

b) 2280 V./(17) and 34 A /

(18).

In general, the higher voltage, lower amperage motor is the better choice in most installations,
since it minimizes power cable losses. The choice of motor voltage may be based on a number
of factors including well depth, casing size, horsepower size, cable size required, initial
equipment cost and operating cost. Also, the power distribution voltage may be a factor.

m. Motor Seal Chamber

1) Referring to Exhibit 1.5 the Model 1 motor seal chamber is for use with single motors for 5½"
casing. It is 4½ feet long and weighs 110 pounds.

n. Power Cable Length

1) The power cable length is the measured pump setting depth (MD) plus 100 feet.

2) For this problem:

o. Power Cable Size Selection

1) Using motor name plate voltage (2280V.) calculate recommended cable voltage drop.

2) Now determine voltage drop per 1000 ft.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:18 2001)
 3) Reference Fig. 12 (Voltage Drop Chart) for operating Bottom Hole temperature (190°F), find the
1.267 /
conductor Voltage Drop Correction factor = (12)

4) Now divide the

Now enter Fig. 12 at 9.9V./1000 Ft. on left hand scale and read horizontally to the right to motor
amperage (34 amps) and choose cable size at or below this point. For 9.9V./1000 Ft. and 34
#2 Copper Cable/
amps this would be a (23), which results in an actual voltage drop of 9V./1000 Ft.

5) Check for motor start-up.

a) Determine actual operating motor voltage drop

b. Determine in-rush voltage drop (4.0 factor considers sag in primary system and other system
losses)

c) Determine motor terminal start-up voltage.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:19 2001)
 d) Calculate start-up voltage at motor as percent of motor name plate voltage.

Since this is greater than 50% of motor name plate voltage motor start-up should not be a
problem. The 50% minimum requirement and the 4.0 In Rush voltage drop factor are determined
by operating experience. Some tests have indicated higher in-rush currents than 4.0.
Manufacturer should be contacted for specific recommendations.

*NOTE: The 5% voltage drop is based on NEC Article 215.2, and results in a reduced power loss and
extended power cable life.

Other limiting methods such as 30V/1000 ft. may be used to determine voltage loss in the power cable.
The amount of voltage drop allowed must consider the ability to start the motor.

p. Power Cable Clearance

(#2 Copper Cable)/

1) Having selected the power cable size required (23), it is necessary to be certain

that there is sufficient clearance for the power cable and equipment in the well bore.

2) The following power cable clearance calculation assumes that an offset pump discharge tubing
head is used on the pump. Therefore, the well diameter (casing I.D.) must be greater than the
largest of the following:

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:19 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:19 2001)
 Therefore the equipment and power cable "bundle" will go in the casing. However, extreme care
should be taken due to this small clearance.

NOTE: Exhibit 1.10 has a table for maximum cable/equipment size combinations.

q. Power Cable Insulation

1) Select power cable insulation based on well bore temperature at pump setting depth, motor
current, and well bore environment. Using Fig. 14 (for #2 power cable) find the well bore
temperature (190°F) on left hand scale, and read horizontally to motor current (34 amps)
intersection. This gives a conductor temperature of 200°F.

2) Since conductor temperature is 200°F select the proper power cable insulation from cable
supplier's information.

CAUTION: Some cable insulations can deteriorate when coming into contact with some types of
corrosion inhibitors.

r. Motor Lead Extension

1) Cable size of the motor lead extension and motor potlead size is determined by the annular
space available. Choose the largest size available that will provide acceptable clearance in the well
bore.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:20 2001)
 2) Next, select the type of armor that is appropriate for the well bore conditions. Available materials
may include galvanized steel, phosphur bronze, and monel. Phosphur bronze armor will be chosen
since this well has no corrosion problem.

3) The motor lead extension length is determined by making it reach at least 5 feet beyond the
pump discharge head. This is calculated as follows:

(a) Pump Length ...................... 29.2 Ft.

(b) Motor Seal Chamber................ 4.5 Ft.

(c) Length Above Pump................ +5.0 Ft.

(d) Additional Accessory Equipment ... 5.0 Ft.

43.7 Ft./
(e) Motor Lead Extension Length ...... (29)

Referring to Exhibit 1.11 a 60 foot motor lead extension is available and is chosen for this
installation.

(4) A motor lead extension cable guard should be chosen to go with this.

s. Cable Bands

1) Stainless steel bands were requested by user so these will be provided.

2) One 25 count bundle of 30" bands is required for securing the motor lead extension.

3) Two 22" bands per tubing joints are required or:

t. Wellhead

1) Select a wellhead sufficient to carry the weight of the tubing, equipment and fluid.

(a) Motor...,...................................................... = 1430 lbs.

(b) Motor Seal Chamber............................................. = 110 lbs.

(c) Pump........................................................... = 863 lbs.

(d) Tubing 4.7 lb/ft. × 9000 ft. ............................... = 42,300 lbs.

(e) Power Cable 1.62 lb/ft. × 9000 ft. ......................... = 14,580 lbs.

(f) Motor Lead 1.70 lb/ft. × 40 ft. ..................................... = 70

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:20 2001)
 (g) Cable Bands 15 lb/100 × 600 ................................... = 90

(h) Fluid = 1.060 sp. gr. × 8.34 lb/gal × 0.1626 gal/ft. × 9000 ft. . = 12,940

72,383 lbs. /
(i) Total Weight on Tubing Head ................................ = (31)

2) Based on this total weight and referring to Exhibit 1.8, the Type B tubing head for 5½" O.D.
casing size by 23/8" tubing size with a pack-off for #2 round cable is chosen.

3) 288 stages × 29 ft./stage × 0.440 = 3675 psi. Therefore all valves and fittings on the tubing must
be rated greater than 3675 psi.

u. Motor Control Panel and Junction Box

1) Calculate surface "no load" voltage:

2280V /
(a) Motor Name Plate Voltage = (17).

(b) Cable Voltage Drop = +104V/(19).

2284V /
(c) Surface Full Load Voltage = (32)

(d) Transformer Drop Factor (3%) X1.03

2456V /
(e) Surface "No Load" Voltage (33).

2) Referring to Exhibit 1.6 a motor control panel is selected which has adequate voltage and amp
rating to accommodate system voltage and current (2456 V. and 34 amps). Therefore, the Size D3
MCP is selected. Various control options are available. Lightning arrestors should be specified if
applicable.

3) A junction box should be specified for the installation.

v. Transformers

1) The transformer rating in KVA is:

2) For 3 single phase transformers:

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:20 2001)
 Therefore, use three 50 KVA transformers. Referring to Exhibit 1.7 for single phase transformers
the 50 KVA for a primary voltage of 14,400/24,940 should be selected. As the note indicates,
additional secondary voltages can be obtained by WYE connecting the secondary. This is how the
2400 V. system voltage is obtained.

5.2 Example Problem No. 2

 Water and Oil Production with Gas

5.2.1

The following exhibit sheets provide data and information required for Example Problem No. 2.

a. Exhibit 2.1 Well Data Sheet.

5.2.2

Unless otherwise specified, data used in sizing calculations comes from the Well Data Sheet (Exhibit
2.1).

a. From Figure 17 determine gas solution (Rs) at 500 PSI PIP = 83 ft.3 /bbl.

b. Enter Figure 18 at 83 ft.3 /bbl. (Rs @ 500 PSI PIP) and determine formation volume factor (B o ) = 1.1

bbl/bbl. STO.

c. Determine formation gas volume factor Bg at 500 PSI PIP as follows:

Use gas compressibility factor (Z) = .85 (Note Z varies with gas Sp. gr., pressure and temperature. Z
= .85 is used as an average).

d. Determine if gas separator is required, that is, if free gas at PIP exceeds 10% by volume:

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:21 2001)
 (3) Gas liberated or Free gas = 96.8 − 18.26 = 78.54 Mcf day.*

*NOTE: If GOR is used instead of Rs this number is slightly larger.

e. Assume gas separator is 90% effective and 10% of gas is not separated or Vg = 10%. Therefore, .1
× 424 = 42 entering the pump.

f. Therefore the total fluid mixture in B/D entering the pump is:
Vo = 242 B/D
Vg = 42 B/D
Vw = 880 B/D
Vt = 1164 B/D

g. The amount of free gas entering the pump as a percent of total fluid is:

While gas represents 3.6% by volume of the fluid being pumped it has no significant effect on the well
fluid composite specific gravity.

h. Now that the total volume of the produced mixture through the pump is known the method of
equipment selection is identical to that shown in Example Problem No. 1, Section 5.1.2.

5.3 Example Problem No. 3

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:22 2001)
  Water and Viscous Oil Production

5.3.1

The following exhibit sheets provide data and information required for Example Problem No. 3.

a. Exhibit 3.1 Well Data Sheet.

5.3.2

Unless otherwise specified, data used in sizing calculations comes from the Well Data Sheet (Exhibit
3.1).

a. Using Fig. 3, find the gas free crude viscosity for 15 deg. API crude at 140°F to be 150 Cp.

b. Using Fig. 4, find the gas in solution at 300 PSI (PIP) to be 50 cu. ft./bbl.

c. Using Fig. 5, find the gas-saturated crude oil viscosity for 150 Cp at a 50 cu. ft./bbl. gas in solution
ratio to be approximately 70 Cp.

d. Well Fluid Composite Specific Gravity

1. - 3.

NOTE: Well fluid composite contains no free gas by volume.

e. Using Fig. 6, convert 70 Cp to SSU using an average specific gravity of 0.985. Read 350 SSU.

f. Using Fig. 7, apply the correction factor for a 20.0% water cut. Read 2.0.

g. The 20.0% water cut increases the actual viscosity by a factor of two. Corrected viscosity would be
700 SSU.

h. Refer to Fig. 11 for correction factors. Since installation is in 5.50 O.D. casing, assume 60%
efficient pump for required volume.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:22 2001)
 1. Capacity Factor (Qvis) = 0.805

2. Head Factor (Hvis) = 0.825

3. Horsepower Factor (bhpvis) = 1.30

The effects of viscosity on the unit have now been determined and the sizing of the unit can now
proceed and the correction factors used where required.

i. Well Fluid Composite Gradient

1.

j. Fluid Over Pump (FOP)

1.

k. Vertical Lift  HD

1.

l. Vertical Lift Corrected for Viscosity  HD-vis

1.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:23 2001)
 m. Tubing Friction Loss  HF (Ref. Fig. 8)

For Proper Selection for the Viscosity of the Fluid to be Pumped.

1. - 2.

n. Producing Tubing Head  HT (ft.)

1. - 2.

1. - 2.

o. Pump Total Dynamic Head (Ft.)

p. Correct 800 B/D Required Rate for Viscosity @ 700 SSU

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:23 2001)
 1.

q. Select Pump for 994 B/D to Fit in 5½" Casing

1. A review of the performance (head-capacity) curves results in a choice of pump Type B (Exhibit
1.2), which shows efficiency (65%) at required capacity (994 B/D).

r. Determine Lift (Head) Per Stage

1. Referring to Exhibit 1.2 read vertically from 994 B/D on the capacity scale to the head-capacity
curve intersection.

2. From intersection read horizontally to left to head in feet per stage = 30.0 Ft./(14)

s. Determine Horsepower Required Per Stage

1. Referring to Exhibit 1.2 read vertically from 994 B/D on the capacity scale to the brake
horsepower curve intersection.

2. From intersection read horizontally to right to brake horsepower per stage of 0.28 H.P. maximum
horsepower/stage is stage frequently used.

t. Number of Pump Stages Required

1.

u. Pump Brake Horsepower Required

1.

SECTION 6 SPECIAL WELL CONDITIONS

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:24 2001)
 6.1 High Bottom Hole Temperature

 Generally, electric submersible pump installations in wells with bottom hole temperatures up to 200°F
are handled as standard installations without special considerations.

6.1.1

For wells with bottom hole temperatures between 200-250°F special consideration must be given to:

a. Power Cable  general cable insulation material temperature limits can be categorized as follows:

Well Bore Conductor

Insulation Material Temp. °F Temp. °F
1. Polyethylene (PE)
Unarmored 140 167
2. PPE with Nitrile
Jacket 170 200
3. EPR with Nitrile
Jacket 257 300

These are general guidelines that can be used when evaluating temperature limits of power cable.
The cable manufacturer should be consulted to determine specific recommendations for given well
conditions.

b. Electric Submersible Pump Unit  Most manufacturers' standard equipment is capable of

operation to 250°F well bore bottom hole temperature.

6.1.2

For wells with wellbore bottom hole temperature above 250°F special consideration must be given to:

a. Power Cable  Lead sheathed flat power cable should be considered for these applications. There
may be other cables also available and the power cable manufacturers should be consulted.

b. Electric Submersible Pump Unit  For operation above 250°F it may be necessary for certain
modifications to be made to the electric submersible pump unit, such as elastomers, insulating
materials and motor oil, or other design and material changes.

6.2 Corrosion

 If general "oilfield corrosion" is encountered normal corrosion resistant materials and coatings are
available to provide protection.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:24 2001)
 6.2.1 Power Cable and Banding Material

a. Galvanized or monel armored cable is available for protection in most corrosive environments.

b. In high H2 S corrosion environments it may be necessary to go to a lead sheathed cable to prevent

copper deterioration.

c. Banding materials in stainless steel or monel are available for corrosive environments.

6.2.2 Electric Submersible Pump Unit

a. Coatings for corrosion resistance are available and range from a standard paint, special plastic
coating, or spray metal coatings such as monel. If special coatings are specified the coating
thickness must be included in the clearance calculations (i.e., Section 5.1.2 p.).

b. Some corrosive conditions may require special metallurgy for the housing or other components. The
pump manufacturer should be contacted to determine what changes may be required.

c. Anodes are also available for connection to the bottom of the motor.

6.3 Solids

6.3.1

If solids are expected to be a problem in an installation the well bore should be cleaned out prior to
installing equipment.

6.3.2

Special considerations can be made by the pump manufacturer to improve the ability of the pump to
handle solids. These may include both material and design changes. The pump manufacturer should be
consulted relative to specific applications.

SECTION 7 OTHER ELECTRIC SUBMERSIBLE PUMP EQUIPMENT CONSIDERATIONS

7.1 Electric Submersible Pump variable speed control and soft start.

7.1.1 Variable Speed Control

 Allows the Electric Submersible Pump speed to be varied above or below normal operating speed in
order to produce the well most effectively. The speed change may be necessary to determine
productivity on a new well or to meet changing conditions in an existing well.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:24 2001)
 a. The variable speed drive takes the place of the motor controller and incorporates all of the normal
regulations and control usually found in a motor controller.

b. By varying pump speed of the centrifugal downhole pump the affinity laws apply as follows:

1) - 3)

1) - 3)
From the above relationships it can be seen that brake horsepower limitations may be quickly
reached with increased speed or that insufficient head (shut off) may be reached with reduced speed.

c. The sizing and application of the variable speed drive is outside the scope of this RP. Equipment
manufacturer should be consulted.

7.1.2 Soft Start

 Equipment that provides a means of limiting in-rush current and voltage intended to reduce electrical
and mechanical stresses at start-up in order to improve unit life.

a. Limiting in-rush current reduces power line voltage losses which may be detrimental to other
equipment on line.

b. Provides less stress on the power cable during start-up

c. Reduces high starting torques that occur on across the line starting, therefore putting lower
electrical and mechanical stress on the downhole pump and motor.

d. The sizing and application of the soft start unit is outside the scope of this RP. Contact the
equipment manufacturer for this information.

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:25 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:25 2001)
FIG. 1 PUMP PERFORMANCE CURVE

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:27 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:28 2001)
FIG. 2 FLOW LOSSES DUE TO FRICTION IN API PIPE

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:28 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:29 2001)
FIG. 3 VISCOSITY OF GAS-FREE CRUDE OIL AT OIL FIELD TEMPERATURES

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:30 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:32 2001)
FIG. 4 PREDICTION OF SOLUBILITY FROM SATURATION PRESSURE AND CRUDE OIL GRAVITY

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:32 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:33 2001)
FIG. 5 VISCOSITY OF GAS SATURATED CRUDE OIL AT RESERVOIR TEMPERATURE & PRESSURE

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:33 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:34 2001)
FIG. 6 VISCOSITY-SAYBOLT SECONDS UNIVERSAL (S.S.U.)

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:35 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:35 2001)
FIG. 7 EFFECT OF EMULSION ON OIL VISCOSITY

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:36 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:37 2001)
FIG. 8 PRESSURE LOSS CHART

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:38 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:39 2001)
FIG. 9 PRESSURE LOSS CHART

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:39 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:40 2001)
FIG. 10 PRESSURE LOSS CHART

FIG. 11 CONVERSION CHART APPROXIMATE CHANGES DUE TO VISCOSITY

(60% MAXIMUM EFFICIENCY PUMPS)

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:41 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:42 2001)
FIG. 12 VOLTAGE DROP IN CABLE

FIG. 13 WELL TEMPERATURE VS. CURRENT

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:43 2001)
FIG. 14 WELL TEMPERATURE VS. CURRENT NO. 2 ROUND CABLE

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:44 2001)
FIG. 15 WELL TEMPERATURE VS. CURRENT NO. 4 ROUND CABLE

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:45 2001)
FIG. 16 WELL TEMPERATURE VS. CURRENT NO. 6 ROUND CABLE

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:46 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:47 2001)
FIG. 17 CHART FOR CALCULATING BUBBLE-POINT PRESSURE OR SOLUBILITY

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:48 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:48 2001)
FIG. 18 CHART FOR CALCULATING FORMATION VOLUME OF BUBBLE-POINT LIQUIDS

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:49 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:50 2001)
FIG. 19 VELOCITY OF FLUID PASSING A MOTOR

FIG. 20 SUBSURFACE EQUIPMENT

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:51 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:52 2001)
FIG. 21 SURFACE EQUIPMENT

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:53 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:53 2001)
FIG. 22 ELECTRIC SUBMERSIBLE PUMP WELL DATA SHEET

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:54 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:54 2001)
EXHIBIT 1.1 ELECTRIC SUBMERSIBLE PUMP WELL DATA SHEET EXAMPLE PROBLEM NO. 1

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:55 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:56 2001)
EXHIBIT 1.2 PUMP TYPE A FOR 5½" O.D. CASING PUMP TYPE A

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:57 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:57 2001)
EXHIBIT 1.3 PUMP TYPE A

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:58 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:55:58 2001)
EXHIBIT 1.4 MOTORS (60 Cycle, 3500 RPM) RATING, SPECIFICATIONS

EXHIBIT 1.5 MOTOR SEAL CHAMBER

EXHIBIT 1.6 MOTOR CONTROL PANEL & ACCESSORIES 440 VOLT, 880 VOLT, 1500 VOLT, 2500 VOLT

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:00 2001)
 DESCRIPTION

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:00 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:01 2001)
EXHIBIT 1.7 TRANSFORMERS

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:01 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:02 2001)
EXHIBIT 1.8 TUBING HEADS RATING, SPECIFICATIONS

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:02 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:03 2001)
EXHIBIT 1.9 CABLE SPECIFICATIONS

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:04 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:04 2001)
EXHIBIT 1.10 EQUIPMENT COMBINATIONS IN VARIOUS CASING SIZES

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:05 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:05 2001)
EXHIBIT 1.11 FLAT CABLE AND SURFACE CABLE SPECIFICATIONS

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:06 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:07 2001)
EXHIBIT 1.12 DOWNHOLE EQUIPMENT WITH OFFSET TUBING HEAD

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:07 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:08 2001)
EXHIBIT 2.1 ELECTRIC SUBMERSIBLE PUMP WELL DATA SHEET

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:09 2001)
[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:09 2001)
EXHIBIT 3.1 ELECTRIC SUBMERSIBLE PUMP WELL DATA SHEET

[RP 11S4] Copyright by American Petroleum Institute (Fri Nov 02 09:56:09 2001)