ESP Sizing Calculator
Calculate total dynamic head, number of pump stages, motor horsepower, and recommended cable size for electric submersible pump installations.
Input Parameters
TDH = Net Lift + Friction Loss + WHP Head | HP = (Q × TDH × SG) / (3960 × η)
Total Dynamic Head
--
ft
Pump Stages
--
stages
Motor HP Required
--
hp
Cable Size
--
AWG
TDH Breakdown
Net Lift
--
ft
Friction Loss
--
ft
WHP Head
--
ft
Pump Efficiency
60%
assumed
How this was calculated
Net Lift: Pump setting depth minus static fluid level. This is the vertical distance the pump must lift fluid.
Friction Loss: Calculated using the Hazen-Williams approximation for tubing flow. Friction head = 2.083 x (100/C)^1.85 x (Q/34.3)^1.85 / (d^4.8655) x L/1000, where C=120, Q in gpm, d in inches, L in ft. Converted to feet of head.
WHP Head: Wellhead pressure converted to feet of fluid head: WHP / (0.433 x SG).
Motor HP: HP = (Q x TDH x SG) / (3960 x pump_efficiency), with pump efficiency assumed at 60%.
Cable Sizing: Based on motor HP and depth: #6 AWG up to 60 HP at 6000 ft, #4 AWG up to 120 HP at 8000 ft, #2 AWG up to 200 HP at 10000 ft, #1 AWG above.
GOR Effect: High GOR (>500 scf/bbl) can cause gas locking and reduced pump efficiency. A gas separator should be considered.
Reference: Guo & Ghalambor, Petroleum Production Engineering; Takacs, Electrical Submersible Pumps Manual.
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Book a free strategy call →Understanding ESP System Design
Electric submersible pumps (ESPs) are the artificial lift method of choice for high-rate wells, typically producing 200 to 30,000+ barrels per day. ESPs consist of a downhole centrifugal pump driven by an electric motor, connected to surface power via a cable run alongside the production tubing.
The total dynamic head (TDH) is the fundamental design parameter for ESP sizing. It represents the total energy the pump must impart to the fluid, comprising three components: the net lift (vertical distance from the dynamic fluid level to surface), tubing friction losses, and the pressure head needed to overcome wellhead backpressure.
The number of pump stages is determined by dividing the TDH by the head generated per stage at the design flow rate. Each stage is a centrifugal impeller-diffuser pair. More stages means more head capability but also a longer pump assembly and higher cost.
Gas handling is a critical consideration. Free gas at the pump intake reduces volumetric efficiency and can cause gas locking. Wells with GOR above 500 scf/bbl typically require a gas separator or gas handler installed below the pump.
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