Artificial Lifts

INTRODUCTION TO HYDROCARBON EXPLOITATION Development Phase
Introduction to Hydrocarbon Exploitation

Production Technology (Artificial Lifts)
Pratap Thimaiah
2005 Abalt Solutions Limited. All rights reserved
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Artificial Lift
Addition of energy or decreasing fluid density in the reservoir system so that commercial hydrocarbons volumes can be boosted and recovered at the surface Why are they Installed ? ? ? Offset effects of declining reservoir pressures Offset effects of water production Overcome excessive friction pressures associated with waxes,crudes etc. Kick off high GLR wells that tend to die during shut ins Accelerate production Remove waxes or scale build up
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abalt solutions limited - 2005
September October 2005

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Types of Systems
Mechanical: Rod (Reciprocating) and progressive capacity (rotating) pumps. Hydraulic: Jet/Piston, turbine or plunger hydraulic pumps. Gas lifts. Electric submersible pumps.
LIFT SYSTE M SUBSYSTE M MIN RATE (bbl/D ) MAX RATE (bbl/D)
Gas
Intermittent Continuous
2.5 250
250 50,000
ESP
250
50,000
Hydraulic
Piston Jet
50 250
5,000 15,000
Turbine
2,500
50,000
Mechanical
Rod PCP
5 5
5,000 5,000
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Types of Systems-Selection
Primary
Production Rate Flowing Pressure GLR
APPLICATION Surface Location COMMENTS For urban locations, conventional rod pumps may be unsightly and gas lift may present a hazard. Offshore, conventional rod pump surface drivers may be too large. Gas lift is great for multiple wells but impractical for single wells. PCP and ESP systems may find this a problem. Turbine pumps are better than ESP. Best handled by PCP or Rod Pumping Best handle by gas lift, turbine pump or ESP with separator. PCP and gas lift are best (avoid moving parts) PCP is most depth limited. Different factors limit different systems Not liked by rod systems. Doglegs not liked by long ESP assemblies Simplest for gas lift and hydraulic free pump systems
Secondary
Viscosity Gravity Well deviation Sand & solids Scales & paraffin Corrosive nature of fluids Completions
Number of Wells High Tempera ture Viscous Fluid Gassy Fluid Sandy Fluid Depth Deviation & Dogleg Servicing
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Others
Operators experience CAPEX and OPEX Field location
What for what ??????
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Types of pumping methods

Sucker Rod Pumping Centrifugal Pumping Hydraulic Pumping Mono Rotary Pumping
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Systems and Efficiency
System Rod Pump Electro Submersible Pump Progressing cavity Pump Jet Pump Hydraulic Pump 30-40 50-60 60-80 10-25 30-40
Efficiency (%)
This are estimates taken for actual field data.
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Sucker Rod Pump

Definition:
A sucker rod is the linking involving the surface pumping unit and the subsurface pump, which is located at or near the bottom of the oil well
There are two types of sucker rod pumps in use this days:
Steel Rods: which are manufactured in lengths of 25 or 30 ft. Fibre-glass Reinforced plastic sucker rods: Which are supplied in 37 - or 30 ft. lengths. Both of the pumps are connected by a 4inch long coupling.
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Sucker Rod Pumping

This system uses a vertical positive-displacement pump consisting of a cylinder and a hollow plunger with a valve. It is run into the tubing screwed onto the end of the rod string. The system is actuated from the surface by a motor that drives a walking beam or a hydraulic elevator.
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Beam Pumps System
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Rod Pump System

Beam pumps are the most widely used artificial lift method in most oil companies. They are best for low to moderate production, primarily on land based installations. Figure shows a beam pump system, with the motor, gear box, pumping unit, well head, rod string extending to the bottom hole pump, and the pump with a travelling valve and standing valve. A tubing anchor is included to prevent downhole stroke shortening due to tubing movement.
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Standard Pump Classification

R ef A B C D Type of Pumps Tubing Type with shoe Tubing Type, with extension shoe and nipple Rod Type, stationary barrel, with top hold down Rod Type, stationary barrel, with bottom holddown Rod Type, travelling barrel Full Barrel TW TWE RWA RWB Liner Barrel TL TLE RLA RLB
RWT
RLT
First Letter: -T = Tubing Type; non inserted, run on tubing -R = Rod or inserted type; run on rods Second Letter: -W=Full Barrel - L=Liner Barrel Third Letter: - E=Tubing Pump with extension nipple and shoe - A=Stationary-Barrel rod pump with top hold down - B=Stationary -Barrel rod pump with bottom hold down - T=Travelling Barrel rod pump
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General Considerations
Pump Components:
Subsurface sucker rod driven pump Sucker-rod string which transmits the surface pumping motion and power to the subsurface pump Subsurface pumping equipment which changes the rotating motion of the prime mover into oscillating linear pumping motion The power transmission unit or speed reducer The prime mover which provides the necessary power to the system.
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Pump Components
Walking Beam
Tail Bearing
Horse Head
Pitman Crank Crank Shaft Saddle bearing
V-belt
Polished Rod
Sampson Post Prime Mover Stuffing box Flow line
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What do we need to Know before a pumping Unit Installation?
Fluid level Pump depth Pumping Speed, in stroke per minute Length of surface stroke Pump plunger diameter Specific gravity of the fluid The nominal tubing diameter (anchor or unanchored) Sucker-Rod size and design Unit Geometry
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What can we calculate with that information? Plunger Stroke (inches) Pump Displacement (in barrels per day bbl/D) Peak Polished Rod Load ( in pounds force) Minimum Polished Rod load ( in pounds force) Peak Crank Torque ( in pound force inches) Polished Rod Horsepower and Counterweight required ( in pounds force)
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Pump Selection
Total Theoretical pump displacement:
V KS p N
V Theoretica l pump displacement (bbl/D) S p Effective Plunger stroke (in.) N pump speed (spm)
Plunger Size (inch)
Constant K
Plunger Size (inch)
Constant K
5/8 7/8 1 1 1/16 1 1 7/16 1 1 1 25/32
0.046 0.066 0.089 0.117 0.132 0.182 0.241 0.262 0.357 0.370
1 15/16 2 2 2 2 3 3 3 4 4
0.438 0.466 0.590 0.729 0.881 1.049 1.231 1.639 2.106 2.630
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Pump Constant K
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Net Lift of Fluid (d=1) (ft) 2000 (m) 600 100 1 1 1/4 3000 4000 900 1200 1 1 1 1/4 1 1 1 1 1/8 200 1 1 1 1 1 1 5000 6000 7000 1500 1800 2100 1 1 1 1 1 1 3360 24
Plunger Size Recommended

Fluid Production in bbl/D-80% efficiency 300 2 1 2 1 2 1 2 1 1 1 2940 21 400 2 2 2 2 2 2 2 1 1 2 2 2 2520 18 500 2 2 2 2 2 2 2100 15 600 2 2 2 2 2 2 2 2 2 1680 12 2 2 2 1260 9 700 2 800 2 900 2 1000 2 Head Rating (psi) 840 (MPa ) 6
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8000
2400
1 1 1/8
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Pumping Speeds
Maximum Sucker rod life comes from minimum pumping speeds because maximum load, range of load and pumping speeds are directly proportional.
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Sucker Rod Pumping

There are two broad classifications of pumps operated by sucker rods.
The older type is now known as a tubing pump. This term indicates that the pump barrel is attached directly to the tubing of a pumping well and lowered to the bottom of the well, or to any desired location for pumping, as the tubing is run into the well. The plunger, or travelling valve, of a tubing pump is run in on the lower end of the sucker rods until it contacts the lower valve (or standing-valve) assembly
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Sucker Rod Pumping

Rod pumps may be
top seating (pump suspended from top of barrel) bottom seating (pump seated at bottom of barrel) stationary barrel (travelling plunger) travelling barrel.
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Sucker Rod Pumping

Barrel
The barrel of an oil well pump is the cylinder into which the well fluid is admitted and displaced by a closely fitted piston or plunger.
Plunger
The pump plunger is a closely fitted tubular piston fitted with a check valve for displacing well fluid from the pump barrel. This may be all metal or equipped with cups, rings or other soft packing to form a seal with the barrel.
Standing Valve
This is the intake valve of the pump and generally consists of a ball and seat type check valve. The valve assembly remains stationary during the pumping cycle.
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Sucker Rod Pumping

Travelling Valve
This is the discharge valve and moves with the plunger of a stationary barrel pump and with the barrel of a travelling barrel pump, is often called a travelling valve.
Standing Valve Puller

This is a tool designed to attach to the standing valve cage of a tubing type pump when the sucker rods are lowered to the bottom.
Valve Rod
Valve rods are used in rod type stationary barrel pumps to connect the lower end of the sucker rod string to the pump plunger.
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Sucker Rod Pumping

Pull Tube
Pull tubes are used in rod type travelling barrel pumps to connect the plunger with the seating assembly or hold down.
Seating Assembly
A seating assembly is an anchoring device for retaining a rod pump in its working position. The seating assembly may be located either at the top or bottom of a stationary barrel rod pump but can be located only at the bottom of a travelling barrel pump. With the mechanical seating assembly, an accurately ground seating ring fitted on a tapered mandrel seats on a mating taper to form a leakproof seal.
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Sucker Rod Pump

The pump itself a single acting and its theoretical output is:
Q SxNxA Where : Q flow rate S The Stroke N Number of strokes per time unit. A the area of the plunger
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How to choose a Pump? (Parameters)

Depth: Pump should be located below the dynamic level which depends on: The Bottom hole flowing pressure
P BH with:
Q PBH PR PI
Where : P Reservoir Pressure R Q Required Flow rate PI Productivity Index Q / PI P is the pressure loss in the reservoir and in the vicinityof the well R
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The average specific gravity of the produced effluent.
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Parameters related to flow rate

The pumped flow rate depends basically on the diameter of the plunger, the pump stroke and the pumping rate (or speed). The same flow rate can be obtained by different combinations of these parameters. In the range offered by manufacturers, choice is made with due consideration
Fatigue depends mainly on the following:
number of cycles (pumping rate) the difference between the maximum tensile load during the upstroke and the minimum tensile load during the down stroke
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Pumping Units
Pumping units are designed to actuate the rod string for a specified pumping rate and stroke. This requires a mechanical walking beam system or a hydraulic elevator on the surface. The energy is supplied by an electric motor or an engine (gas or diesel) that is regulated by an adjustable counterweight.
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Types of Pumping Units

. Walking beam units:
The unit consists of the following components an electric motor or engine (gas or diesel) a gear reducer connected to the motor/engine by belts and equipped with brakes on the inlet pulley a crank and connecting rod system to transform the crankshaft rotation at the reducer outlet into an alternating movement a walking beam, supporting the weight of the sucker rods on one side and on the other the adjustable counterweight a horse head accommodating the polished rod's support cables, and its arcing head which allows the rod to remain in the axis of the well during its stroke
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a Samson post supporting the whole system.
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Beam Pumping Unit
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Function and adjustment of counterweights

The counterweights are heavy weights placed on the walking beam opposite the sucker rods with respect to the center bearing. Their function is to regulate the output of the motor engine.
CE W 0.5 F rf o
CE Counterweight Wrf Weight of the sucker rods in the fluid
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Fo Fluid Load
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Standard units
Most manufacturers supply units classified by API under the heading B or C depending on the position of the counterweights: B unit: the counterweights are on the walking beam (B standing for beam). C unit: the counterweights are on the crank (C standing for crank). The C unit is very widespread and is also termed a conventional unit
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Special units
In addition to these two conventional types of units, some manufacturers supply units that are better adapted to specific problems. This is the case for Lufkin, which supplies
Unitorque designed for a better distribution of engine torque Air-Balanced with a long stroke designed to increase the flow rate.
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Lufkin Mark II Unitorque pumping unit

The geometry of the crank and connecting rod system has been modified on this unit: The beam and its support are articulated behind the reducer. The upper fixed point of the connecting rod is very near the horsehead, and this gives an approximate crank rotation angle of 195 in the upstroke and 165 in the downstroke. The counterweight is always on the crank but offset by 15 in the rotation direction. When the unit runs counter-clockwise, the geometry of the system creates an offset of the counterweight top and bottom dead center in relation to the sucker rods. This gives more evenly distributed and lower torque at the reducer outlet for the same stroke length
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Lufkin A or Air balanced unit

The counterweight effect is provided by accumulated air at a specified pressure in a mov-ing cylindrical chamber (cylinder + air receiver tank) connected to the pump beam and equipped with a piston fixed to the unit's base frame. Not having a counterweight means that: The unit is lighter and can be trailer mounted (for well testing). Longer strokes arc possible, up to 300" (7.60 m). However, an air compressor must be installed to offset leakage and maintenance costs are rather high.
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Hydraulic units
In this type of surface unit, the hydraulic energy of pressurized oil is used to drive the sucker rod string: either by rolling and unrolling or by hoisting with a piston jack. These units are more complex in design than beam units
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Progressive Cavity Pumps (Moineau Pump Systems) Moineau pumps have been historically used for viscous crude or to handle solids. Operation involves a rotating steel rotor inside a rubber stator. Cavities are generated between the stator and the rotor and the cavities move upward as the stator is rotated.
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Progressive Cavity Pumps

The rotor and stator form series of sealed cavities 180 apart. They progress from suction to discharge end of pump. As one cavity decreases the other increases allowing fluid to move at fixed flow rate proportional to speed Construction Stator consists of steel tube with elastomer, moulded in double helix Rotor is chrome plated and machined in stainless steel.
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Environmental benefits Smaller size, fewer moving parts therefore causing minimum injuries. Application flexibility Ranges from API 35 for light oils to API 8 heavy oils. Where gas locking or solids create problems. Can be used in regions which are populated, farms etc. Costs Typically from $10,000 to $15,000 for well depths of 2500 to 3000 ft. Efficiency 60-80 % High volumetric efficiency Higher speed greater efficiency
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Applications Used in heavy oil applications. Regions where irrigation systems are being used by the farming industry. Water flood applications Applications that require smaller motors Slant wells-expose more pay on shallow reservoirs Downhole disposal pumping applications (pumping water or gas from an upper formation for disposal)
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Common Failures: Run Dry
When no fluid or operated in pumped off condition Experiences internal friction due to lack of lubrication. Elastomer surface gets burnt or scotched. Remedy set pump speeds at lower volume desired. Pump off controller.
Hysteresis
Elastomer over pressurized and tears or chunks out. Often dry run is accompanied and pump burns out. Remedy: Correct selection of pump size to match flow lines ,tanks etc.
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Swell
Stator elastomer swells due to BHT, chemicals etc Remedy: Fluid samples tested for chemicals Selecting pump size and materials correctly
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Gas permeation
Gas invades Elastomer resulting in blisters or bubbles. Pump torque increases causing catastrophic failure. Remedy Supply pump supplier good data prior to installation. Stator set below perforations to allow gas to break out and move up annulus .
Rotor failures
Wear and abrasion due to solids in fluids Pitting or corrosion Chrome flaking (lifting flakes of chrome from rotor) of rotor
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Hydraulic Powered Pump System

Hydraulic powered pumps depend on high pressure water or oil supplied from a power fluid (PF) pump at the surface The PF pump can be piston or centrifugal, but in general must provide enough pressure to deliver a pressurized power fluid to the down hole pump. The bottom hole pump may be a piston pump actuated by a pressure driven piston engine on top of the pump. The down hole pump can also be a jet pump, where the power fluid goes through a throat in the jet pump and creates a low pressure area to which the formation is exposed.
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Hydraulic Powered Pump System
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Hydraulic Powered Pumps

the power fluid going down one line and the production and the power fluid coming up another line or tubing. In this installation, gas is free to come up the annulus. Depending on the geometry of the well and tubular, a hydraulic pump can be brought to the surface by reversing the direction of the power fluid and pumping a worn pump to the surface for replacement. The pump can be retrieved by wireline if it is stuck.
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Hydraulic Submersible Pumps

The operating pressures used in hydraulic pumping systems usually range from 2,000 to 4,000 psi. The most common pump used to generate this pressure on the surface is a triplex or quintiplex positive displacement pump driven by an electric motor or a multicylinder gas or diesel engine
Multiplex high pressure pump Control manifold Power fluid tank
Wellhead control valve
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Downhole pump
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Downhole Pumps Type of Installations

The two basic types of installations are the fixed pump and the free pump designs.
In the fixed installation, the downhole pump is attached to the end of a tubing string and run into the well. Free pump installations are designed to allow downhole pump circulation into and out of the well inside the power fluid tubing string.
The downhole pump can also be installed and retrieved by wireline operations
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P rodu ced flu id plu s e xhaus t pow er fluid Pow er flui d Produc ed flui d plus ex haus t powe r fluid
Fixed Pumps Installation ( Conventional)
The pump lands on a seating shoe set in tubing that has a larger ID than the OD of the pump. Power fluid is directed down the inner tubing string, and the produced fluid and the return power fluid flow to the surface inside the annulus between the two tubing strings
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Conventional
Insert Casing
Power fl uid
Gasvent
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Free Pump Installations

Free pump installations permit circulating the pump to bottom, producing the well, and circulating the pump back to the surface for repair or size change. Free pump installations require that a bottomhole assembly (BHA) be run in on the tubing string The pump is run in the hole by placing it in the power fluid tubing string and circulating power fluid in the normal direction.
When the pump reaches bottom, it enters the seal bores, begins stroking, and opens the standing valve. During normal pumping, this valve is always held open by well fluids drawn into the pump suction
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S hut Off and Bleed
P ower oil line Flow line
Pump In
Operate
Pump Out
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S tanding Valve closed
S tanding Valve open
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The benefits of being able to circulate the downhole pump in and out of the well include reduced downtime and the ability to operate without a pulling unit for tubing, cable, or rod removal. Another significant advantage is that pressure and temperature recorders can be mounted on the pump to monitor downhole conditions with different pumping rates. At the conclusion of the test, circulating the pump to the surface also retrieves the recorder.
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Closed Power-fluid System

The power fluid and the produced fluid are mixed together after leaving the downhole pump and return to the surface together in a common flow passage. Jet pumps are inherently open power fluid pumps because the energy transfer depends on mixing the power fluid and produced fluid. Reciprocating pumps, however, keep the power and produced fluids separate during the energy transfer process because there is a separate piston (or piston face) for each fluid
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Jet Pumps
It can be used in hydraulic pumping systems instead of the reciprocating pumps. They can be adapted to fit interchangeably into the BHAs designed for the stroking pumps. In addition, special BHAs have been designed for jet pumps to take advantage of their short length and their high volume characteristics. Because of their unique characteristics under different pumping conditions, jet pumps should be considered as an alternative to the conventional stroking pumps
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Jet Pumps
The diameter of the throat is always larger than the diameter of the nozzle exit, allowing the well fluids to flow around the power fluid jet and be entrained by it into the throat
Power fluid Pump tubing Casing Nozzle Throat Diffuser
Combined fluid return
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Well production
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Jet Pumps
These are normally run in on wireline or as a fixed or conventional installation on continuous coiled tubing, and have been successful in offshore drill stem testing (DST) of heavy crude reservoirs. Other applications include the dewatering of gas wells With different sizes of nozzles and throats, jet pumps can produce wells at less than 50 bbl/D or up to rates in excess of 10000 bbl/D
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Jet Pumps
Because they are high velocity mixing devices, there is significant turbulence and friction within the pump, leading to lower horsepower efficiencies than can be achieved with positivedisplacement pumps. Jet pumps are prone to cavitation at the entrance of the throat at low pump intake pressures, and this must be considered in design calculations
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Electrical Submersible Pump System

Electrical submersible pump systems (ESPs) operate at the bottom of the tubing. Power reaches the motor via an electrical 3-phase cable banded to the tubing from the surface down to the motor. The motor is at the bottom of the assembly for cooling from the produced well fluids.
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Electrical Submersible Pump Systems
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Electrical Submersible Pumps
The System comprises of: A downhole pump Electrical power cable Surface controls
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ESP Characteristics
The standard 60Hz producing range from 100 bbl/D up to 90,000 bbl/D ESP characteristics are based on a constant rotation speed, which depends on the frequency of the AC supply:
3500 RPM with 60 Hertz 2915 RPM with 50 Hertz
Currently operated in wells with BHT up to 350 degF Efficiently lifts fluids in wells deeper than 12,000ft System efficiency ranges from 18 to 68% Has a narrow production rate range It does not handle free gas
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ESP Applications
Historically applied in lifting water or low-cut oil wells Greatest application in moving large volumes (>500 stb/d) of low GLR fluid (<100scf/stb) Relatively high gas/fluid ratio can be handled using tapered design pumps and gas separator Can be used in vertical, deviated and horizontal wells
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ESP Operations
It is a multi-staged centrifugal pump connected by a short shaft to an electrical motor Each stage consists of a rotating impeller and stationary diffuser Energy transfer is accomplished by the rotating impeller, imparting a tangential and radial motion to the fluid The diffuser converts the high kinetic energy into lower velocity, pressure or potential energy
Diffuser Impeller Flow
Typical Stage
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ESP Typical Installation

Power is supplied by a power cable to a switchboard and then through a junction box and wellhead/tubing support. The power cable is run in with the production tubing string and is banded to the tubing. The power cable is spliced to a motor flat cable, which is banded to the exterior of the pump-protector motor unit. The pump is hung on the tubing string by the discharge head. Below the pump is a standard intake. The protector both equalises external and internal pressure and isolates the motor from the well fluid. The lowest component is the motor. Note that the downhole unit is landed above the perforations.
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ESP Typical Installation
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Booster & Injection

In this application, a standard pump-protector motor unit is used to lift fluid from a flowline or other source and simultaneously provide injection pressure for a waterflood, pipeline, or other purpose. In a booster application, the unit is set in a short piece of casing, usually near the surface. (Increase pressure on water supply for injection) This configuration can be used for water injection, power fluid, fluid transfer, water disposal etc
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Bottom Intake & Bottom Discharge

Bottom Intake: The well fluid enters the pump through a stinger landed in a permanent packer. The pump and motor sections are inverted from typical positions. The well fluid is produced through the annulus instead of conventional pumping.
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Bottom Intake & Bottom Discharge
Bottom Discharge: Usually used to inject water from a shallow aquifer into a deeper producing zone. Pump & motor are inverted from typical position. Fluid is produced through a tubing stinger landed in a permanent packer in the injection zone.
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Shrouded Configuration / Cavern Storage

A standard downhole unit that has been fitted with a shroud. Useful configuration in low volume, high GLR wells where drawdown is critical. shroud provides the necessary motor coolingfluid flow
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ESP System Components

Motor
Run at a nominal speed of 3500 rev/min in 60-Hz operation. They are filled with a highly refined mineral oil that provides dielectric strength, bearing lubrication, and thermal conductivity The ESP is a multistage centrifugal type pump. The type of stage used determines the design volume rate of fluid production. The number of stages determines the total design head generated and the motor horsepower required
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ESP Components
Protector
The purpose is to isolate the motor oil from the well fluid while balancing bottomhole pressure (BHP) and the motors internal pressure It connects the pump to the motor by connecting both the housing and drive shafts, houses a thrust bearing to absorb pump shaft axial thrust, It isolates motor oil from well fluid while allowing wellbore motor pressure equalisation, It allows thermal expansion of motor oil resulting from operating heat rise and thermal contraction of the motor oil after shutdown
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Pump Intake
Two types of intakes are used to allow fluid to enter the pump, the static and the rotary type.
The static type induces gas separation by reversing the fluid flow direction The rotary gas separator includes a rotary inducer centrifuge to separate the gas and produced liquids. The well fluid enters the intake ports and moves into the inducer
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Power Cable
Electric power is supplied to the downhole motor by a special submersible cable There is two cable configurations: flat (or parallel) and round. Round construction is used except where casing clearance requires the lower profile of flat construction The standard range of conductor sizes is 1/0 to 6 AWG (American wire gauge).
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Switchboard
The switchboard is basically a motor control device. Voltage capability ranges from 600 to 4,900 V on standard switchboards There are two major construction types electromechanical and solid state.
Electromechanical construction switchboards provide over current overload protection through three magnetic inverse time delay contact relays with pushbutton, manual reset. The solid state switchboards incorporate the highly sophisticated Redalert motor controller. The purpose of the motor controller is to protect the downhole unit by sensing abnormal power service and shutting down the power supply if current exceeds or drops below preset limits.
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Transformer
The ESP system involves three configurations.
three single phase transformers, one three-phase standard transformer, and one three-phase autotransformer.
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Transformers generally are required because primary line voltage does not meet the downhole motor voltage requirement. Oil immersed self cooled (OISC) transformers are used in land-based applications. Dry type transformers are sometimes used in offshore applications that exclude oil-filled transformers
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Wellhead
The ESP wellhead or tubing support is used as a limited pressure seal. It provides a pressure tight pack-off around the tubing and power cable. High pressure wellheads, up to 3000 psi, use an electrical power feed to prevent gas migration through the cable.
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Junction Box
A junction box connects the power cable from the switchboard to the well power cable. The junction box is necessary to vent to the atmosphere any gas that may migrate up the power cable from the well. This prevents accumulation of gas in the switchboard that can result in an explosive and unsafe operating condition.
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Variable Speed Drive

It is a sophisticated switchboard-motor controller. A VSD performs three distinct functions.
It varies the capacity of the ESP by varying the motor speed, protects downhole components from power transients, and provides soft-start capability. Each of these functions is discussed.
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A VSD changes the capacity of the ESP by varying the motor speed, by changing the voltage frequency supplied to the motor and thus motor rev/min, the capacity of the pump is changed also in a linear relationship
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Variable Speed Drive

The soft-start capability of a VSD provides two major benefits.
First, it reduces the start up drain on the power system. Second, the strain on the pump shaft is significantly reduced when compared with that of a standard start. This capability is valuable in gassy or sandy wells. In some cases, slowly ramping a pump up to operating speed may avoid pump damage
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Electric Power Supply-Selection data

1. 2. 3. voltage available and frequency, capacity of the service, and quality of service (spikes, sags, etc.). The power data are important because they partially determine transformer and switchboard requirements. Frequency influences pump rotation speed, capacity, and head.
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Electric Power Supply

Once the required data have been gathered and analysed, the next ESP selection step is to determine the wells production capacity at a given pump setting depth. Two key factors that must be considered are
the minimum pump intake pressure (net positive suction head), which the well will permit without pump off or gas lock, and the producing rate, which draws the fluid level down to an optimal level
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The next selection step is to determine the total dynamic head (TDH). TDH is the sum of: (1) the true vertical lift distance from the producing fluid level to the surface, (2) friction loss in the tubing string, and (3) discharge pressure head at the wellhead. The design TDH determines the number of stages required in a pump
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It is very important to choose a producing rate that is in the recommended capacity range of the specific pump. When a pump operates outside this range, premature failure can result. Once a pump is chosen, the number of stages required can be calculated using the lift feet per stage data from the performance curve. ns = Z / Ls where ns = number of design stages, Z = total dynamic head, ft, and Ls = lift per stage, ft.
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Pump and System Performance

It is usual to select the largest pump that will fit into the production casing or to size the production casing to accommodate the pump Two approaches are commonly used in evaluating an ESP system: 1. To pre-select the production target and corresponding BHFP and determine the TDH and pump size/depth required to meet this rate. This is often carried out by plotting the pressure traverses above and below the pump. 2. To pre-select the maximum pump horsepower, or number of stages, and determine the attainable pump rate with:
A fixed IPR and various tubing sizes. A fixed tubing size and various IPR options.
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ESP Capacity
Casing Size (in) 4.5 5.5 7.0 8.625 10.75 13.375 Pump OD (in) 3.38 4.0 5.62 6.75 8.62 11.25 Motor OD (in) 3.75 4.50 5.43 7.38 N/A N/A Typical Rate (stb/d) 1001900 2005000 100016000 400026000 1200033000 24000100000 Max Power (HP) 50125 100300 200650 400850 5001020 5001030 TDH Capacity(ft)
500012 000 500012 000 500012 000 300010 000 20005000 20003500
Artificial Lifts
Small casing or liners will limit the maximum feasible horsepower and pump capacity
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Pumping Requirements
The requirement is the pumping pressure needed to maintain a desired well bore flowing pressure or a desired production rate. It is determined by combining:
Artificia l Lifts
The well's inflow performance (IPR) The maximum permissible pressure drawdown in the well, or the maximum, allowable production rate, and The wellhead pressure and the pressure traverse in the production string. a), (b) illustrates cases where the pump rate is much lower than the absolute open flow. This situation typically occurs when an operator uses undersized pump equipment already existing in inventory. Undersized pump equipment is usually operated at maximum equipment capacity. The other extreme case is a well pumping near its maximum well capacity, as in Figure (c), (d). It is, then, the inflow performance that limits the possible production rate and not the lift system. A general observation in Figure is that the permissible pumping rate increases with pump setting depth, In fact, maximum rates are possible when the pump is set below the perforations, allowing a minimum backpressure at the well bore and efficient gas separation.
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High Rate Electric Submersible Systems

With liquid-lifting capacities up to 30,000 bbl/D (4770 m3/d), depending on electric power limitations, oilfield submersible pumps are used primarily for medium and high volume production. Improved designs and advanced construction materials, including new metal alloys and elastomers for handing corrosive fluids and harsh subsurface conditions such as extreme temperatures or high ratio gas producers, are continuing to be developed
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Alternative Deployment for ESPs

Techniques for running electric submersible pumps in subsea completions and cable or coiled tubing expand artificial lift applications and increase production flexibility for offshore systems, remote locations with limited rig availability and high-cost workover areas A cable deployed submersible lift alternative technology reduces intervention costs by eliminating dependence on workover rigs. The system is lowered into wells with a power cable banded to a torque-balanced tension cable, and seated in a profile landing nipple of 5 - or 7-in. tubing.
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87
Alternative Deployment for ESPs

In the Middle East, some operators in Qatar used coiled tubing with internal power cables to deploy submersible pumps and produce fluids up the annulus inside 7-in. production tubing. In Brunei, Shell converted a well from gas lift to high rate electric submersible pump with a rigless workover made possible by a coiled tubing deployed system. It reduces the need for conventional rig workovers and minimising downtime as well as deferred production
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Subsea Completions
They are not as adversely affected by well-to-platform distances and offer increased flow rates. Subsea submersible installations were not feasible until recent advances in wet mateable connections. These connectors allow seafloor electrical tie in and eliminate the need for dry connections to be made at the surface.
Power cable Wet-mateable connector
Subsea wellwead
30 in casing Subsurface safety valve 13 3/8 in casing
Artificia l Lifts
Operating satellite wells at greater distances means that fewer platforms are needed; host platforms can be in shallow water; and marginal fields can be produced without platforms, which reduces initial costs and operating expenses.
4 1/2 tubing Y tool bypass Electrical submersible pump 7in liner or open hole Packer Bypass tubing 9 5/8 casing
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Common Problems with ESP Operations

The main problem with ESP operations is short run times and consequently high service costs and production losses. These are commonly caused by:
Poor handling procedures. Inadequate system analysis and design leading to the unit operating outside the recommended range. Inadequate cable insulation for the operating environment. Pumping significant quantities (>10%) of free gas without enlarged intake stages. Sand production or corrosion. Frequent restarts without a soft start controller or VSD. Scale formation on the pump impellers. Omission of the viscosity corrections in designing a system to handle emulsions, waxy crude, or heavy oil. Unstable supply voltage. Poor quality control.
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90

It is not particularly sensitive to temperature, depth, deviation or severe operating environments, Hydraulic transmission gives an alternative to electrical or mechanical means of transferring energy downhole. The major problems are, however, the need for at least two reasonably large conduits to minimize fluid friction losses, the difficulty of maintaining a clean, solids-free power fluid, and the high capital and maintenance costs for high pressure pump units
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The downhole pump acts as a transformer to convert the energy of the power fluid to potential energy or pressure in the produced fluids Another form of hydraulic downhole pump that has become more popular is the jet pump, which converts the pressurised power fluid to a highvelocity jet that mixes directly with the well fluids
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Through Flow lines Installations

TFL installations have been developed for offshore locations to allow circulation of various downhole tools to the bottom of Pump remote wells from a central Lubricator Manifold and instrumentation platform.
Pressure transducers
Platform
Tank
Entry loops
Water Mudline Subsea wellhead Well Circulating point H-member Jet pump location
A typical installation is shown in Figure Because a 5 ft-radius loop is an integral part of the subsea wellhead installation, the size of the tools that can be circulated through it is limited. Of the various artificial lift tools, only gas lift valves and hydraulic jet pumps are sufficiently compact to be compatible with the system.
Artificia l Lifts
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Introduction to Hydrocarbon Exploitation

Production Technology Gas Lift
Pratap Thimaiah
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TYPES OF ARTIFICIAL LIFT
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Periods of Gas Lift Development

Prior to 1864: Some laboratory experiments performed 1864 1900: This era consisted of lifting by compressed air through the annulus or tubing. Several mine shafts were unloaded. 1900 1920: Gulf Coast Area air for hire boom. Such famous fields as Spindle Top were produced by air lift. 1920-1929: Application of straight gas lift with wide publicity from the Seminole Field in Oklahoma. 1929-1945: This era included the patenting of about 25,000 different flow valves. Development of the flow valve. 1947 1970: Since the end of WWII, the pressure-operated valve has practically replaced all other types of gas lift valves. Also in this era many additional companies have formed with most of them marketin g some version of the pressure operated valve. 1970 Present: Schlumberger pioneers the use of Nodal Analysis as a basis for analyzing gas lift wells and predicting flowing performance as a function of the total well system.
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Gas Lift Operations

Gas Lift uses additional high pressure gas to supplement formation gas. Produced fluids are lifted by reducing fluid density in well bore to lighten the hydrostatic column, or back pressure, load on formations.
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Advantages
Advantages:
Takes full advantage of the gas energy available in the reservoir Is a high volume method Can handle sand or trash best Has inherent gas handling capabilities,a sever draw back from other methods Well intervention and accessibility is excellent Gas lift can be applied for deviated and horizontal wells Low operating costs and can be optimized for a large field development
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Disadvantages Disadvantages:
Investment maybe capital intensive due to compression costs,but can be reduced by adopting a central distribution plant. Limited drawdown capability-Many deep wells cannot be lifted. Lift gas not readily available It may exacerbate gas freezing and hydrate,wax problems Causes surges on surface equipment
Artificia l Lifts
Safety precautions must be taken for high pressure gas distribution lines.
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Gas Lift Networks and Facilities
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Continuous Gas Lift

Optimum lift is achieved when gas is injected at the bottom of tubing The principle - energy resulting from expansion of gas from a high pressure to a lower pressure is utilized in promoting the flow of well fluids in a vertical tube or annular configurations. Utilization of this gas energy is accomplished by the continuous injection of a controlled stream of gas into a rising stream of well fluids in lifting the well fluids. It is generally intended that, during continuous flow gas lift, only one valve will be admitting gas to the tubing and that valve will be as deep as the available gas pressure will permit.
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Intermittent Gas Lift

intermittent gas lift operates on the principle of intermittent gas injection. gas lift injection occurs for a certain length of time and then stops. After a period of time has elapsed, injection again takes place and the cycle is repeated. Injection of gas below an accumulated liquid slug to lift it to surface. Used to produce low volumes of liquid from wells with low BHFP(<0.1psi/ft) Found application in wells with Inadequate drawdown and where paraffin deposition is a problem
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Configurations
Allows volume of slug to be maximized by using most of casing volume
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Configurations
Artificial Lifts
Allows use of plunger to eliminate liquid fall back. Used with logic controllers(PLC)
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Intermittent Gas Lift Sequence of Operation-Intermittent Lift

The wellhead valve and flow line remain open so a minimum amount of surface backpressure is held on the well. B-indicates the condition in the well just after gas injection through the valve has commenced. Injection into the annulus starts when the surface controller opens. As gas enters the annulus, the annulus pressure will increase until the opening pressure of the operating gas lift valve is reached. The opening of the gas lift valve allows gas to enter the tubing and displace the slug of well fluids to the surface. When the slug passes the next valve above the operating valve, this valve may also open to pass gas into the tubing. As soon as enough gas has been injected to remove the well fluids, the surface controller closes, injection stops and the gas lift valve closes, (See Figure C).At this point, the buildup of well fluids in the tubing has commenced., the cycle is repeated. The surface controller that regulates the on and off injection gas cycle is what is generally referred to as an "intermitter". Usually there is a clock-driven mechanism in the intermitter that causes a motor valve to open at regular intervals, normally once every hour or once every two hours. Intermittent gas lift is usually applied to wells having low productivity indexes that generally result in relatively low producing rates.
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Sequence of Operation-Continuous Gas Lift

TO SEPARATOR/STOCK TANK
PRESSURE PSI 0
INJECTION GAS CHOKE CLOSED
1000
2000
3000
4000
5000
6000
7000
2000
TOP VALVE OPEN
4000
AS C NG I
U T BI
PR
DEPTH F TTV D
ES
SECOND VALVE OPEN
6000
G N P E R U SS
SU R E
E R
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
TUBING PRESSURE
Artificial Lifts
FIGURE 1-13
CASING PRESSURE
SIBHP
The fluid level in the casing and the tubing is at surface. No gas is being injected into the casing and no fluid is being produced. All the gas lift valves are open. The pressure to open the valves is provided by the weight of the fluid in the casing and tubing. Note that the fluid level in the tubing and casing will be determined by the shut in bottom hole pressure (SIBHP) and the hydrostatic head or weight of the column of fluid which is in turn determined by the density. Water has a greater density than oil and thus the fluid level of a column of water will be lower than that of oil.
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PRESSURE PSI 0 1000 2000 3000 4000 5000 6000 7000
INJECTION GAS CHOKE OPEN
2000
TOP VALVE OPEN
4000
DEPTH FTTV D
6000
SECOND VALVE OPEN
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
Artificia l Lifts
FIGURE 1-14
TUBING PRESSURE CASING PRESSURE
SIBHP
Gas injection into the casing has begun. Fluid is U- tubed through all the open gas lift valves. No formation fluids are being produced because the pressure in the wellbore at perforation depth is greater than the reservoir pressure i.e. no drawdown. All fluid produced is from the casing and the tubing. All fluid unloaded from the casing passes through the open gas lift valves. Because of this, it is important that the well be unloaded at a reasonable rate to prevent damage to the gas lift valves.
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PRESSURE PSI 0 1000 2000 3000 4000 5000 6000 7000
2000
TOP VALVE OPEN
4000
DEPTH FTTVD
6000
SECOND VALVE OPEN
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
Artificial Lifts
FIGURE 1-15
SIBHP
The fluid level has been unloaded to the top gas lift valve. This aerates the fluid above the top gas lift valve, decreasing the fluid density. This reduces the pressure in the tubing at the top gas lift valve, and also reduces pressure in the tubing at all valves below the top valve. This pressure reduction allows casing fluid below the top gas lift valve to be U- tubed further down the well and unloaded through valves 2, 3 and 4. If this reduction in pressure is sufficient to give some drawdown at the perforations then the well will start to produce formation fluid.
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PRESSURE PSI 0 1000 2000 3000 4000 5000 6000 7000
2000
TOP VALVE OPEN
4000
DEPTH FTTV D
6000
SECOND VALVE OPEN
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
DRAWDOWN
Artificia l Lifts
FIGURE 1-16
FBHP
SIBHP
The fluid level in the annulus has now been unloaded to just above valve number two. This has been posssible due to the increasing volume of gas passing through number one reducing the pressure in the tubing at valve two thus enabling the U-tubing process to continue.
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PRESSURE PSI 0 1000 2000 3000 4000 5000 6000 7000
2000
TOP VALVE OPEN
4000
DEP TH FTTVD
6000
SECOND VALVE OPEN
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
DRAWDOWN
TUBING PRESSURE
Artificial Lifts
FIGURE 1-17
CASING PRESSURE
FBHP
SIBHP
The fluid level in the casing has been lowered to a point below the second gas lift valve. The top two gas lift valves are open and gas being injected through both valves. All valves below also remain open and continue to pass casing fluid. The tubing has now been unloaded sufficiently to reduce the flowing bottom hole pressure (FBHP) below that of the shut in bottom hole pressure (SIBHP). This gives a differential pressure from the reservoir to the wellbore producing a flow of formation fluid. This pressure differential is called the drawdown
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PRESSURE PSI 0 1000 2000 3000 4000 5000 6000 7000
2000
TOP VALVE CLOSED
4000
DEPTH FTTV D
6000
SECOND VALVE OPEN
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
DRAWDOWN
Artificia l Lifts
TUBING PRESSURE
FIGURE 1-18
CASING PRESSURE
FBHP
SIBHP
The top gas lift valve is now closed, and all the gas is being injected through the second valve. When casing pressure operated valves are used a slight reduction in the casing pressure causes the top valve to close. With fluid operated and proportional response valves, a reduction in the tubing pressure at valve depth causes the top valve to close. Unloading the well continues with valves 2, 3 and 4 open and casing fluid being removed through valves 3 and 4.
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PRESSURE PSI 0 1000 2000 3000 4000 5000 6000 7000
2000
4000
TOP VALVE CLOSED
D EPTH FTTVD
6000
SECOND VALVE OPEN
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
DRAWDOWN
Artificial Lifts
FIGURE 1-19
FBHP
SIBHP
The No. 3 valve has now been uncovered. Valves 2 and 3 are both open and passing gas. The bottom valve below the fluid level is also open. Note that the deeper the point of injection the lower the FBHP and thus the greater the drawdown on the well. As well productivity is directly related to the drawdown then the deeper the injection the greater the production rate.
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PRESSURE PSI 0 1000 2000 3000 4000 5000 6000 7000
2000
4000
TOP VALVE CLOSED
D EPTH FTTVD
6000
SECOND VALVE CLOSED
8000
THIRD VALVE OPEN
10000
FOURTH VALVE OPEN
12000
14000
DRAWDOWN
Artificia l Lifts
FIGURE 1-20
TUBING PRESSURE CASING PRESSURE FBHP
SIBHP
The No. 2 valve is now closed. All gas is being injected through valve No 3. Valve No 2 is closed by a reduction in casing pressure for casing operated valves or a reduction in tubing pressure for fluid operated and proportional response valves. Valve No 3 is the operating valve in this example. This is because the ability of the reservoir to produce fluid matches the ability of the tubing to remove fluids (Inflow/Outflow Performance). The operating valve can either be an orifice valve or can be a gas lift valve. The valve in mandrel No 4 will remain submerged unless operating conditions or reservoir conditions change.
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FIGURE 1-21: Example of the Unloading Sequence Casing Operated Valves and Choke Control of Injection Gas
2500
2000
Pressure psi
1500
1000
500
0 09:00 PM 12:00 AM 03:00 AM 06:00 AM
Artificial Lifts
09:00 AM Time
12:00 PM
03:00 PM
06:00 PM
PRESSURE CASING
PRESSURE TUBING
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GAS LIFT VALVE MECHANICS
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115
GAS LIFT VALVE MECHANICS
3 basic types of gas lift valve, each available in 1 & 1-1/2 sizes: DUMMY VALVES ORIFICE VALVES
SQUARE SQUARE EDGED EDGED VENTURI VENTURI (NOVA) (NOVA)
UNLOADING VALVES
INJECTION PRESSURE (CASING) OPERATED VALVES PRODUCTION PRODUCTION PRESSURE PRESSURE (FLUID) (FLUID) OPERATED VALVES THROTTLING/PROPORTIONAL RESPONSE VALVES
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Unloading Valves
Diaphragm/ Atmospheric Bellows Spring
Stem Stem Tip Upstream Downstream Port

Artificia l Lifts
Upstream/ Casing
Downstream/Tubing
Pressure Regulator
Spring Operated Gas Lift Valve

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Production Pressure Operated Valves(PPO)

Pros: 1. Deeper Injection achievable for given injection pressure 2. In dual completions, it minimises string interference. 3. Not greatly influenced by fluctuations in casing pressure
Cons: 1. Closer valve spacing required 2. Well performance must be known accurately 3. Not applicable to stable wells 4. Valve behaviour can be affected by small port size
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Injection pressure Operated valves (IPO)

Pros: 1. Better gas lift control-less sensitive to well heading problems. 2. Suitable for high rate applications. 3. Fewer mandrels and valve required. 4. Most commonly used in the industry Cons 1. Higher injection pressure required when compared to PPO. 2. Stable injection gas pressure is required.
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VALVE OPENING & CLOSING PRESSURES
F F= =P PX XA A
Pb
WHEN THE VALVE IS CLOSED TO OPEN IT IT.. .. Fo = Pc1 (Ab - Ap) + Pt Ap
Pc1
Artificial Lifts
Pt Pt
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CLOSING FORCE (IPO VALVE) Fc = PbAb OPENING FORCES (IPO VALVE) Fo1 = Pc (Ab- Ap) Fo2 = Pt Ap TOTAL OPENING FORCE Fo = Pc (Ab - Ap) + Pt Ap
JUST BEFORE THE VALVE OPENS THE FORCES ARE EQUAL Pc (Ab - Ap) + Pt Ap = Pb Ab SOLVING FOR Pc WHERE:
Artificia l Lifts
Pb
Pb - Pt (Ap/Ab) Pc = -------------------------1 - (Ap/Ab) = Pressure in bellows Pt = Tubing pressure Pc = Casing pressure Ab = Area of bellows Ap = Area of port
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Pc =
Pb - Pt (Ap/Ab) ---------------------1 - (Ap/Ab) Pb - Pt (R) ---------------------1-R
Pc =
Pb = Pc (1 - R) + Pt (R)
Artificial Lifts
Where R = Ratio Ap/Ab

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122
Types of Gas Lift Valves

The IPO valves are designed in such a way that the casing pressure is acting on the larger area of the bellows and thus they are primarily sensitive to the casing pressure The drop in casing pressure which occurs during unloading is used to close the valves in the correct sequence. In the PPO valves the flow path is reversed and thus the tubing pressure is acting on the larger area of the bellows making the valve primarily sensitive to the tubing pressure. The drop in the tubing pressure as gas is injected is used to close the valve. Their uses are generally limited to dual wells and also in situations where the injection pressure is prone to fluctuate and the production pressure can be considered the more predictable.
Dome
Pb
Dome
Pb
Chevron Packing Stack Bellows
Stem Tip (Ball) Square Edged Seat Pc
Pc Stem Tip (Ball) Square Edged Seat
Pt Chevron Packing Stack Pt Chevron Packing Stack
Check Valve
Check Valve
Artificia l Lifts
Nitrogen Charged Bellows Type Injection Pressure (Casing) Operated Gas Lift Valve
Nitrogen Charged Bellows Type Production Pressure (Fluid) Operated Gas Lift Valve
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The valve mechanics are basically the same as the IPO valve, the valve is neither a PPO nor an IPO valve. the ball never moves out of the flow stream and thus continues to be sensitive to the tubing pressure then the valve will respond proportionally to the tubing pressure i.e. the greater the tubing pressure the more the valve will open and thus the more gas the valve will pass until critical flow is reached.
Dome Spring
Pb Atmospheric Bellows
Chevron Packing Stack
Pc Large T.C. Ball Tapered T.C. Seat Chevron Packing Stack Pt
Pc Spring Adjustment Nut & Lock Nuts Stem Tip (Ball) Square Edged Seat Chevron Packing Stack Check Valve
Pt
Check Valve
Artificial Lifts
Nitrogen Charged Bellows Type Proportional Response Gas Lift Valve
Spring Operated Injection Pressure (Casing) Operated Gas Lift Valve
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Artificia l Lifts
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125
ORIFICE VALVES
THERE ARE 2 TYPES OF ORIFICE VALVE: SQUARED EDGED ORIFICE VENTURI (NOVA)
Valve designed for accurate gas passage prediction.

Artificial Lifts
One-way check valve for tubing integrity.
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126
NOVA NOVA VALVE VALVE

The problem:
It is important operating at critical flow as this ensures the gas passage through the valve remains constant even if the tubing pressure is unstable As the tubing pressure is dependent on the gas injection rate, any fluctuation in the gas passage will make the tubing pressure more unstable and thus a slugging cycle will start
The solution :
NOVA valve virtually eliminates any effect of tubing pressure on the gas injection rate. Changes in tubing pressure are not allowed to affect the casing pressure. The gas flow rate remains constant and this has a negative feedback effect on any tubing instability. Critical flow is achieved through the valve with as little as 10% pressure drop or less. Conventional valves require between 40 to 60% pressure drop to achieve critical flow and in most cases it is not practical to operate with this much loss. The stabilization of the flowing bottom hole pressure in a well will generally increase the overall production from that well. Stabilizing the injection pressure can lead to reduced maintenance costs too. A spin-off benefit from the use of the NOVA Gas Lift Valve will be the improved controllability of gas lift fields where computer controlled optimization schemes are implemented. Used in Dual gas injections
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127
GAS LIFT MANDRELS, LATCHES & KICKOVER TOOLS
Artificial Lifts
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Solutions
128
GAS LIFT MANDRELS
SIDE POCKET MANDRELS
CONVENTIONAL MANDREL
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129
Conventional Mandrels
Made from sections of tubing Valves and check valves are screwed on before they are run. The valve is vertically positioned with the help of a small guide attached to the mandrel body which serves as a protector during running/pulling operations The main disadvantage is that any trouble with a valve means that the well has to be killed and equipment pulled out.
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130
Side Pocket Mandrels (SPM)

Mandrel made up of forged steel with an aperture. A pocket is connected to the aperture and has a machined valve seat at its base where holes are communicating with the annulus. Two ends have tubing thread and run in empty. Gas lift valves are set by wireline without the need to kill a well at anytime. SPM allow the injection point depth to be adapted as bottom hole pressure declines.
51 /2M M R G -4 ,11/2 P O C K E T R O U N DM A N D R E LD E S IG N
O rie n tin g S le ev e T o o l D is crim in a to r G L a tc h L u g P o lis h e d S ea lB o re
C A M C O
E N G IN E E R IN GD A T A
P A R TN U M B E R S IZ E M A XO .D . M INI.D . D R IF TI.D . T H R E A D T E S TP R E S S U R EIN T E R N A L T E S TP R E S S U R EE X T E R N A L L A T C HT Y P E K IC K O V E RT O O L R U N N IN GT O O L P U L L IN GT O O L M A T E R IA L T E N S IL ES T R E N G T H(E O E C )
C A M C O1 9 9 6
Artificia l Lifts
05 71 2 -00 0-0 00 01 51/2 7.98 2 4.75 6 4.65 3 17L B /F TM A N NB D SBxP 7 74 0P S I 62 80P S I R K ,R K -1,R K P ,R K -S P O M -1,O M -1 M ,O M -1 S R K -115 0 79 15 /8JD S15 1 55 4 1 0S .S .,1 3C R2 2H R CM A X 4 9 0,0 0 0L B S
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Artificial Lifts
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RK / BK LATCH
Latches keep the Gas lift valves in the seat Latches allow the proper installation and positioning of gas lift valves. OTHER LATCHES 1-1/2 RK 1-1/2 RA
Artificia l Lifts
1-1/2 RM T2 LATCHES 1 BK
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KICKOVER TOOL
THE KICKOVER TOOL IS RUN ON WIRELINE AND USED TO PULL AND SET GAS LIFT VALVES. THE ABILITY TO WIRELINE CHANGEOUT GAS LIFT VALVES GIVES GREAT FLEXIBILITY IN THE GAS LIFT DESIGN
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134
KICKOVER TOOL
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135
KICKOVER TOOL
Artificial Lifts
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136
GAS LIFT WELL KICK-OFF

Unload well carefully
50 - 100 psi (3.5 bar) per 10 min 1 - 2 bbl per min
Maximize production choke opening Gradually increase gas injection rate Monitor well stability Get to target position Perform step rate production test Optimise gas injection rate Note - when unloading all valves open!
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GAS CALCULATIONS RELATED TO GAS LIFT SYSTEMS
Gas injection pressure at depth Gas volume stored within a conduit Temperature effect on bellows-charged dome pressure
Artificial Lifts
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138
GAS CALCULATIONS RELATED TO GAS LIFT SYSTEMS GAS INJECTION PRESSURE AT DEPTH
S.G. x L 53.34 x T x Z P@L = P@S x e

Where: e = 2.71828 P@L = Pressure at depth, psia P@S = Pressure at surface, psia S.G. = Gas Specific Gravity L = Depth, feet T = Average Temp Degrees R Z = Average Compressibility for T and average pressure
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139
GAS VOLUME STORED WITHIN A CONDUIT
Internal capacity of a single circular conduit Q(ft3/100ft.) = 0.5454 di2 Q(barrels/100ft.) = 0.009714 di2 Annular capacity of a tubing string inside casing Q(ft3/100ft.) = 0.5454 di2 - do2 Q(barrels/100ft.) = 0.009714 di2 - do2
Where:
Artificial Lifts
di = inside diameter in inches do = outside diameter in inches
Abalt
Solutions
140
GAS VOLUME STORED WITHIN A CONDUIT
To find the volume of gas contained under specific well conditions): P x Tb b = V x ---------------Z x Pb x T
Where: b = gas volume at base conditions V = capacity of conduit in cubic feet P = average pressure within conduit Tb = temperature base in degrees Rankin Z = compressibility factor for average pressure and temperature in a conduit Pb= pressure base (14.73 psi) T = average temperature in the conduit in degrees Rankin
Artificia l Lifts
Abalt
Solutions

141
TEMPERATURE EFFECT ON CONFINED BELLOWS CHARGED DOME PRESSURE
P2 = P 1
Where:
Tc
P1 = Pressure at initial temperature P2 = Pressure resulting from change of temperature Tc = Temperature correction factor
and
1 + 0.00215 x (T2 - 60) Tc = -------------------------------1 + 0.00215 x (T1 - 60)

Where :
Artificial Lifts
T1 = Initial temperature, Deg F T2 = Present temperature, Deg F
Abalt
Solutions
142
Critical Valve Components Reverse Flow Check Valves
Artificia l Lifts
Abalt
Solutions

143
Conventional Tubing Retrievable Gas Lift Valve IPO
Wireline Retrievable Gas Lift Valve IPO
Wireline Retrievable Gas Lift Orifice Valve
Wireline Retrievable Dummy Valve
Artificial Lifts
Abalt
Solutions
144
Artificia l Lifts
Abalt
Solutions

145
Slickline Operations
Artificial Lifts
Abalt
Solutions
146
Surface Flow Control Equipment
Primary Purpose
Control and measure flow from a producing oil and gas well, secondary recovery water or gas injection well injected gas in a gas lift field operation.
Secondary Purpose
Artificia l Lifts
Real time flow control measurement which allows precise valve positioning from a remote location by use of an electronic actuator digital hart communication control.
Abalt
Solutions

147
Surface Flow Control Equipment

Applications
All producing oil and gas wells Platform gas lift manifolds Water or gas secondary recovery/pressure maintenance projects All wells employing electrical submersible pump systems
Artificial Lifts
Abalt
Solutions
148
Manual Injection Control for Gas Lift
CN00998
Packing and trim changed without removing body from line Easy-to-read indicator ring in 1/64 in. scale Variety of trim sizes, materials and connections
Artificia l Lifts
Camco/Merla FCV flow control valve
Abalt
Solutions

149
Remote Flow Control Applications
Actuators for electric control and automation systems

Available for FCV and ACV series valves 120 Vac or 24 Vdc with low current draw for remote applications High modulation rate for precise positioning Digital Hart communication control Corrosion resistance housing
CN01069
Artificial Lifts
FCV with electric actuator
Abalt
Solutions
150
GAS LIFT DESIGN METHOD
Collect Data Create well model Validate the model Perform analysis Generate performance curves Generate design VLP(s) Perform gas lift design (incl. preliminary valve calc.) Loop back Finalize valve calculation
Artificia l Lifts
Abalt
Solutions

151
DATA SHEET FOR GAS LIFT DESIGN

Company : ___________________ Field : __________________Well No : ______________ Company Engineer :_______________ Completed By : _______________ Phone :_________________ Fax :__________________ Date : __________________________
Well Data Mean Sea Level: _____ft.MDRKB
Well Schematic Deviation Survey Yes Yes No No
Inflow Parameters Initial Final Layer Pressure Range Layer Temperature Depth to Mid Perfs PI Range or Test Rate, FBHP & Depth ________________ ________ ________ ________ ________ ________ ________ Gas Lift Data Kick off Pressure ________ Injection Gas S.G. ________ Deepest Point of Inj. ________ Operating Inj. Pressure ________ Lift Gas Availability ________
Well Head Depth: _____ft.MDRKB

(if no, fill in information below)
Size _________ _________ Length Flowline Data: _________ Insulation Diameter: Tubing Data: Casing Data:
Weight __________ __________ O.D __________ __________ Fluid Parameters
Depth (MDRKB) __________ __________ I.D __________
________
Oil API or S.G __________ Production Gas S.G Water Salinity or S.G __________ Formation GOR Expected Water Cut Range _______ to ________ PVT Data
Attach PVT Data Sheet Yes No
__________ __________
Production Information Unloading THP ________ FTHP & Rate ________ @ _________ FTHT & Rate ________ @ _________ Separator Pressure ________ Flow correlation (if any) ____________________ Test Data
Flowing Gradient Survey Yes Well Test Yes Well Test History Yes No No No
Solution GOR (at STD conditions) Pb (at measured Temperature)
__________ __________ @ __________ Temp ________ _ _______
Artificial Lifts
Bo (at pressure & Temp) Uo (at pressure & Temp) PVT Correlation (if any)
Value Pressure ________ _________ ________ _________ _______________________
Current Condition : New Drill Flowing Gas Lifting Total Rate (b/d): _______ Oil Rate (b/d): ______ Water Rate (b/d):______
Abalt
Solutions
152
Artificia l Lifts
Abalt
Solutions

153
Artificial Lifts
Abalt
Solutions
154
Artificia l Lifts
Abalt
Solutions

155
Gas Lift Design Procedure

All discussions which result in a change of information, should be documented.
Contract Review
Draft Version
Customer Review
As per procedure ATP-06.
Data Sheet
Gas Lift Design
Peer Review of Gas Lift Design

Traceability of document and software revisions to be recorded.
To Customer for Review and Approval
Instruction to Workshop
Completed and signed by customer or Gas Lift Engineer.
Require approval via, E-Mail, Fax or Verbal (which requires to be documented)
Completed by Gas Lift Engineer.
Artificial Lifts
Abalt
Solutions
156
Gas Lift System / Automation linked to InterACT

PHASE WATCHER
Schlumberger FCV-A Surface Flow Control Valve w/ Electronic Actuator
Artificia l Lifts
INFLOW
Abalt
Solutions

Artificial Lifts

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2005 Abalt Solutions Limited. All rights reserved

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2005 Abalt Solutions Limited. All rights reserved

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2005 Abalt Solutions Limited. All rights reserved

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2005 Abalt Solutions Limited. All rights reserved

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