Sucker Rod Pumping Workshop

Wyndham Hotel, Houston, Texas

September 11 14, 2007
Beam Pumping with Solids
Present
By
Mark Mahoney, HF Pumps
Jim Lea, PLTech LLC
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 2
Copyright
Rights to this presentation are owned by the company(ies) and/or
author(s) listed on the title page. By submitting this presentation to
the Sucker Rod Pumping Workshop, they grant to the Workshop,
the Artificial Lift Research and Development Council (ALRDC), and
the Southwestern Petroleum Short Course (SWPSC), rights to:
Display the presentation at the Workshop.
Place it on the www.alrdc.com web site, with access to the site to be
as directed by the Workshop Steering Committee.
Place it on a CD for distribution and/or sale as directed by the
Workshop Steering Committee.
Other uses of this presentation are prohibited without the expressed
written permission of the company(ies) and/or author(s) who own it
and the Workshop Steering Committee.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 3
Disclaimer
The following disclaimer shall be included as the last page of a Technical Presentation or
Continuing Education Course. A similar disclaimer is included on the front page of the Sucker Rod
Pumping Web Site.
The Artificial Lift Research and Development Council and its officers and trustees, and the Sucker
Rod Pumping Workshop Steering Committee members, and their supporting organizations and
companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this
Technical Presentation or Continuing Education Training Course and their company(ies), provide
this presentation and/or training material at the Sucker Rod Pumping Workshop "as is" without any
warranty of any kind, express or implied, as to the accuracy of the information or the products or
services referred to by any presenter (in so far as such warranties may be excluded under any
relevant law) and these members and their companies will not be liable for unlawful actions and any
losses or damage that may result from use of any presentation as a consequence of any
inaccuracies in, or any omission from, the information which therein may be contained.
The views, opinions, and conclusions expressed in these presentations and/or training materials
are those of the author and not necessarily those of the Sponsoring Organizations. The author is
solely responsible for the content of the materials.
The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond
the source documents, although we do make every attempt to work from authoritative sources.
The Sponsoring Organizations provide these presentations and/or training materials as a service.
The Sponsoring Organizations make no representations or warranties, express or implied, with
respect to the presentations and/or training materials, or any part thereof, including any warrantees
of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or
suitability for any purpose.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 4
Dont forget to possibly slow unit and pump
continuously and not with POC to keep pumps
from sticking.J Lea
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 5
TYPICAL SAND PROBLEMS
STICKING OF PLUNGER DUE TO SAND TRAPPED BETWEEN THE
BARREL AND PLUNGER
PACKING-OFF CAGES AND PLUNGERS WITH SAND
STICKING VALVES OPEN
STICKING BOTTOM HOLD DOWN PUMPS IN TUBING
PLUNGER / BARREL WEAR
BALLS AND SEATS WEAR
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 6
SAND SIZE
THOUSANDS OF AN INCH
BELOW .003 SILT AND CLAY
.003-.005 VERY FINE SAND
.005-.010 FINE SAND
.010-.020 MEDIUM SAND
.020-.040 COURSE SAND
.040 AND ABOVE VERY COURSE SAND
MICRON= .00003937
100 MICRONS = .0039
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 7
MESH SCREEN SIZE
MESH SIZE GRAIN SIZE
100 .006
65 .008
48 .012
35 .016
28 .023
20 .033
14 .046
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 8
Analysis
Solids from wells are often assumed to be scale or iron sulfide.
Add xylene to the solids to remove oil, paraffin, and asphaltenes.
Check the remaining solids to see if they are acid soluble.
Effervescence will indicate a carbonate scale, calcite (calcium
carbonate) or siderite (iron carbonate.
Iron carbonate will not smell but will cause the acid to turn
yellow. An H
2
S small indicates iron sulfide. If not acid soluble,
try caustic. Caustic followed by acid will tell us whether calcium
sulfate is present. Barium sulfate and sand will be inert to all
attempts.
If no history is available, a more complete analysis is
recommended.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 9
Analysis
When the pump and tubing is pulled, always inspect
the gas and mud anchor for solids.
The presence of solids/scale doesnt necessarily
mean there is a problem. Evaluate these findings with
respect to the current equipment life. For instance if
sand , did it reduce the pump life?
The lack of sand in an insert pump does not always
indicate a "clean well". An aggressive rig operator
can accelerate the rods to a high speed then slam on
the brake causing the pump valves to bounce open
and allow sand to fall from the pump.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 10
Solids or scale problems can be minimized by
three different approaches:
1. Prevent solids from entering the pump.
Must have rathole.
2. Use a proper fit to either keep solids from
the plunger/barrel interface or let them pass
through without sticking the pump.
3. Use a large valve ports to allow sand to
travel through the valves without packing-
off.
Handling Solids with Beam Pumps
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 11
PLUNGER/BARREL CLEARANCE FOR
PUMPING SAND
GENERAL RULE :
TIGHT FIT TO EXCLUDE SAND FROM BARREL/ PLUNGER
INTERFACE. WORKS WITH LARGE GRAIN SIZE (.015-.020
AND ABOVE).
LOOSEN FIT TO ALLOW SAND TO PASS BETWEEN THE
PLUNGER AND BARREL INTERFACE WHEN FINE SAND IS
PRESENT .002 +.
SAND WILL TRAVEL UP TUBING ONLY IF LIQUID RATE HIGH
ENOUGH. SOMETIMES THE SAND JUST STAYS SUSPENDED
ABOVE THE PUMP IF THE UPSTROKE FLOW IS NOT
CAPABLE OF SURFACING THE SAND.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 12
Continuous Operation
If pump sticking during shut down periods
then slow the unit so it runs continuously
so sand will not settle on off cycle and
this may prevent most of sticking
problems.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 13
Exclude sand from pump
Cavin Desanders: They are sized for the size of the particulates
encountered. They use centrifugal force from a swirling motion to
throw sand towards the side walls of the tail pipe while the fluid
stays in the center and enters the pump. These devices have
proven to be effective in many W. Texas installations. Eventually
you must clean out the well or the rat hole.
Prepack Screen and Liner: These are self contained units that are
most often used in unconsolidated sand formations. The prepack
unit has screens and sand with resin, while the screen and liner
has only screens. Wells with scaling tendencies may present a
problem with this type of device.
Installing a screen in place of the perforated nipple has not proven
to be good design
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 14
Location
Above perfs: If the reservoir pressure allows a high fluid
level, consider setting the pump above the perfs to use
the rat hole below the perfs as a natural sump. Use a
properly designed gas anchor if gas reduces the pump
efficiency.
Below the perfs: With low well pressure, set below the
perfs in the rat hole. If the solids settle in the well bore
due to their size and a low production rate, the pump can
be set high with only a seating nipple (if gas is not a
problem). Once the fill reaches the seating nipple the
tubing will have to be pulled and the casing cleaned out.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 15
Mud Anchors and Screens
Install a gas/mud anchor to help remove the solids
from the production. Drill a hole in the bottom of
the bull plug to allow solids to settle out of the mud
anchor. If gas is a problem, then gas anchor
efficiency may be reduced by adding a drain hole
and a purge valve should be used in place of the bull
plug.
Screens should only be used when the pump life is
continually short due to abrasion. Many times the
solids production is temporary due to stimulation or
changes in the production
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 16
Some Filters
Cavins Desander:
Some success in W. Texas
Successful in E. Texas (previous pump lasted 6-8 monthsafter
PAP 12 months with high efficiency.
Stanley Filter:
Successful in medium to light sand production.
Mixed results in high sand
FG filters have problems with sticking/breaking, especially if the
assembly is tagged against fill
Heavy oil/ high temp filter has mixed results as most filters have
troubles with viscous oil
Tagging this pump can cause damage
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 17
Cavens Desander
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 18
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 19
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 20
Filters
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 21
Tight Fit Pumps
These pumps are used to prevent solids from
fitting between the plunger OD and the barrel ID.
The most common types of pumps used for this
are stroke-through pumps with about 0.002 inch
fits. Names such as Pampa, Modified Pampa,
Sand Busters are examples of these types of
pumps.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 22
PAMPA TUBING PUMP
RECOMMENDED FOR WELLS THAT PRODUCE
SAND OR OTHER PARTICULATES THAT HANG UP
OR STICK STANDARD PLUNGERS.
DESIGNED WITH A LONG PLUNGER AND A SHORT
BARREL SECTION.
THE PAMPA PUMP CAN BE CONFIGURED AS A
TRAVELING BARREL, STAIONARY BARREL OR
TUBING PUMP AS NEEDED TO MATCH WELL
CONDITIONS.
PAMPA PUMPS CAN ALSO BE USED WITH LOOSE
FITS TO KEEP THE PLUNGER FRO STICKING WITH
FINE SAND
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 23
Pumps & Attachments
Short Barrel and long plunger: This is extension of the stroke
through pump where the barrel seal is 3-4 and the plunger is
much longer. The advantage is that the solids are not wedged
between the plunger and barrel over the length of the stroke.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 24
P a m p a R H B C I n s e r t P u m p
C o p y r i g h t A p r i l 2 0 0 2 H a r b i s o n - F i s c h e r
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 25
Close Fit Pump : PAP Pump
PAP Pump:
Good success in some areas
Not good for high corrosion areas (wipes the film off
the barrel)
Tubing pump: loose rings and cant fish the SV.
Not recommended for wells with scale problems
PAP in combination with Stanley filter has proven
successful in some areas.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 26
Loose Fit Pumps:
These pumps can be used to allow solids to pass freely
between the plunger and the barrel. This can be
accomplished by using a pump with a long leak path (a
three tube pump), a soft packed plunger ( a Martin
plunger) or a Pressure Actuated Plunger. Large
clearance require minimum of about 10 SPM.
For all of the above alternatives, California style valves
can be used (i.e.., undersized balls and seats in regular
size cages to reduce the possibility of sand from
becoming rapped between the balls and the seats.
It is recommend to first try to exclude sand from the
pump. The next recommended alternative should be a
loose fit PAP pump.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 27
Three Tube Pump: A Three Tube Pump is designed to
pump solids by having a very loose fit (0.015 inches).
And a very long leak path to reduce total slippage..
Additionally, they can wear very quickly.
The do reduce the maximum size pump that can be run in
the tubing .
Desanders and Pressure Actuated Plungers should be
considered as an alternative to a Three Tube Pump. They
have almost zero compression ratio.
Three Tube Pump
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 28
3-TUBE PUMP
RECOMMENDED FOR OPERATION IN SANDY OR
DIRTY FLUID.
DESIGNED WITH THREE LOOSE FITTING TUBES,
PERMITTING PARTICULATES TO PASS THROUGH
THE PUMP, MAKING IT LESS VULNERABLE TO
STICKING.
HAS THE ADVANTAGES OF BOTH A STATIONARY
BARREL PUMP AND A TRAVELING BARREL
PUMP.
AVAILABLE IN CORROSION AND ABRASION
RESISTANT MATERIALS.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 29
C o p yr i g h t Ap r i l 2 0 0 2 H a r b i s o n - F i s c h e r
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 30
VALVES for SAND
APPLICATIONS
NEW 4 -GUIDE CAGE
Stellite Lined
RUBBER LINED CAGE
Viton
Rubber
Guides
Ball
and
Seat
Top
View
Side
View
Copyright April 2002 Harbison -Fischer
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 31
Special Balls and Seats
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 32
Balls & Seats
Ceramics have not run that well. Silicon Nitride is good
for corrosion but is very expensive.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 33
Bottom discharge valves (BDV): BDVs are devices that are
normally used at the bottom of an insert bottom hold down
stationary barrel application. It is designed to discharge fluid on
the down stroke from between the standing and traveling valve
within the barrel to the annular space between the barrel OD and
tub tubing ID. This is done to protect the tubing and barrel with
corrosion inhibition and to reduce the amount of solids that can
pack in around the barrel above the hold down.
BDVs are recommended only when solids problems have been
identified as the reason for sticking an insert pump in the tubing
and when the well depth is lower than that recommended for a
top hold down.
On stationary barrel bottom holddown pumps a BDV is installed
just above the holddown,. 20-25% of the production is discharged
on the downstroke keeping the sand from settling between the
barrel and tubing
Bottom Discharge Valves
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 34
BOTTOM DISCHARGE VALVE
The Bottom Discharge Valve is
designed to be used when sand or
other particulates are produced.
The BDV is assembled above the
standing valve on a standard bottom
hold-down pump.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 35
B o t t o m D i s c h a r g e V a l v e
F l u i d
E x i t t o
T u b i n g ,
d o w n s t r o k e
D i s c h a r g e
V a l ve
P r o d u c t i o n F l u i d
S t a n d i n g
V a l ve
P r o d u c t i o n
F l u i d t h r u
P u m p , u p s t r o k e
C op yri g h t A p ri l 2 0 0 2 Ha rb is on -F i s ch er
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 36
BOTTOM DISCHARGE VALVE
SOLUTIONS
Twenty percent of the produced fluid exits the pump
through ports just above the standing valve,
preventing sand from settling above the seating
nipple.
A secondary benefit is that corrosion chemicals can
be circulated through this normally stagnant fluid
area.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 37
Historically they have been used in heavy solid producing
wells where sand or other materials prop the ball off the
seat. Double valving may reduce the problem in this case,
but other products such as desanders are generally a
better solution. They prevent the sand from entering the
pump where it can cause a problem.
Washing or jetting of the balls and seats can occur if a
sand grain lodges and holds the ball off the seat on either
the TV or the SV. By adding another valve, the chances of
both being off seat at once are greatly reduced.
Remember small valves pack-off easier than large valves
for the same given sand size and double valves increase
the path the sand has to travel
Double Valving
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 38
Pump: Metallurgy
For a metal pump, consider the hardest surface
material for the barrel and plunger for resistance to
abrasion. Chrome plated barrel and sprayed metal
plunger in non corrosive environment nickel-carbide
barrel in corrosive wells
Well that produce solids should be sized to produce
all the time so sand will not settle during down times.
If properly applied metal plunger does not provide
adequate pump life, consider a soft packed plunger.
Continue pump problems with metal and soft packed
plungers due to solids production warrants
evaluating the use of a PCP for depths less than
about 4000.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 39
Special Application
Pumps/Attachments
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 40
TEXAS STIPPER PUMP
DESIGNED FOR SHALLOW, LOW VOLUME WELLS
THAT PRODUCE SAND AND OPERATE WITH
PERIODS OF SHUTDOWN.
BUILT AS A STATIONARY BARREL BOTTOM HOLD
DOWN (RWB) PUMP WITH AN OUTER JACKET THAT
SHIELDS THE DISCHARGE PORTS, PREVENTING
SAND FROM ENTERING THE PUMP DURING SHUT
DOWN PERIODS.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 41
Copyright April 2002 Harbison-Fischer
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 42
Insert- Top Hold down: A top hold down is a first choice. Pumps
discharge is close the NoGo on the seating nipple which
minimizes sand accumulations. Intermittent pumping can allow
sand to settle inside pump sticking the plunger.
Insert-Bottom Hold down: A bottom hold down pump has a large
annular area between the barrel and the tubing which can fill
and sand in the pump. Sand can also settle inside the pump
sticking the plunger. A top sand seal can help if the pump has to
be run as a bottom hold down
Special Pumps Continued
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 43
Pumps & Attachments
Insert-Traveling Barrel: A traveling barrel pump minimizes sand
accumulation between the barrel and the tubing if properly
spaced. Since the traveling valve is on top of the pump, sand
cannot accumulate inside the pump. Also the fluid is discharged
spread out over the stroke length minimizing erosion damage to
the tubing.
Stroke Through Pump: Both the insert top/bottom hold down
pumps extensions to allow the plunger to stroke out of the barrel
top/bottom on each stroke. The minimum stroke length is fixed.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 44
Pumps & Attachments
Pull Tube Discharge Pump: Both the insert A/B pumps can be
equipped with a blind valve rod guide and a pull tube that is
ported above the plunger. A pull tube traveling valve will act as a
sand check. Most of the fluid is displaced through the pull tube
minimizing sand that can wedge between the plunger and the
barrel. Also fluid is discharge spread over the stroke length thus
minimizing the erosion damage to the tubing.
Tubing Pump: Many of the attachments for the stationary barrel
insert pump apply.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 45
Pumps & Attachments
Attachments:
Top Seal: For stationary barrel bottom holddown pumps another
seal bore is run I the tubing string above the seating nipple
which accepts a seal assembly on the pump below the pump
discharge. Issue is spacing.
Top Slide Valve: Added to the pump below the rod guide and is
available for both top and bottom holddown stationary barrels.
On the downstroke, the slide valve closes which minimizes sand
from settling inside the barrel.
Sept. 11 - 14, 2007
2007 Sucker Rod Pumping Workshop 46
Summary
Fair for low viscosity (<10 cp) production.
Improved performance for high (>200 cp)
viscosity cases. May be able to handle up to
0.1% sand. (Hein, Bucarem, Clegg)
Sand reduces run life but with proper choices of
equipment and techniques, sand laden fluids can
be produced with beam systems.