Lectures 11-14 - Natural Gas Production-II

Natural Gas Engineering
Production II,, NGP 604

Byy
Dr. Adel Salem

Asst. Prof. of PE, Faculty of Petroleum & Mining Eng.
S CCanall University
Suez
U i
it
SS 2010
Proposed Contents
1. Introduction
2 Flow
2.Flow
2.
Fl Regime
R i Characteristics
Ch
t i ti in
i RReservoir
i
1. SteadySteady-State Flow;
2 Unsteady2.Unsteady
2.
Unsteady-State Flow;
3.Pseudo
3.
Pseudo steady State Flow.
3 Natural Gas Well Performance
3.Natural
3.
1. Introduction;
2 Static Bottom
2.
Bottom--hole Pressure;
3. Flowing BottomBottom-hole Pressure;
1. Average Temperature and Deviation
Factor Method [Rzasa-Katz method];
2. The Sukkar and Cornell Method;
3. The Cullender and Smith Method.
4. Gas
Gas--Liquid Flow in Wells; Flow Regimes;
5. Prepared Pressure Traverse Curves;
April 30, 2010
6. Inflow Performance Relationship;

Factors Affecting inflow Performance
7. Tubing Performance;
Outflow Performance Curves
7. Choke Performance.
4. Liquid Loading In Gas Wells
5. Methods for Unloading Liquid
I.
Beam Pumping Units;
II
II.
Pl
Plunger
lift;
lf
III.
Small Tubing String;
IV.
Flow Controllers;
V
V.
S IInjection.
Soap
j ti
6.
7
7.
Bean Performance
Artificial Lifting Methods
I.
Gas Lifting
II.
Pumping System
8.
9.
10.
11.
Production Forecasting for Gas Wells

Total System Analysis
Gas Well Completion
Hydraulic Fracturing of Gas Wells
NG Eng. Production II_ Dr. Adel Salem
Lectures 11- 14: Page: 2
L
Lecture
11 14:
14 Artificial
A f l Lifting
L f Methods
M h d
2. Pumping System
May 2010
May
April 30, 2010
A tifi i l Lift M
Artificial
Methods
th d
Dr.Eng.AdelSalem
Asst.Prof.ofPetroleumEngineering
FacultyofPetroleumandMiningEngineering
S
SuezCanalUniversity
C
lU i
i
Egypt
Lecture Nr. 11
II S
II.
Sucker
k R
Rodd PPumping
i
Outlines
Sucker Rod (Beam) Pumps:
3.1. Surface Pumping Facilities,
3.2. Subsurface Equipments,
3.3. Operating Mechanism,
3.4. Sucker and Rod Design, and
Power Requirements, and
3.5. Troubleshooting
Dynamometer.
April 30, 2010
Introduction
Thereareover949,550
There
are over 949,550
producingoilwellsallover
theworld,about93%of
thesewellsareoperated
usingdifferentartificiallift
methodsandroughlyover
th d
d
hl
72%areproducingusing
beam pumping system
beampumpingsystem.
April 30, 2010
Introduction
SuckerrodpumpingisalsoreferredtoasBeamPumping.Itprovidesmechanical
energy to lift oil from bottom hole to surface. It is efficient, simple, and easy for field
energytoliftoilfrombottomholetosurface.Itisefficient,simple,andeasyforfield
peopletooperate.
Itcanpumpawelldowntoverylowpressuretomaximizeoilproductionrate.Itis
applicabletoslimholes,multiplecompletions,andhightemperatureandviscousoils.
y
y
g
Thesystemisalsoeasytochangetootherwellswithminimumcost.
Themajordisadvantagesofbeampumpingincludeexcessivefriction incrooked/
d i t dh l
deviatedholes,solidsensitiveproblems,lowefficiencyingassywells,limiteddepth
lid
iti
bl
l
ffi i
i
ll li it d d th
duetorodcapacity,andbulkyinoffshore operations.
Beampumpingtrendsincludeimprovedpumpoffcontrollers,bettergasseparation,
gashandlingpumps,andoptimizationusingsurfaceandbottomholecards.
April 30, 2010
Main Components
of a Sucker Rod
P
Pumped
dW
Well
ll
Prime Mover
Down Hole Pump

Sucker Rods
Surface Unit
Prime Mover
Surface
pumping
i unit
it
Each of the above mentioned

i
items
can vary in
i size,
i
materials & geometry.
April 30, 2010
Casing
Tubing
Sucker
Rods
Subsurface
pump
Sucker Rod Pump Equipments

Thebeampumpingsystemconsistsessentiallyoffiveparts:
1 Thesubsurfacesuckerroddrivenpump
1.
The subsurface sucker rod driven pump
2. Thesuckerrodstringwhichtransmitsthesurfacepumpingmotionand
power to the subsurface pump. Also included is the necessary string of
powertothesubsurfacepump.Alsoincludedisthenecessarystringof
tubingand/orcasingwithinwhichthesuckerrodsoperateandwhich
conductsthepumpedfluidfromthepumptothesurface
3. Thesurfacepumpingequipmentwhichchangestherotatingmotionofthe
primemoverintooscillatinglinearpumpingmotion
4 Thepowertransmissionunitorspeedreducer
4.
Th
i i
i
d d
5. Theprimemoverwhichfurnishesthenecessarypowertothesystem
April 30, 2010
Surface Equipments
The prime mover is either an electric motor or an internal

combustion engine.
engine The modern method is to supply each well
with
ith its
it own motor
t or engine
i . Electric
El t i motors
t
are mostt d
desirable
i bl
because they can easily be automated. The power from the prime
mover is transmitted to the input
p shaft of a g
gear reducer by
y a Vbelt drive. The output shaft of the gear reducer drives the crank
arm at a lower speed (440 revolutions per minute [rpm]
d
depending
di on well
ll characteristics
h
t i ti and
d fluid
fl id properties).
ti )
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Therotarymotionofthecrankarmisconvertedtoanoscillatorymotionby
meansofthewalkingbeamthroughapitmanarm.Thehorsesheadand
g
g
p
p
thehangercablearrangementisusedtoensurethattheupwardpullonthe
suckerrodstringisverticalatalltimes(thus,nobendingmomentisapplied
tothestuffingbox).Thepolishedrodandstuffingboxcombinetomaintain
agoodliquidsealatthesurfaceand,thus,forcefluidtoflowintotheT
connectionjustbelowthestuffingbox.
b l
h
ff b
April 30, 2010
SR Specifications
Conventionalpumpingunitsareavailableinawiderangeofsizes,withstrokelengths
varying from 12
varyingfrom12toalmost200in
12toalmost200in.Thestrokesforanypumpingunittypeareavailablein
to almost 200 in.
in The strokes for any pumping unit type are available in
increments(unitsize).Withineachunitsize,thestrokelengthcanbevariedwithin
limits(aboutsixdifferentlengthsbeingpossible).
Thesedifferentlengthsareachievedbyvaryingthepositionofthepitmanarm
g
g
p
p
connectiononthecrankarm.Walkingbeamratingsareexpressedinallowablepolished
rodloads(PRLs)andvaryfromapproximately3,000to35,000lb.Counterbalancefor
conventionalpumpingunitsisaccomplishedbyplacingweightsdirectlyonthebeam(in
smaller units) or by attaching weights to the rotating crank arm (or a combination of
smallerunits)orbyattachingweightstotherotatingcrankarm(oracombinationof
thetwomethodsforlargerunits).
Inmorerecentdesigns,therotarycounterbalancecanbeadjustedbyshiftingthe
positionoftheweightonthecrankbyajackscreworrackandpinionmechanism.
April 30, 2010
Beam Pumping Types

Inadditiontotheconventionalone,therearetwoothermajortypesof
pumpingunits.ThesearetheLufkinMarkII
LufkinMarkIIandtheAir
theAirBalancedUnits.
BalancedUnits.The
pitmanarmandhorsesheadareinthesamesideofthewalkingbeamin
thesetwotypesofunits(ClassIIIleversystem).Insteadofusingcounter
weightsinLufkinMarkIItypeunits,aircylindersareusedintheairbalanced
unitstobalancethetorqueonthecrankshaft.
i
b l
h
h
kh f
TheAmericanPetroleumInstitute(API)hasestablisheddesignationsforsucker
The
American Petroleum Institute (API) has established designations for sucker
rodpumpingunitsusingastringofcharacterscontainingfourfields.
Forexample,
C 228D 200 74:
C228D20074:
Thefirstfield
Thefirstfieldisthecodefortypeofpumpingunit.Cisforconventionalunits,
Aisforairbalancedunits,beamcounterbalanceunits,andMisforMarkII
units.
peaktorqueratinginthousandsofinch
p
q
g
Thesecondfieldisthecodeforpeaktorqueratinginthousands
Thesecondfield
poundsandgearreducer. Dstandsfordoublereductiongearreducer.
Thethirdfield
ThethirdfieldisthecodeforPRLratinginhundredsofpounds.Thelastfieldis
the code for stroke length in inches.
thecodeforstrokelengthininches.
April 30, 2010
April 30, 2010
Types of Beam Pump

Allbeamtypepumpingunitgeometriesfallintotwodistinctclasses:
1.
TheClassIleversystemwhichhasitsspeed(gear)reducerrearmounted
with the fulcrumat midbeam,representedbytheconventionalunitand,
withthefulcrumat
mid beam, represented by the conventional unit and,
2.
TheClassIIIleversystem,apushupgeometrywithitsspeedreducer
y
, p
pg
y
p
frontmounted,representedbytheairbalanceandLufkinMarkIIunits,
wherethefulcrumislocatedattherearofthebeam.
3.
Lufkinhasthreetypes;conventional,MarkIIandAirbalancedone.
April 30, 2010
Conventional Type
April 30, 2010
Lufkin Mark II Unit
April 30, 2010
Air Balanced Unit
April 30, 2010
SR Units
CONVENTIONALUNITS TheLUFKINConventional
CrankBalancedUnit,widelyknownandaccepted,is
,
y
p ,
theoldreliable"WORKHORSE"oftheoilpatch.
Thisisthemostuniversallyadaptableunitinthe
"LUFKIN
LUFKINLINE
LINE",simpletooperateandrequires
simple to operate and requires
minimummaintenance.Shownhereisthetwo
pointbasedesigninstalledonfrontandrear
concrete blocks
concreteblocks
MARKIIUNITORQUEUNITS
MARK
II UNITORQUE UNITS TheMarkIIunit,due
The Mark II unit, due
toitsuniquegeometryandphasedcounterbalance
feature,lowerspeaktorqueandhorsepower
requirements The unusual geometry of the Mark II
requirements.TheunusualgeometryoftheMarkII
producesasomewhatslowerupstrokeandfaster
downstrokewithreducedaccelerationwherethe
l di
loadisgreatest,resultinginlowerpeakloadsand
li i l
kl d
d
longerrodlife.
April 30, 2010
SR Units
AIRBALANCEDUNITS Theutilizationof
compressed air instead of heavy cast iron
compressedairinsteadofheavycastiron
counterweightsallowsmoreaccuratefingertip
controlofcounterbalance.Asaresult,theweight
oftheunitisgreatlyreduced,significantlylowering
transportationandinstallationcosts.AirBalanced
units have a distinct advantage in the larger sizes
unitshaveadistinctadvantageinthelargersizes
withlongstrokes,wherecastironcounterweights
onconventionalcrankcounterbalancedunitsmust
besomassivethattheiruseispractically
prohibitive.
BEAMBALANCEDUNITS TheLUFKINBeam
Balanced unit has the same rugged dependability as
Balancedunithasthesameruggeddependabilityas
theConventionalunit.Theseunitsfilltheneedof
economicallyproducingmanyoftheshallowwells
April 30, 2010
SR Units
REVERSEMARKUNITS TheLUFKINRMSeries
Pumping Unit offers the customer an improved
PumpingUnitoffersthecustomeranimproved
alternativetotheconventionaltypegeometry.
AlthoughsimilarinappearancetotheLufkin
Conventionalpumpingunit,theRMunit
geometrycanreducethetorqueandpower
requirementsonmanypumpingapplications.In
some instances a smaller reducer and prime
someinstancesasmallerreducerandprime
movercanbeused.
Lufkinmaintainsanactiveinventoryofusedand
refurbishedpumpingunitsfromvarious
manufacturersandinavarietyofsizestomeet
f
di
i
f i
yourreciprocatingrodpumpingunitneeds.
April 30, 2010
April 30, 2010
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April 30, 2010
SUBSURFACE PUMPS
Roddrawnpumpscanbedividedintothreebasic
types:
(1) Tubing pumps
(2) Insert (rod) pumps
(3) Casing
C i pumps (a
( larger
l
version
i off iinsertt pumps))
Allofthesepumpsareactuatedbyasuckerrod
g
p p g
stringandasurfacepumpingunit.
The functions of he p
pump
p are to admit fluid from
the formation into the producing string and to lift
the fluid thus admitted to the surface. To
accomplish this,
this any pump must contain four
essential elements:
(1) A working barrel
(2) A plunger
(3) An intake valve (standing valve)
(4)
( ) An exhaust valve ((traveling
g valve))
April 30, 2010
subsurface Pumps
p
Tubing pump
Rod or insert pump
April 30, 2010
SUBSURFACE PUMPS
Roddrawnpumpscanbedividedintothreebasictypes:
(1) Tubing pumps
(2) Insert (rod) pumps
(3) Casing pumps (a larger version of insert pumps)
Allofthesepumpsareactuatedbyasuckerrodstringand
a surface pumping unit. Any roddrawn
asurfacepumpingunit.Anyrod
drawnpumpconsistsof
pump consists of
fouressentialelements:
(1) A working barrel
(2) A plunger
(3) An intake valve (standing valve)
(4) An exhaust valve (traveling valve)
WhatisthedifferenceamongallRodTypesmentionabove?
April 30, 2010
Subsurface Pumps
Tubing pump
Rod or insert pump
April 30, 2010
Tubing Pump versus Rod (Insert ) Pump

Tubing Pump
With tubing type pumps, as the name implies, the
pump barrel is an integral part of the tubing string
Larger bore than a rod pump
pump, thus produces a greater
volume of fluid in any give diameter of tubing.
Rod Pump
Complete
C
l t pump attached
tt h d tto, and
d iinserted
t d into,
i t
well tubing with sucker rod string.
As a complete unit, pump may be pulled out of
well without p
pulling
g tubing.
g
April 30, 2010
Pumping Operation
Theadvantageofinsertpumpsisthattheyconnecttothesuckerrodstring,
and the entire assembly can be removed from the well merely by pulling the
andtheentireassemblycanberemovedfromthewellmerelybypullingthe
rodstring.
Withthistypeofpump,theworkingbarrelisloweredonrods;consequently,
somemeansmustbeprovidedtosecurethebarrelintothebottomofthe
tubinginordertoprovidefluidpackoff andtofacilitatetherelativemotionof
theworkingbarrelandplunger.
Severalarrangementsareusedforthispurpose.Seatingcupscanbeprovided
ontheworkingbarrel,oraspecialseatinghousingmaybeprovidedonthe
g
,
p
g
g y p
bottomofthetubing.Holddownanchorscanalsobeusedatthetopor
bottomofthebarrel.
April 30, 2010
Pumping Operational Cycle
April 30, 2010
April 30, 2010
April 30, 2010
Pump Diagnosis: Surface Dynamometer card:

Ideal card (stretch and contraction)
Idealcard(stretchandcontraction),
Idealcardacceleration).
April 30, 2010
April 30, 2010
Surface Dyna-graphs may not tell the whole story!
Complicated
Surface Card
Load ((lbs))
Downhole
Card 65%
Pump Fillage
Position (in)
April 30, 2010
Surface Versus Downhole Crads
April 30, 2010
Record Surface Cards

SurfaceDynamometercardsisthe
plotofmeasuredpolishedrodload
atthevariouspositionsthroughout
a complete stroke
acompletestroke
Itisusedfordesigningand
diagnosingsurfaceproblems.
Surface Card
Pump Card
April 30, 2010
April 30, 2010
April 30, 2010
Net pump stroke is important in

determining pump efficienc
efficiency
Load (lbs)
Surface Card
Pump Card
Position (in)
Unit Stroke
91 in.
Net Stroke
46.9 in.
April 30, 2010
Gross Stroke
84.3 in.
Load (llbs)
Only 30% of the pump stroke is

being used to produce oil
55 BFPD
13.6 MCFG/PD
Position (in)
Oil plus water
Oil Shrinkage
g
Tubing Movement
Gas Compression
Compressed Gas
Pump Leakage
April 30, 2010
Understanding Dynamometer Pump Card Shapes
April 30, 2010
Fluid Pound Problem

FluidPound asexperiencedina
pumping oil well is caused by the
pumpingoilwell,iscausedbythe
pumpnotcompletelyfillingwithfluid
ontheupstroke.Asthedownstroke
begins,theentirefluidandrodstring
loadmovesdownthroughavoiduntil
the plunger hits the fluid level in the
theplungerhitsthefluidlevelinthe
pumpbarrel.
Downhole Pump
Fluid Pound
Thetravelingvalveopens,suddenly
transferringtheloadtothetubing,
causingasharpdecreaseinload,
whichtransmitsashockwavethrough
the pumping system It is this shock
thepumpingsystem.Itisthisshock
wavethatdamagesthepartsofthe
pumpingsystem.
April 30, 2010
Downstroke
Upstroke
Casing
Tubing
R d St
Rod
String
i
Fl id L
Fluid
Levell
Fluid Pound
Pump
April 30, 2010
Lecture Nr.
Nr 12
Sucker Rod Pumping Design
Th used
The
s d reference
f
ffor this L
Lecture
t
is Ch
Chapter
t 5 ffrom:
Craft, B. C., Holden, W. R., and Graves, Jr. E. D.: Well
Well Design, Drilling and Production,
Production
Prentice-Hall, Inc. Englewood Cliffs, New Jersey, 1962.
April 30, 2010
Beam Pump Design

Althoughthebeamsuckerrodsystemismechanicallysimpleandhasproven
to be longlived and economical in operation many factors must be
tobelonglivedandeconomicalinoperation,manyfactorsmustbe
consideredinthedesignofapropersystem.
Thedesignengineermustbethoroughlyfamiliarwiththefunctionand
complicatingfeaturesofeachpartoftheoverallsystemifoptimum
performanceistobeexpected.
Althoughitappearssimple,infieldpracticethebehaviorofthebeamand
Al
h
hi
i l i fi ld
i h b h i
f h b
d
suckerrodsystemissurprisinglycomplex.
Therearebasicformulasforcalculatingthevariousfactorsaffectingthe
selectionofasuitablesystem,andthispartwillpresentthosecalculations.
y
,
p
p
April 30, 2010
1. Theoretical Analysis of Rod Motion

Ifthesuckerrodsweresuspendedstaticallyfromapolishedrodoriftheywererisingor
falling at constant velocity, the force on the polished rod would be the weight, Wr,of
fallingatconstantvelocity,theforceonthepolishedrodwouldbetheweight,W
, of
thesuckerrod.However,underaccelerationtherewillbeonthepolishedrodan
additionalaccelerationloadWr(a/g).
Theaccelerationfactor(
Theaccelerationfactor(
)orthefactorbywhichthedeadweightoftherodmustbe
multipliedinordertoobtainthemaximumaccelerationloadisgivenby:
p
g
y
= ag
Theaccelerationoftheloadinsimpleharmonicmotioncanbeconventionally
investigatedbyconsideringthebodytobeprojection(onthediameterofreference
circle)ofaparticlemovingwithuniformspeedaroundthereferencecircle.
)
p
g
p
IncaseofSRsystem,thediameterofthereferencecircleisequaltothepolishedrod
strokelength,andthetimeofonerevolutionoftheparticlearoundthecircleisequal
k l
h
d h i
f
l i
f h
i l
d h i l i
l
tothetimeforonecompletepumpingcycle.
April 30, 2010

Themaximumaccelerationtakesplaceatthebeginningoftheupstrokeandthe
beginning
beginningofdownstroke,i.e.whentheprojectionhasitsgreatestdisplacementfrom
of down stroke, i.e. when the projection has its greatest displacement from
thecenterofthereferencecircle.Therefore,theaccelerationcanbecalculatedfrom:
a =
v 2p
rc
where
vp is the velocity of the particle, and

rc is the radius of the circle.
Ifthetimeforonerevolutionoftheparticleist,then:
2 rc
t
v
andiftheNisthenumberofrevolutionperunittime,
April 30, 2010
= 2 rc N

SinceN=1/t,substitutingintopreviousequation:
v 2p
rc g
rc N
g
Forapumpingwell,Nisthepumpingspeed,and
Forapumpingwell,Nisthepumpingspeed,andrrc isrelatedtothepolishedrodstrokelength,S,
by:
2 2 SSN
rc = S / 2 , and =
g
Thepolishedrodstrokelengthisnormallystatedininchesandthepumpingspeedisgivenin
strokesperminute,then:
2 2 SN
=
32 . 2
April 30, 2010
in . /min
ft / sec
2
2
1 ft
1 min 2
12 in . 3600 sec
SN 2
=
70500
Example Problem 1:
Oneinchstrokerodsweigh2.88lb/ft.calculatethemaximumpolishedrodload
One
resultingfrom2000ftofone
resulting from 2000 ft of one
oneinchsuckerrodsifthepumpingspeedis18
inch sucker rods if the pumping speed is 18 spm (strokes
inchsuckerrodsifthepumpingspeedis18spm
(strokes
permin)andthepolishedrodstrokelengthis74in.
Solution:
Wr = 2.88 lb / ft 2000 ft = 5760 lb
= 74 182 / 70500 = 0.340

The maximum
ma im m Load = Weight of rods + accleration load
= 5760 + 5760 0.340 = 7720lb
April 30, 2010
2. The Effective Plunger Stroke

TheproducingvolumefromSRpumpsdependsnotonlyofthepolishedrodlengthbut
also
alsothemovementoftheplungerrelativetotheworkingbarrel.Thismovementis
the movement of the plunger relative to the working barrel. This movement is
calledthenetoreffectiveplungerstroke,anditmaydiffersignificantlyfromthe
polishedrodstroke.
Fundamentally,plungerandpolishedrodstrokesdifferbecauseofrodandtubing
p g
g
stretchandbecauseofplungerovertravelresultingfromacceleration.
AstheTVandSVopenandcloseduringthepumpingcycle,thefluidloadistransferred
alternativelytothetubingandtotherodstring.
lt
ti l t th t bi
d t th
d ti
Thisresultsinperiodicelasticdeformations(ofrodandtubing)whichareoutphase
This
results in periodic elastic deformations (of rod and tubing) which are out phase
witheachotherby180o.
Whiledownstroke,SVisclosedandTVisopen.Atthistimethefluidloadisonthe
.Incaseofupstroke,TVcloses,
tubing,causingacertainelongationofthatmember
tubing,causingacertainelongationofthatmember.Incaseofupstroke,TVcloses,
causingelongationoftherods.
g
g
April 30, 2010
The Effective Plunger Stroke

OpeningoftheSVallowsthestretchtocomeoutofthetubing.Restoration
ofthetubingtoitsoriginallengthcausingtheworkingbarreltomove
upward,andelongationoftherodscausestheplungertomovedownward.
Therefore, the effective plunger stroke is decreased by
an amount equal to the sum of rod and tubing
elongation resulting from fluid load.
Foranelasticdeformation,thereisaconstantratiobetweenthestress
appliedtoabodyandtheresultingstrain:
li d
b d
d h
li
i
E=Stress/Strain
EE,theelasticitymodulus,isacharacteristicofthematerialtowhichthe
h l i i
d l i
h
i i f h
i l
hi h h
stressisapplied.Stressisappliedforceperunitarea:
Stress=F/A
and strain is fractional change in length:
andstrainisfractionalchangeinlength:
Strain=e / l
April 30, 2010

Ife expressedininchandl infeet,so:
Strain=e / l
Th f
Therefore,E:
E
E=
The elongation of the member is:

Theelongationofthememberis:
F / A 12 FL
=
e / 12 L
eA
e=
12 FL
EA
Th
Theforceduetofluidloadresultsfromthepressuredifferentialacrossthe
f
d
fl id l d
l f
h
diff
i l
h
plungeractingoverthefullplungerarea,
plungeractingoverthefullplungerarea,A
Ap:
F=P Ap
Ifitisassumedthatthepumpissetattheworkingfluidlevelinthewell,the
pressure differential is the pressure at depth L in a column of fluid of specific
pressuredifferentialisthepressureatdepthLinacolumnoffluidofspecific
gravity:
P=0.433GL
April 30, 2010

ForthemoregeneralcasewhereworkingfluidlevelisatdepthD,thepressure
duetoacolumnoffluidofheight(LD)inthecasingmustbeconsidered:
duetoacolumnoffluidofheight(L
P=0.433GL0.433G(LD)=0.433GD
Therefore, e:
Therefore,e:
e=12 0.433GDAp L/EA=5.20GDAp L/EA
Itisperfectlygeneralequationforanymember,forthetubingcase:
et =5.20GDA
5.20 G D Ap L/EA
L / E At
WhereAt,isthecrosssectionalareaofthetubingwall.Fortherodstring:
er =5.20GDAp L/EAr
Where,Ar,isthecrosssectionaloftherods
April 30, 2010

Incaseoftaperedrodstring,thepreviousequationmustbeappliedto
each section i e :
eachsection,i.e.:
er1 =5.20GDA
5 20 G D Ap L1 /EA
/ E Ar1ande
d r2 =5.20GDA
5 20 G D Ap L2 /EA
/ E Ar2,etc
t
Where er1 is elongation of the L1 foot section of rods of cross
cross
sectional area Ar1, er2 is elongation of the L2 foot section of rods of
crosssectional area Ar2, .. etc
cross
etc.. then total rod stretch is
is::
er = (5.20GDAp / E ) L1 + L2 + ...
A2
A1
April 30, 2010
Rod Elongation by Rod Load

Inadditiontorodstretchcausedbyfluidload,rodelongationsalsoresultfromrod
load, which consists of the dead weight of a rods plus acceleration load.
load,whichconsistsofthedeadweightofarodsplusaccelerationload.
Foranuntaperedstring,theweightofrodssuspendedbelowanyelementofthe
Foranun
stringvariesuniformlyfromzeroatthebottomofthestringto
stringvariesuniformlyfromzeroatthebottomofthestringtoW
Wr atthetopofthe
string.
string
Ontheaverage,theweightofrodstendingtocauseelongationofanelementisW
Ontheaverage,theweightofrodstendingtocauseelongationofanelementisWr /
2.thisisequivalenttoL/2.inanyeventheelongationoftherodsattheendofthe
d
downstrokewillbe:
t k ill b
ed =
12(Wr + Wr )L / 2
EAr
Theelongationoftherodsattheendoftheupstrokewillbe:
eu =
April 30, 2010
12(Wr Wr )L / 2
EAr

Sincetheaccelerationloadswillbeinoppositedirections.Theplunger
overtravel,i.e.thenetelongationresultingfromacceleration,is:
,
g
g
,
e p = ed eu = 12WrL / EAr
Theweightoftherodstringis:
Wr = r LAr / 144
Wherer isthedensityoftherodstringinpoundspercubicfoot.Thedensity
Where
ofsteelisapproximately490lb/ft3,then:
12 L 490 LAr 40.8 L2
=
ep =
Unidiameterrod
144
EAr
E
Empirical for tapered rod:

Empiricalfortaperedrod:
April 30, 2010
32.8 L2
ep =
E

Theeffectiveplungerstrokeisnowseentobethepolishedrodstroke
decreased by the effects of rod and tubing stretch resulting from fluid
decreasedbytheeffectsofrodandtubingstretchresultingfromfluid
loadandincreasedbytheeffectofplungerovertravel.Thenthe
effective plunger stroke is:
effectiveplungerstrokeis:
S p = S + e p (et + er )
Combiningthepreviousequations,weget:
40.8 L2 5.20GDAp
Sp = S +
E
E
L L1 L2
+
+
+
...
At A1 A2
Incaseofanuntaperedrdstring,
40.8 L2 5.20GDAp L 1
1
+
Sp = S +
E
E
At Ar
April 30, 2010
3. Calculation of Polished Rod Loads

Theselectionofsurfaceequipmentforapumpinginstallationis
influenced to a great extent by the anticipated maximum or peak
influencedtoagreatextentbytheanticipatedmaximumorpeak
polishedrodload.
Theprimaryestimationofcounterbalancerequiredisbasedonthe
anticipatedmaximumandminimpolishedrodloads.Therefore,these
quantitiesmustbedeterminedinaccuratemanner.
titi
tb d t
i di
t
Th
Thereare5factorscontributetothenetpolishedrodload:
5f t
t ib t t th
t li h d d l d
1.
2.
3.
4.
5.
Fluid Load,
Dead weight of sucker rods,
Acceleration load of sucker rods,
Buoyancy force on sucker rods submerged in fluid, and
Frictional forces.
Anyothervibrational loadwillbeneglected.
April 30, 2010
Calculation of Polished Rod Loads

Theweightofataperedrodstringisgivenby:
Wr = M 1 L1 + M 2 L2 + M 3 L3 + ...
WhereM1 istheweight,inlb/ft,andL1 isthelength,infeet,ofsection1ofa
tapered
taperedstring,M
string M2 istheweightandL
is the weight and L2 isthelengthof
is the length of of section2..etc.
isthelengthofof
section 2 etc
Maximum acceleration load = Wr
Mi i
Minimum
acceleration
l
ti lload
d = -W
Wr
Rodvolume,orhevolumedisplacedbytherodiscalculatedas:
Volume=wt/ =Wr/490ft3
Byassumingthedisplacedfluiddensity(ofspecificgravityG)is62.4Glb/ft3,
thebuoyancyforceontherods:
Buoyancy force = (Wr / 490 )62.4G = 0.127Wr G
The ve
The
ve signbecausebuoyancyisupwardaction.
sign because buoyancy is upward action
April 30, 2010

Thefluidloadtobeusedincalculatingpolishedrodloadsistheweightsof
the
thefluidcolumnsupportedbytheplunger.Thevolumeofacolumnhavingas
fluid column supported by the plunger The volume of a column having as
itsbasetheplungerandasitsheighttheSRstringwouldbe:
Volume = LAp / 144 ft 3
Thevolumeoffluidisobtainedfrom:
Volume of Fluid = LAp / 144 (Wr / 490 )
Thenthefluidloadis:
W f = 62.4G LAp / 144 (Wr / 490 )

= 0.433G (LAp 0.294W r )
Itisnotedthatthefluidloadisonthepolishedrodonlyduringtheupstroke.
April 30, 2010

Thefrictionloadcannotbepredictedmathematically.Foraninstalledpump,
it
itcanbeestimatedfromdynamometertests.Fornewpumpdesign,sincethe
can be estimated from dynamometer tests For new pump design since the
frictionforcesactinadirectionoppositethedirectionofmotionofthebody,
frictionloadinupstrokeis+FandFonthedownstroke.
frictionloadinupstrokeis+Fand
Insummary,themaximumorpeakpolishedrodload,whichoccursonthe
upstrokeis:
Wmax = W f + Wr + Wr + F
The minimum polished rod load which occurs on the downstroke is
Theminimumpolishedrodload,whichoccursonthedownstrokeis:
Wmin = Wr Wr 0.127Wr G F
FFcanbeneglectedwithoutmuchlossintheaccuracy.
can be neglected without much loss in the accuracy
April 30, 2010
4. Design of the Sucker Rod String

TherearetwopossibleapproachestothedesignofataperedSRstring.
1 Lengthsofindividualsectionsmaybeselectedinsuchamannerastomake
1.
Lengths of individual sections may be selected in such a manner as to make
theunitstressatthetopofeachsectionthemaximumpermissibleworking
stress,or
2. Lengthsmaybeselectedsoastomaketheunitstressesatthetopsofthe
sectionsequal.(moregeneral)
Indeterminingthestressatanypointinarodstring,theforcecausingthe
stressisconsideredtoresultfromfluidloadontheplungerandweightof
rodsbelowthepointunderconsideration.
d b l
h
i
d
id
i
Assumptions:
1.
2.
3
3.
4.
Static conditions, i.e. no acceleration loads,

The specific gravity is 1,
The fluid load acts over the full plunger area,
area and
The pump is set at the working fluid level.
Undertheseconditionthefluidloadis0.433
Undertheseconditionthefluidloadis0.433LA
LAp pounds.
April 30, 2010
Design of Two-way Taper Rod

AtaperedrodsconsistsofL1ofcrosssectionalareaA1inin2,and
the weight M1 pounds per foot and L2 A2 and M2 for the second
theweightM1poundsperfoot,andL2,A2,andM2forthesecond
part.LetR1andR2asfollows:
R1 =L1/LandR2 =L2/L
Where L1+L2 =L,andstressatthetopofthelowersectionisthen:
WhereL
L and stress at the top of the lower section is then
0.433LAp + L1M 1
A1
0.433LAp + LR1M 1
A1
LIKEISE,THESTRESSATTHETOPOFTHEUPPERSECTIONIS:
0.433LAp + L1M 1 + L2 M 2
A2
0.433LAp + LR1M 1 + LR2 M 2

A2
Ifthestressesatthetopsofthesectionsareequals:
If the stresses at the tops of the sections are equals:
0.433 Ap + R1M 1
A1
April 30, 2010
0.433 Ap + R1M 1 + R2 M 2
A2
Forselectedrodandplungersizes,thelengthofeachsectioncanbe
determined by use the previous equation plus the fact that:
determinedbyusethepreviousequationplusthefactthat:
R1+R
R2 =1
1
Fortaperedstringconsistingofmorethantwosections,theequation
willbemorecomplex,forexamplefor4taperedsections:
0.433 Ap + R1M 1
A1
0.433 Ap + R1M 1 + R2 M 2 + R3 M 3 + R4 M 4
A4
And: R1+R2+R3+R4 =1
Incaseoftwo
Incaseoftwowaytaperconsistingof5/8
waytaperconsistingof5/8in(M1=1.16lb/ft)and
in(M1=1.16lb/ft)and
in(M2=1.63lb/ft)rodsyoucouldget:
(
/ )
R1 = 0.759 0.0896 Ap
R2 = 0.241 0.0896 Ap
April 30, 2010
5. Pump Displacement and Production Rate

Thetheoreticalpumpdisplacementcanbecalculatedas:
in
strokes 1440 min/day
N
stroke
min
9702in 3 /bbl
= 0.1484Ap S p N bbl / day
V = Ap in 2 S p
Foragivenplungerdiameter,theterm0.1484Ap isindependentof
Foragivenplungerdiameter,theterm0.1484A
surfaceoperatingconditionsandiscalledthepumpconstant,K,then:
V = KS p N
For API pumps there is Table for K of each pump size
ForAPIpumps,thereisTableforKofeachpumpsize.
Theratiobetweenthefluidactuallyhandledandthepump
displacementisthevolumetricefficiencyofthepump:
Ev = q
April 30, 2010
or
q = VE v
or
V = q
Ev
6. Counterbalance Design
Theprimaryfunctionofthecounterbalancesystemistostoreenergyonthe
downstroke,whenpolishedrodloadislow,andtoreleaseenergyonthe
upstroke,whenpolishedrodloadishigh,thusdistributingmoreuniformly
throughoutthepumpingcycle,theloadsandtorqueswhichmustbe
sustainedbytheprimemover.
Theoretically,theidealcounterbalanceeffect,Ci,wouldbesuchthatthe
Theoretically,theidealcounterbalanceeffect,Ci
,wouldbesuchthatthe
prime
primemoverwouldcarrythesameaverageloadsontheupstrokeandonthe
mover would carry the same average loads on the upstroke and on the
downstroke,thisis:
Wmax Ci = Ci Wmin
The ideal counterbalance effect is then:

Theidealcounterbalanceeffectisthen:
Ci = 0.5(Wmax + Wmin )
Substitutingandusingoneofthepreviousequations:
Ci = 0.5Wr + Wr (1 0.127G )
Fromthepreviousequation,itisseenthattheidealcounterbalanceeffect
balancesone
balancesonehalfthefluidloadplustheweightoftherodsinfluid.
April 30, 2010
Counterbalance Effect of the Counterweight
April 30, 2010
Counterbalance Design
Thefigureshowsthatthecounterbalanceeffect
ThefigureshowsthatthecounterbalanceeffectC
Cw duetoacounterweightofW
duetoacounterweightofWc pounds,
dependsonthegeometryofthepumpingunitandonthestrokelength,aswellasontheweight
andpositionofthecounterweight.
Atagiventime,
At
Atagiventime,
a given time, ,,
, ,,
, are
aretheanglesasshowninthefigure.
the angles as shown in the figure.
d:distancefromcrankshafttothecenterofgravityofthecounterweight.
r:distancefromcrankshafttopitmanbearing.
Fp:tensionforceinthepitman.
i f
i h i
Cw (l2 cos ) = (Fp cos )(l1 cos ) + (Fp sin )(l1 sin )
Fp =
Cwl2 cos
l1 (cos )(cos ) + (sin )(sin )
Taking moments about Point O:

TakingmomentsaboutPointO:
Wc (d sin ) = (Fp cos )(r sin ) + (Fp sin )(l1 cos )

Fp =
April 30, 2010
Wc d sin
r [(cos )(sin ) + (sin )(cos )]
Counterbalance Design
ThelasttwoFpequationsgivesarelationshipbetweenthe
counterweight and its resulting counterbalance effect
counterweightanditsresultingcounterbalanceeffect.
F i lif i
Forsimplifying,consider
id
0,andCos
0 dC
=1,so;
1
Cwl2 cos Wc d sin
i
or C w = Wc (d / r )(l1 / l2 )
=
r sin
l1 cos
Inadditiontotheeffectofcounterweights,somecounterbalance
effectmaybeprovidedbystructuralunbalanceofthesurface
installationitself.IfwecallthiseffectCs,thetotalcounterbalance
effect at the polished rod is:
effectatthepolishedrodis:
C = Cs + Wc (d / r )(l1 / l2 )
April 30, 2010
7. Calculation of Torque
AsshownintheFigure,ifthegeometryofthesurfaceinstallationisnotconsidered(i.e.
l1
l1 =l2)thepreviousreducesto:
l2) the previous reduces to:
C = 2Wc d / S
R=S/2.
ThetorqueTiscalculatedas:
Therefore:
T = Wr sin Wc d sin
and from previous eqn. : Wc d = CS / 2
T = W (S / 2 )sin C (S / 2)sin
Instantaneous torque
on the gear box
T = (W C )(S / 2 )sin
Thisequationisanapproximateexpressionforinstantaneoustorqueonthegearbox.
ThehighestpossiblevalueforvariableWandsin
ThehighestpossiblevalueforvariableWandsin
are,respectively,peakpolishedrod
load Wmax,andsin90(=1).Peaktorqueis,then:
load,W
load,
and sin 90 (=1) Peak torque is then:
Tp = (Wmax C )(S / 2)
April 30, 2010
8. Speed Reduction from Prime Mover to Crankshaft

Poweristransmittedfromtheenginesheave,ofdiameterde,tounitsheave,of
diameterd
diameter du,,bymeansofV
by means of V
Vbelts.IfthespeedoftheprimemoverengineisN
belts. If the speed of the prime mover engine is Ne
revolutionsperminute,thebeltvelocityis:
vb = d e N e in / min
Andthespeedoftheunitsheaveis:
N u = vb /d u = N e (d e / d u ) rpm
IfthegearratioatthegearreducerisZ,pumpingspeedis:
If the gear ratio at the gear reducer is Z pumping speed is:
N = N u / Z = N e d e / Zd u
April 30, 2010
9. Power Requirements of the Prime Mover

Therearetwopowerloadsmustbeconsideredinmovingfluidfrompumpto
surface:
1. HydraulicHorsepower,Hh,and
2. FrictionHorsepower,Hf.
HydraulicHorsepowerH
HydraulicHorsepower
Hh:
Hh =
q bbl/day 350G lb/bbl L ft

= 7.36 10 6 qGL hp
1440 min/day 33000 ft lb/min/hp
FrictionHorsepower,H
Friction Horsepower Hf.
Itisthefractionalenergylossbetweenpumpandpolishedrod.TheEmpirical
formulausedis:
Hf =
0.25Wr SN in lb/min
lb/
= 6.3110 7 Wr SN hp
12 in/ft 33000 ft lb/min/hp
Thetotalhorsepoweristhesumofthepreviousequations.Consideringasafety
factor,then:
H b = 1.5(H h + H f )
April 30, 2010
April 30, 2010
A tifi i l Lift M
Artificial
Methods
th d
Dr.Eng.AdelSalem
S
SuezCanalUniversity
C
lU i
i
Egypt
Lecture Nr. 13
III. Jet Pumps

III
IV PCP Pumps
IV.
Agenda:
4.JetandPCPpumps
4 1 Jet Pump
4.1.JetPump:
Main Components and Operating Mechanisms,
Pump Types,
Types
Performance Curves and Pump Selection,
Required Power Fluid Rate,
Rate
Surface Pressure and Horse Power,
Design of a Jet Pump System.
System
4.2.PCP:
Surface and Sub
Sub-surface
surface Equipment of PCP,
Top drive PCP, Bottom Drive PCP,
Performance curve and p
power requirement.
q
April 30, 2010
Outlines
1. Jetpump:
Maincomponentsandoperatingmechanisms,pump
types,performancecurvesandpumpselectionrequired
powerfluidrate,surfacepressureandhorsepower
2. PCP:
Surface and subsurface equipment top drive PCP
Surfaceandsubsurfaceequipment,topdrivePCP,
bottomdrivePCPandpowerrequirement
April 30, 2010
Pump
Classifications
April 30, 2010
April 30, 2010
Jet Pump: Introduction

The jet pump converts the power fluid received to a high velocity jet
then mixes it with well fluids where enough energy is exchanged to
allow
ll
th return
the
t
off both
b th fluids
fl id to
t surface
surface.
f
.
Th jet
The
j t pump has
h
no moving
i
components
t so maximum
i
production capacities are defined for a given combination of
throat and nozzle
nozzle.. Cavitation p
phenomena caused by
y extremely
y
high flow rates through the annular area of the throat limits
production rate
rate.. Design relationships in the jet pump section of
thi manuall review
this
i
parameters
t
which
hi h better
b tt identify
id tif capacities
iti
and limitations
April 30, 2010
Overview of Jet Pump Operation

Casing
g free installations offer the simplest
p
design
g for review of jet
j
pump operation. The pumping action is achieved through the
energy transfer from the power fluid to the well fluids.
fluids.
High-pressure power fluid passes through a nozzle where its
Highpotential energy
p
gy (p
(pressure)) is converted to kinetic energy
gy in
the form of a high velocity jet stream. Well fluids surround the
exit of the nozzle to intermix with the jet stream in the mixing tube
called
ll d the
th throat.
th
t Th
The momentum
t
off th
the power fl
fluid
id iis ttransferred
f
d
to the well fluids.
The mixture then passes through an expanding area called a
diffuser to convert the mixture kinetic energy to static pressure
by
b slowing
l i d
down the
th fl
fluid
id th
through
h th
the iincrease iin fl
flow area. Th
The
pressure of the mixture must be sufficient to reach the surface.
April 30, 2010
Jet Pump Principle
Performance Characteristics :
Lift capacity of the jet pump is dependant on throat and nozzle
dimensions and the ratio of areas between them. Larger throat
and nozzles have higher flow capacities.
capacities The ratio of nozzle area
to throat area determines relationship between pressure and
flow rate.
April 30, 2010
Jet Pump Application Range
April 30, 2010
Advantage of Jet Pump
April 30, 2010
April 30, 2010
April 30, 2010
Th N
The
New 165 T Surface
S rf
Unit
April 30, 2010
Th N
The
New 165 T Surface
S rf
Unit
April 30, 2010
200 T - 5 Surface
S rf
Unit S
Service
r i In
South DABAA Pet. Co.
April 30, 2010
200 T - 5 Jumbo
J mb V
Vessell M
Manufactured
n f t r dB
By
EGY OTS Service In South DABAA Pet. Co.
April 30, 2010
300 Q 5 H Surface Unit Service In

East Zeit Pet. Co.
April 30, 2010
EGY OTS Team Prepare The

h Pump To operate In The
h Platform
l f
April 30, 2010
300 Q 5 M Surface
S f
U
Unit
i P
Purchased
h dB
By
South DABAA Pet. Co.
April 30, 2010
April 30, 2010
April 30, 2010
Free Style
y Jet Pumpp
April 30, 2010
CConventionall Fl
Flow SSD
Jet Pump
April 30, 2010
Reverse Flow SSD Jet

J
Pump
April 30, 2010
Hydraulic Jet Pumps

P iti ffeatures
Positive
t
N
Negative
ti ffeatures
t
Simple to vary rate
Relatively inefficient lift method
Retrievable without pulling tubing
Design of system is more complex.
No problems in deviated or crooked holes
Pump may cavitate under certain

conditions.
Has no moving parts
Power oil systems are fire hazard
Unobtrusive in urban locations.
g in back
Veryy sensitive to anyy change
pressure
Applicable offshore.
The producing of free gas through

the
h pump causes reduction
d i in
i ability
bili to
handle liquids
Can use water as a power source

Corrosion scale emulsion treatment
easy to perform
perform.
April 30, 2010
Jet Pump Design

TheparameterrepresentedonFigurebelowarethefollowing:
P1
P2
P3
Aj
As
At
q1
q2
V
Powerfluidpressure
Dischargepressure
=Pwf intakepressure
Nozzle area
Nozzlearea
Netthroatarea
Totalthroatarea
Powerfluidrate
Totalliquidrateinreturncolumn
Intakevolume.
April 30, 2010
Jet Pumpp Design

g
Dimensionlessarea:
The ratio R of the nozzle area to the total area of the throat is called the area
TheratioRofthenozzleareatothetotalareaofthethroatiscalledthearea
ratio,
Di
Dimensionlessflowrate:
i l
fl
t
Where:
V: Volume of the produced fluid rate (Liquid + gas).
q1: : Power fluid rate.
Whenpumpingslightlycompressiblefluidssuchasliquids,Vcanbeconsidered
constant and equal to the surface rate
constantandequaltothesurfacerate.
April 30, 2010
Dimensionlesshead:
The dimensionless head (H) is defined as the ratio of the pressure increase
Thedimensionlesshead(H)isdefinedastheratioofthepressureincrease
experiencedbytheproductionfluidtothepressurelosssufferedbythepower
fluid:
Where:
P1
Powerfluidpressure
P2
Dischargepressure'
P3
Intakepressure
April 30, 2010
The parameters represented on are

are:
P1
P2
P3
Ps
Pwhh
q1
q2
V
April 30, 2010
Power fluid pressure

Discharge pressure'
=Pwf intake pressure
Surface operating pressure
wellhead pressure
Power fluid rate
Total
ota liquid
qu d rate
ate in p
production
oduct o
tubing
Intake volume.
Pump Efficiency
Efficiency:
In pumping liquid the efficiency is
Inpumpingliquid,theefficiencyis:
Therefore,itdependsofvariousparameters:
Geometry(shapesdefinedbythemanufacturers),
Geometry (shapes defined by the manufacturers),
Typeoffluid:powerandpumped,and
Flowrate,pressures.
o a e, p essu es
Eachmanufacturerproposesformulascorrespondingto,theirequipments.
April 30, 2010
Dimensionless Performance Curve

AnexampleoftheseequationresultsshowingHandp versusMfor
several values of R is represented in the following Figure (next slide)
severalvaluesofRisrepresentedinthefollowingFigure(nextslide).
Itisgoodfieldpracticetoattempttooperatethepumpatitspeak
It
i
d fi ld
ti t tt
tt
t th
t it
k
efficiency.Inthatcase,theMandHratioswillbefixed;hence:
WhereMp andHparethepeakefficiencyflowratioandthepeak
efficiencyheadratiorespectively.
ffi i
h d ti
ti l
April 30, 2010
Dimensionless Performance Curve
April 30, 2010
Power Fluid and Pressure

Similar to hydraulic pumps, Jet pumps utilize either water or oil as a power
fluid The actual power fluid rate is a function of the pressures P1 and P2 of
fluid.
the flow area of the nozzle Aj, and of the specific gravity of the power fluid 1
.When everything is measured in common oilfield units, the power fluid rate
can be estimated from the following equation:
where
h
q1 fluid fate, bpd
P1 and P3 pressures,
pressures psi
Aj nozzle area, in2.
Innormaloperations,thesurfaceoperatingpressureshouldnotexceed4000
ps o 8
psior28MPa.
a
April 30, 2010
Input Power
Inputpower
The input power requirement is estimated from the following equations:
April 30, 2010
Progressing
i
C
Cavity
it
Pump
April 30, 2010
Global PC Pump Market by Region
U. S. A.
Europe
Africa
Asia
Pacific
ME/CIS
Canada
South
America
April 30, 2010
Typical PC Pump System

Surface drive
Sucker rod or continuous rod
Progressing Cavity Pump
Surface Drive
Casing
Production Tubing
Sucker Rod
Sucker Rod
Coupling
Tubing Collar
Stator
St t connected
t d to
t tubing
t bi
Rotor connected to rod string
Stator
Accessory equipment
Rotor
Tubing Collar
Tag Bar Sub
April 30, 2010
Typical PC Pump
Stator
Double helix geometry
Elastomer
Stationary, attached to tubing
Rotor
S
Single
g e helix
e geo
geometry
e y
Hardened
otates, attached
attac ed to rod
od
Rotates,
string
April 30, 2010
PC Pump Surface Drives

Supplies rotation and torque to downhole
PC pump by
b suspending
di
and
d rotating
i
ad
drive
i
string.
The drive string is typically made up of
conventional or Corod continuous sucker rods.
Configurations available:
Direct electric motor drives
Direct gearbox drives that may be coupled
to an electric motor or gas engine
Hydraulic drive systems for both gas and
electric applications
April 30, 2010
PC Pump Applications
Surface Drive
HeavyOilandBitumen(lessthan12API)with
sandcutsupto50%.
MediumOil(from12to23API)withlimited
H2Scontent.
Casing
SweetLightOil(over24API)withlimited
aromaticscontent.
Production Tubing
DewateringCoalbed Methane.
Sucker Rod
WaterSourceWells.
Sucker Rod
Coupling
Evaluationandtestingofnewareas.
Tubing Collar
Stator
Rotor
Tubing
g Collar
April 30, 2010
Tag Bar Sub

PC Pump System Advantages

High System Efficiency (to 85% w/o gas)
Tolerant
l
off solids
lid (50%
( 0% sand
d slugs)
l
)
Multiphase pumping: oil, water, solids, gas
Low Power Consumption
Low Capital Cost
Low Maintenance Costs
g Sensitive Areas
Low Surface Profile for Visual and Height
Simple Installation, Quiet Operation
Portable Surface Equipment
Horizontal/Directional Wells
April 30, 2010
PC Pump System Limitations

Depths to 11,000 feet (3,400 M)1
Volumes
l
to 4,000
000 BPD (635
(63 M3/day)
/d )1
Temperatures
To 300
T
300F
F (150
(150C)
C) iin oil
il
To 185F (85C) in water
Aromatics and some produced fluids

Low volumetric efficiencies in high-gas environments
Potential tubing and rod coupling wear in deviated wells
(guides or Corod required)
R
Requires
i
Constant
C
t t Fluid
Fl id Level
L
l above
b
Pump
P
_________________
1Depth
and volume limited by drive system torque.

torque
April 30, 2010
System Application Considerations
Operating Depth
Operating Volume
Operating Temp
System Efficiency
TYPICAL
MAXIMUM2
2,000 - 4,500 TVD

600 1,400 m TVD
11,000 TVD
3,440 m TVD
5 2,200 BPD
1 350 m3/day
Over 4,000 BPD

Over 635 m3/day
75 185 F
24 85 C
300 F
150 C
60% to 80%
Prime Mover Type
85%
Electric Motor or Internal Combustion Engine
Solids Handling
Excellent
Gas Handling
Good
Fluid Gravity
Below 45 API
Wellbore Deviation
N/A
Offshore
Good footprint, SSSV issues, surface sand handling
Special Analysis Required

Servicing & Repair
2
April 30, 2010
Build Angle < 15/100 ft (15/30m)
Requires Workover or Pulling Rig
PC Pump Systems
Wellhead Surface Drives
Continuous & Threaded
S k Rods
Sucker
R d
Subsurface PC Pumps
& Accessories
April 30, 2010
Application Guide for Typical Elastomers

NBRM
NBRA
HNBR
FKM
Hardness (Shore A)
65
72
72
72
ACN Content (%)
33
44
42
N/A
Maximum Temp (F)
195
210
300
340
Service Temp (F)
175
190
265
300
Mechanical Resistance
++
++
++
Abrasion Resistance
++
++
Carbon Dioxide
++
Hydrogen Sulfide
++
Aromatics Resistance
++
+++
Hot Water
++
Steam
Heavy crudes with

low contents of
aromatics on
presence of
abrasives.
Light and medium

crudes (26<API <40
) with high aromatics
content.
APPLICATION
Legend:
April 30, 2010
+++ Excellent
++ Very Good
Heavy or medium
crudes (with low
aromatics) under high
temperature on
presence of H2S.
+ Good
- Poor
Typically not
recommended due to
very poor mechanical
properties.
N/A= Not Applicable
PC Pump Technology
Elastomer Benchmarking
Tensile Strength
Elongation
Tear Strength
3500
700
140
3000
600
120
2500
500
100
2000
400
80
1500
300
60
1000
200
40
500
100
20
WFD 59O
Artemis
NO80
Geremia
NBR-M
Kachele 366
Mono A
Moyno 102
Netzsch
NBR01
WFD 59O
Artemis
NO80
Water Swell
Geremia
NBR-M
Kachele 366
Mono A
Moyno 102
Netzsch
NBR01
W A
WFD 59O
903 Oil Swell
35
16
30
14
Artemis
NO80
Geremia
NBR-M
Kachele 366
Mono A
Moyno 102
Netzsch
NBR01
Abrasion
Resistance
Abrasive Wear
200
180
160
12
25
140
10
120
20
100
8
15
80
60
10
4
40
5
WFD 59O
Artemis NO80
Geremia
NBR-M
Kachele 366
April 30, 2010
Mono A
Moyno 102
Netzsch
NBR01
20
WFD 59O
Artemis NO80
Geremia
NBR-M
Kachele 366
Mono A
Moyno 102
Netzsch
NBR01
W A
WFD 59O
Artemis
NO80
Geremia
NBR-M
Kachele 366
Mono A
Moyno 102
Netzsch
NBR01
PC Pump
p Technology
gy
Elastomer Analysis
12 endurance test benches, 1 slurry test bench

Numerous performance test benches, 3 for oils
Chemical analysis
3-D nonlinear finite element elastomer modeling for
temperature, stress, and deflection.
April 30, 2010
Subsurface PC Pumps
Sizefrom6BPD/100rpmto1100BPD/100rpm
/
p
/
p
Liftcapacityto12000feetofequivalentcolumnof
water
Pumpsengineeredforspecificapplications
Fluid compatibility Geometry and fit
FluidcompatibilityGeometryandfit
April 30, 2010
Uniform Thickness Pumps

Improved heat dissipation
Improvedheatdissipation
Uniformelastomer swell
Uniformthermalexpansion
Widerapplicability
Higherpressurerating
Model available with displacement
Modelavailablewithdisplacement
capacitiesfrom60to660BFPD@100RPM
Liftcapacityupto9200feetof
equivalentcolumnofwater
q
April 30, 2010
Insert PC Pumps
Twosettingdesigns:CloverleafandArrowhead
ReducedowntimeandcostrelatedtopullingatubularPCP.
d
d
i
d
l d
lli
b l
C
OnlypieceoftheequipmentinthetubingstringisthePumpSeatingNipple
(PSN).
(PSN)
PSNislocatedatthetoptoavoidsandbuildupbetweenpumpandtubing.
Allow change of capacity/lift of pump without a work over rig No Turn tool
Allowchangeofcapacity/liftofpumpwithoutaworkoverrig.NoTurntool
includedintheconfiguration
April 30, 2010
Surface Drives
Sizesfrom5Hpto250Hp
Varietyofdriveconfigurations
i
fd i
fi
i
Direct/belt
Gear
Hydraulic remote
Integral hydraulic motor
Compactandefficient,lowprofile
HingedBeltGuards
PatentedHollowShaftDesign
StandardWellheadConnections
Recoilspeedadjustmentandtestfeatures
Hydraulicandcentrifugalbrakesystems
Removablestuffingboxes
April 30, 2010
Horizontal Downhole Gas Separator

TheVSlotautomaticallyorientsthetooltothelowsideofthewellbore.
Heavierliquidsentertheseparatorwhilelightergaspassesabovethe
separator.
April 30, 2010
PROGRESSING CAVITY PUMPING (PCP)

Theuseofprogressingcavitypumpsisbecomingthepreferredmethod
of artificial lift in areas having high solids
ofartificialliftinareashavinghigh
solids,heavy
heavy API oil
oil,andhigh
and high
volumes.
volumes
Over50,000wellsworldwidearenowusingPCPforthesedemanding
applications.
applications
Duringoperation,severalfactorscaninhibitthePCPpumpfrom
During
operation several factors can inhibit the PCP pump from
performingoptimally.Varyinginletproductionrates,PCPpumpwear,
and clogged inlet screens can each mask themselves as other problems.
andcloggedinletscreenscaneachmaskthemselvesasotherproblems.
Withoutthecorrectoptimizationsolution,itisverydifficulttodiagnose
currentproblemsandnearlyimpossibletoperformpredictiveanalysis.
April 30, 2010
PCP Pumps of NETZSCH

PCPartificialliftpumpsareidealforshallowtomediumdepthwells
with fluid volumes between 1 bpd and 2200 bpd
withfluidvolumesbetween1bpdand2200bpd.
Thesepumpsefficientlyhandleheavyviscous
Th
ffi i tl h dl h
i
oilandfluidswithahigh
il d fl id ith hi h
contentofsand,gas andwater.Awiderangeofelastomers are
available for various applications
availableforvariousapplications.
1. Higherpumpefficienciesresultsinpowersavings
1
Higher pump efficiencies results in power savings
2. Efficienthandlingofawiderangeoffluids
3 Novalvestogaslock
3.
N
l
t
l k
4. Loweroperatingcosts
5. Resistanttodamage
6. Flowratesto:4000b/d
7. Pressuresto:3400PSI
April 30, 2010
8. Installationdepthto:6700ft
WELLSITE INTELLIGENCE WITH THE PCP SOLUTION

ThePCPsolutionusestheWeatherfordVFD,avectorfluxdrive(VFD)that
provides infinite speed control with constant torque control throughout
providesinfinitespeedcontrolwithconstanttorquecontrolthroughout
thespeedrange.TheVFDcanbeusedbyitselforcoupledwithdownhole
gaugesformoredefinedcontrol.Anintelligentremoteterminalunit
(
(RTU)canadddataloggingcapabilityforfinerresolutionindatacapture.
)
gg g p
y
p
VectorFluxDrive(VFD)
W th f d' PCP l ti
Weatherford'sPCPsolutionusestheWeatherfordvectorfluxdrive(VFD)
th W th f d
t fl d i (VFD)
thatprovidesinfinitespeedcontrolwithconstanttorquecontrol
throughoutthespeedrange.
TheVFDprovidesasystemthatoffersequipmentprotectionwhile
operatingindynamicconditionssuchaswaterfloodsorhighsandcut.
TheVFDconstantlymonitorstherodstringtorqueandautomatically
adjuststhepoweroutputtoensurethesystemdoesnotexceeduserset
limits.Internalprogrammingmakesonlinedecisionstosafelyhandle
accumulationsofsolidsintheproducedfluids,suddenwaterslugs,and
l ti
f lid i th
d d fl id
dd
t l
d
othershorttermconditionswheretheoperatordoesnotwantthewell
toshutdown.
April 30, 2010
VFD
TheVFDprovidesthefollowingbenefits:
1.
2.
3.
4.
Totalspeedcontrol
Totaltorquecontrol
IntegralRTU
Specificprogrammingforliftapplication
DownholeSensors
Weatherford'ssdownholesensorsprovidereliablepressureandtemperaturereadings.
Weatherford
downhole sensors provide reliable pressure and temperature readings
AllofWeatherford'ssensorsaremanufacturedwiththehighestqualitystandardsto
assurestabilityandlongevityintheharshdownholeenvironment.Theuseofhigh
pressuremetaltometalsealsandelastomer
l
l
l
d l
b k
backupassureslongtermreliability.The
l
li bili Th
sensorsarebuiltwithcompactdesignstofitmostapplicationsincludingslimholes.The
sensorsofferhighlevelaccuracyinacostefficientdesign.
April 30, 2010
SAM PCP Progressive Cavity Pump Controller

TheLufkinSAMProgressiveCavityPump(PCP)
Controller works in conjunction with a variablespeed
Controllerworksinconjunctionwitha
variable speed
drive(VSD) tooptimizefluidproductionwhile
protectingthepump. Thepatentedcontrolalgorithm
variesthespeedofthepumpwhilemeasuringthe
amountoffluidproductionfromthepump.
Thecontrollerrampsupthepumpspeedinuser
defined steps, measuring production rate at each step
definedsteps,measuringproductionrateateachstep
andestablishingaspeed/raterelationship.Atthepoint
thatastepincreaseinspeeddoesnotproducethe
proportionalstepincreaseinfluidproductionrate,the
controllerstartstoslowthespeedbystepsuntila
reduction in fluid production rate is measured The
reductioninfluidproductionrateismeasured.
The
controlalgorithmcontinuestotesttheoptimum
productionratebyrepeatingthespeed
increase/decreasesequence.
/
April 30, 2010
New Technology
The resulting high torque and friction losses, as well as the tubing and rod
failure can be reduced by placing the motor downhole this is known as a
Progressing Cavity Electric Submersible Pump.
Pump.
Secondly,lowcostreplacementofthePCPunitcanbeachievedby
makingitwirelineretrievable.
g
April 30, 2010
The Progressing Cavity Electric Submersible Pump (PCESP)

ThePCESPsharethesameelectricmotor,seal,cableandcontrol
technologyasthe
technology as the
conventional
conventionalElectricSubmersiblePumps(ESP).Themajordifferenceis
Electric Submersible Pumps (ESP) The major difference is
thatagearboxisrequiredtoreducethespeedofrotationsincethe
centrifugalpumpemployedwithaconventionalESPisahigh
g p p
p y
g speed
p
centrifugalpumpemployedwithaconventionalESPisahigh
device;whileaPCPisalowspeeddevice.Thelayoutofthetwopump
typesiscomparedinthefigurebelow.
April 30, 2010
Comparison between ESP and PCESP
April 30, 2010
April 30, 2010
NG Eng. Production II_ Dr. Adel

Salem
137
A tifi i l Lift M
Artificial
Methods
th d
Dr.Eng.AdelSalem
S
SuezCanalUniversity
C
lU i
i
Egypt
Lecture Nr. 14
V. ESP Pumps
Electrical Submersible Pumps
5.1. ESP
Basic Components,
Pump Design and Construction, and
Pump Performance, Pump Intakes
5 2 ESP
5.2.
Pump Sizing, Application,
Seal Section & Cable Selection, and
Voltage Drop Calculations.
5.3. ESP
Fixed Speed Drive Transformers,
Transformers Variable Speed Drive
Drive,
Motor Pump Performance at Different Speed Frequencies, and
AMP Charts, and Failure Analysis and Troubleshooting.
II. Comparison and Selectivity of Artificial Lifting

Types
Types
April 30, 2010
Outlines
1. Introduction, General Hydraulics,
2. Hydraulic Pumps,
3. Centrifugal Pumps Fundamental,
4. Electrical Submersible Pump Equipment
Description
p
and Function,,
5. ESP Running & Pulling Procedures, and ESP
Application
6. ESP Design and Selection,
7 ESP Troubleshooting,
7.
Troubleshooting and
II.ComparisonandSelectivityofArtificialLiftingTypes
II.
ComparisonandSelectivityofArtificialLiftingTypes
April 30, 2010
ESP Systems: Introduction

About15to20percentofalmostonemillionwellsworldwidearepumpedwithsomeform
ofartificialliftemployingelectricsubmersiblepumps.Inaddition,ESPsystemsarethe
p y g
p p
,
y
fastestgrowingformofartificialliftpumpingtechnology.Theyareoftenconsideredhigh
volumeanddepthchampionsamongoilfieldliftsystems.
Foundinoperatingenvironmentsallovertheworld,ESPsareveryversatile.Theycan
handleawiderangeofflowratesfrom70bpdto64,000
handleawiderangeofflowratesfrom70
bpdto64,000bpdormoreandliftrequirements
ffromvirtuallyzerotoasmuchas15,000
fromvirtuallyzerotoasmuchas15,000
i t ll
t
h 15 000ftoflift.Asarule,ESPshavelowerefficiencies
ft f lift A
l ESP h
l
ffi i i
withsignificantfractionsofgas,typicallygreaterthanabout10percentvolumeatthe
pumpintake.Giventheirhighrotationalspeedofupto4000
pumpintake.Giventheirhighrotationalspeedofupto4000rpmandtightclearances,
th
theyarealsoonlymoderatelytolerantofsolidslikesand.
l
l
d t l t l
t f lid lik
d
Ifsolidladenproductionflowsareexpected,specialrunningproceduresandpump
Ifsolid
p
p
, p
gp
p p
placementtechniquesareusuallyemployed.Whenverylargeamountsoffreegasare
present,downholegasseparatorsand/orgascompressorsmayberequiredinlieuofa
standard
standardpumpintake.
pump intake.
April 30, 2010
Introduction
ESPsystemscanbeusedincasingassmallas4.5
ESPsystemscanbeusedincasingassmallas4.5inoutsidediameterandcan
beengineeredtohandlecontaminantscommonlyfoundinoil
be engineered to handle contaminants commonly found in oil
beengineeredtohandlecontaminantscommonlyfoundinoil
oilaggressive
aggressive
corrosivefluidssuchasH2SandCO2,abrasivecontaminantssuchassand,
exceptionallyhighdownholetemperaturesandhighlevelsofgasproduction.
Increasingwatercuthasbeenshowntohavenosignificantdetrimental
effectonESPperformance.
ESPshavebeendeployedinvertical,deviatedandhorizontalwells,butthey
should
shouldbelocatedinastraightsectionofcasingforoptimumrunlife
be located in a straight section of casing for optimum run life
performance.
Onacostper
Onacost
perbarrelbasis,ESPsareconsideredeconomicalandefficient.
Withonlythewellheadandfixedorvariablespeedcontrollervisibleatthe
Withonlythewellheadandfixedorvariable
surface,ESPsystemsofferasmallfootprintandlow
surface,ESPsystemsofferasmallfootprintandlow
f
ESP
ff
ll f
i
d l profileoptionfor
fil
i f
virtuallyallapplications,includingoffshoreinstallations.Table1providesa
summaryofESPartificialliftapplications.
su
a y o S a t c a t app cat o s
April 30, 2010
ESP Application Range

Rate: 100
100--100,000 BPD
Power: 1010-1500 HP
Pressure: Up to 10,000 psi
Size: 4
4--1/2 and Larger Casing
4000 volts
lt
140 amps
April 30, 2010
ESP Artificial Lift Application
April 30, 2010
ESP System
InESPsystems,anelectricmotoranda
multistagecentrifugalpumprunona
productionstring,connectedbacktoa
surfacecontrolmechanismandtransformer
viaanelectricpowercable.
Carefulconsiderationmustbegiventoeach
p
downholeandsurfacecomponentofthe
systeminthedesignstage.
AnESPcanpumpintermittentlyor
An
ESP can pump intermittently or
continuously.BecauseanESPcanbeeasily
adaptedtoautomationandcontrolsystems,
numerous surface control and
numeroussurfacecontroland
communicationdevicesareavailable.
Additionally,thedownholecomponentscan
Additionally
the downhole components can
varydependingonthespecificapplicationor
conditions.
April 30, 2010
ESP Basic Components

ESPsareroutinelyusedonshoreand
f
forplatformwells.
l tf
ll
Theyareaversatileformof
They
are a versatile form of
pumping,especiallywherehighrates
arerequired.
Thebasicarrangementforatubing
deployedESPisshowninbeside
Figurewithapumpstage(impeller
and diffuser) shown in Figure as
anddiffuser)showninFigureas
well.
April 30, 2010
Downhole and Surface Components

SubsurfaceequipmentsofESPare:
1. Multistage Centrifugal Pump,
2. Motor,
3 Gas
3.
G S
Separator,
t
4. Seal Section, and
5 P
5.
Power C
Cable.
bl
6. etc
SurfaceComponents:
1 Tubing Head
1.
Head,
2. Fixed or Variable Speed Controllers and Drives,
3 Transformers
3.
Transformers, and
4. Electrical Supply System.
5. etc
April 30, 2010
Subsurface Equipments
Motors:
PUMP
Themotoristhedrivingforceprimemover)whichturns
p p
g y
thepumps.Themotorsarefilledwithahighlyrefined
mineraloilthatmustprovidedielectricstrength,
lubricationforbearings,andgoodthermalconductivity.
INTAKE
Thethrustbearingofthemotorcariestheloadofthe
motorsrotors.Thenonconductiveoilinthemotor
housinglubricatesthemotorbearingsandtransferthe
heatgeneratedinthemotortothemotorhousing.
PROTECTOR
Themotorsnormallyconsistsofalowcarbonsteel
housingandbrasslaminationspressedinside.The
motoraremadeupofrotorsthataremountedona
shaftandlocatedintheelectricalcoilsstators)mounted
withinthesteelmotorhousing.
April 30, 2010
MOTOR
The Motor
THRUST BEARING
Themotorisbasicallymadeupof
y
p
twoparts:
Stator ( Stationary part ),
and
R t (R
Rotor
Rotating
t ti partt )
THRUST RUNNER
MOTOR HEAD
MOTOR LEADS
END COIL
STATOR LAMS
ROTOR
ROTOR BEARING
BRASS LAMS
SHAFT
April 30, 2010
Rotor and Stator

The stator is composed of
9 Housing
g
Housing
Lamination
9 Laminations
9 Windings
The Housing forms the cover for the

motor and is threaded at both ends for
Stator
Wi di
Windings
head and base components.

April 30, 2010
Motor Housing
The housing can be of five different
diameters
3.75 = 375 series
4.56 = 456 series
5.40 = 540 series
55.62
62 = 562 series
7.38 = 738 series
April 30, 2010
Laminations
Laminations are thin sheets of
die-punched
die
punched from steel or
bronze material.
Laminations
April 30, 2010
Motor Stator (Winding)

The image part with relationship ID rId3 was not found in the file.
The windings are made from either

Polyimid or PEEK insulated magnet wires
Primary functions is to energize the

magnetic force around the laminations
Windings
April 30, 2010
St t Lam
Stator
L
Housing
Shaft
Rotor
bar
Windingg
April 30, 2010
Flux
Line
Motor Stator Winding
The stator is hand wound by

experienced craftsmen.
Customized to individual
order
Windings
April 30, 2010
Motor - Rotor
Stator
The rotor is a device

that rotates inside of the
stator core and is keyed Rotor
to the shaft
Shaft
April 30, 2010
Motor - Components
Copper Bar
Th rotor is
The
i made
d up
Rotor
Lam
Rotor laminations that are

smaller in diameter from the
stator laminations
Copper bars with supporting

copper end rings.
April 30, 2010
End Rings
540
562
Rotor Laminations and Rotor Bars in

various
i
designs
d i
April 30, 2010
Motor Rotor Bearing
Rotor Bearings are one of the most

vital parts of the motor.
April 30, 2010
Rotor Bearing
g
The main p
purpose
p
is to
provide the axial and radial
support to the shaft and rotors
April 30, 2010
Motor Rotor Bearing
Not only does its provide axial and

radial support
support, its has fluid holes to
insure oil circulation and to
distribute lubrication evenly over
the entire length of the bearing
surface.
Fluid hole
April 30, 2010
Motor Rotor Bearing
The bearing sleeve (rotating), is a

bronze material construction, is keyed
to the shaft and the hole on the sleeve
is aligned with the hole on the shaft to
insure proper cooling and lubrication.
April 30, 2010
Motor Thrust Bearing
The motor thrust bearing is installed at

the top of the rotor string. It is designed
to hold the weight of the entire rotor
string.
April 30, 2010
Motor - Components
April 30, 2010
Motor - Components
The thrust bearing can be made of either

a standard glacier type or a high load
KMC type of construction.
April 30, 2010
Motor Thrust Bearing
The selection of thrust bearings

g is limited to load
on the selected bearing material, surface area and
temperature rating
1.
Babbitt, fixed pad Thrust Bearing
2.
pad Thrust
All Bronze, fixed p
Bearing
3.
Peek Coated, tilting pad Thrust

Bearing
i
April 30, 2010
Motor-Pothead
The last main component of the motor to
discuss is the Pothead connection.
April 30, 2010
Motor - Pothead
REDA p
production systems
y
mainly
y
use tape
tape-in type potheads versus the
plugplug
-in type pothead to connect the
motor lead to the motor
April 30, 2010
Protectors Or Seal Section

Protectorispositionedbetweenintake/GSand
motor.ItservesasavitallinkintheentireESP
system.
Thesealsectionortheprotectorperformsthe
followingbasicfunctions:
1. Connectsthepumpshousingtothemotor
housingandthedriveshaftsofeach.
2. Housesthepumpthrustbearingtocarrythe
Houses the pump thrust bearing to carry the
axialthrustdevelopedbythepump.
3. Sealsthepowerendofthemotorhousingfrom
thewellborefluidswhileallowingpressure
e e bo e u ds
ea o
g p essu e
communicationbetweenthemotorsandthe
wellbore.
y
4. Providethevolumenecessaryforthe
expansionofthemotoroilcausedbyheat
generatedwithinthemotorhousing
April 30, 2010
Protectors
4. Itequalizesthepressureinsideandoutsideofthesystemandatthesame
timeprovideroomformotoroilthermalexpansion.Italsoseparatesthe
wellfluidfromthemotoroilthroughbagand/orlabyrinthchamber.
/
5. Ittransmitstorquedevelopedbythemotortodrivethepump.
6. Itcarriesupthrust
It carries upthrust anddownthrust
and downthrust (reactionforces)developedbythe
(reaction forces) developed by the
pump
Thedriveshaftofthemotorandthepumparecoupledtogetherbymeansof
Th
di
h ft f th
t
d th
l dt
th b
f
thesealsectionshaftwhichhasacouplingoneachend.Thelowerendsof
thesealshaftiscoupledtothemotorshaftanddesignedtoallowfor
elongation of the motor shaft due to temperature rises
elongationofthemotorshaftduetotemperaturerises.
Thesealsectionallowspressurecommunicationbetweentheinsideand
outsideofthemotorhousing.Itfilledwithablockingfluidwhichisheavier
thanwater,SG=1.8,operatesinUTubemanner.
Allthesedesigndetailsmaynotbeinmuchsignificancetoapumpoperator
butdohaveaneffectonpumpoperation.
April 30, 2010
Labyrinth Protector How it works ?

Top of unit is in contact with well fluid via the pump intake
The heavier gravity
well fluid is
separated by gravity.
A "U-tube"
U tube design
keeps the heavy
well fluid from going
lower into the unit
keeping the thrust
bearing and motor
full of clean oil.
B tt
Bottom
off unit
it is
i in
i direct
di
t contact
t t with
ith motor
t head
h d
April 30, 2010
Labyrinth Protector How it works ?
The fluid
level can
rise and
fall as
needed to
balance the
p
pressure.
April 30, 2010
Labyrinth Protectors Limitations

LabyrinthProtectors
There will be cases where a labyrinth will simply

not work
work. In cases where the well fluid is lighter
gravity than the motor oil (i.e. about 0.85), the
motor oil will go to the bottom of the chamber
rather than the top causing the motor fluid to
be displaced by well fluid pretty quickly.
April 30, 2010
Gas Separator
Thegasseparatorisabolt
Thegasseparatorisaboltonsectionbetweentheprotectorandthepump
where it is serves as the pump intake
whereitisservesasthepumpintake.
The gas separator separates the free gas from the fluid and assists in routing
Thegasseparatorseparatesthefreegasfromthefluidandassistsinrouting
thefreegasawayfromthepumpintake.Itisdifficulttodeterminethe
efficiencyofthegasseparators.
Thegasseparatorisanaidinpreventinggaslockandnormallyprovidesmore
efficientpumpingofgassywells.
ffi i
i
f
ll
April 30, 2010
Dynamic Gas Separators

Dynamic gas separators actually impart energy to the fluid in
order to get the vapor to separate from the liquid.
The original gas separator was called a KGS (short for either
Kinetic Gas Separator or Kobylinski Gas Separator). This design
uses an inducer to increase the pressure of the fluid and a
centrifuge to separate the vapor and liquid.
This design could likewise be called a centrifugal gas separator.
April 30, 2010

Dynamic gas separators have gone through an
evolution
l ti att REDA and
d as with
ith other
th products
d t have
h
been improved upon as newer models have been
i t d
introduced
d
The first REDA dynamic gas separator the KGS was
introduced in 1982 and has been through several
upgrades

DynamicGasSeparators
April 30, 2010

The rotary gas separator design works in a
similar fashion to a centrifuge. The first
model had centrifuge "paddles" spinning
at 3500 rpm and was believed to cause the
heavier fluids to be forced to the outside,
g the crossover and up
p into the
through
pump, while the lighter fluid (vapor) stays
toward the center,
center and exits through the
crossover and discharge ports back into
th well.
the
ll
April 30, 2010
ROTARY GAS SEPARATOR
Fluid come in through the screen, up to

the Inducer
Inducer centrifuges the fluid
Centrifugal effect separates vapor from
the liquid
Heavier fluid moves to the housing, gas
y around the shaft
stays
Liquid is directed to the pump, gas directed
b k to annulus
back
l
April 30, 2010
Advance Gas Handler (AGH):

If ggas is p
present,, then a ggas separator
p
will be installed and attached to the
pump suction to assist in eliminating some of the gas that might be
produced through the pump.
The AGH does not separate gas but conditions it so it can be produced by the
p p
pump.
April 30, 2010
Advance Gas Handler (AGH):

Increasegashandlingability
g
g
y
Methods:
Homogenize the mixture
Pump
Pump
Standard
Intake
AGH
Gas
Separator
Reduce bubble size

P gas bbackk into
Put
i
solution
l i
Help gas to move to main
stream
April 30, 2010
Intake & Gas Separators

IIntake
t k is
i the
th entrance
t
off the
th oil
il into
i t the
th string
t i in
i
order to be lifted by the pump to the surface
(Standard
d d operation).
In some applications, there may be gas produced
q
alongg with the oil and water liquids.
In this case,
case another useful equipment could be
installed, for example:
April 30, 2010
Submersible Pump
Thepumpisamultistagedcentrifugalpump.Each
stage consists of a rotating impeller and a stationary
stageconsistsofarotatingimpellerandastationary
diffuser.Thetypeofthestageuseddeterminesthe
volumeofthefluidtobeproduced.
Thenumberofstagesdeterminethetotalhead
generated and the horsepower required Pumpss
generatedandthehorsepowerrequired.Pump
manufacturersprovideawiderangeofcapacities
forcustomapplicationtovirtuallyallwellconditions
Thesubmersiblepumpimpellersmaybeofthe
The
submersible pump impellers may be of the
floatingorfixeddesign.Floatingimpellersarenot
attachedtotheshaft,butarefreetofloatupand
d
downtheshaft.Fixedimpellersareattacheddirectly
th h ft Fi d i
ll
tt h d di tl
totheshaftbycompressionrings.Thefloating
impellersarethemostcommonbecauseofthehigh
thrustbearingloadassociatedwithfixedimpellers.
April 30, 2010
PUMP
INTAKE
PROTECTO
R
MOTOR
The Pump
Threephysicalcharacteristicofafluid
,i.e.viscosity,compressibility,and
i e viscosity compressibility and
specificgravityaffecttheperformance Max.
Capacity
ofanysubmersiblepump.
TotalDynamicHead(TDH)istheheadPump
(pressure)whichthepumpmustact Liquid
Capacity
against.Itisafunctionof:
1. Feetofleftfromthewellsworking
fluidleveltothesurface.The
u d e e o e su a e
e
workingfluidlevelobtainedfrom
theproductivityindexofthewell.
2. Flowingfrictionlossinthetubing.
3. Surfacetubingdischargepressure.
April 30, 2010
S G
Sp.
Gr.
Viscosity
% Free Gas
Increasing Values
Centrifugal Pumps Definition of stage

Each"stage"consistsofan
g
impellerandadiffuser.
Impeller
Diffuser
April 30, 2010
Centrifugal Pumps
The centrifugal pump is a multistage
Thecentrifugalpumpisamultistage
pump,containingaselectednumberof
impellersinsidecloselyfitteddiffusers.
Thepumpstagesareinstalledinseries
alongtheshaftofthepump.The
l
th h ft f th
Th
multistagepumpisdrivenbyan
electricalmotor.
Diffuser
Impeller
April 30, 2010
Centrifugal Pumps - Operation

A centrifugal pump causes fluid to change
Acentrifugalpumpcausesfluidtochange
velocitybytherotationofaseriesof
vanesinanimpeller.
The motion of the impeller forms a

partial vacuum at the suction end
of the impeller which in turn
draws more fluid into the impeller.
April 30, 2010
Centrifugal Pumps Impeller Function

Theimpeller
The
impellerssfunctionisto
function is to
transferenergybyrotationtothe
l
liquidpassingthroughit,thus
d
h
h
h
raisingthekineticenergyofthe
fluid.
Impeller
April 30, 2010
Centrifugal Pumps
Fromthere,therotationof
From
there the rotation of
thehighspeedimpeller
throwstheliquidintothe
h
h l
d
h
diffuserwhichisthestatic
componentofthepump
stage.
Diffuser
Impeller
April 30, 2010
Centrifugal Pumps Diffuser Function

Thediffusersectionthenconvertsthe
The
diffuser section then converts the
fluidkineticenergytopotentialenergy,
increasingthefluidspotentialenergyas
h fl d
l
itpassesthroughthestage.
Diffuser
Diffuser
April 30, 2010
Impeller
Mixed Flow and Radial Flow Pumps

Therearetwotypesofimpellerdesigns.Thegeometricdesign
determinestheamountfluidflowthattheparticularstagecan
handle
April 30, 2010
Centrifugal Pumps Mixed and Radial Flow

Thedifferencebetweenthesetwo
The
difference between these two
typesofdesignsisdescribedby
thepumpimpellervaneangles
h
ll
l
andthesizeandshapeofthe
internalflowpassages.
April 30, 2010
Centrifugal Pumps Radial Flow Design

Aradialflowimpellerhas
A
radial flow impeller has
vaneanglesatcloseto90
d
degree,andtherefore,are
d h f
usuallyfoundinpumps
designedforlowerflow
rates.
April 30, 2010
Centrifugal Pumps Mixed Flow Design

Amixedflowimpellerhas
A
mixed flow impeller has
vaneangelsatcloseto45
d
degree,andtherefore,are
d h f
usuallyfoundinpumps
designedforhigherflow
rates.
April 30, 2010
Power Cable
Thisprovidesthemeansbywhichthepoweristransferredfromthesurface
switchboard to the downhole motor. The power cable is constructed in either round or
switchboardtothedownholemotor.Thepowercableisconstructedineitherroundor
flatconfiguration.
Conventionalcableiscomposedofthreeconductorsandmaybeeithersolidormulti
strandcopperwire.Theconductorsareindividuallyinsulatedandusuallyusea
p
yp py
p
g
p
thermoplasticPolypropylene)foroperatingtemperaturebelow200Fandthermoset
plastic(Rubber)fortemperatureabove200F.
SSurroundingtheinsulationisajacketmaterialtoprotecttheconductorsfrom
di th i l ti i j k t t i l t
t t th
d t f
mechanicaldamageandtheenvironment.Thejacketedcableisthenwrappedwitha
metalsheathingtofurtherprotectthecablefrommechanicaldamageandtoprevent
swellingdamageinthejacketorinsulationmaterialasgasand/orliquidspermeatethe
protectivematerialatelevatedwellborepressuresandtemperatures.
April 30, 2010
Cables Types
April 30, 2010
Components of a downhole ESP cable
CONDUCTOR
INSULATION
BARRIER
JACKET
ARMOR
INJECTION TUBE (optional)
April 30, 2010
Conductor Selection
Factors to be considered:
SIZE
DAMAGE RESISTANCE
FLEXIBILITY
Conductor
COST
Solid
April 30, 2010
Compacted
St d d
Stranded
Conductor Types
SOLID
- Smallest diameter / lowest cost
- Lower interfacial electrical stress
STRANDED
- Greater flexibility
- Greater damage resistance
COMPACTED
SOLID
STRANDED
COMPACTED
- Up to 10% decrease in diameter

versus round stranded conductor
April 30, 2010
Cable
Thecableconductorsmustbeproperlysizedto
minimize
minimizedownholevoltagedrops.Thecableinsulation
downhole voltage drops The cable insulation
mustbeabletowithstandtheoperatingvoltagesatthe
downholeworkingtemperateandpressure.
Thepropercablesizeisgovernedbytheamperage
voltagedropandspaceavailablebetweenthetubing
collarandcasing.Thebestcablesizeisselectedbasedon
the bottomhole temperature and fluid encountered.
thebottomholetemperatureandfluidencountered.
Thechemicalenvironmenthadthemostsevereeffect
e e a e
o e
ad e os se e e e e
oncablelife.Itcanchangetensileproperties,volume
andhardness.Oneoftheotherfactorshavingsever
effectisgaspermeation.Normally,thisisnotedwhen
ff
i
i
N
ll hi i
d h
pullingthewellduetoanydownholefailureandcare
sshouldbetakeninrerunninganyusedcable.
ou d be ta e
eu
g a y used cab e
April 30, 2010
Armor Types that are available

STANDARDGALVANIZEDSTEEL(CLASSI)
(GSA 0 020"/0
(GSA,0.020
/0.51mm&0.025
51mm & 0 025"/0
/0.64mmthick)
64mm thick)
HEAVYGALVANIZEDSTEEL(0.034"/0.86mmthick)
HEAVY COATING CLASS II GALVANIZED STEEL
HEAVYCOATINGCLASSIIGALVANIZEDSTEEL
STAINLESSSTEEL
MONEL
TWODIFFERENTARMORPROFILES
DOUBLE ARMOR (t o la ers)
DOUBLEARMOR(twolayers)
April 30, 2010
ARMOR PROFILE TYPES
Standard crown p
profile interlocked
Flat profile interlocked
Flat profile
April 30, 2010
REDA Production Systems Cable Options

CONDUCTORS:
SOLID
COMPACTED
STRANDED
INSULATION:
PPE
COPOLYMER
EPDM 1
EPDM 2
EPDM 3
EPDM 4
BARRIERS:
TEDLAR
TAPE
SOLEF
EXTRUSION
FEP
EXTRUSION
HIGH-TEMP
TAPE
LEAD
JACKET:
HDPE
LOW-TEMP
NITRILE
STANDARD
NITRILE
HIGH-TEMP
NITRILE
EPDM
ARMOR:
GALVANIZED
STEEL
HEAVY
GALVANIZED
DOUBLE
GALVANIZED
STAINLESS
STEEL
MONEL
April 30, 2010
The ESP Cable Families
9 POLYETHYLENE: 185
185F ((85
(85C))
PPEPE
9 REDALENE: 205
205F (96
(96C)
POTB
April 30, 2010
PPEO

9 REDAHOT: 250-350F ((121-177C))
ETBO
9 REDABLACK: 300-400F (149-204C)

EER
April 30, 2010
ETBEF

9 REDALEAD: 400400-450
450F (203
(203--232
232C)
ELBE
ELB
KELB
9 MOTORLEADS: 250250-450
450F
(121--232
(121
232C)
April 30, 2010
Accessory Items: 1. Check Valve

1. Checkvalve
Acheckvalveisusedtomaintainafullcolumnoffluidabovethepumpallowingthe
A
check valve is used to maintain a full column of fluid above the pump allowing the
motortostartunderaloadcondition.Itisusuallylocated2to3jointsabovethe
pumpassembly.
Ifthecheckvalvefailstoholdorifitisnotinstalled,leakageoffluidthroughthe
pump can cause a reverse rotation of the subsurface unit when the pump is
pumpcancauseareverserotationofthesubsurfaceunitwhenthepumpis
shutdown.
Inspecialhighgasoilratiowells,morethan3jointsabovethepumpdischarge
maybedesirablelocationforthecheckvalve.Ifthepumpfillswithgasandgas
lock,,thesejointswillallowgastoescapefromthepumpleavingliquidsto
lock
these joints will allow gas to escape from the pump leaving liquids to
permitseffectivestartupandpumpoperation.
April 30, 2010
Accessory Items: 2. Bleeder Valve and 3. Cable Bands

2.BleederValve
Whenever a check valve is used in the tubing string,
string a drain or bleeder
valve must be installed immediately above the check valve to prevent
pulling a wet tubing string.
The drain valve is generally installed one joint above the check valve.
If the check valve is not installed
installed, there is not need to run a drain valve
as the fluid in the tubing will drain through the pump while pulling.
3.CableBands
Cablebandsareusedtostrapthepowercabletothetubing.Twobandsperjointis
bl b d
d
h
bl
h
b
b d
normal.
April 30, 2010
Accessory Items: 4. Cable protection

Thecableprotectorisrigidlyattachedtothetubingand
Thecableprotectorisrigidlyattachedtothetubinganddsigned
dsigned toprotectthepower
cable from being crushed between the outside surface of the tubing and the inside
cablefrombeingcrushedbetweentheoutsidesurfaceofthetubingandtheinside
surfaceofthecasingduringrunningandpullingoperations.
Becausemostdamagetocablesoccursadjacenttotubingcouplings,thecable
protectorshouldbeinstallednofurtherthan2feetfromthecoupling.
Cabledamageisspeciallyseriousandcostlyindirectionaldrilledwells.Serious
considerationsshouldbegiventotheseapplicationsbeforeinstallinganelectric
submersiblepump.
b
ibl
April 30, 2010
Accessory Items: 5. Tubing Head

Aspecialtubingheadmustbeusedtopackofftheconductorcable.Basically,twotypes
are used in conjunction with submersible pumps: the cable plugin
areusedinconjunctionwithsubmersiblepumps:thecableplug
inandthecablepass
and the cable pass
throughtype.
Thepassthroughtypeallowsthecabletoremainintactthroughthetubinghead
Thepass
withouthavingtocutorsplicethecable.Thistypesisreliableinlowpressurewellsto
avoidleakagebetweenthebackoff
g
backoff rubbersandthecable.
avoidleakagebetweenthe
Thecableplug
Thecableplugintubingheadshouldbeusedtohandlewellswithhighshut
intubingheadshouldbeusedtohandlewellswithhighshutinsurface
pressures.Theplug
pressures.Theplug
Th l inheadentailscuttingthecableandsplicingonconnectors.The
i h d t il
tti th
bl
d li i
t
Th
motorscableispluggedintothesocketinthebottomofthetubinghead,andthe
surfacecablefromthejunctionboxispluggingintotheelectricsocketonthetopof
thetubinghead.
April 30, 2010
Accessory Items: 6. Downhole Pressure Monitors

Valuablereservoirandpumpperformancedataisavailablewiththeuseof
downholepressuremonitors.Bycorrelatingreservoirpressurewiththe
p
y
g
p
withdrawalrate,anoperatorcandeterminewhenitisnecessarytochange
pumpsize.
Twotypesofdownholepressuremonitoringdevicesareavailablefromthe
submersiblepumpsuppliers.
p p pp
Onesystemhasthecapabilityofcontinuouslymonitoringbottomhole
pressureatthepumpssettingdepth.Thesystemrequiresnospecialwires.
h
i d h Th
i
i l i
Allsignalsaresenttothesurfaceinstrumentsovertheregularpowercable.
Anoptionalportablepluginstripchartrecordercanbeprovidedtogivea
Anoptionalportableplug
permanentrecordofpressurereadings.
Theotherdownholepressuremonitoringsystemrequiresanadditionalsmall
The
other downhole pressure monitoring system requires an additional small
powerline.Theunitisattachedtothebottomofthepumpingunitandithas
readoutinimpulsesatthesurfacewhichcanbedirectlyconvertedto
pressurereadout.
April 30, 2010
SURFACE EQUIPMENT USED WITH ESPs

1.
1
2.
3.
4.
5.
6.
7.
8
8.
SWITCHBOARDS
TRANSFORMERS
VARIABLE SPEED DRIVES
FACT PACs
WELLHEADS
SURFACE CABLE
JUNCTION BOX
CONTROLLERS
Wellhead Connectors
April 30, 2010
VSD Application Typical setup
Step-Down
Transformer
Bank
VSD
Step-Up
Transformer
Disconnect
J Bo
Box
Note: Skid mounted packages can also be supplied

April 30, 2010
Surface Equipments
1. Transformer
Function to change the primary incoming voltage upward or downward to a
Functiontochangetheprimaryincomingvoltageupwardordownwardtoa
desiredsecondaryoutputvoltagewhichisrequiredbythedownhole
electricmotor.
Therearetwotypesoftransformersemployedintheoilfield:
1. Singlephasetransformers,and
2. Autotransformer.
Inthesinglephasetransformer,therearetwosetsofwindings,oneforthe
In
the single phase transformer there are two sets of windings one for the
primaryvoltageandtheotherforthesecondaryvoltage,thevoltgae willbe
changedinexactproportionstothenumbersofturnsconnectedinseriesin
each windings. For example, if the primary winding consists of 1000 turns
eachwindings.Forexample,iftheprimarywindingconsistsof1000turns
andwasconnectedto5000voltcircuit,asecondarywindingof100turn
wouldgive500volts.
On the other hand the auto transformer has only one windings all of it
Ontheotherhand,theautotransformerhasonlyonewindings,allofit
beingconnectedtotheprimaryvoltageandonlypartofitforthe
secondaryvoltage.
April 30, 2010
TRANSFORMER
April 30, 2010
2. Switchboard
Switchboardisanoperatingcontrolandprotectivedeviceconsistingofamotorstarter,
overload and under load protection, manual disconnected switch time delay.
overloadandunderloadprotection,manualdisconnectedswitchtimedelay.
Busstypefusesareusedtoprotecttheinternalcircuitry.Fusesareinstalledinternally
orinthefeedercircuitrytotheswitchboard.
Theunderloadprotectionguardsagainstlowamperagebeingdrawnbythemotorand
The
under load protection guards against low amperage being drawn by the motor and
viceversa.Theoverloadprotectionguardsagainstthemotordrawingexcessive
amperage.
Animportantfeatureoftheswitchboardistherecordingammeter.Therecording
ammeter records the amperage drawn by the motor on an amperage chart Amp chart
ammeterrecordstheamperagedrawnbythemotoronanamperagechart.Ampchart
mayrecordfora24hoursor7daysperiod.Thesechartsareinvaluableastheyreflect
thepumpingconditionsofhewellandgiveimmediateindicationofproblemsor
abnormal operation
abnormaloperation.
April 30, 2010
Amp Chart
April 30, 2010
Surface Equipment
Shown here is the surface related equipment required for
most down-hole electrical submergible pump systems.
April 30, 2010
Surface equipment -Switchboards
April 30, 2010
Surface Equipment - Switchboards

- Weatherproof
- Either electro-mechanical or
Electronic controls
- Rated for ambient temperature
- Can be operated remotely
g
lights
g
- Signal
- Recording ammeters
- Underload/Overload protection
- Fused disconnects
April 30, 2010
Junction Box
Thejunctionboxislocatedatleast15feetfromthewell
headand35feetfromtheswitchboard.
Thejunctionboxservestwofunctions:
1. Itisajunctionpointtoconnectthepowercablefrom
the switchboard to the power cable from the well
theswitchboardtothepowercablefromthewell.
2. jjunctionboxinstalledtoprovideaventtothe
p
atmosphereofanygasthatmaymigrateupthepower
cablefromthewell.
Acablerackshouldbeprovidedbehindthejubction
boxtocoilsomeextralengthofthepowercable.This
g
p
allowsforfuturerepairswithouthavingtospliceinnew
cableorraisethepumpsettingdepth.
April 30, 2010
J-Boxes
Wellhead Connector
April 30, 2010
Pump Selection
2000 bpd Pump Sizing
Series - O.D.
400 Series - O.D. 4.00
513 Series O.D. 5.13
April 30, 2010
Pump
Type
Monel Shaft
Max BHP
Shaft
Size
Recommended Capacity @ 60 Hz
3
( BPD)
(M /D)
DN280
D400
DN440
DN525
DN675
D950
DN1000
DN1100
DN1300
D1400
DN1750
DN1800
DN2150
DN3000
DN3100
DN4000
44
94
94
94
94
125
125
125
125
125
125
125
125
256
256
256
0.50
0.625
0.625
0.625
0.625
0.687
0.687
0.687
0.687
0.687
0.687
0.687
0.687
0.875
0.875
0.875
100
200
100
300
325
600
700
600
800
900
1200
1200
1400
2000
2400
3400
450
550
550
625
850
1150
1250
1350
1600
1850
2050
2400
2600
3700
4000
5200
16
32
16
48
52
95
111
95
127
143
191
191
223
318
382
541
72
87
87
99
135
183
199
215
254
294
326
382
413
588
636
827
GN1600
GN2100
GN2500
G2700
GN3200
GN4000
GN5200
GN5600
GN7000
GN10000
256
256
256
256
256
375
375
375
375
637
0.875
0.875
0.875
0.875
0.875
0.995
1.00
1.00
1.00
1.187
1200
1650
1800
2000
2200
2500
3900
4000
5000
7000
2000
2500
3100
3400
4150
5000
6600
7500
9000
12000
191
262
286
318
350
398
620
636
795
1113
318
398
493
541
660
795
1049
1193
1431
1908
Electric Submersible Pumps

Wideperformancerangeand
p
g
versatility,
Canoperateinhighangleand
horizontalwells,and
Mostefficientandeconomicallift
method on a cost per barrel basis
methodonacostperbarrelbasis.
April 30, 2010
Tubing must be pulled to

change or repair the
pump,
Depth and GOR restrict
capacity and operating
efficiency, and
Large volumes of gas can
lock up the pump
April 30, 2010
Typical ESP Installation
April 30, 2010
Booster Service Submersible Pump Configuration
Pump
Intake
Motor Protector
Cable
In Booster Service,
Service a
standard pump,
protector and motor
protector,
unit are used to lift
fluid from flowlines or
other sources and
simultaneously
provide injection for
waterflood, pipeline
or other applications.
Motor
April 30, 2010
Bottom Intake Submersible Pump Configuration
In Bottom Intake
Configurations, fluid
enters the pump
Cable through a stinger in a
permanent packer.
Motor
P
and
d motor
t are
Motor Protector Pump
Pump Discharge inverted from
conventional
Pump applications. This
configuration can also
p
by
y small
Packer be suspended
diameter, highstrength cable,
conventional tubing or
coiled tubing to
improve output.
April 30, 2010
Bottom Discharge Submersible Pump Configuration
The Bottom
Discharge Pump is
Cable used to inject water
from shallow aquifers
Motor
into deeper producing
Motor Protector
zones
Intake
Pump
Packer
April 30, 2010
Shrouded Submersible Pump Configuration
A Shrouded
Configuration directs
Cable fluid past the motor
for cooling or allows
free gas to separate
from fluids ahead of
Pump
the intake and allows
Intake pumps to
t be
b sett
Motor Protectorbelow perforations or
producing zones.
Motor
April 30, 2010
Troubleshooting
Sometimeswearefacedwithtryingtoguesswhatiswrongwithapump(or
y g g
g
p p(
well)basedonverylimiteddata.
Thefollowingillustrationsaretakenfromactualexperiencesand,although
notcomprehensive,maybehelpfulindiagnosingproblemwells.
April 30, 2010
Troubleshooting
Saywehaveanewunitinawellandthecustomerisnotsatisfied.Wesolda
unit designed to produce 3000 BPD and it does make 3000 for a few days but
unitdesignedtoproduce3000BPDanditdoesmake3000forafewdaysbut
thenisonlymaking2500BPD.Welookattheampchartsandfindthatthe
amperageislowerthanweexpect.
What could possibly be wrong with the unit?
April 30, 2010
Troubleshooting
One of the most valuable tools in trouble shooting downhole problems is the
amp chart
chart.
Many conditions can be properly diagnosed allowing corrective action to be
taken without the need to pull the equipment or, if the downhole unit must be
pulled, a better decision may be made as to what must be done when re
running the replacement unit.
The amp chart
Th
h
i not the
is
h only
l diagnostic
di
i tooll which
hi h the
h engineer
i
should
h ld use
but it is one of the most important since it can show what happened to the
unit over time.
April 30, 2010
Troubleshooting
TheAmmeterisananalogdevicewhichismountedonmostswitchboards.It
is mechanically driven so does not need any voltage to operate its clock This
ismechanicallydrivensodoesnotneedanyvoltagetooperateitsclock.This
allowsthemetertorunevenwhennovoltageissuppliedtotheswitchboard
asinapoweroutage.
Theammeteritselfhasaroundrecordingchartwithapenwhichmovesinand
outinproportiontotheamountofcurrentwhichthemetersenses.
All A
AllAmmetersoperateon0to5ampswith5ampsbeingfullscale.
0 5
i h5
b i f ll
l
April 30, 2010
Interpretation of Ammeter Charts
Dr. Adel Salem Artificial Lift Methods_HIS_Cairo 17-21 Jan. 2010

Januray 21, 2010
Page: 235

Januray 21, 2010
Page: 236
PUMP STARTED AT 6 A.M.

NORMAL RUN UPTO 915 A
A.M.
M
PRODUCTION RATE DECLAINED.
PRODUCTION BECAME GASSY

GAS LOCKED & TRIPPED AT 1050 A.M.
CORRECTION:LOWER THE PUMP

INCREASE DOWN TIME
CHANGE OUT PUMP IN THE NEXT PULL OUT
Januray 21, 2010
237

Januray 21, 2010
Page: 238

Januray 21, 2010
Page: 239

Januray 21, 2010
Page: 240

Januray 21, 2010
Page: 241

Januray 21, 2010
Page: 242
Troubleshooting
Wewillnowreviewsomeampchartsanddiscusssomeofthepossiblecauses
for the charts shown This is a summary of some common problems and is not
forthechartsshown.Thisisasummaryofsomecommonproblemsandisnot
intendedtobeallinclusive.
Thesechartsarerepresentativeoffieldexamplesandactualchartsmayvary
somewhatfromthoseshownbutbystudyingtheseexamplesandwithsome
fieldexperience,ampchartscanbeanalyzedwithahighdegreeofaccuracy.
April 30, 2010
Troubleshooting
Wewillassumeinallcasesthatweareoperatingaunitatfullloadwitha
motor which has a nameplate current of 40 amps For this 40 amp motor we
motorwhichhasanameplatecurrentof40amps.Forthis40ampmotor,we
wouldsettheoverloadat115%(46amps)andtheunderloadat80%(32
amps).
Should we always
y use these percentages
p
g for overload and
underload?
April 30, 2010
Troubleshooting: Normal
Startup
p
5
8
9
60
50
40
30
20
10
11
N
NOON
MIDNIGHT
M
Normal
11
10
3
4
6 PM
In an actual well the amperage may

Inanactualwell,theamperagemay
notbeexactly40butmaybeslightly
higherorlower.Thisisnoproblemas
longasthechartremainsconsistent
dayafterday.Changesinthechart
may
maybeduetochangingwell
be due to changing well
conditionsorpossiblesystem
problems.
6 AM
10
Thisisa"normal"ampchart.Notethe
p
spikeonstartupfollowedbyanice
smoothandsymmetricallineat40
amps.Thisisanidealcondition.
Thi i
id l
diti
It might be a good idea to

replace the chart
April 30, 2010
Troubleshooting
WiththeESP,theamperagevaries
,
p g
inverselytothevoltageforaconstant
load.Iftheprimarysupplyvoltage
d
decreases,theESPcurrentwillincreaseto
th ESP
t ill i
t
compensate.
S ik
Spikes
5
8
9
60
50
40
30
20
10
11
10
1
2
11
MIDNIIGHT
Primary
Power
Fluctuation
"Spikes"
NOON
10
Themostcommoncauseforthesespikes
Themostcommoncauseforthesespikes
isperiodicheavyloadingonthepower
systemascouldbecausedbystartupof
highhorsepowerequipmentelsewhere
onthesystem.
on the system.
onthesystem
6 AM
9
7
6 PM
April 30, 2010
Couldalsobecausedbylightningstrikes
Could
also be caused by lightning strikes
somewhereonthepowersystem.
Troubleshooting
Hereisachartwhichshowsstartupfollowedbyagradualdecreasein
amperage until about 7:30 AM where the line becomes very ragged At about
amperageuntilabout7:30AMwherethelinebecomesveryragged.Atabout
8:30AM,theamperagetakesadrasticdropandbecomesverysmooth.
Gradual decrease
5
6 AM
11
Amperage
becomes
erratic
ti
10
8
9
60
50
40
30
20
10
T
MIDNIGHT
NOON
11
10
6 PM
April 30, 2010
Troubleshooting: Gas Lock

Whentheunitisfirststarted,thefluidlevelishighso
productionandcurrentareslightlyhigh.Asthefluid
levelisreduced,thecurrentdecreasesuntilthelevelis
so low that gas begins to form at the intake.
solowthatgasbeginstoformattheintake.
Pump has
gas locked
5
NOON
GHT
MIDNIG
Gas
L ki
Locking
11
10
3
4
6 PM
11
April 30, 2010
10
Whenthepumpisgaslocked,itisnotproducingany
fluid.Notethat,eventhoughthepumpisnot
producingfluid,themotoriscontinuingtorun
(amperageisnotzero).Thiswillcausethemotorto
y
eventuallyburnsincethereisnofluidmovementto
coolit.
60
50
40
30
20
10
Thewidevariationisspecificgravitycausetheerratic
amperage.Eventuallyenoughgasformssothatthe
pump"gaslocks".
6 AM
Troubleshooting: Gas Lock Solution

Inthiscase,weneedtoraisetheunderload
settingsothattheunitshutsoffifitgaslocks.
Pump h
P
has
gas locked
6 AM
8
9
60
50
40
30
20
10
11
NOON
10
Shuttingtheunitdownmayclearthegaslock
Shutting
the unit down may clear the gas lock
althoughifacheckvalveisinstalled,itmay
preventitfromclearing.
DNIGHT
MID
Gas
Locking
11
10
Ifpossible,chokebacktheproductiontoraisethe
annularfluidlevel.Itmaybenecessarytolower
thepumpifthereisroominthewelltogain
additionalsubmergence.Itmightalsobewiseto
resizetoasmallerunit.
April 30, 2010
6 PM
IfaVSDisbeingused,reducethefrequency.
Troubleshooting
Onepossiblecauseisthatthepumpis
unloading the well of heavy kill fluid
unloadingthewellofheavykillfluid.
10
11
8
9
60
50
40
30
20
10
NOON
1
T
MIDNIGHT
Unloading
H
Heavy
Kill Fluid
11
10
g g
y
Thehighgravityfluidcausesanincreasein
Thehighgravityfluidcausesanincreasein
currentuntilitisallpumpedoutofthewell
currentuntilitisallpumpedoutofthewell
thenthecurrentdropstoanormalvalue.If
this condition is to be expected it may be
thisconditionistobeexpected,itmaybe
necessarytotemporarilyraisetheoverload
settinguntilthekillfluidisgoneandthenset
it to the normal 115% value
ittothenormal115%value.
6 AM
6 PM
April 30, 2010
Ifthisconditionisexpectedtolastformore
If
Ifthisconditionisexpectedtolastformore
this condition is expected to last for more
thanafewminutes,itmaybenecessaryto
usealargermotorthannormalsothatthe
overload does not cause high internal
overloaddoesnotcausehighinternal
temperatureswhichmayreducethe
operationallife.
Note: If a VSD is being used,

used try
lowering the hertz to reduce the
load until the kill fluid is gone.
Troubleshooting:
Pump Off with Gas Interference
Thisisacasewherethepumpisproducingmore
fluidthanthewellcandeliver.
6 AM
11
NOON
10
Thepumpisloweringthefluidlevel,hencethe
The
Thepumpisloweringthefluidlevel,hencethe
pump is lowering the fluid level hence the
amperage,untilfreegasbeginstoformatthe
intake.
60
50
40
30
20
10
MIDNIGHT
11
10
6 PM
With a VSD try lowering the frequency

WithaVSD,tryloweringthefrequency.
April 30, 2010
Pump Off
with Gas
Interference
Thelowgravitygasmixedwiththehighgravity
Thelowgravitygasmixedwiththehighgravity
fluidcauseswideswingsincurrent.Theunit
eventuallyshutsoffonU/Landautomatically
restartsafterthreehours.Possiblesolutionsare
tochokebackonproduction,lowerthepump
furtherinthehole,orresizetoasmallerunit
furtherinthehole,orresizetoasmallerunit..
Troubleshooting
Pump Off with False Restarts
Theadditionalspikesareduetofailed
p
restartattempts.
Failed Restart
5
NOON
GHT
MIDNIG
Pump Off
w/ False
Restarts
11
10
3
4
8
7
6 PM
April 30, 2010
60
50
40
30
20
10
11
Immediateactionistoincreasethe
automaticrestarttime.Longterm,
theunitneedstoberesized.
6 AM
10
Therestarttimerissettoolowand
thepumpistryingtorestartwhile
there is insufficient fluid in the
thereisinsufficientfluidinthe
wellboreandittripsduetounderload.
Troubleshooting: Pump-Off
Thischartalsolooksverysimilartopumpoffexceptthattherunningtimeisof
very short duration This is very harmful to the SPS and should be corrected
veryshortduration.ThisisveryharmfultotheSPSandshouldbecorrected
immediately.Toomanyrestartsstressthemotorandcauseheatbuildup
whichisneverfullydissipated.
6 AM
11
10
60
50
40
30
20
10
DNIGHT
MID
NOON
11
10
6 PM
April 30, 2010
Troubleshooting: Excessive Cylcing

Thischartcouldbecausedbyapumpwhichis
toolargeforreasonsexplainedbeforeor,
oddlyenough,onewhichistoosmall(i.e.not
enoughTDH).
6 AM
8
9
60
50
40
30
20
10
11
NOON
10
MIDNIGHT
Excessive
Cycling
11
10
Inthelattercase,thepumpmaybeableto
producefluidtothesurfacewhenthefluid
level is high but, as it draws down, the pump
levelishighbut,asitdrawsdown,thepump
cannotproduceenoughTDHtogetittothe
surface effectivelyshuttingthewellin.
g
g
CheckingthePSIreadingorfluidlevelwill
helpdetermineifthisisthecase.
6 PM
April 30, 2010
Closinginthedischargevalveandobserving
Closing
in the discharge valve and observing
thebackpressurewillalsoindicatewhich
conditionexistsbutmakecertainthepiping
can handle the pressure before attempting
canhandlethepressurebeforeattempting
this.
Troubleshooting: Excessive Cylcing

Thischartcouldalsobecausedbya
y
pluggeddischargelineoraclosedvalvein
thewellheadorFlowline.
8
9
11
N
NOON
10
60
50
40
30
20
10
MIDNIGHT
Excessive
Cycling
Somelowpermeabilitywellsareproduced
intentionally by cycling If this is the case
intentionallybycycling.Ifthisisthecase,
asoftstartdeviceshouldbeusedto
reducestressonthemotor.
6 AM
11
2
3
6 PM
April 30, 2010
10
IfaVSDisused,tryalowerfrequency.A
VSDgivesan"automaticsoftstart"so
stressonthemotorisreduced.
Troubleshooting: Free Gas

5
8
9
60
50
40
30
20
10
OON
NO
11
MIDNIGHT
M
Free Gas
in Pump
11
10
3
4
5
7
6 PM
April 30, 2010
6 AM
10
Thischartisalmostinvariablycausedby
y
y
freegasbeingingestedintothepump
althoughitispossiblethatemulsion
productioncouldalsocauseit.Itmaybe
d ti
ld l
it It
b
possibletosmoothoutthelinebychoking
backorloweringthepump.Producing
g
p p
g
freegaswillusuallyreducethestocktank
productionratesoitisbeneficialtoreduce
th ff t M
theeffect.Manypumpsareoperatedwith
t d ith
thiskindofchart.Aslongasthe
underloadissetproperly,thereshouldbe
p p y,
nomajorproblems.
Troubleshooting
Thischartshowsaunitwhichranforawhileandthenwentdownon
underload and never restarted
underloadandneverrestarted.
6 AM
8
9
11
10
60
50
40
30
20
10
MIDNIGHT
N
NOON
11
10
3
4
6 PM
April 30, 2010
Troubleshooting
Thiscouldbecausedbyproducingalow
yp
g
densityfluidwhichisnotproperlyloading
themotor.
8
9
11
N
NOON
10
60
50
40
30
20
10
MIDNIGHT
M
Undercurrent
Load
Ifproductiontestsshowthatfluidis
present try lowering the U/L setting This
present,tryloweringtheU/Lsetting.This
shouldbedonewithcautionassettingit
toolowwillnotprotectthemotor.
6 AM
11
10
6 PM
8
7
April 30, 2010
AnotherpossiblecauseisfailureoftheU/L
timeoutdelayinthemotorcontroller.A
brokenshaftcouldalsoresultinachart
like this
likethis.
Troubleshooting: Underload
6 AM
Idle Amps
60
50
40
30
20
10
11
NOON
1
MIDNIGHT
U/L
set below
"No Load"
11
10
3
4
Thisisacasewheretheunderloadwas
settolow.Underloads needtobe
raisedandunitshouldberesized.
10
Thisisacasewheretheunitpumpedthe
p p
wellofftothepointthattherewasno
fluidbeingproducedsotheunitwas
runningatidleloaduntilenoughheat
i
t idl l d til
hh t
builtuptocausethemotortoburn
whichiswhenittrippedonoverload.
pp
6 PM
8
7
Unit trips on O/L (burns)
April 30, 2010
Troubleshooting: Tank Level Cont

Theproblemhereisthattheautomatic
restart time is set too short When the
restarttimeissettooshort.Whenthe
pumpstops,thefluidinthetubingcolumn
willtendtofallbackdownthroughthe
pumpcausingitto"turbine"orbackspin.
" b " b k
11
NOON
10
60
50
40
30
20
10
NIGHT
MIDN
Tank Level
Controller
11
10
Whilethisisnotaprobleminitself,ifthe
Whil
thi i
t
bl
i it lf if th
unitisrestartedwhilethisisoccurring,a
broken shaft could result. While a check
brokenshaftcouldresult.Whileacheck
valvemayhelpguardagainstthis,theycan
leakandshouldnotbereliedupon.
6 AM
Downtime too
Short
6 PM
April 30, 2010
Togivecompleteprotection,abackspin
relay should be used in the motor control
relayshouldbeusedinthemotorcontrol
circuit.Otherwise,settherestarttimerto
aminimumof30minutes.
Troubleshooting: Overlaod
UntilthecauseoftheO/Liscleared,restartshould
notbeattempted.
8
9
60
50
40
30
20
10
10
11
MIDNIGHT
M
OON
NO
Commoncausesofthisproblemare:
C
Commoncausesofthisproblemare:
f thi
bl
Increased fluid gravity
Sand production
Viscosity increases (emulsion formation)
Mechanical or electrical problems
downhole
Electrical power supply problems, etc.
The complete installation should be
checked out thoroughly.
6 AM
Overload
11
10
3
4
6 PM
8
7
April 30, 2010
Troubleshooting: Solids Handling

5
6 AM
8
9
60
50
40
30
20
10
NOON
11
Incaseslikethis,thewellshouldalwaysbebailed
priortorunningthepumptoremovetheforeign
p
g
p p
g
material.
10
Thisisoftencausedbydebrisbeingpulledinto
thepumpsuchasscale,sand,muds,etc.While
p p
,
,
,
thisisnotuncommon,itisnotdesirableasthese
materialsmayadverselyaffectpumpwear.
T
MIDNIGHT
Pump
Handling
Solids
11
10
3
4
6 PM
8
7
Ifthisiscausedbyunconsolidatedsand,itmay
If
hi i
db
lid d
d i
bewisetopartiallychoke
partiallychokethewellonstartup
andslowlyincreaseproduction especiallyon
wellsnewlyconvertedfromrodswhichproduced
alowerflowrate.
Thereducedrateshouldstillprovideadequate
coolingforthemotorhowever.
April 30, 2010
8
9
60
50
40
30
20
10
N
NOON
11
MIDNIGHT
M
Excessive
Manual
Restarts
11
10
Theserestartscandestroyanotherwisegood
Theserestartscandestroyanotherwisegood
pieceofequipment.IftheO/Lisduetoa
severemotorburn,therestartscanpotentially
cutthemotorintwodroppingthelower
pp g
portionintheholenecessitatinganexpensive
fishingoperation.
6 AM
10
Thischartisnottoounusualexceptforthefive
manualrestartattempts.Anoverloadiscaused
bysomethingandarestartshouldnotbe
attempted until the problem is resolved.
attempteduntiltheproblemisresolved.
6 PM
April 30, 2010
Troubleshooting
5
8
9
60
50
40
30
20
10
N
NOON
11
MIDNIGHT
M
Erratic
Current
11
Somecommonresultsassociatedwith
Some
common results associated with
thiskindofoverloadareafrozenpump,
burnedmotor,burnedcable,blown
fuses(primaryand/orsecondary),etc.
6 AM
10
Widevariationinspecificgravity,
p
g
y,
viscosity,surfacepressuresor
productionofdebrisinthepumpcan
causeachartlikethis.
h t lik thi
10
3
4
6 PM
April 30, 2010
Troubleshooting
Onepossiblecauseisemulsionformationinthe
pumpwhichperiodicallyclears.Ifthisisthe
case,anemulsionbreakershouldbeconsidered.
8
9
11
10
OON
NO
60
50
40
30
20
10
MIDNIGHT
M
Emulsion?
Surface Load?
Generator?
Thiscanalsobecausedbydecreasingsurface
voltageduetootherheavyequipmentonthe
linewhichiscyclingonandoff.Trytoreduce
demandonthesystem
demandonthesystem..
6 AM
10
6 PM
April 30, 2010
11
Thismayevenbecausedbyaunitwhichisona
generatoriftheregulatorisfaultycausing
fl
fluctuationinvoltageorspeedchanges
i i
l
d h
resultinginchangingpowerfrequency.Repair
thegenerator.
References
1. Wang,X.andEconomides,M.:AdvancedNaturalGasEngineering
AdvancedNaturalGasEngineering,Gulf
Publishing Company Houston, Texas, 2009.
PublishingCompanyHouston,Texas,2009.
2. Economides,M.J.,andMarin,T.:ModernFracturing,
ModernFracturing,EnhancednaturalGas
EnhancednaturalGas
Production,EnergyTribune(ET)PublishingInc.,Houston,TX,2007.
Production
3. Ikoku,Chi.U.:NaturalGasProductionEngineering
NaturalGasProductionEngineering,KriegerPublishing
Company,Malabar,Florida,1992.
4. Katz,D.L.,andLee,R.L.:
Katz, D. L., and Lee, R. L. : Natural
Natural Gas Engineering, ProductionandStorage,
NaturalGasEngineering,ProductionandStorage
NaturalGasEngineering,
Production and Storage,
Storage
McGrawHillPublishingCompany,1990.
5. Beggs,H.D.:GasProductionOperations
GasProductionOperations,"Oil&GasConsultantsInternational,
I
Inc.,1984.
1984
6. Smith,R.V.:PracticalNaturalGasEngineering,2nd Edition,PennWellBooks
g
p y,
,
,
PublishingCompany,Tulsa,Oklahoma,1990.
7. Lyons,W.C.:WorkingGuidetoPetroleumandNaturalGasProduction
Engineering,Elsevier,2010.
8 AbdelAal,H.K.,Aggour,M.,andFahim,M.A.:PetroleumandGasField
8.
Abd l A l H K A
M
d F hi M A P
P
PetroleumandGasField
l
d G Fi ld
Processing,MarcelDekker,Inc.,2003.
Processing,
,
g ,
GasReservoirEngineering,SPE,Richardson,
g
g
g,
,
,
9. Lee,J.andWattenbarger,R.A.:GasReservoirEngineering
TX,1996.
April 30, 2010
Thank You For

ThankYouFor
YourAttention
Your Attention
April 30, 2010

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Natural Gas Engineering

Production II,, NGP 604

Dr. Adel Salem

6. Inflow Performance Relationship;

Production Forecasting for Gas Wells

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 2

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 3

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 5

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 6

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 7

Down Hole Pump

Each of the above mentioned

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 8

Sucker Rod Pump Equipments

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 9

The prime mover is either an electric motor or an internal

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 10

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 11

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 12

Beam Pumping Types

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 13

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 14

Types of Beam Pump

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 15

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 16

Lufkin Mark II Unit

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 17

Air Balanced Unit

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 18

April 30, 2010

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 19

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 20

NG Eng. Production II_ Dr. Adel Salem

Lectures 11- 14: Page: 21