SPE 74414

Self-Sufficient System For Continuous Gas Lift In A Very Harmful

Sour Gas Environment
Miguel A. Lozada Aguilar, Hiplito Peregrino Ramos, Ariel ramos Inestrosa, Ramiro Acero Hernndez, SPE, Pemex, PEP
Copyright 2002, Society of Petroleum Engineers Inc.

equipment for this particular application based on the

This paper was prepared for presentation at the SPE International Petroleum Conference and
Exhibition in Mexico held in Villahermosa, Mexico, 1012 February 2002.

well productivity. Because the probability of both

This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
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Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

cracking and corrosion is high, sizing the equipment and

selecting the appropriate material are special issues for
the success of this application.
Based on this pilot test, a major project is being
implemented to install this system in those fields with

ABSTRACT
The

Mora

high
Field

is

located

60

kilometers

from

content

of

sour

gas

and

without

gas

lift

infrastructure.

Villahermosa Tabasco in the southern region of Mexico.

A project of self-sufficient system for continuous gas lift

INTRODUCTION

in a very harmful sour gas environment was performed.

The gas lift infrastructure is not going to be installed in a

In the southern region of Mexico, there are very deep

short time due to many problems such as logistic issues.

natural fractured reservoirs, which after its first stages of

exploitation, they need some kind of artificial lift systems.

The self-sufficient system separates the gas from the

The application of artificial lift systems is very difficult

liquid. Then, it is compressed and injected into the well,

and expensive in these type of reservoirs. Continuous

similar to an artificial gas lift. This system uses special

Gas lift represents a good option to be considered as an

coiled tubing for sour gas handling. In addition, a

artificial lift method due to both relatively low cost and

continuous chemical inhibitor is injected to protect both

easy application.

the tubing and the coiled tubing from either cracking

failure or corrosion, (because the H2S and CO2 content

Mora field produces from the lower cretaceous with

in the mixture is too high).

depths around 5500 meters. Currently, the pressure of

the reservoir is below the bubble pressure. A secondary

The goal of this work is twofold: (1) present a facility

design and (2) present a process to choose the

gas cap is being formed in the top of the reservoir. Both

the reservoir pressure and low gas-oil ratio had caused
the shutting of several wells. Therefore, it is necessary to

M. LOZADA AGUILAR, H. RAMOS, A. INESTROSA, AND R. HERNNDEZ

SPE 74414

implement some kind of artificial lift systems to maintain

Scrubber

the oil production.

To dry the gas, a scrubber is used. This device catches

the liquid from the gas stream and then it is sent to the

Gas lift is the most used artificial lift system in Mexico.

compressor suction.

Almost 50% of the total production comes from fields

equipped with artificial gas lift. Because of logistic

Control equipment

issues, it has not been possible to install a gas lift

This equipment includes the valves and the control

network in Mora field. To implement an artificial gas lift,

devices to keep the compressor, separator and scrubber

two options were taken into account: first, use nitrogen

operating properly. It also helps to regulate the operation

as a gas lift source, but due to corrosion problems and

pressure and the amount of gas to be compressed.

high power demand, this option was eliminated. Second,

use a self-sufficient gas lift system in the well location,

Compressor

suitable for overcoming the corrosion and cracking

This equipment compresses the sour gas. Normally

problems due to the sour gas.

these units have scrubbers and coolers integrated for

each compressor stage.

Self-sufficient gas lift system has been applied for a long

time. To the best of our knowledge, there is no work

Corrosion inhibitors equipment

reported about corrosion and cracking problems in gas

This equipment injects the corrosion inhibitor into the

lift. By using both coiled tubing for injecting the sour gas

gas stream. The equipment is composed by a pneumatic

and corrosion inhibitors, this paper tries to show a new

pump, a corrosion inhibitor deposit and a chemical

application for facing such problems. (See figure 1).

inhibitor. The way the chemical inhibitor protects the

tubing and coiled tubing from the sour gas attack, is by

SYSTEM DESCRIPTION

covering the internal tubing walls through a fine cap.

The proposed self-sufficient gas lift system separates

Coiled tubing and hanger

the gas from the liquid. Then It is compressed, dried and

Coiled tubing is the means by which the sour gas

injected through the coiled tubing mixed with the

together with the chemical inhibitor is injected for gas lift

corrosion inhibitors. The oil is lifted through the annulus

purposes. Coiled tubing hanger has the function of

between tubing and coiled tubing. (See figure 2).

hanging the coiled tubing from the surface and it also

provides the seal between tubing and coiled tubing.

Separator
This equipment separates the gas from the mixture of

CHALLENGES

liquid-gas, which comes from the well. Then, the liquid is

sent through the flow line and the gas stream is sent to

The main challenge to be achieved is to maintain the

the compressor suction.

equipment integrity. It is important to mention that the

gas stream has 4% mole of H2S and 1.44% mole of
CO2, which combined with water could be a very
corrosive mixture. In addition, the high content of H2S

SPE 74414

SELF-SUFFICIENT SYSTEM FOR CONTINUOUS GAS LIFT IN A VERY HARMFUL SOUR GAS ENVIRONMENT

combined with the high pressure can cause cracking

phenomenon.

Safety valves operated with differential pressure

should be installed in order to stop the system
operation when an unexpected leak comes up.

Corrosion is a phenomenon of oxidation when water and

Automatic stop for electrical motor should be

steel are combined with either H2S or CO2. It is greatly

provided for protecting the mechanical components

accelerated as the temperature increases. All of those

of the compressor.

conditions are present in this particular case

Sensor for H2S should be provided in order to stop

the motor when some gas leak comes up.

Cracking phenomenon takes place where the steel

suffers tension and the gas contents H2S at certain

The facility should be supervised by specialists on

safety measures.

pressure. The root of this phenomenon comes from the

hydrogen ionization, which penetrates the steel and

EQUIPMENT SIZING

reacts with carbonate to liberate methane, causing the

steel to be more ductile and therefore more likely to be

The equipment sizing process was done based on the

cracked.

well productivity and the flow properties. The following

procedure was performed to reach this goal:

Figure 3 shows that with 4% mol of H2S into the gas

stream, and 2000 psig of surface pressure, cracking

Calculation procedure:

phenomenon will take place.

1. Choose a reservoir model that matches the historic
To avoid all of these risks, the following measures were

reservoir behavior.

considered:

2. Choose a correlation for vertical flow that matches

with measured data.

Compressor to be used in this application should be

3. Choose a correlation for horizontal flow, which gives a

built for sour gas handling.

good match with the observed data.

A Coiled tubing to inject the sour gas into the well ,

4. Determine the optimum gas injection rate to be

should be used as a first step for avoiding the

injected, by using a commercial software for multiphase

corrosion and cracking problems.

flow.

A chemical corrosion inhibitor should be injected into

5. Determine the flowing gradient all along the tubing, by

the gas stream through the coiled tubing, as a

using the data obtained in the previous step.

second step for avoiding the corrosion and cracking

6. Determine the available gas pressure at different

problems.

depths by using the Culender and Smith procedure. It is

necessary to do a sensitivity analysis with several coiled

Another challenge to be achieved is to make the facility

tubing sizes for determining several gradient curves.

safety for a normal and continuous operation. Regarding

7. Determine the surface injection pressure needed for

this point, the following measures were considered:

injecting the sour gas at certain depths. This step can be

done by comparing the flowing gradient obtained in the
step No.5, and the available pressure obtained in the

M. LOZADA AGUILAR, H. RAMOS, A. INESTROSA, AND R. HERNNDEZ

SPE 74414

step No.6. The surface injection pressure must be read

tubing size, we required 8 HP more of potency.

at the surface from the appropriate gradient curve.

Based on previous calculations, 200 HP motor was

8.- Determine the potency requirements With the

requested for this operation, giving a good security

optimum gas injection rate obtained in the step 3, and

margin.

the surface injection pressure obtained in the step 7.

9.- Select the engine potency required for this particular

It was not possible to get a

application, giving a security margin.

Therefore a 1 coiled tubing size was installed. It was

1 coiled tubing size.

also decided that during the first test stage, the injection
point would be set at 4000 meters. After the first coiled

Comments:
-

Vogel correlation was used as a reservoir model.

tubing revision, the injection point would be set at 4500

Hagedorn and Brown correlation was used for

meters, using a 1 coiled tubing size.

vertical flow correlation. Begs and Brill was used for

horizontal flow correlation.
-

EQUIPMENT DESIGN

According to figure 4, the optimum gas injection rate

for this well is 1 MMSCFD, and It is possible to

Coiled tubing

produce 200 STBD more by using 1 instead of 1

Coiled tubing selection is a very important issue for

coiled tubing size.

keeping the system safety. As we mentioned before,

In figure 5 we can see, that as the injection point

either corrosion or cracking problems inside the tubing

gets deeper, the production rate increases, being

are likely to be happened. The coiled tubing selected for

possible to produce 150 stbpd more, by injecting gas

this particular application is made of an special steel

at 4500 meters instead of 4000 meters. In order to

alloy, which resists the sour gas environment and delays

take the decision where the injection point will be

corrosion problems. The steel alloy for this coiled tubing

located, it is necessary to determine the potency

is as follows:

requirements for each depth.

-

Component

Composition (weight %)

In the figure 6 we can observe that injecting gas at

10-14

4000 meters, it is necessary to have 1700 psig and

Mn

10-90

1850 psig of surface injection pressure, by using 1

2.5 (maximum)

and 1 coiled tubing size respectively. In the

0.5 (maximum)

same figure, we can observe that if we decided to

Si

30-50

inject gas at 4500 meters, 1850 psig and 2050 psig

Cr

50-70

of surface injection pressure is required, by using 1

Cu

25 (maximum)

and 1 coiled tubing sizes respectively.

Ni

20 (maximum)

Mo

21 (maximum)

Finally, from figure 7, we can observe that as the

injection

point

gets

deeper,

the

potency

requirements increases. Taking the desition to inject

gas at 4500 meters, it is required 8 HP more than if
we inject gas at 4000 meters. From the same figure,
we observe that using 1 instead of 1 coiled

Compressor.The compressor selected for this application, is a

reciprocate type with double effect . This compressor
has internal components to operate with sour gas, and it

SPE 74414

SELF-SUFFICIENT SYSTEM FOR CONTINUOUS GAS LIFT IN A VERY HARMFUL SOUR GAS ENVIRONMENT

is moved with a 200 HP electrical motor. It also has two

regime, and the separator is very close to the tubing

stages, because the compression ratio is 13.33 for this

head.

particular case. Suction pressure is ranged between 150

The well instability grade depends on the gas

to 250 psig, as long as the discharge pressure is ranged

injection rate and on the tubing head choke size. For

between 1600 to 2000 psig. Gas to be comprised has

this particular application, it was necessary to

0.8 SG with 4% mol of H2S, and 1.44% mol of CO2 .

produce the well with 5/8 tubing head choke size,

and by injecting 1 mmstcf/d, in order to keep the well
flow stable.

Separator
Separator to be used for this application handles sour

It is very important that the compressor operation

gas. The separator is 56 of diameter and 20 feet length.

must be as stable as possible, because during

This separator is oversized, because it was decided to

unstable conditions the compressor components

use an available one.

degrade faster. Indeed, we had a lot of problems

because the suction valves degraded very rapidly.

Corrosion inhibitor system

This system is designed

for handling 5000 PSIG of

Solutions

pressure and 200 liters per day of pumping capacity.

Some modifications were made to the initial project to

Mexican

make it more efficient, as we describe as follows:

Petroleum

Institute

determined

that

the

optimum inhibitor injection rate required was between 20

In order to keep the compressor pressure stable, it

to 30 liters per day. During normal operation this

was proposed to install two additional scrubbers

injection rate will be adjusted according to the needs.

after the separator, and to change the 2 gas line

which connects the separator with the compressor,
for one of 6.

START UP OPERATION
-

the

relay

valve

from

the

second

compressor stage to the first compressor stage.

The operation started in March of this year. Although it

was necessary to make some modifications over the

Change

Install a device in the separator control, in order to

facilities, it was considered a successful one. The way of

make the communication between the level control

how the system was installed is depicted in figure 8.

and the separation pressure faster.

The diagram after the modification is depicted in

Troublesome during the start up stage

figure 9.

The main problems during this stage are as follows:

-

Well flow instability was presented during pilot test,

RESULTS

mainly because it was on sub-sonic regime and

also due to the flow patterns. Both conditions are

Before the modifications were done, this system had an

related to the well productivity index and the well

instability problem, therefore, the compressor suction

geometry.

valves needed to be changed very often. After this

The system control nature of the separator is the

system was modified, it has been working in a

main factor which makes the system to be unstable.

continuous way up to now, having shutting periods due

As we said before, this well flows on sub-sonic

to the electrical power failures in the area.

M. LOZADA AGUILAR, H. RAMOS, A. INESTROSA, AND R. HERNNDEZ

SPE 74414

In order to start up the system after the shutting periods,

during the normal operation, because this is an

it was necessary to use nitrogen, increasing the

important parameter for getting the well stabled.

operation expenditures; thereby, it was necessary to use

the free gas storage into the casing for this purpose,

ECONOMICAL ASSESSMENT.

giving an excellent result. From July on, we have not

used any nitrogen at all for starting up the system. It is

This

important to mention that natural separation gas is taking

because the initial investment is $500, 000 dollars, and

place into the well, as the tubing is communicated with

the oil production increment in 800 STBD. In figure 10,

the casing.

we can observe the basis for this analysis and the

project

has

excellent

economical

indicators,

indicators gotten from them. The net present value in ten

It was not possible to produce the designed oil rate,

years will be $ 15 MM dollars, with an investment

because the unstable flow condition did not allow us to

efficiency of 30. It seems that those indicators are out of

increase the tubing head choke size. The designed oil

range, but the real point is that the investment is low,

rate is 1000 STBD, and the well is producing only 800

and the oil production increase is high.

STBD.
CONCLUSIONS.
ENHANCED

SELF-SUFFICIENT

SYSTEM

FOR
This work centers on the design of an artificial gas lift

CONTINUED GAS LIFT.

with sour gas. The main findings of this work are:

In

the

following

section,

we

describe

some

recommendations to enhance the self-sufficient system

1. The self-sufficient system for continuous gas lift is

for continuous gas lift:

totally feasible in the way that it is proposed.

Sour gas injection should be done, by using a 1

coiled tubing size, and by injecting corrosion inhibitor

2. This system is an excellent option for those wells in

into the gas stream.

which gas lift is the best option for artificial lift systems,

For compressors moved with electrical motor, it is

and where there is not available infrastructure. In the

recommended to use a

Bellota-Chinchorro Asset, it has been possible to

variable speed driver, in

order to make the gas injection adjustment easier,

produce at least 7000 STBD

which is a very important issue in wells with unstable

-

flow.

3. By using the coiled tubing and the chemical corrosion

It is also important for this kind of wells, to have a

inhibitors, cracking and corrosion will be in high

scrubber in the separator discharge, and to have a

proportion avoided.

6 or 8 gas line between the scrubber and the

compressor suction, in order to avoid the unstable

4. This system involves many disciplines, therefore, it is

flow condition.

very important to form a multidisciplinary group to be

On wells which are flowing on subsonic regime, it is

successful.

also important to have a variable tubing head choke,

in order to make easier the choke size adjustment

SPE 74414

SELF-SUFFICIENT SYSTEM FOR CONTINUOUS GAS LIFT IN A VERY HARMFUL SOUR GAS ENVIRONMENT

5. This project has excellent economical indicators,

Artificial-Lift

having a net present value of $ 15 mm dollars and an

Bucaram, N.W. Heln Jr.

investment efficiency of 30, over ten years of period

Factibilidad de sistemas artificiales de produccin en

analysis.

el campo Crdenas, Instituto Mexicano del Petrleo,

Methods,

SPE,

J.D.

1985, Ing. Horacio Ziga Puente.

6. Currently, a major project with seven wells is taking
place, previous to the installation of the gas lift network.
ACKNOWLEDGMENTS
-

This project would not have been possible without

the support from our authorities.

We thank Ing. Jorge Carranza Becerra for giving us

some excellent ideas for this project.

We thank P.H. Victor Hugo Arana for helping us on

this project.

REFERENCES.
Bombeo neumtico autoabastecido.-- Jos Angel
Gomez Cabrera..- Revista internacional del petrleo
1998.
The Technology of Artificial Methods -volume 2aKermit E. Brown.
Temas selectos sobre bombeo neumtico continuoColegio de Ingenieros Petroleros de Mxico.
Optimizing Production With Artificial Lift Systems,
july 1989, petroleum Engineer, L. Douglas Patton,
Aurora, Colo.
Recommendations and Comparisons for Selecting

Ciegg,

S.M.

M. LOZADA AGUILAR, H. RAMOS, A. INESTROSA, AND R. HERNNDEZ

Pws = 200 kg/cm

24

50 m

Tf = 141C

1002 m

16"

CO2 = 2-3 % mol

3 1/2

H2S = 4-7 % mol

3544 m

10 "
PAKER 7 5/8

4270 m

LINER 5"

4286 m

Water cut = 0%
API = 37

g = 0.74 g/cc

5075 m

7 5/8"

5285-5327 m

PAY ZONE.
5"

5433.50 m
5472 m

Figure 1: Well characteristics in Mora field

ssv

8"

LG

LG

LC

LC

S
8 FLO W
L Q U ID

G A S IN J E C T IO N L IN E
C O R R O S IO N
IN H IB IT O R

C O IL E D
T U B IN G 1 1 /2

T U B IN G

3 1 /2

P A Y ZO N E

Figure 2: System diagram.

L IN E

SPE 74414

SPE 74414

SELF-SUFFICIENT SYSTEM FOR CONTINUOUS GAS LIFT IN A VERY HARMFUL SOUR GAS ENVIRONMENT

PPM OF H 2S INTO THE GAS

1

10

100

1,000

10,000

100,000

TOTAL PRESSURE (PSIA)

10,000
REGIN DE AGRIETAMIENTO DEL
MATERIAL POR
CORROSIN BAJO
CRACKING
REGION
ESFUERZO EN PRESENCIA DE
SULFHIDRICO

1,000

REGIN
NO
CRACKING
SIN AGRIETAMIENTO
REGION
DEL MATERIAL

100

10
0.01

0.001

0.0001

0.1

10

% MOL OF H 2S INTO THE GAS

Figure 3: Cracking diagram.

Production rate (stbpd)

1400
1200
1000
800

1 C.T.

600

1 C.T.

400
200
0
0

0.5

1.5

Gas injection rate (mmstcfd)

Figure 4: Optimum gas injection rate .

2.5

10

M. LOZADA AGUILAR, H. RAMOS, A. INESTROSA, AND R. HERNNDEZ

Production rate (stbpd )

1600

1200

1 C.T.

800

1 C.T.

400

0
3000

3500

4000

Depth

4500

5000

( meters )

Figure 5: Production Vs depth sensitivity.

Pressure(psig)
1000 1250 1500 1750 2000 2250 2500 2750 3000
0

Depth(meters)

-1000
-2000
-3000
-4000
-5000
-6000

Figure 6: Surface injection pressure requirements

CT- 1 1/4"-1800 PSI

CT- 1 1/4"-1900 PSI
CT- 1 1/4"-2000 PSI
CT- 1 1/2"-1600 PSI
CT- 1 1/2"-1700 PSI
CT- 1 1/2"-1800 PSI
Well gradient

SPE 74414

SPE 74414

SELF-SUFFICIENT SYSTEM FOR CONTINUOUS GAS LIFT IN A VERY HARMFUL SOUR GAS ENVIRONMENT

182
180
178
176

HP

174

CT- 1

172

CT-1

170
168
166
164
162
3000

3500

4000

4500

5000

GAS INJECTION DEPTH (METERS)

Figure 7: Potency requirements

S.

NE

C
N2

Figure 8: System diagram before the modification.

11

12

M. LOZADA AGUILAR, H. RAMOS, A. INESTROSA, AND R. HERNNDEZ

SPE 74414

R EC T.
1

S.

R EC T.
2

H.

NE

C
N2

Figure 9: System diagram after the modification.

16000000

N.P.V. (m m dollars

14000000
12000000
10000000
8000000
6000000
4000000
2000000
0
-2000000 0

Ana lysis pe riod (ye a rs)

Figure 10: Economical assessment.

10

12