Continuous Flow Gas Lift Design

By Jack R. Blann

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 2
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Gas Lift appears as Chapter 12 in:

Volume IV
Production Operations Engineering
Edited by Joe Dunn Clegg

Chapter 12 was Co-authored by:

Herald W. Winkler, and
Jack R. Blann
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 Two Types of Continuous Flow
Gas Lift Design

Design for Normal Wells.

Winkler Design for High gas Injection rates.

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 Iranian Gas Lift Well
In Agha Jhari Field

Produced:
Natural Flow = 37,000 B/D
Gas Lift = 43,000 B/D

Had 26 mandrels and valves

to +3000 ft.

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LIBYAN GAS LIFT WELL
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PRODUCTION MANIFOLD IN
LIBYA 7
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LIBYAN GAS LIFT TESTS
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 Continuous Flow Installation Design Based on
Constant Decrease in Operating Injection-Gas
Pressure for Each Succeeding Lower Gas Lift
Valve
All Gas Lift Valves have same port size.
There is a constant decrease in the operating
injection pressure for each succeeding lower
valve.
Port size that allows the injection-gas
throughput for unloading and operating the well.

API DESIGN TECHNIQUE 9

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 This installation design method is recommended
for gas lift valves with small production-pressure
factors.
When the ratio of the port area to the bellows
area is low, the decrease in the injection gas
pressure between gas lift valves, based on
additional tubing effect pressure for the top
valve, is not excessive.

API DESIGN TECHNIQUE

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Injection-Pressure Operated Gas Lift
Valve

Production Pressure
factor =
Ratio of Area of Port to
Area of Bellows

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GAS LIFT VALVE SPECIFICATIONS
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 The effect of bellows-assembly load rate on the
performance of the valves is not considered in
the installation design calculations.
Safety factors included in these calculations
should allow sufficient increase in the operating
injection gas pressure, which is necessary to
provide valve stem travel for adequate
injection-gas passage through each successively
lower unloading valve without interference from
upper valves.

API DESIGN TECHNIQUE 13

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 Selection of a constant injection- gas
pressure decrease, or drop, in the surface
operating injection pressure for each
succeeding lower gas lift valve should not
be arbitrary, as proposed in some design
methods.
The pressure decrease should be based on
the gas lift valve specification to minimize
the possibility of upper valves remaining
open while lifting from a lower valve.

API DESIGN TECHNIQUE 14

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 The additional tubing-effect pressure for
the top gas lift valve is a logical choice for
this decrease in the operating injection-
gas pressure between valves.

API DESIGN TECHNIQUE

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 Closing or reopening of an injection-
pressure-operated gas lift valve is partially
controlled by the production pressure
effect, which is equal to the production
pressure factor for the valve multiplied by
the difference in flowing production
pressure at the top valve depth.

API DESIGN TECHNIQUE

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 The flowing pressure at an unloading-
valve depth changes from the transfer
pressure, (PptfD)min, To a higher flowing
production pressure after the next lower
valve becomes the operating pressure

API DESIGN TECHNIQUE

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 The additional tubing-effect pressure is
the difference between (PptfD)min, and the
maximum flowing-production pressure at
the unlading valve depth, (PptfD)max, after
the point of gas injection has transferred
to the next lower valve.

API DESIGN TECHNIQUE

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 As the unloading gas lift valve depths
increase , the distance between valves
and the difference between (PptfD)min, and
(PptfD)max decrease.
Although the additional tubing-effect
pressure decreases for lower valves, the
injection-gas requirement for unloading
increases with depth.

API DESIGN TECHNIQUE

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 An increased stem travel, or stroke, is
usually needed for the lower valves to
generate the larger equivalent port area
necessary for the higher injectiongas
requirements with the lower pressure
differentials that occur across these
deeper valves.

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 A constant decrease in the operating
injection-gas pressure equal to the
additional tubing effect pressure for the
top valve allows a a greater increase in
the injection gas above initial opening
pressure for lower gas lift valves.

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API Gas Lift Design

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Gradient Curve

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 When the injection-gas pressure
significantly exceeds the flowing-
production pressure, an arbitrary increase
in injection-gas-pressure,
Pio can be added to the initial production-
pressure effect for the top valve for
calculating the spacing and the initial
opening pressures of the unloading gas lift
valves
API DESIGN TECHNIQUE
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 The total decrease in the injection-gas pressure
is distributed equally between each successively
lower gas lift valve rather than having a sizeable
pressure drop across the operating gas lift valve
or orifice-check valve
This reduces the possibility of multipoint
injection through the upper unloading valves by
ensuring that the valves remain closed after the
point of gas injection has transferred to the next
lower valve,

API DESIGN TECHNIQUE

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 API Design Technique
Determination of Valve Depths

Because the final injection gas pressure is

not known until the installation is designed,
a pressure difference of 100 to 200 psi
between the unloading PioD and PpfD
traverses is assumed for locating the
deepest valve depth.

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 API Design Technique
Determination of Valve Depths
The assumption of PioD -PpfD = 100 to
200 psi should ensure calculation of the
operating valve depth.
The static bottomhole pressure, PwsD and
temperature, Twsd are usually referenced
to the same depth, which is the lower end
of the production conduit, Dd.

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 API Design Technique
Determination of Valve Depths
Calculate the maximum unloading GLR
based on the maximum injection gas rate
available for unloading and the maximum
daily design total fluid rate.

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 Well Information
Tubing size = 2 7/8 in. OD
Tubing Length, = 6000 ft.
Max. Valve Depth, Dv(max) = 5970 ft.
Static bottomhole pressure at Dd , Pwsd = 1800 psig at
6000ft.
Daily production rate = 800 STB/D
Water Cut = 50%
Formation GOR = 500 scf/STB
Oil Gravity = 35o API
Gas Gravity g = 0.65
Produced-water specific gravity, w= 1.08
Bottomhole temperature, Twsd=170oF at 6000ft.
Design unloading wellhead temperature, Twhf = 100oF.
Load-fluid pressure gradient, gls = 0.46 psi/ft.
U-Tubing wellhead pressure, Pwhu = 100 psig.
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Flowing wellhead pressure, Pwhf = 100 psig. 2/9/2008
 Well Information
Static fluid level = 0 ft.
Surface kickoff injection-gas pressure, Pko = 1000 psig.
Surface operating injection-gas pressure, Pio = 1000
psig.
Maximum unloading injection-gas rate, qgiu = 800
Mscf/D.
Operating daily injection-gas rate, qgi = 500 Mscf/D.
Wellhead injection-gas temperature, Tgio = 100oF
Assigned valve-spacing pressure differential at valve
depth, PsD = 50 psi.
Test rack valve temperature, Tvo = 60oF.
Assigned minimum decrease in surface operating
injection-gas pressure between valves, Pio = 20 psi.
Minimum distance between valves, Dbv(min) = 150 ft. 30
Gas lift valves : 1.5 inch O.D. nitrogen charged with A2/9/2008
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0.77 in2, and sharp edged seat.
 API Design Technique
Step 1:
Calculate Maximum Unloading GLR
Rgiu =qgiu / qlt
Where
qgiu= maximum unloading injection rate,
Mscf/D,
qlt = total liquid daily production rate,
B/D, and
Rgiu = maximum unloading GLR, scf/STB
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 API Design Technique
Calculate Maximum Unloading GLR

Rgiu =qgiu / qlt

= 800,000 scf/D / 800 STB/D
Rgiu = 1000 scf/STB

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 API Design Technique

STEP 2: DETERMINE FLOWING PRODUCTION

PRESSURE, PPFD AT DD 33
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Gradient Curve

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 API Design Technique

Step 3:Calculate the

unloading-flowing-
pressure-at-depth
gradient, gpfa above
point of gas injection,
gpf .

gpfa = 900-100 / 6000

gpfa = 0.1333 psi/ ft.

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 API Design Technique

Step 4
Calculate the operating injection gas pressure at the lower end of the
production conduit.
where:
Pio = injection-gas pressure at surface, psia
PioD = injection-gas pressure at depth, psia
e = Napierian logarithm base = 2.718.
g = gas specific gravity (air = 1.0), dimensionless.
D = true vertical depth of gas column, ft.
bar T = average gas column temperature, R
bar z = compressibility factor based on gas column average
pressure P and temperature, T, dimensionless.
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 API Design Technique

Step 4
PioD = 1154 psig at 6000 ft.
ggio = (1154 1000) / 6000 = .0257psi/ft

Since Piod - Ppfd = 1154 900 = 254 psi

Exceeds 200 psi, the maximum valve depth
of 5970 ft can be attained.
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 API Design Technique

Step 5:
Calculate the unloading gas lift valve
temperature at depth gradient, gTvu .

Bottomhole temperature,
Twsd =170oF at 6000ft.
Design unloading wellhead temperature,
Twhf = 100oF at surface.

gTvu = (170 100) / 6000 = 0.0117oF/ft.38

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 API Design Technique

Step 6
Dv1 = depth of top valve, ft
Pko = surface kick-off or average field injection-gas pressure
(optional), psig
Pwhu = surface wellhead U-tubing (unloading) pressure, psig
PsD = assigned spacing pressure differential at valve depth, psi
where
gls = static-load (kill) fluid pressure gradient, psi/ft
ggio = injection-gas pressure at depth gradient, psi/ft

Step 6: 39
D v1 = (1000 - 100 50) / (0.46 -.0257)
D v1 = 1957 ft.
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 Step 7
Calculate the minimum flowing-production
pressure, (PpfD1)min, the injection-gas
pressure, PioD1, and the unloading gas-lift
valve temperature, TvuD1, at the top valve
depth by multiplying the appropriate
gradient by the valve depth, Dv1, and
adding to the appropriate surface values
(where n = 1 for top valve):

API DESIGN TECHNIQUE

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 Step 7.
Calculate the minimum flowing-production
pressure, (PpfD1)min, injection-gas pressure,
PioD1, and the unloading flowing temperature,
TvuD1 at Dv1 of 1,957 ft as described on previous
slide:
( PpfD1)min = 100 + 0.1333 (1,957) = 361 psig
PioD1 = 1,000 + 0.0257 (1,957) = 1,050 psig
TvuD1 = 100 + 0.0117 (1,957) = 123 F

API DESIGN TECHNIQUE

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 API Design Technique
Step 8
Calculate the depth of the second gas-lift valve,
Dv2, where n = 2 on the basis of the assigned
minimum decrease in surface injection- gas
pressure, pio, for spacing the gas-lift valves and
the PioD-traverse.
A valve spacing differential of around 20 to 30 psi
will usually be sufficient for most 1.5-in. OD gas-
lift valves. However, 1-in. OD valves with large
ports may require a higher, pio. This can be
checked by calculating the additional production-
pressure effect, Ppe1, after the valve depths are
calculated for the assigned pio . 42
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 API Design Technique
Step 8
(PpfD(n-1))min+gls(Dbv)=[PioD(n-1)-(n-1)Pio]- PsD +ggio(Dbv)

Solve For Dbv:

Dbv = PioD(n-1) [(n-1)Pio]- (PpfD(n-1))min - PsD / (gls ggio

and
Dv(n) = Dv(n-1) + Dbv

The decrease in surface injection-gas pressure for

calculating Dv2 is Pio, and for Dv3 is 2 (Pio), and for Dv4
is 3 (Pio), and this procedure continues for each
succeeding lower valve.
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 API Design Technique
Step 8
Solve For Dbv:
Dbv = PioD(n-1) [(n-1)Pio]- (PpfD(n-1))min - PsD/ (gls ggio)

Dbv = 1050 - 0 - 361 50 / (0.46 0.0257) = 1472 ft.

and
Dv(2) = Dv(n-1) + Dbv

Dv(2) = 1957 + 1472 = 3429 ft.

Repeat steps 7 and 8 for each valve location until reaching

maximum depth
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 The calculated valve spacing for the sixth
valve, Dv6 , would exceed the maximum
valve depth, Dv(max) , of 5,970 ft. Because
an orifice-check valve will be placed in the
bottom wireline-retrievable valve mandrel,
no test-rack valve setting information is
required. This completes the valve spacing
calculations.

API DESIGN TECHNIQUE

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 API Design Technique
Graphical Representation

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 API Design Technique
Determination of Gas-Lift Valve Port Size and
Calculation of Test-Rack Opening Pressures.

The gas-lift valves port ID and test-rack opening

pressure calculations follow:

Step 1. Determine the port size required for the gas-lift

unloading valves and the operating orifice-check valve
orifice ID. The upstream injection-gas pressure, P1, is
based on PoD5 of the last unloading valve corrected to
the orifice-check valve depth of 5970 ft:

P1 = 1,068 + 0.0257 (5,970 5,762) = 1,073 psig at

5,970 ft 47
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 API Design Technique
Determination of Gas-Lift Valve Port Size
and Calculation of Test-Rack Opening
Pressures.
Step 1 (Continued)
The downstream flowing-production pressure,
P2, is equal to the minimum flowing-production
pressure at 5,970 ft.
P2 = 100 + 0.1333 (5,970) = 896 psig at 5,970
ft
Pov = 1,073 896 = 177 psi across the orifice-
check valve
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 API Design Technique
Determination of Gas-Lift Valve Port Size and
Calculation of Test-Rack Opening Pressures.
Step 1 (Continued)
From the Thornhill / Craver correlation, the required
equivalent orifice size is near 14/64-in.; therefore, the
next largest gas-lift valve port ID is 1/4-in. This size is
sufficient for all of the upper unloading valves because
they have a higher injection-gas operating pressure and
a greater differential pressure between PioD and
(PpfD)min.

An equivalent orifice size of 12/64-in. to 13/64-in. is

required to pass the operating injection-gas rate of 500
Mscf/D.
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 50
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 API Design Technique
Determination of Gas-Lift Valve Port Size and
Calculation of Test-Rack Opening Pressures.
Step2
Record the valve specifications for a l.5-in. OD
gas-lift valve having a 1/4-in. ID port with a
sharp-edged seat where Ab = 0.77 sq. in.

from table:
(Ap/ Ab) = 0.064,
(1 Ap /Ab) = 0.936,
and Fp = 0.068.
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 Determination of Gas-Lift Valve Port Size and
Calculation of Test-Rack Opening Pressures.

Step 3
Calculate PoD1
PoD1 = PioD1
where
PioD1 = injection-gas pressure at valve depth, psig
PoD1 = injection-gas initial gas-lift valve opening
pressure at valve depth, psig
PoD1 = 1,050 psig at 1,957 ft

API DESIGN TECHNIQUE

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 Step4
Calculate the test-rack set opening pressure of
the first valve (n = 1), Pvo1, using Eqs. 12.44
and 12.45 or 12.46:
PbvD(n) = PoD(n) (1-Ap/Ab)+ PpfD(n)min (Ap/Ab)
Pvo(n) = CT(n) (PbvD(n)) / (1- Ap/Ab)

PbvoD(n) = 1050 (0.936)+361 (0.064) = 1006 psig

API DESIGN TECHNIQUE 53

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 API Design Technique
Step 5
Pvo(n) = CT(n) (PbvD(n)) / (1- Ap/Ab)
for CT1 = 0.876 (Calculated using TvuD1 =
123oF):
Pvo1 = 0.876 (1006)/0.936 = 942 psig at 60 oF
Step 6
Calculate the injection-gas initial opening pressure
of the second gas-lift valve at depth (n = 2),
PoD(n) = PioD(n) (n-1) Pio
PoD(2) = 1088 20 = 1068 psig at 3429 ft.
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 API Design Technique
Step 7
Calculate the maximum flowing-production
pressure opposite top unloading valve
immediately after the point of gas injection has
transferred to the second (lower) valve,
(PpfD1)max. (PpfD1 )max is shown graphically in
Figure and can be calculated using the following
equation:
(PpfD1)max = Pwf + Dv1 [(PoD2 Pwhf )/Dv2]
(PpfD1)max = 100 + 1957 ((1068 -100)/3429)
(PpfD1)max = 652 psig at 1957 ft. 55
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API DESIGN TECHNIQUE
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 API Design Technique
Step 8
Determine if the assumed decrease in surface injection-
gas pressure, Pio, is sufficient for the required gas-lift
valve port size by calculating the additional production-
pressure effect, Ppe1, at the top valve:
Ppe1 = Fp [(PD1D1)max - PD1D1)min ]
Ppe1 = 0.068 (652 361) = 20 psi.

If Ppe1 is less than or equal to the assumed Pio

proceed with the design. If Ppe1 is greater than the
assumed Pio, then set Pio = Ppe1 and redo the spacing
design. This is a conservative approach and many
operators use actual operating experience to determine
which Pio to use. 57
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 Repeat Steps 6, 4 and 5 for remaining
gas-lift valves:
An orifice-check valve is recommended for
the sixth valve at 5,962 ft. The orifice ID
should be 1/4-in. to pass sufficient gas to
gas lift the well. A tabulation form for
these calculations is given in table.

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API DESIGN TECHNIQUE

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