ARTIFICIAL LIFT SYSTEM

1. Introduction to Different Types of Artificial Lift System

2. Advantages & Disadvantages of Gas Lift System
3. The Design of Continuous Gas Lift System
4. Pressure & Gas Volume Required for Gas Lift System

Prof Dr Ariffin Samsuri

FACULTY OF PETROLEUM & RENEWABLE ENERGY ENGINEERING (FPREE)

1
Innovative. Entrepreneurial . Global
 Outcomes

Students should be able to:

• Describe the working principles of gas lift system
• Graphically design the gas lift system
• Calculate pressure & volume of gas required for gas lift injection

FACULTY OF PETROLEUM & RENEWABLE ENERGY ENGINEERING (FPREE)

2
Innovative. Entrepreneurial . Global
 INTRODUCTION

– Purpose:
To maintain a reduced producing bottom hole pressure so
that formation can give desired reservoir fluids  required
flowing bottom hole pressure can be maintained for certain q

– Design basis:
Maintaining required flowing bottom hole pressure for
desired q

–Requirement based on:

•When well produced less than desired q
•When well dead

FACULTY OF PETROLEUM & RENEWABLE ENERGY ENGINEERING (FPREE)

3
Innovative. Entrepreneurial . Global
 Artificial Lift Fundamental

Reservoir pressure so low  static fluid level below wellhead  no natural flow
If PI sufficiently high & produced fluid contains enough gas  flowing fluid pressure
gradient gives positive wellhead pressure  well can flow but need kicked off by
swabbing or other techniques 4
 Artificial Lift Fundamental

Pump installed create limited drawdown  q

5
 Maximises Potential Drawdown & q

Deeper pump  create larger drawdown on formation & maximum potential

production can be achieved 6
 ARTIFICIAL LIFT SYSTEM TYPE

• Available types:
– Sucker rod pump
– Progressive cavity pump – PCP
– Hydraulic pump
– Electrical submersible pump (ESP)
– Electrical submersible progressive cavity pump (ESPCP)
– Rotating rod pump
– Sonic pump
– Plunger lift
– Gas lift
– etc

7
Various Artificial Lift Technique/Method

8
Pump Classification

9
 SELECTION CONCEPT
• Philosophy : for maximum potential, select most economical type/system
• Methods or steps include:
– Operator experience
– Method available for installation @ certain area
– Possibility of working in adjoining or similar field
– Method will lift @ desired q from required depth
– Evaluating advantages & disadvantages
– Expert system to both eliminate & select system
– Evaluation of initial cost, operating costs, production capabilities, etc

• Generally should consider: geographic location, capital cost, operating cost, production
flexibility, reliability, mean time between failures, reservoir pressure, well productivity, reservoir
fluids, long-term reservoir performance & facility constraints

• In most cases, what has worked best or which lift method performs best in similar field serve
as selection criteria, together with consideration on equipment services available

 type/system which provides highest present value for project life will be selected

10
 ARTIFICAL LIFT TECHNIQUE SELECTION CRITERIA

FACTOR TO BE CONSIDERED:
1. Well & reservoir characteristics
1. Well factor
• Well geometry, performance, especially PI, q
2. Reservoir factor
• Reservoir properties especially drive & type
3. Fluid factor
• Fluid properties particularly GOR, composition, SG, viscosity
2. Field location & environment
• Well location & environment pollution
3. Operational problems
4. Economics
5. Implementation of artificial lift selection techniques
6. Long term reservoir performance & facility constraints
11
 WELL & RESERVOIR CHARACTERISTICS

1. Production casing size

2. Maximum size of production tubing & required production rate
3. Annular & tubing safety systems
4. Producing formation depth & deviation
5. Nature of produced fluids
6. Well inflow characteristics

12
 Influence of IPR on Production @ Drawdown Increased

Influence of IPR on production increase achieved when well drawdown increased

13
 FIELD LOCATION & ENVIRONMENT

• Offshore platform design dictates maximum physical size and weight of artificial lift
equipment can be installed
• Onshore environment strongly influence artificial lift selection:
• Urban location requiring minimum visual & acoustic impact
• Remote location with minimum availability of support infrastructure or regular access to well
• Climatic extremes,
• e.g. arctic operations will limit practical choices
• Wellhead – processing facilities distance will determine minimum wellhead flowing
pressure
• E.g. ESP more attractive than gas lift since extra pressure drop @ flowline, due to injected gas,
makes gas lift unsuitable option
• Power source available for prime mover will impact detailed equipment design &
reliability
• E.g. voltage spikes  reduce ESP’s electrical motor lifetime.

14
 OPERATIONAL PROBLEMS

• Sand production  gas lift more tolerant to solids than

centrifugal pump
• Inhibitor can be carried in the power fluid for hydraulic pump -
 suitable for massive organic & inorganic deposits such as
paraffin, asphaltene, scale & hydrate

15
 ECONOMICS

• Full life cycle of economic analysis : operating cost vs initial capital cost to
installed artificial lift
• If capital cost to installed small as compared to total project costs and benefit to
increased revenue & reduced operating cost  installed artificial lift
• Need to consider:
• Capital cost vs total operating cost & benefit
• Reliability (maintenance & operator costs)
• Energy efficiency
• Maintenance cost depend on: location, service company infrastructure
• Number of well (economic scale)  operating costs
• Need for automation & centralised facilities  operating costs
• Operational staff skill @ artificial lift technique

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 Energy Efficiency Comparison

Energy Efficiency of Various Artificial Lift Method

Only ESP & PCP have EE > 50%
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 IMPLEMENTATION

• Need to consider, how to:

• Determine the optimum type of artificial lift for a given well
• Matching facility constraints, artificial lift capabilities & well
productivity  efficient lift installation ?
• Environmental factor
• Geographical factor
• Production problems: sand & paraffin production
• Reservoir fluid characteristics
Example:
• Populated area : sucker rod pump is not suitable
• GLR: suitable for gas lift but problem for all pumps

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 Long Term Reservoir Performance

Problems in artificial lift selection & sizing  2 approaches

1. Equipment installed can handle well production & production condition
@ lifetime
 oversize equipment based on producing large water
 equipment operate at poor efficiency due to underloading at
early production life
2. Design for current well producing conditions and not worry about future
 many changes in type of lift equipment @ well’s producing life
 low cost operation @ short term but large sums money spent
later to change artificial lift equipment and/or completion

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 Facility Constraints

• In new field development; fluid handling equipment may significantly

increase size & cost of facilities required
– Rod pump & ESP : only produced fluid handled through facilities
– Gas lift requires injection gas compression & distribution facilities
& circulating lift gas increases size of production facilities required
– Hydraulic pump needs power fluid volume equal to produced fluid
volume
• Wellbore size need to be consider for desired flow rate
– Casing designed to minimize drilling cost  limitation on artificial
lift equipment can be installed
– Smaller casing size  higher long term production cost due to well
servicing problems, gas separation problems etc.

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 METHOD/TYPE SELECTION
Examples

1. Well factor
– Big volume shallow well  continuous flow gas lift, centrifugal pump, hydraulic pump
– Small volume shallow well  sucker rod pump
– Small volume deviated deep well  hydraulic pump
2. Reservoir factor
– Water drive reservoir  gas lift if adequate high pressure supply available
3. Fluid factor
– High GOR  Gas lift
– Crude with paraffin content  Not suitable for hydraulic pump
– High viscosity & low gravity crude  Not suitable for hydraulic pump
– High viscosity crude  sucker rod pump
4. Environmental factor
– To reduce pollution  gas lift, hydraulic pump
– Offshore, remote area or wash land area  less maintenance/treatment type, such as
gas lift or hydraulic pump
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Typical application areas of artificial lift techniques

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 SUCKER ROD PUMP

• Oldest and most widely used for oil wells

• 4 principal parts:
– Pump
– Sucker rod string
– Pumping unit
– Prime mover

• Working principal:
– As energy transmitted from prime mover to polished rod, speed reducer @ gear box
reduces the speed
– Rotary motion translated to reciprocating motion through crank, pitman & beam
– Sucker rod string transmit horsepower from beam to pump
– Downhole plunger moved up-down by a rod connected to engine @ surface
– When pump actuated, work done on the well fluid as it is lifted to surface
– Plunger movement displaces produced fluid into tubing via pump (with travelling &
standing valves within pump barrel)
– Moved up-down → fluid displaces → surface @ q

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 Sucker Rod Pump Surface Equipments

Surface Equipment @ Sucker Rod Pump

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Sucker Rod Pump Operation

25
 SUCKER ROD PUMP
Advantages & Disadvantages

• Advantages:
– New wells, lower volume  cost effective over time & simple
system & easier to operate.
– Lifting moderate volume from shallow depth (1000 BPD @
7000 ft)
– Lifting small volume from intermediate depth (200 BPD @
14000 ft)

• Disadvantages:
– Most incompatible with deviated (doglegged) wells
– Limited ability to produce sand-laden fluids
– Paraffin & scale can interfere
– Free gas interference can reduces pump efficiency
– Leaking problems @ polished-rod stuffing box
26
 Sucker Rod Pump Operational Diagnosis

• Pump conditions can be evaluated by measuring load

at top of polished rod as function of its position 
dynamometer card recording
• Practical problems:
– Excessive rod or pump friction
– Restriction in flow-path
– Vibrations
– Sticking plunger, leaking travelling or standing valves
– Gas presence in pump barrel and viscous emulsion
formation.

27
Dynamic load experienced by properly operating pump

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 HYDRAULIC PUMP

• Use high pressure fluid to:

– Drive downhole turbine or positive pump, or
– Flow through venturi or jet, creating low pressure
area which produces increased drawdown and
inflow from reservoir

• Two types:
– Hydraulic jet pump
– Reciprocating positive displacement pump

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 Hydraulic Pump Completion

Hydraulic Pump
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 Hydraulic Pump – Positive Displacement Pump

Positive Displacement Hydraulic Pump Operation

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 Jet or Venturi Pump Operation

Jet or Venturi Pump Operation

•Venturi/nozzle -- reduced pressure  pressure energy converted into

velocity
•High velocity low pressure flow of power fluid commingles with production
flow @ throat 32
•Diffuser reduces velocity, increasing fluid pressure  fluid flow to surface
 Hydraulic pump installation types

Hydraulic pump installation types:

•Open system
•Power fluid supplied to downhole
equipment via separate injection tubing
•Commingle exhaust fluid with production
fluid
•Closed system
•Power fluid supplied to downhole
equipment via separate injection tubing
•Power fluid return to surface via third
separate tubing

33
 HYDRAULIC PUMP CAPACITIES

RECIPROCATING RECIPROCATING JET-FREE

POSITIVE POSITIVE PUMP
DISPLACEMENT DISPLACEMENT
PUMP PUMP

Tubing size (in.) Working Fluid Level (ft) Max.Pump Disp. (BPD) Production (BPD)

2 3/8 6000 - 17000 1311 - 381 3000

2 7/8 6000 - 17000 2500 - 744 6000

3 1/2 6000 - 15000 4015 - 1357 10000

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 HYDRAULIC PUMP ADVANTAGES

• Able to circulate the pump in and out of the well

• Positive-displacement pump capable of pumping depth to 17000 ft and
deeper for large volume
• Working fluid level of jet pump limited to 9000 ft
• By changing power-fluid rate to pump, production rate can be varied from
10 – 100% of pump capacity. Optimum speed 20 – 85% of rated speed.
Operating life significantly reduced if pump operated above the maximum
rated speed
• Suitable for crooked & deviated wells
• Jet pumps, with hardened nozzle throats, can handle sand/solid
• Positive displacement pump with diluents added or power fluid can be
heated, the pumps can handle viscous oils very well
• Corrosion inhibitors can be injected into power fluid for corrosion control.
Added fresh water can solve salt-buildup problems
35
 HYDRAULIC PUMP DISADVANTAGES

• Removing solid from power fluid is very important to positive-displacement

pump. Solid can also affect surface plunger pump. But, jet pump very
tolerant of poor power fluid quality
• Positive displacement pump have shorter life time than jet, sucker rod and
ESP but operating at greater depth and at higher strokes per minute than
beam pump
• Jet pump have very long pump life, lower efficiency and higher energy
costs
• Positive displacement pump can pump from low BHP (<100psi). Jet pump
needs 1000 psi BHP if set at 10000 ft and 500 psi when set at 5000 ft
• Positive displacement pump generally require more maintenance than jet
pump and others artificial lift (pump speed must be monitored daily & not
allowed to become excessive

36
 ELECTRICAL SUBMERSIBLE PUMP (ESP)

• Employs downhole centrifugal pump driven by electric motor

supplied with electric power via cable run from surface
penetrates wellhead & strapped to outside of tubing
• 5 basic components:
- Electric motor
- Multistage centrifugal pump
- Electric cable (surface – pump)
- Switchboard
- Power transformer
• Large volume : 150 – 60000 BPD
• Entire pumping system lowered, suspended on tubing string,
to desired depth
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 Electric Submersible Centrifugal Pump (ESP)

Electric Submersible Centrifugal Pump Well Completion

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 ESP Completion Design with Gas Anchors

•Shroud :
• to make use of casing ability to separate produced
gas from liquid
•Increase maximum ESP diameter
•Suitable for low rate well with large annular clearances &
large bubbles gas (free gas)
•Protector or seal:
•Unit connects electric motor drive shaft to pump or
gas separator shaft
•Isolation barrier between clean motor oil & well fluid
•Expansion buffer for motor oil
•Equaliser for internal motor pressure & well annular
pressure
•Absorber for thrust generated by pump
•Electric motor : 15 – 900 HP
•Downhole sensor package: Measurement of:
•Pump suction & discharge P & T
•Fluid intake T
•Electric motor T
•Motor & pump vibration
•Electrical current leakage to earth
39
 ESP Incorporating Packer & @ Surface Controlled Subsurface Safety Valves

•Regulatory requirement
•Venting gas to surface

40
 Typical ESP Applications

a. Direct water injection

• Aquifer water lifted from
supply zone & pumped
directly to single injection
well
b. Powered dumpflood with ESP
• Water supply well
combine with injection
well
• ESP inverted with pump at
bottom & use to replace
conventional surface
mounted transfer pump
c. Pressure boosting surface pipeline
with shallow, subsurface mounted
ESP
• ESP use to boost pressure
in surface flow line
d. Horizontally mounted ESP surface
pump

41
 Y-tool

•Device to allow wireline or

CT access below ESP,
including:
•Cased hole logging
•Well stimulation
•Perforating
•Setting bridge plugs
(water shut off)
•Pressure memory
gauges installation &
recovery
•Plugs running &
retrieval
•Downhole sampling
•Bypass tubing > 2.375”OD

42
 Pump Duty Requirements

•Pump required to deliver

required pressure (TDH)
• Total dynamic head (TDH)
•Difference between
pump discharge &
suction pressure
•Sum of hydrostatic
head from ESP pump to
surface, tubing pressure
losses
•Required surface
pressure @ q

43
 ESP ADVANTAGES

1. Adaptable to highly deviated wells; up to horizontal but must be set in straight section.
Crooked hole present no problem
2. Adaptable to required subsurface wellheads, 6 ft apart for maximum surface location density
3. Permit use of minimum space for subsurface controls & associated production facilities
4. Quiet, safe & sanitary for acceptance operation in offshore & environmentally conscious
area. Unobtrusive in urban locations
5. Generally considered a high volume pump. Can lift up to 20000BPD in shallow wells with
large casing. Available for different sizes, controllable production rate
6. Provides for increased volumes & water cut by pressure maintenance & secondary recovery
operations
7. Permits placing wells on production even while drilling & working over wells in immediate
vicinity
8. Simple to operate
9. Easy to install downhole pressure sensor for telemetering pressure to surface by cable
10. Corrosion & scale treatment easy to perform
11. Lifting cost for high volume generally very low
12. Efficient energy usage (>50% possible)
13. Access below ESP via Y tool
14. Comprehensive downhole measurements available
15. Quick start after shut down
44
 ESP DISADVANTAGES

1. Pump susceptible to damage by producing solids  tolerate minimal % sand

production
2. Costly pulling operations and lost production when correcting downhole failures
3. Below 400 BPD, power efficiency drops sharply
4. Not suitable for low volume well (<150 BPD)
5. Need relatively large casing size (> 4.5 in OD) for moderate – high production rate
equipment
6. Long life ESP equipment required to keep production economical.
7. Susceptible to damage during completion installation
8. Tubing has to be pulled to replace pump
9. High GOR presents gas handling problems
10. Viscous crude reduces pump efficiency
11. High T can degrade electrical motors
12. Power cable requires penetration of wellhead & packer integrity
45
 ESP Ammeter Chart Monitoring - 24 hours normal operation

•Technique:
•Surface measurement
of current supplied to
pump along with well test
•Supervisory Control &
Data Acquisition
system(SCADA)

46
 ESP Ammeter Chart Monitoring - Pumped off well

•At 8.15am: Pump started  large

initial current surge  motor up to
speed
•Motor speed increase & steady
current for next 3 hours with
decreasing slightly as fluid head
above pump decreases
•At 11.10am: current begins oscillate
rapidly & increases until 1.15pm when
pump shut down
•Suspected gas form problem when
Pwf reduced below Pb  gas locking
& pump ceasing to pump.
•Leaving well fluid level build up 100
minutes & restart pump at 3.05pm
•Same cycle repeated & problems
appear at 6.15pm
•8.20pm: 3rd cycle started after 100
minutes shut-in – current oscillation
starting again after 2 hours production
•11.00 pm : shut-in the well
47
 ESP Ammeter Chart Monitoring - Pumped off well

•Basic problem : Pumping fluid to surface faster than fluid

flowing into well from reservoir (outflow > inflow )
•Continue stopping & restarting ESP motor is not
recommended due to damage to motor winding by initial
high current surge as motor begins to rotate  early
motor burnout
•Option are:
•Install lower capacity pump (smaller pump)
•Operate pump at lower speed using variable
frequency drive (VFD)
•Stimulate well to improve inflow performance

48
ESP Monitoring - SCADA

49
 SCADA – ESP Monitoring

•Prior to energising pump, pump intake & discharge pressure same

•Pump start at A
•Pump discharge pressure increasing
•Motor T warmer than fluid entering pump
•Limited vibration @ surface choke adjustment
•Follows by surface choke adjustment
•At B steady operating conditions
•Pump suction & discharge pressure slowly decline as well Pwf reduced

50
 PROGRESSING CAVITY PUMP (PCP)

• Employs helical, metal rotor rotating inside an elastometric,

double helical stator
• Rotating action supplied by downhole electric motor or by
rotating rods & prime mover
• Popular for viscous crude oil production

51
 Progressing Cavity Pump Completion

Progressing Cavity Pump (PCP) Well Completion

52
 PCP Principle

PCP & Components (Cross Section View)

a. Steel shaft rotor formed into helix
b. Rotor rotated inside elastometric pump body or stator
c. Offset center line of rotor & stator  creating series if fluid filled cavities along the
length of pump
Rotor within stator operates as pump  fluid trapped in sealed cavities progress
along pump length from suction to discharge
53
 PCP – ADVANTAGES & DISADVANTAGES
Advantages
•Simple design
•High volume efficiency
•Efficient design for gas anchors available
•High energy efficiency
•Emulsion not formed due to low shear
pumping action
•Capable of pumping viscous crude oil
•Can be run into horizontal & deviated wells
•Q can be varied with variable speed
controller & cheap downhole pressure sensor
•Moderate cost
•High electrical efficiency
Disadvantages
•High starting torque
•Fluid compatibility problems with elastomers
in direct contact with aromatic crude oil
•Gas dissolves in elastomers, at high bottom
hole pressure
•Upper T limit for stator material  H2S
chemical deterioration
•Frequent stops & starts  several operating
problems (wear & leaking)
•Best efficiency occurs @ gas is separated 
bottomhole separator needed
•If unit pump off the well or gas flows
continuously, stator will be permanently
damaged (overheating by gas compression)
•Gearbox in ESPCP is source of failure if
wellbore fluid or solid leak inside it or if
excessive wear occurs
54
 Progressing Cavity Electric Submersible Pump -PCESP

• Require gearbox to reduce rotation speed since

centrifugal pup in ESP is high speed device & PCP is
low speed device
• Well suitable for handling solids & viscous fluid
• Simple design & rugged construction – very reliable
• Low operating speed (300-600 rev/min)  long
period downhole operation
• Problem of rotating rods & tubular in PCP  PCESP
was introduced (PCP + ESP)

55
 ESP & PCESP Comparison

Comparison Between ESP & PCESP

56
 ROTATING ROD PUMP

• Operates as electrical submergible centrifugal

pump, but utilizes rotating rod as its means of
power (not electrical cable)
• Internal combustion engine as its prime mover
on the surface
• Generally utilized for shallow wells

57
 SONIC PUMP

• Mechanical device actuated by conventional source of

power
• Designed to vibrate tubing string so that series of
valves, installed in tubing collar will lift fluid to surface
• Operates based on elastic characteristics of metal
rod, free both ends that will vibrate according to
simple harmonic motion principle
• When tubing string vibrated at one end at a rate
corresponding to its fundamental frequency,
vibrations transmitted over entire length of tubing
string and form standing wave on tubing (tubing is in
resonance)
58
 PLUNGER LIFT

• Plunger (free piston) fits inside tubing string and

allowed to travel freely in the tubing string
• Provide sealing interface between liquid slug
produced by gas volume and gas volume itself
• Communication between tubing & casing will
accumulated a gas in casing-tubing annular space
between cycles (gas is a source power producing
liquid slug)
• Plunger mechanically closed upon hitting bottom
(provides positive seal for upward travel) and opened
when at the top (provides bypass allowing plunger to
fall back to bottom)
59
 SELECTION METHODS

1. Depth/Rate system capabilities consideration

• Use of depth vs rate chart @ types can function
• Beam pump produces more from shallower depth & less from deeper depth
• ESP can produce large production rate
• Plunger for low liquid rate
• Initial selection possibilities or quick elimination of possibilities
2. Advantages & disadvantages
– Preliminary look of type operation details & capabilities
3. Expert program available
– Computerized artificial lift selection programs, include rules & logic to select best system as function
of user input well & operating conditions
– Module 1: includes knowledge base structured from human expertise, theoretical, rule of thumb 
ranks selected types & issues warning
– Module 2: incorporates simulation design & facility-component specification programs for all selected
types
– Module 3: economic evaluation; cost database, cost-analysis program for lift profitability
4. Net-present-value comparison
– More thorough selection technique depending on life time economics of available types; system
components failure rate, fuel cost, maintenance cost, inflation rate, well anticipated revenue return
– Users required to have good idea on costs, advantages & disadvantages, additional equipment &
costs,

60
 ADVANTAGES

Rod Pump ESP Venturi Hydraulic Pump Gas Lift PCP

•Simple, basic design •Extremely high •High volume •Solids tolerant •Solids and viscous
volume lift using up to crude tolerant
•Unit easily changed 1000 kw motor •Can use water as •Large volume in high
power fluid PI wells •Energy efficient
•Simple to operate •Unobstrusive surface
location •Remote power source •Simple maintenance •Unobstrusive surface
•Can achieve low location with
BHFP •Downhole telemetry •Tolerant high well •Unobstrusive surface downhole motor
available deviation / doglegs location / remote
•Can lift high power source
temperature viscous •Tolerant high well
oils elevation / doglegs •Tolerant high well
deviation / doglegs
•Pump off control – •Corrosion / scale
pump motor off @ treatments possible •Tolerant high GOR
fluid level reached reservoir fluids
minimum safety level
above the pump •Wireline maintenance

61
 DISADVANTAGES

Rod Pump ESP Venturi Hydraulic Gas Lift PCP

Pump
•Friction in crooked •Not suitable for •High surface •Lift gas may not •Elastomers swell in
holes shallow, low volume pressures available some crude oils
wells
•Pump wear with •Sensitive to change in •Not suitable for •Pump off control
solids production •Full workover surface flowing viscous crude oil or difficult
required to change pressure emulsions
•Free gas reduces pump •Problems with
pump efficiency •Free gas reduces •Susceptible to gas rotating rods (windup
•Cable susceptible to pump efficiency FBHP & after spin) increase
•Obstrusive in urban damage during with depth
areas installation with •Power oil systems •Abandonment
tubing hazardous pressure may not be
•Downhole corrosion reached
inhibition difficult •Cable deteriorates at •High minimum FBHP
high temperature •Casing must
•Heavy equipment for •Abandonment withstand lift gas
offshore use •Gas and solids pressure may not be pressure
intolerant reached

•Increased praduction
casing size often 62
 HYBRID SYSTEMS

• Combination of two artificial lift type

• Mostly combination of gas lift with other types (gas above )
• Some benefits of combining gas lift with positive displacement artificial lift method
(ESP, PCP, sucker rod, etc.)
– Increased volumetric efficiency – higher liquid volumes
– Decreased injection gas requirements compared to gas lift alone
– Increased reservoir drawdown & production
– Increase pump installation depth- allows greater reservoir drawdown
– Reduction in pump & motor power requirements
– Lower electrical energy consumption compared to pump alone
– Gas lift provides backup in case of pump failure

63
 GAS LIFT SYSTEM
Gas Lift Theory & Principles
Gas Lift System Design

64
GAS LIFT THEORY & PRINCIPLES

65
 GAS LIFT - INTRODUCTION

OBJECTIVE
To increase drawdown on producing formation by injecting gas into lower part of tubing
string & reducing flowing gradient in production string

Difference with natural flow completion:

•Controlled gas volume & pressure injected into tubing string or casing annulus @ operating
valve
•Tubing string fitted with several gas lift valves @ mandrel

Important parameter @ operational:

•Gas injection pressure : main control on gas injection depth
•Gas injection rate :
•contributes to flowing pressure gradient reduction  production rate
-> can be adjust on daily basis:
Gas lift valve pressure settings (open & close) can be
adjust by wireline operation

66
 GAS LIFT

• Method of lifting fluid where relatively high pressure (250psi)

gas (external source) is used as lifting medium through
mechanical process by continuous or intermittent flow. (Lifting
fluid by injection of gas into the well)
• Injected gas lifts fluid by:
1. Reduced load/weight of fluid column above the injection point
2. Injected gas expansion
3. Fluid displacement
4. Combination – coalescence of gas bubble into large bubbles &
separated by liquid slugs, displace to surface (slug flow)
• Two basic types:
– Continuous flow
– Intermittent flow
67
 BASIC GAS LIFT EQUIPMENTS

• SURFACE EQUIPMENT
– Compressor : To compress gas into the tubing/casing @ certain injection pressure
– Choke : To regulate gas injection velocity
– Timer : To regulate time for gas injection
– Pipeline : To flow gas from source/compressor – injection point
– Pressure recorder : To record P vs time (for operational monitoring)
• SUBSURFACE EQUIPMENT
– Gas lift valve
• To get high injection pressure
• Able to regulate gas injection (as orifice)
• To get deep injection point for high lifted fluid
• Able to change injection point
– Standing valve
– Packer

68
Gas Lift Well Completion

69
GAS LIFT OPERATION

70
 Pressure Traverse of Gas-Lifted Well

•Gas injected at wellhead pressure = 1100 psi

•Gas pressure in annulus increases with depth (typical 30psi/1000ft)
•Initially gas injected at valve 4 at 3800 ft
•Well producing with 500 psi drawdown
•Flowing pressure gradient from producing perforations to operating gas lift valve = 0.44
psi/ft
•Pressure drop across gas lift valve = 250 psi
•Average fluid gradient above injection valve = 0.27 psi/ft
•If gas injected at valve 7 at 5000 ft  pressure drop across gas lift valve = 50 psi only,
drawdown increase to 850 psi 71
 BASIC EQUIPMENT - Function

– Compressor
• To compress gas into the tubing/casing @ certain injection pressure
– Choke
• To regulate gas injection velocity
– Timer
• To regulate time for gas injection
– Pipeline
• To flow gas from sources/compressor – injection point
– Pressure recorder
• To record pressure vs time (for operational monitoring)
– Gas lift valve
• To get high injection pressure
• Able to regulate gas injection (as orifice)
• To get deep injection point for high lifted fluid
• Able to change injection point

72
 Gas Rate Effect on Production Rate

•Injection rate increases  increase production rate  maximum

•At maximum:
•average fluid density reduction @ tubing due to slight increase in gas injection
rate being counterbalanced by frictional pressure losses increased due to
greater mass of fluid flowing @ tubing
•Gas flow rate further increases  friction term increasing relatively faster than
hydrostatic head reduction term  technical optimum gas injection rate

•Maximum economic gas injection rate : gas injection rate @ marginal cost of
providing extra injection gas equal to marginal revenue from extra well production
•Gas lift also can be used for:
•Increase production from natural well flow at lower rate
•Dead well need artificial lift to kickoff before production possible
73
Effect of gas rate on well production rate

74
 Typical Gas Lift System

Gas from production wells separated, compressed & dehydration unit  gas lift manifold
 adjusted injection gas flow rate & casing head pressure  injected @ individual well.
75
Gas Lift Well Metering & Control

76
 Gas Lift Application

•Work better in significant GLR

•Preferred for well with a:

•High GOR produced fluid
•High PI or IPR reservoir
•High BHP

•Two types:
•Continuous flow gas lift
•Intermittent flow gas lift

•Continuous flow gas lift applications:

•Production wells which will not flow naturally
•Increase production rate in flowing wells
•Unload liquid from wells that will flow naturally once on production
•Unload liquid in wet gas wells which would otherwise cease to flow
•Back flow injection wells
•Lift aquifer (water) wells
77
 GAS LIFT ADVANTAGES

– Downhole equipment initial cost usually low

– Long service life
– Low operating cost – low subsurface maintenance
– Minimum surface equipment for high corrosion field environment
– No additional equipment on Christmas tree needed for ocean floor completions
– Can be utilized for high or low production rate wells
– Fairly flexible – over wide range of producing conditions
– Unobtrusive in urban locations
– Power source can be remotely located
– Easy to obtain downhole pressure and gradients
– No problem for lifting gassy wells
– Sometimes serviceable with wireline unit
– No problem with crooked hole
– Applicable offshore
– Gas lift valves operation unaffected by produced solids
– Well completion relatively simple
– Gas lift operation independent of BHT
78
 GAS LIFT DISADVANTAGES

– High initial capital outlay (ex. Compressor station)

– Gas supply not always available or gas supply must be ready available
– Corrosive gas lift gas can increase operation cost
– Not efficient for small fields or one-well leases
– Difficult to lift emulsions and viscous crude
– Gas freezing & hydrate problems
– Problems with dirty surface lines
– Some difficulty in analyzing properly without engineering supervision
– Cannot effectively produce deep wells to abandonment
– Requires makeup gas in rotative systems
– Casing must withstand lift pressure
– Safety problem with high pressure gas

79
Gas Lift Limitations

80
 CONTINUOUS FLOW GAS LIFT

• Continuous small volume of high pressure gas injected into the tubing/casing in order to
aerate /lighten fluid column until reduction of bottom hole pressure allowed sufficient
differential pressure across a sand face, causing well to produce at desired rate

• Can produced :
– 25 BPD with 1 inch macaroni tubing
– 300 – 4000 BPD with normal tubing string size
– 25,000 BPD with casing flow

• Recommended for:
– High volume & high static BHP
– Offshore application (especially strong water drive)
– Waterflood reservoir with good PI & high GOR
– High PI & high BHP
– Well with sand problem, excessive water from BHP surge or sand bridging @ tubing problem
– Water backpressure well
– Small tubing application
– High viscosity crude if Pwf adequate

81
 CONTINUOUS FLOW GAS LIFT FLOW METHOD

Two methods:
1. Tubing flow
– Gas injected through annulus (casing) & production through tubing
– Characteristics:
– High efficiency
– Low gas volume
– High input/injection pressure
2. Casing flow
• Gas injected through tubing & production through casing
• Characteristics:
– Low efficiency
– High gas volume
– Low input pressure
– High q from deep zone application
– Serious corrosion
82
 CONTINUOUS FLOW GAS LIFT ADVANTAGES

– Best for handling sand or solid material

– Can easily lifted for deviated or crooked holes
– Normal design leaves tubing fully open  permits BHP survey, sand sounding &
bailing, production logging, cutting, paraffin, etc.
– High formation GOR are very helpful for gas lift system
– Flexible: wide range of volumes & depths
– Centralized gas lift system to service many wells  lower total capital cost &
permits easier well control & testing
– Not obstrusive; has low profile (in urban environments)
– Well subsurface equipment relatively inexpensive, repair & maintenance normally
low. Equipment easily pulled & repaired or replaced
– Installation is compatible with subsurface safety valves & other surface
equipment. Use of surface controlled subsurface safety valve with ¼ in. control
line allows easy shut in the well
– Can still perform fairly well even only poor data available @ design stage
– High volume artificial method
– Able to overcome sand production problem
– Valve can be wireline or hydraulic operated
83
 CONTINUOUS FLOW GAS LIFT DISADVANTAGES

– Relatively high backpressure may seriously restrict production. Problem

more significant with increasing depth & declining static BHP
– Relatively inefficient, often resulting in large capital investment & high
energy-operating cost. Compressor is expensive, takes up space &
weight (offshore operation). Distribution system onshore cost may be
significant. Increased gas use may increase flowline & separator size
– Adequate gas supply needed throughout project life. Enough gas needed
for easy startups
– Compressor operation & maintenance can be expensive. Need skilled
operators and good compressor mechanic. Downtime must be minimum
– Increased difficulty when lifting low gravity crude (<15oAPI) due to
greater friction, gas fingering & liquid fallback
– Good data required to make good design.
– Potential problem must be resolved (feezing, hydrate @ injection gas
lines, corrosive injection gas, severe paraffin, fluctuating suction &
discharge pressure & wireline problems, changing well conditions – BHP
& PI decline)
84
 INTERMITTENT FLOW GAS LIFT

• Small volume high pressure gas injected at regular intervals by the

intermitter into the casing annulus
• Involves expansion of high pressure gas ascending to a low-pressure outlet
• Valve with large port permits complete volume & pressure expansion
control of gas entering into tubing  regulating lift of accumulated fluid
head above the valve
• Used for:
– Relatively low volume well (150 – 300 BPD), <150 BPD @ 2 3/8”tubing, 300 BPD
@ 3 ½” tubing
– High PI with low bottom hole pressure
– Low PI with low bottom hole pressure
 Consider for low flowing bottomhole pressure & lifted from bottom valve
• Excellent choice for adequate, good quality, low-cost gas supply, shallow
depth, high GOR, low PI or low BHP well with bad dogleg & some sand
production

85
 INTERMITTENT FLOW GAS LIFT

• ADVANTAGES
– Significantly lower producing BHP than continuous flow gas lift
– Ability to handle low volumes fluid with relatively low production BHP
– Wireline or hydraulic operated valve
• DISADVANTAGES
– Limited to low volume well
– Average producing pressure required still relatively high compare with
rod pumping
– Low power efficiency (more gas/bbl than continuous flow gas lift)
– Fluctuation in rate & BHP can be detrimental to well with sand control –
sand may plug tubing or standing valve, gas & fluid handling problems at
surface facilities
– Typically requires frequent adjustments: alter injection rate & time period
routinely to increase production & keep lift gas requirement relatively
low.
– Generate pressure surge @ surface equipment
86
Intermittent Gas Lift

87
 GAS LIFT VALVE REQUIREMENTS

1. Able to achieved efficiency by:

1. Reduce kick-off pressure (unloading)
2. Allowing deeper injection point
3. Reduce production GOR
4. Reduce swabbing

2. For continuous flow

1. Stable
2. No tubing backpressure effect
3. Able to control gas flow
4. Able to forced gas into tubing string
5. Able to maintain pressure inside tubing constant
6. Able to provided orifice size for regulating
7. Can be operated by:
1. Casing pressure buildup
2. Tubing pressure buildup
3. Combination

3. For intermittent flow

1. Able to port full opening @ opening pressure applied
2. Able to hold opening position  closing process
3. Can be operated by:
1. Casing pressure buildup
2. Fluid load buildup @ tubing
3. Combination
4. Size available : 1 – 1 ¼ inch
88
 GAS LIFT VALVE TYPE

• Bellow valve
• Pilot valve
• Continuous flow bellow valve
• Fluid operated valve
• Fluid operated valve with special pilot
• Balanced flexible sleeve valve
• etc

89
 GAS LIFT INSTALLATION

• Important for the success of gas lift operation

• Factor should be considered @ selection:
– Well conditions
– Well completion type
– Possible production problems
•Sand production, water or gas coning
– Future well performance

90
 GAS LIFT INSTALLATION TYPE

• Open installation
• Semi-closed installation
• Closed installation
• Chamber installation
• Macaroni installation
• Dual installation
• Dual flow choke installation
• Multiple completion installation
• Casing flow installation
• etc
91
 CHAMBER INSTALLATION

• Gas lift that incorporates accumulation

chamber @ bottom hole  minimum pressure
obtained, allowing maximum fluid entry
• Successfully used in very low bottom hole
pressure wells

92
GAS LIFT SYSTEM DESIGN

93
 Gas Lift Design Objectives

1. Maximise net value oil produced

• Operating valve as deep as possible
• Gas injection rate = economic limit
• Optimisation @ more wells & insufficient gas supply

2. Maximise design flexibility

• Design able to cope with expected changes @ producing conditions, uncertainties @
reservoir properties & performance

3. Minimise well intervention

• Important especially for subsea or wireline access difficult / impossible
• Extra gas lift valves installed (closed > 150m )
• Ability to modify valve performance

4. Stable well operation

• Constant casing & tubing head pressure
• Produce more oil

94
 Question Need Answers @ Design Process

•How many unloading valves required & at what depths, these valves be placed ?

•What are required settings for unloading valves ?

•What is depth of operating valve ?

•What is gas injection pressure ?

•How much lift gas should be injected ?

•What is tubing head pressure for target flow rate ?

Translated into practice by ensuring gas lift valve spacing & pressure setting are such
that:

•Operating valve have adequate flow capacity & placed as deep as possible

•Available lift gas pressure able to displace fluid in casing to operating valve depth 95
Gas Lift Design Required Data

96
 GAS LIFT DESIGN CONSIDERATION

• Ideally, system chosen & design @ initial oil field

planning phase
• Most production equipments effect gas lift system
design  best to design concurrently with surface
facilities designing phase
– Three major factors:
•Field layout
•Well design
•Gas injection pressure
• Design purpose: to reduce Pwf of the well @ desired q
• Critical factor: gas lift type (continuous or
intermittent)
97
 FIELD LAYOUT & WELL DESIGN FACTORS

• Gas lift operation should be considered in hole

sizing processes & before casing program
design
– Offshore well: all downhole gas lift equipments
(except valves) installed during initial completion
– Onshore well: gas lift effect gathering line &
production station size & location
– Should minimized backpressure generated

98
 GAS INJECTION PRESSURE FACTOR

• Critical in gas lift system design

• For maximum benefit  gas must be injected
as near producing interval as possible with gas
injection pressure at depth > flowing
producing pressure at the same depth
– More fluid above the injection point affected 
higher q
– Greater pressure differential between injected gas
pressure & flowing tubing pressure  greater
valves spacing  less mandrel & valves required
99
 GAS REQUIREMENT

• If efficiency = 100%, gas required for lifting 1bbl oil to surface:

Q = 349 x G x Lw / W
where; Q = cuft gas @ discharge pressure
G = SG oil
Lw = working lifting, ft
W = expansion work / cuft gas
349 = 24 gpb x 8.33 ppg
• General range: 1000 – 2000 cuft/bbl – 12,000 cuft/bbl

• Working fluid level = level by which oil column will rise due to working
pressure at tubing bottom if there is an annulus
• Total lift = working submerge + working lift
• Working submerge = vertical distance (ft) between working fluid level and
tubing bottom or equivalent with fluid column height which
produce working pressure at tubing bottom
100
 GAS LIFT VALVE POSITION

Determine by:
• Available gas pressure
• Fluid weight
• Well IPR @ lifting
• Surface backpressure @ wellhead
• Annulus fluid level
• BHP
• Well production characteristics
101
 Annulus Gas Lift Pressure

•Maximum depth for gas injection controlled by:

•Surface casing pressure
•Pressure drop across valves
•Tubing pressure gradient

•Most gas lift system operate : 1000 – 2000 psi

•Filled with natural gas with high methane content
•Rule of thumb : gas pressure gradient : 30 psi/1000 ft
•Can be calculate:

PL = Ps exp {(RDgas * L)/(53.34*Tave*Z)}

PL = gas pressure at depth L (psia)

Ps = surface gas pressure (psia)
L = true vertical depth (ft)
RDgas = gas relative density (to air)
Tave = average T @ gas column (deg.R)
Z = gas compressibility factor @ Tave & Pave
Pave = (Ps + PL)/2 102
 Surface Gas Network

•Gas lift system performance will depend on:

•Pressure
•Flow capacity of lift gas available at well head

•Surface piping network should be designed to:

•Have minimum (<<100 psi) pressure loss between compressor & most
distant wellhead
•Prevent one well from interfering second well by having sufficient pipe
volume to dampen pressure surges
•Provide individual gas measurement & flow control for each well
•Large diameter pipe (typical : 4.0 inch OD for backbone piping and individual
2.0”OD flow lines @ each well)
•For larger system (more than 1 compressor), ring main system better option

103
 Gas Lift Design Procedures

•Check : gas lift valves can be placed at suitable distances above operating
valve to ensure well can be unloaded using gas lift designed

•Based on gas lift design philosophy, i.e.:

•Maximum production /expected case design would
•Maximise production by injecting gas as deep as possible
•Install extra valves around operating valve to allow its depth can be
adjusted
•Budget for well entries to be required since well may stop producing if
well inflow conditions change

•Philosophy depend on operational conditions & cost scenario

•Specify optimum :
•Tubing size
•Injection gas supply parameters (P & V)
•Installation depth of operating valve (injection point)
•Minimum wellhead flowing pressure 104
 Continuous Flow Gas Lift
Design Considerations

– Capital Cost
•Equipment cost low but compression cost may be high
•Central compression system reduces overall cost per well
– Downhole equipment
•Good valve design & spacing essential.
•Moderate cost for well equipment (valves & mandrels)
•Typically less than 10 valves needed
•Choice : wireline retrievable or conventional valves
– Operating efficiency (hydraulic hp/input hp)
•Fair. Increases for well that require small injection GLR. Low for well requiring
high GLR.
•Typically 20%, but range from 5-30%
– System flexibility
•Excellent. Gas injection rate varied to change rate
•Need correct tubing size
– Miscellaneous problems
•Highly reliable compressor (95% run time required)
•Gas must properly dehydrated to avoid gas freezing
105
 Continuous Flow Gas Lift
Design Considerations

– Operating costs
•Well cost low
•Compression cost varies depending on fuel cost & maintenance
– System Reliability
•Excellent if compression system properly designed & maintained
– Salvage Value
•Fair. Some market value for compressor & mandrel/valve
– System Total
•Requires adequate volume, high pressure, dry, noncorrosive, and clean gas
supply
•Low backpressure beneficial
•Good data needed for valve design & spacing
•API specs & design/operating RPs must be followed
– Usage/Outlook
•Good, flexible, high rate system for well with high bottomhole pressure
•Used on 10% US lifted wells, mostly offshore

106
 Continuous Flow Gas Lift
NORMAL OPERATING CONSIDERATIONS

• Casing Size Limits

– 4.5 & 5.5 in. casing with 2” nominal tubing limits rate to <1000 BPD
– Rate >5000 BPD, >7” casing & >4.5” tubing needed
• Depth Limits
– Controlled by injection pressure, gas & fluid rate
– Typical: 1000BPD with 2.5” tubing @ 1440 psi, 1000GLR, has injection depth
<10000ft, maximum 15000ft
• Intake Capabilities
– Poor. Restricted by gas lifted fluid gradient.
– Typical: moderate rate limited to 150 psi/1000ft injected depth
• Noise Level
– Low at well but noisy at compressor
• Obstrusiveness
– Good low profile, but must provide compressor
– Safety precaution must be taken for high pressure gas lines 107
 Continuous Flow Gas Lift
NORMAL OPERATING CONSIDERATIONS

• Prime Mover Flexibility

– Good.
– Engine, turbine, or motor can be used for compression
• Surveillance
– Good/excellent
– Can be analyzed easily. BHP & production log survey easily
obtained
• Relative Ease of Well Testing
– Fair. Well testing complicated by injection gas volume/rate

108
 Continuous Flow Gas Lift
SPECIAL PROBLEMS & CONSIDERATIONS

• Corrosion/Scale Handling Ability

– Good. Feasible for inhibitor in injection gas/batch inhibiting down tubing
– Steps for injection gas lines corrosion
• Crooked/Deviated Holes
– Excellent. Few wireline problems up to 70o deviation for wireline retrievable
valves
– Typical: 0-50o, maximum: 70o
• Duals Applications
– Fair. Common but good operating complicated & inefficient  reduces rate
– Feasible: parallel 2x2” tubing in 7” casing, or 3x3” in 9 5/8” casing
• Gas Handling Ability
– Excellent. Produced gas reduces need for injection gas
• Offshore Application
– Excellent if adequate gas supply available (common method)
• Paraffin Handling Capability
– Good. Mechanical cutting sometimes required
– Injection gas may aggravate existing problem
109
 Continuous Flow Gas Lift
SPECIAL PROBLEMS & CONSIDERATIONS

• Slimhole Completions (2 7/8” production casing string)

– Feasible but can be troublesome & inefficient
• Solids/Sand Handling Ability
– Excellent. Inflow & surface problems limitation.
– Typical limit: 1% sand
• Temperature Limitations
– Excellent. Typical: 100-250oF with 350-400oF maximum
• High Viscosity Fluid Handling Capability
– Fair, few problem for >15oAPI or below 20cp viscosity
– Excellent for high water cut even with high viscosity oil
• High Volume Lift Capability
– Excellent but restricted by tubing size, injection gas rate & depth
– 4” tubing, 1440psi injection gas & 1000GLR 5000 BPD from 10000ft feasible
• Low Volume Lift Capability
– Fair, limited by heading & slippage
– Avoid unstable flow regime
– Typical: >200 BPD @2” tubing, 400 BPD @2.5” tubing 700 BPD @ 3” tubing
110
 CONTINUOUS FLOW GAS LIFT DESIGN PRINCIPLE

• Fluid pressure distribution:

Pwf = Pt + GfaL + Gfb(D – L)

• Where;
– Pt = tubing pressure
– Gfa = average flowing pressure gradient above injection point
– L = injection point depth
– Gfb = average flowing pressure gradient below injection point
– D = well depth
– Pwf = well bottomhole flowing pressure

• General steps:
1. Flow type selection @ tubing size & desired q
2. Gas injection depth determination
3. Valve spacing
4. Valve selection
5. Gas volume required
6. Injection pressure required
7. Compressor requirements

111
 CONTINUOUS FLOW GAS LIFT DESIGN
RULE OF THUMB

Must considered:
• Continuous gas lift valve requirements
• Separator pressure
• Wellhead flowing pressure
• Top valve position
• Gas injection pressure
• Gas injection volume
• BHT
• Flowing temperature gradient
• Unloading gradient
• Valve spacing
• Tubing size
• Q
• Valve setting
• Installation type
• Well performance especially VLP
112
 CONTINUOUS FLOW GAS LIFT DESIGN
RULE OF THUMB

• Valve selected must be:

– Stable
– No tubing backpressure effect
– Able to control gas flow
– Ex: flexible sleeve valve of unbalanced bellow valve
• Separator pressure & wellhead flowing pressure
– Will determine pressure required to flow fluid from wellhead to separator
– Flow direction to pool or to pressured system will determine top valve position;
• Top valve position
– Must be located at the right position for:
•Well flow at desired q
•Efficient operation
– At initial fluid level or below depending on kill fluid gradient:
•Smaller valve spacing, especially @ injection point
•Smaller valve required

113
 CONTINUOUS FLOW GAS LIFT DESIGN
RULE OF THUMB

• Gas injection volume & pressure

– Regulate q
– Higher gas injection pressure:
•Deeper injection point
•More fluid can be lifted
•Less injected gas volume required
– Maximum depth = (Pc – Pt)/0.15
• BHT & flowing temperature gradient
– Valve operated at higher P & T
• Unloading gradient & Valve spacing
– Valve spacing depends on unloading gradient
• Required pressure
– 100 psi/1000 ft depth lifting
• Required gas volume
– 150 – 250 scf/bbl/1000 ft lifting

114
 CONTINUOUS FLOW GAS LIFT DESIGN
RULE OF THUMB

• Valve setting
– Valve operate based on its characterics
– Ex. Balanced valve drawdown 15 – 25 psi/valve (operational pressure
difference @ surface)
• Tubing size & q
Tubing size (in.) Maximum q (BPD) Minimum q (BPD
1 350 25 – 50
1¼ 600 50 – 75
1 1/2 1000 75 – 125
2 2500 200
2 1/2 3000 250
3 4000 300
3 1/2 5000 -
4 8000 -
115
Continuous Gas Lift Design

116
Continuous Flow Gas Lift

117
 CONTINUOUS FLOW GAS LIFT DESIGN
INJECTION POINT DETERMINATION

1. Draw depth (y-axis) and pressure (x-axis)

2. Marked static pressure (Ps) @ depth
3. From PI calculation, calculate pressure drawdown (/\P) for desired q
4. Calculate Pwf
5. From Ps, draw static pressure gradient/distribution (Gs)  cross-section with y-axis
(A)
A = static fluid level (initial fluid level)
For conventional valve spacing; A = top valve depth

6. From Pwf, draw flowing pressure distribution/gradient below injection point (Gfb)
based on:
• calculated pressure distribution
• suitable flowing pressure distribution chart, or
• Assumption of flowing pressure gradient below injection point = static pressure gradient
 parallel to Ps @ Gs line
7. Marked surface initial pressure or surface kick-off pressure minus 50 (Pko – 50)
8. Marked surface operating pressure (Pso)
(Pso) = Available pressure - 100

118
 CONTINUOUS FLOW GAS LIFT DESIGN
INJECTION POINT DETERMINATION

9. From steps 7 & 8, draw line downward (with consideration of

gas column weight) to flowing pressure distribution below
injection point line (step 6)
10. Marked intersection between two lines (step 9) as B
B = balanced point between tubing & casing
For open installation, B = annulus working fluid level
11. Minus 100 psi casing pressure from point B, marked this point
on flowing pressure distribution below injection point line, as
C = gas injection point
12. Marked surface tubing flowing pressure or wellhead pressure
(Pwh)
13. Connect point Pwh with injection point C by using suitable
pressure distribution chart/curve (presentation of required
produced GLR). If there Is not suitable curve/chart, straight
line injection GLR = GLR – amount of gas in solution 119
Unloading Gradients for Valve Spacing Calculations

120
Gradients for Salt Water Oil Mix

121
Weight of Gas Column

122
Gas Injection Point Determination

123
Gas Injection Point Determination - Graphical

124
Semianalytical Continuous Flow Example

125
 CONTINUOUS FLOW GAS LIFT DESIGN
INJECTION POINT DETERMINATION

• Kick off pressure (Pko) = pressure (measure at gas inlet line @ surface)
required to initiate flow in the gas lift well

– Can be determine from P vs time plot  the highest point or by eq.:

– For tubing flow:

Pko = Pa + 0.434Gh
= {0.434SsG(D22 – D12 + D2)} / D2 , psig

– For casing flow

Pko = {0.434SsG(D22 – D12 + D2)} / { D22 – D12 }

– Where; G = well fluid SG

Pa = atmospheric pressure
Ss = submergence initial
D = ID tubing, in.
D1 = OD tubing, in.
D2 = ID casing, in.

126
 CONTINUOUS FLOW GAS LIFT DESIGN
VALVE SPACING DETERMINATION

Depends on:
1. Valve type
– Balanced valve
• Surface operating pressure – minus ( 15 to 25 psi) / valve downward
– Unbalanced valve
• At surface operating pressure, or
• Reduction of 15 psi/valve downward, or
• Kick off pressure minus 100 psi from conventional operating pressure

2. Well flow direction: to pit or pressured system

3. Static fluid level & kill fluid requirements
– If static fluid level < (Pc – Pt)/Gs
 top valve @ static fluid level
4. Operational pressure
5. Gas source/supply
– Tubing unloading gradient  achieved / not ?

127
 CONTINUOUS FLOW GAS LIFT DESIGN
VALVE SPACING DETERMINATION

1. Draw kill fluid gradient line at :

• Tubing pressure if well unloaded @ tubing pressure
• Zero pressure if well unloaded to pit/pool
2. Extend line step 1 to cross-section with kick off pressure – 50 (Pko – 50)
line  marked intersection point as D (top valve position)
3. From point D, draw horizontal line to left up to cross-section with
following line;
1. Flowing gradient above injection point line, or
2. Unloading gradient line, or
3. Minimum gradient line
 Marked intersection point as E
4. From E, draw line parallel with kill fluid gradient line up to surface
operating pressure gradient line after minus ex. 25psi
 marked intersection as F

128
 CONTINUOUS FLOW GAS LIFT DESIGN
VALVE SPACING DETERMINATION

5. Minus 25psi P @ F and draw new operating pressure

gradient (Pso – 50 or Pf – 25)
6. From F, draw horizontal line to left up to flowing
pressure gradient above injection point 
intersection point marked as G (2nd valve depth)
7. From G, draw line parallel t kill fluid gradient line up
to new operating pressure gradient line (Pf – 25,
step 5)  intersection marked as H (3rd valve
position)
8. Repeat steps 5 – 7 up to injection point
9. For future used, generally installed another 2 valves
below injection point
129
Balanced Valves Spacing (Graphical)- Continuous Flow

130
Unbalanced Valve Spacing (Graphical) – Continuous Flow

131
Fluid-operated Valve Spacing – Continuous Flow

132
Differential Valves Spacing – Continuous Flow

133
Valve Operation Schematic Diagram

134
 Gas Lift Valve Mechanics
•Top valve design: allow fluid in casing/tubing to be unloaded --> deep gas
injection can be achieved
•Upper gas lift ports sized to pass only limited gas volume required for
unloading
•Larger port for operating valve
 gas injection can be increased to optimum value
•Through which gas will be continually passed
•Dummy valves installed in bracketing envelope where live valves not yet
required
•Two types:
•Casing/Injection/Inflow Pressure Operated (IPO) valves
•Tubing Pressure Operated (TPO) valves
•Key factors controlling gas lift pressure required to open:
•Dome pressure
•Tubing pressure
•Bellows & port area ratio
•Valve spread
•= difference between opening & closing pressure
•= Popening – Pclosing
135
 Gas Lift Valve Mechanics

•Casing/Injection/Inflow Pressure Operated (IPO) valves

•Closing force, Fc = Pdome * A bellows

•Opening force, Fo = Ptubing * Aport + Pcasing *(A bellows – Aport)

•Opening & Closing forces are equal just before valve open.

• Pcasing = { Pdome – Ptubing(Aport / Abellows)} / {1 – (Aport / Abellows)}

•Tubing Pressure Operated (TPO) valves

• Ptubing = { Pdome – Pcasing(Aport / Abellows)} / {1 – (Aport / Abellows)}

or

• Pcasing = Pdome – Ptubing( 1 – Aport/Abellows)

136
 CONTINUOUS FLOW GAS LIFT DESIGN
BALANCED VALVE SELECTION

1. Draw geothermal gradient line from surface flowing temperature to BHT

2. Determine depth & related temperature @ each valve at depth
3. Select surface operating pressure for each valve graphically
4. From valve operating pressure graph/chart, or temperature correction
graph/chart, determine valve setting pressure and pressure at valve @
80oF or 60oF
5. Generate table of valve selection as:
Valve no. Depth (ft) Temp.(oF) Surface Pressure Valve
operating at valve setting
pressure (psig) (psig)
(psig

1 - - - - -
6. From table (step 5), and catalog @ valve manufacture, based on required
valve capability, selection valve to used
137
Well Unloading

138
 Unloading Process (Initial) Dead Well

•Fluid level in casing & tubing just below surface & balances Pres.  no flow  dead well
•No gas injected
•All gas lift valves open due to fluid hydrostatic head

•## valve open/closed @ response to tubing / casing pressure

139
 Gas Lifted Well Unloading; stage 1

•Start gas injection into casing / tubing

•Fluid being U-tubed from casing into tubing through all open gas lift valves
•Gas lift pressure sufficient to increase fluid level in tubing to surface  q
•Gas injection rate controlled through injection gas choke 140
 Gas Lifted Well Unloading; Stage 2

•Unloading process lowered fluid level in casing annulus to top gas lift valve
•Gas injection into tubing commenced  evacuates liquid in tubing above top gas lift valve into
separator @ multiphase flow conditions
•Reduces fluid density above top valve  further casing fluid unloaded through valve no. 2,3 & 4
since P @ tubing < Pcasing
•Well start to produce if pressure reduction sufficient to give drawdown @ perforation for q
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 Gas Lifted Well Unloading; Stage 3

•Fluid level in casing lowered  expose gas lift no. 2

•Top 2 gas lift valves open & gas injected through them (1&2)
•All valves below also remain open & continue to pass casing fluid into tubing  tubing
unloaded sufficiently to reduce BHP < Pres  enough drawdown to induces formation
fluid flow from reservoir into wellbore  well starting to produce 142
 Gas Lifted Well Unloading; Stage 4

•Top valve closed due to reduced pressure (casing pressure for casing pressure
operated valves or tubing pressure for fluid operated & proportional response valves)
after gas lift established through valve 2
•All gas injected through valve 2
•Unloading well continues with valve 2,3 & 4 open & casing liquid flowing into tubing via
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valve 3 & 4
 Gas Lifted Well Unloading; Stage 5

•Valve 2 just uncovered  valve 2 & 3 passing gas

•Bottom valve below liquid level also open & liquid unloading from casing annulus into
tubing continues

## deeper injection point lowers PWF  greater drawdown & increase q 144
 Gas Lifted Well Unloading; Stage 6

•Reduction in casing or tubing pressure  valve 3 starts to flow gas & valve 2 closing
•All gas injected through valve 3
•Process continued 145
 Producing Gas Lifted Well Pressure Traverse

•Process continued with pressure reduction  valve 4 exposed & closing of valve 3
•All gas injected through valve 4
146
 Typical Casing & Tubing Pressure Measurement @
Gas Lifted Well Unloading

•Development of tubing head & casing head pressure with time @ unloading process
stage 1-7
•Sequential reduction in casing head pressure as gas successively injected through
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lower gas lift valves
 Safety Factors

•To account for:

•Errors in valve pressure settings
•Errors & fluctuations in:
• well data,
• lift gas injection pressure &
• valve temperature @ flowing conditions estimation
•Pressure drop across valve’s choke & that required to obtain sufficient
movement of stem

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 Gas Lift Valve Spacing Criteria

•Specify minimum number  reduce cost & potential leak paths

•Valves to be installed sufficiently far apart  do not interfere with each other’s
operation (minimum spacing 150 m)
•Continuous gas injection through operating valve occurs as deep as possible
based on current producing conditions.

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 Continuous Flow Gas Lift Design
Analytical Technique

• Can be used when BHP & PI unknown & gas column weight neglected
• First valve depth:
– Dv1 = {(Pko – 50) – Pwh} / Gs
– If well unloaded to atms.  Pwh = 0
– If static fluid level < Dv1  top valve depth = static fluid level
– For balanced valve  reduce 25 psi/valve downward
– For unbalanced valve:
•Spacing @ surface operating pressure constant, or
•Reduction of 10 psi/valve downward

• Where; Dv1 = top valve depth, ft

Pko = kick off pressure, psig
Pwh = surface back pressure @ tubing, psig
Gs = produced fluid gradient, psi/ft
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 Continuous Flow Gas Lift Design
Analytical Technique

• 2nd, 3rd, etc valve depth:

Dv2 = Dv1 + {Pso1 – Gu(Dv1) – Pwh} / 0.5

Dv3 = Dv2 + {Pso2 – Gu(Dv2) – Pwh} / 0.5

Dv4 = Dv3 + {Pso3 – Gu(Dv3) – Pwh} / 0.5

• Where; Pso = surface available operating pressure, psig

Pso1 = 1st. Valve surface operating pressure, psig
Gu = design unloading gradient, psi/ft
Pso2 = Pso – 75 = Pso1 – 25
Pso3 = Pso – 100 = Pso2 - 25
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 GAS LIFT EFFICIENCY

• Gas lift efficiency = G/O theory / G/O actual

• Loss of energy at:
– Lacking inside the casing/tubing
 can be prevented
– Inlet & outlet @ difference pipe diameter
– Slippage losses @ lower outlet section
•Oil drop & gas upward
 prevention: high velocity @ lower tubing section (2-40 ft/sec)
– Friction losses @ upper outlet section
 prevention: velocity change
– Back pressure @ tubing head/flow line

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 Several Gas Lift Completion Designs

Gas Lift Well Completion Design

(a) : Single string continuous gas lift completion
• Gas injected @ annulus & production @ tubing
(b) : Annular flow gas lift completion
• Gas injected @ tubing & production @ annulus
• Higher q
• Casing corrosion
(c) : Continuous gas lift without surface section of casing/tubing annulus being live (filled with gas)
• Gas injected into separate injection string with Surface Controlled Sub Surface Safety Valve (SCSSSV) installed below
dual packer
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 Several Gas Lift Completion Design

Gas Lift Completion Designs

(d) : Dual Gas Lift Well Completion
•Two zone independently produced @ separate production string
(e) : Intermittent, Plunger Lift Well Completion
•Low rate wells
•Plunger prevents liquid fallback @ gas switched off
(f) : Single Valve (Subsea) Well Completion
•Used when intervention difficult/expensive
•Single orifice operating valve minimise operational problems 154
Coiled Tubing Gas Lift Well Completion

155
 Typical Operational Gas Lift Problems

•Gas quality
•Solids
•Reservoir performance change
•Gas supply
•Well startup (unloading)
•Well stability
•Dual gas lift

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 Gas Quality

•Gas injection line blockage due to hydrate formation @ low ambient T.

•Easily removed by depressurising line (hydrate unstable at low pressure,

decomposing into gas & water components) .
• Can be avoided by sufficient drying the gas  water dew point below
lowest expected ambient T

•Casing integrity losses due to corrosive lift gas.

•Present of CO2 & H2S in natural gas

•Present of water especially at bottom of pipeline, low points where partial
CO2 > 30 psi
•H2S partial pressure > 0.05 psia

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 Solids

•May be produced from formation (sand) or formed

from produced fluids (inorganic & organic scales)
•Was is most frequent
•Operation difficulties during wireline operations
•Can be avoided by:
•Install gravel packing
•Scale inhibitor

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 Reservoir Performance Change

•Performance changes with time & maturity

•Typical: water cut & fluid hydrostatic head @

tubing increase and Pres decreases

•Outflow performance reduce, deterioration

inflow performance due to relative K effect by
increasing water cut produced

•Produced at higher drawdown  gas injection

parameters change
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 Gas Supply Problems

•Lift gas available volume less than required for q

•Compressor suction & discharge pressure fluctuation due to

unstable process plant operation and unstable producing
well operation

•Tubing head  large liquid slug produced followed by gas

only or no production at all

•Surface gas distribution network design  pressure

transient propagation

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 Well Start-up (Unloading ) Problem

•To prevent fluid damage to lower gas lift valves as liquid in annulus unloaded
when starting up by avoiding excessive fluid flow rates
•API start-up procedures:
•Provision to monitor tubing & casing pressure and production rate @
unloading process
•Tubing head pressure must be blown down to separator flowline prior to
starting unloading process. Chock should be fully opened @ kick-off process
•Unloading process commenced under casing head pressure control. Casing
gas injection rate adjusted  pressure increases at rate of 10 psi/min until
system pressure reached. Need to monitor liquid level in annulus (by
echometer)
•Maximum lift gas injection rate < 50% planned design rate
•Drop in casing head pressure when gas injected into upper valve &
subsequent lower valve  gas injection rate change
•Need to established steady state flow regime
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•Good practice to check that well unloading process can still proceed with valve
 Well Stability

•Can be in form of:

•Casing head pressure remains constant but tubing
head pressure fluctuate significantly, or
•Tubing & casing head pressure fluctuate
•Valve multi-pointing (gas injected into tubing at
several different level

•Can be improved by choke controlling casing gas

injection pressure  prevents gas flowing out of annulus
into tubing at faster rate than it being replaced by lift gas
supply to well

162
 Dual Gas Lift

•Common: 2 3/8in or 3 1/2in OD tubing run inside7.0”or 9 5/8” OD casing

•Insufficient width for gas lift mandrels in two string to pass one another
•Overcome by designing spacing of side pocket mandrels in two tubing
strings so that gas lift mandrel do not need to pass one another @
completion process

•To prevent interfering each other  install valves with significantly different
operating characteristics in different string (eg. IPO & TPO). Gas allocation
controlled by installed choke in operating valves

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 Inefficient Gas Lift Operation

•Can be caused by:

•Inflow problems due to:

•Incorrect choke size
•Incorrect lift gas pressure
•Fluctuating compressor lift gas pressures
•Incorrect lift gas flow rate

•Outlet problems include:

•Inadequate or restricted gas flow through operating valve
•Increased hydrostatic gradient across tubing due to water cut increase
and production GLR reduction
•Wellhead choke not fully opened
•Separator pressure set too high

•Downhole problems include:

•Hole in tubing
•Incorrect valves operation due to: 164
•Mechanical problems with valve operation
 Trouble Shooting Techniques

•Need systematic investigation  cause

•Analysis techniques:
•Annulus & tubing pressure profile modelling
•Comparison with flowing T & P survey
•Carrying out production test with various gas injection rate
•Analysis of historical well test & production data to identify trends
•Echometer survey to identify fluid level in annulus (echometer : acoustic device
measures transit time for signal generated at surface to travel down annulus &
reflected back to surface from liquid level in annulus  depth ? If velocity known)
• Some operational problem examples:
•Injection pressure rises to maximum while injection rate drops to zero
 upper valve closed before lower valve opened (gas injection point has not
passed to deeper valves)  change setting of one of more valves
•Casing head pressure fluctuates by 5-10 psi but gas injection rate constant
 injection point transferred between two valves
•Casing head pressure fluctuates by 10-20 psi while injection rate changing
 lower valve opened while second, higher valve continually open 165
Some Gas Lift System Management Problems

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THANK YOU

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