(COVER STORY:
PRODUCTION
Alternative gas
-lift design for
unconventional wells
Make more fluid with less gas.
Petia eta
[rztiseria dicason of dierent git design
‘methods, the theory behind them and considering
current practices, one running theme tends to rear its
hhead time and time again: valve spacing. In the existing
plays being sought after in the Permian Basin and else-
‘where, a new design method may be more beneficial In
early 2019, Concho Resources and Production Lift Com-
panies ran a new gaslift design method in two uncon-
ventional wells in the Permian Basin
This new method is designed to exploit the initial
high bottombole pressure (BHP) in nconventional
wells to produce higher rates that, before now, vere
only possible with an electric submersible pump. Getting
trough the highest volumes of the eauliest production
and continuing to be an effective form of artificial lit
into the well’ ater years, this lfe-of-vell design also will
follow the well’s decline and efficiently produce the well
at lower rates. When completed correct, the well can
be switched to plungerasssted gas lit, plunger lift or
gasassisted plunger lift without the need for rig inter-
Vention, thus there is no tubing pull required.
‘The Austin Chalk horizontal wells of South Texas and
Louisiana changed everything in the gastift world, The
waditional gaslift design methods used to design verti
cal wells would not work for horizontal wells. The best
gavlift design method for horizontal Austin Chalk wells
is to run unloading valves until reaching a minimum
spacing of 152 m (500 ft) (Figure 1) and then continue
the 152m spacing down to the packer. The 152m spac-
ing is an aubitrary spacing that is not based on engineer.
ing principles. A group of gaslift professionals came up
‘with 152m spacing by trial and error in the late 1980s,
Since it worked in the Austin Chalk horizontal wells,
this method was thought to be best for al horizontal
‘wells and adopted by the industry at that time as a “best
practice” and has remained the standard today.
Bracketed gas-lit designs
The oil and gas industy naturally had to adjust from
mostly vertical wells to the up-and-coming horizontal
‘wells in the 1980s. Many adaptations happened to make
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HOURE 1. This chart
‘Companies and Concho Resdownhole tools work horizontally that were designed to
‘work vertically, and those adaptations are still happen-
ing today. From completion techniques to artifical lit
methods, constant revisions and iterations of tools and
designs already in use are taking place.
Following suit, the gaelift industry had to adapt too.
‘At the time, most garlift designs were sill being done by
hand, and the Austin Chalk horizontal wells performed
differently than the vertical wells of yesteryear. They
headed teribly and no longer had predictable inflow per~
formance. They made lots of gas, they slugged, made fines
and lent themselves to gas lift very well given gas lift thrives
in gassy wells producing solids, Many things were tied to
lift these wells. Gaslift valves were run around the comer
into the open hole. Dip tubes also were used in an attempt
to lower the pressure and make more fluid. Alas, this did
not help to make more fluid, Those early attempts to
lift these wells worked but were very limited in what they
could produce. The next adaptation for horizontal gas lft
that was attempted was the bracketed gaslift design.
COVER STORY:
PRODUCTION
Bracketing the valves is practice whexe garlift valves
are run on the tubing at an equal spacing below unload-
ing valves to a depth where nodal analysis shows to be the
ideal place to inject gas. This method was typically used
in high-rate vertical wells where the productivity index is
known and relatively constant
Bracketing eventually evolved into a standaed practice
in horizontal wells, because lite reservoir information
‘was known, An equal spacing (like 152 m) allows the lift
system to remain in the hole and follow a well's decline
‘without intervention on the well
Recent flowing BHP surveys have shown that the
nodal-based unloading sections of the Austin Chalk
designs, with the 152m brackets, are actually slowing
the unloading process and causing problems in uncon-
ventional horizontal wells, The unloading valves are
routinely spaced too wide, which retards the transfer to
the next gasift valve and inhibits the unloading pro-
cess, making the possible drawdown of the formation
Iessened and hindering early time production. The
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(COVER STORY:
PRODUCTION
valves will tend to chatter (open and close very quickly)
‘when they cannot transfer to the next valve and may.
cause undue fatigue in the bellows, Chattering causes
the valves to leak and/or fal in addition to hurting well
performance. The surveys identified bad valve spacing
as well as communication between the tubing and annu-
lus in places where none should be present, indicating
a possible tubing leak of some kind and gave rise to the
thought that nodaFbased designs may be missing some-
thing in unconventional horizontal shale wells.
Nodal-based gas-lift designs
Nodal-based gaslift designs have previously worked great
for traditional vertical wells where nodal analysis is used
to create an inflow performance relationship cue to pre-
dict well performance and determine the best depth, or
point of injection, at which to lift fluid from within a well.
Conventional vertical wells typically have a constant BHP,
consistent dive mechanism and support a relatively
constant productivity index. In wells lke these, the use of|
nodal analysis to predict well performance and aid in the
gaslift design is very common and unmistakably useful
Unfortunately, nodak-based well analysis is not a valid
‘method to predict an unconventional well’s performance
over the long term. This method measures a fixed perfor
mance point, but today’s shale wells cannot be gauged by
this metric, With such rapid decline rates in production,
dropping the productivity index and reductions in BHP,
‘unconventional wells change too quickly for nodal to give
an accurate answer (o the longterm performance model,
° 00 2.000 |
2.000 ‘000 5.000
Pros se)
° 680
LOURE 2. Designing for OLR ib
Indicates where formation drawdown be
000
nga
mil of OLR curves (b). The SBHP lineUnconventional GLR-based gas lift
The new High Rate Unconventional GLR-Based Gas Lift
Method can produce higher rates than typical 152-m,
bracketed designs and transition from top valve to bot
tom with ease, using fever valves
The design works best when the gasliquid ratio
(GLR), static BHP (SBHP), flowing BHP and productiv.
ity index are known. With that information, the point
of injection can be pinpointed and will determine
where the bracketed valves need to start. Inthe SBHP is
known, or merely estimated, and nothing else is avail-
able, then the GLR-based method can indeed be used,
although it will require some guesswork by the gaclit
designer, The GLR-based design starts by frst plotting
the SBHP on the graph (Figure 2a) and adding a family
of GLR curves (Figure 2b). The bracket is started at the
highest rate achievable with the given SBIIP and GLR.
This is an estimated depth and becomes more accurate
as more offset well data are acquired and wtilized,
“Multipoint injection is considered a bad thing with
respect to traditional single-point injection gas lift
Gastift valves are primarily a low contol device and,
‘ypically, injecting through one at a time is normally
desired to get the best well performance
High-rate gas lit is a nodab-based gaslift design,
method introduced in the mid-1980s where gaelift
valves are placed in proximity in the tubing sting,
sometimes as closely as 30 m (100 ft) apart. Doing so
‘ill purposefully cause them to interfere with each,
other and ultimately keep the valves open, Interference
COVER STORY:
PRODUCTION
of two valves with one another is known as multipoint
ing. The intention of purposely multipointing is to
assist in the injection of higher volumes of gas into the
sane area while retaining the fexibility of certain valve
and port sizes, Shifting from upper to lower valves, the
reservoir no longer gives up fluid at the same rate it
did initially, thus it’s easier to keep up with unloading
and allovis transition more slowly from one valve to the
next, This provides for the ability (0 adjust the anti-
quated 152m spacing that was arbitrary to begin with,
and adopt a more modern, tailored and suitable lower
valve spacing for unconventional horizontal wells,
Multiple valves open within that close ofa proxim-
ity allows more gas to be injected easier, introduces
more gas in one section of the wel, will lighten the
Auid column and produce move fluid, This allows the
natural reservoir pressure of the formation to become
more effective in overcoming the hydrostatic head of
the uid column and push the uid to the surface.
Differential pressure is needed to inject gas through
the valve from the higher pressured casing to the lower
pressued tubing. A Lin, port valve is used to inject
hundreds of cubic fect of gas into the tubing string and,
given ample clearances in the production casing, a 1.5-
in, gaslift vale is typically used too,
“Multipointing isan inefficient use of lift gas and
should be eliminated when possible,” said Kenneth
Decker of Decker Technology. "The achievement of this
goal is based on the assumption that the gavdift valve has
the capacity to flow the required amount of gas to achieve
wh
Pass (i)
(Gource: Production Lit Companies and Concho Resources Inc.)
aa
COVER STORY:
PRODUCTION
the desived GLR given the current pressure conditions.
‘When lifting from live valves, as is the case when using
2s lift early in the life of unconventional wels, the flow
performance of the valve is much less than an otifice and,
consequently, a single vale is not capable of flowing the
volume of gas needed to achieve single-point injection,
"This is particularly wue for Lin. valves and less so for
1 5:in, valves. Trying to achieve single-point injection
in an unconventional well while the reservoir pressure
is declining rapidly should not be a design goal, nor
should time and expense be put forth to remediate
multipointing at this time, When the reservoir pressure
hhas declined to a faily stable value, engineering efforts
‘can be initiated to achieve single-point injection,
These case study wells were completed with 5.5-in.
production casing. Asa result, L5in, gasdift valves can-
not be used because that size gasift valve requires a
laxger outer diameter mandrel and will not fit into 5.5
in, production casing when ran on 2%in, production
tubing. These unconventional wells require the use of
Jin, gaslift valves in a 2%in, tubing mandrel. The valve
performance with a Lin, gaslift valve will not allow an,
operator to use ports big enough to inject the gas vol-
‘umes needed to produce higher rates in these wells.
Spacing several smaller port valves within proximity,
multipoint injection will occur and allow an operator
to inject enough gas in one area of the well to produce
the highest rates possible at depth in unconventional
‘wells. By spacing these unloading valves so closely, the
opportunity to transfer down through the valves is sped.
up; thus, getting to lower valves sooner is possible, This
theory takes advantage of the early time production and
productivity index of a newer shale well, where produc
tion declines are known to be more severe.
Backpressure in a gasifted well will reduce the
amount of fluid the well can produce, not only now
but for the life of the well. Every pound of pressure
expended to overcome excess surface tubing pressure
is a pound of pressure that could have been lifting
fluid. It is very important to conserve the well’s BHP
to produce every barrel possible. In gas lift, there
is a finite amount of pressure available to lft fluid
Understandably, while anany flowing tubing pressures
will be limited by surface facilities and in turn will be
dictated by sales gas line pressures, getting them as low
as possible will have great ellects on overall production,
Reducing backpressure is not always easy, and there
are many factors that cause backpressure. Flowline size,
number of 90-degree turns in
distance from the tank battery can all be a cause of
excess backpressure, along with many other factors, For
whine, chokes and
PIL LGcL ncaa
FIGURE 4, A consistent drawdown trom th
fon efficient gat
It process demonstrates
_n. (Source: Concho Retources Ine.)
the best performance, backpressure should be kept at a
minimum and ideally at or below 125 psi
Conclusion
The High Rate Unconventional GLR-Based Gas Lift
Method (Figure 3) has plenty of merit in today's uncon-
ventional shale plays. The wansition from upper valves
to lower valves can be greatly expedited on these uncon
ventional wells by closely spacing the higher valves, This
allows the rapid unloading process to create a higher
rate in the critical early time of production. Itis at this
point where the highest natural reservoir pressure is
helping the lifting process, and the productivity index
will be the greatest in the well’ life, The opposite can be
said when getting down to the valves in the lower portion
of the well
Achieving 2,500-plus bbl/d total fluid rates is well
within the grasp of the High Rate Unconventional
GLR-Based Method. Utilizing this system, 270-plus psi
of drawdown (Figure 4) within several days has been
seen following installation of lift, Based on data from
aan installed BHP gauge, accurate pressures have been
tacked and production rates have reached volumes of
more than $,000 bbI/d, All this is from individual well-
head compression in the form of a three-stage 200-hp,
gaepowered natural gas compressor with an operating
discharge pressure of 1,250 psi
Continued installations may be needed to gather
more conclusive data regarding the broad application
of this system, Higher rates can be achieved and fewer
valves can be used, There is no need to
valves to the tight 152m spacing based on the status
quo or arbitrary existing practices. EP
the bottom