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Chapter 4:
Artificial Lift
4.1. Pumping
4.2. Gas lift
4.3. Choosing an artificial lift process
Introduction
Artificial lift allows wells that are non-flowing or insufficiently flowing to be
produced . It can also be used to increase the flow from a well to produce at a
higher rate. Artificial lift is mainly designed for oil producers but the technology
may also be applied to water production or water injection. Most oil wells require
artificial lift at some point in the life of the field, and many gas wells benefit from
artificial lift to take liquids off the formation so gas can flow at a higher rate.
Artificial lift is used in 90% of the wells worldwide. Almost every well in US uses
artificial lift
Artificial lift lowers the producing bottom hole pressure (BHP) on the formation in
order to obtain a higher production rate from the well. Lifting can be done
mechanically by pumping with a positive-displacement down hole pump, such as a
beam pump or a progressive cavity pump (PCP). It also can be done with a down
hole centrifugal pump, which could be a part of an electrical submersible pump
(ESP) system. A lower bottom hole flowing pressure and higher flow rate can be
achieved with gas lift in which the density of the fluid in the tubing is lowered and
expanding gas helps to lift the fluids.
Most pumping operations occur after the fluid is below the bubblepoint pressure
Pumping
There are two major types of pumping (based on mechanism):
Positive displacement pumping such as by sucker rod pump
Principle
This system allows the beam to rock back and forth, moving the downhole
components up and down in the process. The entire surface system is run by a prime
mover, V-belt drives, and a gearbox with a crank mechanism on it. When this type of
system is used, it is usually called a beam-pump installation. However, other types of
surface-pumping units can be used, including hydraulically actuated units (with and
without some type of counterbalancing system), or even tall-tower systems that use a
chain or belt to allow long strokes and slow pumping speeds. The more-generic name
of sucker-rod lift, or sucker-rod pumping, should be used to refer to all types of
reciprocating rod-lift methods.
Linked rods attached to an underground pump are connected to the surface unit. The
linked rods are normally called sucker rods and are usually long steel rods, from 5/8
to more than 1 or 1 1/4 in. in diameter. The steel rods are normally screwed together
in 25- or 30-ft lengths; however, rods could be welded into one piece that would
become a continuous length from the surface to the downhole pump. The steel
sucker rods typically fit inside the tubing and are stroked up and down by the surfacepumping unit. This activates the downhole, positive-displacement pump at the
bottom of the well. Each time the rods and pumps are stroked, a volume of produced
fluid is lifted through the sucker-rod tubing annulus and discharged at the surface.
https://www.youtube.com/watch?v=LVBVlOGR3x8
Pumping cycle
Upward stroke: plunger valve or
traveling valve is closed; the column of
liquid corresponding to the stroke will
be lifted up to the surface
Downward stroke: hollow plunger valve
opens and the standing valve closes
preventing liquid from returning to the
pay zone
Q=SxNxA
pwf p
PI
It is best to choose the pumping rate limit under 20 strokes per minute. Below are
the formulas that can be used to calculate the number of strokes per minute of a
single size rod string and a tapered rod string
(a) For a single size rod string
Home work
Choose an asynchronous pumping rate for a pump located at a depth of 4950ft
driven by a single rod string with K ranges from 1.5 to 6.5. Compare your results
and explain the reason for your choices.
K
N (asy)
1.5
2.5
3.5
4.5
5.5
6.5
Summary
The pump flow rate depends on
1. The diameter of the plunger
2. The pump stroke
3. The pumping speed or rate
Centrifugal Pump
An electric submersible pumping (ESP) assembly consists of a downhole centrifugal
pump driven by a submersible electric motor, which is connected to a power source
at the surface. It is run into it position at the end of the production tubing into the
casing.
There are three (3) main components
of the centrifugal pump namely:
- The pump
- The electric motor
- The protector or seal section
Electric submersible pump systems employ a centrifugal pump below the level
of the reservoir fluids. Connected to a long electric motor, the pump is composed
of several impellers, or blades, that move the fluids within the well. The whole
system is installed at the bottom of the tubing string. An electric cable runs the
length of the well, connecting the pump to a surface source of electricity.
The electric submersible pump applies artificial lift by spinning the impellers on
the pump shaft, putting pressure on the surrounding fluids and forcing them to
the surface. A mass producer, electric submersible pumps can lift more than
25,000 barrels of fluids per day.
The Components
The Pump: goes through different stages which are stacked up inside a liner, and
each of these stages consist of a ROTARY IMPELLER which provides energy (in
form of velocity) to the fluid needed to be pumped. STATIC DIFFUSER which
transforms the kinetic energy into pressure energy before sending it to the
impeller.
The Motor: is enclosed in a steel housing unit with oil to lubricate its bearing. It is
never placed below the perforation where the produced fluid flows up the well,
which may damage the motor especially when there is inadequate fluid flow rate
which could cause abnormal heating. The motor and cable are usually designed to
be use up to a temperature of 150 F, there are some special design which can be
used up to 400 F.
The Seal or Protector: provides a tight connection between the motor and the
pump. It also prevents the oil from moving along the shaft.
Advantages
It is the most efficient lift methods on a cost-per-barrel basis.
It has a high flow rate: 100 to 60,000 B/D, including high water-cut fluids.
It works in high-temperature wells (above 350F) using high-temperature motors
and cables.
The pumps can be modified to lift corrosive fluids and sand.
ESP systems can be used in high-angle and horizontal wells if placed in straight or
vertical sections of the well.
Disadvantages
ESP pumps can be damaged from gas lock. In wells producing high GOR fluids, a
downhole gas separator must be installed.
ESP pumps have limited production ranges determined by the number and type
of pump stages; changing production rates requires either a pump change or
installation of a variable-speed surface drive.
The tubing must be pulled for pump repairs or replacement.
Jet pumps
With a
reciprocating
hydraulic
pump, the
injected power
fluid operates
a downhole
fluid engine,
which drives a
piston to
pump
formation fluid
and spent
power fluid to
the surface.
Hydraulic pump
Advantages
Hydraulic pumping has the following advantages.
Being able to circulate the pump in and out of the well is the most obvious and
significant feature of hydraulic pumps. It is especially attractive on offshore
platforms, remote locations, and populated and agricultural areas.
Positive-displacement pumps are capable of pumping depths to 17,000 ft and
deeper. Working fluid levels for jet pumps are limited to approximately 9,000 ft.
By changing the power-fluid rate to the pumps, production can be varied from 10
to 100% of pump capacity. The optimum speed range is 20 to 85% of rated speed.
Operating life will be significantly reduced if the pump is operated above the
maximum-rated speed.
Deviated wells typically present few problems to hydraulic free pumps. Jet pumps
can even be used in through flow line installations.
Jet pumps, with hardened nozzle throats, can produce sand and other solids.
There are methods in which positive-displacement pumps can handle viscous oils
very well. The power fluid can be heated, or it can have diluents added to further
aid lifting the oil to the surface.
Corrosion inhibitors can be injected into the power fluid for corrosion control.
Added fresh water can solve salt-buildup problems.
Disadvantages
Hydraulic pumping has the following disadvantages.
Removing solids from the power fluid is very important for positive-displacement
pumps. Solids in the power fluid also affect surface-plunger pumps. Jet pumps, on
the other hand, are very tolerant of poor power-fluid quality.
Positive-displacement pumps, on average, have a shorter time between repairs
than jet, sucker rod, and ESPs. Mostly, this is a function of the quality of power
fluid but, on average, the positive-displacement pumps are operating from greater
depths and at higher strokes per minute than for a beam pump system. Jet pumps,
on the other hand, have a very long pump life between repairs without solids or if
not subjected to cavitation. Jet pumps typically have lower efficiency and higher
energy costs.
Positive-displacement pumps can pump from a low BHP (< 100 psi) in the absence
of gas interference and other problems. Jet pumps cannot pump from such low
intake pressures, especially when less than the cavitation pressure. Jet pumps
require approximately 1,000 psi BHP when set at 10,000 ft and approximately 500
psi when set at 5,000 ft.
Positive-displacement pumps generally require more maintenance than jet pumps
and other types of artificial lift because pump speed must be monitored daily and
not allowed to become excessive. Power-fluid-cleaning systems require frequent
checking to keep them operating at their optimum effectiveness. Also, well testing
is more difficult.
http://www.youtube.com/watch?v=IR5EOahkxw4
Rubber stator
Gas Lift
Gas lift involves injecting high-pressure gas from the surface into the producing
fluid column through one or more subsurface valves set at predetermined depths.
This artificial lift production technique can be used to make a non-flowing or
insufficiently flowing well come on stream by reducing the hydrostatic back
pressure between the bottom of the hole and the surface. This is done by injecting
gas at the base of the production string
TYPES OF GAS LIFT
Gas lift can be classified according to
1. Injection Method
2. Surface Injection Circuit
3. Type of Completion
http://www.youtube.com/watch?v=CfWez4ng5JU
http://www.youtube.com/watch?v=ryvl1jgnxDs
http://www.youtube.com/watch?v=vr861tiCfa4
Gas lift injects compressed gas into the well to reestablish pressure, making it
produce. Even when a well is flowing without artificial lift, it many times is using a
natural form of gas lift.
The injected gas reduces the pressure on the bottom of the well by decreasing
the viscosity of the fluids in the well. This, in turn, encourages the fluids to flow
more easily to the surface. Typically, the gas that is injected is recycled gas
produced from the well.
With very few surface units, gas lift is the optimal choice for offshore applications.
Occurring downhole, the compressed gas is injected down the casing tubing
annulus, entering the well at numerous entry points called gas-lift valves. As the
gas enters the tubing at these different stages, it forms bubbles, lightens the
fluids and lowers the pressure.
Injection Method
There are two kinds of injection method:
- Continuous gas lift
- Intermittent gas lift
Completion Type
There are two (2) types of completion used namely
- DIRECT
- REVERSE
In direct method, gas is injected through the casing annulus and produced from
the tubing string.
In reverse method, gas is injected through the tubing string and produced
through the casing annulus
Disadvantages
Relatively high backpressure may seriously restrict production in continuous gas
lift. This problem becomes more significant with increasing depths and declining
static BHPs. Thus, a 10,000-ft well with a static BHP of 1,000 psi and a PI of 1.0
bpd/psi would be difficult to lift with the standard continuous-flow gas-lift system.
However, there are special schemes available for such wells.
Gas lift is relatively inefficient, often resulting in large capital investments and
high energy-operating costs. Compressors are relatively expensive and often
require long delivery times. The compressor takes up space and weight when
used on offshore platforms. Also, the cost of the distribution systems onshore may
be significant. Increased gas use also may increase the size of necessary flow line
and separators.
Adequate gas supply is needed throughout life of project. If the field runs out of
gas, or if gas becomes too expensive, it may be necessary to switch to another
artificial lift method. In addition, there must be enough gas for easy startups.
Operation and maintenance of compressors can be expensive. Skilled operators
and good compressor mechanics are required for reliable operation. Compressor
downtime should be minimal (< 3%).
Key factors that influence the selection of an artificial lift method contd
Well depth: The well depth dictates how much surface energy is needed to move
fluids to surface, and may place limits on sucker rods and other equipment.
Completion type: Completion and perforation skin factors affect inflow
performance.
Casing and tubing sizes: Small-diameter casing limits the production tubing size and
constrains multiple options. Small-diameter tubing will limit production rates, but
larger tubing may allow excessive fluid fallback.
Wellbore deviation: Highly deviated wells may limit applications of beam pumping
or PCP systems because of drag, compressive forces and potential for rod and
tubing wear.
Flow rates: Flow rates are governed by wellhead pressures and backpressures in
surface production equipment (i.e., separators, chokes and flow lines).
Fluid contaminants: Paraffin or salt can increase the backpressure on a well.
Power sources: The availability of electricity or natural gas governs the type of
artificial lift selected. Diesel, propane or other sources may also be considered.
Key factors that influence the selection of an artificial lift method contd
Field location: In offshore fields, the availability of platform space and placement of
directional wells are primary considerations. In onshore fields, such factors as noise
limits, safety, environmental, pollution concerns, surface access and well spacing
must be considered.
Long-range recovery plans: Field conditions may change over time.
Pressure maintenance operations: Water or gas injection may change the artificial
lift requirements for a field.
Enhanced oil recovery projects: EOR processes may change fluid properties and
require changes in the artificial lift system.
Field automation: If the surface control equipment will be electrically powered, an
electrically powered artificial lift system should be considered.
Availability of operating and service personnel and support services: Some artificial
lift systems are relatively low-maintenance; others require regular monitoring and
adjustment. Servicing requirements (e.g., work over rig versus wireline unit) should
be considered. Familiarity of field personnel with equipment should also be taken
into account.
Hydraulic Pumping
ADVANTAGES
It is suited to great depths and deviated wells.
Depending on the installation of the pump, it can be pumped up to the surface so
that it is not necessary to pull the tubing.
Working fluid can serve as a carrier fluid for injecting an additive
Advantages for plunger pump
The size and rate of the pump can easily be modified to adapt to well conditions
Viscous heavy crudes benefit from being mixed with a lighter working fluid
Production is possible with extremely low bottom hole pressures
Advantages for jet pump
High production flow rate is possible with jet pump
It has no moving part inside the well
It has minor problem only if sand or gas are present
DISADVANTAGES
Initial investment in the surface equipment is high and its maintenance is
expensive
Its high pressure pump feed circuit with consequent safety risks
Well testing causes problems especially assessment of produced fluids
Disadvantages for plunger pump
There is rapid wear and tear on the pump if the fluid is corrosive or abrasive
The pump efficiency will drastically lower if free gas is present.
Disadvantages for jet pump
Low efficiency of about 25 to 30% (70% for plunger).
It needs bottom hole flowing pressure of over 3.5 MPa (500psi),else
detrimental cavitation will take place in the flow nozzle.
It is prone to form emulsions or foam.
DISADVANTAGES
It is needed for bottom hole pressure that is not too low, so sometimes the artificial lift
method has to be changed at the end of the wells lifetime
The required injection gas volume may be excessive for wells with a high water cut.
It cannot be applied if the casing is in bad shape
Gas processing facilities (dehydration, sweetening) can compound compression costs.
Foaming problems may get worse
Surface infrastructure is particularly expensive if wells are scattered over a large area.
It has a low efficiency especially in a deep well
General Guidelines