Introduction

37
1 Introduction Artificial Lift Methods

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Transcript of Introduction

Page 1: Introduction

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Introduction

Artificial Lift Methods

Page 2: Introduction

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Artificial Lift - Uses

• In Oil Wells, Gas Wells and Coal Bed Methanewells:– To “boost” or increase production of naturally flowing

wells– To put dead wells back into production– To stabilize the unsteady production of some naturally

flowing wells– To “kick-off” wells that can produce naturally but may

die when closed and can not achieve the naturalequilibrium flowrate without help

• In water injection wells– To “backflow” and clean the injection zone

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Artificial Lift Methods

• There are several artificial lift methods. The most common ones are:–––––––––

Beam PumpingElectrical Submersible PumpContinuous Gas LiftProgressive (Progressing) Cavity PumpHydraulic Jet PumpIntermittent Gas LiftPlunger LiftHydraulic Reciprocating PumpEtc…

• Some methods are used exclusively to dewater gas wells– Foam and soap bars

• For deep water conditions it may be more convenient to install theartificial lift device outside the production well at some point of theseabed. Those methods are called Boosting Methods. The mostcommon ones are:––––

Sub-sea multiphase pumpingRiser gas liftSub-sea separation and pumpingEtc…

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Beam Pump

Pumping Unit

Prime Mover

Polished RodSuffing Box

Tubing

Sucker Rods

Pump

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Electrical Submersible Pumping

Primary Transformer

Switchboard

Wellhead andelectricmandrel

Tubing

Round Cable

Packer

Pump

Separator

Protector

Flat Cable

Motor

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Continuous Gas Lift

Injection Choke

Christmas Tree

Unloading Valve

Gas Lift Mandrel

Tubing

Operating Valve

Packer

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Christmas Tree

Progressing Cavity Pump

Transformer

Polished Rod

Control

Panel Electric Motor

Tubing

Rods

Downhole PCP

Gas Anchor

Anchor

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Hydraulic Jet Pumping

Transformer

Control PanelMotor Power Fluid Treatment

Valve

Christmas Tree

Tubing

Downhole Pump

Standing Valve

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Tubing

Unloading Valve

Valve Mandrel

Operating Valve

Packer

Check Valve

Intermittent Gas Lift

IntermitorChristimas Tree

Pressure Gas

Open

Closed

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ComputerOpenClosed

Nipple

Plunger Lift

Catcher

Control Valve

Tubing

Plunger

Plunger stop

Seating nipple

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Distribution of Artificial Lift Methods

• 90% of the wells in the world produce by some form ofartificial lift method

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Main Important Methods

• Sucker Rod Pump– Most commonly used method worldwide– Used massively in US and in significant number of wells in

Russia, China and South America– Simple to operate and inexpensive compared to other methods,

but usually lower pumping capacity– Problems with high GLR, with small tubing, with deep wells and

with crooked or deviated wells– Can achieve very low bottom hole flowing pressure making it

ideal for very depleted reservoirs• Electrical Submersible Pump

– Second most commonly used method worldwide (+100,000wells)

– Used massively in Russia and in significant number of wells inUS

– Responsible for the highest amount of total fluids produced (oiland water) by any artificial lift method and an ideal method forhigh water cut wells

– Problems with sand production, high gas liquid ratio and highbottom hole temperatures

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Main Important Methods

• Continuous Gas Lift– Very flexible and service through wireline is

inexpensive. Tolerant to sand and solids production,tolerant to high GLR, tolerant with deviated wells

– Requires a stable source of high pressure gas andlooses efficiency as bottom hole flowing pressuredeclines and may require the use of another artificiallift method as reservoir ages

– The high reliability of the method makes it the firstchoice for offshore production instead of ESP

• Progressing Cavity Pump– Less expensive than other methods and tolerant to

solids and sand production– Selection of materials (elastomer for the stator) very

dependent on temperature and fluids composition

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Main Important Methods

• Hydraulic Jet Pump, Intermittent Gas Lift andPlunger Lift– Special circunstances makes those methods very

effective in some applications– Hydraulic Jet Pump

• Very beneficial for high-viscosity crudes where blending witha light power fluid can help in the processing of heavy crudes

– Intermittent Gas Lift• Very beneficial for wells with a reasonably high reservoir

pressure but low productivity where stimulation is not anoption and high gas liquid ratio makes the use of beam pumpdifficult

– Plunger Lift• Used in combination with intermittent gas lift to reduce liquid

fall back or by itself in wells that present casing heading as aform of enhanced natural flow. Very used in dewateringapplications

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Beam Pump

Pumping Unit

Prime Mover

Polished RodSuffing Box

Tubing

Sucker Rods

Pump

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Beam Pump

•••••••••

•

The oldest and most commonly used form of artificial liftFamiliar to most engineers and operatorsAllow very low fluid levels (low bottom hole flowing pressure)Low capital investment for low production at shallow to medium depthsHigh investment for high flow rates in deep wellsAdaptable to scale and corrosion problemsLimitation with casing sizeNot suitable for crooked holesMay have problems with sand production, high viscosity fluids and high GLRwellsEasily installed in remote locations with an internal combustion engine

Pumping Unit

Prime Mover

Polished RodSuffing Box

Tubing

Sucker Rods

Pump

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Electrical Submersible Pumping

Primary Transformer

Switchboard

Wellhead andelectricmandrel

Tubing

Round Cable

Packer

Pump

Separator

Protector

Flat Cable

Motor

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Electrical Submersible Pumping

••

••

••

••••

Very complex system. MTBF average around 2 ½ year worl wideCan be applicable to a wide range of flowrates from 100 bpd up to 100,000 bpd but efficiencyreduces with a decrease in flowrateInvestment cost directly related to the depth due to cable cost and motor horsepowerEfficiency increases with reduction in produced GLR either by reduction of GOR or increase inWC. Efficiency decreases with decrease in flowrateCasing size is not critical for high flowratesRequires work-over to remove a conventional unit although cable and coil deployed options areavailableElectrical systems is the weak link and requires a stable source of electricityElectrical system (cable, motor and protector) very sensitive to operating temperatureCan be flexible with the use of a VSD. Very delicate installation and a high rate of “infant mortality”May have problems with scale, sand and wax

Primary Transformer

Switchboard

Wellhead andelectricmandrel

Tubing

Round Cable

Packer

Pump

Separator

Protector

Flat Cable

Motor

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Continuous Gas Lift

Injection Choke

Christmas Tree

Unloading Valve

Gas Lift Mandrel

Tubing

Operating Valve

Packer

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Continuous Gas Lift

••••

•

•

•

•

Very simple method seen as an extension of natural flowRequires a source of high pressure gas and casing and lines must withstand injection pressureLow investment for deep wells if high pressure gas is availableEfficiency decreases with decrease in production GLR either due to a reduction in GOR orincrease in WCNo problem with sand and crooked wells. Can be used in deviated wells but highly deviated wellsmay have problems retrieving valves with wire lineVery flexible and simple design, applicable in a wide range of flowrates from 50 bpd (macaronitubing) to 40,000 bpd (casing flow)There is a relation between the minimum possible bottom hole flowing pressure, the depth and thefluid propertiesMost design modification and repairs can be done through wire line intervention without the needof a workover

Injection Choke

Christmas Tree

Unloading Valve

Gas Lift Mandrel

Tubing

Operating Valve

Packer

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Christmas Tree

Progressing Cavity Pump

Transformer

Polished Rod

Control

Panel Electric Motor

Tubing

Rods

Downhole PCP

Gas Anchor

Anchor

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Progressing Cavity Pump

••

•

••

Christmas Tree

Is a positive displacement pump that does not rely on valves to pump fluidsUsually has a stator made of an elastomer. Stator material is sensitive to oilcomposition (aromatics) and temperatureHas higher tolerance to free gas than beam pumping, but excess gas can also causelack of lubrication and cooling as well as chemical problems with the elastomerMay have problems with deviated and crooked wellsApplicable for low to medium flowrates

Transformer

Polished Rod

Control

Panel Electric Motor

Tubing

Rods

Downhole PCP

Gas Anchor

Anchor

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Hydraulic Jet Pumping

Transformer

Control PanelMotor Power Fluid Treatment

Valve

Christmas Tree

Tubing

Downhole Pump

Standing Valve

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Hydraulic Jet Pumping

••

•

•••

Very simple methodFrom all artificial lift methods this is the one that has the biggest depth applicationrangeThe use of a light oil as the power fluid makes this a very interesting method for highviscosity fluidsRequires an injection of 5 to 7 times the volume of liquid producedNo moving parts, applicable to deviated and crooked wellsPump can be back-circulated to the surface

Transformer

Control Panel

Motor Power Fluid TreatmentValve

Christmas Tree

Tubing

Downhole Pump

Standing Valve

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Tubing

Unloading Valve

Valve Mandrel

Operating Valve

Packer

Check Valve

Intermittent Gas Lift

IntermitorChristimas Tree

Pressure Gas

Open

Closed

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Intermittent Gas Lift

•

•••

•

Tubing

Unloading Valve

Valve Mandrel

Operating Valve

Packer

Check Valve

Despite the name this is a “pumping” method. The pump is a “gas piston” thatexpands and accelerates to the surface propelling a liquid slug on topSame general characteristics of continuous gas liftUsually used for low flowrate rangeIntermittent gas injection and liquid production can disrupt the separation system aswell as can interfere with other wellsHigh instantaneous consumption of injected gas

IntermitorChristimas Tree

Pressure Gas

Open

Closed

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ComputerOpenClosed

Nipple

Plunger Lift

Catcher

Control Valve

Tubing

Plunger

Plunger stop

Seating nipple

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Plunger Lift

•

•

••

ComputerOpen

Closed

Nipple

A mechanical interface (plunger) used to reduce the liquid fall back inintermittent gas lift wellsCan be used without external gas injection using the production gasaccumulated in the casingPlunger descend velocity will affect production cycle and production flowrateCan be used with and without an external injection of gas

Catcher

Control Valve

Tubing

Plunger

Plunger stop

Seating nipple

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Hydraulic Reciprocating Pumps

• This method is a combination of a positive displacement pump(similar to a sucker rod pump) actuated by a hydraulic system(similar to the power fluid injection system of hydraulic jet pump)

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Auto Gas Lift

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Auto Gas Lift

• Curious application where a gas zone is isolated with 2 packers andused as the high pressure gas source for a gas well

• The gas injection can only be controlled by the injection gas lift valve

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Well Multiphase Pumping

••

Can-K Multiphase PumpsAdvantages

––––

Very Low shear rate and hence, least emulsion compared to ESPPositive displacement pumpCan be installed in vertical, slanted or horizontal wellsHigh temperature capability of up to 287DegreesC (550DegreesF) withCAN-K top drive

• Volume:– 24 m3/day to 8898 m3/day (150 to 56,000 bbl/day)

• Casing Sizes:– From 139.7mm to 339.9mm(5 1/2" to 13 3/8") casing suitability.

• Drive:– Electric Submersible Motor or CAN-K top drive.

• Speed:– Up to 6000 rpm

• Power:– Up to 850 HP

• Installation:– Installed exactly like an ESP system and suitable for all available

Standard electric submersible motors. Alternatively installed with suckerrod

• Prime Movers:– Downhole Electric Motors -

• Will bolt to any existing Downhole electric motor with no modification required– Top Drive

••

Electric or HydraulicRod String

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Hydraulic Driven Centrifugal Pump

•

••

The Weir hydraulic drive downhole pumping system is a newconcept designed specifically to provide reliability andflexibility in downhole pumping applications.Today this technology is offered by Clyde Pumps in GlasgowSpecifications––––

up to 100,000 barrels/dayup to 1,000 hp5000 to 15,000 rpmup to 400°F

•

•

•

•

In a typical application a proportion of the produced fluid isbled off from the well output line and passed through acyclone separator (or equivalent filter) to achieve therequired filtration level of not more than 100 micron/100ppm.The fluid is then boosted in pressure by a suitable surfacecharge pump and passes through a control valve (whichenables the well output to be varied) down the power supplytubing on which the downhole pump set is suspended, andinto the turbine to provide the power required to drive thepump.The pump takes its suction from the reservoir and increasesthe fluid pressure to overcome static and friction heads anddeliver the required quantity to the wellhead at the designedpressure.Outlet from the pump mixes with the turbine exhaust and thecombined fluids flow up the annulus between the powersupply tubing and the production tubing and out of thewellhead into the production line

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Diaphragm Pumps

• There are several Diaphragm pumps available• Smith Lift developed a Hydraulic Diaphragm Electric

Submersible pump• The pump is driven by a 3 phase electric motor that

actuates two diaphragms to positively displace fluids• It was developed for low liquid production (less than 200

bpd) and for wells shallow than 2,500 ft

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Balance Pump

•

•

•

The Balance pump is a hydraulically actuated reciprocating, low-volume pump that can be used to remove liquid from onshore andoffshore gas wellsThe pump, which can be retrofitted, is operated by two hydrauliclines—one filled with oil, the other with waterThe differential hydrostatic pressure between water and oil movesthe pump’s internal piston downward. The application of pressureto the oil line drives the piston upward, lifting the water trappedabove the travelling check and drawing water into the lowerchamber. Removing the pressure from the hydraulic line allowsthe water line to return the piston, after which pressure isreapplied to the hydraulic line

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Curiosities

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Swab


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