SPE 69515
Optimizing Swabbing of Marginal Wells Through Simulation Studies
Anthony Alfaro Prez, Perez Companc.
Copyright 2001, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the SPE Latin American and Caribbean Petroleum
Engineering Conference held in Buenos Aires, Argentina, 2528 March 2001.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
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Abstract:
Oil production through swabbing is an alternative method that
becomes attractive when the production from a well is under
the economic limit of any conventional system of extraction.
This operation consists of running a plunger with rubber cups
into the well, submerge it in the existing liquid and pulling it
up, repeating the procedure until drying the well or until it is
economically profitable for the service company. After some
days to restore the of fluid level the procedure is repeated.
The main objective of this work is to define the optimun
frequency of intervention to maximize cumulative production
(it is different to the maximum volume), thus resulting in
maximize value.
The study allows to obtain sensibility analysis to important
parameters as:
Optimun extraction of annual cumulative volume
Optimun frequency of intervention
Minimum levels of fluid that should be found in the wells
Cost of each swabbing run"
Optimun annual expenses
Maximum annual income
Introduction:
This study has been conducted in Lote X, Northwest Peru,
were over 4000 wells have been drilled since 1900.
Approximately 1500 wells are currently producing under this
system with dayly output of about 1500 bopd. Historically
frequency of interventions has been determined by statistical
information or from the personnel's experience at worksite,
without including information of costs and revenues obtained
by every single swabbing run.
There are 2 types of Swabbing; The Tubing Swabbing, refers
to those wells equiped with production tubing where the
operation is achieved with plunger of 2 3/8" or 2 7/8" or as to
fit the diameter of the tubing and the Casing Swabbing,
referred to those wells without tubing, where the operation is
achieved directly through the casing with plungers of 4 " or
5 ", or as is the diameter of the casing.
With the statistical information of costs and production,
empirical equations of the cost structure for a certain company
were created. Based on flow equations, a model was
developed that defines economic limits and optimum
frecuencies of intervention. Both of these parameters define
the balance in between operators and service company
interests, and assure sustaintability of the proccess.
Development:
Fig. 2 summarizes the development of the work, which
consists of: 1. Find the Revenue Curve; 2. Find the Cost
Curve; 3. By difference, find the Net Revenue Curve; 4. Find
the maximum value of Net Revenue Curve, that is, the
optimun value for frecuency of interventions.
The Revenue Curve is directly related to the fluid production
and the submergence values of the plunger, while the Cost
Curve, is related to the structure of costs of the service
company.
1. Fluid Contribution:
Fluid production is related with the revenues of the
operator.
From fig. 3:
Vol = Q.dT = A.dH ........(1.1)
Where:
2 ANTHONY ALFARO PREZ SPE 69515

Q: flow rate for a given fluid level increment dH Top U + Top L

T: Time H 1 = NF
2
...(1.9)
Being: Top U + Top L
H 2 = NI
A=

4
(DCi 2 DTe 2 + DTi 2 )....(1.2) 2
Equation 1.8 relates fluid levels with time and, with only
2 data inputs (NF and NI) from the swabbing operation
That is valid for both cases, Tubing Swabbing and and through iteration or solving a quadratic equation, the
Casing Swabbing (CS). (in CS the values of the external values of Qmax and He are calculated.
diameters (DTe) and intern (DTi) in the equation 2,
equal zero). 2. Calculation of Maximum Plunger Submergence (S)
and Energy Consumption
Vogels equation for the Inflow Performance of a well is:
In the movement of the plunger up, total weight on the
2 cable, energy consumption, effect of fluid pressure in the
Q Pwf Pwf
= 1 0.2 0.8 .(1.3) annulus, weight of fluid when it arrives to the surface,
Qmax Pr Pr etc, chage continuously. Considering a finite interval:

Where the dynamic bottom pressure (Pwf) can be Maximun Submergence (S)
approximated from the fluid gradient (f) and the liquid
height (H): From fig. 4:

Pwf = f.H .(1.4) L = N + S L .(2.1)

And reservoir pressure, (Pr), is related to the static fluid The displacement of the level of fluid in the annulus
level (He): (N) is:

Pr = f.He .(1.5) AT
N = . L (2.2)
AA
From equations 1.1, 1.2, 1.3, 1.4 and 1.5:

Case 1: N > S (wells of low submergence).

A.dH
dT = ...(1.6)
H H
2
For the interval from L = N + S (L1), and to

Qmax. 1 0.2 0.8
He He
L + N = S

Integring with limits H1 and H2: or

S
A H2 dH L = N+S (L2),
T= AT
2
.....(1.7) 1+
Qmax H1 H H AA
1 0.2 0.8
He He that is until the location of the plunger equals the
which is solved as: fluid level in the annulus and where there is effect of the
pressure of liquid in the annulus over the plunger, the weight
(1.25 He + H 2 ) of fluid (WF) is:
A.He (He H 2 )
T=
WF = F .(A T A C )(
. L + N )
Ln ..(1.8)
1.8 Qmax

(1.25 He + H 1 )
(He H 1 ) A
W = F .(A T A C ). 1 + T .(N + S L )
F
Being Top U and Top L the upper and lower limits of the A A
perforations, and NI and NF initial and final fluid levels, .(2.3)
then the heights of fluid at the begining and end of the
swabbing operation are:
SPE 69515 OPTIMIZING SWABBING OF MARGINAL WELLS THROUGH SIMULATION STUDIES 3

and the total weight (WT1) is: and then from 2.4 or 2.6:

WT1 = WC .L A C .S. F + WF ......(2.4)
= WC .(N + S) + S. F .(A T 2.A C )
S
WMAX
A
AT 1+ T
WT1 = WC F .(A T A C ). 1 + .L



A A
AA

Pot
A WMAX =
A C .S. F + F .(A T A C ). 1 + T .(N + S) V
A A Pot
WC .N
V
S= ..(2.9)
S WC
For the interval from L = N + S (L2) + F .(A T 2.A C )
AT AT
1+ 1+
AA
AA
to L = S (L3) that is until the the fluid slug arrives to
the surface and where there is not effect of pressure of the
liquid in the annulus: Case 2: N S (wells with high submergence)

WF = F .(A T A C ).S ....(2.5)

For the interval from L = N + S (L1) to L = S (L2),
the liquid slug arrives to the surface, but the plunger is below
the fluid level in the annulus and where there is effect of the
WT2 = WC .L + S. F .(A T 2.A C ) ...(2.6) liquid pressure in the annulus over the plunger:

For the interval from L = S (L3) to L = 0 (L4), the AT

WF = F .(A T A C ). 1 + .(N + S L )
A A
fluid weight is:

[
WT3 = WC + F .(A T 2.A C ) .L (2.7) ] ..(2.10)

AT
WT1 = WC F .(A T A C ). 1 +
If
L
AT A
WC > F .(A T A C ). 1 + , A

A A A
the maximum weight occurs when L = N + S , then from the A C .S. F + F .(A T A C ). 1 + T (N + S)
equation 2.4 or 2.6, we have : AA

For the interval from the arrival of the liquid slug to

WMAX = WC .(N + S ) F .A C .S =
Pot
the surface until the point where the level of fluid equals the
V plunger and where there is effect of the liquid pressure in the
Pot annulus over the plunger, that is, L = S (L2), to
WC .N A
V N + S. T
S= .(2.8)
WC F .A C AA
L= (L3),
AT
If 1+
AA
AT
WC F .(A T A C ). 1 + , A
A A
AT
WF = F .(A T A C ). N. 1 + + (S L ). T

AA AA
the maximum weight occurs when (2.11)
S
L = N+S
A
1+ T
AA
4 ANTHONY ALFARO PREZ SPE 69515

AT Energy Consumption:
WT2 = WC F .A C F .(A T A C ). .L +
AA In calculating Maximum Submergence, intervals (L1, L2, L3
and L4) and equations that model the values of weight on
AT A
+ F (A T A C ) N 1 +
wireline in each interval were defined.
+ S T
Energy Consumption for each swabbing run is:
AA AA
L2 L3 L4
E = WT1 .dL + WT2 .dL + WT3 .dL ..(2.15)
For the interval where there is no effect of the liquid L1 L2 L3

pressure over the plunger, that is to say from

A 3. Cost Structure
N + S. T
AA The analysis is made for a given service company with
L= (L3), to L = 0 (L4),
AT the only purpose of showing how to define the Cost
1+ Curve.
AA

WF = F .(A T A C ).L Amortization:

[ ]
WT3 = WC + F .(A T 2A C ) .L ..(2.12) It is a fixed cost and it will be assumed to be constant
during a years, being i the interest rate, the cost in $/hr is:

CAPEX .(1 + i )
If n
Amortization =
AT
WC > F .(A T A C ). 1 +
0
365x24 (1 + i )
a
A A a =n 1
the maximum weight occurs when L = N + S,
then from 2.10: Personnel:

It is a fixed cost, stepped by the quantity of swabbing

WMAX = WC .(N + S ) F .A C .S =
Pot
units. Tables 1 and 2 show the personnel's monthly wages and
V distribution according to the number and type of swabbing
Pot units. Local related costs, such as bonuses, food allowance,
WC .N etc, should be included.
V
S= (2.13)
WC F .A C
Vehicles :
If
Fixed cost that includes purchasing one van-type vehicle
A
WC <= F .(A T A C ). 1 + T every 2 supervisors and renting a van for personnel shifting
plus 20 gal/day gas each.
AA
the maximum weight occurs when L = S
Communications:
and then from 2.10 or 2.11:
AT
WMAX = (WC F .A C ).S + F (A T A C ) (1 +
Fixed cost for radio equipment of each swabbing unit and
.N =
A A
one for each supervisor.

Pot Swabbing Cups:
=
V In this example, statistics are as follows:
A Prof avg / well: 4500 ft
F (A T A C ) 1 + T .N
Pot
N of swab runs avg/well: 6
S=
V A A ...(2.14) Production avg/well: 30 bfpd
WC F .A C Avg # wells with swab/day: 10
Avg swab cups/day: 6
Cost of each swab cups: $18
SPE 69515 OPTIMIZING SWABBING OF MARGINAL WELLS THROUGH SIMULATION STUDIES 5

Q Prof
And the consumption of swabbing rubber cups for distance Packers = 8 0.25 + 0.75 $/run
traveled or for barrels of fluid produced: 300 270000

CupsCons. =
1 cups Maintenance:
45000 ft Travel
1 cups A fixed cost including Preventive and Corrective
CupsCons. = Maintenance for the vans, cisterns and swabbing unit must be
50 bfpd Produced
considered.
The wear out of rubber cups becomes more important when
significant volumes of fluid are produced. We assume 0.25 to General Expenses:
weight the production and 0.75 for the traveled distance. The
equation that relates the consumption of rubber cups with the Fixed expenses cost to include location rent, water
production (Q) and the swabbing depth for each swabbing run consumption, electric power, telephone, stationery, etc, must
is: be estimated and divided into the total number of units.

Q Depth
Cups = 18 0.25 + 0.75 [$/run] Fuel Consumption:
50 45000
Is related with the energy consumption as calculated
Wireline wearout: (variable cost) plus the fuel to mobilize the swabbing units to
the wells.
Because of wireline wear out, average replacement is
one 10000 ft coil every 4 months. Therefore the consumption
for traveled feet or produced barrel is :
4. Calculations

WL Cons. =
324 x 10
1
5
(Coil fttraveled) Revenues:
Are calculated based on contribution of fluids, frequency of
intervention, submergence of the plunger, number of swabbing
WL Cons. =
1 Coil runs and sale price of the oil.
36000 bfpdProduced
Expenses
And the equation that relates the wireline consumption for The equations that model the structure of costs are given in
each swabbing run is: $/hr or $/run. In calculating the time required for a run or an
intervention of a well, the speed of the plunger uphole could
be averaged as 800 ft/min and downhole as about 600 ft/min.
Q Prof
Cable = 4000 0.25
5
+ 0.75 $/run Mobilization, mounting and dismounting of the swabbing unit
36000 324x10 is 1.5 hr in this field.

Net Revenues:
Lubricator Packers
The Net Revenues are obtained by difference between the
An average of one packing per day, at a cost of $ 8 is revenues and expenses.
required. Packers consumption for traveled distance or
produced barrels is:

Packer Cons. =
1
270000
Pkrs (
fttraveled
) 5. Programming

A Visual Basic program has been developed to make

calculations as described. Interfaces with the user (forms) are
Packer Cons. =
1 Pkrs
shown in fig. 5 and 6.
300 bfpdProduced
The logic is as follows:
Therefore the equation that relates the consumption of 1. Assign for the well an intervention frequency (i), which
packings for each swab run is: initially takes the value of 1.
6 ANTHONY ALFARO PREZ SPE 69515

2. The program calculates the Revenues, Expenses and Net - If Net Revenues are negative[ U < 0 ]:
Revenues, for run and for intervention, for the current value of If i < 365 , it returns to the point 1 and fixes a new
i. value of "i"
3. If the value of " i " is 1, it returns to the point 1 and it fixes a
If i 365 , the program stops and sends the
new value of i = i + 1 , that is, 2. If the value of "i" is geater
message of non-economic
than 1, then the following question is asked:
4. Determined the optimun frequency, the value of revenues,
- If Net Revenues (U) are positive [ U > 0 ]: expenses and utilities, for "run" and for intervention are
If U i +1 < U i , the value of "i" is the optimun shown.
frequency.
The following is the flow diagram :
If U i +1 > U i , returns to point 1 and it fixes a new
value of "i".

- If the Net Revenues equals zero[ U = 0 ], then with the

value of " i " the economic limit of intervention is reached for
a well.

Initial(i=0)
i =i+1

Cost
Income
Utilities (U)

NO
i=1

yes
yes
NO NO
U>0 i < 365

yes

NO
Ui+1 < Ui

yes

Non-Economic
Optimun
Frecuency

End
SPE 69515 OPTIMIZING SWABBING OF MARGINAL WELLS THROUGH SIMULATION STUDIES 7

Conclusions: Nomenclature:

1. A model was developed to define economy of swabbing Wc: Linear weight of swabbing wireline
production in Lote X, Northwest Peru. F: Fluid gravity
2. Guidelines are provided to extend the application to other N: Casing fluid level
fields under comparative conditions. S: Plunger Submergence
3. Since the application of the model, studies have shown an Pot: Power of the swabbing unit
increase in the production volumes, optimization of the V: Speed of the Plunger
operations and increasing in the revenues in the order of 15% AA: Area of the annulus
in wells currently under swabbing. AT: Inner section of the Tubing
4. A proposal has been made to extend this technique to AC: Wireline section
other wells. E: Energy consumption
8 ANTHONY ALFARO PREZ SPE 69515

Fig. 1-Types of Swabbing

Tubing
Casing

Cable

Cable

Plunger with
cups
Plunger
with cups

Tubing Swabbing Casing Swabbing

Fig. 3 Fluids level build up

NI

dH
H2

H
NF
H1
TopeS

TopeI
SPE 69515 OPTIMIZING SWABBING OF MARGINAL WELLS THROUGH SIMULATION STUDIES 9

Fig. 4 - Maximun Submergence in Tubing Swabbing

N L

NF
S

Figure N 2
Optimizing of swabbing wells

30000

20000 Optimun

Net Revenues
Revenues
10000

0
us$/year

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
-10000

-20000 Expenses

-30000

-40000
Frecuency(days)
10 ANTHONY ALFARO PREZ SPE 69515

Figure N 5 - Main Menu Input

Figure N 6 - Main Menu Results

Table 1 - Tubing Swabbing workforce

#Eq Manag Superv Maint Welder Clerk Secret Winch Truck Aid Replac Cost
1 0 1 1 1 0 1 2 2 2 1 5800
2 1 1 1 1 0 1 4 4 4 2 11300
3 1 1 1 1 0 1 6 6 6 3 14800
4 1 2 1 1 0 1 8 8 8 4 19300
5 1 2 1 1 0 1 10 10 10 5 22800
6 1 2 2 2 1 1 12 12 12 6 27600
7 1 3 2 2 1 1 14 14 14 7 32100
8 1 3 2 2 1 1 16 16 16 7 35100
9 1 3 2 2 1 1 18 18 18 8 38600
10 1 4 2 2 1 1 20 20 20 9 43100
SPE 69515 OPTIMIZING SWABBING OF MARGINAL WELLS THROUGH SIMULATION STUDIES 11

Table 2 - Casing Swabbing workforce

#Eq Manag Superv Maint Welder Clerk Secret Winch Aid Replac Cost
1 0 1 1 1 0 1 2 2 1 4800
2 1 1 1 1 0 1 4 4 2 9300
3 1 1 1 1 0 1 6 6 2 11300
4 1 2 1 1 0 1 8 8 3 14800
5 1 2 1 1 0 1 10 10 3 16800
6 1 2 2 2 1 1 12 12 4 20600
7 1 3 2 2 1 1 14 14 4 23600
8 1 3 2 2 1 1 16 16 5 26100
9 1 3 2 2 1 1 18 18 5 28100
10 1 4 2 2 1 1 20 20 5 31100