Guidelines & Recommended Practices

Selection of Artificial Lift Systems

for Deliquifying Gas Wells
Prepared by Artificial Lift R&D Council

Status
A second draft has been prepared and is shown below. It is ready for
editing.
Chair: Fenfen Huang, fhuang@nalco.com
Team: Jose Macias, Ewout Biezen, Keith Mamot, Dan Sewatt, Sam
Toscano, Rick Hornsby, Clint Mason, Greg Shindler
Comments: This draft is ready for editing by Dr. Tony Podio.

5.2 Batch Chemical Treatments

This section discusses the practical limits of batch chemical treatments in

terms of liquid production rate, gas production rate, depth, pressure,
temperature, etc. It presents rough guidelines on the relative costs of batch
chemical treatments. Obviously precise costs can not be given as they
depend on many factors. It presents rough guidelines on the relative life
expectancy of batch chemical treatments. Clearly, precise expectations can
not be given as they depend on many factors.

Chemical foaming agents, also known as foamers, are one of the many
artificial lift methods available to deliquify the gas wells. With the addition of
foamer to a wellbore where loading liquids are present, foam is generated
with the agitation from the gas flow. The surface tension and fluid density of
the foam are lower than the liquids so the lighter foam, whose bubble film
holds the liquids, is lifted more easily by a low gas flow rate, often
encountered in the tail end production of mature gas wells. By removing the
liquid column and associated hydrostatic pressure against the reservoir
pressure, the inflow from the reservoir can be improved and ultimately, the
production can be enhanced.

Foamers can be applied either by batch treatment or via continuous

injection. A batch treatment involves the application of a single volume of
foamer to the well at one time, as opposed to a smaller volume applied
continuously as in the case of continuous application. The next batch is
applied after a period of time when the foamer dosage is reduced and
performance starts to decline.

Foamer is a Very Cost-Effective Artificial Lift Method:

Many forms of mechanical artificial lift are utilized to deliquify gas wells,
but there are scenarios where the application of chemical foamers is more
favorable. This is especially the case for mature assets reaching their
Foamer Batch Treatment for Deliquifying Gas Wells Page 2

predicted lifetime, where any sort of Capital Expense (CAPEX) is

unfavorable.

Cost-effectiveness of foamer is proven as the followings:

Low initial investment (CAPEX), requires one chemical pump, filter, valve
and one chemical storage tank, and a secondary containment for the
chemical tank
Low operating and maintenance cost (OPEX and R&M)
Versatility of treatment methods (batch vs. continuous), can be used alone
or in conjunction with other artificial lift methods such as a well-head
compressor, plunger, gas-lift etc.
Multi-functional foamer products are available to revolve corrosion, scale,
paraffin, salt deposition etc. while the liquid is being removed from the
wellbore. Multi-functional chemicals not only offer benefits in reducing
CAPEX (single injection point, pump, tank etc.), it also helps drive the
OPEX including logistics cost and man power etc.
Fast response from the well (usually from 24 hrs to two days depending
on the well depth) to confirm the foamer performance.

Applications for foamer:

For deliquifying gas wells as the primary artificial lift means or the
secondary artificial means that can be combined with gas lift, plungers,
compressions etc.
Can be used to remove liquid holdup in gas transport pipelines
Potential usage in conjunction with a gas-lift system to enhance oil
production
Potential application in pipeline liquid removal
Foamer Batch Treatment for Deliquifying Gas Wells Page 3

Table of Contents

Practical Considerations...........................................................................4
Well Depth Limits
Tubing Size Limits
Pressures Limits
Temperature Limits
Flow Rate (gas and fluids)
Limits with sand, corrosion, erosion, H2S, CO2, etc.
Power Requirements
Operating requirements
Maintenance requirements

Cost Guidelines..........................................................................................6
CAPEX
OPEX
R&M

Practical Limits for Batch Chemical Treatments.. 7

Life Expectancy Guidelines for Batch Chemical Treatments 7

Best Operation Practices for Foamer Batch Treatment ..7

Best Field Application Practices for Foamer Batch Treatment .8

Foamer Batch Treatment for Deliquifying Gas Wells Page 4

Practical Considerations

- Well Depth limits

There are no practical depth limits for batch chemical treatments.
The primary issues associated with depth include fall, soaking, and
flow back times. Success is more dependent upon other factors
such as loading types (partial loading vs. transient loading vs. full
loading vs. depletion), fluids characteristics (pH, salinity, produced
water vs. hydrocarbon ratio, hydrocarbon characteristics), fluid
levels, inflow capability, foamer chemistries, foamer dosages,
differential pressure (downhole/surface), fluid rate and gas rate.

- Tubing Size Limits

There are no practical tubing size limits for batch chemical
treatments. The primary issues include severity of the liquid loading
and fluid level. Success is more dependent upon other factors
mentioned above.

- Pressure limits

Though there is no recognized pressure limits in batch foamer

treatment, it is highly recommended that bottomhole pressure (both
flowing and shut-in) and reservoir pressure be evaluated to access
the likelihood of reservoir depletion and sufficient pressure buildup
after shut-in. To ensure the success of the batch treatment or
foamer application in general, maximized agitation (i.e. rock the
well by extended period of shut in, allowing pressure build up
followed by production to minimum pressure vessel or even
atmosphere) to maximize start up gas flow thus to generate mixing
and foam is critical. Increased line pressures will adversely affect
the ability of the well to adequately lift foamed fluids to the surface
and produce in the system.

- Temperature limits

Thermal stability of chemical foamers under wellbore conditions

(pH, temperature, compatibility with well fluids, and estimated
retention time) needs to be taken into consideration in chemical
batch treatment. Different foamer chemistries have different thermal
stability thresholds and solubility and compatibility with various fluid
characteristics. Chemical foamers with thermal threshold above
downhole temperature need to be used to avoid undesired
degradation, loss of performance or adverse effect such as
increased corrosivity in the wellbore.
Foamer Batch Treatment for Deliquifying Gas Wells Page 5

- Flow rate limits (gas and fluids)

It is traditionally considered that low-rate gas wells with producing

gas liquid ratios (GLRs) between 1,000 and 8,000 scf/bbl are
among the better candidates for foamer treatment, though there are
no limits of GLRs for batch treatment. Batch treatment of foamer
has been carried out on fully loaded wells with encouraging
production increases. Techniques such as rocking, bull heading
are often used to overcome the low gas rate at the beginning of the
field application with the goal to unload the most fluids from
wellbore and tubing.

When the inflow from the well is limited (i.e. in a severally loaded
well with a high level of liquid column), N 2 injection into the fluid
column via coil tubing can be conducted to help generate foam to
remove high level of fluid before the inflow from the reservoir can
resume. Or gas sticks which can slowly release gas while
dissolving in liquids can be utilized to help kick start the foam
generation and liquid removal process.

To maximize the production enhancement, after a successful prove

of concept trial with foamer batch treatment to confirm the
effectiveness of chemistry in foaming the fluids and removing liquid
retention, continuous foamer injection is recommended to ensure
smooth production.

- Limits with sand, corrosion, erosion, H2S, CO2, etc.

Chemical foamer, given its ease of customization, can have built-in

corrosion inhibitor, H2S scavenger, and/or CO2 scavenger to be
multifunctional. It also has tolerance for particulates and sand in the
produced fluids. The foaming agent itself is surface active and
provides a limited corrosion protection to the production asset. If
higher corrosion protection is desired, combinational foamer with
the right type of corrosion inhibitor can be used. Foamer has good
tolerance to H2S and CO2 as well and has been effective in
deliquifying both sour wells and sweet wells.

- Power requirements

It depends on what kind of chemical pump is in use. Often times, a

solar-driven chemical pump eliminates requirements for external
power.

- Operating requirements
Foamer Batch Treatment for Deliquifying Gas Wells Page 6

After the execution of a foamer batch treatment, on-going

monitoring and optimization is crucial to maximize the value of the
program. Close monitoring of the build-up pressure trend prior to
reopening the well, the characteristics of the flow back fluids,
surface separation, and production uplift are highly recommended.
Venting can be used to prompt the most agitation during the start-
up process. If the foamers effectiveness starts declining due to
depletion of chemical, a new treatment needs to be conducted.

- Maintenance requirements

Foamer batch treatment requires low maintenance since there is

minimal new CAPEX investment. Chemical inventory management
and dosage optimization to maintain the maximum production rate
are major maintenance requirements.

Cost Guidelines

The chemical cost of a foamer batch treatment is usually low, starting

from a few hundred dollars in total cost (for personnel training, chemical
supply, and treatment executions). Of course, this depends on the kind
of foamer that is needed, and the volume of foamer is needed to remove
the retained liquid.
- CAPEX

CAPEX of foamer batch treatment is minimum, which usually only

involves a chemical injection pump, a storage tank, and a
secondary containment for the tank. In application with short
retention time of the surface separation (i.e. offshore application),
contingency defoamer program is usually required to quickly break
down potential residual foam on the surface. In rare cases,
emulsion breaking and water clarification program may also need to
be adjusted to count for potential emulsion tendency when liquid
hydrocarbon is present in the produced fluids.

- OPEX

OPEX of the foamer batch treatment is also minimum. Training for

field operational personal is recommended and ongoing monitoring
and optimization of the program based on well response is highly
desired.

- R&M (Repair and Maintenance)

Foamer Batch Treatment for Deliquifying Gas Wells Page 7

R&M cost of the foamer batch treatment is also minimum. Cost of

repairing of chemical injection pump, lines and maintaining
chemical inventory is low.

Practical Limits for Batch Chemical Treatments

Foamer batch treatment requires the well to be shut-in to inject the

foamer (for wells with a packer), thus there is loss of production
during the injection, soaking periods. For wells without packer,
foamer batch can be applied down the backside or via tubing and
shut-in and soaking is still recommended to allow pressure build up
to kick off the foam lift process.
It requires knowledge of the liquid level in the wellbore to estimate
the foamer volume for treatment. It is recommended that liquid
level within 3 days (preferably within 24 hrs) prior to the treatment is
obtained with Echometer or similar technology for chemical batch
volume estimation.
Water flush (or KCl substitute if clay swelling is an issue) is usually
conducted to drive the chemical to mix with liquid in the wellbore to
promote sufficient mixing.

Life Expectancy Guidelines for Batch Chemical Treatments

How long the foamer treatment effectiveness will last depends on the
size of the treatment and amount of liquid that needs to be removed.
Usually, the well can produce for one to two months before another
batch treatment is needed. Lack of response post batch chemical can be
caused by lower dosage of chemical than minimum effective dosage of
chemical (i.e. encounter a larger volume of retained liquid than expected
during field trial). In that case, another batch treatment with size half of
previously injected volume can be administrated, followed by shutting in
to allow soak and pressure buildup before reopen for production. These
steps can be repeated a couple of times when deem necessary to aid
the initial foam unloading given other potential root causes of lack of
response such as reservoir depletion, formation damage, formation
blockage etc. have been ruled out.

Best Operation Practices for Foamer Batch Treatment

o Train operators in liquid loading principles and chemical foamer batch

treatment operation.
Basic understanding of gas well liquid
loading
Firm understanding of foamer and foamer
batch treatment
Train and abide by safe operating principles
Foamer Batch Treatment for Deliquifying Gas Wells Page 8

Establish key performance indicators

(KPIs).

o Develop and implement a consistent optimization strategy.

o Communicate strategy with clearly defined division of responsibility.

o Foamer product recommendation and dosage based on laboratory or

field bench top performance testing using fresh produced fluids need
to be obtained and used as the base to design foamer batch
treatment.

o Close monitoring the pressure build up and flow back fluids. If not
successful, longer soaking time or higher dosage can be trialed. If
overtreatment occurs, less foamer dosage needs to be applied in the
next treatment.

o Always have a defoamer program in place as a start-up contingency

in the pilot trial when short retention time in surface separation is
expected.

o For offshore operation, topside squirt test to check foamers impact

on the oil/water separation or MonoEthylene Glycol (MEG)
regeneration unit is highly recommend before full scale trial. Foamer
and/or anti-foam can be applied across the test separator in live well
fluids and oil/water separation will be examined. Efficiency of MEG
unit needs to be monitored.

Best Field Application Practices for Foamer Batch Treatment

1. Conduct a static fluid level shot 3 days or less (preferably 24 hrs)

prior to batch treatment.
2. Verify valves were serviced less than 3 months prior.
3. Install injections systems (injection manifold with check valve, block
valve, and pressure relief valve (PRV), etc.).
4. Slowly pressure up treatment equipment against closed block valve
until safety shutdown switch kills engine at pre-set pressure settings.
5. Start pumping at low rate (i.e. 0.25 bpm) and gradually increase
pump rate to its maximum capacity to slowly overcome the shut in
wellhead pressure until the foamer dosage based on the laboratory
testing and modeling is achieved.
6. Open upper and lower master valve, leave well shut in at the wing
valve so tubing and casing pressures can be monitored.
Foamer Batch Treatment for Deliquifying Gas Wells Page 9

7. Leave well shut in for overnight or (24 hours if needed) following

batch treatment.
8. After sufficient pressure built up, bring well online with wide open
choke setting to try to unload fluid column in tubing.
9. Once well is unloaded, monitor the flow back fluids and surface
separation to determine the necessity of executing the defoamer
injection (which is usually set up as a start-up contingency).
10. Monitor and report KPIs such as gas rate, fluid rate, pressures etc.
11. After depletion of foamer as indicated by decreasing production
rates, conduct a new batch treatment.

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Selection document where it is presented.

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