Artificial Lift Methods

Khaled FEKI
OGIM
06-08 April 2016
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AGENDA
Introduction
Gaslift concept and design
ESP concept and design
Jet pump concept and design
Sucker Rod pump concept and design
PROSPER software
Workshop
Economical evaluation (Excel files)
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INTRODUCTION

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INTRODUCTION

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INTRODUCTION

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INTRODUCTION

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INTRODUCTION

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INTRODUCTION

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Gaslift

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GASLIFT

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GASLIFT

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GASLIFT

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GASLIFT

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GASLIFT

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GASLIFT

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GASLIFT

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GAS System

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GAS System

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GAS System

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Continuous or intermittent gaslift

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Determination of operating parameters

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Startingup gaslift wells

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Simple startup 1/5

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Simple startup 2/5

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Simple startup 3/5

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Simple startup 4/5

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Simple startup 5/5

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Initial startup 1/6

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Initial startup 2/6

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Initial startup 3/6

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Initial startup 4/6

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Initial startup 5/6

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Initial startup 6/6

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Initial startup

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Side pocket mandrel

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Opening pressure and closing pressure of a gas lift valve

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Type P Gas lift valve Test Rack Opening Pressure

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Type P Gas lift valve Test Rack Opening Pressure

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Type P Gas lift valve Test Rack Opening Pressure

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Gas Passage

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Gas Passage

SG=0,65
Upstream
Pressure=1000 Psi
Downstream Pressure =
800 Psi
Orifice diameter=

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Gas Passage

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Gas Passage

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Gas Passage

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Exercice

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ESP

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Electric submersible pumping: Overview

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Electric submersible pumping: Overview

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History of ESPs
REDA: Russian Electric Dynamo of Arutunoff
estalished in 1930 in Bartlesville, OK
Became Schlumerger-REDA Production Systems in
the late 1990s

Armais Arutunoff

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Principles of an ESP
In order to produce flowrates higher than the natural equilibrium
flowrate the use of an artificial lift system is necessary
If an ESP is installed in the tubing string close to the perforations, the
discharge pressure of the pump must be equal to the OPR pressure and
the intake pressure of the pump must be equal to the IPR pressure

The difference between the OPR and IPR bottom hole flowing

pressure for flowrates bigger than the natural equilibrium flowrate

defines the pressure increment that the ESP must deliver

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Principles of an ESP

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ESP Components

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ESP Components
An ESP system can be divided into two categories:

Surface components
Transformers (Primary and Secondary)
Switchboard or Variable Speed Drive or Soft Start
Junction Box
Wellhead

Subsurface components
Cable
Pump
Gas Separator (Optional)
Seal Section (Protector)
Motor
Sensor (Optional)

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Principles of an ESP
Power passes through a cable running from the transformer to the
switchboard and junction box, then to the wellhead.
The motor, seal, intake and pump assembly, along with the power cable,
goes in the well as the tubing is run. The well power cable is spliced to a
motor cable that is connected to the outside of the downhole assembly.
Below the pump is an intake that allows fluid to enter the pump.
Below the intake is a gas separator and a protector or seal, which equalizes
internal and external pressures and protects the motor from well fluids.
At the bottom is a motor that drives the pump. The assembly is positioned
in the well above the perforations; this allows fluid entering the intake to
flow past the motor and cool it.

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Surface Components - Transformer

Transformer system is used to
step-up or step-down the voltage
from the primary line to the motor of
the submersible pump. Because a
range of operating voltages may be
used for submersible pump motors,
the transformer must be compatible
with the selection of the motor
voltage.

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Surface Components - Switchboard

The

switchboard

controls

the

pump motor and provides overload

and underload protection.
Protection

against

overload

is

needed to keep the motor windings

from burning.
Protection

during

underload

is

needed because low fluid flow rates

will prevent adequate cooling of the
motor.

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Principles of an ESP
The junction box connects the power cable from the
switchboard to the power cable from the well. It provides an
explosion-free vent to the atmosphere for any gas that might
migrate up the power cable from the wellbore.

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SP Subsurface Equipments

pump
Intake
cable

PROTECTOR

Motor

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Subsurface Components Electric Cable

A power cable runs from the junction box then through the
wellhead and all the way to the bottom to supply power to the
pump motor.
Cable is available in round and flat styles

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Subsurface Components Electric Cable

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Subsurface Components Electric Cable

The proper selection of the cable and the conductors depends on:
The expected amperage that will flow through the cable to the
motor
The calculated voltage drop in the line from the surface to the
pump.
The space that exists between the tubing collar and the casing
(even though the cable is banded to the tubing at selected points,
there must be enough space to install and pull the pump without
damaging the cable or hanging it in the well).
The equipment operating environment - such as the operating
pressure and temperature at pump depth.
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Subsurface Components Gas Separator

Separates
the free gas in
order to reduce
the quantity of
gas that flows
into the pump.

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Principles of an ESP

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Protector

BASIC FUNCTION
- Prevent well fluid entering the motor
- Equalize pressure in the internal motor housing with pressure
in the annulus
- Provide chamber for motor oil to expand when temperature
rises during motor running
- Motor will fail when the well fluid enters it

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Protector

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Protector

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MOTOR

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MOTOR

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Principles of an ESP

It is filled with liquid and the impeller is rotated. Rotation imparts energy
to the liquid causing it to exit the impellers vanes at a greater velocity
than when it entered. This outward flow reduces the pressure at the
impeller eye, allowing more liquid to enter. The liquid that exits the
impeller is collected in the diffuser where its velocity is converted to
pressure before it leaves the pumps discharge.

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Principles of an ESP
A pumps impellers are designed to operate efficiently over a specific
capacity range. Operating the pump below its design capacity causes
the impeller to downthrust against the diffuser, resulting in wear on the
bearings and washers. Conversely, if the pump operates above its
design capacity, the impeller upthrusts against the upper part of the
diffuser, causing similar wear. Ideally, the impeller should float freely,
and will do so throughout its recommended operating range. This
recommended operating range will allow the pump to run at highest
efficiency

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ESP Pump

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ESP Pump

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Principles of an ESP

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Principles of an ESP

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ESP Selection (Example)

Pertinent data collected from well X
Production casing size : 9 5/8

Pump Setting Depth (PSD) : 7100 Ft

Production tubing size : 3 1/2

Expected rate

: 1225 bbl/day

SG Oil

: 0.873

Frequency

: 60 Hz

SG Water

: 1.00

Tubing Head Pressure (THP)

SG Gas

: 0.78

Last tests:

Water Cut

: 16 %

Pwf=2135 psi

SBHP

: 2500 psi

Pr=2500 psi

SBHT

: 230 F

Q=550 bbl/day

Deg. API of oil

: 32 @ 60 F

GOR

: 720 Scf/ bbl

Top perforation : 7234 Ft

Bottom perforation

: 8648 Ft

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: 800 psi

ESP Selection

Get the ratio of Pwf / Pr : (FBHP / SBHP)

2135 / 2500 = 0.854

Plot the value of Pwf / Pr in to IPR Vogel to get the value ratio of Q/ Q max.

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ESP Selection
IPR VOGEL
1.0

0.9

0.854

of Qo/ Qmax

0.8

Fraction of shut in pressure (Pwf/ Pr)

From the IPR the fraction

= 0.35

0.7
0.6

0.5

Define value of Qmax =

Q test / (Qmax) =

0.4

550 / 0.35 =

0.3

Q max = 1571 BPD

0.2
0.1

0
0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.35
PRODUCING RATE
FRACTION OF MAXIMUM Qo / (Qo) MAX

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0.8

0.9

1.0

ESP Selection
IPR VOGEL
1.0

0.9

Q / Qmax :

Fraction of shut in pressure (Pwf/ Pr)

0.8

0.46

Define the ratio of

1225 / 1571 = 0.78

0.7
0.6

0.5

Plot Q / Qmax in IPR

Vogel to get the fraction

0.4

of Pwf/ Pr ratio

0.3

From chart = 0.46

0.2
0.1

0
0

0.1

0.2

0.3

0.4

0.5

0.6

0.8

0.7

PRODUCING RATE

0.78

FRACTION OF MAXUMUM Qo / (Qo) MAX

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0.9

1.0

Determine Pwf=
Pwf / Pr x Pr =
0.458 x 2500 =
1146 psi

ESP Selection
DEFINE AVERAGE SPECIFIC GRAVITY OF OIL AND WATER

SG (Average) = (SgW x % water) + (SgO x % oil)

(1.00 x 0.16) + (.873 x 0.84) = 0.893

Define fluid gradient : Water gradient x SG (average)

0.433 x 0.893 = 0.387 psi / feet

DETERMINE PRODUCTION CAPACITY OF WELL
Define well datum : {(Bot. Perf - Top Perf) / 2} + Top perf.

{(8648- 7234) / 2} + 7234 = 7941 Ft

Determine Fluid below pump (FBP) : Datum - PSD (Ft)

7941 - 7100 = 841 Ft

Convert FBP in to pressure : Distance (Ft) x Fluid gradient

841 x 0.387 = 326 psi

Calculate pressure at pump intake : Pwf-FBP

1146- 326 = 820 psi ----------- PIP

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ESP Selection

Q new is Barrel liquid that is

measured at surface after the gas
has separated
(STB / D)

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Principles of an ESP
DEFINE FORMATION VOLUME FACTOR (FVF)
FVF is a factor that is used to determine the total volume of fluid pumped in the
well which includes gas in the well fluid
Data required :
- Temp

- G0R

720 Scf/ Bbl

230 F

- Degree API 32
- SG gas 0.78
Plot all the following data in sequence as indicated on the FVF chart

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ESP Selection
0.78

720
32

230F

1.4

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ESP Selection

DEFINE FORMATION VOLUME FACTOR (FVF)

FVF plotted on the chart = 1.4
Define Q pump = (Qnew x % of oil x FVF) + (Qnew x % of water)

Q pump = (1225 x 0.84 x 1.4) + (1225 x 0.16) = 1637 BPD

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ESP Selection
DETERMINE TOTAL DYNAMIC HEAD (TDH)
PIP (pump Intake Pressure) measured in psi

PIP = 820 psi

Convert PIP in to Feet (FAP = Fluid Above Pump). (PIP / Fluid Gradient)

FAP = 820 psi / 0.387 psi/ft =

2119 Ft

Define Net Lift (NL) . (PSD FAP)

Net Lift = 7100 2119 Ft = 4981 Ft

Define friction loss / 1000 Ft,

Prod rate : 1637 BPD, Tubing : 3 EUE

Plot on the Tubing Friction loss Chart

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ESP Selection

1637

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ESP Selection
DETERMINE TOTAL DYNAMIC HEAD (TDH)
Friction loss / 1000 Ft =
10 Ft ----------> from Chart
Total Friction loss = (PSD/1000) X (FL per1000Ft}
(7100/ 1000) x (10) = 71 Ft
Convert Tubing Head Pressure (THP) in to Ft.
800 (psi) / 0.387 (psi/Ft) = 2067 Ft.
TDH = NL + FL + THP
TDH = 4981 + 71 + 2067 = 7119FT
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ESP Selection
PUMP SELECTION
Select pump OD / Series
Casing OD : 9 5/8, ID : 8.775 can accommodate up to 675 Series
Q = 1637 BPD, (look at pump catalogue), consider electrical frequency (60 Hz),

select pump size that is suitable to the production rate

Select pump :
- DN1750 REDA, 400 series, production range 1200 BPD 2050BPD @ 60 Hz,

- Pump
Efficiency
@ 1637BPD
68to%,liftLift
stage
=19(Lift
Ft @
efficiency
Determine
Total Stage
Required (TSR)
fluidper
= TDH
/ LPS
Permaximum
Stage)

Lift per stage (LPS) = 19 Ft.

Total Stage Required (TSR) = (TDH / LPS) = 7119 / 19 = 375 Stages

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ESP Selection
PUMP SELECTION
Select pump OD / Series
Casing OD : 9 5/8, ID : 8.775 can accommodate up to 675 Series
Q = 1637 BPD, (look at pump catalogue), consider electrical frequency (60 Hz),

select pump size that is suitable to the production rate

-GN1600 REDA, 540 series, production range 1000 BPD 2150BPD @ 60 Hz,
- Pump Efficiency @ 1637 BPD 60 %, Lift per stage = 43 ft @ maximum efficiency
Determine Total Stage Required (TSR) to lift fluid = TDH / LPS (Lift Per Stage)

Lift per stage (LPS) = 43 Feet

Total Stage Required (TSR) = (TDH / LPS) = 7119 / 43 = 165 Stages

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ESP Selection
MOTOR SELECTION DN1750

Find HP/ stage required from the pump curve

HP/ stage = 0.36HP , fluid SG = 1.00

Total HP required (THP) : SG x HP per stg x TSR

THP = 0.893 x 0.36 x 375 = 120. 5 HP ~ Select 120 HP- 890 V 85 AMP)
Motor cooling, see chart FLUID PASSING A MOTOR)
Fluid velocity (from chart) = 0.4 Ft/ second (not fast enough)
3

2.8

Suggested to install Casing

Shroud 7 to get greater fluid
velocity

2.6
2.4
2.2
2
540 7 CASING

1.8

1.5

1.6

With 7 casing shroud we get

1.4
1.2

1,5 feet/second.

1
0.8
0.6

0.4

0.4

540 - 9 5/8" CASING

0.2
0
0

0.4

0.8

1.2

1.6

1637

2.4

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2.8

ESP Selection
MOTOR SELECTION GN1600

Find HP/ stage required from the pump curve

HP/ stage = 0.90HP , fluid SG = 1.00

Total HP required (THP) : SG x HP per stage x TSR

THP = 0.893 x 0.90 x 165 = 132 HP

DN1750

68% / 19 feet lift per stage therefore 375 stages; 120 HP required

GN1600

60% / 43 feet lift per stage therefore 165 stages; 132 HP required

For this example we will use the pump with the greatest efficiency
And the least HorsePower needed i.e DN1750

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Trouble shootting

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Trouble shootting

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JET PUMP

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Jet Pump

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Jet Pump

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Jet Pump

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Jet Pump

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Jet Pump

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Jet Pump

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Jet Pump

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Jet Pump

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Jet Pump

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Sucker Rod
Pumps

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Sucker Rod Pump / Beam

pumping / Rod lift

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Sucker Rod Pump

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Sucker Rod Pump

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Sucker Rod Pump

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Sucker Rod Pump

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Pump Components

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Sucker Rod Pump

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Pump Selection

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Plunger size

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Sucker Rod Pump

The bottom hole pump:
The BH pump is to increase the pressure of the wellbore
fluid to enable it to flow to surface.
The Main working components of the bottom hole pump are the :

Barrel (pump chamber).

Plunger.
Travelling Valve.
Standing Valve.

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Sucker Rod Pump

At the start of the upstroke, fluid trapped
above the travelling valve is lifted up into
the tubing by the plunger.
Because the plunger is moving up the
barrel, a void is created below the
plunger.
Wellbore fluid moves into the void in the
pump chamber through the standing
valve . At this point, the pump intake
pressure is equal to the bottom hole
reservoir pressure

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Sucker Rod Pump

At the end of the upstroke, the plunger

chamber is filled with fluid and the
standing valve closes, trapping the
fluid

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Sucker Rod Pump

As the pump jacks down
stroke begins, the plunger
moves down and compresses
the fluid trapped below the
plunger.
When the pressure below the
plunger is greater than the
pressure above the plunger,
the travelling valve is forced off
its seat, allowing fluid to pass
by and enter the space above
the plunger.

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Sucker Rod Pump

As the down stroke continues, fluid

passes through the plunger. At the
end of the down stroke, the
travelling valve closes. The cycle is
repeated with each pump jack
stroke cycle.

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Sucker Rod Pump

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Pump Displacement
Calculation

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Sucker Rod Pump

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Sucker Rod Pump

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PROSPER

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