PROJECT UR BUSINESS

BINNING OIL TOOLS S.A

GAS LIFT SCHOOL 2012

PETRO-ENERGY E&P , SUDAN

www.refineded.com

E:info@refineded.com

Gas Lift

Gas Lift and Completions

Seminar
Gas Lift
What is gas Lift
Types and applications
Tools
Design options
Troubleshooting and optimization
Completion
Packer Types
Forces to be considered

Day 1

Presentation
Introduction to gas lift
Gas Lift compared to other systems
Gas Lift types and applications
Standards
Components

Day 2

Gradients
Reservoir Types
Gas properties
IP and IPR
Valve types and mechanics
Basic Design

Day 3
Gas Lift Design
Continuous
Intermittent
PPO

Troubleshooting and Optimization

Day 4
Completion
Packer Types
Design Considerations

Roundup and sample cases

Eduardo Tidball

Sales manager BINNING OIL TOOLS S.A.

18 years in the industry
CAMLOW SAIC
CAMCO DE ARGENTINA
SCHLUMBERGER

Wells in the World

Canada
48,200

US
500,0
00

Peru
4,500

North Sea
600
German
y 1,000
Egypt
Oman
1,100
2,300

Venezuel
a 14,200

Nigeria
300

FSU
115,000
China
77,000
India Indonesia
9,500
3,000

Brazil
6,300
Argentin
a13,500

World: 1,000,000 wells

Australi
a 1,100

Artificial Lift Systems

ESP

PCP (Progressive Cavity Pump)

Beam Pump

Hydraulic Lift

Gas Lift
What is Gas Lift?

2006 Artificial Lift Systems Distribution

72000
11%
42000
7%

443000
69%

15000
2%

Beam Pump
PCPs
Hydraulic Pumping

Gas-Lift
ESP
Others

61000
10%
8000
1%

Capacities by AL Method
Typical Artificial Lift Application Range
Ft./Lift
12,000
11,000
10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
1,000

Rod Pumps

2,000

3,000

4,000

PC Pumps

5,000

6,000

7,000

Hydraulic Lift

8,000

9,000 10,000 20,000 30,000 40,000 50,000 BPD

Submersible Pump

Gas Lift

A Little History.
History.

First completions were used for coal mine dewatering in the 18th century
First gas lift production wells: 1846 in the US
In the 1930 there were several gas lift valve
designs
First patented gas lift valve: King Valve in 1944
First patented wire line retrievable valve: 1954.

Gas Lift Advantages

Low down hole equipment costs

Low operating costs
Simple completion designs
Flexible: from 3 to more than 50000 bbls/d
Directional wells, sand, scale, etc
Minimum intervention costs

Gas Lift Disadvantages

High pressure gas source needed

Imported from other fields
Produced
Startup costs might be high
Modify existing platforms
Compressor stations design
Limited by reservoir pressure (cannot
produce to depletion)

Comparison of AL Methods
Condition
Wells

Specific
Single
1 to 20
More than 20

Production

<1000BPD
1000 a
10000bpd
>10000bpd

Well Depth

<2500ft
2500 a 7500ft
>7500ft

Casing Size

4
5
7
>9 5/8

Well Inclination

Vertical
Deviated
Horizontal

BP

PCP

Jet Pump

Hydraulic Lift

Gas-Lift

ESP

Comparison of AL Methods
Condition

Specific

Dogleg Sever.

>3/100ft
3 to 10/100ft
<10/100ft

Temperature

>250F
250 350F
<350F

Safety Barriers

0
1
2

Flowing Pressure

<1000psi
100 a 1000psi
>100psi

Reservoir Access

Requerido
No Requerido

Completion

Single
Dual

BP

PCP

Jet Pump

Hydraulic Lift

Gas-Lift

ESP

Comparsion of AL Methods
Condition
Stability

Specific

BP

Stable
Variable

Production

Primary
Secondary
Tertiary

Properties of produced fluids

Water Cut

Low
Medium
High

Viscosity

>100Cp
100-500Cp
<500Cp

Corrosive Fluids

yes
no

Sands and Solids

<10ppm
10-100ppm
>100ppm

PCP

Jet Pump

Hydraulic Lift

Gas-Lift

ESP

Comparison of AL Methods
Condition
GOR

Specific
<500scf/Stb
500 to 2000scf/Stb
>2000scf/Stb

Treatments

Scale
Corrosion
Solvents
Acids

Location

On-Shore
Off Shore
Remota

Intervention

Workover
Pulling
Coiled Tubing
Snubbing
Wireline

BP

PCP

Jet Pump

Hydraulic Lift

Gas-Lift

ESP

GAS LIFT CLOSED SYSTEM

GAS LIFT
Application Ranges

CONTINUOUS

INTERMITTENT

PRODUCTION

>100 BLPD
> 15 m 3/D

< 300 BLPD

< 50 m3 /D

PRODUCTIVITY
INDEX

> 0,5 BLD/PSI

> 0,1 m 3/D / KG Cm2

N/A

GLR.

< 1500 scf/bbl

< 265 m3/ m3

N/A

Continuous Flow Control

CONTINUOUS FLOW WITH ADJUSTABLE CHOKE

CASING PRESSURE
DURING STARTUP

INTERMITTENT WITH TIME/CYCLE CONTROLLER

CASING PRESSURE

Intermittent Lift Control

STANDING VALVE

INTERMITTENT WITH PILOT VALVE

CASING PRESSURE

Chamber Completions

ISO 9001:2000

IT IS A SYSTEM BASED ON QUALITY

MANAGMENT ISO 9001:2000.

THE ADVANTANGE OF A QUALITY MANAGMENT

SYSTEM IS THAT IT ALLOWS TO KEEP A
REGISTRY OF THE HISTORY OF THE PRODUCT
THROUGH TRACEABILITY AND
DOCUMENTATION EACH STEP OF THE
PROCESS CAN BE IDENTIFIED.

THE STANDARD CAN BE APPLIED TO ANY

PRODUCTION PROCESS

New API Standard

API19G replaces API11V1

API19G Standards


STAMPING IS DONE FOLLOWING STANDARD
REQUIREMENTS DEPENDING OF GRADE


ONLY TO BE APPLIED ON PRODUCTS UNDER
STANDARD SCOPE

 API19G Valve Groups

Group I: IPO balanced IPO y IPO with choke

Group II: PPO PPO with choke
Group III: Pilot differential
Group IV: Orifice Nozzle venturi shear orifice Dump/Kill
Group V: Dummy
Group VI: chemical injection - chemical injection-spring loaded
Group VII: Surface controlled-hydraulic Surface controlledelectric Smart
Group VIII: Liquid injection
Group IX: Other

OTHER API STANDARDS

API RP 11V2: Gas Lift valve testing & modelling

API RP 11V5: Gas Lift Operations
API RP 11V6: Continuous Flow Gas Lift Design
API RP 11V7: Gas Lift Valve Reconditioning
API RP 11V8: Gas Lift Systems
API RP 11V9: Dual gas lift
API RP 11V10: Intermittent gas lift

ISO STANDARDS

ISO 17078 - 1: Side Pocket Mandrels

ISO 17078 2: Gas Lift Flow Control
Devices (valves)
ISO 17078 3: Gas-Lift Running,
Pulling, and Kick-Over Tools, and
Latches
ISO 17078 4: Gas-Lift Guidelines and
Practices

WEB INFORMATION
Artificial Lift R&D Council Web Page

http://www.alrdc.com
Web based discussion boards
for gas-lift

Mandrels

Gas Lift Valve Types

IPO
5/8 1, 1 1
Bellows Operated
Spring Operated
Top Latch
Bottom Latch
PPO
1, 1
Spring Operated
Bellows Operated

Retrievable, Non Retrievable

Valves

IPO Bottom
Latch

Pilot Top
Latch

IPO Top
Latch

IPO
Conventional

Other Valves
Chemical injection valves
Orifice Valves
Square Edged
Venturi

Dummy Valves
Dump/Kill Valves
Circulation Valves
Waterflood Regulators

Chemical Injection

Dummy Valve

Orifice Valve

Waterflood Regulators

Latches

RA

KE or BE

BoK

Flow Configuration
Injection pressure Operated Tubing Flow - CPO Valve

GAS
Fluid & Gas
Main Acting Force

CPO Valve

Flow Configuration
Injection pressure Operated Casing Flow - CPO Valve

GAS
Fluid & Gas
Main Acting Force

CPO Valve with

Special
Mandrel

Flow Configuration
Production pressure Operated Tubing Flow - PPO Valve

GAS
Fluid & Gas
Main Acting Force

PPO Valve

Flow Configuration
Production pressure Operated Casing Flow - PPO Valve

GAS
Fluid & Gas
Main Acting Force

PPO Valve with

Special
Mandrel

Flow Configuration
Injection pressure Operated Tubing Flow - CPO Valve
Valve-- LT Mandrel

GAS
Fluid & Gas
Main Acting Force

Side Pocket Mandrel

with Side Pipe and
CPO Valve

Day 2

METRIC SYSTEM
METRIC SYSTEM
EQUIVALENCIES
1 METER = 3,281 FEET
1 CUBIC METER = 6,29 BARREL US
= 35.3 CUBIC FEET
1 BARREL US = 42 GALLONS US
= 5,61 CUBIC FEET
1 IMPERIAL GALLON = 1,2 GALLONS US
1 KG/CM2 = 14,22 PSI ( PSIG and PSIA)
1 ATMOSPHERE = 14,696 PSI
1 KILO = 2,205 POUNDS

METRIC SYSTEM
GAS/LIQUID RATIO
1 m3 /m3 . = 5.61 Ft3/ Bbl
GRADIENTS
1 PSI PER FOOT = 0,23 KG/CM2 PER FOOT
1 KG/CM2 PER METER = 4.36 PSI PER FOOT
PRODUCTIVITY INDEX
1 BLPD / PSI = 2.261 M3D / KG/CM2
1 M3D / KG/CM2 = 0,442 BLPD / PSI

Gradients
Without gas-lift

Gas Injection

GAS LIFT
DISADVANTAGES
NOT ADEQUATE TO BE USED IN HIGH GLR WELLS
PRESSURE (psig)

DEPTH (Feet)

Packer Depth

GAS LIFT
DISADVANTAGES

NOT ADEQUATE TO BE USED IN HIGH GLR WELLS

DEPTH (Feet)

PRESSURE (psig)

Packer Depth

GAS LIFT
DISADVANTAGES
NOT ADEQUATE TO BE USED IN HIGH GLR WELLS

PRESSURE(psig)

DEPTH (Feet)

Packer Depth

GAS LIFT
DISADVANTAGES
NOT ADEQUATE TO BE USED IN HIGH GLR WELLS

PRESSURE (psig)

Depth (Feet)

Packer Depth

GAS LIFT
DESVENTAJAS
NOT ADEQUATE TO BE USED IN HIGH GLR WELLS

Whp

PRESSURE (psig)

DEPTH (Feet)

Packer Depth

GRADIENTS AND CORRELATIONS

DEPTH ((Feet)

Wellhead Pressure

PRESURE (psig)

GRADIENTS

DEPTH ((Feet)

20

40

PRESSURE (psig)

Vertical Multiphase Gradients

Empirical Models
Gilbert (CA oil wells)-developed 1940 to1950 but published in 1954
Poettmann & Carpenter (no slip) -1952
Baxendell & Thomas (high rate extension of P&C)-1961
Duns & Ros (lab data)-1961
Ros & Gray (improved D&R)-1964
Hagedorn & Brown (most used--slip?)-1964
Orkiszewski (Exxon composite)-1967
Beggs & Brill (incline flow)--1973
MMSM ( Moreland-Mobil-Shell-Method)-1976

Mechanistic Models

Aziz, Grover & Fogarasi-1972

OLGA Norwegian- 1986
Ansari. Et al. 1990
Choksi, Schmidt & Doty-1996
Brill, et al-ongoing*

Shell : Zabaras-1990

CORRELATIONS

GILBERT
CURVES
(1954)

CORRELACIONES BROWN
GRADIENTES DE PRESION VERTICAL

o PRODUCTION:

600 BLSD

o TUBING:

2.875 O.D.

o WATER CUT:

50%

o OIL GRAVITY:

0.85

o GAS GRAVITY: 0.65

o WATER GRAVITY:

1.074

o TEMPERATURE:

140F

POETTMAN - CARPENTER
VERTICAL GRADIENTS

o TUBING SIZE:
o OIL GRAVITY:
o GAS GRAVITY:
o WATER GRAVITY:
o TEMPERATURE:
o RATE: 500BPD

2 I.D.
35API
0.65
1.074
190F

POETTMAN - CARPENTER
VERTICAL GRADIENTS

Exercise

Reservoir Types

Dissolved / solution gas drive

Gas cap drive
Water drive

Dissolved Solution Gas Drive

Constant volume

No water encroachment
Two phase flowing reservoir below bubble point
No gas cap
PI not linear
PI declines with depletion
Formation GOR increases with depletion
Least efficient with circa 15% recovery

Gas Cap Drive

Gas from solution will form gas cap

With production gas cap increases
providing drive
Excessive drawdown can cause coning
PI usually not linear
GOR constant except near depletion
Circa 25% recovery

Water Drive Reservoir

Not constant volume

Reservoir pressure more constant - expansion
of water 1 in 2500 per 100 psi
PI more constant
GOR more constant|
Combination of water drive & gas cap
expansion
Often supplemented by water injection
Most efficient with upto 50% recovery

Depletion Type Drive

Small isolated pockets

No pressure support
High rates initially
Very quick depletion
May use several artificial lift methods
Natural flow initially
Continuous gas lift
Intermittent gas lift

Productivity Index
Q= Rate (BPD)

PI

PI=BPD/Psig

DD

DD=Difference between statid

bottomhole pressure and flowing bottom
hole pressure dinmica de fondo
Example:
PI: 1.5 bpd/psig
Pbhs: 900psig
Pbhf: 600psi
PI=Q/(Pbhs-Pbhf)
Q=PI*(Pbhs-Pbhf)
Q=1.5bpd/psi*(900psi-600psi)
Q=1.5*300
Q=450bpd

IPR Curves

Productivity Index (IPR

Example:

Find maximum potential (Qmax) when Pbhf=500psig

Well Data:
Pbhf: 600psig.
Q1= 400Bpd
Pbhs=900psig
Part 1:
Solution:
Parte1: Determine when Pbhf=0
Step 1: Pbhf=600psig and Q1=400Bpd
Step 2: Pbhf/Pbhs= 600/900=0.67

Paso 3

Step 3

Step 4

Paso 4

Step 4

0.49

Solucin

Step 6: Qmax = Q1/(qo/qmax) = 400/0.49

Qmax = 816 Bpd

Parte 2

Part 2:
Determine potential production when
Pbhf=500psig.
Step 7: Pbhf/Pbhs =500psig/900psig = 0.55

Ultimos pasos

Step 8

Step 9
0.65

Resultado final

From the graph we can determine that

the Qo/Qmax is 0.65

Step 10: Q=816(from step 6) * 0.65

Q = 530Bpd

Exercise
With same data as before,
determine potential production
with a Fbhp: 150psig

CPO FORCE BALANCE

PPO FORCE BALANCE

PILOT VALVE

STANDARD WIRE LINE TOOLS

KICKOVERS TO BE USED IN WELLS WITH DEVIATIONS LOWER THAN 30
30

L (Camco
(Camco)). TWO ARMS. TO BE USED IN 2 3/8 OR 2 7/8 TUBING
*L2D (Camco
(Camco)). TWO ARMS AND A SPRING. MAINLY USED IN 3 TUBING.
*R (Camco
(Camco)). THREE ARMS. MODELS FOR 2 3/8,
2 7/8 AND 3 TUBING
K (Camco
(Camco)). WITH BOW SRPINGS. FOR SLIM HOLE 1 AND 2 3/8 TUBING.

WIRE LINE TOOLS USED

WIRE LINE TOOLS USED

KICKOVERS FOR DEVIATED WELLS

OK
OK--1 TO 7. USED IN MANDRELS EQUIPPED WITH AN ORIENTING
SLEEVE. (1 VALVES)
OM
OM--1 TO 5.
5. USED IN MANDRELS EQUIPPED WITH AN ORIENTING
SLEEVE. 1 VALVES

Wireline Tools to be used

KICKOVERS FOR DEVIATED WELLS
OPERATING SEQUENCE OF OK AND OM

G Series Mandrels

WIRE LINE TOOLS USED

PULLING TOOLS
CAMCO
CAMCO,TYPE
,TYPE JD
OTIS / HALLIBURTON TYPE S
CAMLOW TYPE ED

CORE EXTENSION (REACH IS

IDENTIFIED BY LAST LETTER)

FOR EXAMPLE: A TYPE R LATCH IS PULLED FROM A 1 POCKET USING A 2

CAMCO JDC
JDC OR A 2 OTIS SB
SB
NOTE: IF A JDS IS USED, THIS SHOWS A SHORT CORE EXTENSION, MEANING A
LONGE REACH AND WILL NOT RETRIEVE THE VALVE. THE JD STANDS FOR JAR
DOWN TO RELEASE. THIS MEANS THAT IN CASE OF STUCH VALVES, BY SIMPLY
JARRING DOWN A SAFETY PIN IS SHEARED IN THE PULLING TOOL AND IT IS
FREED FROM THE VALVE. ATTENTION MUST BE TAKEN TO USE THE ADEQUATE
TOOLS TO PULL VALVES FROM MANDRELS
IN THE CASE OF 1 VALVES WITH TOP LATCHES OR BOTTOM COLLET TYPE
LATCHES, THEY ARE ALL RETRIEVED WITH A 1 JD SERIES PULLING TOOL. THE
ONLY DIFFERENCE IS THE CORE EXTENSION (JDS OR JDC)

Gas Properties

NITROGEN

NONE TOXIC
NON CORROSIVE
NON EXPLOSIVE
READILY AVAILABLE
KNOWN PHYSICAL PROPERTIES

Temperature Correction Factor

For N2 Charged Valves
F
61
62
63
64
65

Ct
0.998
0.996
0.994
0.991
0.989

F
101
102
103
104
105

Ct
0.919
0.917
0.915
0.914
0.912

F
141
142
143
144
145

Ct
0.852
0.850
0.849
0.847
0.845

F
181
182
183
184
185

Ct
0.794
0.792
0.791
0.790
0.788

F
221
222
223
224
225

Ct
0.743
0.742
0.740
0.739
0.738

F
261
262
263
264
265

Ct
0.698
0.697
0.696
0.695
0.694

66
67
68
69
70

0.987
0.985
0.983
0.981
0.979

106
107
108
109
110

0.910
0.908
0.906
0.905
0.903

146
147
148
149
150

0.844
0.842
0.841
0.839
0.838

186
187
188
189
190

0.787
0.786
0.784
0.783
0.782

226
227
228
229
230

0.737
0.736
0.735
0.733
0.732

266
267
268
269
270

0.693
0.692
0.691
0.690
0.689

71
72
73
74
75

0.977
0.975
0.973
0.971
0.969

111
112
113
114
115

0.901
0.899
0.898
0.896
0.894

151
152
153
154
155

0.836
0.835
0.833
0.832
0.830

191
192
193
194
195

0.780
0.779
0.778
0.776
0.775

231
232
233
234
235

0.731
0.730
0.729
0.728
0.727

271
272
273
274
275

0.688
0.687
0.686
0.685
0.684

76
77
78
79
80

0.967
0.965
0.963
0.961
0.959

116
117
118
119
120

0.893
0.891
0.889
0.887
0.886

156
157
158
159
160

0.829
0.827
0.826
0.825
0.823

196
197
198
199
200

0.774
0.772
0.771
0.770
0.769

236
237
238
239
240

0.725
0.724
0.723
0.722
0.721

276
277
278
279
280

0.683
0.682
0.681
0.680
0.679

81
82
83
84
85

0.957
0.955
0.953
0.951
0.949

121
122
123
124
125

0.884
0.882
0.881
0.879
0.877

161
162
163
164
165

0.822
0.820
0.819
0.817
0.816

201
202
203
204
205

0.767
0.766
0.765
0.764
0.762

241
242
243
244
245

0.720
0.719
0.718
0.717
0.715

281
282
283
284
285

0.678
0.677
0.676
0.675
0.674

86
87
88
89
90

0.947
0.945
0.943
0.941
0.939

126
127
128
129
130

0.876
0.874
0.872
0.871
0.869

166
167
168
169
170

0.814
0.813
0.812
0.810
0.809

206
207
208
209
210

0.761
0.760
0.759
0.757
0.756

246
247
248
249
250

0.714
0.713
0.712
0.711
0.710

286
287
288
289
290

0.673
0.672
0.671
0.670
0.669

91
92
93
94
95

0.938
0.936
0.934
0.932
0.930

131
132
133
134
135

0.868
0.866
0.864
0.863
0.861

171
172
173
174
175

0.807
0.806
0.805
0.803
0.802

211
212
213
214
215

0.755
0.754
0.752
0.751
0.750

251
252
253
254
255

0.709
0.708
0.707
0.706
0.705

291
292
293
294
295

0.668
0.667
0.666
0.665
0.664

96
97
98
99
100

0.928
0.926
0.924
0.923
0.921

136
137
138
139
140

0.860
0.858
0.856
0.855
0.853

176
177
178
179
180

0.800
0.799
0.798
0.796
0.795

216
217
218
219
220

0.749
0.748
0.746
0.745
0.744

256
257
258
259
260

0.704
0.702
0.701
0.700
0.699

296
297
298
299
300

0.663
0.662
0.662
0.661
0.660

Pb @ 60 F = Pbt Ct
Ct = coef . =

Pb @ 60 F
Pb @ t F

Formula to calculate Temperature

Correction Factor

Ct = 1/(1+0.00215 * (Temp
@ Depth 60)

VALVE CALIBRATOR

PRESSURE RELIEF OR
CHARGE

HIGH PRESSURE
NITRIGEN
NO BACK PRESSURE

GAS LIFT
RULE OF THUMB
Rule of thumb Equation based on S.G. of 0.65,
a geothermal gradient at 1.60F/100ft and a surface
temperature of 700F

P@L = P@S + (2.3 x P@S x L )

100
1000
Where:

P@L = Pressure at depth, psia

P@S = Pressure at surface, psia
L = Depth, feet

NOTE: THIS IS A QUICK REFERENCE NOT TO BE USED

FOR IN DEPTH CALCULATIONS

GAS PRESSURE AT DEPTH

S .G. L
P@L = P@Se 53.34 T Z
Where:

e = 2.71828
P@L = Pressure at depth, psia
P@S = Pressure at surface, psia
S.G. = Gas Specific Gravity
L = Depth, feet
T = Average Temp Degrees R
Z = Average Compressibility for T
and average pressure

Pressure changes due to temperature in a

confined space (Bellows)
P2 = P1

Tc

Where: P1 = Pressure at initial temperature

P2 = Pressure resulting from change of temperature
Tc = Temperature correction factor
and

1 + 0.00215 x (T2 - 60)

Tc = -------------------------------1 + 0.00215 x (T1 - 60)
Where :

T1 = Initial temperature, Deg F

T2 = Present temperature, Deg F

CLOSED LOOP GAS LIFT SYSTEM

MAKE UP GAS REQUIREMENTS

o 4% IN SYSTEMS WITH ELECTRIC COMPRESSORS

o4% + 10 TO 12 SCF/HP WITH GAS OPERATED
COMPRESSORS AS FUEL (NORMALLY RESULTS IN
ABOUT 10% OF THE TOTAL GAS CIRCULATING)

DESIGN THEORY

TUBING EFFECT THEORY

With valve closed about to open

Pbt (A b ) = Pg (A b A v ) + Ptub (A v )
Pbt = Popen (1 Av Ab ) + Ptub Av Ab

Ab-Av

In test bench with Ptub= 0

Pbt = Popen (1 Av Ab )

or
(1)

Popen =

Ab

Pbt
1 Av Ab

Av

And in the well with a certain Pwf:

(2) Popen

Where

Av Ab
Pbt
=
Ptub A
Av
v
1 Ab
1 Ab

Av Ab

1 Av A
b

= TEF (TUBING EFFECT FACTOR)

With valve open about to close

Pbt (A b ) = Pclose (A b )

(3) Pbelows_t = Pclose

CONVENTIONAL VALVE
this means, constant
(at temperature T

TRO VALVE CALIBRATION

 CALIBRATION PRESSURE FOR VALVES AT 60 F
To calculate valve setting pressure (calibration) as 60F (TRO), use
the fact that:

Pclose t = P bellows t = Pb t
Use Temperature v. Depth to determine t1 y t2, etc.
To determine the Pb at 60F, use the correct table for temperature
correction coefficient at 60F

Pb @ 60 F = Pbt Ct
And from there,

Pb @ 60 F
P. vo. = TRO =
1 Av
Ab

PPO Type valve calculation

 Pbt Calculation

Pbt (Ab) = Pp (Ab-Ap) + Pi (Ap)

Where :
Ab = Area of bellows
Pp = Production Pressure
Ap: Area of port
Pi: Injection Pressure at depth

Day 3

Designs

Intermittent Design
Continuous Design
Ppo Design

Design Objectives

Inject as deep as possible

Conserve injection pressure
Ensure that upper valves remain closed
Good gas passage (surface and bottomhole)
Flexible design for dinamic conditions
Avoid instability

Correct assumptions??
assumptions??
We will always have some extra pressure.
Flow line pressure will always be lower than
expected
Reduce the amount of mandrels to the minimum
Temperature is not important

Correct assumptions!!!
assumptions!!!
Always assume there will be less pressure than
informed
Back pressure will always be a little higher
Design for future conditions and use the
necessary amount of mandrels. An extra
mandrel is always cheaper than a workover!!
Temperature is one of the most important
variables!!!

Max. Production with intermittent lift

Important estimations:
Fall Back = 5-7% every 1000ft
Time to complete a cycle:
3 minutes every 1000ft.

Example

Operating valve: 6000ft.

Tubing: 2 Capacity: 0.00579 bbl/ft.
Pt at the moment the valve opens: 500psi
at 6000ft. (using dinamic gradient and P.I.)
Pressure above slug: 100psi
Static gradient of fluid: 0,4psi/ft.

Minimum time per cycle and maximum

quantity per day

Time to complete 1 cycle (3 min x 1000ft)

= (3/1000)*(6000)= 18minutes
Maximum amount of cycles per day:
Where 1440 is the amount of minutes in a
day:
1440/18= 80 cycles per day

Estimating loss due to fall back

Percentage of fall back = 5%/1000.

(5%/1000) * (6000) = 30%

Clculo del tamao de Slug

Initial Slug volume = slug height * tubing

capacity =
500psi-100psi/0,4psi/ft x 0.00579bbl/ft=
5,8bbl/cycle

Maximum Obtainable Production

Production per cycle= Initial slug volume

fall back = 5.8bbls/day 30% = 4,1
bbls/day
Maximum Daily Production = maximum
amount of cycles per day * volume
produced per cycle =
4,1 bbls/cycle * 80 cycle/day= 328 BPD

Gas Consumption per day

Fast Calculation:
350 SCF/bbl*1000ft
350 * 328 * 6= 574000scf/day

Daily gas consumption

Detailed calculation:
1) Calculate slug height from previous example:
Produced Slug Length = Produced Slug Volume/capacity of tubing =
4,1bbls/0,00579bbl/ft = 701 feet.
2) Theoretical pressure under the slug at the time it reaches the
surface: Pus= Pwh + weight of slug = 100psig + (703ft * 0,4psi/ft) =
383psig
Pus= Pressure Under Slug
3) Average pressure in tubing at the moment the slug reaches the
surface = (pressure under the slug+ wellhead pressure)/2 =
Pavg = (383psig + 100psig) /2 = 242psig

Daily Gas Consumption

4) Determine from graph the necessary volume every 1000ft
Qs/1000ft of tubing = 1000 SCFD/1000ft of tubing (considering 242psi
and 2 tubing)
5) Calculate initial slug height = Initial Slug Volume / tubing capacity
= 5,8bbls/0,00579 bbl/ft. = 1002ft.
6) Calculate the required gas per cycle = (Gas volume every 1000ft x
lenght of tubing filled with injected gas) = 1000 cu.ft/1000ft * (6000ft
10002ft) = 4998cu.ft ciclo
7) Total gas need: 4998 cu.ft * 80 cycles/day = 399840 (399MCF)

INTERMITTENT GAS LIFT UNLOADING

INTERMITTENT GAS LIFT UNLOADING

INTERMITTENT GAS LIFT UNLOADING

VALVE SPACING IN INTERMITTENT WELLS

DEPTH OF FIRST VALVE:
(A)

(B)

Kickoff Pressure Separator Pressure

Depth =
Gs (Kill Fluid Gradient )

Static Fluid Level = Total Depth.

PStatic Bottomhole
Gs

First valve is set in whichever is deeper (A or B)

VALVE SPACING IN INTERMITTENT WELLS

Depth of First Valve (upper)
EXAMPLE:

(A)

750 50
Depth =
= 1521.74
0.46

(B)

Static Fluid Level = 6000 feet

1500
= 2739.13
0.46

We use the deepest, in this case, static fluid level = 2739 feet.

VALVE SPACING IN INTERMITTENT WELLS

Considering force balance to valve 2 (point X)
Pclose1 + P12 = Presseparator+ Depth1 (MistGradient) + Depth12StaticGradient.
Mist Gradient = SF (Spacing Factor)

And assuming that P12 (Injection pressure increase between

point 1 and 2) is only necessary to ensure gas flow and that we can
ignore it, the result is:

Depth 1 2 =

Pclose1 Pres separator Depth1 SF

Gs

Intermittent Gas Lift

Spacing Factors
Spacing Factor (SF) in psi/ft

0.16
0.14

1.61"ID

0.12

1.995"ID
2.441"ID

0.1

2.992"ID

0.08
0.06
0.04
0.02
0

100

200

300

Rate in BPD

400

500

VALVE SPACING IN INTERMITTENT WELLS

Depth for second valve:
(A) A closing pressure of 100psi less than available injection
pressure in asigned to the first valve.
(B) If there is not enough injection pressure available:

The first valve closing pressure is

A
Pclose = Pres kickoff 1 v
Ab

Then,

Distance between 1 2 =

Pclose1 Psep. SF (Depth 1 )

Gs

Where S.F = Spacing Factor, that depends on tubing size and flow rate.
Normally between 0.04 and 0.08

VALVE SPACING IN INTERMITTENT WELLS

Second Valve Depth
EXAMPLE:

Distancebetween valvula1 and valvule2 =

650 50 0.04 (2739) 600 110

=
=1065
0,46
0,46

Depth.2= 2739 + 1065 = 3804

For the next valves, keep on using a closing pressure 10 psi less that the
one inmediately before until the bottom of the well is reached .
640 50 0.04(3804)
= 952
0.46
Depth.3 = 3804 + 952 = 4756
Distance between2 3 =

And so on.

CALIBRATION OF TRO VALVES FOR INTERMITTENT

LIFT
 CALIBRATION PRESSURE AT 60 F
To calculate the calibration pressure at 60F use the fact that:

Pclose t = P bellows t = Pb t
Use pressure and temperature graph to determine t1 and t2, etc.
To determine Pb at 60use the Ct table:

Pb @ 60 F = Pbt Ct
And then,

Opening pressure in calibrator. = TRO =

Pb @ 60 F
1 Av
Ab

TYPICAL INJECTION PRESSURE VALVES WITH CHARGED NITROGEN BELLOWS

VALVE
OD

Ab

PORT

(MONEL)

Ap/Ab

Ap/Ab

BELLOWS

SIZE

SIZE

RATIO

(1-Ap/Ab)

(IN)

(IN^2)

(IN)

(1/64")

Mfg

PPEF

-------

-------

-------

-------

(MONEL)

(MONEL)

1 1/2"

0,77"

0,1875

12

0,0380

0,0395

0,77"

0,2500

16

0,0670

0,0718

0,77"

0,3125

20

0,1040

0,1161

0,77"

0,3750

24

0,1480

0,1737

0,77"

0,4375

28

0,2010

0,2516

0,77"

0,5000

32

0,2620

0,3550

0,31"

0,1250

0,0430

0,0449

0,31"

0,1875

12

0,0940

0,1038

0,31"

0,2500

16

0,1640

0,1962

0,31"

0,2813

18

0,2070

0,2610

0,31"

0,3125

20

0,2550

0,3423

0,31"

0,3750

24

0,3650

0,5748

1"

142

Continuous Flow Unloading

Sequence

Gas Lift continuo terminado.exe

Aplicacin

Continuous Unloading
INCRUSTAR FLASH

Continuous Unloading

Gas Lift well startup

Unload well carefully
50 - 100 psi (3.5 bar) per 10 min
1 - 2 bbl per min

Maximize production choke opening

Gradually increase gas injection rate
Monitor well clean up and stability
Get to target position
Perform step rate production test
Optimize gas injection rate
Note - when unloading all valves open!

Typical
Curves
TU
BINGPERTubing
FORMANCE(O
UTFLOW) CURVES

Pwf: BH Flowing Tubing Pressure (PSIG)

Thousands

DESCARGA
DE
FOR
10,000UN
FTWELLPOZO
W/ 1000GLR&CONTINUO
50%CUT
.
5
1.995"
2.441"

2.992"
3.467"

Pwf 3
in
1000
2
psi

3.958"

1
0

Rate in

3
Thousands
1000
BFPD
RATE(BFPD)

Tubing vs Flow Rate guide

1.995 ID=200 to 1000 bfpd
2.441 ID= 500 to 1500 bfpd
2.992 ID=1000 to 3000 bfpd
3.958
3.958 ID=> 3000 bfpd
5 ID => 5000 bfpd

CONTINUOUS DESIGN
PRESSURE (psig)

Depth (feet)

Flowing Pressure

Packer Depth

Continuous Design
Well Head Pressure

PRESSURE(psig)

Depth (feet)

Packer Depth

Continuous Design
Well Head pressure

PRESSURE (psig)

Depth (feet)

Packer Depth

Continuous Design
Well Head Pressure

PRESSURE(psig)

Flow Assurance Pressure

Depth (feet)

50

Packer Depth

Continuous Design
Well Head Pressure

Depth (feet)

PRESSURE (psig)

Pmin 1

Flow Assurance

Pmax 1

50

Packer Depth

Continuous Design
Well Head Pressure

Pmin 1

Depth (feet)

PRESSURE(psig)

Flow Assurance

Pmax 1

50

(*)

= TEF (Pmax1 Pmin 1)

Packer Depth

Continuous Design

PROFUNDIDAD (pies)

Well Head Pressure

PRESSURE (psig)

Pmin 1

Pmax 1

Pmin 2

Flow Assurance

Pmax 2

50

* *

(*)
(*)

= TEF (Pmax1 Pmin 1)

= TEF (Pmax2 Pmin 2
Packer Depth

Continuous Design
Using PPO Valves
Whp

Datum

PRESSURE (psig)

Depth (feet
feet)

25% of (P. Injec. Whp)

Profundidad del packer

Kickoff Pressure.

Continuous Design
Using PPO Valves
Datum

PRESSURE (psig)

Depth (feet
feet)

Whp

Packer Depth

150 PSIG

Continous Design
Using PPO Valves
Datum

PRESSURE (psig)

Depth (feet
feet)

Whp

Packer Depth

150 PSIG

DISEO CONTINUO
DE VLVULAS OPERADAS POR FLUIDO (PPO)
Datum

PRESION (psig)

PROFUNDIDAD (pies)

Whp

Profundidad del packer

150 PSIG

Opening Pressure Calculation

Pb= Pt (Ap) + Pc(Ab - Ap)
Where:
Pb: Pressure in Bellows
Pt: Pressure in tubing
Pc: Pressure in casing

PROPORTIONAL RESPONSE
Calibration Curves

P cierre

PRESSURE (psig)

PROPORTIONAL RESPONSE
Calibration Curves

P closing

PRESSURE (psig)

THORNHILL CRAVER TABLE

Gas Passage through Orifices

Intermittent Design
BINNING OIL TOOLS
Compania:......................................EJEMPLO
Yacimiento:....................540 PSI INYECCION
Pozo No.:....................................................XX

Fecha:.................................21 - Marzo - 2005

Representative:...............................................
Locacion:.........................................................

Profundidad de Perforacion (pies):..........7063

Profundidad de Packer (pies):.................6812
Tuberia OD (pulg.) (selecion):.........2-7/8 inch
Diam. del Casing (pulg.) (selecion):......7" 23#
Produccion deseada (blpd):........................60
% Agua (100=todo agua):............................3
Razon Gas/Liq. de Formation (scf/bbl):...2244
Temp.de Reservorio (Grado F):................167
Presion deReservorio (psig):.....................995
Gradiente de Temp. (Grado F/100 pies):...1.6
Nivel de Fluido de pozo Ahogado (pies):.4511
Gravedad del Petroleo (Grado API):...........37

Indice de Productividad (bbpd/psi):.............05

Presion de Separador (psig):....................100
Factor de espaciamiento (Entrar 0 par calc.):0
Temp. Boca de pozo Fluyente (Grado F):...68
Pres.de Arranque de Gas Inyect. (psig):...525
Pres.de Operacion de gas Inyect. (psig):..525
Gravedad de Gas Inyectado (aire=1.0):......65
Gradiente del Fluido de Ahogo (psi/pie):.....39
Gravedad Especifica del Agua:................1.05
Caida Pres.en Superf. entre Vlvs.(psig):.....10
Tipo de Valvula BOT (selecion):.........N10-RC
I.D. del Asiento (pulg. - selecion):.............5/16

Calculated Spacing Factor = ,04

Valve #
7
6
5
4
3
2
1

Depth (ft) Depth (M)

4512
4952
5337
5714
6080
6436
6782

1375,5
1509,7
1627,2
1741,9
1853,7
1962,3
2067,7

P bt

Temp

Ct

T.R.O.

Sur.Close

484
479
474
469
464
459
453

131
137
143
148
153
158
163

,867
,857
,849
,841
,833
,826
,819

563
552
541
530
519
508
498

425
415
405
395
385
375
365

An estimated gas requirement is: 148323

Continuous Design

Continuous Design

Troubleshooting

Intermittent Gas Lift Well Optimization

Gas Injection Requirements

Only for Intermittent gas lift wells, the GLR should be between 200 to
400 SCF/BBL for every 100 feet of depth. Usually 350 Scf/bbl/1000ft is an
acceptable quantity
In metric: 200m3/m3/1000m.
NOTE: Marginal well (less than 5 BPD) will require a higher GLR to
reduce loss of production. In those cases the usual amount is 700 to
1000scf/BBL/1000ft
In metric: 400m3/m3/1000m.

Continuous Lift Optimization

Gas Requirements

Only for continuous gas lift wells, total gas liquid ratio is that
required to obtain the minimum gradient (least Flowing Bottom Hole
Pressure). In this case formation GLR is also considered in the
equation :

Total GLR = injected gas + formation gas
Thus gas injection requirement = total GLR-formation gas
Note: to do a fast field analysis of a continuous gas lift well, 2500 to 3000 scf/bbl
per barrel as total GLR (injected + formation) can be used to obtain minimum
gradient. (this is a basic calculation and GLR needs is dependant on several
factors
In metric system: 450 to 500m3/m3 are used.
EXAMPLE: A well with a production of 700 Bpd of fluid at 8000ft with 400psig wellhead
pressure (due to this assume the well is actually 4000ft deeper to use gradient curves). We
get a minimum gradient of 3000 scf/bbl at 12000ft according to Kermit and Brown. If the
reservoir is 450 scf/bbl, we will need to inject : 700*(3000-450= 1.785.000 scf per dayU
Note: We talk about RGL and GOR

In metric System
Example: A well producing 100 m3/d at 2000 meters
with 400psi wellhead pressure (Equivalent to1220
meters more depth) . According to Kermit and Brown
our minimum gradient is achieved with 500m3/m3. If
formation GLR is 100m3/m3 the total gas to be
injected is: 100*(500-100)=40.000m3/d.

Reducing Gas Injection Needs

Intermittent Wells using excessive gas

Closed Systems
In this case the objective is to reduce the volume of gas circulating in the
system, thus reducing pressure in the battery and maintaining injection
pressure constant.
1) It is important to prolong times between injection cycles almost
simultanously in all wells, thus avoiding that any gas saved in one well
be injected in the others. At this point a pressure increase in the system
should be noted.
2) At this point compressor input pressure should be reduced until
desired system pressure is reestablished
3) Proceed to increase cycles in desired wells

Reducing Gas Injection Needs

Intermittent Wells using excessive gas
In closed systems
4) Verify that there has been no production loss in none of the wells. If
so increase cycle frequency in affected wells
5) Reduce separator pressure as much as possible without affecting
compressor operation. As this is an intermittent system is is necessary
to maintain enough gas in the system keeping some differential
between separator pressure and compressor intake pressure

System Capacity (in Scf.) =

14.65 x vol gas (aprox, in Scf.)

P (in psi)

6) Review all wells remembering the minimum slug travel time ti

ensure avoiding or reducing interference.

Reducing Gas Injection Needs

Intermittent Wells using excessive gas

In Open Systems

a) Injection cycles are decreased in one well at a time until a

loss in production is detected.
b) Injection cycles are slowly increased until production is
reestabilished

PRESSURE CHARTS
NORMAL OPERATION

PRESSURE CHARTS
Leak in downhole valve

PRESSURE CHARTS
Moto valve seat leaking

PRESSURE CHARTS
Insufficient Injection Time

PRESSURE CHARTS
Intermittent With Pilot Valve.

PRESSURE CHARTS
Normal Operation Continuous Gas Lift Well

PRESSURE CHARTS
Intermittent Well using a bottom hole orifice

CARTAS DE PRESION
POZO INTERMITENTE CON FUGA EN TUBERIA

CARTAS DE PRESION
POZO INTERMITENTE CON ALTA CONTRAPRESIN

Troubleshooting

$$

Q de produccin

UNSTABLE Inyeccin degas inestable

Q de gas teoricamente optimo

Q de gas optimizado al sistema

Caudal de inyeccin

Troublesshooting
Following data should be monitored regularly:

Injection pressure (Annular or tubing)

Injection Rate
Flowing Pressure
Well tests (pressure, temperature, etc)
Total production
Watercut
Temperature

Stability: if a system is unstable inmediate action must be carried out.

Please not that gas lift wells are normally unstable during startup and
comissioning

Troubleshooting
Injection Pressure:
On of the most important variables:
 Indicates operating valves
 Indicates operating depth
A sudden change in pressure can mean:
x Restriction in the injection system
x Opening of an unloading valve
x Change in tubing pressure at depth (change in WC)
x Obstruction in operating valve
x Operating valve has been damaged
x Leak in tubing or injection system

Troubleshooting

Gas injection Rate:

Has a great influence in fluid production
The inability to inject gas usually indicates a mechanical failure

If gas injection rate diminishes, this could indicate:

x An increase in watercut
x Operating through an unloading valve

Troubleshoot

Well tests
Real production and watercut controls
Multi rate tests to better understand well
behaviour
x Water Cut: If erratic indicates an unstable
well

Troubleshooting
Tubing Pressure:
The wellhead pressure and temperature are a clear indication that a well is flowing.
A Reduction in wellhead pressurecan indicate a loss of production because of:
x
x

A change of injection point

Increase in watercut

An increase in well head pressure may indicate:

x
x

Too much gas being injected

Will affect casing pressure

Tubing instability may be caused by:

x
x

Casing instability (multipointing or too large an orifice)

A tubing too large

Troubleshooting

Temperature

Injection Problems

x
x
x
x
x
x
x
x

Choke too large

Choke too small
Casing pressure too low
Casing pressure too high
Verify instruments
No enough gas volume
Too much gas
Unstable compression system

Problemas en descarga

x Restricciones en las vlvulas

x Contrapresin elevada
x Presin de trabajo del separador

Down hole problems

x
x
x
x
x
x
x

Leak in tubing/valve out of pocket

Well circulating gas
Well does not take gas
Well Slugging
Valves open
Excessive valve spacing
Well will not unload

Troubleshooting
Severe slugging in continuous gas lift well

Day 4
Completions

Packer Types
Mechanical Set
Retrievable
Permanent
Semi Permanent
Tension Set
Compression Set
With Hydrulic hold downs

Packer Types
Hydraulic Set
Retrievable
Semi Permanent
With slips
Without Slips

Factors Affecting Completion

Equipment Selection

Well Environment
Depth
Temperature
Dog leg severity
Amount of isolation zones
Well type (open hole, Cased Hole,
multilateral, etc)
Future operations

Force Considerations
When we are designing a completion
ALWAYS think ahead. Will stimulations be
carried out for ex (pressures may be a lot
higher than during production).

Forces Affecting Our

Completion
Mechanical
Tension
Slack Off

Buckling
Balooning
Piston Effect
Temperature

Mechanical
Defined by Hooks Law
where:

L=Change in Length
L = Length of tubing (inches)
F = Force (lbs)
E = Elasticity coefficient
As= Area of tubing (in2)

Mechanical

Slack Off
Defined by a combination of Hooke and
slack-off laws:
Where:

L=Change in Length
L = Length of tubing (inches)
F = Force (lbs)
E = Elasticity coefficient
As= Area of tubing (in2)
r = Radial tolerance between casing and tubing
I = momentum of inertia (in4)
W = weight of tubing in fluid (lbs)

Slack Off

Piston Effect
Mainly influenced by pressure changes and differentials
as related to packer seal areas

Where:
Ap: internal seal bore of packer
Ai: tubing internal area
Ao: tubing external area

Pi: change in tubing pressure at packer depth

Po: change in annular pressure at packer depth

Piston effect according to

packer configuration

Buckling
Tubing movement caused by pressure

Where:
Ap = Internal seal bore area of packer
r = Radial tolerance between casing and tubing

Pi: Tubing pressure change at packer depth

Po: Annular pressure change at packer depth

Buckling

Ballooning
Once again effect caused by pressure

Where:
= Poisson Coefficient (usually 0,3 for steel)
r = Radial tolerance between casing and tubing

Pi: Tubing pressure change at packer depth

Po: Annular pressure change at packer depth

Ballooning

Temperature Effect
Caused by changes in temperature in
wells operation

Where:
As = Transversal tubing section area

t =Average temperature change
L = Initial tubing lenght
B = thermal expansion coefficient

Temperature Effect

Overall effect
The sum of these different
effects all add up what work
in different directions some
times.
It is important to consider all
these variables at the time
we design a completion not
only in actual conditions but
plan for potential future
conditions

Exercises

New
Developments

Comments?
Thank You!

Exclusive Representative for

Sudan
REFINED ENGINEERING DIMENSIONS(RED)

P.O BOX 50 KRT-SUDAN

Omer K.Sharfy
(00249)-9-12348700
osharfy@refineded.org

BINNING OIL TOOLS S.A.