Artificial Lift Tech

Artificial Lift
Overview of Methods, Equipment and Operation
Copyright 2007, , All rights reserved

Inflow Performance
.
Pwh PRESSURE
DEPTH
Well pressure gradient
Pwf actual Pwf initial
Pe actual Pe initial

Gas Lift
Principle
Equipment
Types
Operation
Troubleshooting & Control
Advantages & disadvantages

Gas Lift
SURFACE PRESSURE PRODUCED FLUID
GAS INJECTION
 Injection of gas in the annulus

to decrease the hydrostatic
head below bottom hole
flowing pressure and allow
the well to flow.
SANDFACE
RESERVOIR PRESSURE
PRESSURE BHFP
Copyright 2007, , All rights reserved 4

Gaslift Equipment
Flowline
Gasline
Surface casing
Production casing
Tubing
Bellows
Packer Section
Gaslift completion
Pilot
Section
Side pocket mandrel

Gaslift valve
Gaslift Valves
Bellows
Pilot

Types of Gas Lift
 CONTINUOUS FLOW GAS LIFT Steady State Flow;

mechanisms are lowering density, expanding gas and
pushing to surface. P & T remain constant at process plant.
 INTERMITTENT GAS LIFT Batch Production; for low
productivity wells; process problems.

Continuous Gaslift
Flowline
Gasline
Unloading valve
Operating valve
Tubing
Packer

Gaslift Valve Operation
.
OPENING PRESSURE
Pwh Pr
Val. 1
DEPTH
Val. 2
Val. 3
A
B
VIDEO
Unloading Gas Lift Valve
 Normally required during unloading phase only

 Open only when annulus and tubing pressures are high
enough to overcome valve set pressure
 Valve closes after transfer to next station
 May be spring or nitrogen charged

Operating Gas Lift Valve
 Typically an ‘orifice’ type Gas lift valve

 always open - allows gas across Passage whenever correct
differential exists
 Gas injection controlled by size and differential across
replaceable choke
 Back-check prevents reverse flow of well fluids from the
production conduit

Gas Injection Rate
Gas passage through the orifice valve

GAS INJECTION RATE (MMSCF/D)
SUB-CRITICAL
FLOW
ORIFICE FLOW
PTUBING = 55%
DOWNSTREAM PRESSURE (PSI) PCASING

Gaslift injection
WELL FLOWING PRESSURE (Pwf)
Maximum Production
TASA DE PRODUCCION (QL)

Pr
Well inflow
Optimum Economical
LIQUID PRODUCTION RATE (QL) GAS INJECTION RATE(Qgi)

Intermittent Gaslift
Flowline
Gasline
Unloading valve
Operating valve
Tubing
Packer

Plungerlift
Flowline
Gasline
Unloading valve
Operating valve
Tubing
Packer

Typical Operating Conditions
Typical Range Maximum

• Depth (feet) 2.000 – 10.000 15.000
• Production (BPD) 100 – 10.000 20.000
• Temperature (°F) 100 – 250 N/D

Surface Gaslift Control
GASLIFT GAS
MANIFOLD MANIFOLD
DRY GAS
DRY GAS
RICH GAS LNG
3-PHASE FLOWS GAS PLANT
Gaslift Well
FLOW CRUDE OIL
STATION
WATER

Manual Flow Control Valve
GASLIFT MANIFOLD

Actuated Flow Control Valve 18
INDIRECT METERING OF GAS FLOW TO THE WELL

Connected between the left

wing valve and the choke
box, to record WHP
Connected to the
production casing valve
to record casing-tubing
annulus pressure.

CASING PRESSURE
WELLHEAD PRESSURE
CONTINUOUS FLOW
INTERMITTENT FLOW
Advantages of Gas Lift
 Low initial downhole equipment costs

 Low operational and maintenance cost
 Simplified well completions
 Flexibility - can handle rates from 10 to 50,000 bpd
 Can best handle sand / gas / well deviation
 Intervention relatively less expensive

Disadvantages of Gas Lift
 Must have a source of gas

– Imported from other fields
– Produced gas - may result in start up problems
 Possible high installation cost
– Top sides modifications to existing platforms
– Compressor installation
 Limited by available reservoir pressure and bottom hole
flowing pressure
 Efficiency decreases while BW&S increases

Summary of Gaslift Requirements
 Maximize oil production

 Minimize well intervention (especially in subsea wells)
 Maximize design flexibility without compromising production
 Maximize depth of injection
 Well stability
 Uncertainties in reservoir performance
 Range of reservoir pressures over well life
 Range of watercuts over well life
 Range of gas injection rates
 Valve port sizing and gas passage pressure drops in system
 Valve performance
Types of Artificial Lift Pumping Methods
RP HP PCP ESP

Mechanical Pumping (Sucker Rod Pumps)
Principle
Equipment
Operation
Troubleshooting & Control
Advantages and disadvantages

Mechanical Pumping (Sucker Rod Pumps)

Mechanical Pumps
 The first Artificial Lift method to be used and still very popular
 Simple combination of a cylinder, a piston, intake valve and discharge
valve
 Strokes from a few inches to less than 3,000 bopd
 Suitable for viscous oils (+400 cp)
 Main problems:
– low intake pressure
– high discharge pressure
– sand
– corrosion
– scales and deposits
– handling of gases and condensed vapors

Sucker Rod Pumping
Carrier Bar
Counter weight
Head
Crank arm
Gearbox Elevator
Polished rod
Stuffing Box
Flow line
Gsa line
Casing
Tubing
Rod string
Piston
Riding valve
Standing valve

Sucker Rod Pumping Equipment
RODS
PISTON
BARREL
FLUID
RIDING SETTING
VALVE BALLS

Rod Pumping Troubleshooting and Control

NORMAL FUNCTIONING
UPWARDS STROKE
LOAD
DOWNWARDS
ROD STROKE
PISTON
DISPLACEMENT
RIDING
VALVE
BARREL
FLUID
STANDIN
G VALVE
FLUID
DOWNWARD MOVEMENT UPWARD MOVEMENT


Rod Pumping Typical Problems
Load
Load
Displacement Displacement
Excessive Pumping Speed Restriction in the Well

When a well is pumped at an Restrictions most of the cases reduce
inadequate high speed in the beam’s the volume of fluid entering to the well
motor, it is observed in the chart that and causes in the chart an increasing
the load decreases when beginning upwards load during the piston
the upwards piston stroke and stroke, but with excessive
happens a closing in form of circle at displacement, which indicates little
the end of this piston stroke. work of the pump.

Load
Load
Liquid Blow on the Pump Gas Blow on the Pump
The fluid blow happens when the The gas blow happens when the
barrel of the pump does not fill pump fills partially with gas,
completely during the piston stroke showing a chart’s shape very
upwards and it is characterized by similar to the one of the liquid lock,
a fast unloading at the end of the but the unloading at the end of the
downwards piston stroke. downwards piston stroke is less
pronounced.
Load
Load
Gas Blockade Full Drained

When the pump fills almost totally If there is no entrance of fluid to
with gas it is called gas blockade the pump it generates a chart that
and the chart is recognized shows very few loads with normal
because the load decreases during displacement, but without work of
the upwards piston stroke and the pump.
shows very little work of the pump.

Electric Submersible Pumps (ESP)

Historical Perspective
 1927 - El Dorado Kansas First

ESP Installation
 Early 1930s - First Horizontal
Pumping Unit
 1960s - First Variable Speed
Applications
 1980s - First ESP Performance
Models
 1990s First Subsea Completed
Applications

ESP System Functioning
Pwh
Pwh
gas
Depth
PUMP Pup Pdn
Pdn
ΔP
Pup
Pr
Pwf
Pressure Pwf Pr
Pup = Suction pressure of pump
Pdn = Unloading pressure of pump

ESP System Functioning
Unloading pressure, Pdn

WELL FLOWING PRESSURE (Pwf)
ΔP ΔP
Suction Pressure, Pup
0
0
LIQUID PRODUCTION RATE, QL

ESP System Components
Electrical transformer
Switch board
Well Flare
head box
Tubing
Drainage valve
Retention valve
Unloading head
Pump
Intake
Protector
Power cable
Motor
Motor base
Casing
ESP Downhole System Components
The motors are bipolar, three-phase The pumps are centrifugal of In wells of high GOR a rotary gas
and come full with a very refined several stages. Each stage consists separator removes the free gas from
mineral oil to provide dielectric of a revolving impeller and a fixed the produced fluid through the
resistance, lubrication for seals and diffuser. The used materials are of casing-tubing annulus, the separator
thermal conductivity. special metallurgy for optimal prevents problems with gas blow and
operation in corrosive and/or cavitations, increasing the life of the
abrasive environments. equipment.

 Each "stage" consists of an

impeller and a diffuser. The
impeller takes the fluid and
imparts kinetic energy to it. The
diffuser converts this kinetic
energy into potential energy
(head).

Head and Base Bearing
Compliant Mounted Zirconia Radial Bearings
Stage Bearing

Typical fluid flow path in a

"mixed flow" stage.

The next part of the system is the submergible motor. The motor
is a three phase, squirrel cage, two pole induction design.
The three power phases are "Wye" connected within the motor
itself to establish a "neutral" point.
PHASE 1
PHASE 2
PHASE 3

Because of the way the stator is

wound, the three phase power
establishes a two pole magnetic
field within the stator.
The motor is called a squirrel

cage because this is what the
rotor looks like:

Unloading head
 The next major component of the ESP system is Pump
the "Protector". The Protector is placed between
the pump and connects the motor shaft to the
pump shaft. Intake w/ or wo/
Gas Separator
 The Protector also houses the pump's upthrust
and downthrust bearings and provides for
pressure equalization between the outside of the Protector
motor and the inside.
Motor
Motor base
Protector
Shaft bushing
 Prevents Wellbore Fluids Entering Labyrinth Chamber
Motor Shaft Seals
 Balances Pressure Between Motor &

Annulus Shedder
 Carries Thrust Load of Pump Elastomer Bag
Thrust Bearing
Filter Screen

Between the Protector and the pump is the

pump intake section. This can be either a
standard ported intake or, as shown here,
a centrifugal gas separator to eliminate
free gas from the pumped fluid allowing it
to be produced up the annulus.

Another component of the ESP system is the power cable.

This particular cable shows an optional chemical injection line
which can be incorporated within the cable itself.

ESP Operation
OPERATING CONDITIONS:
Typical Range Maximum
• Depth (feet) 1,000 – 10,000 15,000
• Production (BPD) 100 – 20,000 90,000
• Temperature (°F) 100 – 275 400
ADVANTAGES:
• High temperature resistant
• Highly efficient
• Positive displacement
• High liquid rates
DISADVANTAGES:
• High efficiency
• Affected by high GOR
• Little resistant to solids and sand

The Basic ESP System
Equipment diameters from 3.38” -

(A) series to 11.25” - (P) series
Casing Sizes - 4 1/2” to 13 5/8”
Variable Speed Available
Metallurgies to Suit Applications.

ESP Downhole System Operation
Head: The height

to which the pump
will "lift" the fluid Propane Water Oil
Curves for centrifugal pumps

are normally shown as flow
versus head in feet, meters,
or some other consistent
unit.
A centrifugal pump produces "constant head". This means that,

regardless of the fluid being pumped, it will be lifted to the same height as
any other fluid for the same flow rate.
ESP Downhole System Operation
- S p . S
G N
r .P
12u
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S
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4
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5
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rp
S
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0 .6 S0h1a 6
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6 0 3 .0
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0
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E= 6 8
5 0 2 .5
5 0
0 %
4 0 2 .0
4 0
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3 0 1 .5
3 0
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2 0 1 .0
2 0
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1 0 0 .5
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5
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ty - Barrels p
From this curves we can determine the head produced, brake

horsepower required and hydraulic efficiency at any flow rate.
Progressive Cavity Pumps (PCP)
OPERATION CONDITIONS:
Typical Range Máximum
• Depth (feet) 2.000 – 4.500 6.000
• Volume (BPD) 5 – 2.200 4.500
• Temperature (°F) 75 – 150 225
ADVANTAGES:
• Low investment, operating and maintenence
costs
• High efficiency
• Positive displacement
• Small size surface equipment
DISADVANTAGES:
• Medium to low resistance to high temperatures
• Low resistance to solids
• Incompatibility elastomers - fluid

The Progressive Cavity Pump
 Positive displacement pump without

valves
 Delivers a consistent flow
 Stator being stationary attached to
the tubing string
 Rotor rotates driven from the surface
through the rod string and the stator
is attached to the tubing string
 The rotor is a single threaded helix
and the stator is an elastomer lined
double threaded helical cavity.

Downhole Motor PCP
Opportunity of application:
• Deep wells that requires high

torque
• Horizontal and highly deviated

wells
• Rotating gas separator

The Progressive Cavity Pump
TYPICAL PERFORMANCE OF A PROGRESSIVE CAVITY PUMP
500 500 RPM

18
500 RPM
450 16
400 RPM
400
HORSEPOWER (HP)
400 RPM
14
350
CAPACITY (BFPD)
12
300 RPM
300
300 RPM 10
250
8
200 200 RPM
200 RPM
6
150
100 100 RPM 100 RPM

4
50 2
0 0
0 1000 2000 3000 4000 5000
HEAD (FT. WATER)

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Artificial Lift

Overview of Methods, Equipment and Operation

Copyright 2007, , All rights reserved

Well pressure gradient

Pwf actual Pwf initial

Copyright 2007, , All rights reserved

Copyright 2007, , All rights reserved

 Injection of gas in the annulus

Copyright 2007, , All rights reserved 4

Side pocket mandrel

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 CONTINUOUS FLOW GAS LIFT Steady State Flow;

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 Normally required during unloading phase only

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 Typically an ‘orifice’ type Gas lift valve

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Gas passage through the orifice valve

DOWNSTREAM PRESSURE (PSI) PCASING

TASA DE PRODUCCION (QL)

LIQUID PRODUCTION RATE (QL) GAS INJECTION RATE(Qgi)

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Typical Range Maximum

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RICH GAS LNG

3-PHASE FLOWS GAS PLANT

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INDIRECT METERING OF GAS FLOW TO THE WELL

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Connected between the left

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 Low initial downhole equipment costs

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 Must have a source of gas

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 Maximize oil production

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DOWNWARD MOVEMENT UPWARD MOVEMENT

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Excessive Pumping Speed Restriction in the Well

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Gas Blockade Full Drained

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 1927 - El Dorado Kansas First

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