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Different Enhanced Oil Recovery Techniques

& Designing of Gas Lift Valves for the OS-9A Well

Submitted by:
Archit Sharma
B.tech Applied Petroleum Engineering
Date: 31 /07/09 University of Petroleum and Energy Studies, Dehradun
ACKNOLEDGEMENT

I feel honored in submitting this report on “Different Enhanced Oil Recovery Techniques &
Designing of Gas Lift Valves for the OS-9A Well” as a part of my B.tech Applied Petroleum
Engineering summer internship programme at NIKO RESOURCES LIMITED, Hazira. Firstly
I would like to thank Mr. Amar Jha, Chief General Manager, NRL Hazira, Mr. T.M
Sreekanth Head HR & Administration and Mr. Shammy K.Prahladhan Officer HR &
Administration for giving me this opportunity.
I am grateful to my Mentor Mr. L.C.Ram, Operational Integrity Adviser, NRL, Hazira for
helping me with the project and I feel extremely privileged to get an opportunity to train under
his guidance.
A special thanks to Mr. Shashank Shekhar, (Production Head), Mr. AmitaAnad Sharma
(Petroleum Engineer), Ms. Soniya Mane (Petroleum Engineer), NRL, Varodara
Mr. Rachit Garg (Petroleum Engineer) , Mr. Peeyush Gupta Deputy Manager, Mr. K.P
Karan & Mr. Ravi Sharma (Head Training Officer), NRL, Hazira who at every discrete step in
study of this project contributed their valuable guidance to solve every problem that arose.
Also a special thanks to Mr. Prerak Panchal who helped in formatting this project report .The
library staff must get a special mention for their cooperation and timely help.

Thanking You
Archit Sharma Date:
Bachelor of technology, Applied Petroleum Engineering
University of Petroleum & Energy Studies, Dehradun
Contents

Topics Page no.

Chapter I: Introduction 1

1.1 Overview of the Hazira oil & gas fields 2

1.2 Need of EOR at the Hazira fields 2

Chapter II: Enhanced Oil Recovery 4

2.1 Introduction 5

2.2 Different techniques used for EOR methods 5

2.2.1 Gas injection 5

2.2.2 Chemical injection 6

2.2.3 Microbial injection 6

2.2.4 Thermal recovery 7

2.2.4.1 Insitu combustion 7

2.2.4.2 Steam injection 8

2.2.4.3 Cyclic steam stimulation 8

2.2.4.4 Steam flooding 9

Chapter III: Artificial Lift Techniques 10

3.1 Introduction 11

3.2 Types of artificial lift techniques 11

3.2.1 Hydraulic pumping system 12

3.2.1.1 Reciprocating pumps 12

3.2.1.2 Jet pumps 12


3.2.2 Electric submersible pump (ESP) 12

3.2.3 Progressive cavity pump (PCP) 13

3.2.4 Gas lifts 13

3.2.4.1 Types of gas lifts 13

3.2.4.1.1 Continuous flow of gas lift 13

3.2.4.1.2 Intermittent flow of gas lift 14

3.2.5 Sucker Rod Pumps (SRP) 14

3.2.5.1 Components of SRP 15

3.2.5.2 Hold down seal assembly 20

3.2.5.3 Geometry and structure of the SRP 21

3.2.5.4 Explanation and working of a SRP 22

3.2.5.5 Main drawbacks of a SRP 24

Chapter IV: Gas Lift Techniques 25

4.1 Introduction 26

4.2 Types of Gas lift methods 28

4.2.1 Continuous gas lift 28

4.2.2 Intermittent gas lift 28

4.3 Advantages of gas lift 29

4.4 Different types of gas lift techniques 29

4.4.1 Retrievable cross-flow assembly 31

4.4.2 Dead string with gas lift 32

4.4.3 Annular flow with gas lift 33

4.4.4 Dip tube with gas lift 33

4.5 Working of a Gas lift 34


Chapter V: Types of Gas Injection Control 40

5.1 Choke control 41

5.2 Regulator control in conjunction with a choke intermittent flow 41

5.3 Time cycle controller 42

Chapter VI: Case Study of the Designing for the OS-9A Well 43

6.1 Designing of the gas lift valve assembly of the OS-9 well with 60% water cut 44

6.1.1 Calculation for its designing 44

6.2 Designing of the gas lift valve assembly of the OS-9 well with 90% water cut 47

6.2.1 Calculation for its designing 47

Chapter VII: Analysis and Trouble Shooting of Gas Lifts 51

7.1 Analysis & troubleshooting 52

7.2 Measures for analyzing continuous flow-gas installation 53

Conclusion 54

Reference 57
CHAPTER – I
INTRODUCTION

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1.1 Overview of the Hazira oil & gas fields

Fig.1 HAZIRA – ONSHORE/OFFSHORE WEST COAST INDIA

The Hazira field is located 25 km south west of the city of Surat. The area is surrounded by
the Tapti river in the east and the Arabian Sea in the west, characterized by marshy lands and
water bodies like creeks, estuaries and rivers.
The company has a 33 percent working interest in the 50 square-kilometer Hazira onshore-
offshore block on the western coast of India. The capital expenditures of the company has
been $2.6 million primarily related to work over costs for natural gas wells and other well
completions which have been done over at the Hazira fields.

1.2 Need of Enhanced Oil Recovery EOR techniques at the


Hazira fields
The block has highly permeable unconsolidated reservoirs consisting of Babaguru,
Tarkeshwar and Lower Channel Sands. It is a highly permeable reservoir having
permeability of the order of 500md to 2 Darcie’s. Most of the hydrocarbons producing sands
are at a shallow depth contributing to the unconsolidation.

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Gas wells which have been depleting are enhanced using the artificial lift techniques such as
the sucker rod pump and gas lift out of which most recently a variety of innovative
techniques using gas lift have been applied successfully to wells with long perforated
intervals.
In the past, gas lift was been primarily used for offshore applications. However, land
applications are now occurring with increasing rapidity. It now pays to make the investments
necessary to re-inject gas into a well to improve recovery, rather than use some other
methods of artificial lift such as the sucker rod pump.
In particular, wells with long perforated intervals or multiple zones, producing below critical
rate and with high fluid rates, can today be addressed choosing one of several gas-lift
techniques selected on the basis of application.
Ever since the production of the fields at the Hazira on-shore & offshore has started there has
been a decline in the reservoir pressure of most of the sands leading to increased sand
movements leading to reduction in the permeability and also liquid loading in the gas wells.
In order to overcome these problems so that they do not alter the production of the oil & gas
from the reserves and also to increase the longevity of the well production Enhanced oil
recovery methods are needed to be applied.

A continuous type gas lift technique has also been undertaken for the OS-9 well at the Hazira
offshore block as the well had a water loading problem which had been causing a production
problem in the well to overcome it the continuous gas injection has been taken up.

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CHAPTER-II
ENHANCED OIL RECOVERY

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2.1 Introduction

Enhanced Oil Recovery (EOR)


It is defined as the incremental ultimate oil that can be economically recovered from a petroleum
reservoir over all that can be recovered by conventional primary and secondary methods. Some of
the EOR chemical methods (polymer flooding, surfactant flooding), thermal flooding ( steam
injection, insitu combustion).It is a means of artificially increasing the productive life of an oil
field.

2.2 Different techniques used for EOR methods


Enhanced oil recovery is achieved by gas injection, chemical injection, microbial injection, or
thermal recovery (which includes cyclic steam, steam flooding).

2.2.1 Gas injection


The process of injecting gas into a reservoir for the maintenance of pressure in the producing
horizon in order to allow further recovery of the oil .It is presently the most-commonly used
approach to enhanced recovery. A gas is injected into the oil-bearing stratum under high pressure.
That pressure pushes the oil into the pipe and up to the surface. In addition to the beneficial effect
of the pressure, this method sometimes aids recovery by reducing the viscosity of the crude oil as
the gas mixes with it. Gases commonly used include CO2, natural gas or nitrogen.

Fig.2 Gas injection

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Oil displacement by carbon dioxide injection relies on the phase behavior of the mixtures of that
gas and the crude, which are strongly dependent on reservoir temperature, pressure and crude oil
composition. These mechanisms range from oil swelling and viscosity reduction for injection of
immiscible fluids (at low pressures) to completely miscible displacement in high-pressure
applications. In these applications, more than half and up to two-thirds of the injected CO2 returns
with the produced oil and is usually re-injected into the reservoir to minimize operating costs. The
remainder is trapped in the oil reservoir by various means.

2.2.2 Chemical injection


Several possible methods have been proposed. Some successful applications are injection of
polymers, which can either reduce the crude's viscosity or increase the viscosity of water which
has also been injected to force the crude out of the stratum.

2.2.3 Microbial injection


Microbial injection is part of microbial enhanced oil recovery and is rarely used, both because of
its higher cost and because the developments in this field are more recent than other techniques.
Strains of microbes have been both discovered and developed (using gene mutation) which
function either by partially digesting long hydrocarbon molecules, by generating bio surfactants,
or by emitting carbon dioxide.

Three approaches have been used to achieve microbial injection. In the first approach, bacterial
cultures mixed with a food source (a carbohydrate such as molasses is commonly used) are
injected into the oil field.

In the second approach, used since 1985, nutrients are injected into the ground to nurture existing
microbial bodies these nutrients cause the bacteria to increase production of the natural
surfactants they normally use to metabolize crude oil underground. After the injected nutrients are
consumed, the microbes go into near-shutdown mode, their exteriors become hydrophilic, and
they migrate to the oil-water interface area, where they cause oil droplets to form from the larger
oil mass, making the droplets more likely to migrate to the wellhead.

The third approach is used to address the problem of paraffin components of the crude oil, which
tend to separate from the crude as it flows to the surface. Since the earth's surface is considerably
cooler than the petroleum deposits (a temperature drop of 13-14 degree F per thousand feet of
depth is usual), the paraffin's higher melting point causes it to solidify as it is cooled during the
upward flow. Bacteria capable of breaking these paraffin chains into smaller chains (which would
then flow more easily) are injected into the wellhead, either near the point of first congealment or
in the rock stratum itself.

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2.2.4 Thermal Recovery
Various methods are used in the thermal recovery process-

2.2.4.1 Insitu combustion

It involves controlled burning/heating of heavy oil in the natural position or location of the
reservoir to reduce its viscosity so that it can move up to the surface. The oil sand is ignited,
keeping up the fire-front by injection of air. This helps in recovery of heavy oil by breaking the
oil molecules into lighter ones and coke which catches fire as the fire front advances, the lighter
oil moves ahead of the fire into the hole of the producing well.

Fig.3 Insitu combustion

2.2.4.2 Steam injection

It is an increasingly common method of extracting heavy oil. It is considered an enhanced oil


recovery (EOR) method and is the main type of thermal stimulation of oil reservoirs. There are
several different forms of the technology, with the two main ones being Cyclic Steam Stimulation
and Steam Flooding. Both are most commonly applied to oil reservoirs which are relatively
shallow and which contain crude oils which are very viscous at the temperature of the native
underground formation. Steam injection is widely used in the San Joaquin Valley of California
(USA), the Lake Maracaibo area of Venezuela and the oil sands of northern Alberta (Canada).

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2.2.4.3 Cyclic Steam Stimulation

This method, also known as the Huff and Puff method, consists of 3 stages: injection, soaking
and production. Steam is first injected into a well for a certain amount of time to heat the oil in the
surrounding reservoir to a temperature at which it flows. After it is decided enough steam has
been injected, the steam is usually left to "soak" for some time after (typically not more than a
few days). Then oil is produced out of the same well, at first by natural flow (since the steam
injection will have increased the reservoir pressure) and then by artificial lift. Production will
decrease as the oil cools down, and once production reaches an economically determined level the
steps are repeated again.

The process can be quite effective, especially in the first few cycles. However, it is typically only
able to recover approximately 20% of the Original Oil in Place (OOIP), compared to steam
flooding which has been reported to recover over 50% of OOIP. It is quite common for wells to
be produced in the cyclic steam manner for a few cycles before being put on a steam flooding
regime with other wells.

This mechanism was accidentally discovered by Shell while it was doing a steam flood in
Venezuela and one of its steam injectors blew out and ended up producing oil at much higher
rates than a conventional production well in a similar environment.

Fig.4 Cyclic steam stimulation

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2.2.4.2 Steam Flooding

Fig.5 Steam flooding

In a steam flood, sometimes known as a steam drive, some wells are used as steam injection wells
and other wells are used for oil production. Two mechanisms are at work to improve the amount
of oil recovered. The first is to heat the oil to higher temperatures and to thereby decrease its
viscosity so that it more easily flows through the formation toward the producing wells. A second
mechanism is the physical displacement employing in a manner similar to water flooding, in
which oil is meant to be pushed to the production wells. While more steam is needed for this
method than for the cyclic method, it is typically more effective at recovering a larger portion of
the oil.

A form of steam flooding that has become popular in the Alberta tar sands is steam assisted
gravity drainage (SAGD), in which two horizontal wells are drilled, one a few meters above the
other, and steam is injected into the upper one. The intent is to reduce the viscosity of the bitumen
to the point where gravity will pull it down into the producing well.

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CHAPTER- III
ARTIFICIAL LIFT TECHNIQUES

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3.1 Introduction
Artificial Lift Techniques
Most oil wells, at early stages of their life, flow naturally to the surface. These are called self
flowing wells. The basic prerequisite to ensure flowing production is that the pressure at the well
bottom be sufficient to overcome the sum of pressure losses occurring along the flow path to the
surface. When this criterion is not met, the well stops to flow naturally and “dies”.

To produce wells that are already dead, or to increase the production rate from flowing wells,
some kind of artificial lifting equipment is required.

3.2 Types of artificial lift techniques


Several lifting systems are available to choose from and all work on the principle of supplying the
energy needed from the surface in order to move well fluids up the well. Processes used in
artificial lift methods are sucker rod pumps, gas lift, electric submersible pumps, hydraulic
pumping systems and progressing cavity pumps (PCP).

Fig.6 Percentage of different artificial lift methods

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3.2.1 Hydraulic Pumping Systems

Hydraulic pumping systems transmit energy to the bottom of the well by means of pressurized
power fluid that flows down in the wellbore tubular to a subsurface pump. There are two types of
hydraulic subsurface pumps

3.2.1.1 Reciprocating piston pump

Where one is powered by the injected fluid while the other pumps the produced fluids to surface

3.2.1.2 Jet pump

Where the injected fluid passes through a nozzle creating a jet effect pushing the produced fluids
to surface. These systems are very versatile and have been used in shallow depths (1000ft) to
deeper wells (18,000ft), low rate wells with production in ton’s of barrels per day to wells
producing in excess of 10,000 barrels per day (1,600 m³/d). In addition to this certain fluids can
be mixed in with the injected fluid to help deal or control with corrosion, paraffin and emulsion
problems. They are also suitable for wells where conventional pumps such as the rod pump are
not possible due to crooked or deviated wells. These systems have also some disadvantages. They
are sensitive to solids and it is the least efficient lift method.

3.2.2 Electric submersible pump (ESP)


Electric Submersible Pumps consist of

(a) down hole pump, which is a series of centrifugal pumps (b) separator protector, whose
function is to prevent that produced fluids enter the electrical motor (c) the electrical motor, which
transforms the electrical power into kinetic energy to turn the pump and (d) an electric power
cable that connects the motor to the surface control panel. ESP is a very versatile artificial lift
method and can be found in operating environments all over the world. They can handle a very
wide range of flow rates (from 200 to 90,000 barrels per day) and lift requirements (from virtually
zero to 10,000 ft (3,000 m) of lift). They can be modified to handle contaminants commonly
found in oil, aggressive corrosive fluids such as H2S and CO2, and exceptionally high down hole
temperatures. Increasing water cut has been shown to have no significant detrimental effect on the
ESP performance. It is possible to locate them in vertical, deviated, or horizontal wells, but it is
recommended to deploy them in a straight section of casing for optimum run life performance.
Although latest developments are aimed to enhance the ESP capabilities to handle gas and sand,
they still need more technological development to avoid gas locked and internal erosion.

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3.2.3 Progressing cavity pumps (PCP)
Progressing Cavity Pumps, PCP, are also widely applied in the oil industry. The PCP consists of a
stator and a rotor. The rotor is rotated using either a top side motor or a bottom hole motor. The
rotation created sequential cavities and the produced fluids are pushed to surface. The PCP is a
flexible system with a wide range of applications in terms of rate (up to 5,000 bpd and 6,000 ft).
They offer outstanding resistance to abrasives and solids but they are restricted to setting depths
and temperatures. Some components of the produced fluids like aromatics can also deteriorate the
stator’s elastomer.

3.2.4 Gas Lifts

Gas Lift is another widely used artificial lift method. As the name denotes, gas is injected in the
tubing to reduce the weight of the hydrostatic column, thus reducing the back pressure and
allowing the reservoir pressure to push the mixture of produce fluids and gas up to the surface.
The gas lift can be deployed in a wide range of well conditions (up to 30,000 bpd and down to
15,000 ft). They handle very well abrasive elements and sand, and the cost of work over is
minimum. The gas lifted wells are equipped with side pocket mandrel and gas lift injection
valves. This arrangement allows a deeper gas injection in the tubing. The gas lift system has some
disadvantages. There has to be a source of gas, some flow assurance problems such as hydrates
can be triggered by the gas lift. Gas lift provides artificial lifting energy by the injection of gas
into or beneath the fluid column. The gas decreases the fluid density of the column and lowers the
bottom hole pressure allowing the formation pressure to move more fluid into the well bore.

3.2.4.1 There are two types of gas lifts

3.2.4.1.1 Continuous flow of gas lift


A steady rate of gas is injected in the well tubing which aerates the liquid and thus reduces the
pressure losses occurring along the flow path. Due to this reduction in flow resistance of the well
tubing, the original bottom hole pressure becomes sufficient to move the gas- liquid mixture to
the surface. It follows from the mechanism of this lift method that continuous flow gas lift
requires relatively high bottom hole pressure in order to work.

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3.2.4.1.2 Intermittent gas lift

Gas is injected periodically, whenever a sufficient length of liquid has accumulated in the tubing
relatively high volume of gas, injected below the liquid column, pushes that column to the surface
as a slug. Gas injection is then interrupted until an appropriate liquid level builds up again.
Production of well liquids, therefore, is done by cycles.

3.2.5 Sucker rod pumps (SRP)

Fig.6 Sucker rod pump

Mechanical lifting by pumping is another broad group of artificial lift methods, which involves
the use of a pump installed down hole to increase the pressure in the well. The most common
pumping methods being adopted in the world are:

• Rod Pumping: Sucker rod pumping is a down hole positive displacement pump which is
actuated from the surface via rods and reciprocating system. Sucker rod pumps produce
over 80% of oil produced in the world today. Sucker rod pumps are successfully lifting
wells from 100’ to 15,000. The amount of fluid produced ranges from a few barrels a day
to thousands of barrels per day.
• Hydraulic pumping: It is done by a downhole plunger pump coupled to a hydraulic motor,
by jet pump or by centrifugal turbine pumping.

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• Moyono rotary pumping: Lastly, but much less common and designed for very viscous
crude loaded with sand and having high GOR.

Fig.7 Sucker rod pump

3.2.5.1 Components of the Sucker Rod Pump


The nine primary parts of a pump

A. Plungers

Plungers provide the moving, high pressure seal in the pump. This seal is maintained between the
outer surface of the plunger and the inner surface of the barrel while the plunger is reciprocating
within the barrel. The actual pressure differential across this plunger sealing surface is only
present when the traveling valve is closed.

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B. Pin end metal plungers

The pin end metal plunger is the most popular plunger being used in the rod pump market. This
is due to its durability and its standardization by manufacturers and the American Petroleum
Institute. It is provided with a steel base material and a hard, sprayed metal coating, or a hard
chrome plated surface. The threads on each end are on the external part of the plunger.

C. Box end metal plungers

These are similar to pin end metal plungers in function, but they have internal threads on each
end. This plunger is normally used when fluid restriction is a problem, such as in heavy crude
applications. The inside diameter is larger than on pin end metal plungers due to the plunger
having a thinner wall section. It should not be specified when high strength is needed due to this
thinner wall section.

The approach for choosing a plunger to pass these particles is to estimate the diameter of the
particulates, realizing that they will probably be on both side of the plunger at once, and choose a
plunger minus fit that will allow these particles to pass without causing the plunger to stick in the
barrel. This will result in a plunger minus fit that gives slightly more fluid past the plunger, but
extended pump runs should result if the plunger was originally hanging up or sticking due to
particulates. The increased run time and decreased pulling costs over time should easily pay for
the slightly increased production loss due to greater slippage.

Slippage of fluid past the plunger is necessary to lubricate the metal plunger and thus prevent it
from seizing in the barrel tube during operation of the pump. The rule-of-thumb for the slippage
value is two percent of the produced fluid per day. This is an old rule that was developed by trial
and error. If the produced fluid has a high water cut then the slippage may need to be increased to
prevent early pump failure due to lack of lubrication between the plunger and barrel.

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Fig.8 Plunger lift system in SRP

D. Barrels

Metallurgy of the base material: The criteria for selection of a barrel material is that it be strong
enough to withstand the down hole working pressures, have sufficient corrosion resistance to
withstand corrosive attack of down hole well fluids, and have a hard enough inside surface to last
an appreciably long time in abrasive conditions.
The endless variety of down hole conditions had led to development of a number of barrel
materials and coatings or treatments which give the down hole pump an efficient run time before
replacement. The key is to pick the appropriate barrel material so that the pump runs long enough
yet money is not wasted by using a material which is too expensive for the application.
Plain steel: This is an electric resistance welded (ERW), drawn over mandrel (DOM), cold drawn
(CD) carbon steel. It is not “just a piece of pipe.”
It is a high strength material which was chosen with the above listed manufacturing
characteristics so that it is absolutely round on the inside diameter, the wall thickness is uniform,
and it has high cold drawn strength.

This steel tube starts as a flat piece of steel which is precision cold rolled to the wall thickness
needed for the finished tubing. It is then trimmed to the exact width needed and rolled into a
round, long tube shape while being electric resistance welded along the two joined edges. It is
then heat processed so that the weld becomes an integral part of the wall thickness. The weld is
integrated such that it is difficult to find even under a microscope after heat processing.

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The tube is also drawn over a mandrel to ensure that it is absolutely round on the inside diameter.
This is essential for use as a pump barrel, so that it will form a cylindrical seal for the pump
plunger.
The plain steel barrel is the most popular barrel material and is used for mild to moderate
corrosive conditions and mild abrasive conditions.

E. Hard chrome plated

Chrome plating is the oldest method of increasing the inside surface hardness of pump barrels. It
is applied on the inside of the pump barrel since it is used only for abrasion resistance. The
hardness of the plating is HRC 67 minimum and the thickness is three thousandth of an inch per
side (0.003”). This thickness is enough for two reasons. One reason is that a barrel is normally
worn out when it is used in abrasive conditions and wears six thousandths of an inch on the
diameter (0.006”). The other reason is that the coating normally becomes nonfunctional due to
other reasons before it wears out.

F. Standing valve

Function
The only function of a standing valve are to prevent the fluid in the compression chamber from
returning o the formation during the down stroke of the pump, and admit fluid to the compression
chamber during the upstroke of the pump.
The standing valve cage also contains the standing valve ball and seat. The standing valve ball
and seat actually provide half of the sealing actions as the pump alte3rnates between upstroke and
down stroke. On the pump down stroke the standing valve ball and seat close and form a fluid
seal due to fluid trying to return to the formation. This fluid flow pulls he ball downward onto the
standing valve seat ad fluid pressure holds the ball on the seat.
On the pump upstroke the standing valve ball and seat open and allow fluid to flow into the
compression chamber. The opening of the standing valve is due to the formation pressure being
higher than the compression chamber pressure and pushing he ball off of the seat. Then the fluid
flow into the compression chamber keeps the valve open until the compression chamber is full
and the pump reverses direction.

Types of standing valves: Standing valve come in two configurations, “open” and “closed”
Open standing valves are so called because they are installed either above the plunger in traveling
barrel pumps or in tubing pumps such that the fluid passage around the ball can be machined from
the outside of the cage. The advantage of this type of cage is that it has better fluid flow.

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Characteristics than a closed cage there is reduced fluid friction and less chance of the ball being
stuck in the cage due to free particulates in the production fluid.
The standing valve in tubing pumps and traveling barrel pumps are of the open variety. The
tubing pump standing valve has puller threads machined into the top of the cage so that it can be
removed with the tubing pump plunger. Open cages are available in the stellite lined variety to
increase valve life in severe pumping conditions. They are also available in corrosion resistant
materials.
Closed standing valves are installed on the bottom of insert pump barrels or the bottom of
oversize, slim hole tubing pumps. These cages are designed such that the production fluid must go
around the ball inside the cage and exit at the top of the cage, rather than the sides of the cage as
with an open cage. Their flow characteristics are not as good as with open cages, but they must be
used in the closed configuration due to their particular application.

G. Travelling valve

Its function: The traveling valve, moves with the plunger during the upstroke and down stroke of
most pumps. On any pump, during the upstroke the traveling valve is closed and holds the weight
and pressure of the fluid above the traveling valve. In deep wells, this can be a significant force
and result in high hydraulic pressure. The pressure is sealed by the ball and seat. The force is
carried by the outside of the cage and transferred it to the plunger at the cage connection. On the
down stroke of the pump the valve is open and allows fluid to pass through the plunger as it falls
through the compression chamber fluid. As with the standing valve, the traveling valve opens and
closes many thousands of times per day and is therefore subject to several types of damage from
pumping conditions.
This smaller size yields higher fluid velocities through the traveling valve and thus more ball
action when it is off of the seat on the down stroke of the pump. Traveling valves are also
available in a variety of materials for abrasive and corrosive conditions.

H. Balls

Tolerance and grade of balls: there are several dimensional characteristics of balls which are not
easily measured but are very important to the sealing function of the ball and seat. The sealing
surface on a ball is the entire outside diameter of the ball, due to the ball’s freedom to turn within
the cage during pumping. This is good for the sealing system in rod pumps since the sealing
surface is always changing to a fresh surface. The surface of the ball must have a smooth, flaw-
free finish in order to seal against the valve seat on each stroke of the pump. This is assured by the
selection of a Grade 100 or better grade all when the ball is purchased from the ball manufacturer.
These grades are industry standards and specify the surface finish, the tolerance on the ball
diameter and the tolerance on how much the ball can vary from a spherical shape. The sphericity
is important because an out-of –round ball will not seal even if the diameter and sealing surface
finish are perfect. It will have a gap where it should be sealing against the seal and will allow

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fluid to leak between the ball and the seat, probably turned over to use these optional sealing
surfaces. Corrosion and/or abrasion can damage these during pumping and causing leakage.

I. Seat Materials

These generally reflect the metallurgy used in the ball since they are used in the same corrosive
and abrasive conditions. The exception is when the characteristic difference of the sealing nature
of the two causes a difference in material choice as described under the stainless steel ball.

3.2.5.2 Hold – down seal assembly

The function of the hold-down seal assembly is to separate the fluid which is “in control” from
the fluid which is “out of control”. The formation fluid is the out of control fluid because it has
not been brought past the standing valve into the control of the pump. The fluid which is in
control is that fluid which has passed into the control of the pump. The fluid which is in control is
that fluid which has passed into the pump or been lifted above the pup toward the surface.

Types of hold-down seal assemblies: these are two categories of hold-down seal assembly – the
cup type and the mechanical type. These are characterized by the cup type having “soft” sealing
elements in the form of plastic type seals, and the mechanical type as having “hard” sealing
elements in the form of metal seals. Both types of assemblies are used in top and bottom hold-
down type pumps as well as tubing pumps.

The cup type hold-down seal assembly is the more commonly used type of assembly an should be
used unless temperatures are too high for cups, or other factors preclude its use. An advantage of
the cup type is as the cups are pushed into the seating nipple they swab out the inside of the
nipple, pushing any particulates out of the bottom of nipple. This is convenient so that the
particulates do not come between the pressure sealing elements and the seating nipple.
The mechanical type hold-down seal assembly is used when high temp preclude the use of the
cup-type hold-down, or when higher hold-down forces are needed. Since the sealing elements are
metal they are not limited by high down hole temperatures. The higher holding force is due to the
mechanical type hold-down latching mechanically into the seating nipple. This is no normally an
issue once a well has fluid above the pump to the surface, since the weight and pressure of the
fluid column help to hold the pump in the seating nipple. Another use is that some operators use t
whenever sand or other particulates build up on the top of a cup type hold-down. In these cases
the mechanical type hold-down can be unseated easier since it has a smoother outside
configuration and therefore less area for particulates to build on.

~ 20 ~
The top mechanical hold-down configuration has a narrow seal width and is therefore more
successful in sealing in high temperature, high particulate production conditions. The particulates
have a more difficult time in getting trapped in this narrow seal width. With any type of
mechanical seating assembly there is a corresponding mechanical type seating nipple that must be
installed in the tubing string. Also, the top and bottom hold-down mechanical seating assemblies
use different seating nipples.

Materials for hold-down seal assemblies: All of the normal materials for pump parts are
available for the hole-down seal assemblies, stainless steel, Monel, brass or steel. These have their
particular application in different corrosive and mechanical loading conditions. For instance, any
top hold-down pump hold-down carries the alternating fluid load between the upstroke and down
stroke, so that its strength needs to be considered when choosing its material.

3.2.5.3 Geometry and structure of the SRP

Fig.9 Structure of SRP

A motor and gearbox supply power to turn the power shaft. There is a counterweight at the end of
the crank. A pitman arm is attached to the crank and it moves upward when the crank moves
counterclockwise. The Samson arms support the walking beam. The walking beam pivots and

~ 21 ~
lowers or raises the plunger. The rod attaches the plunger to the horsehead. The horsehead (not
rigidly attached) allows the joint (where rod is attached) to move in a vertical path instead of
following an arc. Every time the plunger rises, oil is pumped out through a spout. The pump
consist of a four bar linkage is comprised of the crank, the pitman arm, the walking beam, and the
ground.

3.2.5.4 Explanation and working of a SRP

Fig.11 working of the SRP

Here the plunger is shown at its lowest position. The pitman arm and the crank are in-line. The
maximum pumping angle, denoted as theta in the calculations, is shown. L is the stroke length.
After one stroke, the plunger moves upward by one stroke length and the walking beam pivots.
The crank also rotates counterclockwise. At the end of the upstroke the pitman arm, the crank,
and the walking beam are in-line.

For name and location of parts, see Figure A.

1. A motor supplies power to a gear box. A gearbox reduces the angular velocity and
increases the torque relative to this input.

~ 22 ~
2. As shown in Figure B, (the crank turns counterclockwise) and lifts the counterweight.
Since the crank is connected to the walking beam via the pitman arm, the beam pivots and
submerges the plunger. Figure B also shows the horse head at its lowest position. This
marks the end of the down stroke. Note that the crank and the pitman arm are in-line at
this position.
3. The upstroke raises the horse head and the plunger, along with the fluid being pumped.
The upstroke begins at the point shown in Figure B. At the end of the upstroke, all joints
are in-line. This geometric constraint determines the length of the pitman arm.
4. Figures C (a) and C(b) show the plunger and ball valves in more detail. These valves are
opened by fluid flow alone. On the upstroke, the riding valve is closed and the standing
valve is open. Fluid above and within the plunger is lifted out of the casing while more
fluid is pumped into the well. On the down stroke, the riding valve is opened and the
standing valve is closed. Fluid flows into the plunger and no fluid is allowed to leave the
well.

Figure C(a) Figure C(b)

Fig.11 Working of the SRP

~ 23 ~
3.2.5.5 Main drawbacks of SRP
• Possible flow decreases severely with depth required for the pump. Maximum
performance is approximately 25m3/d (150 bpd) at 300m (10,000 ft) depth and 250m3/d
(1500 bpd) at 750m (2500 ft), depending on the maximum allowable stress on the sucker
rods.
• Reduced volumetric efficiency in wells with high GORs.
• Beam pumping units take up too much space and are too heavy for offshore platforms.
• Initial investment cost is high for sophisticated large capacity pumps, especially for
hydraulic units.
• Major problem for sucker rod strength when there is a corrosive effluent.

~ 24 ~
CHAPTER-IV
GAS LIFT TECHNIQUES

~ 25 ~
4.1 Introduction

Fig.12 Gas Lift for Liquid Unloading

It is an artificial-lift method in which gas is injected into the production tubing to reduce the
hydrostatic pressure of the fluid column. The resulting reduction in bottom hole pressure allows
the reservoir liquids to enter the wellbore at a higher flow rate. The injection gas is typically
conveyed down the tubing-casing annulus and enters the production train through a series of gas
lift valves. The gas-lift valve position, operating pressure and gas injection rate are determined by
specific well conditions.

Gas lift is an artificial method whereby external gas is injected into the produced flow stream at
some depth in the wellbore. The additional gas augments the formation gas and reduces the
flowing bottom hole pressure, thereby increasing the inflow of produced fluids. For dewatering
gas wells, the volume of injected gas is designed so that the combined formation and injected gas
will be above the critical rate for the wellbore, especially for lower liquid producing gas wells.
For higher liquid rates, much of the design procedure may more closely mirror producing oil well
gas lift techniques.

Gas lift is one of a number of processes used to artificially lift oil or water from wells where there
is insufficient reservoir pressures to produce the well. The process involves injecting gas through
the tubing-casing annulus. Injects gas rates aerates the fluid to reduce its density the formation
pressure is then able to lift the oil column and forces the fluid out of the wellbore. Gas may be

~ 26 ~
injected continuously or intermittently, depending on the producing characteristics of the well and
the arrangement of the gas-lift equipment.

The amount of the gas to be injected to maximize oil production varies based on well conditions
and geometries. Too much or too little gas will result in less than maximum production.
Generally, the optimal amount of injected gas is determined by well tests , where the rate of
injection is varied and liquid production (oil and perhaps water) is measured.

The gas-lift mandrel is a device installed in the tubing string of a gas- lift well onto which or into
which a gas lift valve is fitted. There are two common types of mandrels. In a conventional gas-
lift mandrel, a gas lift valve is installed as the tubing is placed in the well. Thus, to replace or
repair the valve, the tubing string must be pulled. In the side –pocket mandrel, however, the valve
is installed and removed by wire line while the mandrel is still in the well, eliminating the need to
pull the tubing to repair or replace the valve.

A gas lift valve is a device installed on (or in) a gas-lift mandrel, which in turn is put on the
tubing string of a gas- lift well. Tubing and casing pressures causes the valve to open and close ,
thus allowing gas to be injected into the fluid in the tubing to cause the fluid to rise to the surface.
In the lexicon of the industry, gas-lift mandrels are said to be “tubing retrievable” wherein they
are deployed and retrieved attached to the production tubing.

Fig.13 Gas lift technique

~ 27 ~
4.2 Types of Gas Lift
The two fundamental types of gas lift used in the industry today are continuous flow and
intermittent flow. This is the conventional breakdown. However, one could say there are gas lifted
wells and there are gas lifted oil wells. Gas wells can also be lifted by continuous or intermittent
gas lift.

4.2.1 Continuous gas lift


In this type of the gas lift technique a stream of relatively high pressure is injected continuously
into the produced fluid column through a down hole valve or orifice. The injected gas mixes with
the formation gas to lift the fluid to the surface by one or more of the following processes:

• Reduction of the fluid density and the column weight so that the pressure differential
between the reservoir and the wellbore will be increased.
• Expansion of the injected gas so that it pushes liquid ahead of it , which further reduces
the column weight , thereby increasing the differential between the reservoir and the
wellbore.
• Displacement of liquid slugs by large bubbles of gas acting as pistons.

4.2.2 Intermittent gas lift


Often in gas wells as the bottom hole pressure declines, a point is reached where the well can no
longer support continuous gas lift and the well is converted to intermittent gas lift. This
conversion can also employ the identical down hole equipment ( mainly the gas lift valve
mandrels) yet fully adapt the well to intermittent flow. In this case , the unloading valves are
replaced with dummy valves to block the holes in the mandrels and prevent injection gas from
passing into the production stream. The operating valve then is replaced with a production
pressure valve with a newly set pressure capacity reflecting the desired fluid level to be reached in
the tubing before the well is lifted.

Fitting the operating valve with the largest possible orifice will greatly improve the efficiency in
an intermittent gas lift system. The large orifice diameter exerts a minimum restriction to the flow
of the injection gas. The injection gas will then quickly fill the tubing below the fluid, ultimately
lifting the slug of liquid to the surface with the minimum amount of lift gas.

It is being common practice to use a plunger to increase the production from wells on intermittent
lift. The lift gas is injected below the plunger and the plunger acts as a physical barrier between
the lift gas and the fluid to reduce the fluid fallback around the gas slug that is characteristic of

~ 28 ~
intermittent lift operations. The plunger extends the life of the well by more effectively removing
water from the formation. A plunger with extensions can be used so that it can pass by gas lift
mandrels if needed. When a plunger is used over a standing valve and the gas lifts the plunger and
liquid slug above a standing valve, this is more similar to a gas –powered long stroke pump or
plunger assisted chamber lift than conventional intermittent lift.

4.3 Advantages of Gas lift


• Most pumping systems become inefficient when the GLR exceeds some critical value, typically
about 500 scf/bbl (90 m3/m3) ,due to severe gas interference . Although remedial measures are
possible for conventional lift systems can be applied directly to high GLR wells because the high
formation GLR reduces the need for additional gas to lower the formation flowing pressure.
• Production of solids will reduce the life of any device that is placed within the produced fluid
flow stream, such as rod pump. Gas lift systems generally are not susceptible to erosion due to
sand production and can handle higher solids than conventional pumping systems.
• For some applications, a higher pressure gas zone may be used to auto –gas lift another zone.
• In highly deviated wells it is difficult to deploy some pumping systems due to the potential for
mechanical damage to deploying electric cables or rod and tubing wear for beam pumps . Gas
lift systems can be employed in deviated wells without mechanical problems.
• Another advantage that gas lift has over other types of artificial lift is its adaptability to changes
in reservoir conditions. It is a relatively simple matter to alter a gas lift design to account for
reservoir decline or an increase in fluid (water) production that generally occurs in the latter
stages of the life of the field. Changes to the gas lift installation can be made from the surface
without pulling tubing by replacing the gas lift valves via wire line and reusing the original down
hole components . However, many onshore lower volume gas lift installations may choose to use
conventional mandrels where the tubing must be pulled to access gas lift valves and to replace
valves.

4.4 Different Types of Gas -Lift Techniques

Traditional gas lift delivers only limited success in long interval environments. Typically, such
as for a reservoir which does not have enough energy to lift fluid from the bottom perforations to
the packer because of this and other reasons, the overall efficiency of the system of the well
becomes poor as the production rate from the well decreases.
These shortcomings may stem from any of several reasons, including the following:
• Gas injection with no packer is generally not preferred
• Velocity strings are not effective due to fluid volumes.
• Cap strings have limited results due to fluid volume and reduced formation gas.

~ 29 ~
On the other hand, newer techniques are able to overcome these shortcomings.

These include the following-


• Retrievable cross-flow assembly
Allowing for a fluid path between the casing annulus and tail allows for injection of gas below a
packer with fluid and gas flow back into the tubing string through the assembly.

• Dead-string with gas-lift


Tubing below the packer with a ported sub to improve velocities across the perforations.

• Annular flow with gas lift


Concentric gas lift mandrels with internally mounted valves are used with injection down the
tubing and production up the annulus.

• Dip tube with gas lift


For horizontal applications, injection is down the casing to a special hanger mandrel above the
tubing, with gas then injected through the valve into a
dip tube landed below the packer.

In case of a reservoir is found of a lower permeability, or is considered to be “tight gas,” it is


important to consider all possibilities in maximizing production. Because a given method might
have worked well on a few select wells or in a different area, there has been a tendency to focus
on that single method of artificial lift. It is important to note that one tool does not solve all
problems.
In fact, over the past few years, gas well optimization methods have become a serious topic of
conversation. A number of the major E&P companies have assembled teams for the express
purpose of surveying multiple wells within a given field to pinpoint the most suitable lift
technique for each well.
Different techniques and methods are being employed these days with trends for combining
multiple zones having leading to longer perforated intervals and a need to optimize gas for
increasing the production rate of the well.

~ 30 ~
4.4.1 Retrievable cross-flow assembly

Fig.14 Retrievable gas lift

This technique is applicable for wells that are producing moderately high fluid rates (less than 400
b/d depending on the tubing size). To be effective, gas injection must occur as deep as possible
below the packer. Possible disadvantages are that solids production can be a problem; slick-line
operations cannot be performed below the packer; and higher bottom hole pressure is required.

On the other hand, there are advantages. This approach:

~ 31 ~
• Allows for injection below a packer to effectively unload the perforation interval;
• Ensures gas injection pressure is kept off the formation;
• Achieves the lowest flowing pressure possible with the packer in place;
• Provides a lower critical rate due to smaller flow area below the packer; and
• Allows chemicals and surfactants to be introduced along with the injection gas, either through
surface injection or cap string.

Gas is injected down the tubing to a valve directly tied into the cross-flow assembly. Gas is then
directed through the port and into the tubing where internally mounted
valves allow injection into the annulus as deep as possible. The tubing below the cross-flow
assembly also acts as a flow-area reduction string (dead string), increasing the gas velocities
below the packer. The combination of injection gas and reduced flow area allows for maximum
productivity. Fluid and gas are then directed into ports on the outside of the assembly back into
the tubing above the packer and to the surface.

4.4.2 Dead string with gas lift

This technique is suitable for wells producing higher fluid rates, where it is not possible to
effectively inject gas deeper than the packer or the top of the perforated interval.

Possible disadvantages of this technique include the following:


• Solids production can be a problem;
• Blockage/bridging around the dead string can occur.
• It’s not possible to perform slick-line operations unless the tubing string is pulled, although a
retrievable plug could be used and
• An incorrect dead-string design could cause a down hole flow restriction.
On the other hand, advantages include the following:
• Effective unloading of a long interval is achieved via improved velocities;
• The packer ensures injection pressure is kept off the formation;
• A lower flowing bottom hole pressure is achieved and
• Chemicals or surfactants can be introduced into the system through the gas-lift valves or a cap
string. Below the packer, a dead string with a perforated sub is landed directly below the packer
and a bull plug is installed. The dead-string design must be based on achieving the most effective
flow area and least amount of friction pressure.
The resulting reduced flow area below the packer increases velocities and lowers the critical-rate
requirement. Fluid is directed above the packer and lifted to the surface via the operating valve
directly above the packer.

~ 32 ~
4.4.3 Annular flow with intermittent gas lift

This option is suitable for wells producing moderate fluid rates where it is not possible to
effectively unload using a plunger system or a cap string. It is best applied where the bottom zone
or zones are known to be strong contributors to overall flow.

One of the disadvantages of this approach is that it is not possible to perform slick-line operations
unless the tubing string is pulled. In addition, it is very important to determine flow area
requirements properly, as friction pressure could hinder production (similar to a dead-string
design). Finally, the technique may not be viable if CO2 or H2S are present or a corrosive
environment exists and exposure to the casing is not recommended.

However, there are substantial advantages too:


• Effective unloading of the entire interval is possible;
• Injection pressure is contained in the tubing and kept off the formation;
• The lowest flowing bottom hole pressure is achieved based on the fact that the fluid is being
cleared as deep as possible.
• Chemicals and surfactants can be introduced into the system through the gas-lift valves.
• Solids are not a problem
• Unloading periods are shorter since the tubing is dry – only the casing is filled with fluid.

In this approach, concentric mandrels with internally mounted valves are used with injection
down the tubing. In this way, injection gas can be introduced as low as possible in the perforated
interval, with flow up the annulus. The tubing also is used as a reduction string, improving
velocities in the annulus and helping reduce the critical rate requirement. Note that the system
does not require as many valves as are required with other approaches the tubing string is dry to
begin with and no unloading valves are necessary.

4.4.4. Dip tube gas injection

This technique is suitable for horizontal wells that are producing too much fluid for a plunger
system to be effective, i.e., the plunger cannot get deep enough to lift fluid. The main design
parameters for the system are fluid rate and reservoir pressure.

One of the major disadvantages to this system is that it is not possible to perform slick-line
operations unless the tubing string is pulled. Solids can be a problem, due to washing of the

~ 33 ~
standing valve or plugging of the slotted pup. The system is also fluid-rate restricted, so it is best
suited for wells producing less than 200 bbl/MMcf/d.

Advantages to the system are that it creates a more consistent inflow from the reservoir and
effectively reduces flowing bottom hole pressure. Both cases result in increased production. This
is a contained system below the packer; so injection gas is kept off the formation. And the system
is able to operate at lower than normal reservoir pressures (minimum of 400 psi).
Injection flows down the casing to a special hanger mandrel above the tubing. Gas is then injected
through the valve into a smaller dip tube, landed below the packer. The production tubing extends
below the packer into the horizontal section (typically 700 ft MD). Section length actually is
dependent on the deviation of the horizontal section, and ideally extends into the 90° section
where fluid is suspected to be accumulating. The dip-tube string is typically 1 in. to 11⁄4 in. in-
line pipe. By introducing gas injection deeper into the leg, the amount of injection is less than it
would be if it were done above the packer only.
The dip tube is equipped with a standing valve and slotted nipple or pup joint. The standing valve
allows fluid to enter into the tubing without surging back. Dip tube injection assists the fluid up
past the packer and into the tubing string to the surface. The tubing below the packer also assists
in bringing better velocity deeper into the well.

Success at increasing the performance of gas wells using artificial lift methods begins with
accurate collection of well data, including reservoir and surface
pressures, and production history. With so many options available, improved production and
reduced operating costs requires thoughtful first-time selection of the correct artificial lift means.
Understanding the parameters for successful application of each artificial lift method ensures
substantial benefits.

4.5 Working of a Gas lift

Before gas lift injection begins, the fluid levels in both the tubing and casing are at the surface.
The pressure of the weight of this fluid holds the valves open
With reference to figure-15

The gas injection into the casing is done such that all the fluid is U-tubed through all open valves
& no formation fluids is being produced all the fluids is present in between the tubing and casing.

~ 34 ~
Fig.15

From fig- 16
The fluid is being now unloaded to top (#5) valve and the fluid is then aerated above this point in
the tubing and fluid density decreases .The pressure gets reduced at the top valve and also at all
the lower valves and this unloading continues throughout the lower valves.

Fig.16

~ 35 ~
From fig.17

Now the fluid level is below valve #4 this injection gets transferred to valve#4 and the pressure
gets lowered. Also the casing pressure drops and the #5 closes but the unloading continues
through lower valves

Fig17

From fig18
All the gas is being injected through valve#4 but the lower valves continue to remain open a
reduction in the casing pressure causes upper valves to close in sequence.

~ 36 ~
Fig.18

From fig.19
All the gas is being injected through valve#3 and a reduction in casing pressure causes upper
valves to close in sequence. Lower valves remain open .

~ 37 ~
Fig.19

From fig.20
Valve#2 is gets open this the point of gas injection that is here the ability of reservoir to produce
fluid matches the ability of the tubing to remove fluids. Casing pressure is dictated by the
operating valve set pressure and the upper valves are closed. But the valve#1 remains submerged
unless operating conditions change in the reservoir (i.e. formation drawdown)

~ 38 ~
Fig.20

~ 39 ~
CHAPTER- V
TYPES OF GAS INJECTION CONTROL

~ 40 ~
Types of gas injection control

There are numerous ways which exist in of controlling the injection of the gas to a well.
The type of installation (continuous or intermittent flow) influences the type of control to a large
degree.
Different types of gas injection controls are –
1. Choke control
2. Regulator control in conjunction with a choke intermittent flow
3. Time cycle controller

5.1Choke control
In continuous flow it is the most probably the best and simplest method of control here in a choke
is being installed on the injection gas line and is sized to pass the desired volume of gas into the
tubing string. The choke size of the well can be determined by trial and error which can be then
used for the gas injection.

Whereas in the case of an intermittent flow type of the gas well the choke control can be used in
controlling gas injection to intermittent flow wells utilizing unbalanced gas lift valves with
enough spread. This type of control may require much more attention before finding the correct
surface choke size. The injection gas rate must be timed to coincide with the well feed in
characteristics.

Use of an excessive spread will cause the use of too much gas whereas too little spread will cause
the well to load up. A valve with a large spread or marked tubing pressure sensitivity is best
suited for this type of operation

5.2 Regulator control in conjunction with a choke intermittent flow


A regulator is used in series with a choke so when casing pressure builds up to the desired
pressure before the end of the waiting period necessary for the tubing fluid pressure build up, the
regulator will shut off the gas. This means that the choke sizing does not have to quite as sensitive
generally a choke somewhat larger than normally needed can be installed since the regulator will
prevent the choke from allowing too much gas to enter the annular space.

~ 41 ~
5.3Time cycle controller
Continuous flow: This is not recommended type of control for continuous flow as by placing a
time cycle controller on short fast cycles the required amount of gas is injected through a large
seat. And with this type of a controller activity the effective removal of the slug from the well
may also not take place.

Intermittent flow: A time cycle controller or intermitter is the most common means of injecting
gas control foe intermittent flow and is quite easily adjusted. A controller at the surface can be
adjusted to inject gas for almost any length of time and for almost any time interval.

~ 42 ~
CHAPTER- VI
(CASE STUDY)
DESIGNING OF GAS LIFT VALVES FOR THE
OS-9A Well

~ 43 ~
6.1 Data used for the calculation of the designing of the Gas Lift
Valves for the OS-9A well

I. Designing of the GLV of OS-9 with 60% water cut


Depth= 1216-1221 meters

Average reservoir pressure= 1265psia

q L= 1600 barrels (60%) water cut.

Total water produced= 1600x60 = 960 barrels of water & 640 barrels of oil.
100
Barrels m3 (640x.159) = 101.56m3

Tubing size used = 31/2 “


Productivity index= 4.3bopd/psi

Gas gravity =0.59

Bottom hole temperature= 194o F

Surface temperature= 158oF

Surface operating pressure (Pso) =420 psia

Kill off pressure (Pko)= 520 psia

Well fluid gradient= 0.433psi/feet

Pressure at the well head= 200psi.

Bubble point pressure Pb= 895.7psia

Valve closing pressure (Pvc) = 25x420 = 105 + 200 = 305 psia.


100

~ 44 ~
Fig.21- Gas lift valve design of OS-9A well with 60% water cut

Determination of the point of gas injection-

1. Plot the depth scale on vertical (0-1600) meter


2. Plot pressure scale on horizontal (0-1500) psia
3. Plot Average reservoir pressure 1265 psia at 1221 meters depth.
4. From the PI ( productivity index) calculate the pressure drawdown necessary to give the
desired production rate:
Drawdown p= qo = 640 = 148.33psia
P.I 4.3

Where qo= total oil rate


P.I = productivity index

5. Subtract the drawdown from the static BHP to obtain the flowing BHP:

~ 45 ~
( pwf)=Pr - p = 1265-148.837 = 1116.16 psia

6. From the point of static BHP extend the static gradient line up the hole until it intersects
the ordinate. Which is at 460 feet giving the static liquid column.
7. Mark on the abscissa the surface operating pressure Pso i.e 420 psia and the well kick off
pressure Pko which is 520 psia.
8. From the point of flowing BHP extend the line until it intersects with the Pso which gives
the point of balance i.e the pressure balance between the casing and tubing mark this point
(810 meter).
9. Subtract 100psia from the pressure at this point and return up the hole a distance
equivalent to this 100 psi on the flowing BHP line note this as the point of gas injection
(750 meter).
10. Next find the total gas injection necessary-
(Total G/L-Rs)*qo= Gas Volume
Where Rs= Solution gas-oil ratiọ
Rs(SCF/STB)=γg(p/18 x 100.0125(API)/ 100.00091(T) ) 1.2
On calculation Rs= 254.2106 SCF/STB or (divide by 35.3 and multiply with 6.289)
45.2898 m3
Static liquid column calculated is 460 meter
Tota1 G/L= 150 therefore on calculating the total gas injection = 10575m3/day.
Tubing
Casing Surface Pressure pressure
Depth
Valve Pressure operating valve at Temperature
TVD (o
Number (Pc) (Pso) closing(Pvc) transfer F)
(Meter)
Psia Psia Psia point
psia

1 500 520/420 420 380 430 170

2 580 419 420 410 450 172

3 660 418 420 408 458 174

4 730 418 420 409 459 176

Table1- Gas lift valve design for OS 9A with 60% water cut

~ 46 ~
6.2 Designing of the Gas lift valve for the OS-9 with 90% water cut

Depth= 1216-1221 meters

Average reservoir pressure= 1265psia

q L= 1600 barrels (90%) water cut.

Total water produced= 1600x90 = 1440 barrels of water & 160 barrels of oil.
100
Barrels m3 160x.159= 25.44m3

Tubing size used = 31/2 “

Productivity index= 4.3bopd/psi

Gas gravity =0.59

Bottom hole temperature= 194o F

Surface temperature= 158oF

Surface operating pressure (Pso) =550 psia

Kill off pressure (Pko) = 650 psia

Well fluid gradient= 0.433psi/feet

Pressure at the well head= 100psi.

Bubble point pressure Pb= 895.7psia

~ 47 ~
Determination of the point of gas injection-

1. Plot the depth scale on vertical (0-1600) meter


2. Plot pressure scale on horizontal (0-1500) psia
3. Plot Average reservoir pressure 1265 psia at 1221 meters depth.
4. From the PI ( productivity index) calculate the pressure drawdown necessary to give the
desired production rate:
Drawdown p= qo = 160 = 37.2psia
P.I 4.3

Where qo= total oil rate


P.I = productivity index

5. Subtract the drawdown from the static BHP to obtain the flowing BHP:
( pwf)=Pr - p = 1265-37.2 = 1227.8 psia
6. From the point of static BHP extend the static gradient line up the hole until it intersects
the ordinate. Which is at 460 feet giving the static liquid column.
7. Mark on the abscissa the surface operating pressure Pso i.e 550 psia and the well kick off
pressure Pko which is 650 psia.
8. From the point of flowing BHP extend the line until it intersects with the Pso which gives
the point of balance i.e the pressure balance between the casing and tubing mark this point
(830 meter).
9. Subtract 100psia from the pressure at this point and return up the hole a distance
equivalent to this 100 psi on the flowing BHP line note this as the point of gas injection
(770 meter).
10. Next find the total gas injection necessary-
(Total G/L-Rs)*qo= Gas Volume
Where Rs= Solution gas-oil ratiọ
Rs(SCF/STB)=γg(p/18 x 100.0125(API)/ 100.00091(T) ) 1.2
On calculation Rs= 254.2106 SCF/STB or (divide by 35.3 and multiply with 6.289)
45.2898 m3.

Tota1 G/L= 200 therefore on calculating the total gas injection = 3936.61m3/day.

11. Find the point of the valve closing pressure by adding 25% of the Pso to the well head
pressure which is 237.5 from this point extend the line until it intersects the point of gas
injection.
12. Point of balance – 830 meter, Point of gas injection- 770 meter, static liquid level – 475
meter.

~ 48 ~
Fig22- Gas lift valve design of the OS-9 well with 90% water cut.

~ 49 ~
Tubing
Casing Pvc valve
Valve Depth pressure Temperature
pressure closing o
No. meter at transfer F
at depth Pressure
point

1
520 550/650 380 430 173

2 620 540 410 460 176

3 680 545 430 480 178

4 740 540 440 490 180

Table-2 Result Gas lift valve design of OS-9A with 90% water cut

~ 50 ~
CHAPTER -VII
ANALYSIS AND TROUBLESHOOTING OF
GAS LIFTS

~ 51 ~
7.1 Analysis and troubleshooting
There are many ways to analyze both the continuous & intermittent flow installations. These can
be divided into detailed methods and observation methods. Some of the checklist which needs to
be followed is as follows-

1. Is the wing valve open?


2. Is valve on gas line?
3. Is there a choke in the flow line?
4. Is the master valve open?
5. Is the gas injection input choke freezing up?
6. What is the injection gas pressure?
7. Is the well producing on emulsions?
8. What is the well head pressure?
9. What is the separator pressure?
10. What is the flowing wellhead temperature?
11. What tubing size is in the well?
12. What is the flow line size?
13. What is the flow line length?
14. Is the choke body still in the wellhead?
15. Are other restrictions still in the surface well head?
16. What is the gas injection rate?
17. What is the producing rate of the oil, water, gas?
18. Is the well on intermittent or continuous flow?
19. Does the well have a history of making paraffin, forming scale, severe corrosion?
20. Do we have a copy of the valve installation record to compare with records of what was
supposed to be installed?

In the case of the continuous type of flowing wells there is a tendency to over inject the gas into
well when the well is not making its required production and to leave the installation alone when
the well flow appears reasonable.

Although a considerable improvement can be made to the well performance by a thorough


analysis of the wells performance.

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7.2 Measures for analyzing continuous flow gas-lift installations
The following list summarizes the various measurements and procedures used to analyze
continuous flow gas-lift installations

1. Recording surface pressures on tubing and casing


2. Measurement of gas volumes
3. Surface temperature readings
4. Visual observation of surface installation
5. Gauging well for oil and water production
6. Subsurface pressure surveys
7. Subsurface temperature surveys
8. Combination flowing temperature and pressure surveys
9. Fluid level determination by acoustic methods.

On the other hand for the case of the intermittent gas lift performance should also me made which
can be done in by changes in the surface regulation off the injection gas may be all that is required
to improve gas-lift efficiency. A good indication of intermittent gas- lift performance can be
obtained from the surface data. Both the surface casing and surface tubing pressure of a gas lift
installation are important for indicating the performance of the operation.

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CONCLUSION

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Need of the gas lift valves in the OS -9A well
The OS-9A well asset of the Niko Resources Limited at the Hazira offshore is a oil producing
well which has its producing interval in the sand zone of (P3E2 SAND). The well has its
perforated interval at 1216-1221 meters TVD & it has the following reservoir parameters-
1. Effective permeability to oil “k” from buildup – 1550.1 millidarcy.
2. Flow capacity “k h”- 53908.7 Millidarcy –feet
3. Static bottom hole temperature- 80.9 Celsius
4. Extrapolated Reservoir pressure at MPP (1218.5) TVD P*- 1265 psia.

The well bore parameters of the well are


Apparent skin factor - +62.7
P skin - n/c
Flow efficiency- n/c
The Productivity index of the well is found out to be 4.3 bopd/psi.
Sands like Babaguru, Tarkeshwar and Lower Channel Sands are found in the reservoir.
Overtime there has being a decline in the reservoir pressure of the well factors which have caused
this decline in the production are water cut problems, conning, and slippage factor.
The increase of water cut % in the reservoir causes an increase in the hydrostatic level in the well
making it difficult for the well to produce effectively because of the influx of the water and the
density difference between the water and oil which leads to the problem for the oil to flow from
the well effectively.
To overcome these water loading problems in the well use of soap sticks is made which help in
unloading the well by converting the water into froth thereby making the well to flow easily. Also
the use of artificial lift methods is done which can be either a sucker rod pump or a gas lift
method.

Present problems being faced at the OS-9A well

The OS-9A well has a continuous type of gas lift installed .The design of GLV of the OS-9A has
a high setting pressure which is about 460 psia & this high pressure has been causing problem for
its proper working.
So the first gas lift valve has been replaced with circulating valve for the unloading of the water
from the well.
Later with time there would be an increase in the water cut in the well thereby it will lead to water
loading in the well and the present design parameters would not be so effective.

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Solution to the problems of OS-9A well

I have designed the gas lift valves with the given reservoir parameters and with a consideration of
60% and 90 % water cut for the OS-9A well with a consideration of the surface operating
pressure of 420 psi for the 60 % water cut and 550 psia for the 90% water cut & from the
calculation it has been found that there would be requirement of about an average of
7255.805m3/day gas injection requirement in the well for it to produce 1600 barrels of liquid per
day. Other data like the depth setting of the valves and other details has been shown under the
case study report reference fig.21, 22 & table-1, 2.

A requirement of compressor is also desired because at the water cut rate of 90 % there would be
high requirement of the gas injection pressure in the well which can only be solved in by use of a
compressor as the pressure surface operating pressure will not be self sufficient for gas injection
into the well as the desired pressure would be high.

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References
1. Sahay, Bhagwan: “Petroleum exploration and exploitation practices”. Allied
Publishers’ Limited
2. Karan, M.P: “Basics of Upstream Petroleum Industry”
3. Brown, Kermit: “The Technology of Artificial Lift Methods Volume .2a Introduction of
Artificial Lift Systems Beam Pumping: Design and Analysis Gas lift” Penn Well
Books, Penn well Publishing Company, Tulsa, Oklahoma
4. Mathur, Kumar Satish: “Energy & Environment Dictionary” .Technology
Publications, Dehradun
5. Teletzke, G.F, Wattenbarger, R.C and Wilkinson, J.R “SPE, ExxonMobil Upstream
Research Company, Paper journals SPE 118055 Enhanced oil recovery Pilot Testing
Best Practices”
6. Society of Petroleum Engineers, www.spe.org
7. JPT Journals, Oil & Gas Journals, E&P Journals.

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