CONTINUOUS FLOW GAS LIFT DESIGN INTRODUCTION Continuous flow gas lift is analogous to natural flow, but there are gener- ally two distinct flowing pressure traverses. The traverse below the point of gas injection is based upon only the formation GLR; whereas, the traverse above the point of gas injection includes both the formation plus the injec- tion gas. The advent of reliable multiphase flowing pressure gradient curves provided the means to properly design a continuous flow installation and predict the production performance of a well. Gradient curves completely changed the design techniques employed by gas lift design engineers. Maximum production rates could be estimated for the available injection gas volume and correct port sizes could be selected. Valve depths could be accurately calculated rather than being located by a “hit-and-miss" scheme based upon previous ex- perience. Installation design techniques vary with the construction and operating per- formance characteristics of the gas lift valves being employed. This section restricts the design calculations to several types of injection pressure op- erated gas lift valves. Some manufacturers claim significant advantages for their particular construction over their competitors’ equipment. Unfortu- nately, many of these claims are not factual. Several of the more widely used injection pressure operated valves can be described as follows: 1) single-element, unbalanced, bellows-charged; 2) single-element, unbalanced, spring-loaded, proportional response; 3) single-element, unbalanced, bellows~charged, choke upstream of ports._ 4) bellows-charged, variable orifice, throttling stem; ca 5) bellows-charged, differential opening, pressure closing; and 6) charged resilient element, balanced. Although most installation design schemes for injection pressure operated valves include the flowing pressure in the production conduit, the design calculations for the production pressure operated (fluid operated) valve are presented in a separate section.This page and several other pages were reprinted by permission from the Camco Gas Lift Manual. related to a particular manufacturer or Continuous flow ges lift is similar to natural flow. Continuous flow operation consists of con- tolled injection of high pressure gas into a flowing fluid columa to cause aeration from the point of gas injection to the surface to obtain a flowing BHP for a desired tate of production. Injection gas supple ments the formation gos and lightens the flowing The principles outlined on these pages are not design technique. pressure traverse above the point of gas injection to deliver fluid to the surface. MECHANICS OF CONTINUOUS FLOW OPERATION ‘The mechanics of continuous flow operation are iMlustrated in Figure S-1. The flowing BHP in a continuous flow installation can be calculated as follows: Pont Gry Gry Flowing Pay Average [yy] averse [Lap Low Botton Flowing Flowing | Depth] Flowing | Depth Depth Hole. Wellhead , Pressure | of |, Pressure | to _ of | gy Pressure Tubing * Gradient | Oper.|* Gradient [Center Oper. atCenter Pressure Above | Vaive| Below | of Valve atPerts. sig) Point of Lt.) | Point of | Perts. (t.) (sig) Gas Inj. Gas Inj. (i) Grist) Gosiste =f Sta Tek tang Yar tg 7-2‘A flowing pressure gradient above the point of gas injection always exists during continuous flow ‘operation. The minimum flowing BHP is a function of the minimum flowing pressure gradient above the point of gas injection. The important criterion is the depth to the point of gas injection and not the total depth of the well. Whether a well is in the continuous flow or intermittent lift category depends Primarily on the producing rate, the flowing BHP tequired for this producing rate, and the point of gas injection necessary to obtain this flowing BHP. ‘The relationship of injection gas pressure, depth of lift and injection ges requirement is illustrated in Figure 5-2. For a given flowing pressure traverse below the point of gas injection (given flowing BHP ‘and producing rate), the deeper the point of gas injection, the lower the injection GLR and the higher the operating injection gas pressure will be. For a given injection gas pressure and producing rate, the deeper the required point of gas injection and the higher the injection GLR will be. The lower the PI. for the same static BHP, the deeper the point of gas injection and the higher the injection GLR for a given producing rate until the flowing BHP required for this producing rate can no longer be attained by continuous flow. APPLICATIONS OF CONTINUOUS FLOW Continuous flow rather than intermittent lift is recommended for ges lifting most wells which can be lifted efficiently in this manner. Continuous flow is also recommended: 1. For gas lifting extremely high capacity wells. If the capacity of the tubing is exceeded, casing flow is recommended. 2. For wells in which surges in flowing BHP result in sand of water influx. 3. To eliminate pressure and injection gas vol- ume surges in the high and low pressure systems of a closed rotative system. 4. For wells producing sand-laden fluids to prevent sand bridging in the tubing. 7-3 5. For some high viscosity crude production if the average flowing temperature of the crude ined high enough to keep the viscosity of the crude low in the well. can be mai 6. For back-flowing water disposal wells. 7. For gas lifting through small conduit 8. For gas lifting many wells with extremely high GLR's although the producing rates may be low. ADVANTAGES OF CONTINUOUS FLOW ‘The advantages of continuous flow compared to intermittent lift are as follows: 1. The energy of expansion of the injection and formation gas is utilized to the flowing well- head tubing pressure. In intermittent lift, the injection gas pressure in the tubing immediately behind 2 liquid slug at the instant the liquid slug surfaces cannot be utilized for the lifting process. Injection gas for a continuous fiow installa tion enters the well and is produced at a relatively constant rate which eliminates capacity problems in the low and high pres sure systems. 3. A constant flowing BHP is possible in most wells with continuous flow. 4, Most continuous flow installations require only choke control of the injection gas. LIMITATION OF CONTINUOUS FLOW The primary limitation is the minimum flowing BHP (maximum drawdown) possible. A continuous flow installation cannot compete with pumping if 2 high producing rate is required from a well with a ‘working fluid level near total depth. Although the maximum producing rate by gas lift is less, gas lift is employed for some installations due to lower operating costs.err mn reer (1) pee Oa en Gs Puy, Dp te Pt Ge i ane in CLR Pat tree Pi Yad SE Rag pe Pa (8) Lice he PL, Dat Plt toot dither nnn Sn Ping ae. 7-4 Cameo, IncorporatedGAS LIFT VALVE SPACING EQUATIONS Spacing equations are used for calculating valve depths which permit unloading » well to a desired point of gas injection with the available injection pressure, The depth of the operating valve is based fon well characteristics and permits allowable or capacity production by gas lift with the available operating injection gas pressure and the minimum injection ges requirement. STATIC FLUID GRADIENT USED IN VALVE SPACING EQUATIONS. The static fluid gradient used for calculating valve depths in an installation is based on the iquid in the well at the time it is placed on ges Lif. The load fluid in the casing and tubing is produced before formation fluid can enter the tubing. A flowing gradient based on the load fluid, produc- ing rate and zero GLR is used to locate all valves except the top valve in most continuous flow instal- lations. Little aeration of the load fluid can be expected from formation ges until the well hes partially or completely unloaded. DEPTH OF TOP VALVE ‘The depth of the top valve should be as deep as possible based on the injection gas pressure end well conditions. Moximum Kickoff Injection Gos Pressure — If the fluid level is near the surface, the depth of the top valve is based on the maximum kickoff injection gas pressure available at the well. If a well is unloaded into the separator, the depth of the top valve is calculated using the following equation: Pio Poy L, _ Kickotf Injection Wellhead pat, Sas Pressure. — Tubing Pressure Ps i of Top = E218) : (psig) Valve s tt) Static Fluid Gradient @si/ft.) 52 Ifa well is unloaded into a pit, the wellhead tubing pressure term (P,,,) can be omitted. In Equation 5-2 a differential between the injection gas pressure and the tubing pressure at valve depth results from the increase in gos pressure with depth due to gas column weight. Since the fluid in the casing is Ustubed until the top valve is uncovered, little pressure differential is required. Static Fluid Level - If the static fluid level is below the calculated depth L, based on the maxi- mum kickoff injection gas pressure, the top valve ccan be located at the static fluid level, If the static Avid level is located by wireline after the tubing is pulled, consideration should be given to the liquid displacement of the tubing and packer and the possibility of fluid feed-in between the time the fluid level is located and the gas lift valves are If a well is loaded and going to be swabbed after running gas lift valves, the top valve can be located at the static fluid level. Occasionally, the top valve is spaced a shavt distance below the static fluid level based on the ratio of the capacity of the casing annulus to the capacity of the tubing and the injection. gas press ‘This practice is not recommended for tubing flow be- cause an exact fluid level is seldom known due to the displacement of the tubing and packer and fluid feed-in before the tubing can be run and the well kicked off. This procedure for locating the top valve is recommended for many casing flow installations ‘since the tubing rather than the casing is filled with ges. Depressed Fluid Level—The top valve is located at 2 depressed fluid level in some wells if the for- mation will take liquid and this depressed fluid level can be attained. No standing valve can be in the tubing during unloading of an installation with a packer. Injection pressure is applied to the tubing and casing simultaneously. This pressure must be.- maintained until the depressed fluid level is reach- ed. The depressed fluid level is calculated by subtracting @ liquid columa in feet equal to the inject from the static fluid level based on zero wellhead tubing pressure. A safety factor should be used in the calculations such as subtracting 100 psi from the available injection pressur n pressure divided by static fluid gradient 7-5DEPTHS OF REMAINING VALVES, ‘The equation for calculating the distance be- tween casing pressure operated valves (includes valves for casing flow) is derived by equating tub- ing and injection pressures at the same depth. Figure 5-3 is presented for clarification of the symbols used in the equations. Since the deriva: tion is based on 2 well unloading into the separator, the wellhead tubing pressure term appears in the equation. Maximum injection pressure is required at the instant @ valve is uncovered, immediately before gas enters the tubing and aerates the static fluid column between the valves. Any valve above the fluid level is an uncovered valve. Before a valve is uncovered, the casing pressure at valve depth is equal to the injection gas pressure above the fluid level plus the pressure exerted by the liquid column above the valve. At the instant 2 valve is uncovered, the tubing pressure is equal to the injection pres- sure at this depth. The tubing pressure at the depth of the valve just uncovered at the instant before injection gas enters the tubing is calculated as follows: REL = Ry + Gi, (OVA) + G, (OBV) R Pon * Gra! 2 53 Substituting injection pressure at valve depth for tubing pressure: P, @L = Ry + Gy, (DVA) + G, (BV) 54 Solving for distance between valves: ppv = ROL Bn ~ Sra OVA ss G, ‘Therefore, depth of valve: DOV = DVA + DBV 56 Where: DBV = Distance between vaives, ft. DOV = Depth of valve, ft DVA = Depth of valve above, ft. Gz, = Flowing pressure gradient above point of gs injection, psi/ft. G,,= Static fluid gradient, psi/ft. Pe L = Tubing pressure at valve depth, psig injection gas pressure at valve depth, psig ‘owing wellhead tubing pressure, psig, Equations 5-5 and 5-6 apply to spacing all valves below the top valve, The depth of the valve ‘above (DVA) is depth Ly for spacing the second valve, depth L. for spacing the third valve, etc. 7-6 ‘A basic assumption in the derivation of the equa- tion for the distance between valves is that each succeedingly lower valve can be uncovered. It is not valid for a continuous flow installation unless. the next lower valve can be uncovered while the valve above remains open. ‘The injection pressure must be greater than the tubing pressure at valve depth when a valve is uncovered in order that injection gas will enter the tubing. For design of continuous flow installations, the injection gas pressure at depth for calculating the distance between valves is based on the reopen ing pressure of the second valve above. In an intermittent installation the closing pressure of the valve above at valve depth is substituted for the P,@L term in Equation 5-5, FLOWING TUBING PRESSURE GRADIENT USED IN VALVE SPACING EQUATIONS ‘A flowing tubing pressure gradient above the point of gas injection in a continuous flow installa tion is obtained from Camco’s Gradient Curves or calculated by the volumetric balance method. A spacing factor instead of a flowing pressure gradient is used for intermittent lift desiga. amen. TaearnaratedCONTINUOUS FLOW INSTALLATION DESIGN USING SINGLE-ELEMENT, UNBALANCED, BELLOWS-CHARGED GAS LIFT VALVES An understanding of the mechanics involved in unloading a well with single- element unbalanced valves provides an insight into the unloading mechanics using other types of gas lift valves. The unloading sequence is automatic when the installation is correctly designed and the injection gas rate is properly adjusted. Naximum kick-off injection gas pressure available at the well site is used for locating the depth of the top valve. This valve is stationed at the deepest possible depth that will assure uncovering while U-tubing the load fluid. The-depth of the second valve is based on the full operating injec- tion gas pressure. The third valve depth is based upon the reopening pres- sure of the top valve, the fourth valve depth on the reopening of the second valve, the fifth valve depth on the reopening of the third valve, and so on. The valve immediately above must remain open to pass gas for lowering the flowing gradient above the point of gas injection until the next lower valve is uncovered and becomes the point of gas injection. All remaining upper valves in the installation should remain closed. The calculated opening pressure of the top valve is based on the full operating rather than the maximum kick-off injection gas pressure at the well site. The opening pressure of the second valve is based on the reopening pressure of the top valve; i.e., the opening pressure of each valve is based upon the reopen- ‘ing pressure of the valve immediately above. A lower valve must remain open with the decrease in casing pressure required to keep all upper valves closed. In summary, the valve depth is based upon the reopening pressure of the sec- ond valve above, and its set opening pressure is based upon the reopening pressure of the valve immediately above for the third and remaining valves. 7-7caMCO, INC.FLOWING PRESSURE TRAVERSES ILLUSTRATING THE UNLOADING SEQUENCE FOR CONTINUOUS FLOW GAS LIFT UNLOADING OPERATIONSSAFETY FACTORS IN CONTINUOUS FLOW INSTALLATION DESIGN The installation design procedures presented in this chapter are based on a continuous unloading sequence. Valve depths and operating pressures in a well are based on the flowing tubing pressure and injection gas pressure at each valve depth. Most installation design techniques were developed to permit unloading a continuous flow installation with a minimum, if any, Toss in injection gas pressure. A graphical procedure is usually reconmended for locating the valve depths. An advantage of a graphical method is the im- probability of making a serious mistake in the resulting determinations since a significant error will generally be readily apparent in a graphical solu- tion. Most design methods include several safety factors and these factors are recommended for the following reasons: 1) an error in well data which would affect injection gas volume or injection gas pressure at depth; 2) an error in valve operating temperature for temperature sensitive valves; 3) a slight error in setting the valve opening pressure in a tester, particularly if the valve opening pressure must be set in the field; and 4) to overcome the load rate of the gas lift valve, which means that a given psi increase in pressure is required to obtain sufficient stem travel of a gas lift valve. Several safety factors which are incorporated in the design of a continuous flow installation are: 1. A pressure differential across the valve of 50 psi is recommended and used for determining valve depths in most installations. Gen- erally, only a few psi differential would be required theoretically if all assumed data were absolutely correct. 2. The maximum tubing pressure at valve depth used to calculate the reopening pressure of a valve is based on the maximum flowing tubing pressure at this depth while lifting from the next lower valve with the assumed pressure differential across the lower valve. The minimumflowing tubing pressure at valve depth is opposite the upper gas lift valves at the instant a lower valve is uncovered. However, gas lifting may occur from the lower valve depth with the flowing tubing pressure equal to, or near, this maximum flowing tubing pressure. 3. A pressure gradient based on a flowing load fluid gradient curve is used to locate the valve depths. This condition should not exist for the lower valves when the flowing BHP is less than the static BHP and reservoir fluid feed-in occurs. 4. The total producing GLR is assumed to be the injection GLR during unloading operations for the traverse above the point of gas in- jection. In most installations some formation gas will be pro- duced before the unloading operations are completed. 5. Génerally, the unloading traverse for locating the valve depths is based on the desired producing rate and injection gas volume avail- able to unload the well. The actual unloading producing rate can be controlled by varying the injection gas volume. Decreasing the choke size in the injection gas line will decrease the injection gas volume and producing rate during fluid transfer from casing to tubing. Therefore, for high capacity wells a minimum fluid gradient traverse for a lower producing rate may exist until the deliverabil- ‘ity of the well approaches the desired producing rate. Not a1] of the above safety factors will be recomended for all installation design methods. Although many of these factors may be used, the manufactur- ers' literature seldom emphasizes this fact. Experience dictates that certain safety factors should be incorporated in the design calculations to assure un- Joading.TWO-PEN PRESSURE RECORDER CHART ILLUSTRATING TYPICAL CONTINUOUS FLOW UNLOADING OPERATIONS Gas Lift Installation Information: 1. Gas Lift Valves: 1-1/2~inch 0.D, Valves with A, = 0.77 sq. in. 2. Valve Port 1.D. = 1/4-inch 3. Installation Design Same as Outlined for Unbalanced, Bellows- Charged, Injection Pressure Operated Gas Lift Valves.TWO-PEN PRESSURE RECORDER CHART ILLUSTRATING TYPICAL CONTINUOUS FLOW UNLOADING OPERATIONS Gas Lift Installation Information 1. Gas Lift Valves: 1-inch 0.D, Valves with A, = 0.31 sq. in. 2, Valve Port 1.0. = 1/4-inch Poorly Designed Installation with the Difference in Valve Operating Pressure Being Entirely Too Great, Thus Unneces- sary Sacrificing of Injection Gas Pressure.TWO-PEN PRESSURE RECORDER CHART ILLUSTRATING TYPICAL CONTINUOUS FLOW GAS LIFT OPERATIONS This gas lift installation was producing approximately 1000 STB/day through 2-1/2-inch nominal tubing with an injection gas-liquid ratio of 120 scf/STB. ‘The valves are the single-element unbalanced, bellows-charged type of gas lift valve. Note the uniform injection gas and flowing wellhead pressures and the low flowline pressure at the well.PRELIMINARY PRESSURE-DEPTH DIAGRAM FOR LOCATING DEPTH TO POINT OF GAS INJECTION BEFORE DETERMINING UNLOADING VALVE DEPTHS Continuous flow installation designs can be divided into two major categories: 1) depth to the point of gas injection is known and not changing - flowing BHP can be determined and is constant or lifting from imme- diately above the packer, 2) depth to the point of gas injection is unknown and/or changing - flowing BHP is unknown and/or changing. The following detailed procedure for locating the operating (or maximum) depth of lift represents. the initial steps suggested by some manufacturers for in- stallation designs using their valves. Point of Gas Injection Known The first category is unrealistic for most wells because the reservoir pressure will decline as the zone is depleted. An exception occurs when the depth to the point of gas injection is immediately above the packer. The point of gas injection will remain at this maximum depth of lift as the flowing BHP declines. Many gas lift installations are designed based on a calculated flowing BHP. 1. Establish the flowing pressure traverse below the point of gas injection when the flowing BHP is known and not changing and the injection pressure does not exceed the flowing BHP at datum depth. a) Calculate the flowing BHP based on the inflow performance relationship and static BHP of the well and the desired production rate. b) Plot this flowing BHP at the datum depth on the P-D diagram. c) Draw on the P-D diagram the traverse based on the formation GLR be- ginning at the flowing BHP and extending toward the surface to a pressure significantly less than the operating injection gas pressure.2. Draw the operating injection gas pressure at depth curve to the datum depth based on the gas gravity and gas column temperature (should also include friction loss if the injection gas conduit is small as found ‘in some casing flow installations). . Determine the depth to the point of gas injection based on the desired pressure differential across the operating valve (P/@L - Py@L,). The utilized injection gas pressure cannot exceed the flowing BHP. 4. Establish the flowing pressure traverse above the point of gas injection. This traverse begins at the flowing wellhead pressure and passes through the flowing pressure at the depth of the operating valve found in Step 3. There will be only one traverse which can pass through these two points provided the flowing pressure at depth is not to the left of the minimum fluid gradient curve. This one and only traverse will represent the total GLR required to gas lift the well. Point of Gas Injection Unknown And/Or Changing The continuous flow installation design will generally be based on the desired production rate. The installation will be designed to lift the desired produc- tion rate from all valve depths. Since the flowing BHP cannot be calculated, no traverse below the point of gas injection will be drawn. The same problem exists if the flowing BHP is changing. Draw the operating injection gas pressure at depth curve as outlined in Step 2 of the known point of gas injection. 2. Establish the flowing pressure traverse above the point of gas injection. This traverse may be based on a maximum available injection gas volume (maximum GLR), minimum fluid gradient curve (no limitation in injection gas volume), or packer depth. The traverse begins at the flowing well- head pressure and should be extended to the intersection of the injec- tion gas pressure at depth curve unless the traverse first intersects the packer depth.3. Determine the depth to the point of gas injection based on the desired pressure differential across the operating valve at this depth. Li ed Or Un If the minimum fluid gradient curve can be established with the injection gas volume available for a well, the gas volume can be considered unlimited. Additional gas volume would not increase the depth of lift. The distance between valves and the final maximum depth of lift must be based upon reliable available injection gas volumes. As the liquid rate increases, the importance of the maximum attainable injection GLR becomes greater. In many oi] production areas of the world, high rate wells are common. One million cubic feet of injection gas per day will increase the injection GLR by only 50 scf/STB for a well producing 20,000 STB/day. 2 Maximum Depth of Unloading Gas Lift Valves Unloading gas lift valves may be required at greater depths than the final operating gas lift valve. It may not be possible to attain bottomhole pres- sure drawdown from the depth of the final operating valve in a deep high productivity well which has been loaded with salt water. This condition oc- curs as the result of the difference between the load fluid gradient and the Flowing gradient below the point of gas injection. The flowing gradient after "clean-up" may be considerably less than the load fluid gradient be- cause of the formation gas and oil. The difference in flowing BHP with Joad fluid as compared to formation fluids may be hundreds of psi when there are thousands of feet between the operating gas lift valve depth and the mid- point of the perforations. 77DETAILED PROCEDURE FOR THE DESIGN OF A CONTINUOUS FLOW INSTALLATION USING SINGLE-ELEMENT, UNBALANCED, BELLOWS-CHARGED GAS LIFT VALVES The type of valve and initial port size are selected prior to the calculation of an installation. The tubing and casing size may affect the choice of the gas lift valve to be employed. Smaller 0.0. valves are required in smalt casing sizes. The continuous flow installation design can be divided into two parts. The first part consists of calculating the valve depths, and the second part is the calculation of the opening pressures in a tester of the gas lift valves. Determination of the Valve Depths The step-by-step procedure for calculating the valve depths is as follows: 1, Plot Pyy¢ and draw the unloading traverse above the point of gas in- Jection; i.e., the Min P,@L curve. 2. Draw the injection gas pressure at depth line to the datum depth, Pye. 3. Calculate the depth of the top valve, L. 4. Draw a horizontal depth line between the Min P,@L, and Py@L, and record these pressures. 5. Estimate the total GLR for the Min P,@L, and calculate the injection gas requirenent, qg.q- Correct this daily injection gas volune for temperature at valve depth and the actual gas gravity. 6. Calculate the P,@L, (P,@l, = Py@l, for the top valve). 7. Determine the top valve port, or choke, size needed to pass the cor- rected injection gas volume in Step 5 from the gas passage chart. Compare to the assumed port, or choke, size and change if too small. 8. Draw the load fluid traverse below the Min P,@L, to the injection gas pressure at depth line.10. ne V2. 13. 14, 15. 16. 7, 18, 19. 20. 2. 22. 23. 24, Draw the pressure at depth line AP less than and parallel to the POL curve and extend to the intersection of the traverse below top valve. Locate the second valve depth at the intersection in Step 9, Ly. Oraw horizontal line between Min P,@L, and P\@L, and record these pressures. Estimate the total GLR for the Min P,@L, and calculate the injection gas requirement dog, + Correct for the actual conditions at valve depth. : Determine and record Max P,@L, at the intersection of depth L, and an imaginary line between Png and the intersection in Step 9. Calculate the Add'l TE@L, = (Max P,@L, - Min P,@L,) TEF. Calculate the P,@L, (Py@L, = Py@L, - Add"! TE@L)). Determine the port, or choke, size of the second valve from the gas passage chart based on the corrected gas volume in Step 12. Draw the load fluid traverse below Min P,@L, to the injection gas pressure at depth line. Draw a segment of the pressure at depth line AP + Add'l TE@L, less than and parallel to Py@l curve through intersection of the traverse below second valve. Locate the third valve depth at the intersection in Step 18, L3. Draw the horizontal line between the Min P,@L, and P/@L, and record ‘these pressures. Estimate the total GLR for the Min P,@L, and calculate the injection gas requirenent Qggc + Correct for the actual conditions at valve depth. 2 Determine and record Max P,@L> at the intersection of depth L> and an imaginary line between P.,_¢ and the intersection in Step 18. Calculate the Add'1 TE@L, and SAdd'l TE@L, ( BAdd'1 TEL, = Add'l TE@L, + Add'1 TE@LD). Calculate the P,@L, (POL, = Piel, - ZAdd') TEL). 7-1925. 26. Determine the port, or choke, size of the third valve from the gas passage chart based on the corrected gas volume in Step 21, ~ff. Repeat Steps 17 through 25 until the lowest valve depth is reached. Valve Opening Pressure Calculations The step-by-step procedure for calculating the opening pressure at 60°F ina tester for each valve is as follows: Note valve manufacturer and type for referral to the proper valve speci- fications. 1, Valve Number and Depth in feet 2. Port Size, inches 3. Ap/Ay from Valve Specifications 4. POOL. psig 5. Min P,@L, psig 6. Pye = Pol (1 ~ AL/A,) + Min Py (AL/A,)» psig 7. Ty@l. °F 8. Cy from Table 5-1 9. PL = Cy (Pye)s psig at 60°F 10. Pug = Py /(1 - Ap/Ay)s psig at 60°F A tabulation is recommended for the above calculations, Entries for Steps 1, 2,4,5 and 7 are established in the Determination of Valve Depths. 7-20DESIGN CONSIDERATIONS TO PREVENT GAS LIFT VALVE INTERFERENCE IN CONTINUOUS FLOW OPERATION When the flowing surface temperature is selected for the design of a continuous flow installation using pressure charged gas lift valves, the maximum possible temperature will be assumed intuitively as a safety fac- tor in the design calculations. The assumption of a higher than existing flowing temperature results in a safety factor in terms of the required operating injection gas pressure but has the opposite effect in terms of gas lift valve interference. Gas lift valve interference is the inability to close upper valves while lifting from a lower valve. Valve interference will waste gas and limit liquid production by gas lift from a high capacity well. To assure the most efficient gas lift operation, multipoint gas injection should be avoided in continuous flow installations. Single- point gas injection is absolutely essential in many gas lift installa- tions with large production conduits to prevent severe surging. This consideration is particularly important in casing flow installations in which the point of gas injection is through open ended tubing or a large bottomhole choke. If the flowing surface temperature is assumed to be higher than actually exists, the flowing temperature gradient will be less than the flowing temperature gradient for actual conditions. The difference in the actual valve temperature will be less than assumed for design purposes. The temperature of an upper valve will be less in relation to the next valve below. As a result, less injection gas pressure will be required to keep the upper valve open, or reopen this valve, after the next lower valve is uncovered and injection gas is entering the production conduit ‘through the lower valve. The effect of temperature on a pressure charged gas lift valve can be utilized to prevent valve interference after a well is unloaded. If the surface flowing temperature for the tester opening pressure calculations is assumed to be less than the actual flowing temperature, the actual higher valve tenperature will literally “lock” the upper valves closed. The bellows charge pressure in the well will be higher than calculated; there- fore, the resulting greater closing force will assure keeping the up- per valves closed. 7-21There must be an adjustment in the assumed available injection gas pres- sure to compensate for higher valve operating pressures in the well The tester opening pressure of the top valve is calculated based on the lower valve temperature at depth and the full available injection gas pres- sure at depth. The opening pressure of the same valve in the well at the highest predicted valve temperature and the minimum unloading flowing tubing pressure at depth is calculated and compared to the full avail- able injection gas pressure. The difference between these two surface pressures will be the approximate recommended decrease in the injection gas pressure that should be used for design of the installation. Gen- erally, the decrease can be less than calculated above because the higher temperatures will not be achieved during the initial unloading operations while lifting from the upper valves. 7-22CONTINUOUS FLOW INSTALLATION DESIGN BASED ON GAS LIFT VALVE PERFORMANCE A single element gas lift valve is a metering device and is not fully open at the injection gas pressure required to initiate gas passage through a valve port. A gas lift valve is actually closed at the designated tester opening pressure; i.e., the opening force very slightly exceeds the closing force and the valve stem and ball move a minute distance from the seat that results in detectable gas throughput. The increase in injection gas and/or production pressure to fully open a gas lift valve depends on the bellows assembly load rate, the port and ball sizes, and the geometry of the seat. The seat line may be classified as a sharp edge or the ball may contact a tapered seat. The Merla Type L Series gas lift valves are designed to respond proportion- ally in terms of injection gas passage with a change in the flowing produc- tion pressure for a constant injection gas pressure. The stem travel is limited and the valve seat is on a 45 degree taper to assure that the flow- ing production pressure is always exerted over the same effective valve seat area. The valve operates as a variable orifice with the orifice size increasing with increasing production pressure for a constant injection gas pressure at valve depth. Conversely, as the production pressure decreases, the valve stem will throttle closed. Since the injection gas pressure re- mains constant, it is only the production pressure exerted over the effec- tive seat area that moves the valve stem. The stem travel is directly pro- portional to the flowing production pressure. This results in a change in injection gas throughput that is linear to the variation in production pres- sure within the "throttle range" of a valve. An installation is designed to assure operation within this linear throttling range of a valve. As the flowing production pressure increases, the injection gas throughput increases proportionally. Conversely, a decrease in the production pressure decreases the injection gas flow rate for a constant injection gas pressure. 7-231400 1200 800 00 GAS VOLUME MCF/D 400 200 Referen TYPICAL INJECTION GAS VOLUMETRIC THROUGHPUT OF SINGLE-ELEMENT SPRING-LOADED GAS LIFT VALVE (Cure for 1/8” Ori FLOW RATE CURVE LM—12 VALVE MEDIUM TRIM Meza Phy © 100 200 300400600 G00 709-00 TUBING PRESSURE, Py Equation for Gas Lift Valve Performance: Os =H (Pep ~ Py) ce: \, in Mscf/D Gas Flow Rate Q. Proportional Response System, Copywright Teledyne Merla (1972). Tubing Pressure in psi 7-248.0 INSTALLATION DESIGN 8.1 Continuous flow using a constant gas injection pressure. An installation design based on a constant gas injection pressure offers the following advantages: 1, Maximum utilization of available system gas pressure 2. Start up and operation witha minimum of attendance 3. Common annulus dual-zone well operation The Series L valve was specifically designed for continous flow and by utilizing its flow characteristics the installation can be unloaded and operated with a constant gas injection pressure. 8.2 Flow Characteristics Figure 11 shows typical flow curves for the Series L valve. The solid curve is the gas flow rate through the valve as the fluid pressure (P;_) decreases from a value equal to the gas pressure (P,,) to the valve closing pressure (P,). The gas pressure is held constant for this curve. Teledyne Merla: GAS LIFT MANUAL Section 2 - Continuous Flow Gas Lift (1970) 7-28If the gas pressure is increased, an increased flow rate results shown by the dashed curve. It should be noted that as the gas pressure is in~ creased the close pressure (P,) is lowered because of the change in force balance. The valve flow rate curve is controlled by the following variables: 1, Gas pressure (Pog) 2, Adjustment pressure (Pyc) 3. Bellows size (A,) 4. Valve ball size 5. Port size (A,) A change in any of these variables produces a change in the gas flow rate curve which makes it impractical to use a set of emperical curves. 8.3 Mathematical Reproduction of The Flow Curves ‘The important part of the curve is the throttling portion. A series of flow test indicate that this portion is linear. These tests also show that for a given physical configuration, (i.e. , bellows, valve, port, and spring are constant), the slope of the throttling portion of the curve is constant through the normal range of spring adjustment. This permits the use of a simple equation to evaluate the flow rate between the limits of close pressure (P{) and peak flow rate (Q,,), which is: Qs = M (Pee - Py (8-1) Where: Q, = Gas flow rate M = Throttling slope Pyg = Fluid pressure P, = Close pressure The peak flow rate (Q,,) is a function of port size and spring adjust- ment, and can be defined in terms of two ratios: P eet fy On Pr Pet Teledyne Merla: GAS LIFT MANUAL Section 2 - Continuous Flow Lift (1970) 7-26The equation relating cas pressure (Poq), the fluid closing pressure (P), and spring adjustment pressure (Pye) is: P, ve = Pog - Fe (Pet - Py) (8-2) This equation is the same as the static force balance equation except an effective seat ratio (F,) is substituted for the physical seat ratio (F,,), and (F,) is evaluated from the flow rate tests. Using the above analysis, the gas flow rate can be determined for any pressure conditions within the normal operating range. The necessary valve constants are supplied from the performance curves for each valve configuration, Figure 12 illustrates a typical performance curve, the actual performance curve for specific valve types are reproduced in Section V "Specifications and Data". 8.4 The Transfer Operation (Figure 13) The unloading operation begins with the upper valve supplying all of the gas necessary to lower the flowing pressure until the transfer pres- sure P,, is reached. At this point, the next valve is uncovered and starts injection of gas. Since the total injection from the two valves exceeds the amount of necessary to maintain the pressure gradient, the tubing pressure opposite the upper valve will continue to decrease until it reaches the close pressure P;. The injection continues through the second valve alone until the transfer point for the second valve is reached. Each valve must supply sufficient gas to meet the well re~ quirements up to the transfer point, and they must each close when the transfer operation is complete. ‘The important valve characteristic during the transfer operation is the throttling action which pfovides the proper distribution of gas between the two valves, i.e., a larger percentage of the gas is injected through the lower of the two valves as illustrated in Figure 13. Teledyne Merla: GAS LIFT MANUAL Section 2 - Continuous Flow Lift (1970) 7-27vwationQ) Subject Tavs 96 dae 15 July 1970 VALVE PERFORMANCE DATA serame TYPEL VALVE TYPE: LM-12, LM 12R, LS-12 BELLOWS AREA: ADJ. PRESSURE RANGE: 600 - 1500 SPRING: STD. 5674 BALL SIZE 3/8 V2 5/8 SEAT 45° 4s? 45° PORT 0.25 0.25 0.40 Fe 0.22 0.57 0.72 M 1.0 2.6 3.4 a 1 2 3 4 PERFORMANCE CURVE Figure 12 Teledyne Merla: GAS LIFT MANUAL Section 2 - Continuous Flow Lift (1970) 7-28Figure 13 Transfer Operation (A) Transfer After Transfer Pressure Pressure Pet £ s a a 3 2 a a 2 4 s Flow Diagram a Top Valve 8 & ¢ 2 2 3 s 5 Flow Diagram 2 Lower Valve 8 é & Pressure Pressure Note that all the gas is supplied Now injection has started from by the upper valve and none by lower valve and as the tubing the lower valve. pressure at upper valve reduces, the gas injected decreases. Teledyne Merla: GAS LIFT MANUAL Section 2 - Continuous Flow Lift (1970) 7-298,5 Transfer Point Selection ‘The transfer point in the gas lift design is the independent variable, its selection affects the eount of gas required at the valve and the gas flow rate through the valve. 8.51 Gas Requirement A single-phase gradient line is projected from the selected transfer point to the formation depth to arrive at a flowing bottom hole pres~ sure (Pw). This flowing bottom hole pressure can be applied to the IPR curve to find the producing rate (q,)- P Knowing the producing rate (qj), the pressures Pj, at the valve and at the surface, refer to the two-phase pressure traverse curve to determine the required gas-liquid ratio. The curve selected must pass through the surface tubing flowing pressure and the transfer pressure at the depth of the valve. ‘The required gas rate is the product of the production rate q, and the difference between formation gas-liquid ratio (Rj) and produced gas~ Liquid ratio (R,). Qs iy (Ry = Rp) /1000 Mef/D (8-2) 8.52 Gas Supply ‘The amount of gas injected through the valve is determined by the value of the transfer pressure P,, a8 shown in the throttling slope equation , Q,=M (Py PD (e-1) ‘The optimum transfer point can be calculated from the simultaneous solution of equations (8-1) an¢ (8-3): M (Peg ~ PD = 4 (R, ~ RD ‘This ts an equation with two independent variables (M) and (Pid) ‘and requires a trial and error solution. The example design provides ‘a stepwise guide for solving the equation. Teledyne Merla: GAS LIFT MANUAL Section 2 - Continuous Flow Gas Lift (1970) 7-30lee Depth - 1000 feet Pressure - 100 PSI l (ian ca ! ul Teledyne Merla: | i i l ae a ne GAS LIFT MANUAL Section 2 - Continuous Flow Gas Lift (1970) UG2000 | 3600 | 46so | saso | 6000 | 6300 sis | gis | sis | ois | 915 | 91s g60 | 995 | 101s | 103s | toas | 1055 360 | sso | 695 | eis | 900 | 614 aio | 62s | 745 | aso | 960 | 950 2260 | 1ses | 161s | 1430 | 1330 | 1200 Neate 110 330 470 530 600 fm ee [soo | aso | 400 | soo | 460 | 00 eae ° 0 50 100 100 100 wespar | 200 | aso | 250 | 300 | 360 | 500 OD PSP eves 30 | 49.5 ns at 190 300 @Q wan rio | 130 | ass | 170 | 180 | 190 @ 0.985 | 0.939 | 0.920 | 0.909 | 0.902 | 0.894 f@ sem [ona | ses | us| ass | 210 | a6 63 so 78 50 45 so | 336 remarye* | aye | ave | a | sve | sve | 3/8 ome 2.70 | 1.80 | 1.46 | 1.21 | 1.16 | 1.76 eee 0.620 | 0.440 | 0.640 | 0.560 46 42 595 435 650 580 480 444 0.22 0.22 0.57 0.72 72 624 eg [os | eaa |er7— [oan | 948 Jon |o-6n3 | b00 |e |S | 934 6 s 4 3| 2 1 1 1 1 Toa A FIGURE 18 Teledyne Merla: GAS LIFT MANUAL Section 2 - Continuous Flow Gas Lift (1970) 7-32SYMBOLS Aa annulus area A, bellows area Ac chamber area Ag dipetube area Ay piston area A, seat area A, tubing area A, valve area Be oil influx during a cycle 8, ofl produced during a cycle D, injection depth Dg static level depth Dy valve depth Dy well éepth E efficiency noular volume factor Fey €ating/tubing ratio Fey easing volume factor Fe dynamic Tyg F, spring force Fug tubing displacement factor ty factor Fug tubing sensiti Fyy thing volume factor Gy average flowing pressure gradient 5 pressure gradient G,, minimum pressure gradient G, residual pressure gardient Gz static pressure oradient Gy unloading pressure gradient J productivity index Le chamber Length Ly spacing length M_ slope of gas capacity curve Ny eyeles/éay Py atmospheric pressure Peg flowing casing pressure Teledyne Merla: GAS LIFT MANUAL /e 13/t » te 12/t paivte site psi/te psivte psi/tt pei/te BoI/D/psi f. a. Mef/psi ogee PERE P PEP PP OL LOL ceasing opening pressure static casing pressure dome pressut fall-back pressure feed-in pressure kick-off pressure operating pressure separator pressure tubing pressure flowing tubing pressure tubing opening pressure static tubing pressure valve adjustment pressure valve opening pressure lowing botiom hole pressure static bottom hole pressure pressure difference maximum gas injection rate ‘908 injected during an interval gas injection race 625 producing rate quid producing rate oll producing rate water producing rate formation gas/liquid ratio Injected gas/liquid ratio produced (totallgas/liquis ratio temperature correction factor valve temperature bottom hole temperature annular volume chamber volume tubing volume Section 2 - Continuous Flow Gas Lift 7-33 pig psa pate ste psig pate pe pais rig psig psig psig psig tig pst Met/> «3 Met/D #2 “eyo BoD Boyd Bey/ 7 7 18 i fa (1970)CASING (ANNULAR) FLOW INSTALLATION DESIGN Production through the casing annulus is recommended for extremely high producing rates and is not satisfactory for low producing rates. Inter- mittent lift (which includes production pressures operation) is not recom- mended for casing flow. The check disc in the reverse flow check valve seats in the opposite direc- tion for casing flow as compared to a tubing flow installation and allows gas passage from the injection gas tubing to the casing. In the retriev- able series the valve is similar to a production pressure operated valve except the integral check valve is upside down (for gas flow from gas in- jection tubing to casing). The design procedure for an annular flow installation is the same as that for a continuous flow installation through the tubing, except for calculat- ing the depth of the.top valve when a well is not loaded. Since the gross liquid production is generally in the thousands of barrels per day category, selecting valve port sizes for adequate gas passage is very important for annular flow installations. Actual gas lift valve performance based on the bellows assembly load rate should be considered in the design calculations for casing flow installations because of the high injection gas requirements. In otherwords, the increase in the injection gas pressure to overcome the bellows assembly load rate and attain the needed equivalent port area for a required injection gas throughput must be considered. The depth of the top valve in a casing flow installation can be deeper than that in a tubing flow installation if the fluid level is not at the surface and this fluid level is known. The top valve can be located below the fluid level by taking advantage of the ratio of the tubing to the annular capacities. The fluid level in the casing annulus will rise only a few feet when depress- ing the fluid level in the tubing many feet. The following equation can be used to calculate the top valve depth if the static fluid level ts not near the surface. T-CF-1Pico ~ Pu y = SFL + —“-__“ —_ 6 (Reg + 0 . where: G, = Static gradient of fluid in well prior to unloading, psi/ft L, =.Depth of top valve, ft Py = Kick-off injection gas pressure available at well, psig Pun ™ Wellhead tubing pressure, psig Rog = Ratio of capacity of tubing to capacity of casing annulus, V_ / Voqs dimensionless SFL = Static fluid level, ft Selection of the proper sized gas injection tubing string that will deliver the required daily injection gas requirement for unloading and operating is absolutely essential. The Cullender and Smith correlation is recommended for calculating the gas capacity of the injection tubing string. An initial assumption can be an injection tubing size that will deliver the maximum daily injection gas requirement with no pressure loss; i.e., the increase in ‘the injection gas pressure with depth due to gas density is offset by the flowing frictional pressure loss. This should be the smallest nominal tub- ing size considered for the gas injection string. Static injection gas pressure at depth charts cannot be used for the valve spacing calculations. The Cullender and Smith method for calculating the flowing injection gas pres- sure at depth was derived for a gas producing well and not for gas injection. The only difference in the calculations is the friction term. When gas is being injected rather than being produced, the sign for the friction term changes; i.e., the friction term becomes negative in the Cullender and Smith equation for gas injection. 7-CF-2Nomenclature 4 internal diameter, in. D~ internal diameter, ft seth Aig (dP f~ friction factor, SEP (SP Z—compressibility factor ‘ft-lb s-sravitaton!aceleration G— gas gravity (air = 1) H— vertical height, ft I —value of quantity inside integral sign L=length, ft Lg length, miles M- molecular weight P— pressure, psia P.—eritical pressure, psia Pe-P/P, G— flow ‘rate, MMacfd at 14.65 pais and 60 F 20011 QG R,— Reynolds number, 7 T— temperature, degrees Rankin Fer prt deo Rk vores wine 2, oe Yoo pr Se — correction factor to compensate for varia- tion of velocity over the tube cross-section. Value varies from 0.5 in laminar flow to 1 for fully developed turbulent flow. A value of 0.90 is usually satisfactory for practical fas flow problems. A= viscosity, centipoise paras density, 2TEP, wy ver cu Subseripts: 1—up-stream conditions (bottomhole in gas well) 2— downstream conditions (wellhead in gas well) w— wellhead ‘s—sand face Reprint by Permission from PETROLEUM ENGINEER Cullender and Smith Method Another popular form of the basic mechani- cal energy balance equation used in gas flow ‘and static head calculations is known as the Cullender and Smith Method,’ which we shall call Case 2. Part 1 derived the basic energy balance equation and demonstrated that the Kinetic energy (KE) term is quite small in re- lation to other terms in these integrated equa- tions. In the Cullender and Smith forms, the fol- lowing assumptions are made: 1) steady-state flow; 2) a single-phase gas stream; and 3) change in kinetic energy (KE) is small and may be neglected. Static head for vertical or inclined pipes: xo _ (at BS -(ep am For vertical or inclined flow: ? n ag ee 2(B) 7-CF-3Table 1. Caleoated data for Bx. 2 lustratin tomholé pressure of a dry sweet gas well by Cul -step calculations by Eq. 2(B) to calculate static bot- liender & Smith Method and applying Simpson's Rule, te a x Te % L het an P ao 7 3 8 03 Ras oie : som Mame oo Sir ozo. 59 ma > soo {m0 "io 0m am Osim = Sams toms SMS 5 ia it wo m 00 Dis = Ons oes Si) i sa 138 Ty Wem ls =e twee Sk 1 sao ‘so Ti.) Oss = Ose taoets ss 2 wo saa "Sos om soz ome om wes aya i ion Sims os Gas cums §« Oars toes ira i 5 016m ‘Applying Simpson's Rule m1 920 2600 + 920 2AP foantay + 4(0.6408) + 0.18308} 420 pala, For horizontal flow: » = (P/TZ aP saad ~ \o06sre \—e— or, n 269,951 LQ? _ (PaP ac ee (RE... 20) n These equations are based on the work of Cullender and Smith, and all equations in this section may be expressed in the following form: fam... 2 @ where K is the constant containing all terms except the length L (or height H for the static head case) on the left side of the equation, The integral on the right side of Eq. (a) uated by numerical means as follows: xL far =3[@,-Pod, +19 + @-7) (, +1) +...+ @.-P,. Getta] For the practical case where the integral is evaluated between P, and P,, usually only one- intermediate value of pressure, P, is necessary. fr =}[e-romem eae oe Simpson's rule* may also be applied to obtain a better answer for the value of the in- tegral. The interval of integration must be divided into an even number of equal parts. If the interval is divided into two equal parts, the integral may be written as: fur=Lo,-Pp[1+ea + ] 2 css +s + Simpson's Rule . (8) Ima 2-step calculation, the general procedure is first to solve for the intermediate conditions and then repeat the calculations for the final conditions. I is first calculated at known condi- tions. A value for I, is assumed (I= I, may be used as a first approximation) and P, is caleu- lated by Ea. (e) 2K(L/2) = (Pa— PVM +). ‘Using the estimated value of P,, we can calculate 1,. The new value of I, is used to calculate P, from Eq. (e). The calculations are repeated until the two values of P, are within the desired accuracy. The entire procedure is repeated for the second interval. Knowing the values of I,, I, and I,, Simpson's Rule also may be applied ‘to obtain a more accurate answer. The following examples illustrate this pro- cedure. Example 2: Calculate the static bottomhole pressure of a dry sweet gas well using the Cullender and Smith method with the follow. ing well data: Gas gravity = 0.75 Average well depth = 10,000 ft Wellhead temp = 495 R Formation temp = 705 Shutin wellhead pressure T.= 408 R P 7-CF-4Example 3: In a deep sweet gas well, calcu- late the flowing sand face pressure using the following well data by the Cullender and Smith* Method using the relative roughness and fric- tion factor correlations: Gas gravity = 0.75 Flow rate = 4.915 MMcfd ID of the tubing = 2.441 in. ‘Average formation depth = 10,000 ft Flowing wellhead temp = 570 R Formation temp = 705 R Flowing wellhead pressure = 2000 psia ‘T, = 408 R P, = 667 psia Case 3 In Case’3 of this series, the following as- sumptions are made: 1) steady-state flow; 2) single-phase gas flow; 3) change in kinetic energy is small and may be neglected; and 4) friction factor ia constant over the length of the conduit. To calculate static head, either vertical or clined, the same derivation as Eq. 2(A) holds, therefore, Eq. 2(A) = Eq. 3(A) For vertical or inclined flow, Eq. 2(B) = Eq. 3(B) where H/L = for a vertical well. For horizontal flow and the above assump- tions, the equation becomes: ar. 1) ‘Methods used to solve these equations in Case 3 are similar to the methods used to solve the ‘equations in Case 2. The only difference in Case 3 solution is that the friction factor is assumed to be constant. The procedure of solution can be illustrated by the following example. ‘Example 4: A gas well produces 0.75-gravity gas from an average depth of 10,000 ft through 2.441-in. ID tubing. The wellhead pressure at 1 stabilized flow rate of 4.915 MMefd is 2000 psia, The flowing wellhead temperature is 570 R and the formation temperature is 705 R. Calculate the flowing bottomhole pressure using the Cullender and Smith Method. T, = 408 R P, = 667 psia. Cullender and Smith treat the friction factor in the following manner: (wee, ap rr): mR T0900 10006 ss where pa ag) Table 2. Calculated data for Example 3 taken from the Oil and Gas Conservation Board of Alberta, Canada, employing the Cullender and Smith Method and using the relative roughness and friction factor correlations. 7 20011 GG, 20011 OG __(BOOTT) (AAI) ea aor, BGS a R= MOUS, Bout oe 30219; & = 8667; 28885 — 0.090766, @" = 24.157 r erm Ro gt hPL ec Oana S70 1.307 oxo 2.900 0.07 x1. 6=0.0180 $08 oa dee Asime a Som "see 3.580 sas 1.584 0.800 See Las" como woe oes 3m OUT L sono Som 300 3a Sis set Ow Fars Lams Gomi 1.48) 2180 3.983 ONL n=O 10000 Ayeraeforwaton depth) ‘Aste Tne tome “Te Cia me 1.738 oa “Stor comm 167 me 3.8 oss 1 20.0185 tome Ha tie Ms tre as het Ocoiog ora em et Saat Ooi s2—0.085, e > Pa E mt * a ‘ oo SFB sot wtta 5 Tesi oomeis o.oo oWOLSST — O.omTaIO—OwETSSS 1.8 ome Mos oes Sard Lei — o.com oom oonoris— o.ommero © oamssea aw as 3.2 Kerrie — O.ocons —O.aams noon? © Ooms Oust Hao.t teas, 30.7 tml tosis 2 Lari” o.oo onus csonies—omares cms Iss 8. HG@rie Ooms Sours G.oooises__Ocoomois—S.omaol as 8 twets HS 9 “Tpahing Sion Raker onscu~ zszso = 22 1606 + «(1002) +1968), where Li th taal depth 2ap = 848750 _ r49 vi "Yili calculated fr 1368 Burrows corr Py = 2000 + 742. 201, 384 (1980), Car, Kaba done, ADM 22 psiaie 3. Calculated data for Example 4 using the Cullender and Smith Method and a constant friction factor: Based on an example from the Oil and Gas Conservation Board of Alberta, Canada. FE (FQ) = (0.010005 x 4916)" = (0.081583)" = 0.0026608 anaes © 2b 2 One LoP om tT he 2 2 mm Pose 9 000 200 Sto 107 OTS 2687 4.977 O.ONTT) OOROMA mT $208 det "Ass 3 550 4.679, 0.021695 vores 3 fe 3s Fogo Onze Ommseos 0 an oom ms us 4.485 UIs o.omemE oor 100 tos tos 1735 0.ees Suse UA O.cemoss Donn 0 ozr0s “Applying Simpson's Rul snsou = amano = EZPS (rena + «(190.2 +1972), where Lis the total depth 843750 = Taga = 7878 200° 138 = 2738 Be Substituting values of the friction factor based on an absolute roughness of 0.0006 in the fully developed turbulent flow region into Eq. (a), gives: Oy for pipe diameters less than 4.227 in. FQs r= Oe for pipe diameters greater than 4.227 in. Eq. (f) with the appropriate equation for F is used to solve this problem, Importance of Cases 2 and 3 In most practical cases, it is justified to as sume that the friction factor remains constant over the length of a constant diameter conduit. ‘This assumption’ reduces the equations in Case 2 to the equations in Case 3. This set of equa- tions, along with the method ot solution pro- posed by Cullender and Smith,’ represents an extremely accurate and useful procedure for calculating pressure drops in gas wells and transmission lines. The method is suitable for computer programming and involves the least number of assumptions of all the practical methods in use, References 1, Cullender, M. H. and Smith, R. V. “Practical Solution of Gas Fiow Equations for Wells and Pipe Lines with Large Temperature Gradients,” AIME, 207, 281, (1986). 2 Salvadori, M. G. and Baron, M. L. NUMERICAL METHODS IN ENGINEERING, Prentice-Hall Inc., cass2). 7-CF-640k = | GAS GRAVITY = 0.65 = | SRuéction rusine' side ‘SURFACE PRESSURE = 800 PSIG TEMPERATURE,» 170 5 = 14.65 PSIA & Ts = 60 F 2-INCH Nominal 3-INCH Nominal —— —— FEY INJECTION GAS RATE in MMscf/Day 1 12FIGURE A5~5: FLOWING TEMPERATURE GRADIENT FOR DIFFERENT FLOW RATES, GEOTHERMAL GRADIENTS, AND TUBING SIZES. Chart to be used directly for 2% inch tubin For 2 inch tubing multiply the actual flow rate by 2. For 3 inch tubing divide the actual flow rate by 1.5. re é 5 5 Z 8 Fa § 7-1G00 BPD Geothermal Gracink 6 Gee =p Fhoott From va (Co00t) chat Tung 2/40 'F - 11 Foo ty & pose at pape Ta eae + pu (422) 2 pie & 1600 ceCONTINUOUS FLOW GAS LIFT INSTALLATION DESIGN WELL DATA SHEET Company, Date. Gas Lift Valve Manufacturer Type. Port I.D. in. Valve Mandrel Manufacturer Type. tubing C1] Annular Flow Casing 0.0. in, Weight, Jb/ft Setting Depth. ft Liner 0.0., Height, and Setting Depth Perforated Interval or Open Hole. - ft Mid-Point, ft (Show True Vertical Depths - Attach Drilled Depth Profile for Directional Wells) Tubing Size and Thread Length ft Packer, ft Static Bottomhole Pressure psig at, ft Date, Initial Bubble-Point Pressure psig Solution GOR scf/STB Bottonhole Reservoir Tenperature oF at ft Productivity Index $18/0/psi_ Flow Efficiency Multi-Rate Test Data: Gross Production and Flowing BHP at, ft ( s18/D, psig) ( ST8/0, oi9y Injection Gas Pressure: Kickoff. psig Operating psig Temperature of Injection Gas at Surface SF Injection Gas Gravity. Injection Gas Volune for: Unloading Nscf/0 Operating Nscf/0 Static Fluid Level ft Wi1l WelT Be Unloaded to Atmosphere? Design Gross Production Rate sTB/Day Water Cut. x Formation Gas-011 Ratio scf/STB O41 Gravity. sap Specific Gravities: Formation Gas on, Water Flowing Wellhead Tubing Pressure. psig for STB/Day Flowing Wellhead Tubing Temperature. °F for_ STB/Day Flowline I.D.. in. Length ft Elevation Change, ft Header or Separator Pressure at Production Facility. psig Static Gradient of Load Fluid. psi/ft . Setting Temperature of Valve (Opening Clctosing Pressure in Tester__°F Remarks. Ar-2‘THE FOLLOWING RESULTS WERE OBTAINED USING THE CANCO CONTINOUS FLOW GAS LIFT FOR" THe O1GITAL. COMPUTER CONTINUOUS FLOW PRORLE EXAMPLE FOR CAS LIFT SCHOOLS = Pete UaKnOwN weut para TURInG.2e441 INCHES 1060 LENGTH 4000, EET FIC GRAVITY C45 "0.655. OIL “DeSby MATER 1,08 FORMATION. CAS-OIL RATION. "00. CULET./0RC* Srarte rouse tevee seer Sect SCC nor SE UmLoaDeD "INTO PIT GE FLOWING TENPERATURE 140, 0EG.F» AROVE AO 140. OFG+F+ BELOW PT OF Ins ADDITIONAL OAOP, IW casiwe PRESSURE, PSte DELTA'P"AGnosS vatvE OuRine UmeoaoINc “So. #S1. ROTTON HOLE TEWPERATURE. 1700 OECe Fe Wauverrvee azo 70 86 SET AY'e@ Dees F PORT' SIZES ARE LIniteo setveen © AKO 4/16 INCHES DESIRED PRODUCING RATE 800. BLPO. WATER-OIL RATIU. 24.00 FonmATION Gas-LiouIO RATION” 24, Custti/ent + STATIC BOrTOR MOLE PRESSURE 2400. P51G2 RICKDFe INJECTION PRESSURE-AT SURFACE’ “RSQ. AND AY WOTTON WULE 450 PSICe OPERATING INGEETIUN PRESSURE AT SURFACE "AGO. AND AY GOTTUM HOLE "#107 PICs FLOVING WELLHEAD TUBIMG PRESSURE” "100 PSTee PROnUCTIVITY InOEL "8.0 BLeO/PS MAXIMUM’ GAS VOLUME AVATLAMLE FOR GAS "LIFT 1200. nFCDs TENPPAATURE OF IdECTIUN CAS AT SURFACE | AO, DEGePe FLowtwa wet MEAD TueiNG TeRPewATURE 1u3,"ncGeF STATIC caablent OF LOAD FLUID O.nebo PsiZeTs vauve vert Punrsize Minne eer Tecnes 1 so? ene 2 ams ane ma > aes ane me ne 2 . 5205 ane no = 7 sos ane 708 * S708 ane ros ° sn ans 01 ww sem ane a0 VALVE OFPTH CALCULATION TERMINATED, NEXT VALVE AT 6000. FETs Lege Tuan 100 FEET weLow 10TH vate naxtniie UMUCADING PRODUCING RETE IS AOD. ALO AT. SomL FEET THE FOLLOWING RESULTS MERE OBTAINED USING THE CARCU CONTIMUJUS FLOM GAS LIFT PROGRAN FOR THE DICITAL COMPUTER CONTINOUS FLOM PRORLEN EXAMPLE FOR GAS LIFT SCHOULS ~ Pele Ustnown HW 15 4000-00 POVK 15 72627, HHL IS 6000.00 GRADP IS 0.4736 PRODI IS 0.0 ocUMP 1S B4ta2 or niner naxet “Peas Ty" toruny cor. ReOPS" TvaLve ye ‘ste. rie. 128 5 de oh: tne 13) 5 Ral ane 133 ‘ Be TAL 5 ieee tees : wet ier: 10 Tet ie. VALVE DEPTH CALCULATION TERMINATED. NEXT VALVE AT 6000+ FEETs LESS Than 00 FEET RELow LoTm VALVE, maxrhuir imUnaniNg PRMQUCING BATE'TS Ron, ALED AT. S9ML FEET. M7-1GRAPHICAL INTERPRETATION OF COMPUTER CALCULATED CONTINUOUS FLOW DESIGNe-dW GAs METER PRESSURE REDUCING usin Press. onirice eauce FITTING O aoe courRoLen casins PRESS. cause FLow LINE Gas LINE STANDARD ARRANGEMENT OF SURFACE CONTROL EQUIPMENT FOR CONTINUOUS FLOW GAS LIFTUEETION cas PaESSURE se RNS a ee an Ss Rune RN \\ AN (IRR SIS rare ANN ‘ RE eo THREE™ PEN PRESSURE RECORDING CHART ILLUSTRATING CONTINUOUS UNLOADING OF HIGH PLL, HIGH BHP VELL OW GAS LIFT USING A CHOKE 1M THE INJECTION CAS LIME M7=4CONTINUOUS FLOW INSTALLATION DESIGN USING UNBALANCED, BELLOWS-CHARGED, INJECTION PRESSURE OPERATED GAS LIFT VALVES The unbalanced injection pressure operated gas lift valve represents the simplest in construction and the most widely tised type of valve for all gas lift operations and in particular for continuous flow. The calculations outlined in this example do not include the effect of the bellows assembly load rate since most manufacturers do not publish this information. In fact, the actual performance characteristics of most gas lift valves are unknown. The safety factors in the design calculations are assumed to offset the additional injection pressure increase for sufficient stem travel necessary to achieve an adequate equivalent port size for unload- ing and operating conditions. This installation will be designed to lift the desired daily production rate from each gas lift valve depth, The inflow performance of the well is unknown or the average reservoir pressure is assumed to be changing a significantly within a short period of time; i.e., the point of gas injec- . tion is unknown or changing. The result is the same in that the instal- lation must be capable of lifting the design rate over a wide variation in flowing BHP. The installation design calculations are divided into two parts. The valve depths are determined and then the valve set pressures in a tester are calculated. The valve depths are based on a minimum flowing pres- sure gradient above the point of gas injection which requires a slight decrease in injection pressure to close each succeedingly lower valve after the valve immediately below is uncovered. The gas lift valve opening pressures in a tester are based on a bellows charge temperature of 60°F. Data for the installation design are given on the well data sheet. P7-1CONTINUOUS FLOW GAS LIFT INSTALLATION DESIGN WELL DATA SHEET Company, Gas Lift Course a | Field, Lease and Well No. Problem Example Gas Lift Valve Manufacturer___Camco, Inc. Type__R-20 Port 1.0._1/4 _in. Valve Mandrel Manufacturer__Camco, Inc. __Type_MMA [J TubingLJAnnular Flow Casing 0.0.__7 fn Weight__26 lb/ft Setting Depth__6150__ft Liner 0.D., Weight, and Setting Depth None Perforated Interval or Open Hole__6050_-- 6100 _ft Mid-Point_e075__ft (Show True Vertical Depths - Attach Drilled Depth Profile for Directional Wells) Tubing Size and Thread_2-7/8" R___Length__6000_ft Packer__s970__ft Static Bottomhole Pressure__2600 psig at__6000_ft Date__Recent Initial Bubble-Point Pressure. NA psig Solution GOR. 600 scf/STB Bottomhole Reservoir Temperature. 170 oF at. 6000. ft Productivity Index_ NA STB/D/psi Flow Efficiency. NA Multi-Rate Test Data: Gross Production and Flowing BHP at_ ft t sT8/D, psig) ( $18/D,, psidl Injection Gas Pressure: Kickoff 850 psig Operating, 800 psig Temperature of Injection Gas at Surface___80__°F Injection Gas Gravity__0.65 Injection Gas Volume for: Unloading____1200_Mscf/D Operating__1000_Mscf/D Static Fluid Level, 0 _ft WiT1 Well Be Unloaded to Atmosphere?___No Design Gross Production Rate 800__STB/Day Water Cut___96 __# Formation Gas-Liquid Ratio 24 scf/STB Oi Gravity_35 _°API Specific Gravities: Formation Gas 0.65 _011__0.85 _Water_1.08 Flowing We1!head Tubing Pressure, 100__psig for 800 STB/Day Flowing Wellhead Tubing Temperature____103 SF for. 800, sTB/Day Flowline 1... in. Length, ft Elevation Change ft Header or Separator Pressure at Production Facility. 40 psig Static Gradient of Load Fluid___0.468 _psi/ft ( Setting Temperature of Valve [Opening (Closing Pressure in Tester__60__°F Remarks, P7-2DETERMINATION OF VALVE DEPTHS IN A CONTINUOUS FLOW INSTALLATION Since the well has a high water cut, use the gradient curves for 800 BWPD to | establish the unloading flowing pressure traverse above the point of gas in- | Jection. No formation gas should be considered for the unloading traverses | above and below the point of gas injection. Since the well is loaded with water, it may be days before all load water is produced and the well cleans up. Little or no formation gas production can be anticipated until most of the load water has been produced. To simplify the calculations, use the static load fluid gradient for the traverse below the point of gas injection. The inflow performance for the well is unknown; therefore, the installation will be designed in order that the desired production rate of 800 STB/day can be gas lifted from each and every valve in the installation. This is not a unique design consideration. Gas lift installations are designed for many wells before completion. Retrievable gas lift valve mandrels with dumy valves are initially run in the well. When gas lift is required, the dummy valves are replaced with gas lift valves. 1. Draw the unloading traverse above the point of gas injection. Total GLR = Injection GLR = '200,000 S¢F/D — j 00 sct/y @00sT8]p f Actual Chart Pressure Depth Depth ft ft psig : 1000 a 1000 2000 202 2000 3000 304 3000 400° 408 4000 s0e0 512 5000 e000 wt : 6000 000 930 Feut poll em cee 1000744) Ge P7-32. Draw the operating injection gas pressure at depth curve based on the injection gas gravity and temperature gradient for this installation. Boo Fig aX segner Yreveres Jo BIO PURCH Goo! Note: Operating rather than kick-off pressure is used because the operating valve may be the top or second valve. 3. Calculate the depth of the top valve. uv = BO hoe wai Ly woo 2 4o® s i fe © eat = 830 4. Min PL, = 26E & Ply 5. Estimate the maximum injection gas requirement for the top valve and correct for well temperature. Si mbecretdon of 265 066 yritle: (riven {Oat o 7 L kyon T TELAT Yroscr bre Aue hho sea. “Untoaduce\ Doty ot I A ir Corstene! a ei Detty da Faget 20 Scr/ere (2003+ mp) > : Buy usce/p Tg at 804 Woo MoH ke YE oye OF loo! Cap * OOS JO CE Coie OtE pn iouer Ore Ayer Spe (atte gy a1 042 (ou Hser/o) = 3S? Nscr/p 6. For the top valve, P,@L, = P\@L,, since the top valve must remain open until the second valve is uncovered. Pol, = S30 Pay x tpco ur P7-4Determine the maximum injection gas thru-put of the top valve. Pup = Poly = B30 Hy Pan = Min PyeLy Gikine Yow tendition axiat + Pay << fa Pap Yue pert: Shai 14 = 130 HscAl> Capacity vf ln ov tet chedd gy, 2 30 Moet i fa Mote Lajection ops cugnicements pmnugt bt based en tha urtencling on the opuitting, Tray ere. oT sbblish wnlooding Travase ‘(for X92 asaniey privabant pot siveS aut im ) re 2 2 ned ) 8. Draw on tiatie nuts gradient Zraverse below Min Pel. Drais fond ana A inserts YO poanedtiding rowan adlab point of 63 lem 2000 si]. ce Bi/gt < 127440 Plot ovsis OT and 2o00 psig af 4274 Commed mith stainkt fine to establish “Praverse teased an 9s Determine the second valve depth from the P-D Plot. For given AP, = 50 psi, Lp = 2450 = ese ps Pol, = BSPty 9.-10. ‘i = 3 11, Min Pye, = 385 12. Estimate the maximum injection gas requirement for the second valve and correct for well temperature. Rachusittion of 35 Pely wrth. pniimiintin. Geasihe qadbinat eurve Crssume rare so) hype TELE & 625 scrfrs 62S scefsre (Boost8/p) eta Dal ing awe Soe Hscr/p Ty Olas 804 ays0 (BH) sire pa a3s0ge Cot = 0844 SECS (arte) > HOLT Gorter Chart. = 1-053 (SeomseF/p)¥ 529 esta) P7-513. Determine the Max P,@L, based on a straight line traverse. 4 Max Py@l, = 510 Aig atteoe tars 14, Calculate the additional tubing effect for the top valve. Add] TE@L, = (Max Py@L, - Min P,@L)) TEF . 1 wr ety (ere ~ 265) x00 = 18 Pst 15. Calculate the P.@L, based on the decrease in casing pressure required to close the top valve. Poly = Py@lp - Add*? TE@L, : gso - 12 QS2 Ps'4 gk BIS Bete: An ackativnal AP Uerease ig the Amjuttion presiure amey Me piceupa pein calitd yy gle eer 16. Determine the maximum injection gas thru-put of the second valve. - Pela ve = Min Pre, = 932 P94 = 385 ( Oncke Hug conc Gime remain enticnd (Low Chrot LagF BO Hocel> Cor! fy dmete pet Heap rretre wills Wy imo pat wl prrdood the witt CO Gace? SABNECH/D 4 Epair POT elas SH /ee im) de (9 (## hase) = 109s fe4 17. Draw the static fluid gradient traverse below Min P,@Lo. Prnstlel Travere for Gs =0.M6e 05 [TE Je Me tho dom Of We ayia yo pronnene ee degle eacut Pup 18-19. Determine the third valve depth from the P-D Plot. Ap, = App + Add'1 TEL, = 0418 268 psi y= Desf (al Heel Ae mua so ex) ( °. oh 2 ie Pram pe the surat ia ox (Rig Poyen) Jrmntn, semen padres i ee ee20. Min PyeL, = 49S psy Pye, = P90 pry 21, Estimate the maximum injection gas requirement for the third valve and correct for well temperature. Settettdion UAE Rly WH ntninten fawing qpedindk cove ! Apu TOURS gas ser /srb Untonding daly ingect yee « €26 serra (ove st2p)> CeO MECF/> qo ta >for 2450 (INGE)? Masta 2650;7 Cae +0005 44 oro fm 35°F ne Nac | 005 (135+ 460) Chad Soce* loro (60 H2¢r/0) 22. Determine the Max P,@L, based on a straight line traverse. Max Pyl, = 630 fs'g at 2950 pt 23. Calculate additional tubing effect for the second valve and the sum- mation for the third valve. Add"1 TE@L) = (Max Py@Ly - Min Py@Ly) TEF (exe = 38S) ©0872 218 per E Add"1 TE@L, = Add"1 TEL, + Add"1 TE®L, 218 + Ws 30 24. Calculate the P,@L, based on the decrease in casing pressure required to close Valves No. 1 and 2. PoeLy = Py@ls - £ Add'1 TE@L, = 870~3¢ = a4 psig ot 2es0 eT Rinnbicr Of opinion Pom tae Had waive i Ns Unloading foie’ = Reo! Setene ket Beto alter ESTES) PELE Em 1 M80 tae Guorzedaetie gg Seek oS eee ae 7 i: ut 3es0 Bs Cpoumen:2? HH hick valve gat be th fe ae 1 mece uaa pi tcfien Casi Presa Ee eh Mein apen cpcen he mecesnry pw Hoe panyecTinn Casing mre of What ceect val Tent vides wil main Sleds25. Determine the maximum injection gas thru-put of the third valve. Pup 7 Polls eed 4 Pgq = Min Ppl, =UIE eS Fn otk gurcieal ponpnts enthier (omer ea son Baran oh pr tha pat har que F NAS Necro Ge tfy" umes por a Yoon pee Wutle 4 sn co cad mock Maris adh fe ee 2700 Keer D> @ pot sexe 13/e4 a ey ae! s) Zierky Repeat Steps 17 through 25 for Valve No. 4 17. Draw the static fluid gradient traverse below Min LOLs. Penk fiavere Jor J, = 0.468 Pfc ot the joatinsaction of *he Arjen Ger pretrurn at dipth canes 18.-10. Determine the fourth valve depth from the P-D Plot. AP, = AP, + Add'1 TE@L, =62 +16* BG Psi 4 3 ‘3 ( pe smnin 5») Lg = 4225 5 = 380 20. Min Pel, = 558 Piel, = 2 21. Estimate the maximum injection gas requirement for the fourth valve and correct for well temperature. J ebaretEim, 04 550 ty with We prismannn Spend senime Meee» 10s03e'/ 5% ruboudiing Vag, = 050 *H/ste 7 ( Bao Step) > R40 Msc1/p Tee Lys Boe y gas ( 2585 pss or Was" Cate 0-084 Voo-es (as +400) elo oF lysop Cheat an a = 1.071 (840 nee) < oe Meth P7-822. Determine the Max Pyels based on a straight line-traverse. Max POL, = GBS pei at2¢s0" 23. Calculate the additional tubing effect for the third valve and the summa- tion for the fourth valve. Add'1 TE@L, = (Max POL, - Min P,OL,) TEF > (Ges - 425) vo°?2= WS SAdd'1 TECL, = Add"? Teel =u +8 + Add" TEOL st 24, Calculate the Poely based on the decrease in casing pressure required to close Valves No. 1, 2 and 3. Poblg = POL - SAdd'1 TECL, : 10-61 = 229 psig at 4925 25. Determine the maximum injection gas throughput of the fourth valve. = Piety = 829 ps = Min Pp@ly = $50 psi Pup an Chat Chet Sg wove Nece/> fe Yd inch port Hheefort walve with t]y dims gern anDoah ‘the wnst Ser ¥sc 2906 MScF/D a yer size 15/69 inch ANG oF (28%) = wey: Tester Opening Pressure Calculations Form After the gas lift valve depths have been established, the tester set opening pressure of the valves must be calculated. The valve depths are based on assumed gas lift valve operating pressures at the operating temperature of each valve at its depth in the well. The valve opening pressures at a base temperature of 60°F in a tester must be calculated for temperature sensitive valves. These tester opening pressures myst be accurate in order to assure proper unloading and operation and to pre- vent interference from any valve above the operating valve. P7-9OPENING PRESSURE CALCULATIONS FOR SINGLE-ELEMENT, UNBALANCED NITROGEN CHARGED GAS LIFT VALVES Company Ges LieT caunst Field Lease, Well Ho.. Valve Manufacturer Caacea inte Valve Type___@-20 Date, Valve L Port AA, min | Pye | Tet ce P Po Size Pal Cale sor No. ft. in. psig psig | psig °F psig psig oe —_— 4a 1 | too | Welw | coer | eo | aus | aon Jar | ogee 00 ‘fase 2 | ryso | MOH | coor | 232 | 365 | 02 au | oes | os2 | Vtlr40 3 | eso | YY | 5 oes ‘as fo we | ogae | ese | 728/780 4 | aees] leu | once | ees | sso | gto | tst | ogee | eae | US/720 Orit acl valve Pcommindid on Hotton lvalee Pur =| Peet (i}- Av/ap) [+ rin Por (AA Az Cx (fac) Prost A Nit 3 Tre l ¢Wyel |g a trelebt ge valve Wet letwrt tGre(e)= 1g3"t + sar /von (tf) nl Lonepaact pe Bs the| We of the| valves | wake vier have pose Tenpenitce boas | Ba P7-10ti-ad CONTINUOUS FLOW INSTALLATION DESIGN USING UNBALANCED, BELLOWS CHARGED, INJECTION PRESSURE OPERATED GAS LIFT VALVES 2 4 6 8 10 2 4 16 8 PRESSURE - 100 PSIG aDETERMINATION OF OPERATING GAS LIFT VALVE AND DAILY INJECTION GAS REQUIREMENT FOR CONTINUOUS FLOW INSTALLATION The gas lift valve depths were determined and the valve opening pressures at 60°F were calculated in the previous continuous flow installation design. The calculated tester opening pressures at 60°F were based on an actual flow- ing surface temperature of 103°F and a bottomhole temperature of 170°F at 6000 feet. The conditions and other data for the installation design will be assumed correct for determining the operating gas lift valve depth. There will be one and only one possible gas lift valve depth which can rep- resent the point of gas injection. This point of gas injection can be de- fined as the gas lift valve depth that has the highest flowing production pressure which is less than the injection gas pressure at the valve depth. The gas lift installation was designed without reservoir inflow information; i.e., the installation was designed to unload and lift the daily production rate of 800 STB/Day from every gas lift valve in the string. After the gas lift valves are installed and the well has stabilized, the flowing BHP is found to be 1700 psig at 6000 feet for the design rate of 800 STB/Day. This is the starting point for establishing the flowing pres- sure traverse below the point of gas injection. Before determining the flowing pressures at depth to plot this traverse, the Formation GLR must be calculated. Formation GOR _ scf/STB (WOR + 1) Formation GLR = Note that only the produced formation gas is in the flowing pressure tra~ verse below the point of gas injection. From the appropriate set of gradient curves for 800 STB/Day of water through 2-1/2inch nominal tubing, the flowing pressure traverse below the point of P7-13gas injection is defined as follows for a Formation GLR of approximately 25 scf/STB: Depth Pressure a, psig 6000 1700 = Pug 5000 1250 4000 800 304 100 375 tL at —_J 1. Draw the above flowing pressure traverse below the point of gas injec- tion on the same P-D Plot used to locate gas lift valve depths. Deter- mine the depth of the operating gas lift valve and the flowing production (tubing) pressure at the intersection of the traverse below the point of gas injection with the valve depth. line. = 36 = bso i boy 5 ft Flowing P,@Loy psig 2. Determine the daily injection gas requirement to lift the well if the flowing wellhead pressure is 100 psig. Actual Chart Pressure Total Injection Depth Depth GLR GLR ft. ft psig scf/STB scf/STB ° 000 100 acso Meso cso > > 340 as In}. dyge 7 4 * Inj. GLR F B00 srefy (o15 serfow) 252 H seep PEE Ota 4a CAT rade WU oe Whe cheney ct caine, utter lun vee Migr rat eu Tp POA Beem Soe sug clin din pects Pratl, bDovifiee heels che Oo qecerrmtudect odvts boblre gn Lyr cmdnt in emo eordimuegs lew amibadeBums + P7-14PREVENTION OF GAS LIFT VALVE INTERFERENCE IN CONTINUOUS FLOW OPERATION Valve interference can be defined as the inability to completely close upper unloading gas lift valves while lifting from a lower valve. Multi-point gas injection through upper valves in a continuous flow installation results in inefficient operation and a decrease in the liquid production for a given injection gas volume. When upper valve action occurs (upper valves partially open and close), severe surging may occur - particularly in large production conduits. Single point injection is essential to prevent severe surging in many high rate installations. The effect of temperature on a bellows charged gas lift valve can be utilized to eliminate valve interference. The purpose of this problem is to illustrate the design assumptions for flowing wellhead temperature that will prevent valve interference. These principles apply regardless of the installation design technique employed. The continuous flow design in the previous problem will be used to illustrate these calculations. The installation is gas lifting from the third valve. The valve opening pressures were based on a flowing wellhead temperature of 103°F. The flowing tubing pressure at the depth of the two upper unloading valves is — obtained from the flowing pressure traverse above the point of gas injection (not the unloading traverse). Do not use a straight line between the flowing wellhead pressure of 100 psig and the flowing tubing pressure at the depth of the third (operating) valve to obtain the flowing tubing pressure at the depth of the loading valves. Part I: Calculate the surface opening pressure of the two upper unloading valves and the pressure required to hold the third (operating) valve open based on surface flowing temperatures of 60°F, 103°F, and 140°F. Assume the Flowing temperature at depth is linear (a straight line) for calculating each valve temperature at depth. Part II: Compare the difference in the surface operating gas lift pressures calculated in Part I and explain in detail how an installation should be designed to prevent interference from upper valves. Note the design considerations required to assure no valve interference after an installation has unloaded. P7-15SURFACE REOPENING PRESSURE OF UNLOADING GAS LIFT VALVES ABOVE OPERATING VALVE IN CONTINUOUS FLOM INSTALLATION Company Field, Lease Hell No. Valve Manufacturer___Cameo Ine Valve Type___F- 2° Date ee ea, Mls) 0.933 oe valve] P, a“ Te ce P, Poe Peat Pet P esurf No. | at 60°F from at 60°F | PL/c Depth ee o/s psig ft oF psig psig psig psig psig Sa Gael \ 750 leo 39 aT 728 24 zee 277 ayy 2 140 2280 hie 0.903 50 708. 470 786 ay 3 ie 262 ay on bal 774 650 203_| sa Tek 10ste [otsemat Yo carrion cate tal wns \ 20 1600 fa 2824 wwe | 92 - B28 a 2 240 2350 134 2863 véto | wo - ay ns Z 0. 3es0 be ins Cae a = us = Teel = tore | Aelia dS fuatin thon Jarmemet : = . we oe “ & oes er! B40 = . iy on t2 “ 22 pew £56 fos" . a - ise 2.826 x was | bee 837 72 = Prec (ove) P7-16CONTINUOUS FLOW INSTALLATION DESIGN USING GAS LIFT VALVE PERFORMANCE Well data from the previous continuous flow installation design will be used to illustrate the design calculations using published gas lift valve perfor- mance information. The design is based on an increasing Total GLR (TGLR)s i.e., a decreasing, flowing pressure gradient with each succeedingly lower valve. The upper unloading gas lift valves should remain closed after the final point of gas injection has been reached and stabilized flow conditions have been established. The TGLR for the top valve is assumed to be 200 scf/ STB in this installation. In otherwords, the final operating TGLR is assumed to exceed 200 scf/STB and the top valve will remain closed for a TGLR greater than 200 scf/STB. Well Data and Gas Lift Valve Information: 1, Depth of Top Valve = 1600 ft 2. Flowing Wellhead Pressure = 100 psig 3. Merla Type L-12R with 3/8-inch Ball 4, Pyc@ly Based on TLR = 200 scf/STB 5, Temperature of Gas at Depth of Top Valve = 104°F 6. McMurry Gradient Curves for Water Cut = 65% Determine: I. Flowing transfer pressure at 1600 ft (P;@L,) based on the intersection of the Vertical Performance and Valve Performance Curves. woo sep (TELA) Vertical Pel Grakinds. tune see Assumed Chart Depth for Chart Depth for Flow gsc fF TELR Pun = 100 psig Ly = 1600 ft Pel, gS stay scf/STB ft ft psig Nscf/D 50 350 1aso 636 40 100 Heo 2.000 460 be 200 450 2082 Bye 160 400 $00 3102 t 7 Plot P7-17Pe —» Ri Valve Performance: ¥, Pa e gsc (ge) “tM (Pee ~ Pec) Devens Preely Cyredt er TAR Htoo seFbrss fe jut, erat Gaming Ge dace vier 2003/8 : Dn Tin 1 RQ b= 340 FH) e700 F Aeseonns “Werk, Te Lith pbc. WEL Yp mr Bast (M0 Hier/deq-Ai) Fer Get = pyr f ego =H 042 Te plat mbt fagormsce § Atswrme Page ty = 600 2(3 07 Hoo #7 [ke ( soo-2He)é 154 Muct/o From Graph of Gye Versus Pep @ Ly? Pp@ ky Fax arieco gh Capper. 0) %q,,¥ 90 Msclfy my Inj Gee [13 Se6fepg thee tr anstanenes point) II. Establish the depth of the second valve based on the Pr @ uy and full operating injection gas pressure on the P-D plot. by 2 20 z : ae lat 2000 psig at 4944 2000 = 435 aay Ie + seco savy 6 me Pe See bie ‘lope) Calculate the test block closing and opening pressures of the top valve. Ill. Poet Po @ Ly (TAL A) + Pee @ Ly (AL / Ay) Tee E Rar TOC ber ene, Pro = Pep (= Ans A) Vo toda, Lt pete GT 5" beer + fe et Iefpg Peek fo nah bafta ated. Hah Br @20 Corre ja 30 (enna) = 722 A THE eee 8 Qo = 322 ‘O98 WETS oe Fargesafina soueclion beret cht ln apap fonctiel= 6 7-186t-L6 gsc Nsct/D CONTINUOUS FLOW INSTALLATION DESIGN USING GAS LIFT VALVE PERFORMANCE bo PygGh - PSIGCONTINUOUS FLOW INSTALLATION DESIGN BASED ON GAS LIFT VALVE PERFORMANCE 6 8 10 R Ww 6 P7-20OPERATING SURFACE INJECTION GAS PRESSURE FOR A CONTINUOUS FLOW INSTALLATION BASED ON THE BELLOWS ASSEMBLY LOAD RATE OF THE OPERATING GAS LIFT VALVE The bellows assembly load rate of the gas lift valves is ignored in many con- tinuous flow installation design techniques using unbalanced, bellows-charged, injection pressure operated gas lift valves. The gas lift valves are assumed to have the equivalent port size necessary to pass the injection gas require ment for each unloading valve without an increase in the injection ges pres- sure at depth above the calculated valve opening pressure based on the force balance equation. A valve is actually closed with no force being exerted by the tip on its seat for a PL@L based on this equation. An approximate injec- tion gas pressure increase necessary to produce the stem travel for the re- quired equivalent port size can be calculated for a simple unbalanced gas lift valve when the bellows assembly load rate is known. The depth of the operating gas lift valve and the daily injection gas require- ments were determined in a previous problem. The same well and valve informa~ tion will be used to illustrate calculations utilizing a given bellows assembly. Joad rate of the operating gas lift valve in this installation. Well_and Valve Information: 1. Operating Valve: Camco Type R-20 with a 1/4~inch Port 2. Bellows Assembly Load Rate, LR,, = 400 psi/in. Depth of Operating Valve, La, = 3650 ft Bellows Charge Pressure, P,, = 810 psig at 144°F Flowing Production Pressure at Depth, Pp @L,, = 650 psig at 3650 ft Daily Injection Gas Requirenent, Inj. qgcq = 252 Hscf/D Choke Capacity Correction Factor, C, 1.070 for 135°F sonee gt I, Calculate the Initial P,@L,, when Closing Force = Opening Force: Twice Fraley Sot ___— Pre @lov (74) (- Ar fay) = BIO 450 (nore) & 921 pig of 365° e 0.933 P7-21II. Calculate the required increase in the injection gas pressure to fully open the valve; i.e., stem movement for a full port area: EO Mys 20810 inch Cus fig ©=! 0 APL = FO vl tae C= Pelas) vo mile) ane tonom ( 4 Or AS ae III. Calculate the injection gas volumetric throughput of a 1/4-inch port: Pop = #21 “ 14 BRIG 064 Phy oral Rim = 650 fas] Chaat Fgcc# 1os0 Mscr/D fo thy orche pat’ ec G Tau) Joy, = CoE Mere 2 ps0 NAME Gage Mset/D cc 070 Wine Cge = 1070 pr iaser IV. Calculate the fraction that the valve is“open in terms of a full-open port area based on the ratio of the daily injection gas requirement to the full- open corrected injection gas throughput from Part III: Sago = Bauines inf Save. asa Heri 0.25% —_ oe V. Calculate the Actual P,Q@L,, based on the Ap above the Initial P.@Ly, for the bellows assembly load rate to achieve the equivalent port size for the required daily injection gas requirement: BE chet Jniled Pe@lov = Sypo(Fro d P)eo.259 (42 bead Fo @loy 021 Rigas esa-tiy TH a6c0 7 LMral Amrjnce WE HBOS T Sufoa Ja es, P7-22