THE TECHNOLOGY OF ARTIFICIAL LIFT METHODS Volume 2a Introduction of Artificial Litt Systems Beam Pumping: Design and Analysis Gas Lift Kermit E. Brown The University of Tulsa 1 contributing authors John J. Day Joe P. Byrd Joe Mach Pennyell Books PennWell Publishing Company “Tulsa, Oklahoma ve ebh |. LIBRARYInn Yaa ons seewtanere Precedent w een Ice ‘omonsse11 194085 Conyeant © 1980 by PennWell Publishing Company Box 1250, Tulsa. Ox LUbrary of Congress Cataloging In Publication Data (Revised) Brome, Kermit ‘Th technology of arial metas, Includes bibiogrepticalrelarencas. CONTENTS: v. 1. lnlow parformance, muliphase ow in pipes, the owing wal.—y. 2. Inroducton ‘of aril it systems beam pumping 1. Oiwals, 2 Ppo—Flud dynamics. |. Til rNeviesis eez.sde 7659201 SBN 0-87814.091-X (vt) ‘Al rights reserved. No pat of this book may be ‘eproduced, stored na retieval system, oF lranseived in any frm or by any means, sleavoni oF mecnancal. including photocopying and recoding, ‘itnou te price writen parission ofthe pubisher. Incomationst Standard Book Number: O-87614-119-7 Print inthe United States of Amariea 29450899 eatI dedicate this book to my four children and three grandchildren. They are in the order in which God created them: Stephen Wesley, Sandra Kay, Robert Michael, David Earl, Stephen William, Bryan Scott end Robert Wade.Chapter 1 Chapter 2 Contents Introduction of artificial lift systems 1 Introduction 1 441 Purpose of ati lit 2 4112 Usizasion of mutiphese flow correlations for artificial it systems 3 1.121 Introduction 3 4.122 Use of multiphase flow corelations 3 4.1221 Viscosity 3 4.1222 Etfect of slippage of fell-back § 4.129. Summary of multiphase flow 6 Beam pumping: design and analysis, by John J. Day and Joe P. Byr' 2a 22 23 24 25 26 27 28 Introduction 9 General considerations © ‘Subsurfece pumps 11 231 Tubing pumps 12 2.311, Tubing pumps classified according to type of working barrel 12 2.312 Tubing pumps classified according to type of standing valve 12 2313 Tubing pumps classified according fo type of plunger 12 232 Inset pumps 13 233 Casing pumps 14 234 The pumping cycle 14 235 API pump classifications 15 236 Pump size selection 15 ‘The sucker rod string—general considerations 20 2.44 Design ofthe sucker rod sting 23 2442 Modiied Goodman diagram 26 Pumping motion 27 2.51 Simple harmonic motion (SHMA) 27 252 Crank and pitman motion 29 253. The influence of pumping motion on the rod and structural loading of @ beam-type unit 29 ‘The effect of erankcto-pitman ratio on class land class il geometries 32 Effective plunger stroke 33 2.71 Rod and tubing stretch—single rod size 33 2.72 Rod etretch—tapered stings 35 2.73 Plunger overtavel 35 2731 Coberiey's method 35 Calculations for surface equipment 97 2.81 Counlerbalance 38 2.82 Torque considerations 39 2821 Torque factors 40 2.622 An important aspect of energy conservation in a beam and sucker rod pumping system 41 2.83 Prime movers 42 2.84 Prime mover horsepower requirements 43 2edt Neti 43 2.842 Frictional horsepower 44 viivii Contents Chapter 3 p28 2843 Cyctc load factor 44 2.644 Surface offciency in a beam and sucker rod pumping system 45 2.845 Approximate horsepower formulas 47 285 Speed reduction and engine sheave size 50 288 APlunit ratings 50 ‘API recommended design procedure $2 2.10 Dynamometers and dynagraphs 59 2101 The dynamometer card (dynagraph) 60 2102 Limitation of visual interpretation 63 2.103 Loads from dynamometer cards 85 2104 Courterbalance effect from dynamometer cards 65 2.105 Polished rod horsepower irom dynamometer cards 65 2108 Torque from dynamometer cards 69 2.107 Factors infuencing the shape of dynamometer cards 75 2.108 Permissible oad diagrams 78 2.11 Non-synchronous pumping speeds In a beam and sucker rod system 78 2.12 Beam pumping geometry and Its effect on rod and unit loading and pump travel 79 2.13 Modem predictive methods 80 2.191. Precieting polished rod dynamometer card shapes 84 2.14 The diagnostic technique 86 2.16 tnortial torque In a beam and sucker rod pumping system 85 2.151 Aperformence comparison between two beam and sucker rod pumping units of Cssimilar geometry consicaring the influence of inertial torque 68 Nomenclature 91 Roterences 94 Gas lift 34 32 Introduction 95 3.11 Defnitons 95 valve characteristies 96 321 lnraduction 96 322 Gas it valve nomenclature $6 3.23. Design considerations 97 3231 Continuous flow 97 3.232 Intermitent it 97 3.24 Pressure, area, and force relationships 97 3.25 Casing pressure operated valve 98 3.251 Unbalanced belows valve with pressure charged dome as loading clement 98 3.2511 Opening pressure of valve under operating conditions $8 3.2512 Closing pressure of valve under operating conditions 101 32513 Spread 102 3.2514 Gas pressure at depth 103, 3.2515 Test rack opening pressure 104 3.2516 Standard pressure operated gas lit valve summary example 105 3.252 Unbalanced bellows valve with pressure charged dame and spring as loading element 105 32521 Opening pressure of valve under operating conditions 106 3.2522 Closing pressure of valve under operating conditions 105 32523 Spread 107 3.2524 Summary examples 107 9.253. Balanced pressure valve 109 3.258 Pilot valves 110 3.255 Gas passage 111 3.28 Throtting pressure valve 111 327 Fluid operated valve 112 3.271 Opening pressure of fuid valve under operating concitions 112 3.272 Closing pressure of valve under operating conditions 114 9.273 Test rack opening pressure 114Contents "ix 9.274 Summary examples - fd valve _ 116 3275 Gas passage characteristics 117 3276 Dillerential valve 117 3.2761 Opening pressure of ciferentia valve under actual operating conditions 117 3.2762 Closing pressure of differential valve under operating conditions 118 32763. Test rack seting procedure for difarental valve 118, 228 Combination valves 118 3.29 Dynamic considerations 119 3291 Bellows travel and protection 119 3.292 Boliows load rato 119 15.293 Pressure valves 121 3.210 Ciass problems 121 ‘Types of gos litt Installations 123 331 Inoduction 123, 3.82 Open installation 123 333 Semiclosed installations (Fig. 932) 124 3.34 Closed installations (Fig. 3.8) 124 385 Chamber installations 124 2.351 Introduction 128 3.852. Standard two-packer chamber (Fig. 2.25) 125 3.353 Insert chamber (Fig. 896) 125 3.354 Reverse flow chamber instaliaion 125 3.355 Special chamber to save gas for long pay interval 125 12.356 Special chamber instalation for sand removal 126 3.357 Open hole chamber installation 127 3.358 Special chambers for bad casing and/or long perforate or fong epen hole interval 127 3.859 Chamber above packer 128 3.8570 Automatic veni chamber system 128 3.95 Macaroni instatations 128 337 Dual installations 192 338 Packol!instafations 133 3.39 Amular tow 135, 3.310 Installations to backwash injection wells. 135 Design of gas lft installations 137 3.41 Introduction 137 3.42 Continuous flow design 137 3421 Introduction 137 3422 Factors to consider in the design of a continuous flow gas it instalation 128 24221 Requirements of continuous flow valves 138 34222 Separator pressure and wellhead flowing pressure 198, 34223. Location of the top valve 198, 3.4224 Injection gas pressure and volume 199 3.4225 Bottom hole temperature (BHT) and flowing temperatu 3.42251 Invoduetion 139 8.42252 Kirkpatrick's solution 140 2.42254 Shiu's correlations 140 3.4226. Unloading gradients and spacing of gas ift valves 143 34227, Flow configuration sizes and procuction rates 143, 3.4228 Valve settings 144 3.4228. Approximations to be used in continuous fow installations 144 8.42210 Types of instalations 144 3.42211 Use of muliphaco flow correlations 144 9.423. Design procedure for a continuous flow instalation 144 34231 Determining the point of gas injection. 144 ‘3.4232 Determining tow rates possible by gas lt, by Pedro Regnault 147 8.42321 Introduction 147 = 8.42922 Solution for a constant welhead pressure 148 aay 3.428221 Pressure-iow rate Giagram procedure 148 3.423222 Equilibrium cuve procedure 149 3.42928 Solution fora variable welhead pressure, by Hugo Marin 155 3.423231 Wellhead pressure-low rate diagram procedure 155 3.423232 Flowing botiom-hole prassure-fow rate diagram procedure 187 139x Contents 4.424 An sono uty fa continuous How ges Ih wel by Pac Regnauk 162 Steet modseton 162 Bacsz. Earnie problem 162 s.aes Bea of contra tw gos it sialatons based onthe os! econo oui ol gs be beta by Maar cel an sus Pacha 168 Sezst neoascon 68 4282 Gatrnnabn of he met corel toa gas ue fr onan totnece peso” 168 Seater recede fer ho most sxoromial gas tt dein 166 S2ER2. Shonen mabe tor determining the men economia S6- Tul at to 2.12509 Barge problem Hustle the est economical ga it sean 70 ; 214283 eteminaton otha mos! econo! astra ovale wand pressure 179 Ses50 tuoducton 173 S42582.Desotpton ofthe economical spe matad_174 SSS Baten of promt on atv cat of gs ected metiod 178 RSE Gente pobloe ore mont ears gen oagn— tl woead pes 178, | Sasa "Ceenomaal slope meod 178 Side Prof on ol vant of as ected mahod 181 / 4250s teat of veri 108 S425" eet of Poin length 180 Siczecee tet of fowine comet’ 104 4.42506. Danusin of asl 185 SA2507 Consuons, 83 4.426 Opting coun few go stems, by Vicor Gomex and Hay Hong. 198 Beast hrosucion 18 ‘ $1282. Comuacs low ga it design fr pinizakon based on i rman le S87 saan Cont elhead procedure 187 S250 Desurpton of cure fing and opmizaton procedure. 188 Sas oducton 8 Ses Gave tery Teo Sa2s3'3. Optinzato pronto 108 ou2sse Fate rampie 103 4.4064 arate wetheadsoiton | 121 Suzee Computational procewure 181 32602. Decsipon of he opimizabon pocedue 189 S20" ivoauclon 190 SSE) Guns mepolaing scheme 104 aa5t23.Optmissbon procedure 198 2142643, Eaoe ol vanes in epimiaton of vanabla wolnead gat itsytene. Tot Sa26tSTInewuton 194 SGeG2 Etec of ing siz and fowin sie 184 $2005 Elect ol separ prs 198 Sisse.efect of wr ul 13, S:28405 Eft of evalu econ pressure 198 Sete Efecto pocuctiy don T88 Sees? surmeany 198 34285 Concuson ana econmaratons 192 34258 Flu cece of economia optnizaton 190 Sizeet invoctan 160 Sazee2 Oniieebon ge 198 3.603 Examplo provem 200 S.ca00e_ Summa 202 7 2.4ar_Slecton ot gas pura 202 S107! nteducton 202 Sara Michel's procedure 200 S4a73. Spec ago make sdlecton of parameas in coninoue fow gut aor Sever troducion 207 32782. Dean pecedua 207343 Contents "xi 9.42783. Selecting parameters 200 3.42734 Example problem 209 3.428 A new gas lif concept-—"two-step gas fit instalation,” by Juan Faustineli 214 3.4281 Inroducton 211 24282 Description of the two-step gas lit method 211 34283 Proposed well bre completion fora two-step gas iit instalation 214 3.42881 Parallel two-step completion for walls of Lake Maracaibo, Venezuela 214 3.42832 Concenivis two-step completion 214 34284 Tworstep gas it examples 214 3.4285 Summary and conclusions 223, 3.429. Spacing of continuous flow gas it valves 223 3.4291 Introduction 223 3.4292 Universal design and spacing for alltypes of continuous flow gas it valves 224 3.42921 Introduction 228 3.42922 Standard pressure operated valves—constant surtace opening pressure 224 3.4299. Design procedure for pressure operated valves—taking 10-20 psi drop in surface closing pressures between valves. 230 9.4294 Spacing and design procedure for uid operated valves (oressure charged dome)—universal design 232 3.4295 Spacing and design procedure for combination pressure closed, fuid opened valves 233 8.4286 Design example for fluid operated, spring loaded gas lit valves 233 3.4297 Additional spacing procedures 236 ‘3.42971 Intreduction 236 2.42972 Common procedure for analytical spacing of pressure operated asi vaves 236 3.42973 Graphical spacing of pressure operated valves—(26 pel drop in pressure between valves) 230 84298 Discussion on spacing 238 ‘3.4299 Continuous flow design for ciferenial valves, 241 ‘3.42991 Introduction 241 '3.42992 Design procedure for diferential valves (continuous flow) 241 3.42983. Design exernple for differential valves (continuous flow) 241 3.42994. Analyteal procedure for spacing diferentil valves 242 3.42910 Spacing of completely belanced continuous fow valves 242 3.42911 Proportional response sysiem 244 3429111 Invoduction 244 3.429112 Transfer operation 248 34291121 Transfer point selection 246 3.429112 Gas requirements 246 34291123 Gas supply 247 2.429143 Design example—detalled information available 247 34291191 Preliminary wel analysis 248, ‘34291132 Gas it valve spacing and selection 248 3.429114 Compuler designed example 251 2.4210 Continuous flow gas-iting directionally diled wells 253 342101 Introduction 253 342102 Methods for calculating pressure loss in deviated wells 254 3.42103 Design of gas lit instalations 255 3.42104 Example problems and discussion 256 3.42105 Summary 257 3.4211 Summary and logical sequence in continuous flow gas lt design 257 ‘9.4212 Ciass problems "258 Design of intermittent ow installations 260, 8.431 Introduction 260 ~ 3.432. Intermitint gas fit cycle 261 3.433. Analysis of pressure recoicings during intermitent ges lit cycles 261 3.434 Factors to consider Inthe design of an intermitent instalation 264 34341 Type of inctalations 264 34342 Location of top valve depth 265, . 3.4343 Avalable pressures and valve setings 266 24946 Unloading gradients and spacing 257xii Contents 3.435 3.4345. Ditferential between valve pressure and tubing load to lit 267 3.4946 Gasiit valve por size 263, 34947 Percent recovery 272 8.4343. Gas volume requirements for intermitont lit 279 3.4349 Cycle requency and pressure stabilzain time 273 3.43410 Types of valves for intermittent lit 274 8.49411 Single point vs. mulipoint injection for itermttant it 275 3.43412 Summary of design considerations in intermittent it 275 ‘sign and spacing procedures for inlermittent gas it installalons 275 94951 Introduction 275 3.4952 Design procedure for intermittant gas Ht well 276 34953 Graphical procedure—pressure operated valves (ime cycle control at the surface) 279 9.4954 Analytical pracedure—pressure operated valves (lime-cycla control at the surtace) (25 psi drop in presaure bedween valves) 281 3.4955. Graphical procedure—pressure operated valves (choke control at the surface) (25 psi drop in surtace opening pressure between valves) 262 3.4358 Pressure operated valves-—graphical pracedure, constant valve closing pressure (time cycle control and choke control) 264 3.4357 Design procedure, fluid operated valves for multipoint injection 286 3.49571 Nivogen charged fluid valve 287 3.49572 Design example for multipoint intermittent it—spring charged valve 268 9.4958 Intermitent optitlow design procedure 290 34358 Dasign for combination Mid oponed, pressure closed valves 292 3.49591 Introduction 292 ‘9.43592 Ossign procedure | for the combination pressure closad tubing ‘pressure opened valve (choke contol or time cycie contol) 293 3.49593 Design procedure Il for combination pressure clasad tubing Pressure opened valves 294 3.49510 Design procedure for complataly batanced valves 298 3.435101 Graphical procedure for designing a low productivity intermittent instalation for balanced valves 298, 3.49511 Design example in which the static ld lave is fw inthe well and the well hhas not been loaded with “ki” fhuid—balanced valves 298 ‘3.49512 Designing chamber gas Iitinstafations for intermittent it 298 3495421 Introduction 298 3.495122 Procedure for designing standard chamber installations 298 3.4951221 Example problem No. 1 299 3.498122 Example problem No. 2 301 3.495129 Example problem for insert chamber S03 3.435124 Special chamber design for deep wells and fow surface gas operating pressure 304 34951241 introduction 904 3.4351262 Design procedure—intermiter contral (chamber valve to be operating valve) 305 3.4951249 Desion procedure—chamber choke control— chamber vaive to be oparating valve 306 9.4951244 Special design 308 3.4951246 Fisid example of deep chamber for low operating pressure 307 3.4351246 Field case no. 2—chamber it (chamber valve = ‘operating valve) 308, 34951247 Summary 309 9.498 Detailed design for intermittent fow—a method for determining the production rate 309 3.4961 Introduction 309 3.4962 Caloulatng the weighted average BHP 310 3.43621 Example 1—calculating the minimum BHP that occurs for one cele of intermittent it 310 9.49622 Example 2—calcuialing the weighted average BHP for one ‘completo cycle (without standing valve) 311 3.438221 Reducing the weighted average BHP 312 3.49623, Example 3—caiculating the weighled average BHP for one Complete cycia (with stancing valve) 3133437 3.498 Contents xiii 19.4983 Detalled design of intermittent instalation 919 Effect of variables in intermitent bk 316 3.4971 Detailed design for intermittent flow—etfect of variables 316 343711 Effect of differential between valve pressure end tubing load 316 3.43712 Eflect of Pl 316 3.4372. Computer solution to the problem 316 3.43721. Efiect of ctferental and Pl 317 3.43722 Ettect of depth 317 3.43723. Prediction of BHPS 318 Class problems, intermittent design probloms 318 8.44 Comparisons of continuous, slandard intermittent and chamber gas lit methods, by Folx Eslat 320 341 3449 Introduction 320, Ettect of changing static pressure 320 Ettect of wellhead pressure 321 Effect of productviy index $22 Etfect of tubing size 322 Etfect of the slippage 924 Etfect of surface injection pressure 924 Etiect of pressure cifferntial across the valve 925 Effect of eiferential and cycle time 825 3.4410 Summary 325 ‘3.45 Multiple completions, by Jeny B. Davis and Kermit E. Brown 326 3.451 3.452 3.453 3.454 3.485, 3.456 3.457 Introduction ° 326 ‘Types of instalations 326 34521 Introduction 325 3.4522. Paralll tubing sting installations 926 3.4823. Concentric tubing string installations 327 3.4524 Commingling of zones. 327 Valve salecton for a dual installation producing both zones by continuous lit 327 3.4531 Introduction 327 3.4582 Two strings of combination fluid opened and pressure ofuid closed valves 327 3.4533, Two strings of fuid operated valves (open and close on tubing tid pressure) 327 3.4534 ‘Two strings of pressure operated valves 327 3.4835. One string of fluid operatad valves (open and close on tubing fig pressure) and one siring of pressure operated valves 927 Valve selection for a dual installation producing both zones by intermittent it $28 3.4541 Introduction 328 3.4542 Two strings of combination fui opened and pressure closed valves, 928 3.4543 Two stings of plot operated valves $26 3.4564 Two strings of standard pressure operated betows valves 829, 3.4545 Two stings of fuid Valve selection for a dual installation producing one zone by continuous lit and one zone by intermittent I 329 3.2551 Two strings of combination fi opened and pressure closed valves 929 3.4552 One string pressure operated bollows continuous fit valves and one sting of pict operated intermittent valves, 823 3.4853 Two strings of pressure operated betiows valves $30 ‘3.4554 One string of fd operated valves (opened and closed by tubing luis pressure) and one string of pressure operated belows valves 330 3.4585 Two strings of Tuld-operated valves (opened and closed by tubing id pressure) 390 Design of dual gas lit installations 930 Example designs 330 3.4871 Example set #1 220 3.4872 Example sat #2 339 9.4573. Example set #3 (mandrels in piace) 299 35 Compressor systems 338 351 Introduction 336 3.52. Classification of compressor systems 996 ‘353. Design of the compressor system 337 3.sat 3.532 Inoduction 837 Factors fo consider when designing a compressor system 998xiv Contents ‘88321 Location of alllease equipment 338 3.5922. The individual gas it valve design for each wel 308 35329 Gas volume needed 339 35924 Injection gas pressure 339 38925 Separator pressure and suction pressure 908 25926 Distibution system 339 38327 Low-pressurea gatnoring system 341 35328 Availability of make-up gas 942 35223. Avalabilly of a gas sales outlet 342 259210 Freezing conditions (nydrates) 242 9.593 Compressor selection 344 35331 Inveduction 344 3.5332. Sizing the compressor 344 8.54 Design ofa rotative compressor system 351 8.85 Summary 954 355 Problems 365, 3.6 Gas lift operation, analysis, and trouble shooting 355 3.61 Introduction’ 355 3.62 Operation of gas i systems 356 3.621 Unloading processes 356 3.6211 Continuous flow unioading process 356 36212 Intermittent fow unloading process 387 8.622 Types of gas injection contol 356 36221" Choke contro! 358 8.6222 Regulator control in conjunction with a choke intermitent flow 959 3.6223. Time cycle controler 359 3.63 Analysis and trouble shooting 350 3.631 Introduction 360 3.632 Pressure surveys—continuous llow 981 38921 Introduction 361 3.6322 Hypothetical case of owing prassures surveys 262 3.6323. Field cases of flowing prasaure surveys 265 3.633. Flowing temperature surveys—continuous fow wells 967 8.694 Combination fowing pressure and flowing tamperature surveys (for continuous fow wets) 369 3.635 Pressure survays—intemmittent it 372 3.6951 introduction 372 3.8952 Hypothetical pressure surveys 973 3.6353. Field cases of intermittent pressure surveys 973, 3.696 Well sounding devices 376 9.6961 Introduction 976 3.6362 Field cases of acoustic surveys 977 8.637 Surtace recordings of casing and tubing pressures 378 36971 Introduction 378 3.6372 Continuous tow recorder charts 979 363721 Hypothetical charts 379 3.63722 Field cases of two-pen surtace recorder charts for continuous flow 363 3.6373. Intermitent low recorder charts 38 3.63731 Hypothetical charts 363 3.69782 Field cases of two-pon recorder chars for intermittent flow 999 3.698 Surface wethead pressure 435 3.6381 Intreducton 435 9.6982 Effect of back-pressure for continuous How 435 8.6383 _Eifect of back-pressure for intermittent fow 437 3.639 Injection gas pressure 439 3.6310 Injection gas volumes 441 3.6311 Total output gas volumes 443 3.6312 Total lid recovery 443 3.6313 Tomperature of the fowine and Christmas tree 443 3.6314 Miscellaneous 443, 3.6315 Field case of improved operations 444 3.6316 Summary 444 AppendixPreface For the first time, all the artifical lift methods are presented in one volume. Volume 2 is published in two Separate books, Vol. 2A and Vol. 2B, and is complete ‘with sufficient charts, curves, etc. to plan, design, ana- Iyze, and compare all artificial lift methods. Volume 1, published in 1977, gives all the preliminary informa. Hon needed to use Vol. 2. Volume 1 includes (1) the inflow ability of the well, (2) multiphase flow in pipes, ‘and (8) the flowing well. Although not absolutely neces- sary, Volume 1 should be studied and used in con- junction with Volume 2. Volume 3, which is also available, includes over 2,200 flowing pressure traverse curves for multiphase vertical fiow and horizontal flow, {as production, gas injection and water injection curves. T want to thank the many individuals that helped write this text. I Iso want to thank their companies that relinquished time for them to do so. These indi viduals and their respective companies are listed below: Jokn J. Dey Joe P. Byrd Joe Mach Jerry B, Davis Bill Richards Ed DeMoss Gene Riling Clarence Dunbar Satish Goel Don Rhosds Phil M. Wilson Hal L. Petrie Bolling A. Abercrombie Phil Patillo ©. R Canalizo RH, Gault George Thompson Bill Waters KC. McBride Forrest. E. Chancellor W.G. Skinner LAS: Hank Arendt Rusty Johnston ‘Tom Doll J.T, Dewan Purvis J. Thrash Luiz Couto The University of Tulsa Latkin Industries, Ine Tohnston Maceo Schtumberger Otis Engineering Corp Teledyne Merle Teledyne Merle TRW-REDA TRWREDA OILINE KOBE Centrtif, Ine. KOBE KOBE ‘MeMurry-Hughes ‘Amnoco Research Otis Bagineering Corp. Bethlehem Ste! Corporation TEC Of Field Pomp Hydrogas-Lift Systera EI Paso Neturel Gas Co, Chancellor Oi! Tots, Inc. Mid-Continent Supply Mid-Continent Suppl Otis Boaineerng to. Otis Engineering Corp. Louisiana Land and Exploration Tiinko, Lindaht! & Schwetkhardt, Ine. Otis Engineering Corp. Petrobras ‘There are numerous other individuals that I want to thank for their assistance and contributions: Spencer Duke, Victor Gomez, Harry Hong, Hugo Marin, Felix Eslait, Juan Faustinelli, Victor Mitchell, Pedro Ragnault, Jesus Pacheco, Carlos Woyno, Luis Menezes, Gustavo Lopes, Mario Sanchez, Nelson Velloso, Frank ~xvi Preface Zarvinal, Roman Omana, Humberto Calderon, Edgar LaFuentes, Celio Fonseca, Abad Loreto, Mohammed Yousaf, Cesar Camacho, Nelson Cordozo, Alvaro Fuentes and Carlos Ney. Thanks is due to the following companies for per- mission to reproduce certain art work: Centrilit, Inc., Otis Engineering Corp., Lufkin Industries, Inc., TRW-REDA, KOBE, Fluid’ Packed Pumps United States Steel and Johnston MaccoSchlumberger. Volume II offers sufficient flexibility to be used as a text or to be used by the engineer in industry in designing installations. Example problems are worked and numerous class problems are included. Eventually, an answer guide will be available. I want to thank The University of Tulsa for the ‘opportunity to publish this text. Also, thanks is due to Evelyn Washburn, Nelda Whipple and Betty Finnegan for their help in typing the manuscript. Finally, I want to thank my wife, Katherine, for her patience, love and understanding while I com- pleted this text. Kermit B. BrownChapter 1 Artificial lift systems 1.4 INTRODUCTION This text will discuss the various types of artificial lift systems available today. More and more wells in the world are being placed on artifical lift, and the number will contioue to increase. The selection of the ‘most suitable type of artificial lift for a well or group of wells ean be dificult or easy, depending upon the conditions, Generally, more than one method of lift can be used, Each method of lift may be classified from excellent to poor in accomplishing the objective. Depending upon the economic considerations, two types of lift (one used later) may possibly be prescribed for a group of wells. For example, in a “depletion” type reservoir, high initial production rates may be needed, but decreasing pressures and declining inflow capability may require a low rate in the future. In this case, an initial instal lation of continuous flow gas lift or electrical submers- ible pumping may be changed to intermittent gas lift, sucker rod pumping, or hydraulic pumping at a later date, or vice versa. ‘The following list probably represents the relative standing of lft systems based on the number of instal- Jations throughout the world. This differs from field to field, state to state, and country to country. (1) Sucker rod pumping (beam pumping) (2) Gas lit, 3) Electrical submersible pumping () Hydraulic pumping (8) Jet pumping (6) Plunger (Gree piston) lift (7) Other methods ‘As these methods are discussed, complete design procedures wil be given along with numerous example problems. In addition, other methods are continually being developed and tested. A short discussion on the ball pump and the gasactuated pump are also given. The ball pump was tried many years ago, and new interest hasrecently sparked additional development of this it method. The ball pump uses spherical flexible balls that pass down one tubing string and return through ‘another in order to eliminate the slippage of gas past the liquids. Gas is used as the source of power. ‘The ges pump has been in the experimental stage for many Years. Several field trials have been performed and are installed at the present time, The pump uses gas to actuate a downhole pump and can be used in conjunction with gas lit. In particular, gas lit unload- ing valves may be used to reach the pump. Rothrock presented Table 1.1, showing the distribu- tion of 518,867 oil wells based on a 7% sampling from 200 operators with information on 37,100 wells.! TABLE 14 CGAUDE PRODUCING WELLS (JAN, 187) Calegory Number Pescert od pumping 40997 e521 Gas it 51,964 1080 Eleccal submersble 3708 Hydric “Tolal US. aii US. towing of wals ‘Tots! LS. procucing ll wes ion00% Of the 518,867 wells, 481,146 or 92.7% are being lifted artificially. These are further broken down into 85.2% rod pump, 10.8% gas lift, 2% submersible, and 2e hydraulic. Approximately 383,000 of the artificial wells are strippers (producing less than 10 B/D). Assuming that 100% of the stripper wells are on rod pump, then Table 1.2 shows a redistribution of the remaining wells TABLE 12 ARTIFICIAL LIFT WELLS (LESS STRIPPER WELLS) catepoy Number Percent Rod pumping esr 28 Gas it B16 Electrica! sutmersiole yoraute "Tolal wets Table 12 shows that the largest percentage of the wells are on gas lift after eliminating stripper wells. Gas lift predominates on offshore wells but, according to Rothrock, isnot keeping pace with other lit methods in areas other than offshore. ‘Submersible pump use is inereasing rapidly in West ‘Texas and in some Rocky Mountain areas. noted that hydraulic pumping is not growing at the rate of other methods. However, jet pumping is now taking 50% of the hydraulic market, and its popularity will probably continue to grow.2 The Technology of Artificial Lift Methods—Volume 2a Table 13 breaks down total maintenance cost into failures, failure rates, cost per failure, total cost, and percent of each failure spent for well servicing. Also included are costs and rates for well workover. ‘Two main types of downhole equipment failures are pumps and rods. Each pumping well has a 57% chance of pump failure and a 44% chance of rod failure each year. These rates are additive so each wel will average 1.01 failuresyear. Costs to maintain these wells total $346,000,000, including $230,000,000 for well servicing. Remaining expenditures translate to approximately 34,000,000 fect of rods and 31,000 bottomhole pumps needed for replacement of worn out equipment plus an additional repair of 180,000 purnps. Submersible pump failure rates apparently are decreasing based on the 7% sample. Repairs to submnersibles by manufacturers are running considera~ bly less than in previous years. ‘The survey indicates that failure incidence in hydraulic pumps is increasing. Again, this may be due to the small number of hydraulic pumps contained in the survey. In any event, the growth of the hydraulic piston pump market appears to be declining and jet pumping is on the increase. Gas lift failure rate is the lowest of any form of arti- ficial lift (21%) but costs of individual failures are high compared to the average of all failures. A high portion of these costs, however, is attributable to high cost of service units, crows, and related equipment. Various lift methods are compared in Chapter 9. Comparisons are quite difficult, but some choices of lift methods are obvious. One example is high volume wells where either electrical submersible pumping or continuous flow gas lit should be considered. Very deep lit must look at hydraulic pumping with installa- tions presently pumping from 15,000 to 18,000 feet, with rates of 300 to 500 B/D. Although these pumps are set at these depths, the effective lift depth may be less. Effective lift refers to that depth to which the flowing bottom hole pressure will support the producing fluids. For example, ifthe flowing bottom hole pressure is 700, psi and the average fluid gradient is 0.30 psift, the 700, psi will support the fluid 700/.90 = 2933 ft. Therefore, if the pump is set ala total depth of 16,000 fit is really only lifting feom 16,000-2,383 = 12,667 ft and theoret- ically could be set at that depth and produce the same amount of fuids (neglects tubing well-head back pres- sure). ‘Availability of certain power sources will influence the decision on type of lif. All these factors are diseussed in detail in Chapter 8. 4.11 Purpose of artificial ‘The purpose of artifical lift is to maintain a reduced producing bottom hole pressure so the formation can, give up the desired reservoir fluids. A well may be capable of performing this task under its own power. In ite latter stages of flowing life, a well is capable of producing only a portion of the desired fluids. During this stage of a well’ flowing life and particularly after the well dies, a suitable means of artificial lift must be installed so the required flowing bottom hole pressure can be maintained. ‘Maintaining the required flowing bottom hole pres- sure is the basis for the design of any artificial lift installation; if a predetermined drawdown in pressure can be maintained, the well will produce the desired fluids, This is true regardless of the type of lift installed. : Tn gas lift operations, @ well may be placed on contin- uous or intermittent lif. In continuous flow, the flow- ing bottom hole pressure will remain constant for a particular set of conditions, while in intermittent flow the flowing bottom hole pressure will vary with the particular operation time of one cyele of production. In this latter case, a weighted average flowing bottom hole pressure must be determined for one cycle and, hence, for a day's production. Economics enters into the design of any lift installation, Many types of artificial lift methods are available: beam-type sucker rod pumps, piston-type sucker rod pumps, hydraulic oil well pumps, electrical submerg- ible centrifugal pumps, rotating rod pumps, plunger Tit, gas lit, and others. The advantages and disadvan- TABLE 13 DOVINHOLE COSTS TO MAINTAIN US. PRODUCING Ol. WELLS (YEAR 1977) Face ‘Number of ‘Average Percent wel ‘a0 tales cos, 8 Total cost, S sonicing Subeuriace od pumps 3 210277 1078 226857,000, 6 ‘Sucka ross 4s 162.118 729 119,685,000 cy Submersible pumps 35 3.390 7873 6,030,000, 5 Hysraute pumps 1.86 41,411,000 0 as itt 21 47713,000 7m using 12 115,027,000 3 Cesing coat 176,742,000 st Total 2 753,285,000 et falces Wiorkovers 20 10.888 1.128.532,000 58 Total maitonanco cost 1.376.777,000, 9