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Najeebullah Lashari*
Department of Petroleum Engineering, Universiti Teknologi PETRONAS, 32610 Seri
Iskandar, Perak Darul Ridzuan Kuala Lumpur, Malaysia
Mohamed Oun
Department of Production Engineering, Petronas Carigali, Kuala Lumpur, Malaysia
Imtiaz Ali
Department of Petroleum Engineering, Universiti Teknologi PETRONAS, 32610 Seri
Iskandar, Perak Darul Ridzuan Kuala Lumpur, Malaysia
Department of Petroleum and Gas Engineering, BUITEMS, Quetta, Pakistan
ABSTRACT
The utmost objective of oil and gas companies is to enhance the hydrocarbon
recovery in a cost effective way for the entire field, and more importantly, to minimize
both capital and operating costs, which can be achieved by selecting the optimum
design of the field’s production systems from the reservoir to surface facilities. The
introduction of lift gas to a non-producing or low producing well is a common method
of artificial lift. The gas lift systems are designed to help natural reservoir energy
power of formation fluids to the surface at target rates, to maximize the life of oil wells
generating. The concept of gas lifting is the reduction of the hydrostatic pressure in
the production pipe by injecting lightweight fluid into the annulus, which pumps
natural gas into the well at high pressure from the casing to wellbore and blends it
with the fluids of the tank. This paper describes a unique gas lifted developed methods
using gas lift pack-off, DGL, and deep-set techniques. Case studies from Asian oil
fields were selected to apply the developed methods. The results show a notable
production increment for all wells, which will extend the lifetime of the oil wells by
applying some modifications to the existing gas lift system without adding more cost.
Keywords: Deep gas lift; orifice valve; gas lift pack-off gas lift; mandrel; deep lift set;
completion string.
Cite this Article: Tarek A. Ganat, Najeebullah Lashari, Mohamed Oun, Daniel
Asante Otchere and Imtiaz Ali, Develop Optimum Gas Lift Methods to Improve Gas
Lift Efficiency Using Gas Lift Pack-Off, Deep Gas Lift, and Deep Lift Set,
International Journal of Advanced Research in Engineering and Technology, 11(11),
2020, pp. 1096-1114.
http://www.iaeme.com/IJARET/issues.asp?JType=IJARET&VType=11&IType=11
1. INTRODUCTION
The high price of oil is a deterrent to discovery and growth, marginal field development and
projects for enhanced oil recovery. "The average global oil recovery factor could well
increase significantly, due to technology development, from the current figure, by about 35%,
adding enormous resources to the bases of reserves" [1].
If the pressure in the reservoir is not strong enough to have sufficient water movement
levels, fluid changes may be accomplished by means of artificial lifting methods. The gas lift
system is an exceptional economic benefit form of artificial boost, its versatility requires a
robust commodity, service and production enhancement and ultimate reserve recovery
portfolio in all gas lift applications.
At the other side, the gas lifting technique is based at pumping gas into the lower part of
the production pipe to lower hydrostatic pressure in the pipe. The gas lifting system helps to
reduce the backpressure in the well induced by fluid in the pipeline, thus increasing the
injection and production efficiency from the well [2, 3].
A crucial aspect is the volume of injection gas when a lower value will dramatically
decrease production and raise operational costs with the usage of compression and power. For
certain situations, oil output may be checked to a maximum value for a given flow rate of gas
injection [4]. Several papers have been published about this optimization problem
determining the optimal operating conditions to extract the maximum quantity of oil for
single well models, multiple wells model and gas-lift wells modeling optimization and control
[2, 5-10].
Gas lift uses an external source of high-pressure gas for supplementing formation gas to
lift the well fluids. Gas injected through the injection point into the production tubing reduces
the density of the fluids in the tubing to lower the flowing bottom hole pressure (BHP) at the
bottom of the tubing [11]. The increased pressure differential induced across the sand face
from the in-situ reservoir pressure assists in flowing the produced fluid to the surface (Fig. 1).
The method is easy to install, economically viable, robust, and effective over a broad range of
conditions, but does assume a steady supply of lift gas [12].
After a production period reservoir energy dissipate, reservoir pressure depleted, and the
fluid level in tubing fall below the lowest gas lift valve, it causes a lack of gas lift efficiency
and loss of compression energy by circulating gas lift above the fluid level. A substantial part
of the gas-lifted wells worldwide remained ineffective. More frequently than not it is
attributable to 'multiple-pointing' when any (unintentionally) inject into the tubing through
one or more of the shallower unloading valves instead of the whole lifting gas through the
operating valve at the intended injection level. For some situations, wells will fail because
with the available gas lift pressure the intended injection depth cannot be met. [13]. The
question of gas lift optimization discussed in this paper is to optimize the routine production
of hydrocarbons by choosing optimized methods to boost well performance, subject to gas
injection pressure and water reduction constraints.
Figure 3: Installation of the gas lift valve at the depth above packer setting depth
Gas deep lifting (pack-off, DGL, deep set) are both methods for establishing a gas lifting
passage in the target position from the annulus of the hydrocarbon well. Thanks to its easy use
and lower costs than a mechanical unit or rig, the methods should be selected. This techniques
used for wells having high water cut and depleted reservoir pressure, if the fluid level in
tubing fall close or below the lowest gas lift valve, in this case, a dual pack off stringer having
GLM is inserted in the tubing below the lowest mandrel to reach out the fluid level and
communication is made through opening SSD, etc. In this way, gas can be reached without
having a big work-over job. A system which can offer a deeper location in a wellbore gas
injection point. A switching suspension mandrel can be inside a side pocket mandrel and can
be attached on one end with a gas lift valve and on the other end with a spindle. The side
pocket mandrel will cover a length of production tubing. The production tubing will require a
production packer to attach the annulus from the tubing to the casing pipe. The switching
suspension mandrel can be installed in order to direct gas entering the gas lift valve through
the coil into the well below the production packer. A plug on the bottom of the coil can be
mounted to avoid blasting when the gas lift system is assembled.
Fig. 4 below shows the schematic of the entire gas lift optimization system to determine
(and set) optimal gas injection rates and gas lift valve depth for each well. Examine various
levels of gas lift “optimization” in current practice and review contemporary gas lift available
technology to the revival of shut-in wells by selecting the optimum well design &
Implementation along with avoidance of costly workovers/re-entries.
The gas lift pack-off can be installed in natural flow completion inside the existing production
string. As illustrated in Fig. 6. Injection gas raise from the well annulus to the tube flow
region at the target position via the orifice valve. This method is rig less, so it would be
preferred due to its simple application and lower project cost.
Figure 10: Schematic of the gas lift string of the well K-1
Most of the wells are completed at a depth that should flow for some time after they put
on production. But because of decreasing the reservoir energy, the reservoir pressure was
insufficient to lift the fluid to the surface. Consequently, the wells cease to flow or producing
at a meager production rate. Therefore, the developed method was applied on well K-1 and
redesign the valve setting depth with an optimum injection rate. To estimate the productivity
index, the well model is built using nodal analysis, as seen in Fig. 11. The plot shows the
incremental oil rate obtained from the developed method by using the same gas lift system.
The well was shut-off at rate 120 STB/D, and after installing the gas lift pack-off at optimum
setting depth, the average oil rate increased, as seen in Table 3 and Fig. 12
Figure 11: Illustrates the incremental oil rate that can be stretch by using developed methods
Table 3: Shows the well K-1 production performance before and after installing a gas lift pack-off
Oil Rate Water Rate
Well K-1 Year Liquid Rate (STB/D)
(STB/D) (BBL/D)
2001 650 - -
2002 500 - -
Before installing
2003 140 - -
gas lift pack-off
2004 120 - -
2005 Closed for 13 years
2015 530 1600 2130
After installing
2016 480 1800 2280
gas lift pack-off
2017 470 1750 2220
Figure 12: Well K-1 production history before and after install Pack-off system
the top insert string and orifice insert string below packer is emphasized, the fitted system is
ready to lift fluid through the gas. This well immediately back to the production line once
installed the pack-off system, after had been dead for 13 years. Fig. 14 shows the extension of
the well production performance after using the pack-off system. The pack-off completion
improved the well production rate, which now produces approximately 100 BOPD at FTHP
100 Psig, as seen in Table 4 and Fig. 15.
Figure 13: Schematic of the gas lift string of the well M-2
Figure 14: Illustrates the incremental oil rate that can be stretch by using the pack-off system
Table 4: The well M-2 production performance before and after installing a gas lift pack-off.
Oil Rate Water Rate Liquid Rate
Well M-2 Year
(STB/D) (BBL/D) (STB/D)
1998 250 0 250
1999 220 0 220
Before install gas lift 2000 200 0 200
pack-off 2001 150 0 150
2002 50 0 50
2003 Closed for 13 years
After install gas lift 2016 100 0 100
pack-off 2017 100 0 100
Well-X1 is a petroleum well situated offshore Southeast Asia, the well was drilled with
dual string and, after a long production period, also with the long tubing pitched gas
lift mandrels of 681 ft over the production zone decayed considerably. After a detailed review
of applicable methods, it was decided to extend the depth of the gas lift injection point by
installing a DGL system using CT to increase the drawdown and optimize the gas lift
production performance.
In January 2017, the well was equipped with gas lift mandrels immutably above the
packer some 681ft above the lower producing zone. After long years of operation, the
producing rate had declined significantly, and this situation prompted the operator to perform
some testing on it to ascertain the possibilities of improving production.
Figure 15: Well M-2 production history before and after install Pack-off system
Two pack-off installed inside the tubing (upper pack-off and lower pack-off), and the gas
lift injected from the annulus into the injection valve below the packer inside the tubing,
where gas will pass through Cross-flow Diverter Sub (CDS) (Flow area 1.16 inch Production
& 0.78 inch Injection (Fig. 16)) mix with the liquid and flow together to the surface as seen in
Fig. 17.
…..
Figure 19: Illustrates the current incremental oil rate that can be stretch by using DGL.
Figure 20: Illustrates the incremental oil rate that can be stretch by select 1st option of DGL installation
Figure 21: Illustrates the incremental oil rate that can be stretch by select 2nd option of DGL installation
Figure 23: IPR & VLP plot illustrates the incremental oil rate (before and after optimization) that can
be stretch by using deep lift set for well Y-1
The principle of gas lift is that gas injected into the tubing reduces the density of the fluids
in the tubing, and the bubbles have a “scrubbing” action on the liquids. Both factors act to
lower the flowing bottom hole pressure (BHP) at the bottom of the tubing, as seen in Fig. 25
and Fig. 26 after installing the deep lift set system in the well Y-1 and well Q-5.
Figure 24: IPR & VLP plot illustrates the incremental oil rate (before and after optimization) that can
be stretch by using deep lift set for well Q-5
Figure 25: Bottom hole pressure drawdown before and after installing deep lift set at the well Y-1
Figure 26: Bottom hole pressure drawdown before and after installing deep lift set at the well Q-2
In total, the operation was executed as proposed and proved to be an effective acceptable
way of moving the point of gas injection further downhole from the lowermost gas lift
mandrel below the packer above the perforation zone. The well Y-1 was producing 53 BOPD
for a long time before the installation of the deep lift set. Once the installation was completed,
the gas lift was restarted, and drawdown was doubled as that within few hours, oil and water
were observed at the surface, and once the resulting production had stabilized the oil
production and increased to 172 BOPD, an increase of over 300%. Same results for the well
Q-5, the production rate improved from 59 BOPD to 95 BOPD, an increase of over 161%, as
seen in Table 6.
Table 6: Improvement oil recovery by using deep lift set comparing with the conventional method.
Well Conventional gas lift
Oil Rate Avg. SBHP Avg. BSW
Water Rate (BBL/D)
(STB/D) (Psia) (%)
Well- Y1 53 13 1180 18
Well- Q2 59 258 1500 80
Well Deep lift set
Well- Y1 172 49 880 22
Well- Q2 95 332 1350 76
5. CONCLUSION
This paper describes a unique gas lifted developed methods for deep gas lift bypass packer
technique. The purpose of this work is to identify an economically viable method of artificial
lift to restore oil production in a dead well, which has high water cut and depleted reservoir
pressure when the dynamic fluid level in tubing fall below the depth of the lowest gas lift
valve. The developed methods were proposed to improve gas lift efficiency by creating the
gas lift passage from the well annulus into the tubing flow area at a desired location depth
below the packer. The three methods are simple applications and have lower project costs.
Case studies from Asian oil fields were selected to apply the three developed methods.
The results show a remarkable production increment for all the wells, which will extend the
lifetime of the oil wells by applying some modifications to the existing gas lift system without
adding more cost.
The three applications are optimum to apply at any wells that have low reservoir energy
(low reservoir pressure and low production rate), where the fluid level is close to the last
injection point. Table 7. shows the comparison of the completion string between the gas lift
pack-off, DGL, and deep lift set.
Table 7: Comparison of the well completion string between gas lift applications
Max
Deep lift Downhole SSSV Tubing size
Running unit depth Retrievable Cost
type excisable Restriction ID
angle
3 1/2", 2
Pack-off slick line Poor WL SSSV 5 yes Low
7/8"
DGL slick line/CT Poor WL SSSV 3 1/2" up to 5 yes Low
Outside
Deep-set Rig Excellent No 5 permanent High
tubing
Fig. 27, shows improving lift efficiency for each nominated well. Because each well has
specific oil producing characteristics, it is a matter of setting optimum injection levels for
each well to ensure that there is no restriction to competitive development in another well
over injection at one well. The improvements in the characteristics of well production, such as
the inflow or water volume, often demand that they be run at specific optimum gas injection
levels. Under a wide range of flows, flow monitoring and control equipment must be flexible.
Fig. 28, demonstrate the expected extension of the oilfield lifetime as a result of using the
developed gas lift methods at the middle operation stage, extending the existing gas lift by
pack off, deep gas lift, and deep lift set.
Well X-1
Well X-1
900 (STB/D)
Well K-1
470 (STB/D)
Well Y-1
Well K-1 172 (STB/D)
120 (STB/D)
Well M-2
100 (STB/D)
Well Q-2
95 (STB/D)
Well Q-2 Well Y-1
Well M-2 59 (STB/D) 53 (STB/D)
50 (STB/D)
Figure 28: Expected extension of the artificial lift performance improved by the developed gas lift
applications
ACKNOWLEDGEMENT
Tarek A Ganat would like to thank Universiti Teknologi PETRONAS Malaysia for the
support and thanking Petronas Malaysia for the data support.
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