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Major forms of Artificial Lift
PRODUCED FLOWRATE
WELL OUTFLOWRELATIONSHIP
WELL INFLOW (IPR)
SURFACE PRESSUREAt Wellhead
Pwf
WELL FACE PRESSURE
Reservoir Pressure- Pr
Available Pwf as function of the flowrate
Required Po to produce desired rate
Po
• If Po < Pwf, the well will flow naturally
– (~6% of wells by number)
• If Po Pwf, the well will require Artificial Lift
– (~94% of wells worldwide)
INFLOW AND OUTFLOW PERFORMANCE
The concept of Artificial Lift• Artificial Lift is needed when reservoir
pressures do not sustain acceptable flow rates or there is no fluid flow at all.
• Lift process transfers energy downhole or decreases fluid density in the wellbore to reduce hydrostatic pressure on formations.
Gas Lift (SLB)
ESP’s (SLB)
DuraLiftPC Pumps
HydroLiftHydraulic Pumps
Beam pump
MAIN ARTIFICIAL LIFT METHODS
Artificial Lift Market 94% of Wells are on AL
World: 890,000 wells
Canada 48,200
US 541,000
Argentina 13,800
Russia 121,000
Indonesia 9,500
Venezuela 15,000
Brazil 7,400Peru
4,600
Egypt 1,200 Oman
2,600
China 76,000
India 3,000
Australia 1,300
North Sea 600
W.Europe 9,000
Libya 1,760
RevenueSpears 2004
MM$Rod Pumps 717Electric Submersible Pumps 1725PCP's 369Gas Lift 130Hydraulic Pumping 30Others 320
Total Expenditures 3291
WellsSpears 2004
% WW Wells WWRod Pumps 79% 669,716Electric Submersible Pumps 12% 98,065PCP's 4% 30,144Gas Lift 3% 26,892Hydraulic Pumping <1% 5,000Others 2% 14,856
Total Systems 100% 844,673
Ft./Lift12,00011,00010,000
9,0008,0007,0006,0005,0004,0003,0002,0001,000
1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 20,000 30,000 40,000 50,000 BPD
Typical Artificial Lift Application Range
Rod Pumps PC Pumps Hydraulic Lift Submersible Pump Gas Lift
ARTIFICIAL LIFT – Application Ranges
0
10
20
30
40
50
60
70
80
90
100
PCP Hydraulic PistonPumps
Beam Pump ESP Hydraulic JetPump
Gas Lift(Continuous)
Gas Lift(Intermittent)
Artificial Lift Type
Ove
rall
Syst
em E
ffici
ency
(%)
ARTIFICIAL LIFT – System Efficiency; includes all mechanical
losses
Artificial Lift Selection
Making artificial lift decisions is primarily a process of choosing the lift method most applicable to expected surface, reservoir, fluid and operational conditions
AL Methods Applicability – not ‘one size fits all’
Condition Rod Pumps Hydraulic PumpsPCP's Gas Lift ESP'sScale fair fair/good* fair good poorSand fair very good/poor* good very good fairParaffin poor fair/good* good poor goodCorrossion good fair fair fair fairHigh GOR poor fair fair excellent fair/good*Deviation poor excellent poor/good very good goodRate poor good fair very good goodDepth fair very good fair good goodFlexibility very good very good good very good good (with VSD)
Temperature very good very good poor good fair/good*Efficiency good poor/very good* very good*fair good
Reciprocating Displacement Rod Pumps
Transfer of mechanical energy from surface via rod string to downhole pump
Rod Pumps combine a cylinder (barrel) and piston (plunger) with valves to transfer well fluids into the tubing and lift the fluid to the surface.
Rod Pumping SystemWalking Beam
Pitman Arm
Saddle Bearing
Horsehead
Bridle
Hanger
Ladder
Wrist Pin
Crank ArmCounterweight
Prime MoverBrake
Lever
Base
Samson Post
Equalizer Bearing
Brake Cable
Polished RodStuffing Box Seal
Flow Line
Flow TeeRod String
Downhole Pump
Production Tubing
Production Casing
Drawings Courtesy of Lufkin Industries, Inc. Lufkin, Texas
Types of Pumping Units
Mark II
Low Profile Air Balanced
Beam Balanced
Drawings Courtesy of Lufkin Industries, Inc. Lufkin, Texas
How a Downhole Pump Works
Ball & seat
Seating nipple
Standing valve closed
Barrel
Traveling valve open
Plunger Moving Down
Tubing
Cage
Plunger Moving Up
How can we change the flow rate ?
• Change the pump stroke length– Typical range 54 – 306 inches
• Change the number of strokes– Typical range 5 –15 spm
Downhole Pumps
• Insert Pump - fits inside the production tubing and is seated in nipple in the tubing.
• Tubing Pump - is an integral part of the production tubing string.
Insert Pumps
• Pump is run inside the tubing attached to sucker rods
• Pump size is limited by tubing size
• Lower flow rates than tubing pump
• Easily removed for repair
Insert Pump
Ball & seat
Seating nipple
Standing valve
Barrel
Traveling valve
Plunger
Tubing
Cage
Tubing Pumps
• Integral part of production tubing string
• Cannot be removed without removing production tubing
• Permits larger pump sizes
• Used where higher flow rates are needed
Tubing Pump
Ball & seat
Standingvalve
Barrel
Travelingvalve
Plunger
Tubing
Cage
Connectionw/tubing
Prime Mover HorsePower -estimations
• Hydraulic Horsepower = power required to lift a given volume of fluid vertically in a given period of time
= 7.36 x 10-6 x Q x G x L
where Q = rate b/d (efficiency corrected), G= SG of fluid,L = net lift in feet
• Frictional Horsepower
= 6.31 x 10-7 x W x S x N
Where W=weight of rods in lb, S=stroke length,N=SPM
• Polished Rod Horsepower (PRHP)= sum (hydraulic, frictional)
• Prime mover HP = PRHP x CLF / surface efficiency
where CLF = cyclic load factor dependent on model of motor typical range 1.1 to 2.0
Sonolog Fluid Level Survey
Sound reflection
Tubing collars
Fluid level
Sonolog
Charge ignited
Fluid level
Beam PumpsAdvantages:• Most widely used AL method• Best understood by field personnel• Usually the cheapest (where
suitable)• Low intervention cost
• Remote locations without electricity
• Readily accommodates volume changes
• Reliable diagnostic tools available• Can often pump below perforations
Disadvantages:• Restricted flow and depth
• Susceptible to free gas• Frequent maintenance• Deviated wellbores are difficult (rod
and tubing wear)• Reduced tubing bore• Susceptible to corrosion• Potential wellhead leaks
Progressing Cavity Displacement Pumps
Progressing cavity pumps are based on rotary fluid displacement. This spiral system consists of a rotor turning inside a stationary stator.
Mechanical energy transfer via rotation sucker rods (top drive) orelectricity (bottom drive).
Introduction to PC PumpsHistory
• Invented by Rene Moineau in 1932.
• Initial uses in industrial pumping applications.
• Used as power sections for directional drilling since mid 1950’s.
• First artificial lift applications in early 1980’s.
THEORECTICAL PC PUMP LIMITS90% Volumetric Efficiency
0500
100015002000250030003500400045005000
0 500 1000 1500 2000 2500 3000 3500 4000 4500DISPLACEMENT @ 425 RPM (BFPD)
PRES
SUR
E (P
SI)
6.875"Dia5.25" Dia4.2" Dia.
Application Range
Characteristics
• Interference fit between the rotor and stator creates a series of isolated cavities
• Rotation of the rotor causes the cavities to move or “progress” from one end of the pump to the other
• Non Pulsating• Pump Generates Pressure Required To
Move Constant Volume• Flow is a function of RPM
Flow Characteristics
PCP Description
E 4E
D
P
D
P = Stator Pitch length
D = Minor Diameter of StatorMajor Diameter of Stator
• The geometry of the helical gear formed by the rotor and the stator is fully defined by the following parameters:– the diameter of the Rotor = D– eccentricity = E – pitch length of the Stator = P
• The minimum length required for the pump to create effective pumping action is the pitch length. This is the length of one seal line.
Pumping Principle
• Each full turn of the Rotor produces two cavities of fluid.
• Pump displacement = Volume produced for each turn of the rotorPD = C *D*E*P
C = Constant (SI: 5.76x10-6, Imperial: 5.94x10-1)• At zero head, the flow rate is directionally
proportional to the rotational speed N:Q = PD*N (remember to account for Bo)
Pumping Principle
• Manufacturers rate the pressure capability of a pump as a function of the number of pump stages. Pressure capability is determined by the number of stator pitches
• One stage is defined as the pump length required to offset 100 psi of differential pressure.
Stages
Stator Pitch
Rotor Pitch1 Stage = 1.5 Stator Pitches
(or 3 Rotor Pitches)
• Lifting capacity is typically referred to in feet of water, rather than stages.– 1 stage = approx. 100 psi– 1 stage = approx. 231 ft of lift– 1 stage = approx. 70 meters of lift– 1 stage = approx. 690 Kpa
• An 18 stage pump (1800 psi) is commonly referred to as a 4000 ft (1200 meter) pump.
Progressing Cavity Pump BasicsStage Ratings
PCP performance
• Positive displacement pump theoretically not affected by pressure across the pump
• But with higher pressure differential the seal between cavities is not adequate and slippage of pumped fluid results
• Pump efficiency is a function of – the “fit” between rotor and stator– Viscosity of the fluid
Efficiency, Pressure and Slip
S40G65
0
10
20
30
40
50
60
70
0 1000 2000 3000 4000 5000 6000 7000
Feet of Lift
(BFP
D)
20% Slip @ rated Pressure
So for a head of 4000 feet the production is 52 bfpd
• The horsepower requirements for a PC pump can be broken down into two categories:– Hydraulic: Work to lift fluid to the surface, directly
proportional to pressure and speed.
– Frictional: Work to overcome losses in the pump due to rotor/stator compression fit and speed.
• One of the reasons PC Pumps are such an efficient artificial lift method is because the frictional horsepower is very low.
Progressing Cavity Pump BasicsHorsepower Requirements
Progressing Cavity Pump BasicsHorsepower Requirements
HHOORRSSEEPPOOWWEERR
VVOOLLUUMMEE
DEPTH IN FEETDEPTH IN FEET
25002500
20002000
15001500
10001000
500500
0000 3000300015001500 250025002000200010001000500500
00
1010
2020
3030
4040
5050
6060
7070
• The Elastomer Reacts with its Environment– Temperature changes cause large dimensional
changes– CO2 and aromatic compounds cause swelling and
softening– Sulfur causes hardening and embrittlement
• These Factors are Considered When Designing a Pumping System
Elastomer Characteristics
ElastomersSelection Guide
CompoundMax Temp
Deg. FMax API
Max H2S
Physical Properties
Abrasion Resistance
Aromatic Resistance
Standard Nitrile 180 20 2% Excellent Acceptable LowSoft Nitrile 180 20 2% Excellent Superior LowSuper-saturated Nitrile 200 38 2% Good Poor GoodHNBR 225 25 4% Excellent Fair FairEnhanced HNBR 250 38 6% Excellent Poor Good
• Cause: Production Flow Line Valve Closed / Plugged Pump
• Result: Over Pressure
Failure Modes – High Pressure
Failure Modes – Abrasion
• Identification:– Roughened, worn or scuffed surfaces usually
on the minor diameter of the stator.• Cause:
– Due to normal wear and abrasion. Influenced by quantity and abrasiveness of fluid solids content, pump speed, elastomer type.
• Remedy– Reduce particle velocity through the pump,
running pump at lower speeds, and by adding more stages to the pump.
Failure Modes – Chemical Attack
• Identification:– Signs of chemical attack or fluid incompatibility
include elastomer swelling, softening or blistering
– Results in a loss in pump efficiency and an increase in the torque to turn the pump.
• Cause:– Light end hydrocarbons and aromatics result in
an increase in volume of the elastomer and softening of the surface.
• Remedy– Proper elastomer selection.– Pump sizing practices.
Failure Modes – High Temperature
• Identification:– Surface of the elastomer will be hard, brittle and
extensively cracked.• Cause:
– High temperatures result in an increased rate of oxidation causing loss of tensile strength and increase of hardness of elastomer.
– High temps result from pump being run dry or high operating temperature.
• Remedy– Monitor fluid levels and adjust pump speed.– Select proper elastomer for operating
temperature.
Failure Modes - Rotor Failures
• Abrasive wear along seal lines.• Fluid incompatibility.
Rare Occurrence
Rod design
• Consider– Weight of rod and rotor– Maximum stress in rod (torque and load)– Yield strength– Environment– Fatigue loading
• Provides safe controlled release of the stored energy in rod string– Backspin energy components include:
• Elastic rod string energy• Fluid level equalization
Drivehead Design
Standard PC Pump - Topdrive
• Down-hole pump components:– Rotor.– Stator.
• Sucker rod string.• Surface drive head.• Accessories:
– Torque anchor.– Rod protectors / centralizers.– Etc.
Top Drive System Design
• Has to:– Suspend rod & carry axial loads
– Deliver torque to rod
– Rotate rod
– Prevent backspin
– Prevent escape of fluid
• Typical HP range = 10 – 100 HP
• HP = 1.904 x 10-2 x Rod torque (ft.lbs) x N (rpm)/ Drive efficiency
PC Pumps Applications
• Heavy & viscous oils.
• Production of solids-laden fluids.
• Medium to sweet crude.
• Coal bed methane / gas well de-watering.
• Urban areas.
• Agricultural areas. Lower surface footprint than Beam Pumps
ProgressingCavity Pump
Tubing
Casing
Intake
Gear Box &Flex Drive
Protector
Motor
Perforations
Alternative PC Pump – BottomDrive*
• Down-hole pump components:– Rotor.– Stator.
• Intake.• Gearbox.• Protector.• Motor.• Cable.
• FCE• VSD• Junction Box• Transformer• Rotor Adapter• Stator Adapter
*mark of Schlumberger
Motor
Protector
GearboxIntake
StatorRotorCable
FCE
PC PumpsApplication
• Top Drive– Target wells with minimal deviation– Low volume – Shallow pump setting depth
• Bottom Drive– Target wells
• Severe dogleg• Horizontal• Higher Rate• Deeper• Environmentally Sensitive
Progressing Cavity PumpsAdvantages• Simple two piece design.
• Excellent for viscous crude
• Resistant to abrasives and solids
• Non-pulsating. Does not gas lock or emulsify fluid.
• Oil Gravities from 5 to 42 API
• Fairly flexible application method
• Efficient power usage
Disadvantages• Sensitive to overpressure
• Sensitive to pump off
• Restricted flow rate (< 5000 bpd)
• Restricted setting depths (< 8000 ft)
• Limited operating temp (normally < 250 F)
• Not compatible with some chemicals, H2S 6%, CO2 30% Aromatics 12% and high API Gravity Oils
Gas LiftGas Lift uses additional high pressure gas to supplement formation gas. Produced fluids are lifted by reducing fluid density in wellbore to lighted the hydrostatic column, or back pressure, load on formations.
APPLICATIONS OF GAS LIFT
• TO ENABLE WELLS THAT WILL NOT FLOW NATURALLY TO PRODUCE
• TO INCREASE PRODUCTION RATES IN FLOWING WELLS
• TO UNLOAD A WELL THAT WILL LATER FLOW NATURALLY
• TO REMOVE OR UNLOAD FLUID IN GAS WELLS
• TO BACK FLOW SALT WATER DISPOSAL WELLS
• TO LIFT AQUIFER WELLS
• CAN BE INTERMITTENT OR CONTINUOUS
INJECTION GASCHOKE CLOSED
TO SEPARATOR/STOCK TANK
TOP VALVE OPEN
SECOND VALVEOPEN
THIRD VALVEOPEN
FOURTH VALVEOPEN
0
2000
6000
8000
10000
12000
14000
4000
2000 4000
PRESSURE PSI
DEP
TH F
TTV
D
SIBHPTUBING PRESSURECASING PRESSURE
30001000 5000 6000 7000
INJECTION GASCHOKE OPEN
TO SEPARATOR/STOCK TANK
TOP VALVE OPEN
SECOND VALVEOPEN
THIRD VALVEOPEN
FOURTH VALVEOPEN
0
2000
6000
8000
10000
12000
14000
4000
2000 4000
PRESSURE PSI
DEP
TH F
TTV
D
SIBHPTUBING PRESSURECASING PRESSURE
30001000 5000 6000 7000
INJECTION GASCHOKE OPEN
TO SEPARATOR/STOCK TANK
TOP VALVE OPEN
SECOND VALVEOPEN
THIRD VALVEOPEN
FOURTH VALVEOPEN
0
2000
6000
8000
10000
12000
14000
4000
2000 4000
PRESSURE PSI
DEP
TH F
TTV
D
SIBHPTUBING PRESSURECASING PRESSURE
30001000 5000 6000 7000
INJECTION GASCHOKE OPEN
TO SEPARATOR/STOCK TANK
TOP VALVE OPEN
SECOND VALVEOPEN
THIRD VALVEOPEN
FOURTH VALVEOPEN
0
2000
6000
8000
10000
12000
14000
4000
2000 4000
PRESSURE PSI
DEP
TH F
TTV
D
TUBING PRESSURECASING PRESSURE
30001000 5000
DRAWDOWN
6000 7000
FBHP SIBHP
INJECTION GASCHOKE OPEN
TO SEPARATOR/STOCK TANK
TOP VALVE CLOSED
SECOND VALVEOPEN
THIRD VALVEOPEN
FOURTH VALVEOPEN
0
2000
6000
8000
10000
12000
14000
4000
2000 4000
PRESSURE PSI
DEP
TH F
TTV
D
TUBING PRESSURECASING PRESSURE
30001000 5000
DRAWDOWN
6000 7000
FBHP SIBHP
INJECTION GASCHOKE OPEN
TO SEPARATOR/STOCK TANK
TOP VALVE CLOSED
SECOND VALVEOPEN
THIRD VALVEOPEN
FOURTH VALVEOPEN
0
2000
6000
8000
10000
12000
14000
4000
2000 4000
PRESSURE PSI
DEP
TH F
TTV
D
TUBING PRESSURECASING PRESSURE
30001000 5000
DRAWDOWN
6000 7000
FBHP SIBHP
INJECTION GASCHOKE OPEN
TO SEPARATOR/STOCK TANK
TOP VALVE CLOSED
SECOND VALVECLOSED
THIRD VALVEOPEN
FOURTH VALVEOPEN
0
2000
6000
8000
10000
12000
14000
4000
2000 4000
PRESSURE PSI
DEP
TH F
TTV
D
TUBING PRESSURECASING PRESSURE
30001000 5000
DRAWDOWN
6000 7000
FBHP SIBHP
FIGURE 3-8: Example of the Unloading SequenceCasing Operated Valves and Choke Control of Injection Gas
0
200
400
600
800
1000
1200
1400
1600
1800
2000
12:00 AM 03:00 AM 06:00 AM 09:00 AM 12:00 PM 03:00 PM 06:00 PMTime
Pres
sure
psi
PRESSURE CASING PRESSURE TUBING
3 basic types of gas lift valve, each available in 1” & 1-1/2” sizes:
Dummy valves Orifice valvesUnloading valves
• Square edged• Venturi (nova)
• Injection pressure (casing) operated valves
• production pressure (fluid) operated valves
• Throttling/proportional response valves
GAS LIFT VALVE MECHANICS
UNLOADING GAS LIFT VALVE
• Normally required during unloading phase only
• Open only when annulus and tubing pressures are high enough to overcome valve set pressure
• Valve closes after transfer to next station
• May be spring or nitrogen charged
Pressure Regulator
Diaphragm/Atmospheric Bellows
Spring
Stem
Stem Tip
Port
DownstreamUpstream
Spring Operated Gas Lift Valve
Upstream/Casing
Downstream/Tubing
VALVE OPENING & CLOSING PRESSURESF = P X A
Pc1
Pd
Pt
WHEN THE VALVE IS CLOSEDTO OPEN IT…..Pd x Ab= Pc1 (Ab - Ap) + Pt Ap Pd
Pc2
WHEN THE VALVE IS OPENTO CLOSE IT…..Pd x Ab = Pc2 (Ab)
GAS LIFT VALVES CLOSE IN SEQUENCE0
2000
6000
8000
10000
12000
14000
4000
1000 2000
DEP
TH F
TTV
D
TUBING PRESSURECASING PRESSURE
1500500 2500
DRAWDOWN
3000 3500
FBHP SIBHP
NORMAL GAS LIFT VALVE• Bellows
• Check valve
• Stem travel
• Metallurgy
• Elastomers
• Max fluid rate
ORIFICE GAS LIFT VALVE
• Typically an ‘orifice’ type Gas lift valve
• always open - allows gas across Passage whenever correct differential exists
• Gas injection controlled by size and differential across replaceable choke
• Back-check prevents reverse flow of well fluids from the production conduit
ORIFICE VALVES
THERE ARE 2 TYPES OF ORIFICE VALVES:
• SQUARED EDGED ORIFICE
• VENTURI (NOVA)
OPERATING PRINCIPLE OF THE VENTURI
00
2020
4040
6060
8080
100100
120120
140140
160160
180180
200200
0 0 100 100 200 200 300 300 400 400 500 500 600 600
Tubing PressureTubing PressureTubing Pressure
Flow
Rat
e (M
CF/
d)Fl
ow R
ate
(MC
F/d)
The Square-edged orifice performance curve
CHARACTERISTICS OF A SQUARE-EDGED ORIFICE
• Large sub-critical flow regime
• Gas passage dependent on downstream pressure until 40 - 50% pressure lost
• Poor pressure recovery = large pressure drop & large energy loss
NOVA VALVENOVA VALVE
PRESSURE (PSI)
SUB-CRITICAL FLOW
PCASING
PTUBING = 90%PTUBING = 55%
CRITICAL FLOW
CRITICAL FLOW
GA
S IN
JEC
TIO
N R
ATE
(MM
SCF/
D)
NOVA VALVENOVA VALVE
INFLOW
GL Typical System
Gas Lift
Advantages• Fairly low operational cost
• Flexibility - can change rates by
adjusting injection rates and/or
pressures. Also, easy to change
gas lift valves without pulling
tubing
• High volume lift method 35,000
bpd typical
• Very good for sand / deviated
wells
Disadvantages• Must have a source of gas
• If gas is corrosive it will require
treatment
• Possible high installation costs
• Top sides modifications to
existing platforms
• Compressor installation &
maintenance
• Limited by available reservoir
pressure
Hydraulic-Lift Pumping SystemsHydraulic systems transfer energy downhole by pressurizing special power fluid, usually water or a light refined oil or pumped through well tubing or annulus to a subsurface pump, which transmits the potential energy to produced fluids. Common pumps consist of jets (venturi and orifice nozzles), reciprocating pistons, or less widely used rotating turbines.
Two Types of Hydraulic Pumps
• Jet Pump• Piston Pump
Jet Pump - Principles of Operation
• Jet pumps can be used as an alternate to Piston pumps– They can fit interchangeably into BHA’s– Shorter BHA’s can be used
• Jet pump assemblies can be shorter and higher flow
• Referred to as far back as 1852• First patents for oil wells usage in 1930
Jet Pump Overview
• Pumping action achieved with energy transfer• High pressure fluid passed through the nozzle
– Potential energy (pressure) is converted to kinetic energy in form of high velocity jet stream
• Well fluids intermix at the exit (in throat)– Momentum entrains well fluid
• Mixture passes through expanding area (diffuser) slows down the liquid
• Pressure of the mixture must be sufficient to reach the surface
Well in Flowing Condition through BHA with no Communication with Casing Annulus
Well no Longer Flowing Standing Valve Drop down Tubing until Seated
Pressure is exerted against the standing valve & gate is open
Pump is then Drop and placed in bottom hole assembly
Injected power fluid goes into nozzle converting to pressure head to a velocity stream, pressure is lower at the discharge of nozzle allowing pressure from formation to flow and mixed in with jet stream, allowing production & power fluid to circulate to surface
Bernoulli’s Equation of State
P+ vgh 2
2g + Constant
If pressure goes up, velocity….
If velocity goes up, pressure….
Pressure Head
Velocity Head
Power Fluid Mixture
Well Fluids
Jet Pump Overview Cont'd
• No moving parts• Flow passages can use exotic materials for:
– Heavy oils, paraffin, gas, sand and corrosives• Reservoir needs relatively ‘strong drive’
– 100 psi / 1000 ft as a guideline• Has to be sufficient tubular space in well
– To avoid excessive friction loss• Offer ruggedness, reliability and volume
Jet Pump Overview Cont'd
• Guidelines:– PF pressure 2000 – 4000 psi (5000 psi max)– Maximum well depths 3000 – 12,000 ft
• Higher lifts = higher pressure– Production capacities from 50 – 10,000 bpd– Abrasion resistant nozzles in ceramic, SS or
Tungsten Carbide– Total length of jet pump section can be ~1.5 ft– Gas can lead to reduced return flowing gradient
= less HP
Nozzle and Throat Sections
Performance - Nozzle to Throat Area
• Ranges from 20 – 60% ratio• Different N to T combinations provide range
of lift capacity• Selection defines defines:
– Effectiveness of power fluid injected– Power fluid to lift– Input horsepower
• Higher lift = more pressure = more efficiency (up to 5000 psi max)
Area Ratio
Fad= An/At
Where:Fad= dimensionless area ratioAn= area of nozzle, sq. in.At= area of throat, sq. in.E.G. Large throat to nozzle ratios have higher flow capacities
OBJECTIVE IS TO MINIMIZE HP TO MAXIMIZE EFFICIENCY
N/T Characteristics Examples• High head, low flow pump
– When nozzle is 60% of the area of the throat
• LESS flow area around nozzle for well fluids to enter
• Low production rate capacity compared to power fluid rate
– Deep wells with high lift may need this configuration
• Low head, high flow pump– When nozzle is 20% of the
area of the throat
• MORE flow area around the nozzle for well fluids to enter
• High production rate capacity compared to power fluid rate
• Higher injection pressures required to meet defined lift
– Shallow wells with low lift
Velocities are typically 200 - 300 fps in throat area!
Equipment Selection –Balancing the Following:
• Jet pump components– Nozzle too small
• Will only circulate PF• PF pressure could be too high for required lift
– Throat area is too small = cavitation• Defining minimum annular area is a key part of
the design
• Power fluid supplied– Goal = minimal HP and maximum production
• Friction considerations– Goal = keep losses to a minimum for application
Jet Pump Application RangeTubing Size Max Production (B/D) Capacity (Ft.)
1-1/4” 1,000 B/D 10,000 Ft.2-3/8” 2,500 B/D 15,000 Ft.2-7/8” 8,000 B/D 15,000 Ft.3-1/2” 10,000 B/D 15,000 Ft.
Advantages of Hydraulic Jet Pumps Reverse flow retrievable Flexible production capacity
Deviated & crooked wells Deep wells
Multiple wells Offshore platforms
Remote & urban locations Environmentally friendly
Multiple zones Economical
Unitized & transportable Complex well completions
Low Profile Field repairable
No-moving parts Sand & solids
Gas & water Paraffin & heavy oil
Corrosive fluids DST, well cleaning & testing
Low maintenance
Standard Wellhead and Downhole Pump
Advantages of Jet Pumping• No moving parts, can tolerate solids & deviated
wellbores• No rig required to replace pump (due to wear or
productivity changes)• Simplifies completions significantly• Chemicals can be injected with power fluid• Low capital cost per unit production
Disadvantages of Jet Pumps
• Low system mechanical efficiencies (5 to 30%)• High fuel/energy running costs• High GOR impacts performance• High surface maintenance costs if using piston
power fluid pumps• Cavitation can occur with high GOR
Hydraulic Piston Pumps
• Offered as an alternative to jet pumps– Higher efficiencies (up to 95%)– Reciprocating piston to lift product to surface– Hydraulically retrievable– Similar flexibility in design and application
Piston Pump
• Same reciprocating action as rod pump
• Ideal for low flow rates
• Low intake pressure
• Higher efficiency
• Maximum drawdown
Piston PumpsFree Piston Pump Application Range
Tubing Max Production (B/D) Max HeadSize at Depth Capacity
2-3/8” 1317 B/D at 8700 ft. 18,000 Ft.2-7/8” 2400 B/D at 8700 ft. 18,000 Ft.3-1/2” 4007 B/D at 8700 ft. 18,000 Ft.4” 5005 B/D at 5005 ft. 18,000 Ft.
Advantages of Piston Pumps Hydraulic retrievable Flexible production capacity Deviated & crooked wells
Deep wells Multiple wells Offshore platforms
Remote & urban locations Environmentally friendly Multiple zones
Economical Unitized & transportable Complex well completions
Low profile High Efficiency (95%) Low fluid levels
Typical Hydraulic System
PD Pump Set Up
Optional Hydraulic Pumping System
HPS + Surface System
Electric Submersible Centrifugal Pump SystemsElectric submersible systems use multiple pump stages mounted in series within a housing, mated closely to submersible electric motor on the end of tubing and connected to surface controls and electric power by an armor protected cable.
Transfers electricalenergy that is converted to torque.
Electrical Submersible Pump• The Electric Submersible Pumping (ESP) System
transfers electrical energy from the surface to a down hole motor that converts it into a mechanical force (torque). This rotational movement turns the pump’s impellers and lifts the well fluids to the surface.
• The ESP was introduced as a means of Artificial lift by REDA in the late 1920s.
• There are a wide variety of pump sizes, capacities, motor horsepower, and voltage ranges for different applications
REDA
Russian
Electrical
Dynamo
Artunoff
The multistage centrifugal pump consists of numerous impellers and diffusers (application dependent) to provide the lift (pressure) required. The pump has a discharge head that the tubing screws into.
ESP Pump
ESP - Pumps
A Centrifugal Pump is a machine that moves fluid by spinning it with a rotating impeller inside a stationary diffuser that has a central inlet and a tangential outlet. The pressure (head) develops against the inside wall of the diffuser as the curved wall forces fluid to move in a circular path upwards and into the impeller and diffuser above.One impeller and diffuser make one pump stage.
0 2000010000 30000
20000
10000
0
Tota
l Dyn
amic
Hea
d -F
eet
15000
5000
Flow Rate - BPD (60 Hz)
Maximum Head-Capacity for Pumps
5.5" Casing7" Casing
4.5" Casing
ESP's operate at 3,500 rpm on a 60-cycle power supply or 2,900 rpm on a 50-cycle power supply.
PumpPerformanceCurves
In some applications, there may be gas produced along with the oil and water liquids.
If gas is present, then a gas separator can be installed and becomes the pump’s intake. This assists in eliminating some of the gas that might be produced through the pump.
ESP Gas Separators
ESP Protector
The protector is located directly above the motor.
The motor is a three phase, squirrel cage, two pole induction design.
It’s the “heart” of the system since it provides the torque required by the downhole pump.
ESP - Motor
Motors are available in a number of different Sizes, Voltages, and Horsepower ranges depending on the application
ESP - Motor Selection
Electric power is transferred to the motor through an electrical cable banded to the tubing.
ESP - Power Cable Motor Lead Extension
Power
Cable
MLE
Cable
The electrical cable has been refined over the years to be used specifically for oilwell applications.
The size of the cable selected is based on amperage and voltage drop.
Bottom Hole Temp and fluid properties are critical for the selection of cable.
Power Cable consists of three copper conductor wires extending from the top of the motor flat cable lead to the wellhead.
ESP - Power Cable
•The conductor - electrical properties
•Insulation material - protects and covers the conductor
wire
•Barrier Jacket - protects and covers the insulation.
•Jacket Material - rubber compound designed for
temperature, chemical, and gas considerations.
•The exterior armor - the outer shield that holds it all
together
ESP – Power Cable Components
ESP - Surface Equipment
Transformers
VSD’s J-BoxesWellhead Connectors
The Wellhead is the device that is installed at the surface on the wellbore casing.
Purposes: to support the tubing string, cable & ESP and contain high pressures conditions often present within the casing.
Special wellheads are required to allow for cable and/or connector passage.
ESP - Surface Equipment
ESP – J BoxA Junction box or vent box:
Provides a connection point for the surface cable from the motor control panel or VSD to the power cable in the wellbore.
Allows for any gas to vent that may have migrated through to the power cable.
Provides easy/safe accessible test point for electrically checking downhole equipment.
Electrical transformers are required to deliver the correct voltages at the motor terminals.
- Step-down transformers:- Step-up transformers:
Transformers can be either single phase or three phase.
ESP - Surface Equipment
ESP Switchboards
The switchboard is used to energize the motor
It contains a motor controller which monitors running parameters and provides protection to the system.
The controller also provides the capability to monitor the REDA Production system with the use of a recording instrument.
The variable speed controller allows for flexibility of the downhole system for flow control capabilities.
It provides a constant ratio of between voltage and frequency for proper operation.
VSD’s
Perforations.
Protector
Pump intakePump
1 joint Tubing
Check valveDrain valveCasing
MotorPothead
Motor flat cable
Primary cable
Production
WellheadJunction
box
Motorcontroller
Transformers
ESP ‘s Advantages• Good efficiency over the widest range of production rates• Can achieve high production rates• When VSD operated, can offer flexibility to
accommodate changing conditions in time (PI, water cut, Pwf, Pr, etc.)
• Can be used at low bottom hole pressures.• Can operate reliably in deviated and offshore wells.• Can sometimes operate below perforations.• Can operate under conditions such as higher bottom hole
temperate with the use of alternative materials.• Can be utilized to test wells by using a portable VSD
ESP ‘s Disadvantages
• A pulling unit is required to retrieve the failed ESP, regardless of failed component.-expensive intervention costs.
• High temperatures affect cable and motor insulation.• High dog leg severities are a problem.• Available electrical power for required horsepower.• Use of Switchboards (constant speed) limits the flexibility
of production rates.• Higher gas content can limit system capabilities.• High solids may cause rapid wear and premature failure.
END of MODULE Two