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10th Annual Sucker Rod Pumping
Workshop Renaissance Hotel
Oklahoma City, Oklahoma
September 16 - 19, 2014
Jim McCoy
Ken Skinner, Lynn Rowlan - Echometer Company
Down-Hole Gas Separator Performance Simulation
Gas Separator Simulation Program
• The simulation program shows how a gas
separator separates the liquid from the gas.
• Viewing the simulation should help operators
understand how gas separators work and
improve the results of the separators that they
are running.
• Operators can analyze a particular separator
configuration and view how the gas separator
separates the liquid from the gas and also
determine separator capacity.
2014 Sucker Rod Pumping Workshop 2 Sept. 17 - 20, 2014
Pump Video
2014 Sucker Rod Pumping Workshop 3 Sept. 17 - 20, 2014
Echometer Gas Separator Simulation Program (Free)
Program from Studies Performed at UT
Podio, Tony, J. N. McCoy, M. D. Woods, Hanne Nygard, and B. Drake, “Field and Laboratory Testing of a Decentralized Continuous-Flow Gas Anchor”, Proceedings of the 46th Annual Technical Meeting of the Petroleum Society of CIM, 1995.
Guzman, M.: “Downhole Gas Separator Performance in Sucker Rod Pumping System,” (master’s thesis, University of Texas at Austin, 2005).
Lisigurski, O.: “The Effect of Geometry on the Efficiency of Downhole Gas Separators,” (master’s thesis, University of Texas at Austin, 2004).
Robles, J. and A. L. Podio, “Effect of Free Gas and Downhole Gas Separation Efficiency on the Volumetric Efficiency of Sucker Rod Pumps and Progressing Cavity Pumps,” Proceedings of the 43rd Annual Meeting of the SWPSC, 1996.
R. Bohorquez, V. Ananaba, O. Alabi, A. L. Podio, O. Lisigurski, and M. Guzman, “Laboratory Testing of Downhole Gas Separators,” SPE 109532
Videos can be viewed at http://www.utexas.edu/ce/petex//aids/pubs/beamlift/toolbox/#downholeseparator
2014 Sucker Rod Pumping Workshop Sept. 17 - 20, 2014 5
http://www.utexas.edu/ce/petex//aids/pubs/beamlift/toolbox/#downholeseparator
Bubble Behavior
Effect of Liquid Velocity
5 inch/sec
243 BPD
6 inch/sec
275 BPD9 inch/sec
420 BPD2014 Sucker Rod Pumping Workshop Sept. 17 - 20, 2014 6
Sept. 17 - 20, 2014 2014 Sucker Rod Pumping Workshop 7
Separator Downward Flow rate 243 BPD 5 in/sec Video
Casing
Separator Outer
Barrel
Dip Tube
Sept. 17 - 20, 2014 2014 Sucker Rod Pumping Workshop 8
Separator Downward Flow rate 243 BPD
5 inches /Second
Separator Downward Flow rate 275 BPD
6 inches /Second
Sept. 17 - 20, 2014 2014 Sucker Rod Pumping Workshop 9
Separator Downward Flow rate 420 BPD
12 inches /Second
Sept. 17 - 20, 2014 2014 Sucker Rod Pumping Workshop 10
Describe Variables and Display using Program
11 2014 Sucker Rod Pumping Workshop Sept. 17 - 20, 2014
Net Pump Displacement Simulation
Separator Liquid Flow Rate ProfileMaximum Rate is 3.77 times Average
Profile selected from dynamometer data on higher volume wells.
400
300
200
100
0
Time as % of stroke Period
Average Production Rate Sepa
rato
r Li
quid
Infl
ow
Pro
file
, per
cent
o
f Ave
rage
Rat
e
100 %
48%5 %
Actual plunger movement
of a beam pumping unit or
RotaFlex or Hydraulic unit
does not materially affect
separator performance
except slower units require
longer dip tubes
2014 Sucker Rod Pumping Workshop 12 Sept. 17 - 20, 2014
Dip Tube Length (Length Below Separator Ports)
13
Gas Movement
All gas that is in the separator below the inlet ports at
the beginning of the upstroke will eventually move into
the pump chamber.
The gas separator capacity should exceed the net
pump displacement rate so that gas bubbles will not
exist in the separator annulus at the beginning of the
upstroke.
A long dip tube that is in excess of the required net
dip tube length does not increase the separation
capacity of the separator. It often hurts pump fillage
by restricting liquid flow into the pump chamber
2014 Sucker Rod Pumping Workshop 14 Sept. 17 - 20, 2014
Maximum Gas Separator Capacity Performance
Operating a gas separator with a net pump
displacement in excess of gas separator capacity will
cause gas to be pulled into the pump.
Generally, the pump will be about 25-40 % filled with
liquid if the pump displacement exceeds the gas
separator capacity excessively.
The simulation program showns in the next slide the
performance when net pump displacement is below,
at and above gas separator capacity.
2014 Sucker Rod Pumping Workshop 15 Sept. 17 - 20, 2014
Maximum Capacity Behavior Run a 2 3/8 Poor boy at 80 and 96 and 120 BPD Pump Capacity
Operating a Separator Above its Capacity
Tubing Anchor 10,471 Feet
Pump and 10,530 Feet
2 3/8 poor boy Separator
Casing Perforations10,621
SBHP = 1924 psi PBHP = 416 psi
Pump Displacement = 141 BPD
Separator Capacity = 96 BPD
Franks #1
17 Sept. 17 - 20, 2014
Poor Boy Separator Franks #1
34.4” Effective Plunger Stroke
with 34% Pump Fillage
Show: 2 3/8 Poor Boy Simulation and Capacity
2014 Sucker Rod Pumping Workshop 20 Sept. 17 - 20, 2014
Run 2 3/8 Collar Size Simulator
2014 Sucker Rod Pumping Workshop 20 Sept. 17 - 20, 2014
Collar Sized Gas Separator Franks #1
Production of 100 BPD
with a Full Pump
21 Sept. 17 - 20, 2014 2014 Sucker Rod Pumping Workshop
SPM Effect Slower Speed Needs Longer Dip Tube 2 3/8 collar size separator at 6 and 3 SPM at 242 BPD
22
Low Capacity Gas Separator 2 7/8 inch Poor-Boy Separator with 60 foot dip tube What is capacity?
Seating Nipple
6 foot 2 7/8 sub
6 foot 2 7/8 Perforated Sub
60 Foot 1 ¼ inch dip tube
Tubing Plug
6 foot Perforated sub
Baker Latch Assembly
2014 Sucker Rod Pumping Workshop 23
RotaFlex Unit (Constant Plunger Speed)
Stroke Length 306 Inches
SPM 4
Casing Pressure 140 psi
Separator 96 feet long 2 7/8 Poor Boy Separator
OD 2.875 Capacity is 147 BPD
ID 2.5
Dip Tube 60 feet long Simulation program recommends
OD 1.66 a minimum length of 27 inches.
ID 1.38 Long dip tubes cause gas to be
released from the oil.
Pump Displacement 324 BPD
Reported high fluid level no test
Pump card shows high pump intake pressure that indicates high
fluid level.
2014 Sucker Rod Pumping Workshop 24 Sept. 17 - 20, 2014
Separator Capacity 147 BPD Pump Displacement 324 BPD
2014 Sucker Rod Pumping Workshop 25 Sept. 17 - 20, 2014
RotaFlex Unit
Indicates high PIP
Gas Free Liquid Fillage
23 BOPD
3 BWPD
2014 Sucker Rod Pumping Workshop 26 Sept. 17 - 20, 2014
Phantom Poor Boy Separator Net Pump Displacement = 168 BPD 6.82 SPM
27
Modified Poor Boy Separator Net Pump Displacement 168 BPD
2014 Sucker Rod Pumping Workshop 28 Sept. 17 - 20, 2014
Phantom Poor Boy Separator Net Pump Displacement = 140 BPD 6.14 SPM
2014 Sucker Rod Pumping Workshop 29 Sept. 17 - 20, 2014
Simulation Program to Field Tests Comparison
• The simulation program predicts how a
separator will perform in the field so that the
proper gas separator and pump can be
selected.
• Field tests will be compared to the simulation
program to determine what bubble rise
velocity should be used in that particular field.
• The industry uses 6 inches/second for the
bubble rise velocity. Is this the correct rise
velocity?
2014 Sucker Rod Pumping Workshop 30 Sept. 17 - 20, 2014
Simulation Program and Field Tests Comparison
• Echometer plans to work with operators to
obtain field data so the simulation program can
be compared to field data.
• Most separator configurations can be input and
saved into the program for simulation studies.
• The comparison studies will be distributed.
• Hopefully, the study will result in a standard
separator that is efficient and predictable in its
performance.
• Please contact us if interested.
2014 Sucker Rod Pumping Workshop 31 Sept. 17 - 20, 2014
Gas Separator Simulation Program
The program and updates can be
downloaded free from:
www.Echometer.com
Or requested from ken@ echometer.com
Or on Echometer USB [email protected]
2014 Sucker Rod Pumping Workshop
32 Sept. 17 - 20, 2014
Final This presentation and other presentations in addition to
downhole pump animations showing gas compression,
pump chamber pressure and pump fillage and also
descriptive papers on the different gas separators
discussed are available from Echometer Company.
Videos of gas/liquid separation in laboratory models can
be obtained at the University of Texas website
http://www.utexas.edu/ce/petex//aids/pubs/beamlift/toolbox/#d
ownholeseparator
2014 Sucker Rod Pumping Workshop 33 Sept. 17 - 20, 2014
http://www.utexas.edu/ce/petex//aids/pubs/beamlift/toolbox/#downholeseparator
Sept. 17 - 20, 2014 2014 Sucker Rod Pumping Workshop 34
Copyright
Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Sucker Rod Pumping Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to:
– Display the presentation at the Workshop.
– Place it on the www.alrdc.com web site, with access to the site to be as directed by the Workshop Steering Committee.
– Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee.
Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Sucker Rod Pumping Workshop where it was first presented.
Sept. 17 - 20, 2014 2014 Sucker Rod Pumping Workshop 35
Disclaimer
The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Sucker Rod Pumping Web Site.
The Artificial Lift Research and Development Council and its officers and trustees, and the Sucker Rod Pumping Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Sucker Rod Pumping Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.
The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials.
The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.
