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Artificial Lift Selection

Marda Vidrianto
Outline

Introduction

AL selection

AL Types
Introduction
Definitions
the use of artificial means to increase the flow of
liquids, such as crude oil or water, from a
production well (wikipedia)
Method used to lower the producing bottomhole
pressure (BHP) on the formation to obtain a
higher production rate from the well (PEH
Artificial lift section-James F. Lea)
Global surveys
Weatherford
KEY FACTS Schlumberger
23% 19% GE Oil & Gas
About 65% of the global artificial lift market is found in
the US and Canada. Over the last 10 years, artificial lift Baker Hughes
2%
has grown at a CAGR of 13%, fueled by rapidly 16%
6% Dover Corp.
increasing drilling in US oil plays over the last 5 years.
We think going forward, the CAGR will be somewhat BORETS
6% 14% 14%
lower. Novomet
The US is the worlds largest lift market, followed by Others
Canada. With over 1 million producing wells in North $18,000
America, most incur at least one artificial lift expense
per year. The fastest growing regional markets are $16,000
found in the US. These markets include the Permian $14,000
and the Rockies.
$12,000
International artificial lift tends to favor high-end ESP
Millions

$10,000
systems and high-end gas lift.
$8,000
Even gas wells use artificial lift to de-water wellbores.
Rising gas well drilling will drive more lift demand. $6,000
$4,000
Lift companies embrace international manufacturing
of components, but look to the US and Canada for $2,000
customers. $0
2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015
Others

WFT
SLB
GE

2014
2013
2012
Global Market Share

2011
2010
Global surveys

2009
2008
2007
2006
2005
90%

80%

70%

60%

50%

40%

30%

20%

10%
100%

0%
Summit ESP
Kudu
Companies Ranked by Total Revenues

Tenaris
Halliburton Corp.
John Crane
NOV
Cameron
Novomet
BORETS
Dover Corp.
Baker Hughes
GE Oil & Gas
Schlumberger
Weatherford

$500
$3,000

$2,500

$2,000

$1,500

$1,000

$0
Million
Global surveys
Artificial Lift Market by Type of Lift
$16,000

$14,000
10%
NoAm
$12,000

17% Other
LaAm $10,000
Plunger
Gas Lift

Millions
$8,000 Hydraulic
Eur/Afr/CIS
8% PCP
65%
$6,000 ESP
Rod Lift
ME/Asia
$4,000

$2,000

$0 2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
Global surveys
Artificial lift Selection
Artificial lift Selection
Consideration of depth/rate system
capabilities
Screening advantages vs disadvantages
Selection by NPV comparison
Sample run life information
Consideration of depth/rate
Artificial lift Selection
system capabilities
Gas lift is somewhat depth limited,
primarily from compressor pressures
required, but has a wide range of
production capacity.
Beam pump produces more from
shallower depths and less from deeper
depths because of increasing rod weight
and stretch as depth increases.
Electric submersible pumps (ESPs) are
depth limited because of burst
limitations on housings and energy
considerations for long cables, but can
produce large production rates.
Plunger lift is for low liquid rates,
although some wells can produce more
than 300 B/D. Plunger lift is not
particularly depth limited because of the
increased energy storage in the casing
annulus as depth increases.
Along with advantage/disadvantage lists, the
depth-rate charts are tools for artificial lift
selection or quick elimination of possibilities. The depth-rate charts show how hydraulic
NOTE: The depth-rate curves are only a
relative comparison of the different lift forms systems can pump from the greatest depths,
and not absolutes. For example, a jet pump
has been used to produce 25,000 bpd from because of the U-tube balancing of produced
5000 feet.
fluid pressures with the hydraulic fluid
pressure.
Screening
Artificial lift Selection advantages vs disadvantages
Electrical
Progressive Cavity
Sucker Rod Pump Gas Lift Plunger Lift Jet Pump Submersible
Pump
pump
Operating depth (ft TVD) 100-16000 2000-6000 5000-15000 8000-19000 5000-15000 1000-15000
Well deviation Vertical Horizontal Deviated <20 deg Deviated Horizontal
Operating rate (bpd) 5-5000 5-4500 200-30000 1-5 300-15000 200-30000
Operating temperature (F) 100-550 75-250 100-400 120-900 100-500 100-400
Corrosion handling Good to Excellent Fair Good to Excellent
Excellent Excellent Good
Gas handling Fair to Good Good Excellent Excellent Good Poor to Fair
Solids handling Fair to Good Excellent Good Poor to Fair Good Poor to Fair
GLR: 300
Fluid gravity (API) >8 <35 >15 scf/bbl/1000 ft >8 >10
depth
Workover/pulling Workover/pulling Wireline/workover wellhead Hydraulic or Workover/pulling
Servicing
rig rig rig catcher/wireline Wireline rig
Multicylinder or
Prime mover Gas or Electric Gas or Electric Compressor Reservoir energy Electric motor
Electric
Offshore apllication Limited Good Excellent N/A Excellent Excellent
Overall system efficiency
45-60 45-70 10-30 N/A 10-30 35-60
(%)
High for
High for power High for power
Capital cost low to moderate compressor and Moderates low to moderate
generation generation
distribution
Moderate for
Operating cost Low to moderate Moderate to High Low Low Moderate to High
power fluid pump
Large for
Facilities Footprint Medium Small Large Large Small
compressor
Flexibility Excellent Excellent with VSD Excellent Poor Good To Excelent Excellent with VSD
Selection by NPV comparison
Artificial lift Selection
A more thorough selection technique depends on the lifetime
economics of the available artificial lift methods. The economics, in
turn, depend on:

Failure rates of the


system components
Fuel costs
Maintenance costs
Inflation rates
Anticipated revenue
from produced oil and
gas
Other factors that may
vary from system to
system
To use the NPV comparison method, the user must have a good
idea of the associated costs for each system. This requires that the
user evaluate each system carefully for the particular well and be
aware of the advantages and disadvantages of each method and
any additional equipment (i.e., additional costs) that may be
required. Because energy costs are part of the NPV analysis, a
design for each feasible method must be determined before
running the economic analysis to better determine the efficiency of
a particular installation. These factors force the consideration of all
the applicable artificial lift methods to generate the necessary
information for the NPV analysis.
Sample run life information
Artificial lift Selection
CNOOC ESP Q1 2015 Fail Description Cable Burn Out
Cable Low Reading
10 9 Holes in Pump Housing
11% 10% 3
10 1
3% Motor Burn Out
4 11% 1% 12
Artificial lift Selection 4%
13% Motor Low Reading

Sample run life information 2 Penetrator Low Reading


2% Protector Shaft Broken
1 32 Protector Shaft Parted
1% 34% Pump Bushing Broken
8
9% 1 Pump Shaft Broken
1% Pump Stuck
Tubing Leak
Artificial lift Selection

Consideration
Screening
of depth/rate
advantages vs
system
disadvantages
capabilities

Selection by Sample run


NPV life
comparison information
Artificial lift Types
Types
Sucker-Rod
Beam pumping, or the sucker-rod lift
method, is the oldest and most widely
used type of artificial lift for most
wells. A sucker-rod pumping system is
made up of several components, some
of which operate aboveground and
other parts of which operate
underground, down in the well. The
surface-pumping unit, which drives
the underground pump, consists of a
prime mover (usually an electric
motor) and, normally, a beam fixed to
a pivotal post. The post is called a
Sampson post, and the beam is
normally called a walking beam.

http://petrowiki.org/Sucker-rod_lift
Sucker-Rod
Beam pumping, or the sucker-rod lift
method, is the oldest and most widely
used type of artificial lift for most
wells. A sucker-rod pumping system is
made up of several components, some
of which operate aboveground and
other parts of which operate
underground, down in the well. The
surface-pumping unit, which drives
the underground pump, consists of a
prime mover (usually an electric
motor) and, normally, a beam fixed to
a pivotal post. The post is called a
Sampson post, and the beam is
normally called a walking beam.
SRP common problems

Problems Cause Solution


Pump failure Design Corrosion
Tubing failure deficiencies inhibitor
Rod failures Improper Tubing anchor
selection of Pony rods
material Better
Manufacturing metallurgy
deficiencies API RP11BR
Errors in
assembly
Sucker-Rod
Gas Lift
Gas lift is a method of artificial lift that
uses an external source of high-
pressure gas for supplementing
formation gas to lift the well fluids.
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 bottomhole
pressure (BHP) at the bottom of the
tubing. There are two basic types of
gas lift in use todaycontinuous and
intermittent flow.

http://petrowiki.org/Gas_lift
Gas Lift
Gas lift is a method of artificial lift that
uses an external source of high-
pressure gas for supplementing
formation gas to lift the well fluids.
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 bottomhole
pressure (BHP) at the bottom of the
tubing. There are two basic types of
gas lift in use todaycontinuous and
intermittent flow.
Gas Lift
Continuous injection Intermittent injection
GL common problems

Problems Cause Solution


Inlet (surface); Closed choke Run warm gas
hi-lo casing Faulty gauges Methanol
pressure, Tubing leaks injection
froozen Gas injection
Scale build up
Outlet rate
(surface) adjustment
Downhole Chemical
injection
API RP11V5
Gas Lift
Hydraulic Pumping
Hydraulic pumping is a proven AL
method that has been used since the
early 1930s. It offers several different
systems for handling a variety of well
conditions. Successful applications
have included setting depths ranging
from 500 to 19,000 ft and production
rates varying from less than 100 to
20,000 B/D. Surface packages are
available using multiplex pumps
ranging from 15 to 625 hp. The
systems are flexible because the
downhole-pumping rate can be
regulated over a wide range with fluid
controls on the surface. Chemicals to
control corrosion, paraffin, and
emulsions can be injected downhole
with the power fluid, while fresh water
can also be injected to dissolve salt
deposits.

http://petrowiki.org/Hydraulic_pump
ing
Hydraulic Pumping
Hydraulic jet pump Reciprocating hydraulic pump
free Hydraulic Pumping

The unit is pumped into the well with the standing valve closed. It
seats on the bottom, with the standing valve held open by a magnet,
ready for operation. To retrieve the pump, power fluid is reverse-
circulated down the return line, causing the pump to unseat and travel
to the surface.
HP common problems

Problems Cause Solution


eroded nozzle Sand/solid Hardened
Low efficiency Viscous oil nozzle
corrosion Corrosive fluid Heated power
fluid
Pump
corrosion
inhibitor
Hydraulic Pumping
Plunger lift
Plunger lift has become a widely
accepted and economical AL.
alternative, especially in high-
gas/liquid-ratio (GLR) gas and oil wells
Plunger lift uses a free piston that
travels up and down in the wells
tubing string. It minimizes liquid
fallback and uses the wells energy
more efficiently than does slug or
bubble flow. As with other artificial lift
methods, the purpose of plunger lift is
to remove liquids from the wellbore so
that the well can be produced at the
lowest bottomhole pressures.

http://petrowiki.org/Plunger_lift
Plunger lift
Whether in a gas well, oil well, or gas
lift well, the mechanics of a plunger-lift
system are the same. The plunger, a
length of steel, is dropped through
the tubing to the bottom of the well
and allowed to travel back to the
surface. It provides a piston-like
interface between liquids and gas in
the wellbore and prevents liquid
fallbacka part of the liquid load that
effectively is lost because it is left
behind. Because the plunger provides
a seal between the liquid and the
gas, a wells own energy can be used
to lift liquids out of the wellbore
efficiently.
Plunger lift
PL common problems

Problems Cause Solution


Tubing failure Surface Routine
Tubing Tight Facilities Inspection
Spots Holes in Tubing plunger for
Plunger stuck Tubing Tight problems or
Spots wear
Scale, Paraffin, Scale
inhibition
Sand
Metallurgy
improvement
Plunger Lift
Progressive Cavity Pumps
Progressing cavity pumping (PCP)
systems derive their name from the
unique, positive displacement pump
that evolved from the helical gear
pump concept first developed by Rene
Moineau in the late 1920s.[1] [2] [3]
Although these pumps are now most
commonly referred to as progressing
cavity (PC) pumps, they also are called
screw pumps or Moineau pumps. They
are increasingly used for artificial lift,
and have been adapted to a range of
challenging lift situations (e.g., heavy
oil, high sand production, gassy wells,
directional or horizontal wells).

http://petrowiki.org/Progressing_cavi
ty_pump_(PCP)_systems
Progressive Cavity Pumps
The two key features that differentiate
PCP systems from other forms of
artificial lift are the downhole PC
pumps and the associated surface
drive systems. Although other major
components, such as the production
tubing and sucker rod strings, are
found in other downhole lift systems,
the design and operational
requirements typically differ for PCP
applications. Also, many additional
equipment components may be used
in conjunction with PCP systems to
contend with specific application
conditions.
Progressive Cavity Pumps
Installation:
Surface Rod Drive System
Downhole Electric motor System
PL common problems

Problems Cause Solution


Rod wear Dog leg Rodless PCP
Flow rate drop severity issue with DH motor
No flow Tubing leak Improve
Elastomer elastomer
swelling selection
Metallurgy
improvement
Progressive Cavity Pumps
ESP
The electrical submersible pump,
typically called an ESP, is an efficient
and reliable artificial-lift method for
lifting moderate to high volumes of
fluids from wellbores. These volumes
range from a low of 150 B/D to as
much as 150,000 B/D (24 to 24,600
m3/d). Variable-speed controllers can
extend this range significantly, both on
the high and low side.
The ESPs main components include:
Multistages centrifugal pump
Three-phase induction motor
Seal-chamber section
Power cable
Surface controls

http://petrowiki.org/Electrical_subm
ersible_pumps
ESP Applications
ESP Parts

Pump Pump
ESP Parts

Gas Separator Gas Separator


ESP Parts

Protector Protector
ESP Parts

Motor Motor
ESP Parts

Sensor Sensor
ESP Parts

Cable Cable
ESP Surface Equipment
ESP common problems

Problems Cause Solution


Low or No flow Tubing leaks Frequency
Cable blown Pump wear adjustment
Motor burnt Water Sand control
Sand, scale intrusion to Scale inhibitor
Gas lock motor Metallurgy
Protector fail improvement
ESP
Artificial Lift Type
Progressive Cavity Electrical
Sucker Rod Pump Gas Lift Plunger Lift Jet Pump
Pump Submersible pump

Operating depth (ft TVD) 100-16000 2000-6000 5000-15000 8000-19000 5000-15000 1000-15000
Well deviation Vertical Horizontal Deviated <20 deg Deviated Horizontal
Operating rate (bpd) 5-5000 5-4500 200-30000 1-5 300-15000 200-30000
Operating temperature (F) 100-550 75-250 100-400 120-900 100-500 100-400
Corrosion handling Good to Excellent Fair Good to Excellent Excellent Excellent Good
Gas handling Fair to Good Good Excellent Excellent Good Poor to Fair
Solids handling Fair to Good Excellent Good Poor to Fair Good Poor to Fair
GLR: 300
Fluid gravity (API) >8 <35 >15 scf/bbl/1000 ft >8 >10
depth
Wireline/workover wellhead Hydraulic or
Servicing Workover/pulling rig Workover/pulling rig Workover/pulling rig
rig catcher/wireline Wireline
Multicylinder or
Prime mover Gas or Electric Gas or Electric Compressor Reservoir energy Electric motor
Electric
Offshore apllication Limited Good Excellent N/A Excellent Excellent
Overall system efficiency (%) 45-60 45-70 10-30 N/A 10-30 35-60
High for power High for compressor High for power
Capital cost low to moderate Moderates low to moderate
generation and distribution generation
Moderate for power
Operating cost Low to moderate Moderate to High Low Low Moderate to High
fluid pump
Large for
Facilities Footprint Medium Small Large Large Small
compressor
Flexibility Excellent Excellent with VSD Excellent Poor Good To Excelent Excellent with VSD
Thanks
CNOOC SES Ltd Artificial Lift
Nuke Suciati
CNOOC Overview
CNOOC SES AL
Why do CNOOC use ESP for Artificial Lift?
Most cost effective solution available?
Small unmanned wellhead platforms
No space for surface facilities
Gas Compression
Hydraulic Power Pack
Insufficient gas available for gas lift
Hydraulic / Piston Pumps or Jet Pumps inefficient and not
suitable for large volume lift
PCP not suitable due to high volume lift and highly
deviated wells
So what methods are left?
ESP
Artificial lift method of last resort
CNOOC SES AL
Artificial lift method of last resort, why?
Anyone think its a good idea to put electrical equipment into liquids?
CNOOC SES AL
Artificial lift method of last resort, why?
Technical Risk
We have experience, we know what works
ESP technology has evolved and improved
Reliability
We have changed the technology to improve the run lives
Wells / performance are well understood
Intervention costs
CNOOC improvements has reduced these costs
Simplified completions
Downtime / Barge availability
Minimized through efficiency and planning
Active well inventory
CNOOC SES AL
Artificial lift method of last resort, why?
Changing production environment
VSD application
Change pump type at next intervention
Sand production
Improved pump bearing technology
Alternative metallurgy
Scale production
Chemical stimulation
High temperature fluids
Pump setting depth
Higher temperature Motor design
Hi Temp Elastomers
Historical Run life
Historical Run life
ESP Management Process
ESP challenges

Sand Scale Gas Low Influx Quality Logistic Operation

Well Issues ESP Issues


PE+RE AE

Problems
ESP challenges

Pressure Depletion
ESP challenges
ESP challenges
Plugged Stages

S Holes at Pump
Housing

A Parted Shaft

N Overload (High
Start/Stop Freq.)

D No Build Up
Pressure
SUNDARI A-11
Run Life: 17 days (TRL: 718 days)
Troubleshooting History:
Tripped OL many times
Manual off due to no BUP
SUNDARI A-11
Run Life: 17 days (TRL: 718 days)
Troubleshooting History:
Tripped OL many times
Manual off due to no BUP
YANI AC-12
Run Life: 7 days (TRL: 150 days)
Troubleshooting History:
Tripped Hi Temp
Tripped SCCT, OL, Stall, LO
Cable reading P-G: low reading
Pothead burnt
S
Plugged Stages
C Parted Shaft

A Trip Overload (High


Start/Stop Freq.)

L No BUP

E
ZELDA D-01
Run Life: 180 days (TRL: 365 days)
Troubleshooting History:
Got loss flow problem
Restarted using VSD at various frequencies
No BUP
ZELDA D-01
Run Life: 180 days (TRL: 365 days)
Troubleshooting History:
Got loss flow problem
Restarted using VSD at various frequencies
No BUP
ZELDA D-05
Run Life: 521 days (TRL: 365 days)
Troubleshooting History:
Tripped OL
Restart with VSD on both rotation (Still OL)
ZELDA D-05
Run Life: 521 days (TRL: 365 days)
Troubleshooting History:
Tripped OL
Restart with VSD on both rotation (Still OL)
Gas Lock

G Loss Flow

Increased
A Start/Stop Number

S Cable Blown

Housing Leak
(combine with sand)
KARMILA A-04
Run Life: 281 days (TRL: 619)
Pulling finding :
Cable blown out below hanger
Flat cable burn out
GITA A-01
Run Life: 29 days (TRL: 150 days)
Pulling result:
Parted at gas separator
Flat cable burn out at parted section
GITA A-01
Run Life: 29 days (TRL: 150 days)
Pulling result:
Parted at gas separator
Flat cable burn out at parted section
LOW
Tripped Underload
I
N Tripped High
Temperature
F
Causes Protector
L Failure

U Motor Overheats

X
YANI AC-11
Run Life: 45 days (TRL: 200 days)
Pulling finding :
Protector bag broken
Protector ORing melted
YANI AC-11
Run Life: 45 days (TRL: 200 days)
Pulling finding :
Protector bag broken
Protector ORing melted
TUBING
By Corrosion and
L Erosion

E Good Quality ESP


Will Also Suffer

A Causes Pay Balance

K 26 Wells Suffered
Tubing Leak on
S 2015
NEIA A-14
Run Life: 387 days, Tubing since 2010 (6 years)
Pulling finding :
Tubing leak above head pump
NEIA A-14
Run Life: 387 days, Tubing since 2010
Pulling finding :
Tubing leak above head pump
CNOOC challenges

Scale Sand Gas Low Influx

Inhibit Equipment Equipment Workover


Continues protection protection Hydraulic
Injection VSD VGSA fracturing
Recycle system Better Material AGH - PGP Well stimulation
Anti scale device (5530) Poseidon Reperforation
Encapsulated Automatic Facility Equipment
Squeezed diverter valve Modification Impovement
treatment Downhole sand Continues venting Wide Range Pump
Remove separator system Reservoir
Acid treatment Soft starter Reservoir Management
Advance protector Management Water
Workover Water injection/pressure
Resin/polymer injection/pressure maintenance
injection maintenance
Sand control
installation
Smaller Increase carrying
Tubing velocity

Use compression pump


ESP Tungsten carbide bearing
Enhancement: VSD release pump stuck
Use real time monitoring

Sand bailer
Workover: Sand screen Installation
Gravel pack
Smaller tubing
(3-1/2 2-7/8)
Issues:
Tubing Stock & Quality
Tubing accessories
stock
Tubing strength issue
due to deep wells
ESP Enhancement
Wide range pump
Inconnel Shaft
Tungsten carbide
bearing
Real Time Monitoring
Observes anomalies
real time
Well adjustment by
offshore team
20+ wells monitored
Inject
CISI continuously
via control line

Spot
Encapsulated encapsulated
with tubing

Scale
Squeeze into
Squeeze the perforation
Inhibitor
zone (3 ft)
Continuous Injection Scale Inhibitor

Use control line CISI


@tubing hanger down
to intake
Chemical Pump on Top
Deck
Encapsulated
Before install new pump
Spot at rat hole
Chemical Pump on Top
Deck
Squeeze Inhibitor
Before install new pump
Squeeze to formation
Squeeze Inhibitor
TITA-05 Well Performance
1000

140
900
After Scale Inhibition
PRC: 98
800 120
ppm

700
PI increased 100
Before Scale Inhibition Longer ESP Run Life
600
More stable
performance 80
500

400 60

300
40

200

PRC: 2 20
100 ppm

0 0

Actual Liquid (BFPD), A1 Actual Oil (BOPD), A1 PBHP (psi), A1 PRC, A2


Increase
setting
depth

Produce
with lower
rate (reduce
drawdown)

Use venting
system
Venting System
Lower system pressure
Safely release gas to
atmosphere
>100 wells (SBU)
Real Time Monitoring
Observed increase in
gas (RA fluctuation)
Adjust TP to prevent gas
lock
Stimulation

Reperforation

Pressure
maintenance

Use High
Temp
Resistant
Pump
Reperforation
Add SPF on old well
From 4 to 12 SPF
ESP Enhancement
Hotline ESP
YANI AC-12
Hotline cable
Hotline motor
Hotline advance protector
Max temperature rating
of 500oF
Enhance
material
CNOOC SES
ESP General Operation Guidelines
Way forward
NBU AREA
SBU AREA
CBU AREA
Manage
operation,
reduce shut
Strict down
Standardize
Warehouse
QC Reporting
QC

Contract Key Sharing


Compliance Enablers Platform
Improvement Plan
Remote
Optimization
(Smart Well)

Other Key Advanced ESP


Artificial Lift
Enablers

Operation
Excellency
Digital
Oilfields
Real time
wellhead Multi well
Real time optimization connection
wellhead Process
Conventional monitoring Add Digital connection
wellhead surface
monitoring Add SCADA P&T Gauge
Add VSD Modified
Controller
Advance ESP
Operation Excellency
Other AL method?

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