5.1 Artificial Lift - GL, SRP, PCP, ESP PDF

Module 5
Productivity Enhancement Through Artificial Lift
1 Copyright ©2012 NExT. All rights reserved

Introduction to Artificial Lift Methods

Objectives
• Explain the Artificial Lift Concept
• Identify the main types of Artificial Lift methods
• Identify the various Artificial Lift types applications and

limitations

Why Artificial lift?
.
Wellhead Pwh PRESSURE
Well pressure gradient

DEPTH
Current Pwf Initial Pwf

Reservoir
depth Current Pe Initial Pe

Artificial Lift
• Required when reservoir pressure is not sufficient

to lift fluids to surface
• May be desirable to increase production rates

above naturally flowing rates
• Uses alternate sources to lift or lighten fluid

column

Artificial Lift
psurf
ph The well:
Flows if pwf > ph + psurf
Dies if ph + psurf  pwf
pwf p

Artificial Lift
Assisted Production
6500 INITIAL PRODUCTION PERFORMANCE
Outflow
6000
NATURAL FLOW
5500
Pwf, psi
Inflow
5000
4500
4000
0 3000 6000 9000 12000 15000
Flow Rate ( STB/day )

Artificial Lift
Assisted Production
6500 FINAL PRODUCTION PERFORMANCE
Outflow
6000
NOT FLOWING
5500
Pwf, psi
5000
Inflow
4500
4000
0 3000 6000 9000 12000 15000

Artificial Lift
Assisted Production
6500
6000
BACK TO PRODUCTION BY
ARTIFICIAL LIFT
5500 Outflow
Pwf, psi
5000
4500
Inflow
4000
0 3000 6000 9000 12000 15000

Artificial Lift
Decreases backpressure against reservoir, which

increases pressure difference (draw-down) between
reservoir and wellbore.
q   p  pwf 

Artificial Lift
Performance of Flowing Wells

Artificial Lift decreases Pwf and increases Q

Global Breakdown of Artificial Lift Units

Comparison of Lift Methods
Typical Artificial Lift Application Range

Ft./Lift
12,000
11,000
10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
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
Rod PC Pumps Hydraulic Lift Submersible Pump Gas Lift

Pumps

Comparison of Lift Methods
System Efficiency by Artificial Lift Method
100
90
Overall System Efficiency (%)
80
70
60
50
40
30
20
10
0
PCP Hydraulic Piston Beam Pump ESP Hydraulic Jet Gas Lift Gas Lift
Pumps Pump (Continuous) (Intermittent)
Artificial Lift Type

6.2 Gas Lift Systems
SCHEMATIC OF A CONTINUOUS GAS LIFT WELL
Gas Lift involves the supply of high pressure gas to

the casing/tubing annulus and its injection into the
tubing deep in the well. The increased gas content of
the produced fluid reduces the average flowing
density of the fluids in the tubing, hence increasing
Flowline
the formation drawdown and the well inflow rate.
Gas Injection
Pwh Pressure
Surface Casing
Production Casing
Depth
Static
Tubing gradient
Gaslift valves
Operating Valve
Packer
Pwf Pr Video 1

Gas Lift
Reduction of Fluid Density Expansion of Gas Displacement of Liquid

by Gas

Subsurface Gaslift Equipment
SIDE POCKET MANDREL WITH GAS LIFT VALVE
Flowline
Gas Injection
Surface Casing
Production Casing
Tubing
Gaslift valves
Operating Valve
Packer

Basic Components of a Gaslift Valve
ball seat lung
stem bellows
ports to
nose tubing ports to annulus
packing
nitrogen
charge

Pressure Gas Lift Valve Schematic
DIAPHRAGM
SPRING
STEM
BALL
Up Stream
Up Stream Down Stream
Pressure
Pressure Pressure
Ap
PORT
Down Stream
Pressure
Pressure Regulator Gas-Lift Valve

(a) (b)

Changing Gaslift Valves with Wireline
https://www.youtube.com/watch?v=_Bfwm_MeshM
22 Copyright ©2012 NExT. All rights reserved 22
Gaslift Surface Equipment
Gas Plant
Gas line
Gas Sales Scrubber
Gas Manifold
Separator
Gas Line Oil Tank

Wellhead Configuration

Gas Lift Types
Injected
Injected gas
gas
Continuous gas lift Intermittent gas lift

Continuous Gas Lift
Range of application
• Medium-light oil (15 - 40 °API)
• GOR 0 - 4000 SCF / STB
• Depth limited to compression capacity
• Low capacity to reduce the bottom hole flowing pressure
• High initial investment (Gas compressors cost)
• Installation cost low (slick line job)

Gas Lift
Advantages Disadvantages
• Takes full advantage of the gas • Can not pump off the well
energy available in the reservoir • Very sensitive to backpressure
• A high production volume method • Pressure increases both with depth
• Equipment can be centralized and volume
• Can handle sand and solids • Must have a source of gas
• Valves can be wireline or tubing • May require a compressor
retrieved • Must treat corrosive gasses (must be a
• Works wells with subsurface safety dry gas)
valves • Selection and placement of equipment
• Minimal down hole mechanical can be complex and expensive
devices
• Full tubing bore capabilities
• Low maintenance
• Excellent in deviated wellbores

PRESSURES AND PRESSURE
GRADIENTS VERSUS DEPTH IN
CONTINUOUS GAS LIFT
WELLHEAD GAS INJECTION

PRESSURE PRESSURE
PRESSURE
AVAILABLE
PRESSURE
INJECTION POINT
DEPTH
BALANCE
POINT
BOTTOMHOLE
FLOWING
PRESSURE
100 PSI
AVERAGE.
RESERVOIR
PRESSURE

Gas Lift Design Introduction - YouTube
GAS LIFT DESIGN FOR CASING PRESSURE OPERATED VALVES
Psep Pwh
Available gas surface pressure
pko pressure
Closing pressure
Opening pressure
cpv1
cpv2
depth
cpv3
Tubing flowing pressure
https://www.youtube.com/watch?v=RA3V42bdrDk
GAS LIFT UNLOADING SEQUENCE
FIGURE 3-8: Example of the Unloading Sequence

Casing Operated Valves and Choke Control of Injection Gas
2000
1800
1600
1400
1200
Pressure psi
1000
800
600
400
200
0
12:00 AM 03:00 AM 06:00 AM 09:00 AM 12:00 PM 03:00 PM 06:00 PM
Time
PRESSURE CASING PRESSURE TUBING

30
Gas lift Troubleshooting

Gas lift typical problems

Rod Pump Systems
ROD PUMPING SYSTEM
Walking Beam
Counter Balance
Pitman arm Horse Head
Gear Box Elevator

Polish Rod
Stuffing Box
Flowline
Prime Mover
Gas line SUCKER RODS
PLUNGER
TRAVELING
Casing
Crank arm VALVE
Tubing
FLUID WORKING
Sucker Rods BARREL
STANDING
VALVE
FLUID
Plunger PLUNGER MOVING DOWN PLUNGER MOVING UP

Traveling Valve
Standing Valve
Video
Main Components
• Downhole rod driven plunger

• The rod transmitting the pumping motion
• Surface equipment converting rotational motion
into linear motion
• Speed reducer (Gear Box)
• Prime mover (power)

Rod Pumping System
Subsurface Components
SUCKER ROD
Pump Barrel PLUNGER
BARREL
TRAVELING BALLS AND

VALVE SEATS

Types of Pumping Units
Mark II Beam Balanced
Low Profile Air Balanced

Drawings Courtesy of Lufkin Industries, Inc. Lufkin, Texas
ROD PUMPING SYSTEM
SURFACE COMPONENTS
38 Copyright ©2012 NExT. All rights reserved Courtesy of Lufking

Wellhead Configuration
Polished rod
Stuffing box
Pumping tee
Tubing
Slip type Sampling
tubing hanger valve
Tubing
HP
spool
Check valve
Flow line valve
Casing head
High pressure fittings
Sucker Rod Pumping
2000
Rate dependent
on tubing size
1000
Production (B/D)
800
600
Area where
sucker rod pumping
400 is most widely applied
200
0
0 2000 4000 6000 8000 10000 12000 14000
Depth (feet)
File-Odessa_TX_Oil_Well_with_Lufkin_228D_pumping_unit
Controlling Sucker Rod Pumping
How can the

Change we change the flow
pump stroke rate ?
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
Tubing
• Pump is run inside the tubing
attached to sucker rods
Plunger
• Pump size is limited by tubing
size
• Lower flow rates than tubing
Traveling valve
pump
Barrel
• Easily removed for repair
Standing valve
Seating nipple
Ball & seat
Cage

Tubing Pumps
Tubing
Connection
w/tubing • Integral part of production
tubing string
Plunger
• Cannot be removed without
removing production tubing
• Permits larger pump sizes
Traveling
valve • Used where higher flow rates
Barrel are needed
Cage
Standing
valve
Ball & seat

Design of a Sucker Rod Pump Installation

Rod Types
Steel rods (various steel grades)

 25 or 30 feet (7.6 or 9.1 m) in length
Fiberglass rods
 30 or 37 1/2 feet (9.1 or 11.4 m) in length
 Both connected with a 4 inch (101.4 mm) connector
Co-rod (less common)
 As long as needed
Tapered strings (Different sizes Combination)

Rod Types
Diameters
– 1/2, 5/8, 3/4, 7/8, 1, 1-1/8 inches
Grades
• Grade K [nickel/molybdenum]
• Grade C [carbon steel]
• Grade D [chrome/molybdenum]
• Grade D [special alloy]

Sucker Rod Coupling
Key
Compression Tension
Point of wrench flat break.

Tension in pin due to proper tightening.
Undercut.
Compression in coupling.
Point of pin failure.
Point of coupling failure.
Maximum tension in coupling.

Conventional Rod

Continuous Rod
Corod
Service
Sucker rod Tubing Corod Unit
size O.D. size
7/8”S.H. 2 3/8” #6
(60.3 mm)
(1”)
2 7/8” #7 #7
1”S.H. (73.0 mm)
1 1/16” (1 1/16”)
Tension
Cutaway drawing
shows coiled rod
held by its own
tension. Transport reel
Continuous Rod

Rod Design Considerations
Weight of rod string

Weight of fluid
Maximum stress in rod
Yield strength of rod material
Stretch
Buckling
Fatigue loading
Inertia of rod and fluid as goes through a stroke
Buoyancy
Friction
Well head pressure
https://www.youtube.com/watch?v=3GPU3Zi9J1U
Sucker Rod Problems
Rod breaks or parts can result from:

• Corrosion
• Over stressing due to
– Poor rod connection
– Rod size too small for fluid load
– Excessive pumping speed
• Compression
This results when fluid intake is too low (“pumped off”)
Production tubing failures can result from:
Erosion by reciprocating steel rods inside tubing
•
Surface unit gearbox can be overtorqued by:
• Excessive pumping speeds
• Excessive fluid and rod loads
Tubing Anchors
No buckling
It has been proven that the Neutral point
lower part of freely suspended
tubing buckles during the
upstroke portion of the pumping
cycle. The cause of this
phenomenon is the fact the
pressure inside a pipe
terminated by pistons exerts a Buckling
buckling effect on the pipe.

Testing also found that the
forces are equal to the
differential pressure across the Downstroke Upstroke
pump plunger multiplied by the Standing valve closed; full
fluid load stretched tubing
Traveling valve
portion of fluid
closed;
load
plunger area. The force must down to most elongated
position. Tension in tubing
transferred to rods. Tubing
relieved of load contracts.
exceed some critical value in at maximum for cycle. No
buckling
Tension in tubing at
minimum for cycle. Buckling
order for the tubing to buckle. occurs from pump to neutral
point
Breathing “F”

Swivel Couplings for Horizontal Wells

Identifying Problems with
Rod Pumping
• Dynamometer
– Measures the load applied to the top rod in a string
of sucker rods (the polished rod)
– A “dynamometer card” is a recording of the loads on
the polished rod throughout one full pumping cycle
(upstroke and downstroke)
– A dynamometer load cell can be permanently
installed on a well to continuously monitor rod loads
and dynamics. This device is called a “Pump-off
Controller”

Dynamometer
The work done by the engine at the surface is translated downhole through the polished rod and the rod string
into work at the pump. The work at the surface of the pumping unit is measured by a surface dynamometer,
capable of recording the position and load of the rod string.

Dynamometer Card

Sonolog Fluid Level Survey
Charge ignited
Sonolog
Sound reflection
Tubing collars
Fluid level
Fluid level

PUMP ROD PERFORMANCE FROM
CONVENTIONAL DYNAGRAPH CARD
Load
Dynagrams
PUMP ROD PERFORMANCE FROM
CONVENTIONAL DYNAGRAPH CARD

DYNAGRAPH CHART CAPTURE
(Load vs. Position Sensor)

DYNAGRAPH CHART CAPTURE
(Electrical Current Sensor)

PUMP OFF CONTROLLER
Pump off Controller

Automated Equipment for Identifying Problems with
Rod Pumping
Polished Rod Transducer

Measures polished rod load and position with
sufficient accuracy for most dynamometer
analysis.
Remote Fire Gas Gun

The Remote Fire Gas Gun utilizes a high
performance microphone with an excellent
signal-to-noise ratio along with a 12 cubic inch
volume chamber.
A solenoid valve releases gas from the gas
gun volume chamber into the well.
Current Transducer
Measures motor current for determination of
motor loading and motor balance.

Progressive Cavity Pump (PCP)

Introduction to Progressive Cavity Pumps
History
Initial application of PCP in 1940’s was for pumping fluids through pipelines on surface.
First artificial lift applications in early 1980’s (Canada and Venezuela).
 In the early 1980's, the PCP began to be utilized as an artificial lift method in the petroleum industry in
Canada and Venezuela, mainly to produce highly viscous fluids with high concentrations of sand. The
capability of the PCP system to effectively produce heavy oil was demonstrated, and the development and
use of the PCP started progressing very quickly.
 Manufacturers began to make developments to improve the system in terms of elastomer capabilities and
lifting capacity.

Progressive Cavity Pump - Basic Principle
When the rotor and stator are in place, defined sealed cavities are formed. As the rotor turns within the
stator, the cavities progress in an upward direction. When fluid enters a cavity, it is actually driven to the
surface in a smooth steady flow.
Gear Box
Drive head Electric motor
Wellhead Flowline
ROTOR
CHROME PLATED STEEL
EXTERNAL HELIX
Casing STATOR STATOR
Tubing CAVITY ELASTOMER
Rod String
Rotor
Stator
Stop
pin
https://www.youtube.com/watch?v=IR5EOahkxw4
Introduction to Progressive Cavity Pumps
Applications
Specific areas of application for artificial lift:
 Heavy oil and bitumen
 Medium crude oil
 Light oil
 Low temperature wells(<250°F)
 Coal Bed methane dewatering
 CHOPS (Cold Heavy Oil Production with Sand)

Progressing Cavity Pump Basics
PC Pump Types
CONVENTIONAL 1:2 MULTILOBE 2:3
The stator has always one more lobe than the rotor

Lobe Ratio
• Ratio of rotor lobes (Lr) to stator lobes (Ls) .

– Typically denoted as Lr: Ls (e.g. 1:2, 2:3, etc.)
• Stator always has one more lobe than rotor.
• Single lobe pumps have a 1:2 lobe ratio.
• Multilobe pumps include all other combinations.
– PC pumps are typically 2:3.
– Mud motors vary between 2:3 and 9:10.

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

Flow Characteristics
Stator Pitch Stator Rotor
(one full turn)
Eccentricity
 Non Pulsating
 Pump Generates Pressure Required To Move
Constant Volume
 Flow is a function of RPM

Pulsationless Flow
• The Rotor turns eccentrically within the
Stator.
• Movement is actually a combination of

two movements:
– Rotation about its own axis
– Rotation in the opposite direction of
its own axis about the axis of the
Stator.
Q FLOW RATE = A CAVITY AREA x VFLUID CAVITY

PCP – Subsurface Components
ELASTOMERS
The Elastomer Reacts with its Environment
 Temperature changes cause large
dimensional changes
 Aromatic compounds cause swelling and
softening
 Sulfur causes hardening and
embrittlement
These Factors are Considered When

Designing a Pumping System

PCP – Subsurface Components
ELASTOMERS
Characteristics of Commercially Available Elastomers
Max Temp Max Max Physical Abrasion Aromatic

Compound Deg. F API H2S Properties Resistance Resistance
Soft Nitrile 180 20 2% Excellent Superior Low
Standard Nitrile 180 20 2% Excellent Acceptable Low
High Nitrile 200 38 2% Good Poor Good
Hydrogenated Nitrile 225 25 4% Excellent Fair Fair
Enhanced Hyd.Nitrile 250 38 6% Excellent Poor Good

PCP – Subsurface Components, Drive Rods
Very similar to sucker pump rods, but specifically designed to meet
the torque requirements of progressing cavity pump systems.

PCP Surface Equipment, Well Head Configuration
CLAMP GEAR BOX
MOTOR
DRIVE HEAD
STUFFING BOX POLISHED ROD
Pumping tee
Tubing
Slip type Sampling
tubing hanger valve
Tubing
HP
spool
Check valve
Flow line valve
Casing head
High pressure fittings
PCP Surface Equipment

PCP Surface Equipment, Drive Head
POLISHED ROD
CLAMP
GEAR BOX
MOTOR
BRAKE SYSTEM
HYDRAULIC PUMP
DRIVE HEAD
STUFFING BOX
PCP Surface Equipment
PCP Drive Head Functions
Suspends drive string and carries the axial load.
Transmits the rotational movement from the drive system
(prime mover) to the drive string.
Delivers the required input torque.
The hollow shaft design allows the vertical movement of the
rotor without the removal of the drivehead (Flush-by).
Stuffing box prevents leakage of wellbore fluids into
surrounding environment.
Provides prime mover support.
Backspin control for safety.

PCP- Application Range
THEORETICAL PC PUMP LIMITS

90% Volumetric Efficiency
80% Pressure Loading
5000
4500
4000
PRESSURE (PSI)
3500
3000 6.875"Dia
2500
5.25" Dia
2000
1500 4.2" Dia.
1000
500
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500
DISPLACEMENT @ 425 RPM (BFPD)

82
PROGRESSIVE CAVITY PUMP SYSTEM
Advantages
System Efficiency by Artificial Lift Method
100
90
Overall System Efficiency (%)
80
70
60
50
40
30
20
10
0
PCP Hydraulic Piston Beam Pump ESP Hydraulic Jet Gas Lift Gas Lift
Pumps Pump (Continuous) (Intermittent)
Artificial Lift Type
• Because the frictional horsepower is very low, the overall system efficiency is very high.

Advantages
Low environmental impact
Agricultural areas.
Urban areas.

Advantages
Able to produce:
•High concentrations of sand (viscous fluids with solids

content up to 50 % by volume)
•High fluid viscosities (up to 10,000 Cps at reservoir

conditions)
•High percentages of free gas, does not create gas

lock(GOR: 0 -5000 SCF/ STB)
•High abrasive fluids

Advantages
•Simple two piece design (reduces wear)
•Does not emulsify fluid
•Low energy consumption
•Low surface and subsurface maintenance costs
•High volumetric efficiencies

Advantages
•In many cases, the only cost-effective way to produce a

well is with a PCP, for example, wells producing Cold Heavy
Oil Production with Sand (CHOPS)

Progressive Cavity Pump
Limitations
Elastomer incompatible with certain fluids/gases

 Aromatics (12%)
 H2S (max. 6%), CO2(max. 30%)
 Other chemical additives (e.g. diluents)
Max. Temperature up to 250 ºF.

PCP Design
500 500 RPM

18
500 RPM
450 16
400 400 RPM
14
HORSEPOWER (HP)
400 RPM
350
CAPACITY (BFPD)
12
300 300 RPM
300 RPM 10
250
8
200 200 RPM
200 RPM
6
150
100 100 RPM

4
100 RPM
50 2
0 0
0 1000 2000 3000 4000 5000
HEAD (FT. WATER)

PCP CONTROL SYSTEM
Pump Speed Control

The drive provides a number of options for manual, remote, and automatic Production Monitors
control of pump speed. Speed commands can be selected from a number of A pump flow monitor provides a continuous estimate of flow without the need
for additional instrumentation. Pumping speed and pump effective volume are
sources including potentiometer adjustments, keypad presets, serial data
used to estimate the actual production rate. Pump flow is totaled in a resettable
communications, and internal optimization controllers. The motor can be
production accumulator. Estimated well production is displayed for the operator
operated up to twice base speed at constant power. This allows the overall
and is available for remote well monitoring through a serial communication port.
gear ratio to be increased, thereby providing increased low-speed torque Fluid Level Monitor
without loss of maximum pump speed. Dual motors can be controlled from a A fluid level monitor provides a continuous estimate of level from pump
single drive for operation of large pumps. The system can be configured for head, fluid properties, tubing pressure, and casing pressure. Tubing and casing
optimization of fluid production, gas production, energy efficiency, and/or pressures can be entered as parameters for relatively fixed pressures or input
power flow. from analog sensors for significantly variable pressures.
Production Optimization System Protection
Level control maximizes fluid production by regulating the downhole pump Torque limiting protects the motor from excessive torque loads and the rod
inlet pressure. An optional surface flow sensor can be used to automatically string against breakage. Stick-slip oscillation damping reduced rod string
locate the point of maximum production while protecting the system from a fatigue failures. Excess flow line pressure can be used to prevent damaging
pump-off condition. A search routine uses an optional gas flow sensor input to pump loads. Low speed detection protects the system in case of a stall
automatically select the fluid level that maximizes gas production in coalbed condition, such as a stuck pump or blocked flow line. Breakaway torque
methane pumping applications. Current limit control increases production by detection identifies pump problems during starting. Low torque detection
raising motor speed during periods of reduced pump load. A power flow indicates a rod break, belt failure, or plugged sand screen. Sensing of pump
optimizer maximizes production from gassy wells by allowing the drive and inlet and outlet differential pressure is used to protect the pump from
motor to operate at their maximum thermal capacities. overloading.
Pump-Off Control Automatic Restart
Pump-off control maximizes well production for any given inflow The drive can automatically recover from fault conditions and intermittent
characteristic. Fluid level over the pump intake is precisely controlled by power outages to ensue continuous operation of unattended wells. Auto restart
control sequences starting of multiple pumps after power outages to eliminate
differential sensing of casing gas and pump intake pressure. A pump-off
surges in power demand. Start/stop events are automatically logged for
control allows the pump to dwell for a programmable period of time to protect
subsequent retrieval.
the pump and to control average flow. A dwell period minimum pump speed
can be used to prevent sanding in the well.

Electric Submersible Pumps (ESP’s)

ESP’s
ESP - a downhole electric pump which lifts the produced

fluids to the surface.
 Subsurface equipment
 Electric motor, Protector assembly, Gas separator, Pump,
Cable
 Surface equipment
 Junction box, Motor control or switchboard, Variable speed
controller, Related sensing equipment, Transformers

Typical ESP Installation
video
Characteristics of the ESP Systems
Q = 100 - 30,000 BPD

D = Installed to 15,000 ft
d = Equipment diameters from 3.38”
to 11.25”
Casing Sizes = 4 1/2” to 13 5/8”
Variable Speed Available
Metallurgies to Suit Applications

ESP ASSEMBLY
Impellers
(Stages)
Pump
Protector
Motor

ELECTRICAL SUBMERSIBLE PUMP SCHEMATIC
Oil flows up, through

suction side of
impeller, and is
discharged with
higher pressure, out
through the diffuser.
Impeller
Diffuser
Shaft
video
General Characteristics of ESP’s
• Designed to pump at very high flow rates (up to 30,000

BPD)
• May be less efficient than other methods
• Relatively expensive
• Sensitive to solids and free gas (<15%)
• If conditions are favorable, ESPs can run several years
• Usually require workovers every 2-3 years to repair ESP
system

General Characteristics of ESP’s
• Extra heavy - light (8.5 - 40 °API)
• Maximum Temperature: 500 °F
• Very sensible to solids production and pump

off condition.

ELECTRICAL SUBMERSIBLE PUMP
Range of Application
20000
15000
Head, ft
10000
5000
0
0 10000 20000 30000 40000 50000
Flow Rate, BPD

4.5" Casing 5.5" Casing 7" Casing 9.625" Casing

ESP Run Time
(Mean-Time Between Failures)
1400
1200
Active ESPs
MTBF, Days
1000
800
600
400
200
0
1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997
THUMS California
Electric Submersible Pumps
Electric Submersible Pumps
Individual Components

Centrifugal Pumps
Each "stage" consists of an impeller and a diffuser….
The impellers transfer energy by rotation to the liquid

passing through it, thus raising the kinetic energy.

Centrifugal Pumps
The diffusers convert this kinetic energy into potential

energy (head), raising the discharge pressure.

Electrical Submersible Pump
Pump Intake

Pump & Intake
Thrust washer
Impeller
Diffuser
Complete stage
Pump & Intake

ESP’s
Three types of gas separators

• Motor shroud
• Reverse flow
• Rotary gas separator

Dynamic Gas Separator (Vortex)
Gas
Liquid
Fluids from the well

Rotary Gas Separator
Diffuser
separator assy.
Impeller
Screen
suction

Typical ESP with Shroud
Fluid entry
Pump
Shroud hanger
Shroud jacket
Seal
Motor

Protector Assembly
The protector (seal) section connects the drive shaft of the motor to the
pump or gas separator shaft
Mechanical
seal
Thrust
bearing
component

Protector Functions
Primary Functions:
1) To keep well fluid out of the motor.

2) To carry the upthrust or downthrust.
3) To couple the torque developed in the
motor to the pump.
4) Pressure Equalization

Protector Functions
1) Keeping the well fluids out of the motor:
- Aggressive environment
- Wide swings in pressure
- Internal heating
- Pressure equalization

112
Protector Functions
2) Carry the upthrust or downthrust generated by the pump.
- Thrust Bearing Upthrust

bearing
- Clean Oil Environment Thrust
Runner
- Check Bearing Rating Downthrust

bearing

113
Protector Functions
3) Couple the torque generated by the motor to the pump.
- Shaft Selection

114
Rotor
Stator
The motor is a three Cable
phase, two pole

induction design.

ESP Motor Problems
Major causes of motor overheating

• Overloading
• Well pumped off
• Gas locked
• Stuck pump
• Lack of cooling

Electrical Submergible Cable
Power is supplied to the electric

motor by electric cable.
Power Cable

VSD Variable Speed Driver
 Provide lightning protection for the downhole

equipment
 Eliminate the need for chokes in the system
 Provide inherent soft start no inrush currents.
 Protect the downhole equipment from pump off
 Enable remote operation/automation
 Enable smooth response to torque changes
 Provides constant torque through the entire speed
range
 Can be used manually to set the V/Hz ratio for
specific applications (Base Speed)
 Provides reduced starting capabilities (Soft Start)
 Optimizes the output of the well (Avoids cycling of
the well and equipment)

ESP Equipment
Additional equipment
 Downhole pressure & temperature monitors
 Check valves
 Drain valve
 Centralizers
 Cable bands
 Booster pump
 Wellhead

ESP’s
Care should be taken when designing an ESP intake as it is an extremely

crucial component.
 Do not operate an ESP for extended periods in formation fluids with a
formation volume factor greater than 2.5 rb/stb
 Do not operate an ESP in fluids that exhibit a fluid gradient less than
0.28 psi/ft
 Do not operate a gas separator under a packer or where the casing is
not vented

p Perform
age(s)
- 3500
-RED
G
RP
R ev
6.625 .
in AF lu
ches
eet Hp
EfB
Q =
H =
P =
0 60
6 0
0%
E =
0 50
5 0
0%
0 40
4 0
0%
0 30
3 0
0%
0 20
2 0
0%
0 10
1 0
0%
120
,0
3
,0
40
,0
5
0
,00
6
0
,
0 0
7
0
,
0 0
8
0
,
0 0
0
,
0 0
0
0 0
0
- Barrels
Identifying Problems with ESP
 May notice gradual increase in power usage and gradual

decrease in flow rate as indicators of pump problems
 Power spikes and frequent automatic shut-downs may
indicate electrical leakages or other problems
 Check for solids in fluid
 Tubing, cable, and pump must be pulled to find exact cause
of a problem. Spool required to handle cable
 Pump, seal, motor, and cable must be sent to manufacturer
for testing in order to locate the exact problem

Ammeter Charts
Startup
5 6 AM 7 8
4 9
60
3 50
10
40
30
20
11
10
NOON
This is a "normal" amp chart. Note the
1
spike on startup followed by a nice smooth Normal
MIDNIGHT
1
and symmetrical line at 40 amps. This is
2
an ideal condition.
11
3
10
4
9 5
8
7 6 PM

Ammeter Charts
Pump has
When the unit is first started, the fluid level is high so gas locked
production and current are slightly high. As the fluid 6 AM 8
level is reduced, the current decreases until the level is
5 7
4 9
60
so low that gas begins to form at the intake. The wide 3 50
10
40
30
variation is specific gravity cause the erratic amperage. 20
11
10
Eventually enough gas forms so that the pump "gas
NOON
1
locks". When the pump is gas locked, it is not producing Gas
MIDNIGHT
Locking
any fluid. Note that, even though the pump is not
1
producing fluid, the motor is continuing to run (amperage
2
11
is not zero). This will cause the motor to eventually burn
3
10
since there is no fluid movement to cool it. 9
4
5
8
7 6 PM

Ammeter Charts
This is a case where the pump is producing more 5 6 AM 7 8

4
fluid than the well can deliver. The pump is lowering 60 9
3 50
the fluid level, hence the amperage, until free gas
10
40
30
begins to form at the intake. The low gravity gas

20
11
10
mixed with the high gravity fluid causes wide swings
NOON
1
in current. The unit eventually shuts off on U/L and Pump Off
MIDNIGHT
automatically restarts after three hours. Possible
1
with Gas
solutions are to choke back on production, lower the Interference
2
11
pump further in the hole, or resize to a smaller unit.
3
With a VSD, try lowering the frequency.
10
4
9 5
8
7 6 PM

Ammeter Charts
This is also a case of "pump-off"

except that there is not much gas in 4
5 6 AM 7 8
9
60
the reservoir to cause interference in 3 50
10
40
the pump. Corrective measures are 30
20
the same as before. If this conditions
11
10
develops after several months (or
NOON
1
Pump Off
years) of normal operation, it may be
MIDNIGHT
(no Gas
1
that skin damage is reducing the well Interference)
productivity. Stimulation may restore
2
11
the productivity to the original level (or
3
better).
10
4
9
5
8
7 6 PM

ESP PRESSURE GRADIENT PROFILE
Pwh
Pressure
Pwh
gas
Depth
ESP Pup Pdn

Pdn
ΔP
Pup
Pwf
Pwf Pr

NODAL ANALYSIS FOR A PUMPING SYSTEM
FLOWING PRESSURE Discharge Pressure, Pdn
ΔP ΔP
Intake
Pressure,
Pup
0
0
FLOW RATE, QL
HP = 1.72x10-5ΔP (QoBo + QwBw)

ELECTRICAL SUBMERSIBLE PUMP PERFORMANCE CURVE
OPTIMUM
HEAD CAPACITY RANGE
HEAD, ft / stage
HP MOTOR LOAD
100
PUMP EFFICIENCY,%
PUMP EFFICIENCY
HORSE POWER
SP. GR: =1.0
0 0
0
130 Copyright ©2012 NExT. All rights reserved FLOW RATE, QL
ESP SELECTION
1) TOTAL DYNAMIC HEAD = ΔP / fluid gradient
2) FROM TYPICAL PUMP PERFORMANCE CURVE

DETERMINE HEAD (FT) PER STAGE AND EFFICIENCY
TOTAL DYNAMIC HEAD

3) NUMBER OF STAGES =
FEET/STAGE
4) HORSE POWER REQ.(HP) = 1.72x10-5ΔP (QoBo + QwBw)


5.1 Artificial Lift - GL, SRP, PCP, ESP PDF

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5.1 Artificial Lift - GL, SRP, PCP, ESP PDF

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Module 5

Productivity Enhancement Through Artificial Lift

1 Copyright ©2012 NExT. All rights reserved

2 Copyright ©2012 NExT. All rights reserved

• Explain the Artificial Lift Concept

• Identify the main types of Artificial Lift methods

• Identify the various Artificial Lift types applications and

3 Copyright ©2012 NExT. All rights reserved

Wellhead Pwh PRESSURE

Well pressure gradient

Current Pwf Initial Pwf

4 Copyright ©2012 NExT. All rights reserved

• Required when reservoir pressure is not sufficient

• May be desirable to increase production rates

• Uses alternate sources to lift or lighten fluid

5 Copyright ©2012 NExT. All rights reserved

6 Copyright ©2012 NExT. All rights reserved

Flow Rate ( STB/day )

7 Copyright ©2012 NExT. All rights reserved

Flow Rate ( STB/day )

8 Copyright ©2012 NExT. All rights reserved

Flow Rate ( STB/day )

9 Copyright ©2012 NExT. All rights reserved

Decreases backpressure against reservoir, which

10 Copyright ©2012 NExT. All rights reserved

Performance of Flowing Wells

11 Copyright ©2012 NExT. All rights reserved

12 Copyright ©2012 NExT. All rights reserved

13 Copyright ©2012 NExT. All rights reserved

Typical Artificial Lift Application Range

Rod PC Pumps Hydraulic Lift Submersible Pump Gas Lift

14 Copyright ©2012 NExT. All rights reserved

System Efficiency by Artificial Lift Method

15 Copyright ©2012 NExT. All rights reserved

Gas Lift involves the supply of high pressure gas to

17 Copyright ©2012 NExT. All rights reserved

Reduction of Fluid Density Expansion of Gas Displacement of Liquid

18 Copyright ©2012 NExT. All rights reserved

19 Copyright ©2012 NExT. All rights reserved

ball seat lung

20 Copyright ©2012 NExT. All rights reserved

Pressure Regulator Gas-Lift Valve

21 Copyright ©2012 NExT. All rights reserved

Gas Sales Scrubber

Gas Line Oil Tank

23 Copyright ©2012 NExT. All rights reserved

24 Copyright ©2012 NExT. All rights reserved

Continuous gas lift Intermittent gas lift

• Medium-light oil (15 - 40 °API)

• GOR 0 - 4000 SCF / STB

• Depth limited to compression capacity

• Low capacity to reduce the bottom hole flowing pressure

• High initial investment (Gas compressors cost)

• Installation cost low (slick line job)

26 Copyright ©2012 NExT. All rights reserved

27 Copyright ©2012 NExT. All rights reserved

WELLHEAD GAS INJECTION

28 Copyright ©2012 NExT. All rights reserved

Tubing flowing pressure

FIGURE 3-8: Example of the Unloading Sequence

PRESSURE CASING PRESSURE TUBING

30 Copyright ©2012 NExT. All rights reserved

31 Copyright ©2012 NExT. All rights reserved