Master Ingegneria g g del Petrolio 2006-2007

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Stage Subject

Techniques of artificial lift for viscous oil

San Donato Milanese October the 22nd-23rd 2007
Author Ing. g Stefano Mazzone Company Tutors Ing. g Roberto Fanciulli Ing. Salvatore Pilone University Tutor
Division Dept.

Exploration & Production

SPEO/COMP

Prof. Ing. Francesca Verga

Master Ingegneria g g del Petrolio 2006-2007

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Artificial lift techniques for viscous oils

Summary y
9Description of traditional systems of artificial lift ( piston type pumps, jet pumps, rod pumps, progressive cavity pumps, electric submersible pumps) 9High viscosity effects on Electric Submersible Pumps (ESP) performance 9Comparison between Progressive Cavity Pump (PCP) and ESP performances in presence of heavy / viscous oils

Master Ingegneria g g del Petrolio 2006-2007

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Medium Heavy Oil 25> API > 18 100 cP P > > 10 cP P mobile at reservoir conditions Extra Heavy y Oil 20> API > 7 10 000 cP > > 100 cP mobile at reservoir conditions Tar Sands T S d and d Bitumen Bit 12> API > 7 > 10 000 cP non mobile at reservoir conditions

Master Ingegneria g g del Petrolio 2006-2007

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Artificial lift techniques Systems overview

Description p of traditional systems y of artificial lift Piston pumps Jet Pumps Rod Pumps Progressive Cavity Pumps - PCP Electric submersible pumps - ESP

Master Ingegneria g g del Petrolio 2006-2007

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Hydraulic piston pumps

There are two types of piston pumps The open power fluid system (OPF) allows the exhausted power fluid to mix with the produced fluid The The closed power fluid system (CPF) keeps the power fluid separated from the produced fluid Disadvantages Di d t low capacity power fluid solid control essential
(to avoid excessive wear)

Advantages Ad t high pressure head good efficiency depth up to 17.000 feet resists to high temperatures
(300 -500F)

Master Ingegneria g g del Petrolio 2006-2007

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H d Hydraulic li Jet J t pumps

The Jet p pump p has no moving gp parts. Power fluid ( (water, , crude oil or diluent) at high pressure is supplied to the nozzle which converts the pressure head into a high velocity jet reducing the pressure in the throat and so entraining the production fluid. fluid The two fluids mix together in the throat, recover pressure in the diffuser and proceed upwards. Advantages gp parts ( (low wear) ) no moving suitable for low quality production fluids suitable for gassy wells resists to high temperatures Disadvantages g suction p pressure ( (to avoid cavitation) ) high high input horse power due to low efficiency (up to 30%) possible emulsion former

Master Ingegneria g g del Petrolio 2006-2007

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Rod Pumps
The p pumping p g capacity p y of these devices depends p on stroke length, pumping speed, volumetric efficiency (i.e. the percentage of pumps volume effectively filled by new fluid) fluid). Advantages economic resists to high temperatures efficiency range from 50% to 60% Disadvantages g unsuitable for deviated wells seal wear low depth (10,000 ft)
Tubing Connection w/tubing

Plunger

Traveling valve Barrel Cage Standing g valve Ball & seat

Master Ingegneria g g del Petrolio 2006-2007

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Progressive Cavity Pumps

A PCP is a positive displacement pump made up of a helical rotor which rotates inside a double internal helical stator stator. It can be driven from surface by rotating rods or by a bottom hole electric motor via a gear reducer (max speed 500 rpm) Advantages high efficiency (50%-70%) (50% 70%) suited for high viscous and/or abrasive fluids reduced emulsion for no pulsating motion works at high temperatures up to (300 F) Disadvantages low capacity (max speed 500 rpm) suitable mostly for shallow wells (5000 ft) if rod driven low ability to handle free gas (low efficiency)

Master Ingegneria g g del Petrolio 2006-2007

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Electrical Submersible pumps

Submersible pumps are multi-staged centrifugal pumps. Each stage consists of a rotating impeller and a stationary diffuser. The impeller imparts kinetic energy and some pressure head to the fluid The diffuser converts some of the fluid kinetic energy into pressure head and directs it to the next stage. Stage after stage the total head required is obtained.

Advantages high capacity good efficiency for high rates

50% for BFPD>1000

Disadvantages depth limitations due to input horsepower limitation sensitivity y to high g temperatures gas locking problems

good head
less than volumetric pumps

Master Ingegneria g g del Petrolio 2006-2007

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Master Ingegneria g g del Petrolio 2006-2007

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ESPs typical curves

Rev. A
Minimum Casing Size 6.625 inches OD Check Clearances

Fluid Specific Gravity 1.00

B.E.P. Q = 5511 H = 2833.84 P = 173.95 E = 66.12

F Feet
6,000

H Eff Hp
600 60%

5,000

500 50%

4,000

400 40%

3,000

300 30%

2,000

200 20%

1,000

100 10%

1,000

2,000

Capacity - Barrels per Day

3,000

4,000

5,000

6,000

7,000

8,000

Master Ingegneria g g del Petrolio 2006-2007

G R O U P

Artificial lift techniques

Summary
9Description of traditional systems of artificial lift ( piston type pumps, jet pumps, rod pumps, progressive cavity pumps, electric submersible pumps) 9High viscosity effects on electric submersible pumps (ESP) performance 9Comparison between progressive cavity pump and ESP performances in presence of heavy / viscous oils ( 8-20 API)

Master Ingegneria g g del Petrolio 2006-2007

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Whats the problem?

ESPs performance is always evaluated

pumping water At moderate to high viscosity ESPs performance is affected by:
increase of break horse power head and capacity reduction efficiency losses

Master Ingegneria g g del Petrolio 2006-2007

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Current correction methods Affinity Affi it laws l for f rotational t ti l speed d correction ti
(applicable to inviscid fluids)

For viscosity correction :

Hydraulic Institute charts, Stepanoff, S ff Turzo etc..

Master Ingegneria g g del Petrolio 2006-2007

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Hydraulic Institute (1955)

9Tests based on single g stage g pumps p p handling g viscous oils. 9 Equations used for corrections, when water performances are known : BEP (Qw,Hw) Fluid viscosity

vis = Cw

Hvis = ChHw

Qvis = CqQw

BHPvis =

H vis Q vis vis 3960

Master Ingegneria g g del Petrolio 2006-2007

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Turzo et al (2000)
Turzo proposed the use of correlations instead of Hydraulic institute charts:

( ) C = 1 3.3075 10 q + 2.887510 (q ) Ch1 = 1 3.68 10 q 4.36 10 (q ) 10 q 4.1810 (q ) Ch2 = 1 4.4723 10 q 1.4110 (q ) Ch3 = 1 7.0076 Ch4 = 1 9.0110 q 1.3110 (q )
Cq =

1 4.032710 q 1.72410 q
*
2 * 4

* 2

* 2

* 2

* 2

* 2

* 2

Master Ingegneria g g del Petrolio 2006-2007

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Stepanoff (1957)
Stepanoffs S ff experiments i showed h d that h at constant rotational i l speed d N the h specific speed Ns (defined at the best efficiency point) remains constant either pumping viscous oil or water :

Ns =

N q H

1/ 2 oil bep

3/ 4 oil bep

N q

1/ 2 wbep

3/ 4 Hw bep

q oil H oil = qw H w

3/ 2

1.5 ( ) = Cq C H

Master Ingegneria g g del Petrolio 2006-2007

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Defining a Reynolds number-like as indipendent variable Rstepanoff =

oil N qbep w H bep oil

Stepanoff proposed the following correction chart for head, capacity and efficiency at the B.E.P. :

Master Ingegneria g g del Petrolio 2006-2007

G R O U P

Master Ingegneria g g del Petrolio 2006-2007

G R O U P

Artificial lift techniques

Summary
9Description of traditional systems of artificial lift ( piston type pumps, jet pumps, rod pumps, progressive cavity pumps, electric submersible pumps) 9High viscosity effects on electric submersible pumps (ESP) performance 9Comparison between progressive cavity pump and ESP performances in presence of heavy / viscous oils ( 8-20 API)

Master Ingegneria g g del Petrolio 2006-2007

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Comparison between water design and oil design of an ESP for a viscous oil (8 Api, ( p 336 cp p at T = 100C) ):
Required parameters : Head = 782 feet Capacity = 3336 RB/day

Pumps Pump s characteristics

Water Water design design
Size : 5,13 Efficiency at the required point : 73% N b of Number f stages t : 31 BHP required : 26.1 Frequency : 50 Hz

Oil design design Oil

Size : 5.13 Efficiency at the required point : 15.9% Number of stages : 87 BHP required : 119.8 q y : 50 Hz Frequency

Master Ingegneria g g del Petrolio 2006-2007

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Water design ( = 1 cp)

Performances f ( (31 stages) )
1400 1200 1000 H (feet) 800 600 400 200 0 0 1000 2000 3000 4000 5000 6000 7000 Q (RB/day) (RB/d )

Water Required q p point

Master Ingegneria g g del Petrolio 2006-2007

Oil design ( = 336 cp)

Performances (87 stages)

Water
4000 3500 3000 2500 H (feet) 2000 1500 1000 500 0 0 1000 2000 3000 4000 5000 6000 7000 Q (RB/day) (RB/d )

Turzo Stepanoff Edvocia Required point

Master Ingegneria g g del Petrolio 2006-2007

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Excel sheet linking to Prosper

Qwbep (RB/d) 60Hz 4053.700 stages 31 Pump Manufacturer Hwbep (ft) 60Hz 37.100 Q req 3335 0 3335.0 Pump Name (cp) 317.000 H req 783.0 783 0 Size n (rpm) 2897.981 (sp. gr.) Cq 0.962 Ch 0.718 0.802 Qobep Hobep 2425.491 640.412 Link to Prosper Water a e pe performance o a ce Hobep 636.100

STEPANOFF
Cq 0.711 Ch 0.796 Qobep 2401.034

CENTRILIFT

E127

5.13

EDVOCIA
0,6*Hwbep 32.7 0.8*Hwbep 29.7 Hwbep 25.8 1.2*Hwbep 20.7 Cq 0.688 Ch3 0 758 0.758 Ch4 Ceff 0.231 Ch1 Ch2 0.835 0.811 qcorrette hcorrette 0.694 0 694 1394 900 1394.900 846 325 846.325 1859.867 747.545 2324.833 605.459 2789.800 444.731 Stepanoff

Edvocia

Turzo coefficients 5.750E+01 -6.316E-03 2.073E-06 -6.431E-10 6.093E-14 -2.259E-18 Q (RB/d) 0.000 315.789 631.579 947.368 1263.158 1578.947 1894.737 2210.526 2526.316 2842.105 3157.895 3473.684 3789.474 4105 263 4105.263 4421.053 4736.842 5052.632 5368.421 5684.211 6000.000 H (ft) 1237.853 1192.006 1154.819 1122.691 1092.576 1061.940 1028.717 991.262 948.304 898.905 842.409 778.398 706.651 627 089 627.089 539.741 444.687 342.022 231.803 114.009 -11.508 Qmax 60 Hz RB/ 7200 Hz 50

TURZO

Performances
1500

w ater Stepanoff Edvocia Turzo required point

1000

H (feet)
500

0 0 2000 4000 Q (RB/day) 6000 8000

Master Ingegneria g g del Petrolio 2006-2007

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ESPCPs performances operating viscous oil

Master Ingegneria g g del Petrolio 2006-2007

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Rod driven PCPs performances operating viscous oil

Master Ingegneria g g del Petrolio 2006-2007

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Comparison between ESP and ESPCP ( = 336 cp) ESP

BHP required : 119.8 Efficiency : 15.9%

ESPCP
BHP required : 23.0 Efficiency : 68.5%

Master Ingegneria g g del Petrolio 2006-2007

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Conclusions
9 Both ESPs and PCPs are suitable to handle high viscous oils 9 PCPs are q quite insensitive to oil viscosity y showing g no reduction in head, capacity. 9 ESPs do loose head, capacity and efficiency performances requiring heavy oversizing. However this low efficiency ends up in heating the produced oil hence reducing its viscosity.

Master Ingegneria g g del Petrolio 2006-2007

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Future developments for ESPs in viscous oils

Master Ingegneria g g del Petrolio 2006-2007

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Future technologies to operate viscous oil