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Objectives
Production Engineering
Objectives
New
Production
Wells
Design
Optimization
Maximize
Profit
Production Engineering
Objectives
Production
Wells
Monitor Performance
Performance
Deviations
Analyze
Maximize
Profit
Design
Optimization
Production Engineering
Objectives
In order to accomplish those
objectives the production engineer
must fully understand the nature of an
oil well and must master the
interaction between all other subdisciplines
He must also fully understand the
potential and limitations of artificial lift
techniques
Oil Well
1.
2.
Oil Well
3.
equipment,
chokes
and
any
other
Fluid Production
Path of produced fluids
Reservoir
Perforations, gravel pack, etc.
Downhole equipment, casing, tubing.
Downhole artificial lift equipment
Mixed with lift gas or lift fluid
Wellhead, production chokes
Flow lines
Mixed with production from other wells (manifolds)
Separator
Tank or Compressor
Porous Media
Perforations
Production String
Downhole Equipment
Restrictions
Surface Flowline
Production
Separator
Surface Equipment
Restrictions
Fluid Production
In each flow segment, the fluids interact
with the production components
Pressure and temperature changes.
Mixing with other fluids
Fluid properties constantly changing
Driving Force
The driving force that moves fluids along the
reservoir and production system is the energy
stored in the form of compressed fluids in the
reservoir.
As the fluids move along the system components,
pressure drop occurs. The pressure in the
direction of flow continuously decreases from the
reservoir pressure to the final downstream
pressure value at the separator.
Driving Force
Driving Force
Reservoir
Individual
Pressure
Components
Pr
Pressure,
Temperature and
Composition
Ps
Separation
Pressure
Changes
Pc ( q )
Equilibrium Flowrate
The flowrate value at which a specific well
flows using only the energy stored in the
compressed reservoir fluids is called
natural equilibrium flowrate.
Pr Ps = Pc ( q)
Changes in Production
with Time
Changes in Production
There is a reduction on the ability of the
reservoir to deliver fluids after the perforations
at a sufficient pressure to overcome the
pressure losses through the the production
system.
Therefore, the well seeks a new equilibrium
point of lower flowrate with lower pressure
losses in the reservoir and in the system.
2500
Changes in
Production
2000
qe
1500
1000
500
2500
0
0
0.4
0.6
0.8
1.2
2000
Equilibrium Flowrate (bpd)
0.2
qe
1500
1000
500
0
0
200
400
600
Time (days)
800
1000
1.4
1.6
Changes in Production
The natural equilibrium flowrate declines
with time
There are situations however, when such
an equilibrium point does not exist any
longer and the well cannot produce
naturally any more and ceases to be a
naturally flowing well and dies.
Changes in Production
We need then to know:
What is the minimum equilibrium flowrate ?
Does the well let you know it will die ?
Can we forecast how long a well will produce
under natural flow conditions ?
Can we detect when a well is approaching the end
of the natural flow conditions life ?
Corrective Measures to
Increase Natural Equilibrium
Flowrate
Corrective Measures
In order to modify the natural equilibrium flowrate
decrease that would occur with time we can usually
act in three ways:
1.
Open Chokes
Tubing size
Flowline size
Production Layout
Corrective Measures
2. The second option is by increasing the ability of the reservoir
to deliver fluids at higher pressures at the perforations
Stimulation techniques
Perforation Density
Corrective Measures
3.
Corrective Measures
In this last case we have no more a
naturally flowing well since now the
equilibrium flowrate will be determined
by the ability of the reservoir pressure to
overcome the pressure drops in the
system after the perforations with the
help
of an external source of
horsepower.
Artificial Lift
Artificial Lift
In the beginning of the oil industry it was
recognized that the pressure of fluids inside
the porous media provided the necessary
energy to lift the fluids to the surface.
Techniques that use an external source of
horsepower to help the reservoir in
overcoming the pressures losses in the
production system after the perforations
receive the generic name of Artificial Lift.
Artificial Lift
Artificial lift is the area of petroleum engineering
that studies methods used to promote an
increase in the production rate of flowing wells
or to put wells back into production by using an
external horsepower source to help the reservoir
pressure to overcome the pressure drops in the
system downstream of the perforations.
Beam Pumping
Continuous Gas Lift
Electrical Submersible Pump
Progressive Cavity Pump
Hydraulic Jet Pump
Intermittent Gas Lift
Hydraulic Pump
Plunger Lift
Auto Gas Lift
Other Traditional Methods
Boosting Methods
Etc
Pumping Unit
Beam Pump
Prime Mover
Polished Rod
Suffing Box
Tubing
Sucker Rods
Pump
Beam Pump
Pumping
Unit
Prime
Mover
Polished Rod
Suffing Box
Tubing
Sucker
Rods
Pump
Unloading Valve
Gas Lift Mandrel
Tubing
Operating Valve
Packer
Injection
Choke
Unloading Valve
Gas Lift
Mandrel
Tubing
Operating Valve
Packer
Primary Transformer
Switchboard
Wellhead and
electric
mandrel
Tubing
Round Cable
Packer
Pump
Separator
Protector
Flat Cable
Motor
Electrical
Submersible
Pump
ESP
Primary
Transformer
Switchboard
Wellhead
and
electric
mandrel
Tubing
Round Cable
Packer
Pump
Separator
Protector
Flat Cable
Motor
Electric Motor
Christmas Tree
Tubing
Rods
Downhole PCP
Gas Anchor
Anchor
Transformer
Control Panel
Motor
Tubing
Downhole Pump
Standing Valve
Open
Closed
Tubing
Unloading Valve
Valve Mandrel
Operating Valve
Packer
Check Valve
Operational Conditions
Failure Control
Monitoring Strategy
Onshore
Offshore
Dry completion
Satellite well
Existing Infrastructure
Remote well
New well in a new field
New well in a existing field
Existing well in a existing field
Bottomhole Temperature
Solids Production
Gas Production
Corrosive fluids
Scale Problems
Stability
Changes in production conditions with time
Casing condition
Etc...
Beam Pumping
Continuous Gas Lift
Electrical Submersible Pump
Progressive Cavity Pump
Hydraulic Jet Pump
Intermittent Gas Lift
Hydraulic Pump
Plunger Lift
Auto Gas Lift
Other Traditional Methods
Boosting Methods
Rod Pump
Fair
Poor
Poor
Poor
Excellent
Fair
Fair
ESP
Fair
Good
Poor
Excellent
Fair
Fair
Fair
Gas Lift
Excellent
Poor
Excellent
Good
Fair
Excellent
Excellent
Onshore
Offshore
Artic
Etc..
Existing Infrastructure
Remote well
New well in a new field
New well in a existing field
Existing well
The
method
selection
sometimes
becomes a personal decision. Operators,
service companies, product manufacturer
may have some preferences not usually
justified by a technical analysis.
Attribute
Sucker Rod
Pumping
Progressing Cavity
Pumping
Electrical
Submersible
Pumping
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Competitive with
sucker-rod pump.
Cost increases with
high horsepower
Well equipment
costs low but lines
and compression
costs may be high.
Central
compression
system reduces
cost per well.
Same as
continuous flow
gas lift.
Capital Cost
Low to Moderate:
increases with
depth and larger
units.
Low: increases
with depth and
larger rates.
Relatively low
capital cost if
commercial electric
power available
Downhole
Equipment
Reasonably good
rod design and
operating practices
needed. Data bank
of rod and pump
failures beneficial.
Good selection,
operating, and
repair practices
need for rod and
pumps.
Requires proper
cable in addition to
motor, pumps,
seals, etc. Good
design plus good
operating practice
essential.
Requires computer
design programs
for sizing. Tolerant
of moderate solids
in power fluids. No
moving parts in
pumps: long
service life; simple
repair procedures
Unload to bottom
with gas lift valves;
consider chamber
for high PI and low
BHP wells
Operating practices
have to be tailored
to each well for
optimization. Some
problem with
sticking plungers.
Excellent: may
exceed rod pumps
for ideal cases.
Reported system
efficiency 50% to
70%. More
operating data
needed.
Fair to poor.
Maximum
efficiency only
30%. Heavily
influenced by
power fluid plus
production
gradient. Typical
operating
efficiencies of 10%
to 20%.
Poor: normally
requires a high
injection gas
volume/barrel fluid.
Typical lift
efficiency is 5% to
10%; improved
with plungers.
Excellent for
flowing wells. No
input energy
required because it
uses the energy of
the well. Good
even when small
supplementary gas
is added.
Poor: pumps
usually run at a
fixed speed.
Requires careful
sizing. VSD
provides more
flexibility but added
costs. Time cycling
normally avoided.
Must size pump
properly.
Good/excellent:
Can vary power
fluid rate and
speed of downhole
pump. Numerous
pump sizes and
pump/engine ratios
adapt to production
and depth needs.
Good to excellent:
power fluid rate
and pressure
adjusts the
production rate and
lift capacity.
Selection of throat
and nozzle sizes
extend range of
volume and
capacity.
Excellent: gas
injection rate varied
to changes rates.
Tubing needs to be
sized correctly.
Efficiency
Flexibility
Excellent total
system efficiency.
Full pump fillage
efficiency typical
about 50 to 60%
feasible, if well is
not over pumped.
Attribute
Sucker Rod
Pumping
Miscellaneous
Problems
Stuffing box
leakage may be a
messy and a
potential hazard.
(Antipollution
stuffing boxes are
available)
Operating Cost
Electrical
Submersible
Pumping
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Requires a highly
reliable electric
power system.
Method sensitive to
rate changes.
More tolerant of
power fluid solids;
200 ppm of 25
micron particles
acceptable.
Diluents may be
added if required.
Power water (fresh,
produced, or
seawater)
acceptable.
A highly reliable
compressor with
95% run time
required. Gas must
be dehydrated
properly to avoid
gas freezing.
Labor intensive to
keep fine tuned;
otherwise, poor
performance.
Maintaining steady
gas flow often
causes injection
gas measurement
and operating
problems.
Plunger hangup or
sticking may be a
major problem.
Varies: if
horsepower is high,
energy costs are
high. High pulling
costs result from
short run life. Often
repair costs are
high.
Same as
continuous flow
gas lift.
Varies: excellent
for ideal lift cases;
poor for problems
areas. Very
sensitive to
operating
temperatures and
electrical
malfunctions.
Good with a
correctly designed
and operated
system. Problems
of changing well
conditions reduce
downhole pump
reliability. Frequent
downtime results
from operational
problems.
Excellent if
compression
system properly
designed and
maintained.
Excellent if there is
an adequate
supply of gas and
an adequate low
pressure storage
volume for injection
gas. System must
be designed for the
unsteady gas flow
rates.
Good if well
production is
stable.
Good: easily
moved. Some
trade in value. Fair
market for triplex
pumps.
Progressing Cavity
Pumping
Reliability
Good: normally
over pumping and
lack of experience
decreases run
time.
Salvage Value
Excellent: easily
moved and good
market for used
equipment
Fair/poor: easily
moved and some
current market for
used equipment.
Attribute
System (Total)
Usage/Outlook
Sucker Rod
Pumping
Straightforward
and basic
procedures to
design, install, and
operate following
API specifications
and recommended
practices. Each
well is an individual
system.
Excellent: used on
about 85% of U.S.
artificial-lift wells.
The normal
standard artificiallift method.
Progressing Cavity
Pumping
Simple to install
and operate.
Limited proven
design, installation,
and operating
specifications and
procedures. Each
well is an individual
system.
Limited to relatively
shallow wells with
low rates. Used on
less than 0.5% of
U.S. lifted wells.
Used primarily on
gas-well
dewatering.
Electrical
Submersible
Pumping
Fairly simple to
design but requires
good rate data.
System not
forgiving. Follow
API recommended
practices in design,
testing, and
operation. Typically
each well is an
individual
producing using a
common electric
system.
An excellent high
rate artificial lift
system. Best suited
for <200 F and
>1000 BFPD rates.
Most often used on
high water cuts
wells. Used on
about 4% of U.S.
lifted wells.
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Computer design
program typically
used for design.
Basic operating
procedures needed
for downhole pump
and wellsite unit.
Free pump easily
retrieved for onsite
repair or
replacement.
Downhole jet often
requires trial and
error to arrive at
best/optimum jet
An adequate
volume, highpressure, dry, noncorrosive and clean
gas supply source
is needed
throughout the
entire life. System
approach needed.
Low backpressure
beneficial. Good
data needed for
valve design and
spacing. API
specifications and
design/operating
recommended
practices should be
followed.
Simple manual or
computer design
typically used. Free
pump easily
retrieved for
servicing.
Individual well unit
very flexible but
extra cost. Central
plant more
complex; usually
results in test and
treatment
problems.
Same as
continuous flow.
Individual well or
system. Simple to
design, install, and
operate. Require
adjusting and
plunger
maintenance.
Often used as
default artificial-lift
well system.
Flexible operation;
wide rate range;
suitable for
relatively deep,
high volume, high
temperature,
deviated oil wells.
Used on <2% of
U.S. lifted wells
Often used as a
default artificial lift
method in lieu of
sucker rod pumps.
Also a default for
low bottomhole
pressure wells on
continuous gas lift..
Used in < 1% of
U.S. wells
Essentially a low
liquid rate, high
GLR lift method.
Can be used for
extending flow life
or improving
efficiency. Ample
gas volume and/or
pressure needed
for successful
operation. Used on
<1% of U.S. wells
Attribute
Sucker Rod
Pumping
Problems only in
high rate wells
requiring large
plunger pumps.
Small casing sizes
(4.5 and 5,5 in.)
may limit free gas
separation
Depth Limits
Good: rods or
structure may limit
rate at depth.
Effectively, about
500 B/D at 7000 ft
and 150 B/D at
15000 ft.
Progressing Cavity
Pumping
Electrical
Submersible
Pumping
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Normally no
problem for 4.5 in.
casing and larger,
but gas separation
may be limited.
Lager casing
required for parallel
free or closed
systems. Small
casing (4,5 and 5.5
in.) may result in
excessive friction
losses and limits
producing rate.
Small casing
suitable for this low
volume lift. Annulus
must have
adequate gas
storage volume.
Usually limited to
motor horsepower
or temperature.
Practical depth
about 10000 ft.
Excellent: limited
by power-fluid
pressure (5000
psig) or
horsepower. Low
volume/high lift
head pumps
operating at depths
to 17000 ft.
Excellent: similar
limits as
reciprocating
pump. Practical
depth of 20000 ft.
Controlled by
system injection
pressure and fluid
rates. Typically for
1000 B/D with 2.5
in. nominal tubing,
1440 psig lift
system, and 1000
GLR, has an
injection depth of
about 10000 ft.
Usually limited by
fallback; few wells
>10000 ft.
Poor: restricted by
the gradient of the
gas-lifted fluid.
Typically moderate
rate is limited to
about 100 psi/1000
ft injected depth.
Thus, the
backpressure on
10000 ft. well may
be >1000 psig
Good: bottomhole
pressures <150
psig at 10000 ft. for
low rate, high GLR
wells.
Same as hydraulic
reciprocating
pumps.
Same as
continuous gas lift.
Low
Same as hydraulic
reciprocating
pumps.
Same as
continuous gas lift.
Good
Poor: limited to
relatively shallow
depths, possibly
5000 ft.
Intake Capabilities
Noise Level
Fair: moderately
high for urban
areas.
Good: surface
prime mover
provides the only
noise.
Excellent: low
noise. Often
preferred in urban
areas if production
rate is high.
Obtrusiveness
Fair to good:
wellhead
equipment has low
profile. Requires
surface treating
and high pressure
pumping
equipment
Attribute
Sucker Rod
Pumping
Prime Mover
Flexibility
Good: both
engines or motors
can be used easily
(motors more
applicable and
flexible).
Surveillance
Excellent: can be
easily analyzed
based on well test,
fluid levels, etc.
Analysis improved
by use of
dynamometers and
computers.
Testing
Excellent if well
can be pumped off.
Progressing Cavity
Pumping
Electrical
Submersible
Pumping
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Good: both
engines or motors
can be used.
Fair: requires a
good power source
without spikes or
interruptions.
Higher voltages
can reduce I2R
losses.
Excellent: prime
mover can be
electric motor, gas,
or diesel fired
engines or motors.
Same as hydraulic
reciprocating
pumps.
Good: engines,
turbines, or motors
can be used for
compression.
Same as
continuous gas lift.
None normally
required.
Fair: electrical
checks but special
equipment needed
otherwise
Good/fair:
downhole pump
performance can
be analyzed from
surface power-fluid
and pressure,
speed, and
producing rate.
Bottomhole
pressure obtained
with free pumps
Same as hydraulic
reciprocating
pumps.
Good/excellent:
can be analyzed
easily. Bottomhole
pressure and
production log
surveys easily
obtained.
Optimization and
computer control
being attempted
Fair: complicated
by standing valve
and fallback.
Good: depends on
good well tests and
well pressure chart
Same as hydraulic
reciprocating
pumps. Three
stage production
test can be
conducted by
adjusting
production step
rates, pressured
recorder in place to
monitor intake
pressure
Not applicable.
Time Cycle is
necessary for
efficient operation.
Pump Off is not
applicable.
Fair: analysis
based on
production and
fluid levels only.
Dynamometers
and pump-off cards
not possible to use.
Poor: avoid
shutdown in high
viscosity/sand
producers.
Attribute
Sucker Rod
Pumping
Corrosion/scale
handling ability
Good to excellent:
batch treating
inhibitor down
annulus used
frequently for both
corrosion and scale
control.
Crooked/deviated
holes
Fair: increased
load and wear
problems. High
angle deviated
holes (>70
degrees) and
horizontal wells are
being produced.
Some success in
pumping 15
degrees/100 ft.
using rod guides.
Duals application
Fair: parallel 2 x 2
in. low rate duals
feasible inside 7 in.
casing. Duals
inside 5.5 in.
casing currently not
in favor. Gas is a
problem from lower
zone. Increased
mechanical
problems
Electrical
Submersible
Pumping
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Good: batch
treating inhibitor
down annulus
feasible
Good/excellent:
batch or
continuous treating
inhibitor can be
circulated with
power fluid for
effective control.
Good/excellent:
inhibitor with power
fluid mixes with
produced fluid at
entry of jet pump
throat. Batch treat
down annulus
feasible.
Good: inhibitor in
the injection gas
and/or batch
inhibiting down
tubing feasible.
Steps must be
taken to avoid
corrosion in
injection gas lines.
Same as
continuous flow
Fair: normal
production cycle
must be interrupted
to batch treat to
well.
Poor to fair:
increased load and
wear problems.
Currently, very few
known installations.
Good: few
problems. Limited
experience in
horizontal wells.
Require long radius
wellbore bends to
get through.
Excellent. If tubing
can be run in the
well, pump
normally will pass
through the tubing.
Free pump
retrieved without
pulling the tubing.
Feasible operation
in horizontal wells.
Excellent: few
wireline problems
up to 70 degree
deviation for
wireline retrievable
valves
Same as
continuous flow
Excellent.
No known
installations. Larger
casing would be
needed. Possible
run and pull
problems.
Same as hydraulic
reciprocating pump
except can
possibly handle
higher GLR but at
reduced efficiency
Same as
continuous flow
No known
installations.
Good/fair:
concentric fixed
pump or parallel
free permits gas
venting with
suitable downhole
gas separator
below pump intake.
Casing free pump
limited to low GOR.
Similar to hydraulic
reciprocating
pump. Free gas
reduces efficiency
but helps lift. Vent
free gas if possible.
Use a gas anchor
Excellent:
produced gas
reduces need for
injection gas
Same as
continuous flow
Excellent.
Progressing Cavity
Pumping
No known
installations.
Attribute
Sucker Rod
Pumping
Offshore
application
Progressing Cavity
Pumping
Paraffin handling
capability
Fair/good: hot
water/oil treating
and/or use of
scrapers possible,
but increase
operating problems
and costs.
Slim hole
completions (2 7/8
in. production
casing string)
Feasible if low
rates, low GOR,
and shallow depths
but no known
installations.
Solids/sand
handling ability
Excellent: up to
50% sand with high
viscosity (>200 cp.)
crude. Decreases
to <10% sand for
water producers
Electrical
Submersible
Pumping
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Good: must
provide electrical
power and service
pulling unit.
Fair: feasible
operation in highly
deviated wells.
Requires deck
space for treating
tanks and pumps.
Water power fluid
can be used.
Power oil a
fire/safety problem
Good: produced
water or sea water
may be used as
power fluid with
well site type
system or power
fluid separation
before production
treating system
Excellent: most
common method if
adequate injection
gas available
Poor in wells
needing sand
control. Use of
standing valve
risky. Heading
causes operating
problems
Excellent for
correct application.
Good/excellent:
circulate heat to
downhole pump to
minimize buildup.
Mechanical cutting
and inhibition
possible. Soluble
plugs available.
Free pumps can
be surfaced on a
schedule
Same as hydraulic
reciprocating pump
Good: mechanical
cutting sometimes
required. Injection
gas may aggravate
an existing problem
Same as
continuous flow
Excellent: cuts
paraffin and
removes small
deposits
No known
installation.
Same as hydraulic
reciprocating pump
Same as
continuous flow
Good: similar to
casing lift but must
have adequate
formation gas.
Poor: requires
<200 ppm. Solids.
Improved wear
resistant materials
available at
premium cost
Fair/good: jet
pumps are
operating with 3%
sand in produced
fluid. Power fluid to
jet pump can
tolerate 200 ppm of
25 micron particle
size. Fresh water
treatment for salt
buildup possible
Excellent: limit is
inflow and surface
problems. Typical
limit is 0.1 % sand
for inflow and
outflow problems.
Sucker Rod
Pumping
Progressing Cavity
Pumping
Electrical
Submersible
Pumping
Hydraulic
Reciprocating
Pumping
Hydraulic Jet
Systems
Continuous Gas
Lift
Intermittent Gas
Lift
Plunger Lift
Temperature
limitation
Excellent: currently
used in thermal
operations (550 F.)
Fair: limited to
stator elastomer.
At present normally
bellow 250 F.
Limited to <250 F
for standard and
<325 F with special
motors and cable
Excellent: standard
materials to 300 F
and to 500 F
feasible with
special materials
Excellent: possible
to operate to 500 F
with special
materials
Excellent; typical
maximum of about
350 F. Need to
known
temperatures to
design bellows
charged valves.
Same as
continuous flow
Excellent.
Fair: limited to
about 200 cp.
Increases
horsepower and
reduces head.
Potential solution is
to use core flow
with 20% water
Good/excellent:
production with up
to 800 cp possible.
Power oil of >24
API and <50 cp or
water power fluid
reduces friction
losses
Same as
continuous flow
Normally not
applicable.
Poor: restricted to
relatively small
rates. Possibly
2000 B/D from
2000 ft. and 200
B/D from 5000 ft.
Excellent: limited
by needed
horsepower and
can be restricted
by casing size. In
5.5 in. casing size,
can produce 4000
B/D from 4000 ft.
with 240
horsepower.
Tandem motors
can be used but
will increase costs
Excellent: up to
15000 B/D with
adequate flowing
bottomhole
pressure, tubular
size, and
horsepower
Excellent:
restricted by tubing
size and injection
gas rate and depth.
Depending on
reservoir pressure
and PI, with 4 in.
nominal tubing
rates of 5000 B/D
from 10000 ft
feasible with 1440
psig injection gas
and GLR of 1000.
Poor: limited by
cycle volume and
number of possible
injection cycles.
Typically about 200
B/D from 10000 ft.
with <250 psig
pump intake
pressure
Poor: limited by
number of cycles.
Possibly 200 B/D
from 10000 ft.
Fair: limited by
heading and
slippage. Avoid
unstable flow
range. Typically
lower limit is 200
B/D for 2 in. tubing
without heading;
400 B/D for 2.5 in.
and 700 B/D for 3
in tubing.
Good: limited by
efficiency and
economic limit.
Typically to 4
bbl/cycle with up to
48 cycles/day
Attribute
Fair: restricted to
shallow depths
using large
plungers.
Maximum rate
about 4000 B/D
from 1000 ft. and
1000 B/D from
5000 ft
Excellent: most
commonly used
methods for wells
producing <100
B/D
Generally poor:
lower efficiencies
and high operating
costs for <400 B/D
Good: limited by
tubular and
horsepower.
Typically 3000 B/D
from 4000 ft and
1000 B/D from
10000 ft with 3500
psig system.
Our Objective
Our objective
Our objective
Is to maximize profit through an intelligent
management of operational and investment costs. A
well designed system will balance costs, production
and reliability under the various physical, economical
environmental, human and technical constraints.
Investment Costs
Investment Costs
The investment costs can then be calculated for certain applications.
Usually the investment cost should not be the only criteria for
selecting a artificial lift method.
There are several references comparing artificial lift investment costs.
Generally those costs can not be generalized due to:
Investment Costs
Rod Pumping Investment Costs (US$)
Lift Depth (ft)
Flowrate
(bpd)
2000
3000
4000
5000
6000
7000
100
6345
8675
11235
13595
16520
19930
200
7455
10115
12845
16000
19770
21640
300
8635
11935
14410
18760
22050
25480
400
9865
13630
17370
22210
26570
28480
500
10720
15870
19160
25990
32850
600
11840
18380
22990
31150
700
12950
20210
25290
800
15700
20400
28710
900
16190
20620
1000
16590
23220
1100
17690
26180
Investment Costs
Hydraulic Pumping Investment Costs (US$)
Lift Depth (ft)
Flowrate
(bpd)
2000
3000
4000
5000
6000
7000
100
12240
13860
15480
17100
18720
20340
200
13140
14750
16360
17920
19540
21160
300
13650
15270
16890
18510
20130
21750
400
14830
16450
18070
19690
21310
22930
500
15820
17440
19060
20680
22300
23920
600
15820
17440
19060
20680
22300
23920
700
17380
19300
21220
23140
25060
26980
800
19610
21530
23450
25370
27290
29210
900
23190
25510
27830
30150
32470
34790
1000
23930
26250
28570
30890
33210
35130
1100
25935
28350
30770
33190
35610
37830
Investment Costs
Electrical Submersible Pumping Investment Costs (US$)
Lift Depth (ft)
Flowrate
(bpd)
2000
3000
4000
5000
6000
7000
400
12170
12170
12170
12170
12170
12170
600
15650
15650
15650
15650
15650
15650
800
18900
18900
18900
18900
18900
18900
1000
22740
22740
22740
22740
22740
22740
1200
26470
26470
26470
26470
26470
26470
Beam Pumping
35000
Lift Depth (ft)
7000 6000
30000
5000
4000
25000
3000
20000
2000
15000
10000
5000
0
0
200
400
600
Flowrate (bpd)
800
1000
1200
Hydraulic Pumping
40000
35000
30000
25000
7000
20000
5000
15000
3000
2000
10000
200
400
600
Flowrate (bpd)
800
1000
1200
40000
Lift Depth (ft)
35000
7000
30000
6000
25000
5000
20000
4000
3000
15000
2000
10000
5000
0
0
200
400
600
Flowrate (bpd)
800
1000
1200
35000
30000
25000
Electrical Submersible Pump
20000
Hydraulic Pumping
15000
Beam Pumping
10000
5000
0
0
200
400
600
Flowrate (bpd)
800
1000
1200
7000
35000
6000
30000
5000
25000
4000
20000
3000
15000
2000
10000
5000
0
0
200
400
600
Flowrate (bpd)
800
1000
1200
6000
5000
4000
Beam Pumping
3000
2000
0
200
400
600
Flowrate (bpd)
800
1000
1200
Operational Costs
The operational costs should also be considered
when selecting an artificial lift method.
Usually the operational cost should not be the only
criteria for selecting a artificial lift method. The
operational cost should be an imput to the economical
analysis to be performed.
Operational cost is consituted by three terms:
Fixed Costs
Costs that do not depend on the production but occur on a
regular basis
Variable Costs
Costs that are directly related with the production levels and
occur on a regular basis
Workover Costs
Costs that are related with failure of the system or components
of the system and occur at certain points in time.
Operational Costs
C = C fixed + Cv (q ) + Cworkover
C
Cfixed
Cv(q)
Cworkover
= Workover Cost
Cv = Co qo + Cw qw + C g qg + Chp HP
WORp
GORp
S = (So + S g GORp ( qo ) ) qo
S
So
Sg
S = Soe ( qo ) qo
S oe (qo ) = So + S g GOR p ( qo )
P = S C
P = S oe (qo ) qo C fixed C workover Coe ( qo ) qo Chp HP ( qo )
e
o
e
o
dP
=0
dqo
dHP ( qo )
dP dPoe ( qo )
e
=
qo + Po ( qo ) C hp
=0
dqo
dqo
dqo
dPoe
qo
+ Poe
dHP
dqo
=
dqo
Chp
The relationship between the HP and the well
equilibrium flowrate qo is extremly important to
determine the optimum profit flowrate. The
relationship between the equilibrium flowrate and
the horsepower consumption is called Artificial Lift
Method Performance Curve.
Equilibrium Flowrate -
1400
1200
dPoe (qo )
qo
+ Poe (qo )
dHP( qo )
dqo
=
dqo
Chp
1000
800
600
400
Maximum Profit
nf
e
200
0
0
200
400
600
Horsepower
800
1000
800
Gas Fraction = 15%
600
Maximum Motor HP
400
VSD Operating Envelope
200
Minimum Stable Flowrate
0
0
100
200
300
Horsepower (HP)
400
500
Choke Size
VSD Frequency
Gas Injection Pressure
Stroke length and SPM
Etc
800
Gas Fraction = 15%
600
Choke Control Operating Envelope
400
200
Minimum Stable Flowrate
0
0
100
200
300
Horsepower (HP)
400
500
1000
Design Point
800
600
P
or
Np
400
200
Minimum Stable or Pump Range Flowrate
0
0
100
200
300
Horsepower (HP)
400
500
dN p
qe ( N p )
= dt
N p (t )
qe (t )
dN
pv
p
= dN p (t ) e
in
t
k
= q (t ) e
in
t
k
dt
If a forecast for oil sale and production costs is known we can also calculate the
economic present value for the system
800
Production Envelope
600
400
Optimum Economical Flowrate
200
System Failure
0
0
100
200
300
Horsepower (HP)
400
500
50000000
45000000
40000000
Waiting Time
35000000
30000000
Failure
25000000
20000000
MTBF 720 Days
15000000
10000000
Workover
5000000
Design Efficiency
0
0
500
1000
1500
2000
Time (days)
2500
3000
3500
4000
50000000
45000000
40000000
35000000
720
30000000
25000000
20000000
360
15000000
10000000
5000000
180
0
0
500
1000
1500
2000
Time (days)
2500
3000
3500
4000
Equilibrium Flowrate -
1400
1200
dPoe (qo )
qo
+ Poe (qo )
dHP( qo )
dqo
=
dqo
Chp
1000
800
600
400
Maximum Profit
nf
e
200
0
0
200
400
600
Horsepower
800
1000
dP
e
qo
+ Po
dHP
dqo
=
dqo
Chp
dPoe
qo
+ Poe
HP HP dPwf
dqo
+
=
qo Pwf dqo
C hp
Production System
Behavior
Economics and
Production Conditions
Managing Production
Managing the production characteristics
of each individual well can also have
dramatic effects on the economic
results.
Example
347 Wells
qo 10 - 20 bpd
qw 0 - 176 bpd
Managing Production
30000
25000
20000
15000
10000
5000
0
0
5000
10000
15000
20000
25000
30000
Managing Production
If we can really isolate and identify the
fixed, variable and energy cost we can
optimize a pool of wells responding to
changes in the oil price.
P + C f = So qo Co qo Cw qw Chp HP
So = 15 US$/stb
Co = 4.9 US$/stb
Cw = 4.9 US$/stb
Chp = 1 US$/(HP day)
HP = 0.1 HP/stb (water or oil)
Managing Production
Profit + Fixed Cost (US$/d)
160000
140000
120000
100000
80000
60000
40000
20000
0
0
5000
10000
15000
20000
25000
30000
Managing Production
So = 11 US$/stb
Co = 4.9 US$/stb
Cw = 4.9 US$/stb
Chp = 1 US$/(HP day)
HP = 0.1 HP/stb (water or oil)
Managing Production
Profit + Fixed Cost (US$/d)
80000
70000
60000
50000
40000
30000
20000
10000
0
0
5000
10000
15000
20000
25000
30000
Managing Production
160000
Profit + Fixed Cost (US$/d)
15 US$/stb
140000
120000
100000
80000
60000
11 US$/stb
40000
20000
0
0
5000
10000
15000
20000
25000
30000
Interesting Data
Energy Source
Energy Content or
Equivalence (BTU)
21,400,000
Barrel of Crude
5,800,000
HP day
61,066
KWh of Electricity
3,412
1,027
Ton of coal
(907.2 kg)
Barrel of
Crude
HP day
KWh of
Electricity
Cubic Feet of
Natural Gas
Ton of coal
(907.2 kg)
21,400,000
3.7
350
6272
20837
Barrel of
Crude
5,800,000
95
1700
5647
HP day
61,066
18
60
KWh of
Electricity
3,412
3.3
Cubic Feet of
Natural Gas
1,027
References
1.
2.
Brown, K. E.: The Technology of Artificial Lift Methods, Vol. II-B, Chapter
9, Pennwell Books, Tulsa, OK, 1979.
3.
4.
5.
6.
References
7.
8.
Clegg, J. D., High Rate Artificial Lift, SPE 17638, Journal of Petroleum
Technology, March 1988.
9.
10. Duke, S.: Artificial Lift Which Method Best Fits your Needs ?,
Southwestern Petroleum Short Course 1981.
11. Fleshman, R., Lekic, H. O., Artificial Lift for High Volume Production
1999.
12. Jacobs, E. G. Artificial Lift in the Montrose Field, North Sea, SPE 15869
1986.
13. Johnson, L. D. Here are Guidelines for Picking an Artificial Lift Method,
The Oil and Gas Journal, August 1968.
References
14. Kahali, K., Rai, R., Mukerjie, R. K. Artificial Lift Methods for Marginal
Fields, SPE 21696 1991.
15. Lea, J. F., Winkler, H. W. New and Expected Developments in Artificial Lift,
SPE 27990 1994.
16. Lea, J. F., Adisoemarta, P. S., Nickens, H. V. Artificial Lift for Horizontal
Wells, ETCE/OMAE 2000 Joint Conference Energy for the New
Millenium, February 14-17, 2000 New Orleans, LA.
17. Lea, J. F., Cox, J. C., Adisoemarta, P. S. Artificial Lift for Slim Holes, SPE
63042 2000.
18. Naguib, M. A., Shaheen, S. E., Bayoumi, E., Eman, N. A. Review of
Artificial Lift in Egypt, SPE 64508 2000.
19. Naguib, M. A., Bayoumi, A., Battrawy, A. Guideline of Artificial Lift Selection
for Mature Field, SPE 64428 2000.
20. Neely, A. B.:A. B. Neely Discusses Artificial Lift Techniques, Uses and
Developments. Journal of Petroleum Technology September 1980.
References
21. Neely, A. B., Gbison, F., Clegg, J., Capps, B., Wilson, P. Selection of
Artificial Lift Method, SPE 10337 1981.
22. Renfu, W., Xlankan, C. Artificial Lift Techniques in China, SPE 14866
1986.
23. Saputelli, L. Combined Artificial Lift System An Innovative Approach,
SPE 39041 1997.
24. Stair, C. D., Artificial Lift Design for the Deepwater Gulf of Mexico, SPE
48933 1998.
25. Valentin, E. P., Hoffmann, F. C. OPUS: An Expert Advisor for Artificial Lift,
SPE 18184 1988.
26. William B., Gargord, D. W.: High Capacity Artificial Lift Alternatives in the
Offshore Environment. European Offshore Petroleum Conference and
Exhibition 1978 SPE 8070.
27. Lessons in Well Servicing and Workover Artificial Lift Methods Lesson 5
The University of Texas at Austin 1971.