Diseño de Gas Lift

Continuous Flow Gas Lift Design
By Jack R. Blann
2/9/2008
2/9/2008
Petroleum Engineering Handbook

Gas Lift appears as Chapter 12 in:
Volume IV
Production Operations Engineering
Edited by Joe Dunn Clegg
Chapter 12 was Co-authored by:
Herald W. Winkler, and
Jack R. Blann
2/9/2008
Two Types of Continuous Flow

Gas Lift Design
z
Design for Normal Wells.
Winkler Design for High gas Injection rates.
2/9/2008
Iranian Gas Lift Well

In Agha Jhari Field
Produced:
Natural Flow = 37,000 B/D
Gas Lift = 43,000 B/D
Had 26 mandrels and valves
to +3000 ft.
2/9/2008
Libyan Gas Lift Well
2/9/2008
Production Manifold in Libya
2/9/2008
Libyan Gas Lift Tests
2/9/2008
API Design Technique

Continuous Flow Installation Design Based on
Constant Decrease in Operating Injection-Gas
Pressure for Each Succeeding Lower Gas Lift
Valve
z All Gas Lift Valves have same port size.
z There is a constant decrease in the operating
injection pressure for each succeeding lower
valve.
z Port size that allows the injection-gas
throughput for unloading and operating the well.
2/9/2008

z This
installation design method is

recommended for gas lift valves with small
production-pressure factors.
z When the ratio of the port area to the
bellows area is low, the decrease in the
injection gas pressure between gas lift
valves, based on additional tubing effect
pressure for the top valve, is not
excessive.
2/9/2008
10
Injection-Pressure Operated Gas Lift

Valve
Production Pressure
factor =
Ratio of Area of Port to
Area of Bellows
2/9/2008
11
Gas Lift Valve Specifications
2/9/2008
12

z
The effect of bellows-assembly load rate on the

performance of the valves is not considered in
the installation design calculations.
Safety factors included in these calculations
should allow sufficient increase in the operating
injection gas pressure, which is necessary to
provide valve stem travel for adequate
injection-gas passage through each successively
lower unloading valve without interference from
upper valves.
2/9/2008
13

z Selection
of a constant injection- gas

pressure decrease, or drop, in the surface
operating injection pressure for each
succeeding lower gas lift valve should not
be arbitrary, as proposed in some design
methods.
z The pressure decrease should be based on
the gas lift valve specification to minimize
the possibility of upper valves remaining
open while lifting from a lower valve.
2/9/2008
14

z The
additional tubing-effect pressure for

the top gas lift valve is a logical choice for
this decrease in the operating injectiongas pressure between valves.
2/9/2008
15

z Closing
or reopening of an injectionpressure-operated gas lift valve is partially

controlled by the production pressure
effect, which is equal to the production
pressure factor for the valve multiplied by
the difference in flowing production
pressure at the top valve depth.
2/9/2008
16

z The
flowing pressure at an unloadingvalve depth changes from the transfer

pressure, (PptfD)min, To a higher flowing
production pressure after the next lower
valve becomes the operating pressure
2/9/2008
17

z The
additional tubing-effect pressure is

the difference between (PptfD)min, and the
maximum flowing-production pressure at
the unlading valve depth, (PptfD)max, after
the point of gas injection has transferred
to the next lower valve.
2/9/2008
18

z As
the unloading gas lift valve depths

increase , the distance between valves
and the difference between (PptfD)min, and
(PptfD)max decrease.
z Although the additional tubing-effect
pressure decreases for lower valves, the
injection-gas requirement for unloading
increases with depth.
2/9/2008
19

z An
increased stem travel, or stroke, is

usually needed for the lower valves to
generate the larger equivalent port area
necessary for the higher injectiongas
requirements with the lower pressure
differentials that occur across these
deeper valves.
2/9/2008
20

zA
constant decrease in the operating

injection-gas pressure equal to the
additional tubing effect pressure for the
top valve allows a a greater increase in
the injection gas above initial opening
pressure for lower gas lift valves.
2/9/2008
21
API Gas Lift Design
2/9/2008
22
Gradient Curve
2/9/2008
23
Gradient Curve
2/9/2008
24

z When
the injection-gas pressure significantly

exceeds the flowing- production pressure, an
arbitrary increase in injection-gas-pressure,
Pio can be added to the initial productionpressure effect for the top valve for
calculating the spacing and the initial opening
pressures of the unloading gas lift valves
2/9/2008
25

z
The total decrease in the injection-gas pressure

is distributed equally between each successively
lower gas lift valve rather than having a sizeable
pressure drop across the operating gas lift valve
or orifice-check valve
This reduces the possibility of multipoint
injection through the upper unloading valves by
ensuring that the valves remain closed after the
point of gas injection has transferred to the next
lower valve,
2/9/2008
26

Determination of Valve Depths
z Because
the final injection gas pressure is

not known until the installation is
designed, a pressure difference of 100 to
200 psi between the unloading PioD and
PpfD traverses is assumed for locating the
deepest valve depth.
2/9/2008
27

assumption of PioD-PpfD = 100 to 200
psi should ensure calculation of the
operating valve depth.
z The static bottomhole pressure, PwsD and
temperature, Twsd are usually referenced
to the same depth, which is the lower end
of the production conduit, Dd.
z The
2/9/2008
28

z Calculate
the maximum unloading GLR

based on the maximum injection gas rate
available for unloading and the maximum
daily design total fluid rate.
2/9/2008
29
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Well Information
Tubing size = 2 7/8 in. OD

Tubing Length, = 6000 ft.
Max. Valve Depth, Dv(max) = 5970 ft.
Static bottomhole pressure at Dd , Pwsd = 1800 psig at
6000ft.
Daily production rate = 800 STB/D
Water Cut = 50%
Formation GOR = 500 scf/STB
Oil Gravity = 35o API
Gas Gravity g = 0.65
Produced-water specific gravity, w= 1.08
Bottomhole temperature, Twsd=170oF at 6000ft.
Design unloading wellhead temperature, Twhf = 100oF.
Load-fluid pressure gradient, gls = 0.46 psi/ft.
U-Tubing wellhead pressure, Pwhu = 100 psig.
z Flowing
2/9/2008
wellhead pressure, Pwhf = 100 psig.
30
Well Information
Static fluid level = 0 ft.
z Surface kickoff injection-gas pressure, Pko = 1000 psig.
z Surface operating injection-gas pressure, Pio = 1000
psig.
z Maximum unloading injection-gas rate, qgiu = 800
Mscf/D.
z Operating daily injection-gas rate, qgi = 500 Mscf/D.
z Wellhead injection-gas temperature, Tgio = 100oF
z Assigned valve-spacing pressure differential at valve
depth, PsD = 50 psi.
z Test rack valve temperature, Tvo = 60oF.
z Assigned minimum decrease in surface operating
injection-gas pressure between valves, Pio = 20 psi.
z Minimum distance between valves, Dbv(min) = 150 ft.
Gas lift valves : 1.5 inch O.D. nitrogen charged with Ab =31
z
2/9/2008
0.77 in2, and sharp edged seat.
z

Step 1:
Calculate Maximum Unloading GLR
Rgiu =qgiu / qlt
Where
qgiu= maximum unloading injection rate,
Mscf/D,
qlt = total liquid daily production rate,
B/D, and
Rgiu = maximum unloading GLR, scf/STB
2/9/2008
32

Calculate Maximum Unloading GLR
Rgiu =qgiu / qlt
= 800,000 scf/D / 800 STB/D
Rgiu = 1000 scf/STB
2/9/2008
33
Step 2: Determine flowing Production

pressure, Ppfd at Dd
2/9/2008
34
Gradient Curve
2/9/2008
35
Step 3:Calculate the

unloading-flowingpressure-at-depth
gradient, gpfa above
point of gas injection,
gpf .
gpfa = 900-100 / 6000

gpfa = 0.1333 psi/ ft.
2/9/2008
36
Step 4
Calculate the operating injection gas pressure at the lower end of the
production conduit.
where:
z
Pio = injection-gas pressure at surface, psia
z
PioD = injection-gas pressure at depth, psia
z
e = Napierian logarithm base = 2.718.
z
g = gas specific gravity (air = 1.0), dimensionless.
z
D = true vertical depth of gas column, ft.
z
bar T = average gas column temperature, R
z
bar z = compressibility factor based on gas column average
pressure P and temperature, T, dimensionless.
2/9/2008
37

Step 4
PioD = 1154 psig at 6000 ft.

ggio = (1154 1000) / 6000 = .0257psi/ft
Since Piod - Ppfd = 1154 900 = 254 psi
Exceeds 200 psi, the maximum valve depth
of 5970 ft can be attained.
2/9/2008
38

Step 5:
Calculate the unloading gas lift valve
temperature at depth gradient, gTvu .
Bottomhole temperature,
Twsd =170oF at 6000ft.
Design unloading wellhead temperature,
Twhf = 100oF at surface.
gTvu = (170 100) / 6000 = 0.0117oF/ft.

2/9/2008
39
Step 6
Dv1 = depth of top valve, ft
Pko = surface kick-off or average field injection-gas pressure
(optional), psig
Pwhu = surface wellhead U-tubing (unloading) pressure, psig
PsD = assigned spacing pressure differential at valve depth, psi
where
gls
= static-load (kill) fluid pressure gradient, psi/ft
ggio = injection-gas pressure at depth gradient, psi/ft
Step 6:
2/9/2008
Dv1 =
Dv1 =
(1000 - 100 50) / (0.46 -.0257)

1957 ft.
40

Step 7
Calculate the minimum flowing-production
pressure, (PpfD1)min, the injection-gas
pressure, PioD1, and the unloading gas-lift
valve temperature, TvuD1, at the top valve
depth by multiplying the appropriate
gradient by the valve depth, Dv1, and
adding to the appropriate surface values
(where n = 1 for top valve):
2/9/2008
41

Step 7.
Calculate the minimum flowing-production
pressure, (PpfD1)min, injection-gas pressure,
PioD1, and the unloading flowing temperature,
TvuD1 at Dv1 of 1,957 ft as described on previous
slide:
z (PpfD1)min = 100 + 0.1333 (1,957) = 361 psig
z PioD1 = 1,000 + 0.0257 (1,957) = 1,050 psig
z TvuD1 = 100 + 0.0117 (1,957) = 123 F
2/9/2008
42
Step 8
Calculate the depth of the second gas-lift
valve, Dv2, where n = 2 on the basis of the
assigned minimum decrease in surface injectiongas pressure, pio, for spacing the gas-lift valves
and the PioD-traverse.
A valve spacing differential of around 20 to 30
psi will usually be sufficient for most 1.5-in. OD
gas-lift valves. However, 1-in. OD valves with
large ports may require a higher, pio. This can
be checked by calculating the additional
production-pressure effect, Ppe1, after the valve
depths are calculated for the assigned pio.
2/9/2008
43

Step 8
(PpfD(n-1))min+gls(Dbv)=[PioD(n-1)-(n-1)Pio]- PsD +ggio(Dbv)
Solve For Dbv:
Dbv = PioD(n-1) [(n-1)Pio]- (PpfD(n-1))min - PsD / (gls ggio

and
Dv(n) = Dv(n-1) + Dbv

The decrease in surface injection-gas pressure for
calculating Dv2 is Pio, and for Dv3 is 2 (Pio), and for Dv4
is 3 (Pio), and this procedure continues for each
succeeding lower valve.
2/9/2008
44

Step 8
Solve For Dbv:
Dbv = PioD(n-1) [(n-1)Pio]- (PpfD(n-1))min - PsD / (gls ggio
Dbv = 1050 - 0 - 361 50 / (0.46 0.0257) = 1472 ft.

and
Dv(2) = Dv(n-1) + Dbv

Dv(2) = 1957 + 1472 = 3429 ft.
Repeat steps 7 and 8 for each valve location until reaching
maximum depth
2/9/2008
45

z The
calculated valve spacing for the sixth

valve, Dv6 , would exceed the maximum
valve depth, Dv(max) , of 5,970 ft. Because
an orifice-check valve will be placed in the
bottom wireline-retrievable valve mandrel,
no test-rack valve setting information is
required. This completes the valve spacing
calculations.
2/9/2008
46

Graphical Representation
2/9/2008
47

Determination of Gas-Lift Valve Port Size and
Calculation of Test-Rack Opening Pressures.
The gas-lift valves port ID and test-rack opening
pressure calculations follow:
Step 1. Determine the port size required for the gas-lift
unloading valves and the operating orifice-check valve
orifice ID. The upstream injection-gas pressure, P1, is
based on PoD5 of the last unloading valve corrected to
the orifice-check valve depth of 5970 ft:
P1 = 1,068 + 0.0257 (5,970 5,762) = 1,073 psig at

5,970 ft
2/9/2008
48

Determination of Gas-Lift Valve Port Size
and Calculation of Test-Rack Opening
Pressures.
Step 1 (Continued)
z The downstream flowing-production pressure,
P2, is equal to the minimum flowing-production
pressure at 5,970 ft.
z P2 = 100 + 0.1333 (5,970) = 896 psig at 5,970
ft
z Pov = 1,073 896 = 177 psi across the orificecheck valve
2/9/2008
49

Step 1 (Continued)
From the Thornhill / Craver correlation, the required
equivalent orifice size is near 14/64-in.; therefore, the
next largest gas-lift valve port ID is 1/4-in. This size is
sufficient for all of the upper unloading valves because
they have a higher injection-gas operating pressure and
a greater differential pressure between PioD and
(PpfD)min.
An equivalent orifice size of 12/64-in. to 13/64-in. is
required to pass the operating injection-gas rate of 500
Mscf/D.
2/9/2008
50

Step2
Record the valve specifications for a l.5-in. OD
gas-lift valve having a 1/4-in. ID port with a
sharp-edged seat where Ab = 0.77 sq. in.
from table:
(Ap/Ab) = 0.064,
(1 Ap /Ab) = 0.936,
and Fp = 0.068.
2/9/2008
51

Step 3
Calculate PoD1
PoD1 = PioD1
where
PioD1 = injection-gas pressure at valve depth, psig
PoD1 = injection-gas initial gas-lift valve opening
pressure at valve depth, psig
PoD1 = 1,050 psig at 1,957 ft
2/9/2008
52

Step4
Calculate the test-rack set opening pressure of
the first valve (n = 1), Pvo1, using Eqs. 12.44
and 12.45 or 12.46:
PbvD(n) = PoD(n) (1-Ap/Ab)+ PpfD(n)min +(Ap/Ab)
Pvo(n) = CT(n) (PbvD(n)) / (1- Ap/Ab)
Pvo(n) = 1050 (0.936)+361 (0.064) = 1006 psig.
2/9/2008
53

Step 5
Pvo(n) = CT(n) (PbvD(n)) / (1- Ap/Ab)

for CT1 = 0.876 (Calculated using TvuD1 =
123oF):
Pvo1 = 0.876 (1006)/0.936 = 942 psig at 60 oF
Step 6
Calculate the injection-gas initial opening pressure

of the second gas-lift valve at depth (n = 2),
PoD(n) = PioD(n) (n-1) Pio
PoD(2) = 1088 20 = 1068 psig at 3429 ft.
2/9/2008
54

Step 7
Calculate the maximum flowing-production
pressure opposite top unloading valve
immediately after the point of gas injection has
transferred to the second (lower) valve,
(PpfD1)max. (PpfD1 )max is shown graphically in
Figure and can be calculated using the following
equation:
(PpfD1)max = Pwf + Dv1 [(PoD2 Pwhf )/Dv2]
(PpfD1)max = 100 + 1957 ((1068 -100)/3429)
(PpfD1)max = 652 psig at 1957 ft.
2/9/2008
55
2/9/2008
56

Step 8
Determine if the assumed decrease in surface injectiongas pressure, Pio, is sufficient for the required gas-lift
valve port size by calculating the additional productionpressure effect, Ppe1, at the top valve:
Ppe1 = Fp [(PD1D1)max - PD1D1)min ]
Ppe1 = 0.068 (652 = 361 = 20 psi.
If Ppe1 is less than or equal to the assumed Pio
proceed with the design. If Ppe1 is greater than the
assumed Pio, then set Pio = Ppe1 and redo the spacing
design. This is a conservative approach and many
operators use actual operating experience to determine
which Pio to use.
2/9/2008
57

z Repeat
Steps 6, 4 and 5 for remaining

gas-lift valves:
z An orifice-check valve is recommended for
the sixth valve at 5,962 ft. The orifice ID
should be 1/4-in. to pass sufficient gas to
gas lift the well. A tabulation form for
these calculations is given in table.
2/9/2008
58
2/9/2008
59
2/9/2008
60
High Rate Continuous-Flow Installation

Design ( Winkler)
The application of the injection-gas rate throughput
performance for injection-pressure-operated gas-lift valves is
illustrated in the high daily liquid rate continuous-flow
installation design. The importance of valve performance data
for high daily injection-gas rates is shown, and its
unimportance for low injection-gas rate installation designs is
illustrated. Valve performance data is of no value in selection of
the top two unloading gas-lift valves in this installation. For
these two upper valves, an assumed reasonable decrease in
the surface injection-gas pressure of 20 psi for each valve
ensures unloading the well and these upper valves remaining
closed while lifting from a lower valve. When the required daily
injection-gas rate increases for lifting from the third and fourth
gas-lift valves, valve performance information becomes very
important. A pressure vs. depth plot for this continuous-flow
installation
is shown in the Figure
61
2/9/2008

Design ( Winkler)
2/9/2008
62

Design (Winkler)
z
Although the flowing-production transfer pressure traverse

method for locating the depths of the valves may require an
additional valve, or valves, in some installations, this design
method has several advantages in wells requiring a high daily
injection-gas rate for unloading. Because the injection-gas
requirement to uncover the next lower valve is reduced, smaller
valve ports can be used and the increase in the injection-gas
pressure to stroke the valve stem is less. The unloading
operations are faster because of the lesser difference in
injection-gas requirement between unloading valves.
2/9/2008
63
High Rate Continuous-Flow

Installation Design ( Winkler)
z
The surface origin and final downhole

termination pressures for the flowing-production
transfer pressure traverse are arbitrary. The
20% in this example for locating the surface
transfer pressure traverse is widely used. The
unloading injection-gas requirements for
uncovering each lower valve increases as the
percentage decreases and decreases as the
percentages increase. The flowing-production
transfer pressure at datum depth should be at
least 100 to 200 psi less than the available
design operating injection-gas pressure at the
same depth
2/9/2008
64
Simplified Mathematical Gas-Lift Valve

Performance Model
Because performance equations for specific gas-lift
valves are not available from gas-lift valve
manufacturers, a simplified gas-lift valve
performance computer model was used to
illustrate the calculations in this paper. The
model is based on static force balance equations
and several simplifying assumptions. This
computer model describes qualitatively the
injection-gas rate throughput of unbalanced,
single-element gas-lift valves using the
Thornhill-Craver equation.
2/9/2008
65
High Rate Design Data
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Tubing size = 4-1/2-in. OD (ID = 3.958-in.) and Length = 6,000 ft

Casing size = 8-5/8-in. OD, 44 lb/ft (ID = 7.725-in.)
Datum depth for bottomhole pressures and temperature, Dd = 6,000 ft
Bottomhole temperature at Dd, Twsd = 170 oF
Shut-in (static) bottomhole pressure at Dd, Pwsd = 2,000 psig
Maximum depth for bottom valve, Dv(max) = 5,900 ft
Productivity index (gross liquid), PI = 6.3 BPD/psi
Oil gravity = 35 oAPI (o = 0.850)
Gas specific gravity (air = 1.0), g = 0.65
Water specific gravity, w = 1.08
Water fraction, fw = 0.50 (50%)
Formation gas/oil ratio, Rgo = 400 scf/STB
Formation gas/liquid ratio, Rglf = 200 scf/STB
Assigned minimum daily unloading production rate, qlu = 1,000 BPD
Design total (oil + water) daily production rate, qlt = 5,000 BPD
Wellhead U-tubing unloading pressure, Pwhu = 100 psig
Surface flowing wellhead pressure, Pwhf = 100 psig
Static load (kill) fluid pressure gradient, gls = 0.468 psi/ft
2/9/2008
66
High Rate Design Data (Continued)

z
z
z
z
z
z
z
z
z
z
z
z
Surface operating injection-gas pressure, Pio = 1,400 psig (at wellsite)

Assigned daily injection-gas rate, qgi = 2,000 Mscf/day
Unloading wellhead temperature, Twhu = 120oF (basis for calculation of
Pvo)
Wellhead injection-gas temperature, Tgio = 120oF
Surface kickoff injection-gas pressure, Pko = 1,400 psig (at wellsite)
Minimum assigned surface injection-gas pressure decrease between valves,
Pio = 20 psi (represents minimum surface injection-gas pressure increase
for stroking gas-lift valve)
Valve spacing design line percent factor at surface = 20% (fpt = 0.20)
Minimum transfer-production pressure difference (Piod Pptd) at Dd, Pptd =
200 psi
Valve spacing pressure differential at valve depth, PsD = 50 psi
Minimum distance between valves Dbv(min) = 400 ft
Gas-lift valve test-rack setting temperature, Tvo = 60 oF
Gas-lift valves: 1.5-in. OD wireline-retrievable, unbalanced, single-element,
nitrogen-charged bellows with Ab = 0.77 in.2, Blr = 600 psi/in., and square
sharp-edged seat.
2/9/2008
67
Valve Performance First Valve
2/9/2008
68
Valve Performance First Valve
2/9/2008
69
Winkler High Rate Gas Lift Design
2/9/2008
70
Continuous Flow Gas Lift Design

As Presented in
2007 SPE PRODUCTION
ENGINEERING HANDBOOK
2/9/2008
71

Diseño de Gas Lift

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Continuous Flow Gas Lift Design

Petroleum Engineering Handbook

Two Types of Continuous Flow

Design for Normal Wells.

Winkler Design for High gas Injection rates.

Iranian Gas Lift Well

Libyan Gas Lift Well

Production Manifold in Libya

Libyan Gas Lift Tests

API Design Technique

API Design Technique

installation design method is

Injection-Pressure Operated Gas Lift

Gas Lift Valve Specifications

API Design Technique

The effect of bellows-assembly load rate on the

API Design Technique

of a constant injection- gas

API Design Technique

additional tubing-effect pressure for

API Design Technique

or reopening of an injectionpressure-operated gas lift valve is partially

API Design Technique

flowing pressure at an unloadingvalve depth changes from the transfer

API Design Technique

additional tubing-effect pressure is

API Design Technique

the unloading gas lift valve depths

API Design Technique

increased stem travel, or stroke, is

API Design Technique

constant decrease in the operating

API Gas Lift Design

API Design Technique

the injection-gas pressure significantly

API Design Technique

The total decrease in the injection-gas pressure

API Design Technique

the final injection gas pressure is

API Design Technique

API Design Technique

the maximum unloading GLR

Tubing size = 2 7/8 in. OD

wellhead pressure, Pwhf = 100 psig.

API Design Technique

API Design Technique

API Design Technique

Step 2: Determine flowing Production

API Design Technique

Step 3:Calculate the

gpfa = 900-100 / 6000

API Design Technique

API Design Technique

PioD = 1154 psig at 6000 ft.

API Design Technique

gTvu = (170 100) / 6000 = 0.0117oF/ft.

API Design Technique

(1000 - 100 50) / (0.46 -.0257)

API Design Technique

API Design Technique

API Design Technique

API Design Technique