Gas Lift Design with Self-Well Gas for AZN-02

R&D Center, Tuha Oilfield Company

January 15, 2014

1. Technical principle
1.1 Technical principle
Gas lift with gas from self-well is a
development method used for a well with
independent 2 sets of oil and gas zones. As to
this technology, the external high pressure gas
source is not needed. The high pressure gas
zone is used for the production of other oil
zones. The high pressure gas from gas zone is
continuously injected into tubing with regulated
volume via gas lift valves, where the gas well
mixes with the well fluids to form mixed fluids.
By doing so, the well fluid density is decreased
and the purpose of gas lift oil production is
realized. This method can not only rationally
control the production of high pressure gas
zone, but also the purpose of producing from
the oil zones can be realized.
1.2 Techncial features
The oil production cost is lowered by using the produced gas from self-well
gas zone;
The injection volume of the gas zone produced gas is controlled by gas lift
valves and the inter-layer interference of gas and oil zones is avoided, therefore, the
commingled production of oil and gas is realized;
The independent oil production requirements is satisfied by forming the single
well production system.
1.3 Scope of applicaiton
The oil and gas are in different zones with stable barriers in between;
The gas zone pressure coefficient is larger than 0.9MPa/100m;
The gas zone gas production must satisfy the gas demand of oil well
production, i.e.5000m3/d;
The barrier thickness of oil and gas zones shall be larger than 5m.
2. Purpose and requirement of construction
The high pressure gas source from AG 2D-1 zone of Well AZN-02 is used for the
pilot test of gas lift with self-well gas and the crude oil in the three zones of AG-2D-3,
AG-2D-5, and AG-2F-1 will be lifted.
3. Basic data

3.1 Basic data

Tubulars
Conductor
Surface Casing
Intermediate Casing
Production Casing
Production Tubing

Size
N/A
244.5mm
N/A
177.8mm
88.9mm

Weight
N/A
59.5kg/m
N/A
43.0kg/m
13.84kg/m

Grade
N/A
K-55
N/A
K-55
J-55

Set at
N/A
1123
N/A
1700

Make

Size

WP

Stream Flo

52.38 mm

14 Mpa

Stream Flo

279.4 mm

21 Mpa

134628-15

Stream Flo

279X179 mm

21 Mpa

136991-07

Stream Flo

79.37 mm

21 Mpa

JMP

79.37 mm

21 Mpa

N/A

Stream Flo

52.38

21 Mpa

N/A

Stream Flo

52.38

21 Mpa

N/A

3.2 Wellhead data

Wellhead:
Casing Vent:
Casing Bowl:
Tubing Head:
Master Valve:
Wing Valve:
Casing Valve:
Casing Valve:

3.3 Existing string configuration

Serial Number
N/A

Fig. 2 String configuration of AZN-02

4. Optimization design
4.1 Basic data of gas lift well with gas from self-well
Table 4-1 Basic data of gas lift well AZN-02 with gas from self-well
Gas zone

AG-2D-1

Pay zone

AG-2D-3, AG-2D-5,
AG-2F-1

Perforation interval of gas zone

1672~1675

Mid-depth of oil zone(m)

1864

Mid-depth of gas zone (m)

1673.5

Temperature of oil zone()

83

Temperature of gas zone ()

73

Formation pressure (psi)

2000

Gas zone pressure (psi)

2183

Water cut (%)

40

Gas rateMMscf/d

Liquid production index (STB/d/psi)

Oil rateblpd

300~400

Saturation pressure (MPa)

Specific gravity of produced gas

0.734

Specific gravity of produced water

(m)

Casing size (mm)

177.8

Specific gravity of crude (g/cm )

0.822

Tubing size (mm)

89

Wellhead tubing pressure (MPa)

1.5

Production GOR (m3/m3)

4.2 Process design for gas lift production with gas from self-well
1Calculation of gas injection pressure and volume

Stock-tank liquid flowrate at outlet

Gas lift depth

Lift gas flowrate

Fig. 3 Gas injection volume and depth of gas lift production with gas from self-well

It is calculated that when gas injection pressure is 7MPa and gas injection rate is
28317m3/d1mmscf/d, the lift depth can be 1620m and the production capacity of
the well can be well performed. The pressure of gas source zone of AG-2D-1 is high
as 15.05 MPa (2183psi), which can fully satisfy the requirement of gas lift.
2Gas lift design

Fig. 4 Gas lift design

It is calculated that the liquid production rate of three horizons of AG-2D-3, AG-2D5, and AG-2F-1 is 850STB/d.
Table 4-2 Design production parameters
Projected oil rateSTB/d

510

Gas injection volume (mmscf/d

Projected liquid rateSTB/d

850

Gas injection depthm

1620

Water cut%

40

FBHPpsi

1105

Table 4-3 Design gas lift valve parameters

Stages

Model

Measured depth
m

Valve port size

mm

Opening pressure for

adjustment
psi/MPa

KFT-B-25.4

1620

4.8

870/6.05

Table 4-4 Technical parameters of matching tools

Description

Total

Max. ODmm Min. IDmm Connectio

lengthmm

Tools

n thread

quantityset

27/8EUE

KPX-127 gas lift mandrel

2000

127

60

KFT-B-25.4 gas lift valve

260

25.4

Y211-148 packer

1670

148

62

2 /8EUE

Bell mouth

165

78

50.6

2 /8EUE

KZF-94 landing nipple

327

94

56

27/8EUE

KHT-105 slickline sliding

1021

105

57

27/8EUE

sleeve
Cross over

27/8EUE conversion to 31/2EUE

5. Procedure of construction
5.1 Wellbore prepoaration

Gas injection depth

5.1.1 Release bridge plug, kill and flush well

5.1.4 Run drift gauge
Run 1501.8 2.0m drift size gauge tool to artificial well bottom or current
plug surface. Flush well reversely until the inlet and outlet liquids are identical. Pull
up the drifting string. During drifting, no exerting pressure abruptly. When obstruction
is encountered or the hanging weight changes, advise relevant parties timely. (Before
running drifting gauge, check its integrity and the velocity of running in string shall
be less than ). (While pulling up, infill liquid to maintain the liquid level
at wellhead)
5.1.5 Scraping and pressure test for tubing
Run in 7" casing scraper below the perforation interval and repeat scraping at
least 3 times in the Y211-148 packer location to guarantee the inner wall of casing
clean, burr-free and then pull up the scraping string.
5.2 Run in the gas lift completion string

Configure and run in string: run the gas lift string with gas from self-welll to the
design location as shown in Fig. 5. The string is composed of packer and gas lift
mandrels etc. From bottom to top are bell mouth+KZF landing nipple+Y211 pakcer+
KHT slickline operation sleeve+KPX gas lift mandrel.
(2) Measure the length of each tubing and completion tool to be run in hole (the error
shall be less than 1/1000) and record the data;
(3)Clean the dirt in tubing. When tubing is run, the 3 1/2heavy weight tubing shall be
drifted with 73mm0.5m gauge. When unqualified ones are found, replace in time;
(4) When string is connected, the arrow direction of side pocket mandrel (i.e. box
side) must be upward. The protection tape shall be taken off and gas lift valves shall
be installed in mandrels.
(5) When string is run, strictly prevent the adherence of foul or clay to avoid the
plugging of valve ports.
(6) When running in gas lift completion string as per the gas lift completion string
schematic (when tubing and tubing, tubing and completion tool are connected), PTFE
tape coated with sealing grease must be applied to the tubing threads and completion
tools. The threads shall be tightened to guarantee no leakage under the pressure of
35MPa; when string is run, the operation shall be stable, and no running and puling
violently. The net running time for joint shall be no less than 20s and the drillpipe net
running time shall be no less than 45s.
(7) Depth calibration and string adjustment: magnetic depth calibration shall be
conducted. The strings shall be adjusted as per the result of depth calibration to match
the design location. Ensure the accuracy of packer setting location.
(8) Set Y211: when the casing is fully filled, set Y211-148 packer. Pull up string by
1.0 1.2m, and record the maximum load. Slowly lower the string and the hanging
weight decreases 810 tons to set Y211-148 packer.
(9) Install wellhead according to the requirements. Well connect gas injection
pipelines, oil outlet pipeline and casing & tubing pressure gauges. Guarantee no
leakage and the integrity of gauges.
5.3 Induced flow commissioning
(1) Install the flowline and carry out commissioning with the format of open flow;
(2) If production cannot be achieved, commissioning shall be made by injecting N 2
produced from Nitrogen trailer into annulus and deliquification shall be conducted
from tubing;

6. Requirements of construction
Killing fluids shall be filled from casing in time during tripping and the liquid
level shall be maintained at wellhead.
All the tools to be run in hole shall be checked and made sure qualified by the

operation supervisor before their RIH.

6.1 Requirements of open flow commissioning
Before open flow, the tubing and casing flowline, wellhead separator, and
wellhead ignition system shall be installed. Based on the season wind direction of
local area, the open flow system shall be installed in the downwind side. The outlet
shall be more than 30m from wellhead. The surface flowline must be metal and
straight. The included angle must be larger than 120 and flowline shall be fastened
with ground anchor each 10-15m. No significant throttle shall occur to the flowline
and the flowline must be securely fastened.
6.2 Requirements to commissioning with N2 trailer
6.2.1 Before gas lift commissioning, the whole gas injection process shall be purged
with N2 to guarantee the gas injection pipeline clean and free from foreign matters;
the surface gas injection pipeline shall be tested with 25MPa pressure N 2 and no
leakage shall occur. When qualified, open the casing control valve to inject gas into
the casing and tubing annulus;
6.2.2 Control the flow rate of N 2 trailer and slowly control the gas lift gas into the oil
well. Initially, the gas injection rate shall be controlled so that the casing pressure
increases 2MPa each hour until the wellhead casing pressure increases to 3MPa;
6.2.3 Increase gas injection rate so that the casing pressure increases 4MPa per hour
till the gas lift valves start to injection gas;
6.2.4 After 12 hours of continuous deliquification, when the deliquification stabilizes
or the production is in stable condition, the N2 trailer can stop and the production will
convert to gas lift with gas from self-well. If the oil well cannot produce normally, the
n follow 6.2.5;
6.2.5 Vent the casing and tubing annulus till ignition can be made at the end of
flowline;
6.2.6 Close casing valve, stop open flow and convert to production with gas from selfwell;
Note:
1If the gas injection is too intense, the valves ports may be damaged.
2During unloading, wellhead back pressure shall be lowered as much as possible
to guarantee the smooth commissioning of gas lift well.

7. Requirements to well control

7.1 Determination of killing fluid density
The relevant downhole operation well control regulations of GREATER NILE
PETROLEUM OPERATING COMPANY shall be strictly followed.

7.2 Notice to risk of string tripping in and out

7.2.1 Before running in string, the wellbore preparation procedure including drifting,
scraping and flushing shall be well followed. The string with packer shall avoid
sticking and the damage to the rubber sleeve shall also be prevented;
7.2.2 Before running in hole, the respective tools and tubing shall be accurately
measured. The threads shall be cleaned with diesel and steel brush. The unqualified
tubing shall be picked out. The threads of tubing to be run in hole shall be applied
with sealing grease. The specified torque for tubing threads shall be applied with
hydraulic tongs to avoid bad sealing performance;
7.2.3 Connect the downhole tools such as packer. Back-up wrench shall be applied
during tightening to avoid the turning of string, which may lead to the setting of
packer mid-way. Lower the string at even speed. No running and puling violently. The
net running time for joint shall be no less than 20s and the drillpipe net running time
shall be no less than 45s. If obstruction is encountered, the pressure exerted shall not
exceed 30kN;
7.2.4 In order to guarantee the performance of tools to be run in hole, all the threads
of tools shall be applied with sealing tape and sealing grease.
7.3 Notice to commissioning risk
7.3.1 The gas injection rate shall be strictly controlled in accordance with the process
design. If the gas injection rate is too high, the valve ports will be damaged.
7.3.2 If the start pressure cannot satisfy the requirement of gas lift design, normal
unloading will not occur to the oil well. In such case, the wellhead back pressure shall
be lowered as much as possible to realize the smooth unloading and normal
production of gas lift wells.
7.3.3 During gas lift production, the wellhead casing pressure is about 1911psi. In
order to guarantee long-term safety production, pressure test shall be conducted
for the wellhead. The relevant standards for pressure testing of GREATER NILE
PETROLEUM OPERATING COMPANY shall be referred to. When result of
pressure test is qualified, the gas lift production with gas from self-well can be
conducted.
7.3.4 During gas lift production, the monitoring to the pressure of surface casing
and intermediate casing shall be well performed. If there is anomaly with the
pressure, report to the Operation Department shall be made immediately and
relevant operation shall be carried out by following the instruction from the
Operation Department.
7.4 Requirements to blow out prevention
7.4.1 Careful check shall be made to the wellhead blowout prevention facility to
guarantee they are in full function. The well site shall be furnished with high quality

killing fluids and equipments. The preparation for the installation of wellhead during
emergency shall be made. The wellhead shall be installed immediately once well kick
is discovered to carry out well killing operation. The well control measures shall be
strictly executed to strictly avoid environmental pollution.
7.4.2 The blowout prevention shall be able to seal the operation string of all sizes.
7.4.3 When continuous operation cannot be made to the well with natural flow
capacity, the wellhead facility shall be well installed to avoid blowout.
7.4.4 During tripping, the blowout prevention facility (such as tubing control valve
and tubing cocks etc.) capable of plugging tubing shall be prepared.
7.4.5 During tripping operation, if the wellbore fluids touch the string, the wellhead
blowout prevention facility shall be shut off under the premise of guaranteeing the
smooth operation of string and then the following step shall be adopted.
7.4.6 During tripping operation, the killing fluids in wellbore shall be maintained
permanently fully filled. Killing fluids shall be supplemented once for each tripping
of 10 20 pieces of tubing. Opening while blowout occurs is not allowed. The
blowout prevention facility shall be immediately shut off once the string is tripped
out.
7.5 Precautionary measures
7.5.1 The relevant norms and standards in terms of blowout prevention and pollution
prevention for oil well operation shall be strictly executed.
7.5.2 No smoking in the operation job site.
7.5.4 The pressure test of the pipeline must conform to the requirement of design.
7.5.5 Nitrogen purging must be carried out to the high pressure gas pipeline during
welding to guarantee the safety of welding operation.
7.5.6 After the high pressure pipeline is installed, air tightness test shall be made to
verify the leak points. Open the surface gas supply valves and slowly control the
pressure to 20MPa to check if there are leak points. If there are such points, vent the
pipeline, fasten connections and reliably seal; dedicated personnel shall be designated
to check the leak points. The irrelevant personnel shall stay 30m from the operation
site and no fire source shall be taken into the operation area.
7.5.7 The speed of tripping operation shall be controlled within 30 pieces per hour.
The blowout preventer shall be well installed. Once well kick or blowout occurs, swift
handling shall be made in accordance with the well control emergency procedure.
7.5.8 Before construction, the pressure test shall conform to the design requirement.
The overpressure operation shall be prohibited; during construction, the field
operators shall wear the personal protection equipment and shall stay out of the safety
distance from the high pressure zone.

7.5.9 The field operators shall pay high attention to safety and be aware of the escape
route.

31/2 tubing

KPX-127 gas lift mandrel 1620m

1672m
Gas zone
1675m

KHT-105 slickline operation sleeve 1680m

Y211-148 packer 1700m

Depth adjustable to casing collar size

1717m
Oil zone
2012m

KZF-94 landing nipple 1710m

Bell mouth 1720m

Fig.5 Completion string for gas lift well AZN-02 with gas from self-well