1.

INTRODUCTION
A subsurface hydraulic pump is a closely coupled reciprocating engine and pump. The unit is installed below the working fluid level in a well, high pressure power fluid is directed to the engine through one conduit and spent power fluid and well production are directed to the surface through another conduit. The high pressure power fluid causes the engine to reciprocate much like a steam engine except the power fluid is oil or water instead of steam. The pump, driven by the engine, pumps the fluid from the well-bore. The pump can be circulated out for repairs, thereby eliminating pulling unit operations. Some of its other advantages are: . has good flexibility on rates !. can handle deviated wells ". easily adapted to automation #. easy to add inhibitor $. is suitable for pumping heavy crudes %. one well or multiple well units are available &. simple well heads accommodate closely spaced wells, covered or cellered well heads and wells in visually sensitive areas. As shown in fig. 'engine end(, high pressure power fluid is directed to the top of the engine piston while exhausted power fluid from the lower side of the piston is directed to the relieved area of the engine valve where it is discharged. )hen the piston reaches the end of the down-stroke, the reduced diameter at the top of the valve rod allows high pressure fluid to enter under

the engine valve, as shown in fig.!. *ecause the valve has a large area at its top, it will move upwards. )ith the engine valve in the up position, as shown in fig. ", the flow paths to the piston are reversed. The pump, therefore, begins its up-stroke. )hen the piston reaches the end of the up-stroke, as shown in fig.#, the reduced diameter near the lower end of the valve rod connects the area under the valve to the discharge, or low pressure, side of the engine. )ith high pressure on the top of the valve and only exhaust pressure at the bottom, the valve will move to its down position and the cycle will be repeated. The pump end of the pump is shown making down-stroke in fig. $. This pump is double acting 'it pumps on the up and down-strokes(. The arrows show that the well fluid is entering on the left and filling the upper part of the cylinder while the well fluid below the piston is being discharged through the ball check valve at the lower right. The complete pump is shown in fig.%. +n the up-stroke well fluid enters the lower part of the cylinder while being discharged from the upper part of the cylinder. The purpose of the hollow lower rod is to balance the areas 'forces( on the up-stroke and the down-stroke. ,ost hydraulic pumps are installed as free pumps, i.e., they are free to be circulated in and out of the well, as the se-uence in fig. & illustrated. A complete hydraulic pumping system is shown in fig. .. /ower fluid pumping systems consists of: ( the tank at 'A( !( surface pumps '*( "( control manifolds '0( #( well heads '1( $( tubing arrangements '2(

fig. 1 engine end stroke

fig. 2 engine end of down

fig. 5 Pump end in down-stroke

fig 3 engine up-stroke upstroke

fig. 4 engine end of

fig. 6 complete pump

fig. 7 Free pump installation

fig. !omplete "#draulic pumping s#stem

THE POWER FLUID SYSTEMS

There are two basic types of power fluid systems: . The Closed Power Fluid '0/3( system where the surface and subsurface power fluid stays in a closed circuit and does not mix with the produced fluid. !. The O e! Power Fluid '+/3( system where the power fluid mixes with the production down hole and return to the surface as commingled power fluid and production.

The choice of oil or water for power fluid can be based on a number of factors. 3ollowing is a list of most of the factors involved in this choice: . water is preferred for safety and environmental reasons. !. for 0/3 installations the addition of chemicals to power water for lubrication and corrosion is not large factor 'fresh water is used(. ". for +/3 installations the addition of chemicals to power water can be a significant cost factor because the power water is commingled with production. This re-uires continual in4ection of chemicals which will add to the operating cost. #. treating power oil is seldom a large cost factor mainly because it seldom needs chemical additives for lubricity. +ne exception is when high gravity oils are used at very high bottom hole temperatures. $. maintenance on surface pumps is less when using oil because metal to metal plungers and liners are usually used instead of packing. Also, valves last longer and are usually the ball and seat type rather than the disc or poppet type normally used for water. Additionally, the low bulk modulus of water causes much larger pressure pulses than oil, and these pulses are detrimental to pipe connections and contributing to fatigue failures of pump components.

%. subsurface pumps are sensitive to viscosity and lubricating -ualities of the power fluid. *ecause water has practically no lubricating ability at bottom hole temperatures, it can, if not ade-uately treated, contribute to shorter pump life. 5eakage of power fluid past the various sliding fits in the pump is a function of the viscosity and is greater with water than with most crude oils. &. testing a well for production is sub4ected to an added source of error when oil is used for power fluid. The power oil must be metered in and small errors in metering can be significant when the ratio of power oil to produced oil is large, as when the well is producing a large percentage of water. .. usually, the surface pressure re-uired will be less when using power water as compared to using power oil. 6. although hydraulic pumps handle viscous crudes very well, it has sometimes served other purposes to use a higher gravity oil for power fluid and use the +/3 system. This commingles the two crudes at the discharge of the pump, thus diluting the heavy oil for ease in transporting it at the surface.

2.1 CPF S"s#e$

7n the 0/3 system, an extra down hole conduit must be provided for returning the spent power fluid to the surface. Thus, the system is more expensive than the +/3 system, so its use is not widespread. *ecause the power fluid tanks are relatively small, this system is popular for urban locations and offshore platforms where surface space is at a premium. 3re-uently, 0/3 systems use water for the power fluid because: . it is less ha8ardous and

!. it presents fewer ecological problems than higher pressure oil. )ater, however, should have: . a lubricant added. !. should be inhibited against corrosion. ". all oxygen removed. 2.1.1 Power Fluid $ank %!PF& 7n most down hole pumps, the pump end is lubricated with the power fluid and part of the power fluid is purposely 9leaked: to the production. This loss of power fluid must be replaced with clean fluid. The power fluid tank in fig. 6 remove abrasive particles form the make up fluid and part of the re-circulated fluid. +ne misconception concerning the 0/3 system is that the power fluid will remain clean because it has no source for contamination. 7n actual practice, three factors are constantly working together to corrupt this theory: . the power fluid tank does not completely remove all of the solid particles from the make up fluid ; cleanliness is relatively, not absolute. !. the power fluid is not completely non-corrosive. Again, this factor is relative, not absolute, and the products of corrosion are generally abrasive solids. ". when fluid containing solids, even a very small percentage of solids, is leak through a long closely fitted clearance space, as in a down hole pump, the solids tend to be held back. This means that the fluid emerging from the fit is cleaner than the fluid trying to enter the fit. The tendency, then, is for the power fluid circuit. To lose clean fluid and to retain the solid particles.

fig.' surface facilities for a closed power fluid %!PF& s#stem +ver a period of time these three factors allow the power fluid in the closed circuit to become 9dirtier: than the fluid emerging or the fluid entering the closed circuit, unless a part of the re-circulated power fluid is continually cleaned by the power fluid settling tank 'fig. (. This 9continuous cleaning of part of the re-circulating power fluid: is an important feature in the design of the 0/3 system. )hen water is used for power fluid, filters may be used instead of settling tanks for the cleaning process. These filters should remove particles down to < microns.

2.2 OPF S"s#e$ 7n the +/3 system only two down hole paths are needed: one for conducting power fluid to the engine and one for conducting spent power fluid plus production to the surface. These conduits can be two strings of tubing or tubing string and the tubing=casing annulus. The bold lines on fig. < show the surface facilities for an +/3 system with two wells. 0entral plant of this type can be used for any number of wells. >sually, the triplex pump and control manifold are located at the central tank battery, but control manifold can be located at satellite locations. 2ven triplex pumps can be located at satellite locations if a small pump is used at the battery to get the fluid to the suction of the triplex pump. 2.2.1 Power Fluid $ank %(PF& +il generally enters the gas boot in surges and contains gas not removed in the treater. The gas boot removes the last remnants of the gas which would otherwise keep the tank stirred up. The top section of the boot should be "% in. to be effective and, even with this diameter, surges fre-uently occur that cause the oil to be carried over the top through the gas line. 1ied oil 'gas free( then enters the bottom of the tank which should have a level spreader. The oil entering her is power oil plus production. At the vertical mid-point, production is drawn off through the outside riser that keeps the tank full. 3rom the mid point up, the power oil settling process takes place. The light solids settled out are carried with the production to stock, while the heavier particles are settled to bottom and must be removed periodically.

fig.1) *urface facilities for an open power fluid %(PF& s#stem

fig. 11 sc"ematic of (PF power fluid tank

INDI&IDU'L WELL SITE POWER PL'NT

A well site power plant is a package of components, installed at or

near a well site, that accomplishes the functions normally performed by a central plant. The basic components consist of: a( a li-uid gas separator b( centrifugal separators for removing solids from the power fluid. c( and a surface pump. These units have the advantages of: . portable ". flexible !. simple #. compact

They are always used with an +/3 tubing arrangement, but they have one feature similar to a 0/3 system. The net production from the well goes into the flow line while the power fluid is re-circulated at the well site. This feature simplifies well testing and does not increase the load on the treating system at the tank battery. ?enerally, there will be a choice of either a central system or an individual will site system. Some choices are obvious, such as: . a central system for an offshore platform !. any cluster of wells, such as in a downtown area or island constructed for that purpose. 3or that wells that are isolated or on wide spacing, the individual well site system will probably be preferred. The following flow schematics 'fig.@s !, " and #( show models of Aobe 'solo unit(, fluid packed '>nidraulic( and Bohnson-3agg '2conodraulic( well site power plants. These units must: . provide gas free fluid to the surface pump. !. provide means to choose oil or water for the power fluid.

". remove the solids from the power fluid. #. provide surge and reserve capacity for circulating a subsurface pump to the surface after a pump failure.

fig. 12 +o,e solo unit Cemoving solids from the power fluid is usually accomplished by cyclone centrifugal separators, fig $. These cyclones re-uire "<-%< psi pressure drop from inlet 'feed( to top outlet 'overflow(. The ratio of overflow to underflow out the apex of the cone is controlled by the relationship of overflow pressure to underflow pressure. >sually the overflow pressure must be $- < psi greater than the underflow to insure a

positive rather than a negative underflow rate. The cyclone internals, feed no88le, vortex feeder and apex can be si8ed to accommodate various rates of flow.

fig. 13 sc"ematic diagram unidraulic s#stem

fig. 14 -conodraulic fluid flow s#stem

fig. 15 !#clone centrifugal separator

SURF'CE PUMPS
the surface pumps commonly used are designed specifically for power

fluid service and are supplied by the down hole hydraulic pump manufacturers. 3or high pressure clean oil services these pumps usually use metal to metal plungers and liners, and ball type valves-components which re-uire little or no maintenance. 3or water services, plungers and liners with packing are usually used. ,ost surface pumps are skid mounted with electric motors or gas engines. The discharge lines from the relief valve and back pressure control valve should not be connected directly to the suction line of the pump but should be connected to a separate line going back to the tank. The reason for this is that when oil, even dead oil, is suddenly taken from high pressure to low pressure, some gas will flash out of solution. This gas will cause a loss of volumetric efficiency if allowed to enter the pump. A pulsation dampener may be re-uired in some cases. The pulsations will be pronounced with water. 3or long suction lines an accumulation chamber may be re-uired to prevent separating the li-uid into slugs. A cross-section of a triplex pump is shown in fig. %.

fig.16 cross-section of surface pump

CONTROL M'NIFOLDS
/ower fluid distribution manifolds, used at central plants, are supplied

).1 M*!i+olds by the down hole pump manufacturers and are made in modular header sections that can be added to or subtracted from the manifold easily. These manifolds usually contain pilot-operated control valves that keep the volume of power fluid going to each well constant, regardless of pressure changes in the system. A pressure controller 'back pressure regulator( is also used to maintain a constant pressure on the surface pump. Additionally, high pressure meters and gauges are included for each well. The following summari8e the purpose of these manifolds: . distribute the flow of power fluid to the individual wells !. regulate the flow rate to individual wells

". provide a means of metering the flow to each individual well #. provide a means of measuring pressure to each individual well $. provide a means for running soluble plugs in surface lines %. provide a manual or automatic valve to control manifold pressure by by-passing excess power fluid ?enerally, << to "<< psi. more fluid pressure is brought to the manifold than goes to the wells. ).2 Co!s#*!# +low ,o!#rol -*l-es constant flow valves used in these manifolds work on the principle of a constant pressure drop across the main control valve as shown in fig. &. A spring=diaphragm=pilot valve combination maintains the constant pressure differential across the main valve regardless of changes in the upstream and downstream pressures.

WELL HE'DS
. direct the power fluid down the tubing for 9pump in and operate:. !. direct the power fluid down the proper conduit for 9pump out:. ". shut power fluid line and provide a means to bleed pressure from the tubing. #. catch and hold the pump. $. be a safety device to prevent high pressure from accidentally being applied to the casing.

The well head for a free pump should provide the following functions:

TU0IN1 'RR'N1EMENTS
)hen the pump is screwed onto the power tubing and lowered into the

well by that tubing, it is called a fixed type pump. )hen the pump fits inside the power tubing and is free to be circulated to bottom and back out again,

fig.17 constant flow control .al.e it is called a free pump. 2ither type can be a 0/3 or +/3 system. Dydraulic pumps are particularly suitable for: . deep wells !. directionally drilled wells ". multiple completed wells #. offshore platform wells

/.1 Fi2ed i!ser# 3ixed inserts is the name applied to the tubing arrangement shown in fig. .. in this arrangement gas is vented through the casing. /.2 Fi2ed ,*si!3 3ixed casing is the name applied to the arrangement shown in fig. 6, where the casing is used for one of the flow paths. 7n this arrangement, the gas must be handled by the pump. 7nstallations of this type generally use large pumps. Sometimes a separate tubing string is used to vent the gas from beneath the packer, as shown in fig. !<. Eenting is necessary for wells producing below the bubble point with high gas-li-uid ratios. /.% P*r*llel +ree /arallel free installations are shown in fig. ! , !! and !". The pump in fig. !" is unseated through the power return tubing, hence it is referred to as power return unseat '/C>(. The pump in fig. ! and !! are the conventional production unseat type gas is vented through the casing in these arrangements. /.( C*si!3 +ree 0asing installations are shown in figs. !#, !$, !% and !&. 3ig. !$ is sometimes used instead of fig. ! to reduce friction, since the return column is the large annular flow area. All of the gas must be handled by the pumps in figs. !#, !% and !&. ,ore hydraulic pumps are installed, as shown in fig. !#, than any other type of installation because it is the lowest-cost type.

 )hen venting of gas is necessary, figs. ! and !! are the most popular installations. 3or large production rates in small casing, fig. 6 is the most popular.

fig.1 Fi/ed 0nsert $u,ing 1rrangement %(PF&

fig.1' Fi/ed !asing $u,ing 1rrangement

fig. 2) Fi/ed !asing 2it" 3as 4ent %(PF& 1rrangements

fig.21 Parallel Free $u,ing

fig. 22 Parallel Free $u,ing 1rrangement

fig.23 Parallel Free $u,ing 1rrangement

fig. 24 !asing Free $u,ing 1rrangement

fig. 25 !asing Free $u,ing 1rrangement

fig. 26 !asing Free $u,ing 1rrangements /.) O#her Tu4i!3 'rr*!3e$e!#s 7.5.1 5e.erse !irculation

fig. 27 !asing Free $u,ing 1rrangements

3ig. !. shows the reverse circulation system where power fluid is directed down the small string and production up the large string. This system allows the largest flow rate, power fluid plus production, to use the largest tubing string to reduce the overall fluid friction in the system. The pump re-uires an automatic latching device to hold it down during the pumping operation and re-uires a releasing tool to be dropped before the pump can be pumped to the surface. 7.5.2 6ual 2ells when two 8ones have different reservoir pressures, it is not practical to allow to allow communication between them because the higher pressure 8one will flow into the lower pressure 8one . There are many variations possible for dual wells. Two separate power fluid tubes are almost always used because the separate 8ones will undoubtedly re-uire different surface operating pressures. 7f only one tube were to feed two pumps, speed control would be hopeless. +ne possible tubing arrangement is shown in fig. !6. 7.5.3 $andem Pump when the well capacity re-uirements exceeds what can be produced by a single pump, it is possible to install two pumps in parallel or tandem to double the displacement of the downhole e-uipment. The pumps are physically connected to form a single unit, but each pump is free to run independently. 3ig. !6 is a method of installing two pumps in a single 8one well to double the capability of the e-uipment.

7.5.4 *afet# 4al.es +ffshore wells and urban town-site wells usually re-uire subsurface safety valves in the tubing. These valves re-uire an auxiliary pressure source to keep them open. 7f disaster strikes and the well head is broken off or damaged these valves, set some distance down the tubing, close and keep the well under control. 3ig. " shows such a valve set between the packer and a hydraulic pump. The actuating pressure is obtained from the high pressure

fig. 2 5e.erse circulation tu,ing arrangement

fig. 2' 6ual 2ell $u,ing 1rrangement

fig. 3) $andem Pump

power fluid. 7f disaster strikes at the surface, the power fluid pressure will be released and the safety valve will shut in the tubing and the casing as well.

fig. 31 *afet# 4al.e 1rrangement

DESI1N CONSIDER'TIONS 'ND C'LCUL'TIONS

)hen designing a hydraulic pumping installation the following

decisions must be made: . decide on an +/3 or a 0/3 system. !. decide whether to vent the gas or to pump the gas ". choose a down hole tubing arrangement. #. choose a pump to fit the tubing and the well re-uirements. $. choose a central or a well site power plant. %. choose a surface pump. &. design the power fluid cleaning system. 5.1 OPF or CPF 7f surface space at the battery is limited, as in a town-site location or on an offshore platform, or if ecological factors are important, choose a closed system. >sing water will minimi8e the ha8ard of leaks causing ecological and fire problems but will cause the surface pump to be more expensive and will re-uire considerable operating expense for additives 'lubricant and oxygen scavenger( to the power water. 7f none of these factors are compelling, then choose an open power fluid system '+/3(. +il should generally be chosen because the chemical additives for water are lost in the open power fluid system and re-uire continuous in4ection.

5.2 &e!# 3*s or u$ 3*s The lowest-cost installations are those that don@t vent the gas 'figs. 6, !#, !%, !&( but these installations are undesirable in wells that have both low producing bottom hole pressures and high gas-oil ratios. >sually an installation that vents the gas 'figs. ., !<, ! , !!, !" and !$( is a necessity when the gas-li-uid ratio is over $<< S03=b and the pumping bottom hole pressure is lower than #<< psi. Eent the gas to obtain greater efficiency values. A hydraulic pump is well suited to pump the gas without gas locking problems, but the efficiency is much better if the gas can be vented. .2.1 4enting 3as 7nstallation that vents the gas are shown in figs. ., !<, ! , !!, !", !$ and !.. 7f friction in the return tubing were too great for the simple parallel free 'fig. ! (, then the casing free with gas vent 'fig. !%(, the reverse circulation 'fig. !.(, or the fixed casing with gas vent 'fig. !<( could be used. >sually more gas will be vented through the casing than through a tubing vent, but usually favor the tubing vent type of installation. .2.2 Pumping 3as for installations that re-uire the pump to compress free gas, fig. "! gives the theoretical li-uid pump and displacements at different gas-oil ratios and bottom hole pressures. 7f the indicated displacement is low '"<#<F(, the gas should be vented instead of pumped. At this point the 7/C curve for the well should be consulted to determine if a higher bottom hole pressure can be allowed. 7f the well is being produced the bubble point,

Eogel@s reference curve 'fig. ""( for solution gas drive well@s is used in calculations.

fig. 32 $"eoretical 4olumetric -fficiencies (f !asing Pumps

fig. 33 4ogel7s 5eference !ur.e

5.% Pu$ s The schematic drawings in appendix A show each pump making an upstroke in an +/3 casing free installation. Some of the pumps have two engine pistons and some have two pump pistons. 2ngine reversing valves are located at the top of some pumps, in the middle of some pumps, and in the engine piston of other pumps. .3.1 Pump *election 7n many cases the proper pump for a given well can be chosen directly from the specification tables. The first column lists the pump si8e, which also identifies the tubing si8e that it will run in. The second column lists values for -uantity called /=2 these values are related to the surface pressure re-uired for a given lift. To limit surface pressure to the generally acceptable maximum of $<<< psi, use the following rule of thumb e-uation: <<<< ,aximum /=2 G Het 5ift, ft The third column of the specification table lists the maximum pump displacement. 7t is good practice to design for .$F or less of the pump@s maximum rated capacity. >sually when two or more pump si8es can be used, the one with the greatest maximum fluid lift capability 'lowest /=2 value( will be chosen. This is because it will re-uire less surface power fluid pressure to operate. This will be easier on the surface pump and will have less high pressure power fluid slippage in the bottom hole pump itself.

The power fluid rate re-uired to produce a given amount of production depends on the values in columns four and five of the pump specification tables. .3.2 Power Fluid 5ate /ower fluid rate is a function of: /ump end efficiency. 2ngine end efficiency. The displacement per S/, from the specification tables. The following symbols will be used: - G engine end displacement per S/,, b=d per S/, I@ G theoretical power fluid rate, b=d'- x S/, ( I G actual power fluid rate, b=d -# G pump end displacement per S/,, b=d per S/, I@# G theoretical production rate, b=d '-# x S/,( I# G actual production rate, b=d 'I# G I$ J I%( I$ G oil production rate, b=d I% G water production rate, b=d I@ =I G engine end efficiency I#=I@# G pump end efficiency The values for - and -# are obtained from columns four and five of the pump specification tables. A new pump has an engine end efficiency around 6$F and a pump end efficiency above 6<F. ?ood design practice is to use 6<F engine end and .$F pump end efficiencies and to select a pump that will operate below .$F of its rated speed.

7f the pump is pumping from beneath a packer and conse-uently handling gas, the pump end efficiency should be obtained from fig. "!. The above definitions can be written:

I# G I@# 'I# = I@#( G '-# x S/,('I# = I@#(

I@ I G I@ = I O-er*ll -olu$e#ri, e++i,ie!,"6 N7 89 : %pump end efficienc#& / %engine end efficienc#& GI#=I@# x I@ =I G I#=I x I@ =I@# G I#=I x -#=.3.3 Pump Friction The pressure re-uired to operate a hydraulic pump under 9no load: conditions is shown in fig. "#. This chart represent the mechanical and hydraulic friction in the pump. 3rom the curves in figs. "$ and "%, the power fluid viscosity at the bottom hole temperature can be obtained to use with the pump friction chart. The values obtained from fig. "# show maximum values based on the largest pump piston operating at << F pump end efficiency. )hen the fluid rate through the pump end is reduced by smaller piston or by gas, the total friction will be somewhat lower than the chart predicts. This is because approximately !$F of the total friction is fluid friction in the pump end of the pump. 7n e-uation form the K/ from fig. "# is: K/ G 322 J 3/2 where : G I@ = I - x S/,

322 G engine end friction G <.&$ K/ 3/2 G pump end friction G <.!$ K/

fig. 34 Pressure 5e;uired $o (perate 1 <#draulic Pump =nder 8o >oad !onditions

fig. 35 Power Fluid 4iscosit# 1t ?ottom <ole $emperature

fig. 36 Power Fluid %2ater&4iscosit# at ?ottom <ole $emperature

fig. 37 Pressure and Friction >osses 1ffecting <#draulic Pumps

.3.4 *urface Pressure !alculations

The various pressures, friction losses, and fluid densities involved in 0/3 and +/3 systems are shown in fig. "&. / G the total pressure available to drive the engine /! G the total pressure the engine must discharge against. /" G the pressure against which the pump end must discharge /# G the pressure by which the pump end being filled. 3ig. ". illustrate those cross section areas of the Aobe A pump which are involved with the various pressures. To find /s we must first find S/,, 3p, I , 3 'and 3! for the 0/3 system(, ?" and 3". the procedure in detail is: . from I#, pump end efficiency, and pump displacement 'from specification tables, b=d per S/,( calculate S/, using e-uation: I# G I@# 'I#=I@# ( G '-# x S/,( ' I# = I@# ( !. follow the procedure in section .."." to find 3p. 'use viscosity at bottom hole temperature from figs. "% or "&. specific gravity from table ". from S/,, engine end efficiency and engine displacement 'b=d per S/,( calculate I using e-uation:

I@ I G I@ = I
#.

- x S/, G I@ = I

using the tubing friction charts of appendix figs. * to !&* and I , and 3 and 3!. use average temperature of column for determining viscosity.

$. 0alculate ?" using:

I ? J I$?$ J I% ?% ?" G I J I# )here: I# G I$ ' oil production ( J I% ' water production ( %. >sing the tubing friction charts of figs. * through !&* and I# '0/3( or I" '+/3( and 3", where the specific gravity of I" is obtained by dividing ?" by <.#"". The viscosity is obtained by:

I L J I$ L$ J I% L% L" G
I J I# &. substituting in the following e-uations and solve for /s: / ; /! ; '/" ; /#(/=2 ; 3p G < / ; /" ; '/" ; /#( /=2 ; 3p G <

fig. 3 pressure acting on a +o,e t#pe 1 pump

.3.5 <orsepower calculations A useful oil field hydraulic horsepower e-uation is: Dorsepower G K/ x I x .& x <-$ )here: K/ G change in pressure, psi I G li-uid rate, b=d This e-uation can be used for surface horsepower and for work done by the pump end of the down hole pump.

DESI1N OF COMPLETE SYSTEM

this procedure serves as a guide to select a pump and determine the

8.1 Pro,edure For The Desi3! O+ E9ui $e!# For O!e Well surface pressure needed for one well. . determine the re-uired flowing pressure for the desired rate. !. decide upon the type of installation and whether or not to vent the gas. ". find the pump displacement to produce the desired rate. 'find the fluid displacement factor and use a pump efficiency of about .< F(. #. select a tentative pump to handle the re-uired displacement. Hormally we try to select a pump such that the desired displacement rate is no greater than .$ F of the maximum pump capacity. $. check the re-uired pump speed. %. determine the power oil re-uirements assuming an engine volumetric efficiency of .< F.

&. determine the total volume of return fluid and the pressure exerted by the return fluid column. .. determine the friction loss of power fluid going downwards. 6. determine pressure loss due to friction for return fluid. <.find total return fluid pressure. .find effective pressure of column of power oil. !.determine pump friction. ".determine surface operating pressure of power oil. #.select an appropriate triplex pump.

1: URF'CE TROU0LESHOOTIN1 1UIDE

the following listing will serve as a guide for analy8ing and troubleshooting the subsurface pumping unit.

INDIC'TION
( Sudden increase in the operating pressure ; pump stroking

C'USE
a( 5owered fluid level which causes more net left. b( /araffin build-up or obstruction in power oil line, flow lone or valve. c( /umping heavy material, such as salt water or mud. d( /ump beginning to fail. a( ?radually lowering fluid level. Standing valve or formation plugging up b( Slow build ; up of paraffin. c( 7ncreasing water production

REMEDY
7f necessary, slow pump down. Cun soluble plug, hot oil or remove obstruction. Aeep pump stroking ; don@t shut down. Cetrieve pump and repair. Surface pump and check. Cetrieve standing valve. Cun soluble plug or hot oil Caise pump S/, and watch pressure. Alternately increase and decrease pressure. 7f necessary, unseat and reseat pump. 7f this fails to start pump, surface and repair. Caise setting on relief valve. 0heck power oil supply. 5ocate and correct.

!( ?radual increase in operating pressure ; pump stroking

a( /ump stuck or stalled "( sudden increase b( Sudden change in well conditions in operating pressure ; pump not re-uiring operating pressure in excess of triplex relief valve setting. stroking c( Sudden change in power oilemulsion, etc. d( 0losed valve or obstruction in production line #( sudden decrease a( Caising fluid level ; pump in operating efficiency up. pressure ; pump b( 3ailure of pump so that part of stroking. power oil is bypassed ' Speed could be c( ?as passing through pump.

Surface pump and repair.

INDIC'TION

C'USE
d( Tubular failure ; downhole or in surface power oil lone. Speed reduced e( *roken plunger rod. 7ncreased speed f( Seal sleeve in bottom hole assembly washed or failed. Speed reduced a( /ump not on seat. b( 3ailure of production unit or pump seat. c( *ad leak in power oil tubing string.

REMEDY
0heck tubular Surface pump and repair /ull tubing and repair bottom hole assembly. 0irculate pump back on seat Surface pump and repair 0heck tubing and pull and repair if leak 5ocate and repair 0heck volume of fluid discharged from triplex. Ealve failure, plugged supply line, lower power oil supply, excess bypassing, etc., all of which could reduce available volume. Surface pump and repair 0heck gas vent system 1ecrease pump speed 5ocate and repair Surface pump and check. Cetrieve standing valve. Test to determine best operating speed Surface pump and repair

increased or reduced (

$( sudden decrease d( *ad leak in surface power oil line. in operating pressure ; pump not stroking. e( Hot enough power oil supply at manifold.

%( drop in production ; pump speed constant

a( 3ailure of pump end of production unit b( 5eak in gas vent tubing string c( )ell pumped ; off pump speeded up d( 5eak in production return line e( 0hange in well conditions f( /ump or standing valve plugging g( /ump handling free gas

&( gradual or sudden increase in power oil re-uired to maintain pump speed. 5ow engine efficiency

a( 2ngine wear b( 5eak in tubulars ; power oil tubing, bottom hole assembly, seals or power oil line.

5ocate and repair

INDIC'TION

C'USE

REMEDY
Surface pump and repair

.( erratic stroking at a( 0aused by failure or plugging of widely varying engine pressures a( )ell pumped off ; pump speeded up.

1ecrease pump speed. 0onsider changing to smaller pump end Surface pump and up. 6( stroke 9downb( /ump intake or downhole e-uipment 7f in down-hole e-uipment, kicking: instead of plugged. pull standing valve and 9up ; kicking: back flush well. c( /ump failure 'balls and seats(. Surface pump and repair. Cecheck meters. d( 7naccurate meters or measurement. Cepair if necessary. a( System not full of oil when pump 0ontinue pumping to fill up was started due to water in annulus > ; system. /ull standing valve. tubing after circulating, well flowing or 7f pump surfacing is slow standing valve leaking. and cups look good. Cecheck meters. <( apparent loss of, b( 7naccurate meters or measurement. Cepair if necessary. or unable to account for, system fluid. c( 5eaking valve, power oil or 5ocate and repair production line or packer. d( Affect of gas on production 7mprove gas separation metering. e( pump not deep enough. 5ower pump. ( well not Surface unit and repair. producing ; a( 2ngine plugging, flow line plugging, 5ocate restriction in flow 'a( pressure broken engine rod, suction plugged. line. increase, /ull standing valve. stroking. 'b( pressure b( Standing valve leaking. /ull standing valve. loss, Tubular leaking. 0heck tubulars. stroking.

11 'D&'NT'1ES 'ND DIS'D&'NT'1ES

11.1 'd-*!#*3es . depth is not a limiting factor. ,any installations are below !,<<< ft producing rates of $< ; "<< b=d. !. the speed and si8e of the pump can be easily changed to keep up with well conditions. ". highly viscous and heavy crudes benefit from mixing with a lighter power oil. #. the pump may be circulated to the surface without pulling the tubing. 7nspection, service, and replacement costs are usually low. $. a central station at the surface may handle a number of wells. This allows the wellsite landscaping or camouflage. Also, corrosion can be minimi8ed in a closed system if the oxygen is less than $< b=d. %. modern day one-well units offer a compact unit for isolated wells. 11.2 Dis*d-*!#*3es . initial capital cost is high. Digh pressure e-uipment, power fluid lines, and wellheads are re-uired. 3acilities must be provided to filter, clean and treat the power fluid. Tubulars must be of sufficient si8e and must be of high pressure tight. !. corrosion and abrasives will reduce operating life due to close tolerances on the surface and downhole e-uipment. ". for power oil systems the volume re-uired may become highly expensive at today@s crude prices and especially so if power fluid losses are ma4or.

#. since this is usually a high pressure operation, maintenance costs for surface e-uipment may be -uite high. $. high temperatures can cause the packing cups to fail, thereby preventing ease of pumping out the pump for repairs. %. it needs well ; trained people to operate efficiently. &. fire ha8ard for gas engine operation ; if there is a high pressure leak in the power pump, a fire could burn up the whole installation including power oil and stock tanks. .. well testing in central systems is a problem if wells make water. 3or accurate well tests, only one well at a time can be operated without special metering, manifolding and test e-uipment, which ups the initial cost. 6. corrosive production, in pumps set on packers, fixed or free , there is no means of treating the pump end for corrosion inhibition. An exception is when a vent string is installed and a chemical can be put down the vent string to treat the pump end. 7nhibitor is power fluid only protects the engine and tubing.

12 REFERENCES
. 9$"e $ec"nolog# (f 1rtificial >ift @et"ods: Eol. !b.

!. APetroleum -ngineering <and,ookB third printing, S/2.