G19PA

Production Technology-1 Tutorials

Chapter 4 Selection and Design

of Artificial Lift

Heriot-Watt University

Edinburgh EH14 4AS, United Kingdom

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 2

CONTENTS

PART1 ARTIFICIAL LIFT SELECTION CRITERIA

PART2 SIMPLIFIED ELECTRIC SUBMERSIBLE PUMP DESIGN

PART3 ARTIFICIAL LIFT TUTORIALS

PART4 GAS LIFT DESIGN

Produced by Heriot-Watt University, 2015

Copyright 2015 Heriot-Watt University

All rights reserved. No part of this publication may be reproduced, stored

in a retrieval system or transmitted in any form or by any means without
express permission from the publisher.

This material is prepared to support the degree program in Petroleum

Engineering.

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 3

1 ARTIFICIAL LIFT SELECTION

The well's Inflow Performance Relationship (IPR) will determine the economic benefit
from installing artificial lift. A straight line IPR, associated with a dead oil, is more
favourable than the curved Vogel relationship observed when the FBHP is below the
fluids bubble point. The following example illustrates the IPR's impact on the
production increase when the flowing bottomhole pressure decreases.

A straight line IPR case

Liquid production rate at flowing bottomhole pressure of 500 psi = 780 BFPD
Liquid production rate at flowing bottomhole pressure of 3000 psi = 200 BFPD
Increase in liquid production rate by changing flowing bottomhole pressure
780200
from 3000 psi to 500 psi = = 2.9 = 290 %
200

Vogel type inflow relationship

Liquid production rate at flowing bottomhole pressure of 500 psi = 460 BPD
Liquid production rate at flowing bottomhole pressure of 3000 psi = 200 BPD
Increase in liquid production rate by changing flowing bottomhole pressure
470200
from 3000 psi to 500 psi = 1.4 = 140 %
200

The increase in production for the same reduction in bottom hole pressure is
more than double in the "straight line" IPR case compared to a "Vogel" IPR.
The presence of the latter indicates that "free" gas will be present at the inlet to
the artificial lift equipment. This, depending on the GOR, may change the type
of equipment selected.

The shape of the Inflow Performance Relationship determines the production increase
when well drawdown is increased

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 4

2 Simplified Electric Submersible Pump Design

Comprehensive ESP design is available as an option in many of the commercially

available well performance programs, e.g. WellfloTM. The simplified procedure
outlined below to evaluate the installation of an ESP into the vertical Edinburgh-1 well
follows the same basic steps as the more complex, computerised, design procedures.

Table 1 Data for Well Edinburgh 1

Table 1 summarises the Edinburgh-1 well ESP design data.

We first need to calculate the Total Dynamic Head (TDH) the pump needs to provide
so that the well can produce the required rate, as explained in Chapter 4. TDH includes:

The pipe friction loss (P f ) at the desired well production is given by:

where f m is the moody friction factor, v is the fluid velocity and g the acceleration due
to gravity {32.173 (ft/s2) (lb m /lb f )}. Now:

The value of f s , is a function of the Reynolds Number, the pipe roughness and the fluid
properties can be found from the Moody Diagram (a value of 0.03 for this calculation).

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 5

P d = P s + P f + P HH
where P d is the required pump discharge pressure and P HH is the hydrostatic head due
to the 7000 ft column of fluid. P s is the wellhead pressure required to transfer the fluid
to the surface facilities (50 psi).

P d = 50 psi + 81 psi + (0.433 psi/ft) * (7,000 ft) = 3,162 psi

The Flowing Bottom Hole Pressure and the pump intake pressure (P In ) are the
same for the Edinburgh-1 well and can be calculated from:

FBHP = P In = P r - Q/PI = 1,700 - 1,400/2 = 1,000 psi

N.B. It is essential that P Intake > 50 psi to ensure that there is a minimum height of fluid
in the annulus above the pump inlet so that it doesn't "run dry" (or "pump-off").

Using the pump performance chart shown in Figure 1, the head per stage (H) at
1,400 b/d is 58 ft and the hydraulic horsepower per stage (HHP) is 0.52.

Figure 1 An example pump characteristic curve for a centrifugal pump

The number of pump stages (N) and the minimum electric motor power (HHP) required
can now be calculated for a pump running at 2,915 rpm.

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 6

and HHP = 86 (stages)*0.52 (HHP/stage)*( f ) = 45 HP

where f is the specific gravity of the fluid (unity in our case of water pumping)

An electric motor to power the pump may now be chosen (minimum 45 HP at 50

Hz).

N.B. Choosing a pump speed other than 2915 rpm introduces extra complications since
the pump rate of an ESP is proportional to the speed

where (1) denotes the initial rate (2,915 rpm) and (2) refers to the new speed of the motor
(and the pump, since ESPs do not have a gearbox). Further, the motor speed also
controls the hydrostatic head produced. The power required may now be calculated

Variable Frequency Drive (VFD) provides the ability to change the pump and electric
motor speed by altering the frequency of the electricity supply. The pump characteristic
performance curves are also measured by the manufacturer for a range of conditions
(e.g. Figure 2).

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 7

Figure 2 Typical changes in pump/motor characteristic performance

as a function of electric supply frequency.

The final stage in this simplified design procedure is to evaluate the robustness of
the design for a series of well inflow conditions i.e. changes in well productivity
index or reservoir pressure or WC etc. These are performed by carrying out a
nodal analysis on the ESP pump. Figure 3 is a typical example of the results
N.B. This is not the same case as discussed above.

Cable selection which depends on pump power, voltage selected and downhole
temperature, etc. - may now be made.

Further correction will be made for the fluid's GLR, viscosity, pump and motor
wear factor, electric current losses, etc. in a comprehensive ESP design routine.

Further details can be found in API RP 1154 Recommended Practice for Sizing
and Selection of Electric Submersible Pump Installations.

The ESP manufacturers have their own software which analyses the pump's mechanical
performance as well as performing a more sophisticated design than that described here.
Further, many of the well design of nodal analysis packages included data from the
pump manufacturers so that the well analysis and selection process can be automated.

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 8

Figure 3 Well productivity index and pump inflow.

This figure shows that:

The well fluid level above the pump (1000 psi or 2310 ft TVD) is high if the
wells PI was 2 STB/d/psi and 1400 STB/day were being produced i.e. the well
is not being pumped off and a larger pump could have been installed. The
production rises to 1540 STB/d (and the fluid level to 1315 psi or 3035 ft TVD)
if the well productivity index increased to 4 STB/d/psi

The well production reduces to 1190 STB/d for the lower well productivity index
of 1 STB/day. The lowest well PI plotted (0.5 STB/d/psi) results in a negative
well inflow pressure. The well has now been pumped off an unacceptable
situation which would be corrected by restricting the tubing outflow with a choke.
The minimum well inflow pressure will be dictated by the minimum pump
charging pressure required (depends on pump design), gas interference e.g.
bubble point etc.

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 9

3 ARTIFICIAL LIFT METHODS TUTORIAL

QUESTION 1

Hardly any artificial lift equipment was installed during the first 10 years of Oil
Production in the North Sea when large high permeability oil fields were being
developed. Suggest four factors that could explain this.

SOLUTION 1.

Artificial lift was not required due to properties of developments typical in that period:

Light oil being produced from high permeability reservoirs i.e. (relatively low
drawdowns),

Reasonable high GOR aided natural flow,

Water Injection supported reservoir pressure above the bubble point pressure at
near hydrostatic or greater pressures, allowing the production wells to continue
to flow under natural flow

Large reservoirs and distant well spacing delayed water breakthrough

High water cut wells were shut-in. Other, lower watercut wells produced in
preference to watered out wells since production was facility or pipeline
constrained.

QUESTION 2

Two types of artificial lift were installed once it became apparent that production
pressure boosting would be required. Which types were these and what were the reasons
that they were chosen?

SOLUTION 2.

The two artificial lift types are:

Gas Lift

High GOR water drive reservoirs

High reservoirs permeabilities

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 10

No need for very low FBHPs (Water Injection, drawdown was relatively low)

High Pressure gas availability, often surplus to power or export requirements

OK for (reasonably) deviated holes

Wireline equipment maintenance no extra demand placed on drilling rig which

could continue drilling development wells

Tolerant to some sand production

No extra space required at production wellhead

Full-access to oil producing formation

ESPs

High production rates even at high water cuts

Suitable for highly deviated wells

Logging/coiled tubing access to formation via Y tool

Flexible flow rate controllable over a wide range

downhole flow measurement and pump condition monitoring available

Efficient use of Energy

Can pump against high wellhead pressures e.g. for satellite wells

No extra space required at production wellhead

QUESTION 3

New completion technology has contributed to reduction of the Operating costs of

Artificial Lift Equipment. Name two significant developments.

SOLUTION 3.

Examples of new technology:

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 11

Coiled tubing for:

- Insert strings
- Conveyed pumps

Wireline maintainable pumps

Variable speed drives for ESPs

Downhole measurement & control for ESPs

QUESTION 4

Which IPR Curve (AL1 or AL2) is more beneficial for Artificial Lift?

SOLUTION 4.

A straight line inflow performance relationship associated with a dead oil is more
favourable than the curved Vogel relationship found when well inflow takes place
below the fluids bubble point. This is because for a straight line inflow performance
relationship the % Increase in production is directly related to the % increase in

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 12

drawdown achieved by the introduction of the form of artificial lift. The increase in
production is considerably less for a curved Vogel relationship.

QUESTION 5

Why are these curves different?

What impact might this have on the selection of the Artificial Lift type?

SOLUTION 5.

A straight-line IPR assumes that oil is undersaturated and only slightly

compressible. This condition does not apply to gases or saturated oil wells, both
of which are highly compressible. The effect of compressible gas and two-phase
flow (relative permeability values are much lower than for a single phase flow)
on IPR results in larger-than-linear pressure drops being required to increase
the production rate i.e. a curved IPR is observed in this case. The rate pressure
relation tends to show a more pronounced curvature at higher production rates.

By applying the same drawdown, i.e. producing under similar flowing bottomhole
pressures, wells with the Straight line IPR (dead or undersaturated oils) would
yield higher production rate than wells with the curved Vogel IPR. The
increasing production of associated gas due to producing below the bubble point
pressure in the latter case would tend to favour the installation of Gas lift while,
for example, Rod Pumps can be applied to the dead oil or undersaturated oil wells.

QUESTION 6

List up to 6 key features for both Rod Pumps and Gas Lift that form the basis of the
following statement:

Worldwide, 85% of Artificial Lift equipment installed is rod pumps. This is mainly in low
production rate wells while gas lift is the most popular artificial lift technique for medium
rate wells.

SOLUTION 6.

Rod Pump Main features

The vast majority of wells produce at low rates (generally less than 100 bpd) and
moderate depths

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 13

Relatively cheap, so their use can be justified on such low rate wells

Rod pumps are mechanically simple to operate and easy to

repair/maintain/replace. Can be operated by inexperienced personnel

Sensitive to gas and solids (wax/scale/sand) Solids can cause wear as well as
damage moving parts which then need to be replaced

Not suitable for (highly) deviated wells (most land wells are near vertical)

Obtrusive in urban locations. Equipment too heavy for offshore use

Pump can be easily changed and performance monitored using relatively simple
and inexpensive techniques

Viscous oil can be pumped

Gas Lift Main features

Suitable for medium to high rates

Suitable for water drive reservoirs with a high bottomhole pressure

High well PIs and high permeabilities mean FBHP can be excessively high,
limiting production

High GOR => advantage rather than a drawback

Gas has to be available

Wireline serviceable at deviation up to 65o. Coiled tubing can service more highly
deviated/horizontal wells

Limited surface requirements once gas available

can be used off-shore or in urban locations

Fully open tubing giving access for production logging

Subsurface tubing, and annular, safety valve

Flexible gas lift string design can be adjusted as well conditions change

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 14

Forgiving of poor design & operation, but difficult to run efficiently

Can handle (tolerate) produced solids

QUESTION 7

What considerations are important when choosing an Artificial Lift Method for subsea
wells for a satellite development at a distance 30 km from a host platform?

SOLUTION 7.

ESPs are normally the preferred Artificial lift method for the following reasons:

Can generate high pump pressures to overcome extra friction from 30 km pipeline

Does NOT use power fluid (gas for gas lift, liquid for hydraulic pumps) which
would lead to extra friction in pipeline.
Hence electricity probably preferred source of power
Remote control capability at long distances

Advantageous to place pump so as to minimise length of flowline with multi

phase flow

System design (artificial lift type/tubing/flowline/reception facilities) should be

suitable for complete life of oil field

Long pump lifetime (reliability to complement lifetime design)

Multiphase pumping means Subsea pressure boosting can also be considered as an

option as well as ESPs

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 15

4 GAS LIFT DESIGN

Design a gas lift installation for the following conditions:

Tubing 3.958 in
Required Production Rate 3000 STB/day
Oil Cut 100%
Gas Oil Ratio 100scf/bbl
Gas Specific Gravity 0.65
Average Flowing Temperature 150F
Reservoir Productivity Index 4 bpd/psi
Reservoir Depth 10,000 ft
Reservoir Pressure 3400 psi
Lift Gas Injection Gradient 20 psi/1000 ft
Minimum flowing tubing head 250 psi
pressure to transfer fluids to facility
Dead Oil Density 35 API or 0.368 psi/ft
Gas Oil Ratio 100 scf/bbl
Brine Density 0.44 psi/ft
Lift Gas Injection Rate 3,000,000 scf/d

A pressure traverse curve is provided following.

Assume that the well is closed in with dead oil in the tubing and brine in the
casing/tubing annulus.

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 16

QUESTION 1:

Does this well require artificial lift to produce?

SOLUTION 1:

Dead oil in tubing height 3,400 / 0.368 = 9,239 ft

Fluid level = 10,000 - 9,239 = 761 ft
Well is dead with fluid level at 761 ft

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 17

QUESTION 2:

What depth should the gas lift valve be installed in a single valve lift installation in order
to achieve the required production?
HINT: Note that the relevant portions of the pressure traverse curve can be approximated
by straight lines. Arbitrary depths can be selected to calculate the pressure gradients.

SOLUTION 2:

GOR after gas injection = 3,000,000 / 3,000 + 100 = 1,100 SCF/STB

From pressure traverse plot:

* Average flowing gradient supposedly after lift gas injection

(arbitrary depths are 6000 ft and 0ft):
between 6,000 ft and surface = 600 / 6,000 = 0.1 psi/ft

* Average flowing gradient supposedly prior to lift gas injection

from 10,000 ft to 4,000 ft = (3,040-900)/(10,000-4,000) = 0.357 psi/ft

FWP + P above valve + P below valve + Draw down = Reservoir Pressure

Drawdown = Production Rate/PI = 3,000 / 4 = 750 psi
Let depth of valve = x

250 + 0.1* x + (10,000 x) * 0.357 + 750 = 3,400

0.1x 0.357x = 3,400 1,000 3,570
x =1,170 / 0.257
x = 4,550 ft

Install gas lift valve at 4,550 ft. (Note that this depth is also sufficiently close to our
above assumptions of arbitrary depths being before and after the gas injection).

HERIOT-W ATT UNIVERSITY September 2015 v1

Tutorials: Chapter 4 - Selection and Design of Artificial Lift 18

QUESTION 3:

What is the minimum surface gas injection pressure to kick the well off in the
configuration described?

SOLUTION 3:

Minimum surface gas injection pressure (P)

P + Gas gradient = Hydrostatic head at 4,550 ft + FWHP
P + (4,550) 0.02 = (4,550) 0.44 + 250
P = 2,252 - 91
P = 2,161 psi

HERIOT-W ATT UNIVERSITY September 2015 v1