19 - Artificial Lift Methods

Artificial Lift Systems – Overview
Objectives of this Module

At the end of this module, you will be able to:
Understand Artificial Lift Requirements, Describe the
Operational Principle, Components and Advantages and
Disadvantages of the Main Artificial Lift Methods:
 Sucker Rod Pumps
 Gas Lift
 Electric Submersible Pumps
 Hydraulic Pumps
 Plunger Lift
 Progressive Cavity Pumps
2 Copyright ©2015 NExT. All rights reserved
Artificial Lift Systems
Any system that adds energy to the fluid column in a

wellbore with the objective of initiating and improving
production from the well. Artificial-lift systems use a
range of operating principles, including rod pumping,
gas lift and electrical submersible pumps.
In the process the pressure in the bottom of the well is
reduced (drawdown) and the reservoir fluids can flow
to the well.

 As compensation for declining reservoir pressure
 Offsetting the effect of increasing water (liquid)
production in oil and gas wells
 To overcome high friction pressures associated
with the production of viscous or waxy crudes, or
with high flow rates in restrictive production
conduits
 To kickoff high gas–liquid ratio wells that may die
when shut in
 To reduce the effect of flow line back pressure
against which the well must produce
 Well Inflow Performance
 Capacity of Artificial Lift Systems
4000
Bottomhole Pressure
Prequired
(lbs/pulg2)
3000
2000 Prequired
Pavailable
1000
0
0 2000 4000 6000 8000
Flowrate (BPD)
 Well Inflow Performance
 Capacity of Artificial Lift Systems
Bottomhole Pressure (psi)
4000
Prequired
3000
2000 Prequired
Pavailable
1000
0
0 2000 4000 6000 8000
Flowrate (BPD)

Sucker Rod Pumps

Sucker Rod Pumps – Operational Principle
An artificial–lift pumping system using a surface

power source to drive a downhole pump
assembly.
A beam and crank assembly (pumping unit)

creates reciprocating motion in a sucker–rod
string that connects to the downhole pump
assembly.
The pump contains a plunger and valve

assembly to convert the reciprocating motion to
vertical fluid movement.
Sucker Rod Pumps – Facts
Most common artificial lift method (in >80% of

onshore wells)
Used mostly in shallow to middle-depth oil fields (<

10,000 ft [3048 m]) and < 1000 BLPD.
Identified by characteristic “pump unit” – “nodding

donkey”
Surface pumping unit is connected via sucker rods

to a downhole pump.
Sucker Rod Pumps – Main Components
Walking Beam Saddle Bearing
Equalizer
Bearing Horsehead
Samson
Post
Bridle
Pitman Arm Ladder
Hanger
Wrist
Prime Pin
Crank Arm
Brake Mover
Counterweight
Lever
Brake Polished Rod
Cable Stuffing Box Seal
Flow Line
Rod String
Flow Tee
Base Production Tubing
Production Casing
Downhole Pump

Sucker Rod Pumps – Surface Equipment
Typical Pumping Well Christmas Tree

Sucker Rod Pumps – Subsurface Equipment
Rods:
Consist of 25’ joints or 30’ joints
Threaded male connection on both ends
Sizes of rods increase in 1/8 in. starting with 5/8’’; largest
rod = 1-1/4”
25’-0” +/- 2” FOR 25’ RODS

30’-0” +/- 2” FOR 30’ RODS

Insert Pump Action
 Complete pump attached to, and inserted into well
tubing with sucker rod string
 As a complete unit, pump may be pulled out of well
without pulling tubing

Tubing Pump Action

 Barrel assembly of this type of pump is screwed onto, and becomes
part of tubing
 Larger bore than a rod pump, thus produces a greater volume of fluid
in any give diameter of tubing

Sucker Rod Pumps – Advantages
Advantages
 Pumping capacity, within the limits, can easily be
changed to adjust for changes in the well inflow
performance. Intermittent operation is also
feasible.
 Rod pumps account for approximately 80% of
onshore artificial lift completions
 Industry accepted, economic in the correct
application
 Not gas dependent
 Under average conditions, it can be used until the
end of a well’s life, up to abandonment.
Sucker Rod Pumps – Disadvantages
Limitations
 Limited efficiency, maintenance
intensive and require vertical wellbores
 Well depth and deviation limitations
 Sand and gas sensitive
 Surface pumping unit requires a big
space; it is heavy and obtrusive
 Wireline access not possible
 Production tubing
Gas Lift

Gas Lift – Principle of Operation
An artificial–lift method in which gas is injected into

the production tubing to reduce the hydrostatic
pressure of the fluid column. The resulting reduction
in bottom hole pressure allows the reservoir liquids to
enter the wellbore at a higher flow rate. The injection
gas is typically conveyed down the tubing–casing
annulus and enters the production train through a
series of gas–lift valves. The gas–lift valve position,
operating pressures and gas injection rate are
determined by specific well conditions.
Gas Lift – Network and Facilities

Gas Lift – Cycle
TO SEPARATOR/STOCK TANK TO SEPARATOR/STOCK TANK
INJECTION GAS
INJECTION GAS

Gas Lift – Cycle
TO SEPARATOR/STOCK TANK TO SEPARATOR/STOCK TANK
INJECTION GAS INJECTION GAS
PLUGGED

Gas Lift – Cycle
PRODUCED FLUID
INJECTION GAS

Gas Lift – Types
TYPES OF GAS LIFT
 Continuous Flow Gas Lift

 Intermittent Gas Lift

Gas Lift – Types
Continuous Gas Lift

is a method in which a
continuous volume of high
pressure gas is injected in
the production tubing to
reduce the specific gravity in
the wellbore fluids. The
lighter column of fluids in the
tubing decreases the
bottomhole pressure to a
point that will allow a
sufficient pressure differential
across the sand face to
produce the well at the
desired flowrate.
Gas Lift – Types
Intermittent Gas Lift
 Intermittent injection into the tubing
 Low bhfp
 Choke controlled utilizing a pilot operated valve or
motor controlled
 3 types of completion: open, semi-closed or closed
 Fallback losses typically 5 – 7% per 1,000 ft of tubing
 Requires rapid injection of gas = pilot operated gas lift
valve

Gas Lift – Valves
3 Basic types of gas lift valve, each available in 1” & 1-1/2” sizes:
Dummy Valves Orifice Valves Unloading Valves

 Plug  Square edged  Injection pressure (casing)
 Venturi (nova) operated valves
 Production pressure (fluid)
operated valves
 Throttling/proportional
response valves

Gas Lift – Valve Features
Bellows protection
Max dome charge
Check valve
Stem travel
Metallurgy
Elastomers

Gas Lift – Unloading Valve
Unloading valve
Normally required during unloading phase only
Open only when annulus and tubing pressures are high

enough to overcome valve set pressure
Valve closes after transfer to next station

May be spring or nitrogen charged

Gas Lift – Operating Valve
Operating valve
Always open – allows gas across Passage whenever

correct differential exists
Gas injection controlled by size and differential across

replaceable choke
Back-check prevents reverse flow of well fluids from the

production conduit

Gas Lift – Advantages
Advantages
 Initial downhole equipment costs lower
 Low operational and maintenance cost
 Simplified well completions
 Production rate can be controlled at the surface
 Flexibility – can handle rates from 10 to 80000 bpd
 Can best handle sand / gas / well deviation
 Intervention relatively less expensive

Gas Lift – Disadvantages
Limitations
 Must have a source of gas
– Imported from other fields
– Produced gas – may result in start up problems
 Possible high installation cost
– Top sides modifications to existing platforms
– Compressor installation
– Casing at high pressure
 Limited by available reservoir pressure and bottom
 hole flowing pressure
Electric Submersible Pumps
(ESP)

ESP – Principle of Operation
An artificial–lift system that utilizes a down hole pumping

system that is electrically driven. The pump typically
comprises several staged centrifugal pump sections that
can be specifically configured to suit the production and
wellbore characteristics of a given application. Electrical
submersible pump systems are a common artificial–lift
method, providing flexibility over a range of sizes and
output flow capacities.

Electric Submersible Pump
The submersible pump

consists of an electric motor MLE Cable
SubmersiblePu
attached to a multistage mp
centrifugal pump and protector

with other key component Intake
parts as described in this
Protector
section which are run into the
well on production tubing.
Motor

Main Components


Electric power is
conducted to the
assembly through an
electrical cable
attached to the tubing.
Power Cable MLE Cable

Electric Motor
The motor is a
three phase,
squirrel cage, two
pole induction
design.

Electric Motor
The motors are
available in a
number of Different
Sizes, Voltages, and
Horsepower Ranges

Downhole Sensor
Single Pressure
Dual Pressure

Downhole Sensor
Parameter Range Accuracy Resolution
Pump Discharge Pressure Pressure Intake / Sandface 0-5000psi +/-3psi 0.03psi

Pressure Discharge 0-5000psi +/-5psi 0.1psi
Pump Discharge
Temperature Temperature 0-150C +/-1.0C 0.1C
Pump Discharge Vibration 3 Motor

Temperature 0-409C +/-1.0C 0.1C
axis Intake Pressure
Pump
Vibration 0-30g +/-0.5g 0.1g
Pump Intake Temperature
Current Leakage 0-25mA 0.05mA 0.001mA
Pump Intake Vibration 3 axis Y- Point Voltage 0-2000Vrms 5% 10Vrms
Motor Temperature Physical
Temperature Rating 150C (302F)

Motor Vibration in 3 axis Pressure Rating 400 Bar (5800psi)
Outside Diameter 4.5”
Y-Point Voltage Length
Metallurgy
22”
Stainless Steel AISI 420
Current Leakage
Sand Face Pressure (Sapphire)

Sand Face Temperature
42 Sand
Copyright ©2015 NExT. Face
All rights Vibration(x,y,z)
reserved
Protector
The protector is
the piece of
equipment that is
typically placed
above the motor.

Intake or Gas Separator
In some applications, there
may be gas produced along
with the oil and water liquids.
If gas is present, then a gas

separator will be installed and
attached to the pump suction
to assist in eliminating some
of the gas that might be
produced through the pump.

Vortex Gas Separator
Smaller Increased Shedder Advanced

Rotating Mass Independent Encapsulated Vortex
Support Bearing Hydraulics
Reduced
Bearing Span

Centrifugal Pump
The centrifugal pump is a
multi-stage pump, containing a
selected number (application
dependent) of impellers
equipped with vanes, inside a
closely fitted diffuser, located
in series on an axial shaft,
driven by the electrical motor.

Pump Performance Curves

These motors
normally operate
at 3,500 rpm on a
60-cycle power
supply or 2,900
rpm on a 50-cycle
power supply.

Advanced Gas Handler

The primary aim of the Advanced Gas Handling
system is to avoid "gas-locking" in the pump which
can result in inefficient cyclical operations and
possible premature mechanical failure if not properly
controlled.
The AGH does not separate gas but conditions it so it
can be produced by the pump.

Advanced Gas Handler

Surface Equipment
SURFACE JUNCTION
SURFACE BOX
SWITCHBOARD CABLE
CABLE
TRANSFORMER

Variable Speed Drive (VSD) describes equipment used

to control the speed of the motor which drives the pump.
The VSD functions are:
 Provide lightning protection for the downhole equipment
 Eliminate the need for chokes in the system
 Provide inherent soft start no inrush currents.
 Protect the downhole equipment from pump off
 Enable remote operation/automation
 Enable smooth response to torque changes

Variable Speed Drive (VSD)
 Every application can benefit

from variable speed!
 ESPs are no exception
 Extend your equipment life
 Improve your system efficiency
 Enable optimization as well
conditions change

Wellhead
The Wellhead is the
equipment that is installed
at the surface of the
wellbore.
It’s purpose is to suspend

the tubing string in the
well, and to monitor and
control high pressures
conditions often present
within the well.
REDACoil

Advantages
 High fluid volume capability
 Can be fitted with downhole pressure sensor (data
transmission via power cable)
 Compatible with crooked or deviated wellbores
 Corrosion and scale treatments are relatively easy to
perform
 Available in a range of sizes and capacities
 Lifting cost for high volumes ($/bbl) typically very low

Limitations
 Cable insulation deteriorates in high temperatures
 System is depth limited (+10,000 ft) due to cable cost
and inability to provide sufficient power
 Large casing/liners are required
 Entire system is downhole, therefore, problems and
maintenance require the unit to be retrieved from the
wellbore

Limitations (cont.)
 Not generally compatible with multiple completions
 Only applicable where electric power is available
 High voltages (1000 V) carry intrinsic risk
 Impractical in shallow low or volume wells
 Equipment changes increases cost
 Power cable causes complicates tubing
handling/running procedures

Hydraulic Pumps

Hydraulic Pumps – Principle of Operation
An artificial-lift system that operates using a downhole

pump (piston or jet pump). A surface hydraulic pump
pressurizes crude oil called power oil, which drives the
bottom pump. When a single production string is used,
the power oil is pumped down the tubing and a mixture
of the formation crude oil and power oil are produced
through the casing-tubing annulus.

Hydraulic Piston Pump
Advantages
 Can lift large volumes from
great depths
 Compatible with deviated hole
 Operating parameters can be
easily changed
 Gas, diesel or electricity can be
used

Hydraulic Piston Pump
Limitations
 Oil as a power fluid presents a
fire hazard
 Large oil inventory required
 Not compatible with solids
 Operating cost can be high
 Dual fluid conduits may be
required

Hydraulic Jet Pump
Advantages
 Tubing and downhole
components are kept clean
 Water can be used as power
fluid
 Treatments for corrosion, scale
and emulsion are easy to apply

Hydraulic Jet Pump
Limitations
 Inefficient lift method
 Large volumes of high pressure
fluid are required
 Systems using oil as a power
fluid present a hazard
 Dual fluid conduits may be
required

Plunger Lift

Plunger Lift – Principle of Operation
A type of gas-lift method that uses a

plunger that goes up and down inside the
tubing. The plunger provides an interface
between the liquid phase and the lift gas,
minimizing liquid fallback. The plunger
has a bypass valve that opens at the top
of the tubing and closes when it reaches
the bottom. Plunger-lift methods are used
to remove water and condensate from a
well, but they can handle only a limited
column of liquid. Typically, these methods
are applied on gas wells with high gas
liquid ratio (GLR) to operate only with
formation gas.
Plunger Lift – Principle of Operation
The Plunger Lift Systems consist of a (piston) plunger, two

bumper springs (one located at bottom hole and the other at the
welhead, a lubricator to sense and stop the plunger as it arrives
at the surface, and a surface controller of which several types
are available. Various ancillary and accessory components are
used to complement and support various application needs.
Plunger lift is most used to extend the life of oil and gas wells.
However, with a packer, standing valve, intermittent gas lift valve
and external gas power source may provide better results than
using intermittent gas lift alone.

Plunger Lift

Plunger Lift
Advantages
 Components can be retrieved
without pulling completion
 Low cost
 Systems has no moving parts
 Can be used in deviated holes

Plunger Lift
Limitations
 System may not be capable of
producing well to depletion
 Low rate wells
 Requires supervision
 Plunger sticking and problems
associated with sand production
 Surging flow may hamper the
effectiveness of the surface
equipment assembly
Progressive Cavity Pumps
(PCP)

Progressive Cavity Pumps
Principle of Operation
PCP systems typically consist of a surface drive and a
down hole progressing cavity pump with a single helical-
shaped rotor that turns inside a double helical elastomer–
lined stator. The stator is attached to the bottom of a
production tubing string and, in most cases, the rotor is
attached to a rod string suspended and rotated by the
surface drive.

Progressive Cavity Pump – Main Components
D
A. Progressive Cavity Pump
C E
B. Rod String
C. PC Drive Head I F
H
D. Sheave & Belts Transmission J
E. Electric Motor
B
F. Vector Flux Drive
G
G. Downhole Pressure/Temperature
Gauges A
H. Casing Wellhead Gauge

I. Tubing Wellhead Gauge
J. Surface Data Acquisition
Progressive Cavity Pump – Main Components

Progressive Cavity Pump
Characteristics
 Driven by motor at surface
or downhole
 Flow rate adjusted by
Rotational speed
 Shallow wells and Viscous
crude oils
 Can handle significant
amount of solids

Progressive Cavity Pump Drive

PCP – Top Drive Brake System



Characteristics
 Driven by motor at surface Cable
Rotor
Stator
or downhole
 Flow rate adjusted by Intake
Rotational speed Gearbox
 Shallow wells and Viscous Protector
crude oils FCE
 Can handle significant Motor
amount of solids
Advantages
 Can pump up to 5000 bpd
 Easy to install and simple to operate
 Easy to transfer location - only pick up truck required
 Require small 'foot print' and ground space
 Reported system
 Sand is handled efficiently
 Easy to vary the rates as a speed range can be adjusted
 without any change of the downhole equipment
 Low capital cost (25% – 50% less than SRP)
 Energy saving from 60% to 70 % efficiency between 60% to 70%
 Excellent for viscous fluids
Limitations
 Elastomer affected by temperature (> 250 degree F)
 Tubing need to be retrieved for stator repairs
 Short run life in stator
 Not accessible for downhole pressure survey
 Sensitive to time cycle and pump off, thus shutdown
especially in high viscosity or sand producer must be
avoided

Applications
 Heavy oil and bitumen.
 Production of solids–laden fluids.
 Medium to sweet crude.
 Coal bed methane/gas well de–watering.
 Agricultural areas.
 Urban areas.

19 - Artificial Lift Methods

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

19 - Artificial Lift Methods

Uploaded by

Copyright:

Available Formats

Artificial Lift Systems – Overview

Objectives of this Module

Any system that adds energy to the fluid column in a

3 Copyright ©2015 NExT. All rights reserved

7 Copyright ©2015 NExT. All rights reserved

8 Copyright ©2015 NExT. All rights reserved

An artificial–lift pumping system using a surface

A beam and crank assembly (pumping unit)

The pump contains a plunger and valve

Most common artificial lift method (in >80% of

Used mostly in shallow to middle-depth oil fields (<

Identified by characteristic “pump unit” – “nodding

Surface pumping unit is connected via sucker rods

11 Copyright ©2015 NExT. All rights reserved

Typical Pumping Well Christmas Tree

25’-0” +/- 2” FOR 25’ RODS

13 Copyright ©2015 NExT. All rights reserved

14 Copyright ©2015 NExT. All rights reserved

Tubing Pump Action

15 Copyright ©2015 NExT. All rights reserved

18 Copyright ©2015 NExT. All rights reserved

An artificial–lift method in which gas is injected into

20 Copyright ©2015 NExT. All rights reserved

21 Copyright ©2015 NExT. All rights reserved

22 Copyright ©2015 NExT. All rights reserved

23 Copyright ©2015 NExT. All rights reserved

TYPES OF GAS LIFT

 Continuous Flow Gas Lift

24 Copyright ©2015 NExT. All rights reserved

Continuous Gas Lift

26 Copyright ©2015 NExT. All rights reserved

Dummy Valves Orifice Valves Unloading Valves

27 Copyright ©2015 NExT. All rights reserved

28 Copyright ©2015 NExT. All rights reserved

Normally required during unloading phase only

Open only when annulus and tubing pressures are high

Valve closes after transfer to next station

29 Copyright ©2015 NExT. All rights reserved

Always open – allows gas across Passage whenever

Gas injection controlled by size and differential across

Back-check prevents reverse flow of well fluids from the

30 Copyright ©2015 NExT. All rights reserved

31 Copyright ©2015 NExT. All rights reserved

33 Copyright ©2015 NExT. All rights reserved

An artificial–lift system that utilizes a down hole pumping

34 Copyright ©2015 NExT. All rights reserved

The submersible pump

centrifugal pump and protector

35 Copyright ©2015 NExT. All rights reserved

36 Copyright ©2015 NExT. All rights reserved

37 Copyright ©2015 NExT. All rights reserved

Power Cable MLE Cable

38 Copyright ©2015 NExT. All rights reserved

39 Copyright ©2015 NExT. All rights reserved

40 Copyright ©2015 NExT. All rights reserved

41 Copyright ©2015 NExT. All rights reserved

Pump Discharge Pressure Pressure Intake / Sandface 0-5000psi +/-3psi 0.03psi

Pump Discharge Vibration 3 Motor

Motor Temperature Physical

Temperature Rating 150C (302F)

Sand Face Pressure (Sapphire)

43 Copyright ©2015 NExT. All rights reserved

If gas is present, then a gas

44 Copyright ©2015 NExT. All rights reserved