Selection and Design of Artificial Lift

Tahir Mammadov
 Learning Objectives
Rod (Beam) Pump
• Describe the concept and component parts of a Beam
Pump.
• Select well conditions suitable for beam pump installation.
Electric Submersible Pump (ESP)
• Identify the components of an Electric Submersible Pump.
• Describe the preferred applications and the mode of
operation of the (ESP).
Gas Lift
• Describe the gas lift process
• Identify application areas/advantages for gas lift
Recovery mechanisms
 Need for artificial lift
Artificial lift is required when well:
• will no longer flow
• production rate is low to be economic
 Need for artificial lift
Is it possible for this well to flow
naturally under any conditions?
Well TVD=15000 ft

Yes, if the well PI is sufficiently

high and the produced reservoir
fluids contain enough gas that the
flowing fluid pressure gradient
gives a positive WHP.
 The need for Artificial Lift • 7% of wells
produce under
natural flow
(1994)
However, the well
• This well must first be “kicked
off’” by swabbing.
is unable to
initiate
flow
 Well Start-up: Swabbing

• Plunger inserted into well & pulled rapidly upwards

• BHP reduced due to fluid removed from tubing
•The process is repeated until a sufficient fraction of oil produced
• “Live” reservoir fluid (with gas) flows into well which may continue
flowing if the producing GLR is sufficient
 Well Start-up: Coiled Tubing with gas Nitrogen
injection
•When the well shut-in any gas in the
tubing will separate from the liquid and
collect at top of the tubing  Heavy fluid
remains
• Flow is initiated by pumping nitrogen gas
via a coiled tubing to reduce the BHP
•Well may continue to flow if the producing
GLR is sufficient Otherwise a permanent
solution is required (Pump, Gas Lift, etc.)
 • Pump initiates flow
• Low drawdown only
• Place pump below perforations
- Maximum Drawdown
Maximum Production Rate
 Artificial
Lift
Techniques
Pump Classification
 Artificial Lift Application
• Selected type
of Artificial Lift
varies according
to particular
conditions of the
oilfield being
USA 1992
produced

Major Int. company (2005)

 Increased Artificial Lift Application
(maximum production with cost reduction)
• Field Development Characteristics
– Absence of pressure maintainance
– Depleted / High Water Cut Production
– Long (Sub sea) Flowlines-extra pressure drop
• Business drivers
– Maximise Well Rate:- Advanced Well Design +large diameter tubing
+ horizontal well
– Early installation of artificial lift
– Marginal Fields (possible subsea):- Minimise Well numbers with
little or no intervention (Reliability)
– More realistic Design Software and Operational Control (down hole
measurement)
– Better training of wellsite personal who install and operate
the equipment
 Integration of Artificial Lift into Field
Development
• Tools for “Thinking in Systems” are now available (1995):
– reservoir / well / production system models

• Minimise “total lifetime cost i.e. (CAPEX + OPEX)

Real-Time Production Management Advantages

• Implementation of a Supervisory, Control and Data

Analysis (SCADA) system in a large artificial lift
project (> 500 rod pumped wells) resulted in:
(a) 6% production increase
(optimise lift conditions + alarms when wells cease producing)
(b) 50% reduction in well entries
(early problem recognition allows preventive maintenance)
(c) 5% reduction in energy consumption
(wasteful “over-lifting” recognised immediately)
 New Technologies reduce Failure Frequency

• Failure frequency of pumps in a field for wells which are

using automated systems and non-automated wells
Artificial Lift Selection Criteria
 Well Characteristics
• Production casing size & Oil Production Rate required
• Maximum Size of tubing - required gross production rate
• Annular / tubing safety systems
• Depth
• Deviation & doglegs - planned & unplanned
• Nature of Produced fluids
– Oil Viscosity & Gas - liquid ratio
– Water cut (gross production rate & Emulsion formation)
– Sand / Wax / Asphaltene deposition
• Well Inflow characteristics
Some of the following discussion is after material from Lea and
Patterson[1] and Lea and Nickens[2].
 Reservoir Characteristics
Artificial lift considerations should ideally be part of the well planning process. Future lift requirements
will be based on the overall reservoir exploitation strategy, and will have a strong impact on the well
design.

Some of the key factors that influence the selection of an artificial lift method.

IPR: A well’s inflow performance relationship defines its production potential

Liquid production rate: The anticipated production rate is a controlling factor in selecting a lift method;
positive displacement pumps are generally limited to rates of 4000-6000 B/D.

Water cut: High water cuts require a lift method that can move large volumes of fluid
 Reservoir Characteristics
Gas-liquid ratio: A high GLR generally lowers the efficiency of pump-assisted lift

Viscosity: Viscosities less than 10 cp are generally not a factor in selecting a lift method; high-viscosity
fluids can cause difficulty, particularly in sucker rod pumping

Formation volume factor: Ratio of reservoir volume to surface volume determines how much total fluid
must be lifted to achieve the desired surface production rate

Reservoir drive mechanism: Depletion drive reservoirs: Late-stage production may require pumping to
produce low fluid volumes or injected water.

Water drive reservoirs : High water cuts may cause problems for lifting systems

Gas cap drive reservoirs : Increasing gas-liquid ratios may affect lift efficiency.
 Well Inflow Characteristics

• Production increase with artificial lift depends on:

– Increase in drawdown
– well inflow characteristics
 Hole Characteristics
Well depth: The well depth dictates how much surface energy is needed to move fluids to surface, and
may place limits on sucker rods and other equipment.

Completion type: Completion and perforation skin factors affect inflow performance.

Casing and tubing sizes: Small-diameter casing limits the production tubing size and constrains multiple
options. Small-diameter tubing will limit production rates, but larger tubing may allow excessive fluid
fallback.

Wellbore deviation: Highly deviated wells may limit applications of beam pumping or PCP systems
because of drag, compressive forces and potential for rod and tubing wear.
 Surface Characteristics
Flow rates: Flow rates are governed by wellhead pressures and backpressures in surface production
equipment (i.e., separators, chokes and flowlines).

Fluid contaminants: Paraffin or salt can increase the backpressure on a well.

Power sources: The availability of electricity or natural gas governs the type of artificial lift selected.
Diesel, propane or other sources may also be considered.

Field location: In offshore fields, the availability of platform space and placement of directional wells are
primary considerations. In onshore fields, such factors as noise limits, safety, environmental, pollution
concerns, surface access and well spacing must be considered.
 Field Location
• Onshore
– Urban / Farming / National Park / isolated
– Desert / Jungle / Mountainous / Arctic
• Offshore
– platform size & facilities
– distance to processing facilities
• Isolated Well or Close Spacing
• Power source for prime mover
– natural gas /mains electricity /diesel powered
electricity generating set
 Operational Problems
• Sand / formation fines production
• Solid deposition: Remove or Inhibit depositsby
chemical injection formation
– Paraffin (Temperature reduction)
– Asphaltenes (Pressure reduction)
– (Inorganic) Scale (CaCO3, BaSO4, NaCl etc.)
– Hydrates (low temperatures)
• Construction Materials
– Bottom Hole Temperature
– Corrosive conditions (e.g. H2S, CO2 )
– extent of solids production
– producing velocities (erosion)
 Field Operating Characteristics
• Long-range recovery plans: Field conditions may change over time.

• Pressure maintenance operations: Water or gas injection may change the artificial lift requirements
for a field.

• Enhanced oil recovery projects: EOR processes may change fluid properties and require changes in
the artificial lift system.

• Field automation: If the surface control equipment will be electrically powered, an electrically
powered artificial lift system should be considered.

• Availability of operating and service personnel and support services: Some artificial lift systems
are relatively low-maintenance; others require regular monitoring and adjustment. Servicing
requirements (e.g., workover rig versus wireline unit) should be considered. Familiarity of field
personnel with equipment should also be taken into account.
General Guidelines (Weatherford 2005)
General Guidelines (Weatherford 2005)
General Guidelines (Weatherford 2005)
 Economics
• Initial CAPEX
– Centralised Facilities?
• Operating Costs
– Equipment Life
– Energy efficiency
• Run lifetime
– downhole
monitoring
– training
Relative Advantages of Artificial Lift
Methods
Relative Disadvantages of Artificial Lift
Methods
Artificial Lift:
Rod Pumps
 Sucker Rod or Beam Pump

• Most frequently used artificial lift method

• Land oil fields only
• Main Application to reservoirs with:
• Shallow to middle-depth (< 10,000 ft )
• Low to medium (< 1,000 BLPD) production rates
• Surface pumping unit is connected via steel sucker rods
to a downhole pump.
• Surface pump unit is well known
 Sucker Rod or Beam Pump
• 85% of artificially lifted USA wells use beam pumps
(72% are stripper wells making <10 bopd)
• Mechanically simple (can operate with inexperienced staff)
• Relatively low production rates:
– 1,000 bfpd @ 7,000 ft to 200 bfpd @ 14,000 ft
• (API) Standard interchangeable equipment
• Rods, pumps etc. subject to fatigue (choice of materials /
corrosion protection)
• Incompatible with solids (sand, scale, paraffin & asphaltenes)
& crooked or reasonably deviated holes
• Gas - liquid separation capability limited (gas locking)
 Sucker Rod Pump
• Pump is driven by the surface unit
• Pump and surface unit connected by sucker rods
• The downhole pump does the actual pumping and
lifting of the produced liquid.
• The pumping capacity is controlled by the:
• Pumping speed,
• Stroke length,
• Pump type
• Pump diameter
• Pump efficiency.
 The Pumping Unit
• Gearbox reduces electric motor (prime mover)
rotation from 600 rpm to 20 strokes/min
• Stuffing box seals on polished rod
 Sucker Rod Pump
• Pump is driven by the surface unit
• Pump and surface unit connected by sucker rods
• The downhole pump does the actual pumping and
lifting of the produced liquid.
• The pumping capacity is controlled by the:
• Pumping speed,
• Stroke length,
• Pump type
• Pump Diameter and
• Pump efficiency.
 The Sucker Rods

Sucker Rods are the connection between the

surface and the Downhole pump
• Length:- 25 – 30 ft, Diameter:- 0.5 - 1.125 in
• Screwed together via couplings with Square Flat
surfaces so that they can be tightened by a wrench
• Rods are subject to fatigue from weight of fluid and
the Sucker Rods themselves
• Load minimised by tapered string
 Sucker Rod Pump
• Pump is driven by the surface unit
• Pump and surface unit connected by sucker rods
• The downhole pump does the actual pumping and
lifting of the produced liquid.
• The production capacity is controlled by the:
• Pump speed,
• Stroke length,
• Pump type
• Pump diameter and
• Pump efficiency.
 Insert Pump

The Insert Pump fits inside the production tubing

• Pump unit is run inside the tubing
• Pump attached to sucker rods
• Seated in tubing nipple
• Smaller diameter than tubing
• Lower flow rate than tubing pump
• BUT Can be repaired without removing tubing (Rods only)
 Tubing Pump
• The Tubing Pump is
installed at the bottom of
the production tubing
• Plunger moves against
polished Pump Barrel of
same diameter as the tubing
• Larger pump rate than insert
pump
• BUT Tubing has to be
recovered to repair pump
 How a Dowhole
Pump Works
• Hollow plunger seals against
pump barrel
• Traveling & Standing valves
consist of Ball & Seat in a cage
• Fluid moves from casing to
tubing by UP & DOWN motion
of plunger & valve operation
• Travelling Valve Open &
• Standing Valve Closed during
downward rod movement
 The Downhole Pump
• Valve operation is reversed when
rod begins to move upwards
• Travelling Valve Closed &
• Standing Valve Open during
UPWARD rod movement
• UPWARD movement of plunger:
– Lifts fluid above plunger to
surface
– Reduces the pressure in the
barrel (drawdown).
– Sucks fluid from perforations
into the barrel
 The Downhole Pump

• Rod falls downwards due to gravity

• Rod’s downward movement forces
the fluid in the barrel to flow through
the hollow plunger
• The Travelling Valve is Open &
• The Standing Valve Closed during
DOWNWARD movement of plunger
• Any solids in the produced fluid
result in excessive pump wear
The Downhole Pump
Rod Pump equipped with Pump-Off Control
powered by Solar Energy
 “Sonolog” or “Echometer” Fluid Level Survey
• Measurement of
fluid level in annulus
allows monitoring of
pump efficiency
• Maximum
production requires
pump speed just
sufficient to “pump
well-off” i.e. fluid
level in annulus is
just above pump
 Gas Separators
• A rod pump is designed to pump and lift liquids (no
gas)
• Gas should be separated from the produced liquids
and vented to annulus before it can enter the pump.
• Gas entry into pump reduces pumping efficiency
• Excessive gas entry will cause damage due to gas lock
or fluid pound.
 Gas Influx:
A simple Gas Anchor

• Gas Influx reduces

pump efficiency

• Placing pump
below perforations
maximises gas
separation capacity
 Centralisers are
required in deviated /
crooked holes
 Pump Problems

• Downhole pump failures result from:

– Normal wear
– Abrasion from solids
– Corrosion (galvanic, H2S, CO2 or acid)
– Scale buildup
– Gas locking
 Dynamometer
Identifying Problems with Rod Pumps

– Dynamometer load cell measures

the load applied to the polished rod
at the top of a string of sucker rods
– A “dynamometer card” records the
load on the polished rod during the
pump cycle (up- & down-stroke)
– The load cell is permanently
installed as a “Pump-off Controller
for continuously monitoring the
dynamic rod loads during pumping
 Diagnosis of Pump
Operating Problems
• Problems such as excessive
friction, sticking plunger, gas
lock etc. need to be detected
• Diagnosed from deviations
from ideal shape of the
dynanometer card
• Upper & middle slides
illustrate theoretical cards
• Lower picture is full
simulation
Dynanometer
Cards
• Inelastic rods
reflect “perfect”
up & down
movement
• Stretching of
Elastic Rods
results in
gradual load
uptake
 Complete Dynanometer Card

• Complete Simulation of a perfectly operating pump

• Operational problems (gas, worn seals, stuck valves etc.)
can be diagnosed from the shape of the dynanometer card
 Artificial Lift:
Electric Submersible Pump (ESP)
Electrical Submersible Pump (ESP)
A downhole centrifugal pump which lifts the
produced fluids to the surface.
• Subsurface equipment
– Electric motor, Downhole Sensors,
Protector or seal, Gas separator, Pump,
Cable
• Surface equipment
– Junction box, Switchboard or Variable
speed controller, Pump Monitoring
Instruments, Transformers
-High Voltage electricity supply
- VFD: soft start & speed control
- Vent box
- Wellhead penetrator
- Cable
- Pump unit {many (10-100)
rotating centrifugal impellers
with stationary diffusers
driven by shaft }
- Pump intake
- Protector/Seal
(barrier, motor oil expansion,
thrust absorber)
- Electric Motor
- Sensors (signal via cable)
 General Characteristics of ESPs

• Can be designed to pump at very high flow rates (up to

100,000 BPD) & high pressure boost (up to 6,000 psi)
• Often more efficient than other AL techniques
• Relatively expensive
• Sensitive to solids and free gas
• ESPs can run several years with favorable conditions
• ESP repair almost always requires a Heavy Workover
 Electric Submersible
Pumps Applications

• ESPs can be installed in deviated

wells at angles up to 80o
 ESP Motors
• Generally 3 phase and 2 pole motors.
• Consists of two main parts: the Rotor and Stator.
• Pump performance is dependent on the frequency of
the electrical power.
– The higher frequency the better the performance
– Designed to run at 60 Hz in USA & 50 Hz elsewhere
– may run at other frequencies (VFD).
• Requires sufficient cooling from fluid flow past the
motor to operate properly.
• Size ranges from 20 Hp to 1200 Hp
 Motor Protector or Seal
• An important ESP downhole component (often overlooked)
• Provides pressure equalization system for the motor.
• Provides seal system to protect the motor winding from
the well fluids
• Absorbs a significant portion of the up- & down-thrust
force.
 Centrifugal Pump
• Multiple stages
• Each stage consists of an
impeller and a diffuser
• Impeller provides kinetic
energy by throwing fluid to
the edge of the impeller
• Diffuser changes kinetic
energy into potential energy
(pressure) by reducing the
fluid velocity
 Gas Handling
• Efficiency of standard ESP
centrifugal impeller reduces
when gas fraction > 20%
• Mixed flow impellers can
handle up to 40% vol. gas
• Greater Gas / Liquid ratios
require rotary gas separator
or gas anchor (shroud)
• Vented casing required
 Junction Box
• Vents gas that diffuses out of well via the cable
• Prevents the gas from diffusing through cable and
creating an explosion hazard in the switchboard
Motor Controller
• Starts and stops the motor
• Provides current recording (amp chart)
• Downhole sensor readout possible
• Enables remote monitoring and control
• Provides under and overload protection
• Automatic shutdown following pump-off or gas-lock
• Provision for automatic restart possible
 Check and Drain Valves

• Check valve is installed to:

– prevent back spin
– reduce the volume of debris falling through
pump
– reduce pump out time
• Drain valve:
– avoids pulling wet string
– enables well killing by circulation
 Sensor Package
• Measurements include:
– Fluid intake & motor temperature
– Pump suction / discharge pressures & temperatures
– Vibration
– Current leakage
• Provides data on pump / motor operating conditions
• Prevents dangerous motor conditions e.g. well pumped
off & attempt motor restart under backspin conditions
due to unloading of fluid in string
• Data triggers alarms - analysed at wellsite or main office
• Provides continuous FBHP measurements - data
transmitted to the surface via the power cable
• Well test analysis after each pump shut down
 ESPs: Advantages and Disadvantages
Advantages Disadvantages
 Can achieve very high  Full workover required to
rates using high power change pump
motors (~1,000 kw)  Cable susceptible to
 Unobtrusive surface damage during installation
location  Cable and motor
 Downhole telemetry deteriorate more rapidly at
available higher temperatures
 Tolerant high well  Gas and solids intolerant
deviation / doglegs  Increased casing diameter
 Corrosion / scale may be required for higher
treatments possible production rates
 Basic Pump Selection
• Max. Pump pressure difference
above annulus is +6,000 psi
• Total Dynamic Head equals:
+ Fluid Hydrostatic head from
ESP to the surface is product
of:
- (average) fluid density ()
- ESP vertical depth (TVD)
- acceleration due to gravity (g)
 Friction loss in the tubing (Pfth)
 The surface pressure (Psurf)
required to overcome flowline
back pressure (may be a high
value e.g. satellite wells 50 miles
from the host platform)
 Pump Performance
• The pump head (ΔP), or increase in pressure per stage,
is expressed in terms of the pressure generated by an
equivalent column of water (h).
ΔP = *g*h
N.B. This needs correction for any changes in viscosity
• Pump power = pump rate * the generated pump head or
Mechanical Power = work done / time = q*ΔP
• Converted to required electric motor power via pump
efficiency (E)
E = hydraulic power / mechanical Power
• Operate Pump operation within 10% of max. efficiency
 Pump Performance Chart

• ESP is a dynamic pump:

– pump rate is high for low pressure head generation
– pump rate is low for high pressure head generation
 Simplified Pump Design (1)
• The pipe friction loss (ΔPf) is given by:
 L  ν 
2
Δpf =  f  ρ f     
 d   2g 
where f is the friction factor, v is the fluid velocity and g
the acceleration due to gravity {32.173 (ft/s2) (lbm/lbf)}
• v is calculated from the pipe dimensions while the
friction factor is found from the Moody Diagram
• ΔPd =Pm +ΔPf +ΔPHH is the pump discharge pressure
where Pm is the safety margin
• Pump intake pressure = Pin = FBHP = Pres - Q/PI
Simplified
Pump
Design (2)

• Pump performance chart shows head per stage (H) and

Power {Kilowatt} or brake horsepower per stage (BHP)
{where 1 BHP = 0.746 KW}
• Check robustness of design against a wide range of
(possible) future operating conditions
Simplified
Pump
Design (4)

• Reliable ESP operation requires correct ESP design

• Reliability or “Mean time before failure” increases with
evaluation of failed equipment
Artificial Lift:
Gas Lift
 Gas Lift
• Basics
– Problem: The bottom hole pressure is too low to
support the fluid column in the well
– Remedy: Reduce the density of the fluid column by
injecting gas into the tubing
– Dilemma: Excess gas injection creates additional
back pressure which reduces production rate
– Necessity: Optimise extra production for gas
injected
A Continuous Flow
Gas Lift Completion
• Gas Injection through
the operating valve
increases the
producing GLR
sufficiently to allow
the well to flow
• Slug flow efficiently
moves liquid to the
surface
 Nodal Analysis for Gas Lift
• Wellbore at perforation depth is node for “Nodal Analysis”
– Inflow to Node (the perforations):
Preservoir – Pdrawdown = Pperforations
– Outflow from Node (the perforations):
Pseparator + Pflowline + Pchoke + P(tubing above operating
valve) + Ptubing below operating valve = Pperforations
• Calculate using Multiphase flow correlations/gradient curves:-
Ptubing below operating valve: use the “natural” gas liquid ratio &
Ptubing above operating valve: use the “enhanced” gas liquid ratio
achieved after lift gas injection
Benefit of deeper gas injection
Valve 4 - 500 psi drawdown
Valve 7 - 700 psi drawdown
The Gas Lift System
 The Gas Lift
System: metering &
control equipment
 Gas Lift Applications

• Continuous Flow gas lift works well with:

– high GOR/GLR produced fluids
– high Productivity Index completions
– relatively high bottom hole pressures (water
drive/aquifer support or water injection)
 Gas Lift: Advantages and Disadvantages
Advantages Disadvantages
 Solids tolerant  Lift gas may not always
 Large volumes lifted in high available throughout field life
Productivity Index (PI) wells  Not suitable for viscous crude
 Unobtrusive surface location oil or emulsions
/remote power source  Lift gas susceptible to gas
 Tolerant of high well hydrates at low temperatures
deviations/doglegs  High minimum FBHP. Planned
 Tolerant of high GOR abandonment pressure may not
reservoir fluids be reachable
 Low cost wireline  Casing must withstand lift gas
maintenance for wells with pressure
deviation <65˚
 Gas Lift projects require an adequate supply of
lift gas at all times
Considerations:
• Gas supply decreases as water cut increases
• Will gas be available to start up the first well after
facility shutdown?
• Lift gas supply pressure often fixed by sales gas
pipeline pressure
– gas compressor specifications specified at an
early stage of the oil field’s design
• High pressure separator operation creates a high
back-pressure (FBHP), restricting well production
 Describe the
advantages &
disadvantages
of these
completions
 Describe the
advantages &
disadvantages
of these
completions
 Gas lift design requirements
• Maximise value of net oil production
– inject gas at maximum economic rate as deep as possible
• Maximise design flexibility due to uncertainties in
reservoir performance without sacrificing
production.
– Range of reservoir pressures & PI’s over well life
– Range of watercuts over well life
– Range of gas injection rates
• Minimise well intervention
– Particularly subsea wells!
– wireline change of gas lift valves for dry trees < 60o