artificial lift (filling the gap @ low spm) · artificial lift (filling the gap at low spm) lebro...
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Gas Well Deliquification WorkshopSheraton Hotel, Denver, Colorado
February 23 - 26, 2009
Artificial lift (Filling the Gap @ Low SPM)
Companies:BP Devon Pioneer Questar NCX Inc.
Alex Rodriguez (BP) & Colin Foust (NCX Inc.)February 24, 2009
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Pump Jack (Filling the GAP at Low SPM)
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Ways to slow down the Pump Jack
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Challenges @ Low SPM
Challenges:• Artificial lift that works at low SPM at efficient working
parameters• Cost effective Artificial lift technology • Low maintenance• Easy installation• Lift low volumes of murky fluid without pumping off• Height issues (For wells within irrigation systems)• Decrease moving parts (Safety)• Smaller footprint (Environmental issues)
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Artificial Lift (Filling the GAP at Low SPM)
LeBro Pump Actuator is an Artificial lift technology that can fill the
Gap for low SPM pumping needs.
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Comparing / Contrasting Units (with a focus on LOW SPM)
Pros:• Reliable (Good History)
• Efficient at High Strokes Per Minute (spm) (>5 spm)
Pump JackPump JackCons:
• Not good pump efficiency at low spm due to slippage
• Not very power efficient at low spm
• Need extra auxiliary equipment to slow down the pump below 5 spm.
• Cost and maintenance.
• Installation
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Comparing / Contrasting Units (with a focus on LOW SPM)
Cons:• Not efficient at high spm
(>7spm)
• New or modified technology
• Very little history (~3 yrs)
LeBro PumpLeBro PumpPros:
•High efficiency at low spm (< 5 spm)•Power efficiency greatly increased•Cost and preventive maintenance decreased•No outside moving pieces (Safety)
•Smaller footprint (Environmental)
•Height greatly reduced (Irrigation)•Installation•Stuffing box eliminated.•Able to long stroke pump (Rig less)
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Cost, Maintenance, & Power Comparison
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Cylinder Classification
32” Stroke32” Stroke
60” Stroke60” Stroke
120( + ) ” Stroke120( + ) ” Stroke
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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First LeBro Pump Installation– Bywaters Estate #2-399
• Bywaters Estate #2-399 Reactivation
• Well T&A since 11/1998 (PBTD 3252’)
• Texas Hugoton Reactivation program
• Estimated for well to make about 40-50 bbls/d initially and decreases down to ~<10 bbls/d.
• Initially LeBro Pump set at 4 SPM lifting ~40 bwpd. Later on pump was adjusted to 6.5 SPM lifting ~55bwpd.
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Height Comparison
Pump Jack LeBro Pump
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Timer that controls the Upstroke and Downstroke time.
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LeBro Sealing Arrangement
LeBro seal design arrangement prevents outside wellhead leaks.
• The benefit of this mechanical seal arrangement is that in case of seal leakage, ie: end gland seals damaged or worn, the hydraulic fluid would leak inside of the wellbore rather than outside the wellhead. Furthermore, a low liquid level sensor is set up in the hydraulic fluid reservoir (on skid) to shut-down the equipment when it detects a low level hydraulic fluid on the reservoir tank. Thus, the shut down of the equipment will minimize any probable hydraulic leakage.
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PNR Application (Well is located in the Texas West Panhandle field. It’s a Red Cave well with a TD of 2,260’ and PERFS at 1,772’ – 1,994’.)
- 54” stroke actuator, Initial rate 38 bbls/d @ 6 SPM. Fluid production decline down to 5 bbls/d @ 1SPM. Continuous pumping.
- In May 2008 the pump got stuck due to very thick oil (~23 gravity oil) – replaced the pump
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Pump got stuck due to thick oil
MC
FD
Time
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PNR Application (Well is located in the Texas West Panhandle field. It’s a Red Cave well with a TD of 2,200’ and PERFS at 1,741’ – 1,980’.)
- 54” stroke actuator, Initial rate 65 bbls/d @ 5-6 SPM. Fluid production decline down to 16 bbls/d @ 2 SPM. Continuous pumping.
- Nov. 08’ there was a problem with the temperature switch on the pump. The switch was replaced and haven’t had any problems since.
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Problems with temperature switch on pumpSwabbing on the well
before the pumping unit was installed
MC
FD
Time
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CBM Application Questar
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Arkoma Basin ( 2 x Wells )
Problems: Pump losses of 6 x per day in 91 degree horizontal well.
Project Goal: Address total pump loss from coal dust
Candidacy: LeBro USDTM due to demonstrated ability to pump at lower velocity, attain continual fluid movement and long stroke (purge) the pump on demand
System Design: 2HP LeBro USDTM system with NG generator. 54” Surface stroke and 1 x stroke every 1.5 minute(s)
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CBM Application – Questar (Cont.)
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Preliminary findings: 4 x pumps total have been pulled due to complete filling of the horizontal bore with coal dust. These pumps were reported to have no damage, cleaned and ran back in. 1 x well has demonstrated an increase in production. The NG generator not observed to handle application as reliable as NG engine.
Developed Ideas: New design of Coal Dust Self Purging Pump TM – No pump changes since this design installed
Design of direct NG engine / hydraulic drive power source
Arkoma Basin ( 2 x Wells )
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Questar CBM Application (54” stroke actuator, current fluid production decline is 0.5 bbls/d @ 1stroke every 2 minutes. Continuous pumping.)
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Questar CBM Application( 54” stroke actuator, current fluid production decline in 0.8 bbls/d@ 1stroke every 1 ½ minutes. Continuous pumping)
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Devon CBM Application
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Installed: 01/19/2009Total Cost: $35,200**AFE Total
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Devon CBM Application
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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2005 06 07 08 091
5
10
50
100
500
1000
Date
Dly
Gas
Rat
e ( M
cf/d
)
Dly
Wat
er R
ate
( bbl
/d )
Dly
Oil
Rat
e ( b
bl/d
)
Csg Pressure ( psig )
DENNY 1-2H Gas Cum : 464 MMcfOil Cum : 0 MbblWater Cum : 14 Mbb
Installation of LeBro UnitInstallation of LeBro Unit
Production fell off due to liquid loading Production fell off due to liquid loading
PROSCheaper than pump jack
Delivers similar results
Limited pump speed (4 SPM max)
CONSTakes longer to drain backside treated water due to low SPM (Currently set around 1.5 SPM)
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Feb. 23 - 26, 2009 22
Artificial lift Comparison (Semi-Deep Application)
Compared environmental footprint
Compared environmental footprint
2009 Gas Well Deliquification Workshop Denver, Colorado
Traditional Platform
(86” Stroke)
LeBro USD platform
(86” Stroke)
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Deep well application (NCX inc.)OBSTACLES:• Weight of the rods plus hydrostatic • Weight applied to well head equipment.• Pump efficiency (possibility of slip in lower metal
plunger)• Compressibility of well fluids. • Static stretch.• Rod compression, normal loss of down hole stroke
length and over travel. • Actuator friction and heat. Well deviation at surface.• Hydraulic system shock when valves open or close at
higher fluid gpm rates.
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Deep well application(NCX inc.)SOLUTIONS:• Increase size of actuator accordingly to exceed
lifting weight.• Use x-heavy fittings and insure well head is
flange and not slip type.• Decrease plunger clearance or increase fall rate.• Allow additional hp and spm for loss of pump
displacement if high gravity oil.• LeBro pump design stroke cycle results in less
loss of static stretch.• Retaining static stretch reduces or eliminates
rod compression. • Surface controls, proximity sensors, and
replaceable wear guide to protect shaft and end glands. Adjustable soft shift hydraulic valves.
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Lifting Coupler
Polish Rod to Rod-string
Hammer Union
Wellhead Configuration
• Versatility – Currently installed on both oil and gas wells in multiple fields
• Range – Volumes of ¼ bpd to 65bpd
• Depth – 2100’ to 6000’ also pursuing deeper applications
• Incorporates Harbison Fischer Components / GasVent ™ Pump
• Interchangeable to Wellhead / existing infrastructure / SCADA
• Transportable to location by pickup
• Reduced lifting costs : Pump changes, power consumption, pump purging (long stroke), lower hp demand
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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LeBro Pumping System
Optimal in lowering fluid levels with low strokes per minute
Optimal in lowering fluid levels with low strokes per minute
Applications Electric * NG * Solar
Applications Electric * NG * Solar
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Conclusion (LeBro Pump actuator)
Pros:• Artificial lift that works at low SPM at
efficient working parameters• Cost effective• Energy efficient• Low maintenance• Easy installation• Lifts low volumes of murky fluid
without pumping off.• Solves height issues (Irrigation)• Greatly decreases moving parts
(Safety)• Smaller footprint (Environmental)
Stuffing box eliminated.• Able to long stroke pump to clean up
obstruction or fill. (Rig less)
Cons:• Reliability. Not enough history
(~3 yrs)• Not efficient at high spm
(>7spm)
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Q&A
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Cylinder To Wellhead
Stuffing Box is eliminated
Hammer Union feature allows for quick installation and spacing to rod string
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Rapid Fill / Gas Vent Functions
Gas lock eliminated
Only restriction is the weight needed to lift valve ball off of seat
Non- PSI difference between compression chamber and formation fluid
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HF Actuator Cylinder
Specs on the HF Cylinder:• Collapse PSI: 12,000 psi• Burst PSI: 12,000 psi (based on tensile strength)• Cylinder ID: 3.250"• Drift: 3.250"• Literal Yield Strength: 60,000 psi• Diagram for the Modified End Gland with Brass Wear Ring is
attached. Specs: 2.875" OD x 1.500" ID x 5.500" length, steel construction with brass inserted guides for wear.
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Other pictures
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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LeBro USD™ Pumping SystemOriginal design targeted cost effective measures associated with marginal wells
Specific focus on maximizing fluid movement in wells with low PSI and / or depleted reservoirs
Workover &Pulling
Workover &Pulling
TreatingTreating
Power ConsumptionHP Demand
Power ConsumptionHP Demand
ReplacementsPump, motor
Etc.
ReplacementsPump, motor
Etc.
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Copyright
Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Gas Well Deliquification Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to:
– Display the presentation at the Workshop.– Place it on the www.alrdc.com web site, with access to the site to be
as directed by the Workshop Steering Committee.– Place it on a CD for distribution and/or sale as directed by the
Workshop Steering Committee.Other uses of this presentation are prohibited without the expressed written permission of the company(ies) and/or author(s) who own it and the Workshop Steering Committee.
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Disclaimer
The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Gas Well Deliquification Web Site.The Artificial Lift Research and Development Council and its officers and trustees, and the Gas Well Deliquification Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Gas Well Deliquification Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials.The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.