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Gas Well Deliquification Workshop
Sheraton Hotel, Denver, Colorado
February 19 – 22, 2012
Diverter Gas Separator
Jim McCoy
Lynn Rowlan, Dieter Becker, Ken Skinner
Echometer Company
Tony Podio - University of Texas – Austin
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liquid in
anchor
pump
slip
gas in
anchor
Basic Principles of Downhole Separator
System
Gravity separation is the
governing principle for
downhole gas separators.
2
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GAS BUBBLES FLOW UPWARD IN OIL OR WATER AT A RATE OF APPROXIMATELY
6 INCHES PER SECOND. THUS, GAS BUBBLES WILL BE RELEASED FROM A LIQUID
COLUMN IF THE DOWNWARD LIQUID VELOCITY IS LESS THAN 6 INCHES PER
SECOND.
A LIQUID COLUMN HAVING AN AREA OF 1 SQUARE INCH TRAVELLING AT A
VELOCITY OF 6 INCHES PER SECOND IS A RATE OF APPROXIMATELY 50 BPD
Gas Rise Velocity in oil and
water is approximately 6 inches
per second.
If the downward liquid velocity
is greater than 6 inches per
second, gas is drawn
downward.
Gas Separation from Liquid
Gas Separator Liquid
Capacity is based on
the principle that gas
is lighter than liquid
and tends to rise.
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 3
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Natural Gas Anchor
The most efficient downhole gas separators locate the pump intake below the lowest gas entry point.
2012 Gas Well Deliquification Workshop
Denver, Colorado Feb. 19 – 22, 2012 4
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Improved Natural Gas Anchor
Maximum flow
area in casing
annulus below
pump.
2012 Gas Well Deliquification Workshop
Denver, Colorado Feb. 19 – 22, 2012 5
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Liquid Capacity for Various Annular Areas
Natural Gas Anchor
2012 Gas Well Deliquification Workshop
Denver, Colorado Feb. 19 – 22, 2012 6
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“Poor Boy” Gas Separator above perforations
A small, long dip tube
within a small
diameter separator.
Very poor design with
a small outer tube ID
and long flow paths.
Only acceptable for
low volume wells.
7
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2012 Gas Well Deliquification Workshop
Denver, Colorado
“Poor Boy” Gas Separator
Seating Nipple
Collar
Perforated Sub
Collar
Joint of Tubing
Dip Tube
Tubing Collars
prevent perforated
sub from laying
against casing wall
where liquid
accumulates
Casing
Limited Flow Area
and Small
3/8 inch holes in
perforated sub limit
gas exit flow and
liquid entry thus
reducing separation
efficiency
Feb. 19 – 22, 2012 8
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“Poor Boy” Gas Separator Liquid Capacity
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 9
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Collar Size Separator Increases Liquid Capacity
A good separator must
strike a balance between
annular flow area,
separator flow area, dip
tube diameter and
pressure drop.
Outer barrel OD same as collar OD.
Thin wall outer barrel and dip tube.
Short flow conduits.
Large inlet ports.
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 10
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To get gas capacity of a specific installation multiply the
table value by the Pressure at the Pump Intake (psi)
and divide by 14.7 2012 Gas Well Deliquification Workshop
Denver, Colorado
11
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Packer Gas Separator
• Uses gravity separation
like the “Poor Boy”
except much more
separation area and
capacity.
• Higher cost and higher
risk of mechanical and
sand problems.
2012 Gas Well Deliquification Workshop
Denver, Colorado Feb. 19 – 22, 2012 12
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Concentric Packer Gas Separator
A concentric packer type gas
separator offers additional liquid
and gas capacities.
2012 Gas Well Deliquification Workshop
Denver, Colorado Feb. 19 – 22, 2012 13
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Diverter Gas Separator Animation
Pump
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Diverter Gas Separator Animation
Pump
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Pump
Reservoir Fluid Discharge Above Diverter
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Liquid Inlet Ports
The liquid falls to these
ports and is directed into
the pump inlet using large
ports and short tube to
minimize pressure drop
from inlet ports to pump
inlet.
5 Feet
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Diverter Cups The diverter cups are
constructed from high
temperature, flexible,
wear-resistant, premium
elastomer.
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Diverter Cups
Multiple cups can
be utilized as
desired
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2012 Gas Well Deliquification Workshop
Denver, Colorado
Shear Pins
Shear pins are located below the
diverter cups. The force required to
shear the shear pins is operator
selectable. Factory setting is 4000
pounds.
If the diverter cups are not
retrievable with the gas separator,
the cups will be left in the well with
the shear pins and shear collar.
Pump
Feb. 19 – 22, 2012 20
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Sand Accumulation
Sand or debris may deposit above the swab cup
flow diverter. If 5 inches of sand accumulates
over the diverter between the gas separator and
the casing wall, the flow of liquid into the gas
separator will cease and production from the
tubing will cease.
When sand or debris is blocking the gas
separator liquid inlet ports, a fluid level test will
indicate a high fluid level in the casing annulus
and a dynamometer pump card will indicate low
or no pump fillage. The well will require
servicing.
The diverter cups can be located further from the
inlet ports if desired.
Pump
2012 Gas Well Deliquification Workshop
Denver, Colorado 21
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Sand Accumulation
When the pump is unseated, liquid in the tubing
will flow down the tubing and discharge out of the
gas separator through the gas separator liquid inlet
ports. The discharging liquid will be at high
pressure. This will wash the sand and debris away
from above the diverter. The discharging liquid will
flow up the casing annulus and carry the sand.
Probably ½ of the liquid and sand will flow down
through the gas separator into the lower portion of
the casing below the diverter. The discharging
liquid should carry some of the sand from above
the diverter to below the diverter.
Reseat the pump and pump the well. Perform the
liquid level test and dynamometer test to insure the
well is operating properly.
Pump
2012 Gas Well Deliquification Workshop
Denver, Colorado 22
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Sand Accumulation - Shear Pin
Sand can accumulate above the gas separator
diverter and cause difficulty in removing the gas
separator and diverter from the well.
Retrieval of the gas separator and diverter may still
be a problem even after flushing sand from above
the diverter. A shear pin is located at the bottom of
the swab cup diverter on the gas separator so that
the gas separator can be removed from the diverter
and retrieved from the well. The shear pin holds the
diverter swab cups to the gas separator. When the
shear pin is sheared, the gas separator can be
separated from the diverter swab cups and
removed from the well. The shear pin will shear at
4000 # (pre-set or as desired).
Pump
2012 Gas Well Deliquification Workshop
Denver, Colorado 23
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2012 Gas Well Deliquification Workshop
Denver, Colorado
Fluid Pressures
Surrounding Separator
Pump
58 psi Fluid Discharge Pressure
60.5 psi Liquid Inlet Pressure
60 psi Separator Inlet Pressure Feb. 19 – 22, 2012
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Producing BHP Recommendation
PBHP 10% of SBHP insures producing 97% of Well’s Max Rate
25
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Producing BHP Recommendation
PBHP 25% of SBHP produces 90% of Well’s Max Rate
3600 3240
SBHP PSI
0 3600
720
1080
1440
1800
2160
2520
2880
26
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Echometer Test Equipment
5000 psi gas gun 15,000 psi gas gun 1500 psi Compact Gas Gun Liquid Level Tracking Pressure Transient Testing Plunger Lift Analysis Plunger Tracking Pump Animation Wireless Equipment
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Insufficient Gas Separator
A good Gas Separator will separate the gas from the
liquid in the casing annulus and cause the liquid to
enter the pump if sufficient liquid exists in the casing
annulus.
If a well has a high fluid level and the pump is not full,
the separator capacity is not sufficient for the well.
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 28
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Insufficient Gas Separator
• The pump is not at fault when gas is present
in the pump and liquid exists in the casing
annulus. Do not blame the pump.
• The gas separator capacity is not sufficient
for the well.
• This is a common error of many operators.
• However, the gas and liquid capacity of the
well may exceed the separation capacity of
the available space in the Casing/Tubing
combination.
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 29
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High Fluid Level High Casing Gas Flow Rate
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Fo max Fo from fluid level Fo Plunger
Feb. 19 – 22, 2012 31
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Fluid Level Test and Analysis
Cobra Oil and Gas
Feb. 19 – 22, 2012 32
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Stabilized Surface Dynagraphs
COBRA
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 33
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Surface Dynagraphs and Pump Card
Cobra
Feb. 19 – 22, 2012 34
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Diverter Gas Separator Laboratory Test System
Available for demonstration on request
On Memory Stick 2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 35
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No Gas at Pump
No gas was flowing with the water
in this slide. The liquid enters the
separator and falls to the diverter
water inlet to the pump.
The rate is 600 BPD with no gas.
2012 Gas Well Deliquification Workshop
Denver, Colorado
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Fluid Level At Separator
The top of the gaseous column at 1
to 3 feet above the top of the diverter
gas separator was used to determine
maximum gas flow rate for a certain
water rate in these tests and these
numbers were used in the calculation
of the Diverter Performance
Calculator.
The water rate was 400 BPD with a
gas rate of 45 MCF/D in this slide.
2012 Gas Well Deliquification Workshop
Denver, Colorado
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High Fluid Level
The casing above the diverter
separator is full of gaseous liquid
column up to the top of the test
fixture. This rate is 400 BPD with
90 MCF/D
The gas rate is greater than is
used in the Performance
Calculator Spreadsheet. 2012 Gas Well Deliquification Workshop
Denver, Colorado Feb. 19 – 22, 2012
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Pressure Across Diverter Cups
At 400 BPD
and 75 MCF/D
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Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
40
Diverter Gas Separator Performance Calculator
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Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
41
Diverter Gas Separator Performance Calculator
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Diverter Calculator Input and Analysis
On Memory Stick 2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 42
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Analysis at 300 BPD – 4.7 ID – 150 psig PIP
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 43
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Diverter Gas Separator Configuration
Tubing String
Tubing Anchor
1 joint of tubing
Pump
Seating Nipple
Diverter Gas Separator
Diverter cups
Separator
Fluid Inlet
Fluid
Outlet
Liquid
Inlet
A 2 foot sub is needed below the seating nipple
if a short strainer nipple is run below the pump. 2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 44
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Diverter Cups – After Roundtrip
The Diverter Gas Separator was run
to 7500 feet. The pump and rods
were installed. The rods unscrewed
from the pump. The tubing and
separator were pulled to retrieve the
pump. Shown are the diverter cups
in good shape.
Water was discharged at a show
rate into the casing annulus while
the separator was run into and out of
the well. The liquid level was at
3000 feet.
2012 Gas Well Deliquification Workshop
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Negligible free Gas at Pump
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 46
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Full Pump – Limited Free Gas
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 47
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Grantham 12 Fluid Level Test
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 48
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Grantham 12 Casing Pressure Buildup Gas Flow 285 MCF/D in Casing Annulus and at Pump
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 49
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Grantham 12 Casing Pressure Buildup Gas Flow 285 MCF/D in Casing Annulus and at Pump
Gas Flow at Pump (Volume)
285 * 15 / 491 = 8700 CF/D
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 50
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Grantham 12 Dynamometer
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 51
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Pump Position, Velocity and Rate
Strainer nipple (64 - 3/16 inch holes) and 2 standing valves may cause excessive pressure drop and cause free gas to be in pump
Pump Position Velocity
Maximum Rate is 1258 BPD
Upstroke
Upstroke
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 52
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Pump Rate During a Stroke
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 53
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Grantham 12 Fluid Level Test 02/12/2012
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 54
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Grantham 12 Dynamometer 02/13/2012
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 55
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Grantham 12 Fluid Level Test 02/14/2012
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 56
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Grantham 12 Dynamometer 02/14/2012
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 57
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Grantham 12 Dynamometer
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 58
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Grantham 12 Fluid Level Test
2012 Gas Well Deliquification Workshop
Denver, Colorado
Feb. 19 – 22, 2012 59
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Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
60
Use Efficient Downhole Gas Separators to
INCREASE OIL AND GAS PRODUCTION
IMPROVE EFFICIENCY OF THE LIFT SYSTEM
CORRECT ARTIFICIAL LIFT PROBLEMS
CAUSED BY INCOMPLETE PUMP FILLAGE
DUE TO GAS INTERFERENCE
REDUCE OPERATING COST
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Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
61
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 use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Gas Well Deliquification Workshop where it was first presented.
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Feb. 19 – 22, 2012 2012 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.