10 Artificial Lift Systems

IPM – DPT Course – Artificial Lift
Schlumberger Private
FTC/PTC
May - 2003
Title – slide 1
OBJECTIVES
By the end of this section, you should be able to :
• Describe the concept of Inflow & Outflow Performance and how this relates to Artificial
Lift
• Identify the 5 most common Artificial Lift methods
• Describe the principle of operation of each type
• Compare and contrast the 5 AL methods
• Describe the main components for each AL method
• Describe and define the types of application, advantages & disadvantages for each AL
method
slide 2 / 109
AGENDA
• INFLOW AND OUTFLOW PERFORMANCE – RECAP
• ARTIFICIAL LIFT METHODS – OVERVIEW
• ROD PUMPS
• HYDRAULIC PUMPS
• PROGRESSING CAVITY PUMPS
• GAS LIFT
slide 3 / 109
INFLOW AND OUTFLOW PERFORMANCE
– RECAP-
RECAP-
slide 4 / 109
INFLOW AND OUTFLOW PERFORMANCE
SURFACE PRESSURE PRODUCED FLOWRATE
At Wellhead
• If Po < Pwf, the well will flow naturally

• (~10% of wells by number)
• If Po ≥ Pwf, the well will require Artificial Lift
• (~90%)
WELL OUTFLOW
RELATIONSHIP
Po
Required Po to produce desired rate
Pwf
Reservoir Pressure- Pr WELL
INFLOW (IPR)
WELL FACE
PRESSURE Available Pwf as function of the flowrate
slide 5 / 109
• INFLOW PREFORMANCE RELATIONSHIPS:
• Straight Line (PI):
• Pwf = Pr – Q / PI
• Vogel Relationship:
• Qo/Qomax = 1 – 0.2 (Pwf/Pr) – 0.8 (Pwf/Pr)2
slide 6 / 109
Straight line vs. Vogel – Graphically
slide 7 / 109
OUTFLOW PREFORMANCE RELATIONSHIP:
Po = Ph + Pfr + Pwh
Where,
Ph = Hydrostatic pressure
Pfr = Pressure drop due to friction losses
Pwh = Tubing - Wellhead Pressure
Several correlations have been developed to better model mixed flow

considering different factors such as flow-regime, water cut, viscosity,
well inclination, roughness, holdup, etc.
slide 8 / 109
INFLOW AND OUTFLOW GRAPHICALLY
Tubing Outflow
∆P = AL (e.g ESP)
Reservoir Inflow
slide 9 / 109
Pressure to Head Conversion
To convert pressure to head:
Fresh water gradient = 0.433 psi/ft
Head (in feet )= Pressure (psi) / (SG x 0.433)
Pressure (psi) = Head (in feet ) x (SG x 0.433)
slide 10 / 109
ARTIFICIAL LIFT METHODS - OVERVIEW
slide 11 / 109
The concept
• Artificial Lift is needed when reservoir drives do not sustain

acceptable rates or no fluid flow at all
• Lift process transfers energy downhole or decreases fluid
density in the wellbore to reduce hydrostatic load on formations.
• Artificial Lift improves recovery by reducing the bottomhole

pressure at which wells become uneconomic and are
abandoned.
slide 12 / 109
ARTIFICIAL LIFT METHODS
Camco Gas Lift (SLB) Beam pump (not SLB)

DuraLift HydroLift
PC Pumps (SLB) Hydraulic Pumps (SLB)
REDA ESP’s (SLB)
slide 13 / 109
AL Methods Applicability
Applicability of AL Methods
Condition Rod Pumps Hydraulic Pumps PCP's GL ESP's
Scale fair fair/poor fair fair poor
Sand fair fair good very good fair
Paraffin poor fair good poor good
Corrossion good fair fair fair fair
High GOR poor fair fair very good fair
Deviation poor very good fair/good very good good
Rate poor fair fair very good good
Depth fair very good fair good fair
Flexibility very good very good good good good (with VSD)
Temperature very good good poor good fair
slide 14 / 109
AL Methods vs. Wells
• Worldwide, there are approximately 890,000 oil wells in production;

94% of them utilize some form of artificial lift system
Hydraulic
By Wells & Lift Method Pumping Others
ESP’s Rod
% WW Wells WW
Pumps
Rod Pumps (reciprocating) 40% 308,160
Gas Lift 34% 261,936
PCP's 5% 38,520 PCP's
Electric Submersible Pumps 18% 138,672
Hydraulic Pumping 1% 7,704
Others 2% 15,408 Gas Lift
100% 770,400
Lifting Systems by Type World Wide
slide 15 / 109
ARTIFICIAL LIFT – Application Ranges
Typical Artificial Lift Application Range

Ft./Lift
12,000
11,000
10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 20,000 30,000 40,000 50,000 BPD
Rod Pumps PC Pumps Hydraulic Lift Submersible Pump Gas Lift
slide 16 / 109
ARTIFICIAL LIFT – System Efficiency
100
90
Overall System Efficiency (%)
80
70
60
50
40
30
20
10
0
PCP Hydraulic Piston Beam Pump ESP Hydraulic Jet Gas Lift Gas Lift
Pumps Pump (Continuous) (Intermittent)
Artificial Lift Type
slide 17 / 109
ARTIFICIAL LIFT
SELECTION
Selection involves many parameters,

criteria and constraints.
Making artificial lift decisions is
primarily a process of choosing the
lift method most applicable to
expected surface, reservoir, fluid and
operational conditions.
Because there are many strategies
for developing oil fields, artificial lift
alternatives need to be identified and
evaluated based on technical,
commercial, risk and overall system
factors.
slide 18 / 109
ROD PUMPS
slide 19 / 109
Rod Pumps
Rod Pumps combine a cylinder
(barrel) and piston (plunger) with
valves to transfer well fluids into
the tubing and displace them to the
surface.
slide 20 / 109
ROD PUMPS – BEAM PUMPS
• Most common artificial lift method
• 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.
slide 21 / 109
Sucker Rod Pumping
• Pumping unit actuates the downhole pump, which does

the actual pumping and lifting of liquid.
• Pumping capacity controlled by:
Pumping speed (typical 5 –15 strokes/min)
Stroke length (typical 54 – 306 inches)
Pump type, size, and efficiency (70%-80%).
slide 22 / 109
Principal Components
• Downhole rod driven plunger
• The rod transmitting the pumping motion
• Surface equipment converting rotational motion into linear motion
• Speed reducer
• Prime mover (power) – Electric or gas
slide 23 / 109
Rod Pumping System
Saddle Bearing
Walking Beam
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
Drawings Courtesy of Lufkin Industries, Inc. Lufkin, Texas
Downhole Pump
slide 24 / 109
How a Downhole Rod Pump Works
Tubing
Plunger Moving Up
Plunger Moving Down
Traveling valve open
Barrel
Standing valve closed

Seating nipple
Ball & seat
Cage
slide 25 / 109
Tubing Anchors
• Often a device is No buckling
used to prevent the Neutral point
tubing string from

moving with the rod
pump during
actuation.
Buckling
• A tubing anchor
prevents the tubing
from moving, and
Downstroke
allows the tubing to Standing valve closed; full
Upstroke
Traveling valve closed; most
of fluid load transferred to
be left in tension fluid load stretched tubing
down to most elongated rods. Tubing relieved of fluid
position. Tension in tubing load contracts. Tension in
which reduces rod at maximum for cycle. No
buckling
tubing at minimum for cycle.
Buckling occurs from pump
wear. to neutral point

Breathing “F”
slide 26 / 109
Rod Pumps
Advantages: Disadvantages:
Disadvantages
- Most widely used AL method - Restricted flow rates

- Best understood by field personnel - Susceptible to free gas
- Some pumps can handle sand or trash - Frequent repairs
- Usually the cheapest (where suitable) - Deviated wellbores are difficult
- Low intervention cost - Reduced tubing bore
- Low intake pressure capabilities - Subsurface safety difficult
- Readily accommodates volume changes - Doesn’t utilize formation gas
- Works in high temperatures - Susceptible to severe corrosion
- Reliable diagnostic and troubleshooting - Potential wellhead leaks or spills
tools available - Problems with deep producing
- Economic value less than 1,000 BPD intervals & gas
slide 27 / 109
HYDRAULIC PUMPS
slide 28 / 109
Hydraulic-
Hydraulic-lift Pumps
Hydraulic systems transfer energy

downhole by pressurizing a special
“power fluid”, usually a light refined
or produced oil, that flows through
well tubing to a subsurface pump,
which transmits the potential energy
(lift) to produced fluids.
Once on surface the commingled

fluids (produced oil and power fluid)
need to be separated.
slide 29 / 109
Hydraulic Pumps
• There are 3 types of systems:
• Jet (venturi) pump,
• Piston pump, or
• Turbine pump (less widely used) – not a SLB product offering
• Reasonable efficiency is attainable and can be improved with

water as power fluid due to lower viscosity.
slide 30 / 109
Basics of Hydraulic Pumping
• Power fluid:
– Typically 2000 – 4000 psi at surface
– Typically requires 2:1 to 4 :1 P.F. to well fluid ratio
– Oil or water
• Application ranges
– 1,000 – 18,000 ft setting depths
– Production rates 100 – 10,000 BPD
– Can be used to maximize drawdown
slide 31 / 109
Hydraulic Pumps
• Advantages • Disadvantages
• “Free pump” feature common to most • Vulnerable to solids (piston pumps)
designs allows pump to be easily • Surface equipment: pump, motor,

circulated in and out of well. valves and separator
• High volumes from depth (1-10,000 BPD • Low efficiency Artificial Lift
from up to 18,000 ft) method (jet pumps)
• Can pump heavy & viscous fluids • Accurate measurement required for
• Multiple zones & multiple wells well testing.
• Chemicals can be injected with power

fluid to control paraffin, corrosion and
emulsions
• Short length applicable to deviated wells
slide 32 / 109
First Style of Hydraulic Pumps
• Jet Pumps
– High velocity power fluid entrains well fluid and lifts the
co-mingled liquid to the surface for separation
– Jet pumps fill intermediate rate lift capacity between

low rate Sucker Rod Pumping & high rate Electric
Submersible Pumping
– Weatherford holds near monopoly position with

purchase of Trico & National product lines
slide 33 / 109
Jet Pumping
Pressure
Velocity
slide 34 / 109
Jet Pumping
• Production tubing
• Packer nose assembly
• Jet and nozzle throat
area
• Well casing
Key:
= Well fluid
= Power fluid from surface pump
= Commingled fluid to surface
slide 35 / 109
Advantages of Jet Pumps
• Tough D.H. applications
• Flexible AL method
– Deep Wells
– High volumes can be produced from
– Sand & solids (small qties.)
great depths
– Corrosive fluids
– Pumps can be changed (circulated out)
• Gas & water
without pulling the tubing
– Heavy oils and paraffin
– Heavy and viscous fluids are easier to
– Complex well completions
produce after mixing with lighter power
– Deviated & crooked wells
fluids
– Multiple zones
– Remote & urban locations
• Low / easy maintenance – Offshore platforms
– Field repairable – Low profile on surface
– No-moving parts – Flexible production capacity
– Multiple wells from single surface
• Environmentally friendly system = less $ per well
– Self contained systems recycle
power fluid
slide 36 / 109
• Unitized & transportable
Disadvantages of Jet Pumps
• Low system mechanical efficiencies (can be 30%)

• High fuel/energy running costs
• Well testing can be difficult due to power fluid included in the
production stream
• Traditionally had high surface maintenance costs when using
reciprocating power fluid pumps. Utilizing Reda-HPS for power fluid
pump will minimize maintenance.
• Rather vulnerable to solids
• The industry is not familiar with the systems due to past monopoly
supply & poor marketing/product knowledge
slide 37 / 109
Second Style of Hydraulic Pumps
• Hydraulic Piston Pump
– Power fluid provides the motive force to a downhole
piston pump assembly that lifts the well fluid to surface
– Separation is required.
– Can be single or double pump ends
– Can be single or double engine pistons for higher lift
– Offered as an alternative to jet pumps
– Higher efficiencies (up to 95%)
– Hydraulically retrievable
– Similar flexibility in design and application to jet pumps
slide 38 / 109
Hydraulic Piston Principle of Operation
• Hydraulic linkage to surface
• Double acting is key difference

– Pumping on up and down stroke
– Allows pump to operate slower
• Reduces wear
• Higher displacement
– Displacement capacity defined by:
• Plunger diameter
Key: • Plunger stroke

= Well fluid
• Speed
= Power fluid from surface pump
= Commingled fluid to surface
slide 39 / 109
Piston Pumps
• Downstroke • Upstroke
– P.F. acts on the engine – P.F. acts on the engine
piston (P.F. exhausted piston (P.F. exhausted
also) also)
– Common rod in pump – Common rod in pump
plunger pushes down plunger strokes up
– Downward motion lifts – Upward motion lifts and
and closes ball checks opens ball checks
– Well fluid is drawn in – Well fluid is drawn in
– Well fluid pressurized – Well fluid pressurized on
on other side of plunger other side of plunger
slide 40 / 109
Advantages of Piston Pumps
• Flexible AL method for: • For challenging applications:

– Remote & urban locations – Deep Wells
– Offshore platforms – Corrosive fluids
– Low profile on surface – Gas & water
– Flexible production capacity – Heavy oils (as low as 8 API)
– Multiple wells from single – Complex well completions
surface system = less $ per well – Retrofit applications
– Maximize drawdown – Deviated & crooked wells
– Maximize efficiency (up to 95%) – Producing from multiple zones
– Hydraulically retrievable
slide 41 / 109
Disadvantages of Piston Pumps
• Require cleaner liquids

• Close tolerances on moving components
• Not as easy to service as a jet pump
• - Technician require detailed training
• - ‘Workshop only’ rebuild
• The industry is not familiar with the systems due to past
monopoly supply & poor marketing/product knowledge
slide 42 / 109
REDA-
REDA-HPS used to pressurize power fluid
slide 43 / 109
PROGRESSING CAVITY PUMPS
slide 44 / 109
Progressing Cavity
Displacement Pumps
Progressing cavity pumps are based on
rotary fluid displacement. This spiral
system consists of a rotor turning inside
a stationary stator.
slide 45 / 109
PC Pumps Applications
• Heavy & Viscous oil and

bitumen.
• Production of solids-laden
fluids.
• Medium to sweet crude.
• Coal bed methane / gas well
de-watering.
• Agricultural areas.
• Urban areas. Lower surface footprint than Beam Pumps
slide 46 / 109
System Overview - Topdrive
• Down-hole pump components:

– Rotor.
– Stator.
• Sucker rod string.
• Surface drive head.
• Accessories:
– Torque anchor.
– Rod protectors / centralizers.
– Etc.
slide 47 / 109
System Overview – Bottomdrive
Tubing
• Down-
Down-hole: • Casing
Surface: Progressing
Cable
Cavity Pump Rotor
Stator
• PC pump • VSD Intake
• Intake. • Junction Box Gear Box & Intake
Gearbox
• Gearbox. Flex Drive
• Transformer
• Protector. Protector
Protector
FCE
• Motor.
Motor
• Cable & FCE Motor
• Rotor Adapter Perforations

• Stator Adapter
slide 48 / 109
PC Pumps Basics
Stator Pitch
Eccentricity
Stator Rotor
slide 49 / 109
PC Pumps Basics
D = Minor Diameter of Stator D

Major Diameter of Stator
D
P P = Stator Pitch length
slide 50 / 109
PC Pumps Pulsationless Flow
• Q FLOW RATE =A V
CAVITY AREA FLUID CAVITY VELOCITY
slide 51 / 109
PC Pumps Lobe Ratio
• Ratio of rotor lobes (Lr) to stator lobes (Ls) .

– Typically denoted as Lr: Ls (e.g. 1:2, 2:3, etc.)
• Stator always has one more lobe than rotor.
• Single lobe pumps have a 1:2 lobe ratio.
• Multilobe pumps include all other combinations.
– PC pumps are typically 2:3.
– Mud motors vary between 2:3 and 9:10.
slide 52 / 109
PC Pumps -Lobe Ratio and Pitch
• Pitch is length of one revolution of helix.

Rotor Lobes (Lr) Rotor Pitch (Pr)
=
Stator Lobes (Ls) Stator Pitch (Ps)
– 1:2 Rotor Pitch = ½ Stator Pitch
– 3:4 Rotor Pitch = ¾ Stator Pitch
Single lobe
pump
PSTATOR PROTOR
slide 53 / 109
PC Pumps Pumping Principle
• The geometry of the helical gear formed by the rotor and the
stator is fully defined by the following parameters:
– the diameter of the Rotor = D
– eccentricity =E
– pitch length of the Stator = P
• The minimum length required for the pump to create effective

pumping action is the pitch length. This is the length of one
seal line.
slide 54 / 109
PC Pumps Pumping Principle
• Each full turn of the Rotor produces two cavities of fluid.

• Pump displacement = Volume produced for each turn of the
rotor:
V = C *D*E*P
C = Constant (cubicMPD: 5.76x10-6 ; BPD: 5.94x10-1)
• At zero head, the flow rate is directly proportional to the

rotational speed N:
Q = V*N
slide 55 / 109
Example
Given:
– Pump eccentricity (e) = 0.25 in
– Pump rotor diameter (D) = 1.5 in
– Pump stator pitch (p) = 6.0 in
– Pump speed (N) = 200 RPM
Find:
– Pump displacement (bbls/d/rpm)
– Theoretical fluid rate (bbls/d)
slide 56 / 109
PC Pumps - Design Parameters
• Flow rate is a function of rotor diameter, eccentricity, pump

pitch length and RPM.
• Pressure capability is determined by the number of stator
pitches
slide 57 / 109
PC Pumps - Stages and Head
• Manufacturers rate the pressure capability of a pump as a function of the

number of pump stages or seal lines. Pressure capability is determined by
the number of stator pitches
• One stage is defined as the pump length required to offset 100 psi of
differential pressure.
1 Stage = 1.5 Stator Pitches

Rotor Pitch (or 3 Rotor Pitches)
Stator Pitch
slide 58 / 109
PC Pumps - Stage Ratings
• Lifting capacity is typically referred to in feet of
water, rather than stages.
– 1 stage = approx. 100 psi

– 1 stage = approx. 231 ft of lift
– 1 stage = approx. 70 meters of lift
– 1 stage = approx. 690 Kpa
• An 18 stage pump (1800 psi) is commonly

referred to as a 4000 ft (1200 meter) pump.
• For metal / elastomer interference fit:

– ∆P = 35 to 44 psi per cavity seal line.
– One stator pitch = 2 seal lines = 70 to 88 psi.
– One stage = 1.5 stator pitch = 105 to 132 psi.
• Can change pressure rating according to elastomer.
slide 59 / 109
PC Pumps – Flow Characteristics
• Interference fit between the rotor and stator creates a series of

isolated cavities .
• Rotation of the rotor causes the cavities to move or “progress”
from one end of the pump to the other.
• Non Pulsating.
• Pump Generates Pressure Required to move constant volume.
• Flow is a function of RPM.

slide 60 / 109
Progressing Cavity Pumps
Advantages Disadvantages
• Simple two piece design. • Sensitive to pump off
• Good for viscous crude • Sensitive to overpressure
• Resistant to abrasives and solids • Restricted flowrate (3 – 5000 bpd)
• Non-pulsating. Does not gas lock • Restricted setting depths (< 6500 ft)
• Oil Gravities from 5 to 42 API • Limited operating temp (< 250 F absolute
max)
• Will not emulsify fluid.
• Not compatible with some chemicals
• Reliable when properly applied
and H2S
• Efficient power usage
• Need controlled backspin
• Elastomer swells
slide 61 / 109
GAS LIFT
slide 62 / 109
Gas Lift
Gas Lift uses additional
high pressure gas to
supplement formation gas.
Produced fluids are lifted
by reducing fluid density
in wellbore to lighten the
hydrostatic column, or
back pressure, load on
formations.
slide 63 / 109
Gas Lift as an Artificial Lift Method
Gas lift injection decreases fluid average density,

density, thus the
hydrostatic load on formations is reduced so that available
reservoir energy can cause inflow, and commercial
hydrocarbon volumes can be boosted or displaced to the
surface.
By injecting relatively high pressure gas from the surface

to a predetermined depth in the wellbore,
wellbore, the average
specific gravity of the fluid decreases which causes a drop
in the well face pressure (Pwf
(Pwf)
Pwf ) generating additional draw-
draw-
down which –according to Darcy’s Law- Law- turns on increased
fluid production.
slide 64 / 109
GL Equipment overview: Typical System
INFLOW
slide 65 / 109
Gas Lift – Advantages & Disadvantages
Advantages Disadvantages
• Low operational and maintenance cost
• Must have a source of gas
• Simplified well completions
• If gas is corrosive will require
• Flexibility - can handle rates from 10 to 80000
treatment
bpdmax, • Possible high installation cost
• Typical rates go up to 35000 bpd • Top sides modifications to existing
• Can best handle sand / gas / dev well

platforms
• Low CapEX (Capital Expenditures) • Compressor installation &

maintenance
• Limited by available reservoir pressure
• Limited by bottom hole flowing pressure
slide 66 / 109
Types of Gas Lift Application
CONTINUOUS FLOW GAS LIFT

•ENABLE
ENABLE WELLS THAT WILL NOT FLOW NATURALLY TO PRODUCE
•INCREASE
INCREASE PRODUCTION RATES IN FLOWING WELLS
•UNLOAD
UNLOAD A WELL THAT WILL LATER FLOW NATURALLY
•REMOVE
REMOVE OR UNLOAD FLUID IN GAS WELLS
•BACK
BACK FLOW SALT WATER DISPOSAL WELLS
•LIFT
LIFT AQUIFER WELLS
INTERMITTENT GAS LIFT:

•LOW
LOW Pr, PI, Pwf
•CHOKE
CHOKE CONTROLLED UTILISING A PILOT OPERATED VALVE OR MOTOR
CONTROLLED
•REQUIRE
REQUIRE RAPID INJECTION OF GAS = PILOT OPERATED GAS LIFT VALVE
•FALLBACK
FALLBACK LOSSES TYPICALLY 5 - 7% PER 1 000 FT OF TUBING
slide 67 / 109
Continuous Gas Lift
• ONLY ARTIFICIAL LIFT METHOD THAT FULLY UTILIZES THE ENERGY FROM THE
FORMATION GAS PRODUCTION
• EXTENSION OF NATUAL FLOW BY SUPPLEMENTING THE FORMATION GAS WITH
ADDITIONAL HIGH PRESSURE GAS
• GAS IS INJECTED CONTINUOUSLY INTO THE PRODUCTION CONDUIT AT A

MAXIMUM DEPTH BASED ON AVAILABLE GAS PRESSURE
• INJECTION GAS MIXES WITH THE PRODUCED WELL FLUIDS AND DECREASES THE
FLOWING PRESSURE GRADIENT OF THE MIXTURE
• THE LOWER FLOWING PRESURE GRADIENT REDUCES THE FLOWING BOTTOM

HOLE PRESSURE TO ESTABLISH ADDITIONAL DRAWDOWN
slide 68 / 109
Continuous Gas Lift
0
Casing pressure when
Flo
Injection gas Produced fluid well is being gas lifted
win
1000
g
tub
ing
pre
2000
ssu
re g
3000
rad
i
ent
Depth
(ft TVD) 4000
5000 Operating gas

lift valve
6000
SIBHP
7000
FBHP
0 1000 2000
Pressure (psi
( psi)
psi )
m6_csys_1
slide 69 / 109
Intermittent Gas Lift
slide 70 / 109
Gas Lift – Vertical Gradient Curves
PRODUCED FLUID CONSTANT FLOW GAS LIFT WELL
PRESSURE (PSI)
INJECTION GAS 0 1000 2000
0
FL
OW
ING
1000
TU
CASING PRESSURE WHEN
WELL IS BEING GAS LIFTED
BIN
G
PR
2000
ES
SU
RE
DEPTH (FT TVD)
3000
GR
AD
IEN
OPERATING GAS LIFT VALVE
T
4000
5000
6000
SIBHP
7000
FBHP
slide 71 / 109
Gas Lift – Unloading Sequence
TO SEPARATOR/STOCK TANK TO SEPARATOR/STOCK TANK
INJECTION GAS INJECTION GAS
slide 72 / 109
TO SEPARATOR/STOCK TANK
TO SEPARATOR/STOCK TANK
INJECTION GAS
INJECTION GAS
slide 73 / 109
TO SEPARATOR/STOCK TANK TO SEPARATOR/STOCK TANK
INJECTION GAS INJECTION GAS
PLUGGED
slide 74 / 109
PRODUCED FLUID
INJECTION GAS
slide 75 / 109
Gas Lift Unloading Animation
Shortcut to GL Unloading Sequence_rev6.exe.lnk
slide 76 / 109
GL Equipment overview: Types of Valves
3 basic types of gas lift valve, each available in 1” & 11--1/2” sizes:
Dummy Valves Orifice Valves Unloading Valves
(operating valves)
• Square edged • Injection pressure (casing)

• Venturi (Nova) operated valves
• Production pressure (fluid)
operated valves
• Throttling/proportional response
valves
slide 77 / 109
GL Equipment overview: Unloading Valves
• 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 due to a casing
pressure drop (additional gas rate causes ∆P)
• Valves may be nitrogen charged (need to be calibrated for
temperature & pressure) or spring loaded (temperature
independent)
slide 78 / 109
GL Equipment overview: Unloading Valves
Unloading valves are designed to be open during the unloading of the well and
then to close. Basically, there are 3 types of unloading valves:
valves :
Dome Pb
Pb Pb
Dome Dome Spring
Chevron Chevron Chevron
Packing Packing Packing
Stack Stack Stack
Bellows Bellows
Bellows
StemTip (Ball)
Square Edged
Pc
Seat Pc
Pc
Stem Tip (Ball)

Large T.C. Ball
Square Edged
Seat Tapered
T.C. Seat
Pt
Chevron Chevron Pt
Packing Packing Chevron
Pt
Stack Stack Packing
Stack
Check Valve Check Valve

Check Valve
Nitrogen Charged Bellows Type Nitrogen Charged Bellows Type

Injection Pressure (Casing) Operated Gas Lift Valve Production Pressure (Fluid) Operated Gas Lift Valve Nitrogen Charged Bellows Type
Proportional Response Gas Lift Valve
slide 79 / 109
GL Equipment overview: Operating Valves
• Always open - allows gas across Passage whenever correct

differential exists
•
• Gas injection controlled by size and differential across
replaceable choke
• Back-
Back-check prevents reverse flow of well fluids from the
production conduit
slide 80 / 109
1. KBMG Series SPM
2. MMG Series SPM
3. MTG Series SPM
1 2 3
slide 81 / 109
GL - Surface Control Equipment
• Primary Purpose
– Control and measure flow from a producing oil and gas
well, secondary recovery water or gas injection well and
injected gas in a gas lift field operation.
• Secondary Purpose
– Real time flow control measurement which allows precise
valve positioning from a remote controller by use of an
electronic actuator with 4-
4-zoma or digital hart
communication control.
slide 82 / 109
GL - Summary
• Takes full advantage of the gas energy

available in the reservoir
• High volume lift method
• Valves may be retrieved by slickline or tubing
• Handle abrasives and sand
• Must have a gas source

• Freezing and hydrates are problematic
• Difficulty depleting low productivity and low
pressure wells completely
slide 83 / 109
ELECTRIC SUBMERSIBLE PUMPS
slide 84 / 109
Electric Submersible Pumps – ESP’s
Electric submersible systems use

multiple pump stages mounted in series
within a housing, mated closely to
submersible electric motor on the end of
tubing and connected to surface
controls and electric power by an armor
protected cable.
slide 85 / 109
ESP’s - Basics
The main function of an Electric Submersible Pumping (ESP)

System is to bring fluid from the reservoir to surface.
The ESP was introduced as a means of Artificial lift by REDA in the
late 1920s.
There are a variety of pump sizes, capacities, motor horsepower,

and voltage ranges for different applications
slide 86 / 109
ESP – Centrifugal Pump
The multistage centrifugal

pump consists of numerous
impellers and diffusers
(application dependent) to
provide the lift (pressure)
required
slide 87 / 109
ESP - Pumps
• A Centrifugal Pump is a machine that

moves fluid by spinning it with a rotating
impeller in a stationary diffuser that has
a central inlet and a tangential outlet.
• The path of the fluid is an increasing
spiral from the inlet at the center to the
outlet tangent to the diffuser.
• The pressure (head) develops against
the inside wall of the diffuser as the
curved wall forces fluid to move in a
circular path upwards and into the
impeller and diffuser above.
slide 88 / 109
ESP
Pump
Performance
Curves
ESPs operate at
3,500 rpm on a
60-cycle power
supply or 2,900
rpm on a 50-
cycle power
supply.
slide 89 / 109
ESP Gas Separators
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.
slide 90 / 109
ESP Gas Separators
There Are Several Methods

of Separating the Gas From
Solution. Two Different
Types of Gas Separators
Include:
• Static Dynamic
ESP Gas Separators
A gas separator is still an intake, but with some special
features designed to keep free gas from entering the pump.
Static Type - Allows the well fluid to enter past a multitude
of passages where reversals in flow direction occur,
creating a pressure drop, and seperating gas from solution
to escape to the annulus.
Since this type of gas separator does no real
"work" on the fluid, it is also called a "static" gas
separator.
Dynamic Type - Allows entry of fluids and gas at the

base of the separator into a rotating centrifuge with and
inducer and straightenting vanes. Heavier fluids move to
the outside and the gas to the inside. Gas passes through Static
a crossover and up the annulus. Dynamic
slide 92 / 109
ESP Protector
The protector is the

piece of equipment
that is located directly
above the motor.
slide 93 / 109
ESP - Functions for the Protector
– Couples the torque developed in the motor to the

pump via the protector shaft.
– Prevents entry of well fluid into the motor.
– Provides pressure equalization.
– Houses the bearing to carry the thrust developed
by the pump and keep it off the motor
slide 94 / 109
ESP - Motor
The motor is a three

phase, squirrel cage,
two pole induction
design.
It’s the “heart” of the

system since it provides
the torque required by
the downhole pump.
slide 95 / 109
ESP - Motor Selection
They are available in a
number of different
Sizes, Voltages, and
Horsepower ranges
depending on the
application
slide 96 / 109
ESP - Power Cable
And Motor Lead Extension
• Electric power is transferred

to the assembly through an
electrical cable attached to
the tubing.
MLE Cable
Power Cable
ESP - Power Cable
Electrical power cable is used to transmit the power

from the surface to the submersible motor.
Power Cable consists of three copper
conductor wires extending from the top of the
motor flat cable lead to the wellhead.
The size of the cable selected is based

on amperage and voltage drop.
Bottom hole temperature is critical for

the selection of cable.
The electrical cable has been refined

over the years to be used specifically
for oilwell applications.
slide 98 / 109
ESP – Power Cable Components
The conductor - electrical properties
Insulation material - protects and covers the conductor wire
Barrier Jacket - protects and covers the insulation.
Jacket Material - rubber compound designed for temperature,
chemical, and gas considerations.
The exterior armor - the outer shield that holds it all together
slide 99 / 109
ESP - Surface Equipment
Shown here is the surface related equipment required for
most down-
down-hole electrical submergible pump systems.
Transformers
VSD’s J-Boxes
Wellhead Connectors
slide 100 / 109

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.
Special tubing hangers are

required to allow for cable
and/or connector passage.
slide 101 / 109

Electrical transformers are required to

deliver the correct voltages at the
motor terminals.
- Step-
Step-down transformers:
- Step-
Step-up transformers:
Transformers can be either single

phase or three phase.
slide 102 / 109

Transformers
Motor
controller
Wellhead
Junction
box
Production
Casing
Primary cable
Drain valve
Check valve
1 joint Tubing
Motor flat cable
Pump
Pump intake
Protector
Pothead
Motor Perforations.
slide 103 / 109

ESP – J Box
• A Junction box or vent box:
Provides a connection point for the surface

cable from the motor control panel to the power
cable in the wellbore.
Allows for any gas to vent that may have

migrated through to the power cable.
Provides easy accessible test point for
electrically checking downhole equipment.
ESP Motor Controllers - Switchboards
The controller is a device that can be used as

to drive the motor and provide protection
capabilities (overload, under load, etc).
The controller also provides the capability to
monitor the REDA Production system with the
use of a recording instrument.
The two types of controllers offered are

electro-mechanical relays (switchboard)
or solid-state control circuitry (VSD).
ESP Motor Controllers – VSD’s
The variable speed controller allows

for flexibility of the downhole system
for flow control capabilities.
It provides a constant ratio of
between voltage and frequency
for proper operation.
ESP ‘s Advantages
Can achieve high production rates

When VSD operated, can offer flexibility to accommodate
changing conditions in time (PI, water cut, Pwf, Pr, etc.)
Can be used at low bottom hole pressures.
Can operate reliably in deviated wells.
Can be used effectively for offshore applications.
Can operate at high temperatures with the use of alternative
materials.
Can be utilized in corrosive and scaling conditions with
alternative materials.
slide 107 / 109

ESP ‘s Disadvantages
A pulling unit is required to retrieve the failed ESP

Cable temperature limits must be identified.
High deviations and dog leg severities will be a problem.
Available electric energy for the required horsepower
must be available.
Usage of Switchboards at constant speed limit the
flexibility of the production rates.
Higher gas content can limit system capabilities.
High solids may cause rapid wear and premature failure.
slide 108 / 109

ESP - Summary
Electric submersible systems use multiple pump
stages mounted in series within a housing, mated
closely to submersible electric motor on the end of
tubing and connected to surface controls and
electric power by an armor protected cable.
• Wide performance range and versatility (VSD
only)
• Can operate in deviated wells and off shore
• Most efficient and economical lift method on a
cost-per-barrel basis
• Tubing must be pulled to change or repair the
pump
• Depth and GOR restrict capacity and operating
efficiency
• Large volumes of gas can lock up the pump
slide 109 / 109

10 Artificial Lift Systems

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10 Artificial Lift Systems

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IPM – DPT Course – Artificial Lift

• Identify the 5 most common Artificial Lift methods

• Compare and contrast the 5 AL methods

• Describe the main components for each AL method

• ARTIFICIAL LIFT METHODS – OVERVIEW

• PROGRESSING CAVITY PUMPS

• If Po < Pwf, the well will flow naturally

• Straight Line (PI):

• Qo/Qomax = 1 – 0.2 (Pwf/Pr) – 0.8 (Pwf/Pr)2

Several correlations have been developed to better model mixed flow

Head (in feet )= Pressure (psi) / (SG x 0.433)

• Artificial Lift is needed when reservoir drives do not sustain

• Artificial Lift improves recovery by reducing the bottomhole

Camco Gas Lift (SLB) Beam pump (not SLB)

• Worldwide, there are approximately 890,000 oil wells in production;

Typical Artificial Lift Application Range

Rod Pumps PC Pumps Hydraulic Lift Submersible Pump Gas Lift

Selection involves many parameters,

• Most common artificial lift method

• Used mostly in shallow to middle-depth oil fields (< 10,000 ft [3048

• Identified by characteristic “pump unit” – “nodding donkey”

• Surface pumping unit is connected via sucker rods to a downhole

• Pumping unit actuates the downhole pump, which does

Traveling valve open

Standing valve closed

Ball & seat

• Often a device is No buckling

used to prevent the Neutral point

tubing string from

wear. to neutral point

- Most widely used AL method - Restricted flow rates

Hydraulic systems transfer energy

Once on surface the commingled

• There are 3 types of systems:

• Jet (venturi) pump,

• Reasonable efficiency is attainable and can be improved with

• “Free pump” feature common to most • Vulnerable to solids (piston pumps)

designs allows pump to be easily • Surface equipment: pump, motor,

• Multiple zones & multiple wells well testing.

• Chemicals can be injected with power

• Short length applicable to deviated wells

– Jet pumps fill intermediate rate lift capacity between

– Weatherford holds near monopoly position with

• Packer nose assembly

• Low system mechanical efficiencies (can be 30%)

• Hydraulic Piston Pump

– Power fluid provides the motive force to a downhole

• Hydraulic linkage to surface

• Double acting is key difference

Key: • Plunger stroke

= Commingled fluid to surface

• Flexible AL method for: • For challenging applications:

• Require cleaner liquids

• Heavy & Viscous oil and

• Down-hole pump components:

• Rotor Adapter Perforations

D = Minor Diameter of Stator D

P P = Stator Pitch length

• Ratio of rotor lobes (Lr) to stator lobes (Ls) .

• Pitch is length of one revolution of helix.

• The minimum length required for the pump to create effective

• Each full turn of the Rotor produces two cavities of fluid.

• At zero head, the flow rate is directly proportional to the

• Flow rate is a function of rotor diameter, eccentricity, pump