Hydraulic Piston Pump Field Trial

Transcription

1 Gas Well Deliquification Workshop Sheraton Hotel, February 23 25, 215 Hydraulic Piston Pump Field Trial Kees Veeken, Sjoerd den Daas, Tim Ebare, Erik Riemsma, Bert Lugtmeier (Shell-NAM, NL) David Bolt, Travis Bolt (Cormorant Engineering, USA) Armand Vasseur (BakerHughes, NL)

2 Contents Business case Pump selection Surface and subsurface equipment Trial setup Trial results and discussion Permanent application Conclusions Feb , Gas Well Deliquification Workshop 2

3 Business Case Onshore gas asset features ~265 wells that will all (eventually) require deliquification Firm deliquification scope consists of combination of compression, velocity string and continuous foam But technical limit requires either pump, gas lift or plunger assisted intermittent gas lift (PAIGL) Gas lift (and PAIGL) can be applied where lift gas is available Other locations can benefit from pump, scope is inversely proportional to cost Currently 5-15 wells qualify for pump, actual numbers will depend on performance and reliability Carried out 2-week manned trial to prove performance Feb , Gas Well Deliquification Workshop 3

4 Pump Selection m (8,-12, ft) 9-13 degc (2-27 degf) 55% 3.5, 45% 4.5 tubing 75% 2 m 3 /d (12 bpd) liquid (low CGR, condensed water only) no ESP, energy efficiency not important Need functioning master gate valves no BP or PCP Prefer minimum surface facilities no JP or SRP Selected Cormorant 1.5 action hydraulic piston pump: fits inside 4.5 tubing and delivers 2 m 3 /d from 3 m for 2+ years; very low energy efficiency Production Rate - BPD TT SA SRP TC SA Well Depth 1m DA 5 Feb , Gas Well Deliquification Workshop 4

5 1.5 Action Hydraulic Piston Pump 3 OD hydraulic driven piston pump Deployed on 1-1/2 x 7/8 concentric coiled tubing (CCT), annulus contains hydraulic oil, inside contains produced liquid Hydraulic power is applied on both conduits Connector between CCT and pump features shear disconnect and force compensation Feb , 215 Pump includes poor boy gas separator at bottom 215 Gas Well Deliquification Workshop 5

6 Hydraulic Skid Surface System 2x 1 ft container Hydraulic skid delivers hydraulic pressure (up to 2 bar or 29 psi) to both hydraulic oil and produced liquid systems, and records pressures and volumes Water skid contains miniseparator and accumulator, and records gas/condensate level Modified to more stringent EU standards for pressure vessels, pipes and fittings, electronics etc. Water Skid Feb , Gas Well Deliquification Workshop 6

7 Trial Setup Pump installed at 32m (99 ) inside 5.5 completion, equipped with memory P/T gauges Power Hung off on CCT and operated via CCT for 12 days, pumping.5-1. m 3 /d (3-6 bpd) Liquid Gas Produced liquid and gas measured in well test separator, samples taken 5 Feb , Gas Well Deliquification Workshop 7

8 Inject 1 m 3 water Inject 1 m 3 water Inject.5 m 3 water Cumulative Liquid (m 3 ) Gas Rate (e3 Nm 3 /d), BHP (bara) Start pumping Gas Production & BHP Gas production increased to 27, Nm 3 /d (95 Mscf/d) compared to normal 12, Nm 3 /d (42 Mscf/d, bubble flow), matched by memory BHP which shows liquid level dropping 7 Liquid Gas BHP m 3 /d m 3 /d A B C D 2 1 Feb , Gas Well Deliquification Workshop 8

9 CITHP (barg) Pressure Build-Up (PBU) Surface PBU shows full unloading after 5 days pumping 4 PBU 27/5/214 11k PBU 9/8/214 32k PBU 18/8/214 18k PBU 31/8/14 23k 1d DP PBU 1/9/14 23k 2d DP PBU 7/9/14 27k 8d DP PBU 4/9/14 27k 5d DP Liquid Column SI Time (min) Feb , Gas Well Deliquification Workshop 9

10 BS&W, SG, ph/1 (-) Cumulative Liquid (m 3 ) Liquid Sampling B: pump stalls after 4 m 3 (25 bbl) cumulative liquid C: recovers after pumping ~.4 m 3 (2.5 bbl) condensate 1.2 BS&W SG ph/1 Liquid Liquid Column A B C D. Feb , Gas Well Deliquification Workshop 1 1

11 BS&W, ph/1 (-) SG (-) Water Sampling Fresh water filling inner CT stagnant brine across bottom of wellbore produced fresh condensed water brine dumped in well 1.2 BS&W ph/1 SG A B C D..95 Feb , Gas Well Deliquification Workshop

12 Hydrocarbon GC Analysis Wellbore contained contaminated (black) stripped condensate, which (temporarily) stalled pump Wellbore contained about 1 L of very fine metal debris probably suspended at interface, which caused (temporary) plugging of pump inlet Condensate 3-Sep Sep-214 Feb , Gas Well Deliquification Workshop 12

13 Reconstruction of Events B: pump stalls due to hydrocarbon and debris A B C D Feb , Gas Well Deliquification Workshop 13

14 Gas (Sm3) Gas Volume Gas volume produced is minimal and not responsible for pump stalling.5 Expected solution gas.2-.4 Sm 3 /m 3 ( scf/bbl) Measured solution gas.1 Sm 3 /m 3 (.6 scf/bbl) Liquid (m3) Feb , Gas Well Deliquification Workshop 14

15 Pressure (barg) Position (in.), Volume (L) Piston Pump Efficiency Piston displacement calculated from accumulator volume (Volume in chart) close to theoretical optimum 3 Oil Pressure Water Pressure Gas Separator Accumulator 3 25 Pump signature at.5 m 3 /d 9 cycles of 2.5L per hour Feb , Gas Well Deliquification Workshop 15

16 Pressure (barg) Position (in.), Volume (L) Liquid Volume Pumped Liquid production calculated from accumulator volume (Volume in chart) agrees with well test separator measurement 3 Oil Pressure Water Pressure Gas Separator Accumulator x 2.5L (.66 gal) = 12.5L (3.3 gal) Feb , Gas Well Deliquification Workshop 16 5

17 Pressure (barg) Position (in.), Volume (L) Gas Level Position? Vega radar level gauge (Position in chart) should indicate gas level in separator but in this case probably records hydrocarbon level instead 3 25 Oil Pressure Water Pressure Gas Separator Accumulator Dumping hydrocarbon Feb , Gas Well Deliquification Workshop 17

18 Depth (m AHTBF) Flowing Pressure Gradient (FPG) FPG before shows liquid above perfs from loading FPG after shows liquid above perfs from holdup FPG 3Aug14 25e3Nm3/d 3.9barg 2hrs FTHP~5 bara (73 psia) FPG 11Sep14 21e3Nm3/d 3.6barg BHP (bara) Condensed water moves top to bottom Annulus is not dry! 2 25 A D Sign of plugging 3 Min BHP~12 bara (174 psia) Feb , Gas Well Deliquification Workshop 18 35

19 Trial Evaluation Excellent gas separation (and pump deep enough) Excellent surface monitoring of pump performance Excellent surface handling of produced fluid add radar detection of gas level in separator Maximum pumped capacity 1 m 3 /d (6 bpd), probably restricted by partial plugging of pump inlet, sufficient for this well Pump design did not allow unexpected amount of metal debris extend sump Pump design did not allow unexpected amount of (stripped) condensate increase produced liquid pressure Feb , Gas Well Deliquification Workshop 19

20 Permanent Installation Requires spool piece and special CCT hanger (Cameron) to maintain functioning master gate valves Requires SC-SSSV exemption Requires integration in unmanned surface facility and instrumentation Requires minor modifications of well and surface equipment Requires procedures for cutting CCT and connecting CCT to hanger Feb , Gas Well Deliquification Workshop 2

21 Conclusions Hydraulic piston pump trial provided confidence to proceed with permanent installation Pump trial revealed surprising amounts of contaminated stripped condensate and suspended metal debris Pump trial identified modifications required for pump and surface equipment Pump trial was too short to prove reliability Permanent installation will establish reliability and cost prior to deciding on deployment of pumps in other wells Feb , Gas Well Deliquification Workshop 21

22 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 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. Feb , Gas Well Deliquification Workshop 22

23 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. Feb , Gas Well Deliquification Workshop 23