THE APPLICATIONS OF SURFACE JET PUMP TECHNOLOGY TO INCREASE OIL & GAS PRODUCTION D Nj B Clt Dr. Najam Beg, Caltec
Contents 1. Jet pump principle of operation 2. Design and performance of jet pumpsp 3. Gas production applications with filed examples Production boosting LP back out De bottlenecking compressors De liquification wells Flare gas 4. Oil production applications with field examples 5. How to identify jet pump applications 6. Some other points 7. Closing remarks
Jet Pump / Eductor/ Ejector HP source HP wells HP gas from process system Compressor re cycled gas HP oil / water (injection water)
Jet Pump Flow Dynamics HP Nozzle Mixing tube Diffuser Discharge LP 1 2 3 4 5 6 7 8 HP Flow ocity Velo LP Flow Combined Flow sure Press
1 4 P2 3 2 P1 Deck level 5 6 7 8 GAS OIL 9 WATER Oil and Gas Production Flow Path
Jet Pump Applications High Pressure Jet Pump (HP) Stream Discharge Stream Typical jet pump Low Pressure (LP)Stream High Pressure Jet Pump (HP) Stream Discharge Stream Jet pump for just pressure boosting Low Pressure (LP) Stream High Pressure Jet Pump (HP) Stream Discharge Stream Jet pump for just backpressure lowering Low Pressure (LP) Stream High Pressure (HP) Stream Low Pressure (LP) Stream Jet Pump Discharge Stream Jet pump for backpressure lowering and pressure boosting
Jet Pump Performance Curves Pressure Flowrate Pressure Flowrate Low Pressure (LP) Pressure e Flowrate Discharge Press sure Flowrate Pressure e Pressure Pressure Flowrate Flowrate High Pressure (HP) Flowrate
Key Factors For Performance Discha arge to LP Pres ssure Ratio 5 4.5 PR=2 4 3.5 3 25 2.5 PR=3 PR=5 PR=7 PR=10 PR=15 PR=20 HP to LP Pressure Ratios Curves COMMERCIAL-IN-CONFIDENCE Gas Jet Pump/Ejector Performance Curves HP/LP pressure ratio LP/HP flow ratio Discharge/LP pressure ratio Other Factors; Temperature, Z factor, Molecular weight, Cp/Cv ratio etc. 2 1.5 1 0 0.5 1 1.5 2 2.5 3 3.5 4 LP to HP Mass Flow Ratio
Jet Pump HP Nozzles Performances 110 ure (barg) HP Press 100 90 80 70 Nozzle # 1 Design conditions HP Pressure = 84 barg HP Flow rate = 35MMscfd & 53 bbl/d 60 Nozzle # 2 Design conditions HP Pressure = 62 barg HP Flow rate = 33MMscfd & 45 bbl/d 50 20 25 30 35 40 45 HP Gas Flowrate (MMscfd)
Jet Pump Performance 12 11 10 Jet Pump Performance LP pressures vs. LP intake flowrates at three HP pressures Jet Pump Required Discharge Pressure = 11.5 barg 9 Inlet LP pre essure (barg) 8 7 6 5 4 3 Operating curve 2 Operating curve 1 Operating curve 3 Maximum flow through jet pump before choking Jet Pump design point : HP = 65.2 MMscfd @ 75barg LP = 25.5 MMscfd @ 4 barg Discharge = 11.5 barg 2 0 5 10 15 20 25 30 35 40 Inlet LP flowrate (MMscfd) HP=65.2 MMscfd @ 75barg HP=57 MMscfd @ 65barg HP=70 MMscfd @ 80barg
Production Characteristics of Wells : PI-Effect
Universal Jet Pump/Eductor/Ejector Discharge Side (Removable Diffuser) High Pressure Side (Removable HP Nozzle) Low Pressure Side Patented Universal Design Ejector / Jet Pump Diffuser Nozzle Removable Nozzle Removable Mixing tube / Diffuser
Example layout EXAMPLE JET PUMP LAYOUT (TOP / PLAN VIEW) Jet pump orientation where LP comes from side Discharge Line Gas Jet Pump High Pressure (HP) Discharge Silencer Optional Acoustic jacket LP Silencer EXAMPLE PROJECT NORTH Low Pressure (LP)
GAS PRODUCTION APPLICATIONS
Gas Production Applications Boost LP gas pressure to a higher value Prevent flaring VLP gas Eliminate intermediate compressors De-bottleneck compressors Lower pipeline pressure in manifolded system Boost production from LP wells Well de-liquification Prevent LP wells backout Prevent HP gas wells imposing back pressure on LP wells Lower separator pressure to increase oil/gas production Pipeline liquid build up reduction
SNS, Inde, UKCS Solution: Used HP recycled gas to power jet pump, to draw-in low pressure Shell wells Benefits Used 68 MMscfd of gas from LP Shell wells into the exiting facilities. Production increased by 25% Increased intake capacity of compressor Davy Line Bessemer Line Separator Low Pressure Gas Wells Compressor Dp Jet Pump Export De- bottlenecked exiting compressor Kilo Subsea Line Multi Awards winning solution
SNS, Platform, UK Solution Using high pressure gas from the well to power the jet pump enabled to draw-in the backed-out low pressure wells Benefits Backpressure on the LP wells reduced by 5 bar giving extra 22 MMscfd of gas (production increased by 110% ). Better use of already available energy with minimum modification to the existing piping. Increased the producing life and stability of the LP wells. Delivered the combined flow at the required higher downstream pressure. High Pressure Wells Gas Eductor on Platform To Dow wnstream Process s/pipelines Low Pressure Wells (initially backedout)
Chevron, USA (GOM) Solution ; HP gas from the existing compressor on recycle used to power the jet pump Benefits Lowered arrival pressure at the platform by 200 psi enabling loaded wells to produce consistently Higher gas velocities, lowered liquids accumulated in the pipeline, causing a further 140psi drop at the wellhead Production increased by 24% due to wellhead pressure reduction and lower pipeline loss. 2.5 Bscf of otherwise lost reserves recovered. Flow delivered at higher pressure to compressor suction increased compressor throughput. process 200 psig 40MMSCFD 400 psig 7.4 MMSCFD 850 psig Ejector Recycle gas GEMINI Sub sea manifold Export Sales 1250 psig
Offshore, Indonesia Solution Used a jet pump and HP gas from a satellite to reduce the operating pressure of the Separator and increase oil production from platform A Benefits Good use of available wasted energy Lowered separator pressure by 105 psi. HP GAS Platform B 7 miles pipeline JET PUMP LP GAS GAS TO GATHERING STATION Extra oil production of 400 bbl/d was achieved with additional associated gas Platform A LP WELLS Separator OIL TO PUMPING SYSTEM
Onshore, Holland Solution Wellcom gas system. The high pressure gas well was used as motive flow to boost pressure of gas from low pressure well. Benefits Closed LP well is back in production which is now producing 140,000 Nm3/d using energy from HP well. Pressure boost of 130% The total production is going directly to HP compression section, thus allowing the LP compressor to be switched off. Additional saving on the fuel gas of the LP compressor.
Dual Jet Pump Application At Gathering Site At Well Site HP Gas Well High Pressure (HP) Gas Stream Gas Jet Pump # 2 Re-c cycle line Gas Jet Discharge Pump #1 Silencer XX Km LP Silencer Discharge Silencer Existing compressor LP Silencer Low Pressure (LP) Gas Stream LP Gas Well
SNS, UK Solution To cover a wide operating range of RS field, three jet pumps were used in parallel. Each jet pump p could be switched on/off depending upon the demand. High pressure gas from the existing compressor was used to power these jet pumps Benefits The jet pump could be operated between 9 MMscfd to 107 MMscfd thus handling LP flow variations. High Pressure HP Production increased up to 20% due to wellhead pressure reduction on RS. On average backpressure reduction of 7 to 8 bar with additional incremental flowrate of 6 to 8 MMscfd. Jet Pump 1 Jet Pump 2 Flow From RS Low Pressure Wells (LP) Jet Pump 3 Sep & Slug Catcher Discharge Silencer Anti-Surge Flow Control Valve RS Gas Scrubber and Compressor Increased intake capacity of compressors Debottlenecking exiting compression facilities From ECA1 LP Silencer Sep & Slug Catcher LP Flow By- Pass Line Deliver the combined flow at higher pressure at the compressor suction. From ECA2 Sep & Slug Catcher
Dutch Sector of North Sea Solution Installed a Universal Gas Jet Pump (UJP) in the recycle line of the existing Compressor to lower the FWHP of the inlet wells whilst also boost FWHP pressure. Benefits Total gas production increased by 91MMscfd JP s changeable internals allows production to be maximised as wellhead pressures decline. Replaced requirement for compressor re-wheeling, saving capital and accelerating the benefit Requirement for 1 st stage compressor was eliminated saving the client 10m capital cost UJP RECYCLE VALVE COMPRESSOR EXPOR T
SNS, UK Solution Remove the 1 st stage compressor by utilising the available energy from recycle gas from the HP compressor Benefits Save fuel gas by removing LP compressor Make use of available recycle gas Saving g a compressor for use elsewhere Export line
Offshore, Indonesia Solution: Using re cycle gas from compressor to de bottleneck 1st stage compressor LP Gas Wells 1 st Stage Gas Compressor 2 nd Stage Gas Compressor Jet Pump 1 Jet Pump 2 To Pipelines Re-cycle Line Benefits Gas from 3rd stage used to boost pressure of some of the gas from 1st stage to that of 2 nd stage System gas handling capacity increased Inlet pressure of 1 st stage maintained Eliminated re wheeling the compressor
Middle East : Compressor replacement Solution ; High pressure gas from the 1 st stage separator was used to power the jet pump Benefits ; 2 MMscfd at 1bara captured, and delivered at the suction pressure of 2 nd stage compressor. Used energy that is available Existing compressors Installed jet pump after compressor removal 1 st stage compressor was removed from service. It simplified system operation & reduced maintenance costs. Gas no longer burned to power this compressor, Jet Pump 4 th Stage 1 st 2 nd 3 rd 4 th 2 nd Route 3 rd stag e 2 nd Stage 1 st Stage
Well Revival on shore, Italy Source of HP flow; HP gas well Benefits; Gain in gas production by 23,000 sm3/d (0.812MMscfd)For almost two years
On-Shore, Alaska, USA Solution Used HP gas from long-string to off- load the well via surface jet pump Benefits Used available wasted energy to off-load the well. Total production from well jumped to 7 MMscfd from 2.5 MMscfd. Production increased by 180%. Liquid loading cycle was reduced, hence more sustain production gain. Additional gas was produced from casing. HP Gas Gas Jet Pump LP Wet gas Dual Completion Wellhead
North Sea, UK Solution Installed a Jet Pump (JP) using HP gas as motive force from Export compressor at 150barg. Benefits Flaring from this source eliminated 15mmscfd to zero Recovered gas boosted and exported also used as fuel gas. Achieved both commercial and environmental objectives. HP Gas Jet Pump Export / Fuel Gas 1 st Stage To flare Wells 2 nd / 3 rd Stage
Flare Gas Recovery with Liquid, Nigeria Solution Using high pressure spare oil pump as the motive source for the jet pump to draw in the low pressure flare gas Benefits Flare gas pressure is boosted by 4 bar. Using 17,000 b/d of oil / water at 60 bar No flaring High Pressure Liquid Jet Pump Recovered 0.7 MMscfd of flare gas Flare LP Gas Intermediate Pressure Use existing spare oil and water pumps. The total production delivered at the separator inlet pressure. Low Pressure Wells x stage Separator Oil To Process System Or Pumping System
Extra Production gain with Wellcom System and Gaslift High Pressure (HP) source [Gas or liquid} Wellcom System Gaslift injection system Wellhead Well production To downstream process Surface Production via Tubing Well l Flowrate Additional production Wellcom system & Gaslift injection Lift gas Produced Oil Gaslift injection Gaslift Injection Flowrate Pay zone Pay zone Wellbore
Offshore Malaysia : Prevent New HP Well Restricting Production From LP Wells + Well Revival
Well Revival Using Test Separator HP Gas Well Revival Gas Jet Pump HP Liquid Well Revival Liquid Jet Pump Test Header Gas LP Wells M Production Header Test Separator M Liquid REVIVAL APPLIES TO BOTH GAS AND OIL WELLS
OIL PRODUCTION APPLICATIONS
EFFECT OF LIQUIDS PRESENT IN LP GAS
Actual Field Performance of Multiphase Jet Pump GVF OF THE LP FLOW N=(DP-LP)/ (HP-DP)
WELLCOM SYSTEM
On-Shore, Italy Solution Using high pressure oil well and oil pump as the motive source for the Wellcom multiphase system the backpressure on the low pressures oil wells was reduced. Benefits A massive backpressure reduction on the well of up to 11 bar was achieved. Simple to operate with no rotating parts Net extra oil gain of 350 bbl/d with additional 1.5 MMscfd of gas was achieved. The total production was delivered at the export pipeline pressure of 55 barg. Multi Awards winning solution
Off-Shore, Malaysia Wellcom oil system ; multiphase HP wells were used to bring in closed low pressure oil wells. Benefits Jet Pump I-SEP Used available energy from HP well 20% pressure boost for LP wells. Increased production by over 35% GAS ( 150 b/d ) Improved flow regime in well bore, stabilising production. FROM HP WELL I-SEP LIQUID JET PUMP COMMINGLER TO PROCESS SYSTEM FROM LP WELL
Record of flowing bottomhole pressure before and after installing the jet pump system 1200 1150 1100 1050 1000 950 900 850 800 750 700 Flowing bottomhole pressure (FBHP) Dp at wellhead=17.4 psi FBHP Dp =140 psi 06:0 06:5 07:5 08:5 09:4 10:4 11:4 12:3 13:3 14:3 15:3 16:2 17:2 18:2 19:1 20:1 21:1 22:0 23:0 00:2 01:1 02:1 03:1 04:0 05:0 06:0 07:0 07:5
Multiphase Boosting: Malaysia Solution By borrowing some of the available high pressure export gas as the Gas Compressor motive source for the Wellcom multiphase system, the backpressure on the low pressure oil wells was reduced and the discharge pressure increased. LP Separation System Benefits Optional Gas Jet Pump HP Gas Commingler LP Gas LP Liquid To Downstream Process/ Manifold A backpressure reduction, A boost in the pressure of 8 barg was achieved. Simple to operate, using existing and available HP gas. This was installed on two installations. Additional production was achieved by lowering the back pressure on the wells,but maintaining the discharge at the required value. This also prolonged the life of the wells considerably by allowing the wells to continue to produce at the required delivery pressure. Production increased by 24% and 34% respectively. Net extra oil gain of 700 bbl/d with additional 2.5 MMscfd of gas was achieved. Low power consumption compared to alternative solutions. LP Wells Liquid Booster Pump
Wellcom Boost System Using Two Jet Pumps Gas Compressor HP Gas Gas Jet Pump Optional Commingler LP Separation System LP Gas To Pipelines LP Liquid Pump LP Wells HP Injection Water Liquid Jet Pump
Dual Wellcom Boosting System TABLE 1: COMPARING THE PERFORMANCE OF SINGLE AND DUAL WELLCOM SYSTEMS Case High Pressure (HP) Low Pressure (LP) Discharge Pressure Pressure barg Liquid flowrate m 3 /h Gas flowrate sm 3 /d GVF (%) Pressure barg Liquid flowrate m 3 /h Gas flowrate sm 3 /d GVF (%) barg A 70 100 423069 75 30 40 221662 90 34 B-1 70 0 423069 100 30 0 221662 100 40 B-2 70 100 0 0 30 40 0 0 45 Case A: Single WELLCOM system Case B-1 & B-2: Dual WELLCOM system gas & liquid jet pumps
What if There is No HP Source? HP LP Discharge Liquid Pump Flow Flow Discharge Inlet Outlet Inlet rate Pressure rate Pressure Pressure Pressure Pressure Hydraulic Shaft Power GVF [bbl/d] [barg] MMscfd [barg] [barg] [barg] [barg] P [bar] Power [kw] [kw] 70% 5000 155 0.66 10 40 10 155 145 133 222 50% 5000 120 0.29 10 40 10 120 110 101 169 30% 5000 105 013 0.13 10 40 10 105 95 87 146 10% 5000 96 0.033 10 40 10 96 86 79 132 70% 5000 40 0.66 10 13 10 40 30 28 46 50% 5000 40 0.29 10 15.5 10 40 30 28 46 30% 5000 40 0.13 10 17.3 10 40 30 28 46 10% 5000 40 0.033 10 18.8 10 40 30 28 46 I-SEP / HI-SEP LP Gas + Liquid Multiphase Jet Pump
Production Boosting with Jet Pumps
How to Identify Jet Pump Applications Locations At the Wellhead At the manifold At the transportation line At pipes connections ( e.g.tee) At the by-pass line Upstream, inlet of a separator Downstream, at the outlets of a separator (production/test) t) Upstream of compressor suction line From the re-cycle line of compressor Downstream of compressor Between compressor stages Upstream of a pump Location is in most cases dictated by site conditions
Additional Examples of Jet Pump Applications Gas Compressor HP Gas Jet Pump Gas to process / pipeline 1 st Stage Separator To flare High Pressure Gas Gas Jet Pump Discharge Gas LP Wells 2 nd / 3 rd Stage Separator Low Pressure Gas To pipeline/export Re-cycle Line HP Gas Gas Eductor Discharge Gas Silencer High Pressure Gas Jet Pump LP Gas Silencer Gas Compressor Low Pressure Wells LP Gas Intermediate Pressure Gas X Stage Separator Wells Manifold Separator Liquid to downstream process/liquid pump Oil To Process System Or Pumping System
How to Identify Jet Pump Application HP Well HP Well 2 1 LP Wells LP Wells Lowering the whole mainfold pressure with HP well Assisting weaker LP wells with with HP well HP Well HP Well 3 4 LP Wells LP Wells Lowering the whole line pressure with compressor re-cycle Lowering LP manifold pressure with compressor re-cycle, And by-passing the HP well Note: Above illustrations are valid for gas and multiphase (oil) jet pump applications. The intermediate separators/kov/pumps/valves are ignored here.
How to Identify Jet Pump Application.. cont HP Well HP Well LP Wells 5 LP Wells De-bottlenecking 1 st Stage compressor with next stage compressor re-cycle (taking part of the gas) Removing 1 st Stage compressor with next stage compressor re-cycle 6 HP Well HP Well 8 7 LP Wells LP Wells Increasing production on LP wells with HP well, lowering pipeline pressure with compressor while providing required compressor suction pressure De-bottlenecking compressor Some LP+HP wells by-pass Note: Above illustrations are valid for gas and multiphase (oil) jet pump applications. The intermediate separators/kov/pumps/valves are ignored here.
Some Other Points! Instrumentations Control Noise Vibrations Low Temperatures Erosion Start-up/Shut Down Safety Erosion/Handling Sand (Material Selection) Maintenance
Typical Instrumentation for a Jet Pump HP Gas Vent P T P T Jet Pump Discharge Silencer Drain Discharge Flow P T LP Silencer
Some Control approaches Gas HP LP MP Gas A HP LP C MP B Gas Separator PT Gas PT Liquid
In-line Silencers In-line acoustic silencers
Jet Pump Systems Pressure rating ANSI 1500# ~ 1.5 m Jet Pump Skid ~ 4 m Vent ~ 2.4 m Jet Pump Silencers Skid ~ 35m 3.5 Vent ~ 2.4 m ~ 1.5 m Discharge Silencer Material CTP sizes (Jp-6) CTP sizes (Jp-10) CTP sizes (Jp-16) LTCS NACE HP 3, LP 4, Discharge 6 HP 6, LP 8, Discharge 10 HP 8, LP 12, Discharge 16 CTP HP Gas Drain Tie-in Point (CTP) Drain LP Gas LP Silencer Drip Pan
CLOSING REMARKS Simplicity and cost effectiveness make surface jet pump solutions very attractive & economical in most cases An effective use of surplus and normally wasted energy to assist the existing production Minimum maintenance requirement. Pipeline code design Short payback period Installing tie-inin points during shut downs simplifies installation when needed Rental option justifies very short operation life Deferring Capex such as compressor upgrading