Handling Sand & Gas in Permian Artificial Lift Charlie Fowler – VP Technology
May 24, 2016 DUG Conference
2 PROPRIETARY AND CONFIDENTIAL
What have unconventionals taught us about handling sand and gas?
Key Lessons
No perfect solutions
Each well is unique
Lots of trial and error
Requires a multi-pronged approach
Unconventionals have ACCELERATED improvements to all forms of lift for handling sand and gas.
Multi-pronged Approach
Prevent Produce Control
3 PROPRIETARY AND CONFIDENTIAL
Preventing Sand and Gas Basic Principles
SLOW FLOW to “encourage” natural separation
DIRECTIONAL changes to “break” gas out of solution
TOOLS to “re-direct” gas to annulus
FASTER FLOW to “encourage” density separation
SPIRALS to centrifugally separate
REVERSE FLOW at to induce sand fall
GAS REMOVAL
SAND REMOVAL
Sand
Oil/Water Gas
Prevent Produce Control
4 PROPRIETARY AND CONFIDENTIAL
Preventing Sand and Gas HYBRID Separator
Modelling Inputs: Scenario 1
Results
90% Solids Separation
83% Gas Separation
Flow: 100 BBL/Day
Viscosity: 7.5 Cp
Gas 20%
Solids 10%
Particle Size 0.040
Multi-phase
Sand
Gas
Liquid
Liquid
Liquid
Gas
Sand
1
2
3
4
4 CFD
Model
Prevent Produce Control
5 PROPRIETARY AND CONFIDENTIAL
Preventing Gas in an ESP Gas Anchor + Separators
Gas Rise
and Exit
Multi-phase
entry Fluid Changes
180 & Sheds
More Gas
Rotary or Vortex
Separators
Shed More Gas
MOTOR PROTECTOR INTAKE
SEPARATOR SEPARATOR PUMP
1
Entering
The
Pump
Cooling
the
Motor
3 2
Fluid up
Tube 4 5 6
7
Prevent Produce Control
6 PROPRIETARY AND CONFIDENTIAL
Producing Sand
Challenges Solutions
Abrasion
Shape Size 1 Hard Materials
2 Pump Geometries
Typical SR
Pumps
Trap Sand
Sand
Flush
Plunger
Flushes
Sand
away
from
Barrel
Concentration
ESP Carbide
Bearings
Sand Flush
Plungers
increased run
life from 604 to
1,333 days in
161 wells.
2.2X
Prevent Produce Control
7 PROPRIETARY AND CONFIDENTIAL
Producing Gas
Challenges Solutions
Failure Modes
Slugging Bubble Size 1 ESP: Optimizing stage types & combinations
2 Sucker Rod Pump Ratio
VSP
Challenge
When gas enters the pump, it cannot
effectively compress fluid on the down
stroke
Solution
Patented VSP utilizes fluid slippage
technology to equalize pressure and
allow pump to effectively compress
fluids.
ESP
Cavitation
Motor Overheat
Pump Seize
Sucker Rod
Fluid Pound
String Damage
Lost or Limited Production
Compress
Homogenize
Produce
Prevent Produce Control
8 PROPRIETARY AND CONFIDENTIAL
Controlling Gas in Sucker Rod Pumps
VSP
Prevent Produce Control
What do we look at?
• Dyna-card shape
• Amps
• Load (pounds)
• Polished Rod Position
What can we do with it?
• Slow down to increase fill
• Match Inflow to Outflow
• Protect Equipment
• Optimize well
• Steady state to prevent
sand fallback
• Rapidly respond to slugging
9 PROPRIETARY AND CONFIDENTIAL
Controlling Gas in an ESP
VSP
Prevent Produce Control
Amps
Intake PSI
Vibration
Disch. PSI
Motor Temp
What do we look at?
• Amps
• Pump Pressure
• Motor Temperature
• Vibration
What can we do with it?
• Speed up/slow down to
break gas lock
• Match Inflow to Outflow
• Shut down
• Delay re-starts
• Protect equipment
• Protect well
10 PROPRIETARY AND CONFIDENTIAL
When all else fails consider a Jet Pump
11 PROPRIETARY AND CONFIDENTIAL
Jet Pump Operation
Power fluid is pumped from surface down to the nozzle, where the venturi effect takes
place. High velocity fluid exiting the nozzle creates a low static pressure area.
Formation fluid is drawn to the low pressure area and comingles with the power fluid
jet in the throat area.
Comingled fluids travel to the diffuser where the flow area diverges converting the fluid
to low velocity / high pressure to lift to surface.
12 PROPRIETARY AND CONFIDENTIAL
Jet Pump Advantages
Flexibility
– Easy to deploy…pump in/out or wireline
– Easy to repair or change…1-2 hours
– Easy change-out as well declines
High Reliability
– No Moving Parts
– No connection to surface
Wide application envelope
– Solids
– Corrosives
– High GOR
– High viscosity
13 PROPRIETARY AND CONFIDENTIAL
De-Sanding Permian Well with Jet Pump
Customer Spending $30k per month on ESP
Case Study: Wolfcamp Basin
Replacing ESP every 3-4 Mos.
Down Time, Rig Time, ESP Repair
Rental Fees
Situation Solution
Consulted with Hydraulic Jet Pump Team on Solution
14 PROPRIETARY AND CONFIDENTIAL
De-Sanding Permian Well with Jet Pump
1) 200hp Power Fluid Pump Skid
2) Separator Vessel Installed
3) Downhole Jet Pump Installed with Large Throat/Nozzle
combination to handle solids
Case Study: Wolfcamp Basin
1 2
3
15 PROPRIETARY AND CONFIDENTIAL
De-Sanding Permian Well with Jet Pump Case Study: Wolfcamp Basin
Increased production from 400 bbls/d to 464 bbls/d
Run time increased with one jet pump pull to
clean solids – no workover rig or crew
needed
40% reduction in operating expense
Superior handling of solids with larger
Nozzle/Throat combination
ESP #1
80 Days ESP #2
70 Days
JET #1
90 Days & Running
Increased BBL/DAY
16 PROPRIETARY AND CONFIDENTIAL
Conclusions
Conclusion 1
Technology is evolving to:
Prevent Conclusion 2
AL providers need to improve:
Scientific understanding
Application Tools
Field Trials
Conclusion 3
Jet Pumps are a viable alternative to severe applications.