ASME/API/ISO Spring 2004 Gas-Lift Workshop

Sofitel Hotel, Houston, Texas, USA February 10-11, 2004

Increase Efficiency of Intermittent Gas-Lift By Use of Plunger lift

PREPARED BY
Slavoljub Stojanovic, NIS NAFTAGAS, SERBIA & MONTENEGRO Predrag Radanovic, NIS NAFTAGAS, SERBIA & MONTENEGRO

February, 2004.

Prepared by: Slavoljub Stojanovic

Increase Efficiency of Intermittent Gas-Lift By use of Plunger lift

Abstract Gas lift method (continual and intermittent) has been the most widely applied a recovery method, and a number of wells, almost 70% have been recovered by this method. In initial phase, immediately after the flowing period, continual gas lift was applied. But as the time went by, some changes of conditions occurs in a reservoir such as: (reservoir pressure draw down, water content increase, near well zone damage, fluid inflow decrease), and because of a permanent increase of specific gas consumption (from 250m3/m3 to 1100m3/m3) the continual gas lift method became inefficient. A detailed analysis has been performed afterwards, and the continual gas lift method was replaced with the intermittent on more than 70% of the wells. The intention was to decrease gas consumption and increase the total energy efficiency of the system. The realized results, after the intermittent gas-lift method had been applied, appeared to be good for economical work of the system. As the reservoir conditions kept changing, the intermittent gas lift system has reached the phase of no optimal performance from the point of view of hydrodynamic conditions in the wells and in the injection system, and from the standpoint of energy, the system has reached the phase of performing in inefficient and uneconomic manner. In process of finding a solution of high specific gas consumption and nonefficiency of an intermittent gas-lift, because of the increased fall back, we tried with use of a Plunger lift. This paper discusses the use of a plunger lift in wells where intermittent gas lift has been applied. An analysis of a Plunger lift has been shower both before and after its usage. Key words: Gas lift, Intermittent, Optimization Introduction With the aim to increase the oil and gas production in order to decrease its costs, the efficiency of a plunger lift method has occupied a special attention. A plunger lift system is based on the free plunger, moving inside of existing tubing string using differences in pressure above and below the plunger. The main characteristic of plunger lift is to decrease effects of fluid fall back and to lift it on the surface. The use of a plunger lift is possible if there are satisfying amounts of gas for lifting of accumulated fluid slug, when the amount of needed gas is not on satisfying level (GLR) than it is necessary to inject a gas from an outer source. But, when we are deprived of such conditions a plunger lift use is not possible. It is known that a plunger lift could be used in the following occasions: a) Removal of Liquids from Gas wells b) Hi-Ratio Oil Well production c) Paraffin and Hydrate Control d) Increased Efficiency of intermittent Gas Lift Wells This paper will only discuss a field of increasing work efficiency of the system for Intermittent Gas lift method.

February, 2004.

Prepared by: Slavoljub Stojanovic

Applications The main problems which have mostly influenced on work of intermittent gas lift are liquid fall back, as well as an intensive paraffin deposition. Well fluid is lifted in the form of a slug, and efficiency of lifting depends on several factors. An important condition for normal functioning of this system is a proper inner tubing diameter that goes by the whole length of tubing. As fluids move to the surface a certain friction appears, which as a consequence has slower speed of a slug, irregular shape of the top of fluid slug, as well as more intensive fall back of fluids by the inner wall of tubing. At the comes to the point of its more intensive break through the fluid, by which the fall back has been significantly increased. A plunger installed in the intermittent gas lift system works as a mechanical separator between liquid slug and gas, and in such a way makes work more efficient. A bumper spring is installed above operating gas lift valve. By opening of the gas lift valve injection of gas under the slug is done, and starts its traveling to the surface by contemporal lifting of accumulated fluid slug above a plunger. The valve on injection flow line is closed by the automatic controller, casing pressure decreases, a plunger also decreases on a bumper spring, and after that it is ready for a next cycles.

February, 2004.

Prepared by: Slavoljub Stojanovic

SUB-SURFACE EQUIPMENT FOR THE PLUNGER LIFT WELLS

February, 2004.

Prepared by: Slavoljub Stojanovic

WELL

Mk-75

The well belongs to the category of low productivity, with the average production of 7.75 bbl/day before the plunger lift was built in. The complete data about the well, reservoir and gas lift system are shown in table 1. Well and reservoir data
Initial reservoir pressure (Pri): Current reservoir pressure (Pr): Current Reservoir temperature (Tr): Well completion type: Middle perforation depth (Hf): Perforations number (np): Well depth (HB): Packer depth (Hpak): Static fluid gradient (Gs): Outside casing diameter (Doc): Inside casing diameter (Dic): Outside tubing diameter (Dot): Inside tubing diameter (Dit): Wellhead tubing pressure (Pwh): Wellhead temperature (Twh): Porosity (): Bubble point Pressure (Pb): Flow line pressure (Pn): Separator pressure (Ps): Casing pressure (Pc): Oil specific gravity (qo): 3045 [psi] 1886 [psi] 230 [F] Cased hole 6942.3 [ft] 24 [hole/ft] 6971.8 [ft] 6689.6 [ft] 0.371343 [psi/ft] 7 [in] 6.26 [in] 2.87 [in] 2.44 [in] 101.5 [psi] 59 [F] 0.192 [fr] 2973.3 [psi] 50.8 [psi] 43.5 [psi] 58 [psi]
o 32 [ API]

February, 2004.

Prepared by: Slavoljub Stojanovic

TECHNICAL WELL DATA

WELL

Mk-75
NIS-NAFTAGAS Serbia & Montenegro

CHRISTMAS TREE CASING

CASING
7
Diameter ( in )

"CANADA"
95/8 x 7 x 27/8 for 3000 psi
lb/ft

95/8

40

J-55

depth ( ft ) 2624.7

23

J-55

7024.3

CASING
2624.7 ft

3244.8 ft
1. 2.

EQUIPMENT
Tubing Dt=27/8 in EU, J-55 Gaslift valve Gaslift valve L1 L2 L3 J-20 J-20 J-20

Depth (ft) 6896.3 3244.8 4858.9 6381.2 6384.5 6689.6 6886.5 6889.8 6971.8

4858.9 ft

3. 4. 5. 6.

Operating Gaslift valve "D" NIPLE with bumper spring N-1 Packer "P. L." Packer "D" NIPLE Bottom hole

6381.2 ft
7.

6382.1 ft

8.

(ft)

PERFORATED INTERVAL
5
6689.6 ft

6952-6932.4 6830.7-6817.6 6807.7-6794.6

1886 230

ISOLATED INTERVAL ISOLATED INTERVAL

RESERVOIR PRESSURE (psi) RESERVOIR TEMPERATURE (F)

6794.6 ft
ISOLATION INTERVAL

DESIGN FLUID PRODUCTION (bbl/day) WATER CUT (%)

63
65

6807.7 ft 6817.6 ft
ISOLATION INTERVAL

6830.7 ft

6886.5 ft 6889.8 ft

7
6896.3 ft 6932.4 ft
PERFORATED INTERVAL

6952 ft

6971.8 ft
Design

Slavoljub Stojanovi, Artificial Lift & Well Completion Engineer

DATE 30 Jan, 2004

7024.3 ft

PRODUCTION DEPARTMENT

February, 2004.

Prepared by: Slavoljub Stojanovic

Fluid Production Qf m3/dan

10 12 14 16 18 20 22 24 26 0 2 4 6 8

February, 2004. Prepared by: Slavoljub Stojanovic

Year

Production Rate History (after the last workover)

Qf

Workover ROB-l (UKL) (20.11.2000.)

maj.77 nov.77 maj.78 nov.78 maj.79 nov.79 maj.80 nov.80 maj.81 nov.81 maj.82 nov.82 maj.83 nov.83 maj.84 nov.84 maj.85 nov.85 maj.86 nov.86 maj.87 nov.87 maj.88 nov.88 maj.89 nov.89 maj.90 nov.90 maj.91 nov.91 maj.92 nov.92 maj.93 nov.93 maj.94 nov.94 maj.95 nov.95 maj.96 nov.96 maj.97 nov.97 maj.98 nov.98 maj.99 nov.99 maj.00 nov.00 maj.01 nov.01 maj.02 nov.02 maj.03 nov.03
7

Workover and stimulation history Workover Type

NO1

Date
19.05. 31.05.19781.

Reasons for Workover and Short Description of Workover Operation (WO)

Interval 70086995 ft was perforated with 12 bullets.

Notes

01.06. 08.06.1981.

NO2

06.11. 11.11.1994.

DO +UGL

19.10. 20.11.2000.

ROB-L (UKL)

After unloading of Well, it started producing oil with height water cut 80 %. Immediately after initial natural flow was obtained, the well stopped After unloading of producing. Two more trays of unloading didn't result in fluid natural Well, it started flow, so it was decided to close the existing interval and to perforate producing oil with new one at shallow depth of the same reservoir. natural flow. The existing interval was isolated with setting drillable cement retainer at 6924 ft. Interval 6952-6933 ft was perforated with 12 bullets/m'. During the period after the last workover, the well was producing fluid with natural flow after which started the increase of water cut and decrease of operating pressure. Those were the reasons why the well stopped producing. Previous interval, 6952-6933 ft, was re-perforated with 12 bullets/m' Reservoir pressure couldn't establish fluid natural flow and artificial lift method should have been designed. Well was equipped with 4 gas-lift valves Well had been producing fluid due to intermittent gas-lift from the last workover (1994.) to the year of 2000. During that period production rate had permanent slope from beginning point of 50.3 bbl/day to last First installations of measured data that was 11.3 bbl/day. Plunger lift in the Well was equipped with 3 gas-lift valves (operating valve at well with Intermittent 6381.2 ft) and bumper spring at 6384.5 ft. Gas lift. There was a try of installing a Plunger lift in order to dissolve a problem of a big fall back, accumulated paraffin in column of tubing.

Gas-lift Valve and Gas Injection System Characteristics

No.
1. 2. 3.

Depth
[ft]

Type
NITROGEN NITROGEN NITROGEN

Name
J-20m J-20m J-20m

Port Inside Diameter

[in]

R=Ap/Ab
0.067 0.067 0.067

3244.8 4858.9 6381.2

0.25 0.25 0.375

Injection Gas Composition and Characteristics: Component

%

C1
86.47

C2
5.09

C3
2.42

nC4
0.88

iC4
0.85

nC5
0.27

iC5
0.33

C6
0.10

C7+
0.01

CO2
/

N2
2.08

H2S
1.50

Kick-off Injection Gas Pressure (Pko): Operating Injection Gas Pressure (Pinj): Injection Gas Specific Gravity (g) air=1: Available Injection Gas Rate (Qginj): Test Rack Opening Pressure (Tsh):

870 [psi] 812 [psi] 0.65 unlimited [scf/day] 59 [F

February, 2004.

Prepared by: Slavoljub Stojanovic

ANALYSIS OF WELL WORK BEFORE THE INSTALATION OF PLUNGER LIFT

Two Pen Chart Data Date: Valve Closing Pressure (Pvc): Valve Opening Pressure (Pov): Tubing Maximum Pressure (Pwhmax): Tubing Minimum Pressure (Pwhmin): Duration of Lift Period (tlift): Number of Cycles (nc): Duration of Gas Injection Period (tinj): Production Test Data 19.08.2000 609.2 [psi] 623.7 [psi] 159.5 [psi] 58.1 [psi] 420 [sec.] 24 [cyc/day] 240 [sec.]

Date: Fluid Production Rate (Qf): Water Cut (WC): Injection Gas Rate (Qgu): Specific Injection Gas Consumption (GORinj):

19.08.2000. 7.8 [bbl/day] 65.00 [%] 63.56 [Mscf/day] 260 [bbl/ft3]

February, 2004.

Prepared by: Slavoljub Stojanovic

Figure 3. Casing and Tubing Pressure Diagram (Date: 19.08.2000)

February, 2004.

Prepared by: Slavoljub Stojanovic

10

Two Pen Chart Visual Analysis

Date:

19.08.2000. Low productivity Qf= 7.75 bbl/day ; WC= 65 % - Intermittent gas-lift well. Automatic cycles controller a) Unequal peaks of pressure show that some of cycles are empty or that a realized production by a cycle is too small.

WELL TYPE: MAIN OPERATING PROPERTIES: 1. Tubing Pressure Curve:

2. Casing Pressure Curve:

a) According to the shape of casing pressure curve (round and low peaks) it could be concluded that the time of gas injection is too high, and that because of a small range of valve affect insufficient gas amount is injected.

Quantitative Casing & Tubing pressure Diagram Analysis By using the new Model

Date of analysis:

19.08.2000.

The entering data for the model application are divided into three groups. The first group contains the data concerning well completion, and reservoir and fluid characteristics, the second group concerns specification, gas lift valve input depth, and gas injection system characteristic. The data obtained from the two-pen pressure and production measuring diagram chart are in the third group. The data on well bore pressure and temperature measuring, and on the valve depths, are graphically shown as the final results. All the data are directly taken from the program (Solea,M., Cvetianin, S.:" POVLIFT - Computer program for designing and optimizing intermittent gas lift The sixth SPE Computer conference, June, 1991. Dallas, Proceedings, Pg. 6888 SPE Paper No. 22296.)
.

Model application results:

Two Pen Chart Computer Analysis Date: GAS-LIFT VALVES OPERATING PARAMETERS No.
1

PVC
[psi]

TRO
[psi]

TVL
[F]

PTL
[psi]

609.2

609.2

131

174.1

February, 2004.

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Operating Valve Depth (Lov): Tubing Pressure at Operating Valve Depth (Ptl): Fluid Production Rate per Cycle (Qfcik): Initial Liquid Slug Length (hsli): Surface Liquid Slug Length (hslp): Initial Liquid Slug Volume (Vsli): Liquid Fallback (FB):

2943 [ft] 392 [psi] 0.322 [bbl/cyc] 781 [in] 53 [in] 4.53 [bbl3] 69.8 [%]

As it can be seen from the shown results, the operating valve is 2943 ft depth, which means that the designed injection point was not reached, and that the well was not relieved. The conditions of well performance have been simulated based on these data (Figure 4).

Figure 4. Operating valve depth determination and well performance conditions simulation
Solea,M., Cvetianin, S.:" POVLIFT - Computer program for designing and optimizing intermittent gas lift The sixth SPE Computer conference, June, 1991. Dallas, Proceedings, Pg. 68-88 SPE Paper No. 22296. February, 2004. Prepared by: Slavoljub Stojanovic

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RECOMMENDATIONS FOR FUTURE WORKS

According to the results of the two-pen surface pressure qualitative analysis, as well as to quantitative analysis with the POVLIFT, better working conditions of the well performance ( first of all, consumption) can be expected, if the following recommendations are realized. Provide the gas injection point be dislocated to the last valve (6396.1 ft). Solve the emulsion problem by demulgator injection through bend tubing, and after that make the detailed pressure measuring. If the results are not satisfying, perform the well workover with the new valve schedule and testing. The reverse inflow high value (FB=69.8 %), as well as the paraffin problem, are the facts which could make the use of plunger successful.

Analyzed date (production rate history, reservoir and fluid characteristics) have been used in computers programmed POVLIFT and GKLIP in order to get a projected parameter, and also a suggestion of well equipment.

Gas-lift Design

Date:

18.10.2000

WELL NAME: M-75

Inside No Valve Depth
[ft]

Valve Name

Port Diameter
[in]

Temper ature Closing pressure at Valve at Surface at Valve Depth Depth Valve
[psi] [psi] [F]

Bellows Charge Pressure

[psi]

Test Rack Opening Pressure

[psi]

1 2 3

3244.8 4858.9 6381.2

J-20m J-20m J-20m

0.25 0.25 0.375

754.2 740 667.2

816.8 828.5 751.3 56.6 bbl/day

139 178.4 215.2

702.6 610.89 567

750.6 710.5 665.3

Designed production rate

Depth of down hole Stop Assembly

6382.1 ft

February, 2004.

Prepared by: Slavoljub Stojanovic

13

ANALYSIS OF WELL WORK AFTER THE INSTALATION OF PLUNGER LIFT

Two Pen Chart Data

Date:

15.01.2001 639.6 [psi] 699.1 [psi] 382.9 [psi] 60.9 [psi] 320 [sec.] 24 [cyc/day] 540 [sec.]

Valve Closing Pressure (Pvc): Valve Opening Pressure (Pov): Tubing Maximum Pressure (Pwhmax): Tubing Minimum Pressure (Pwhmin): Duration of Lift Period (tlift): Number of Cycles (nc): Duration of Gas Injection Period (tinj):

Production Test Data

Date:

15.01.2001 64.1 [bbl/day] 65 [%] 57.5 [Mscf/day] 29.4 [bbl/ft3]

Fluid Production Rate (Qf): Water Cut (WC): Injection Gas Rate (Qgu): Specific Injection Gas Consumption (GORinj):

February, 2004.

Prepared by: Slavoljub Stojanovic

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Figure 5. Casing and Tubing Pressure Diagram (Date: 15.01.2001)

February, 2004.

Prepared by: Slavoljub Stojanovic

15

Two Pen Chart Visual Analysis

Date. 15.01.2001 WELL TYPE: MAIN OPERATING PROPERTIES: 1. Tubing Pressure Curve: Production increase to Qf= 64.1 bbl/day ; WC= 65 Specific Gas Consumption is decreased to 29.4 bbl/scf - Intermittent gas-lift well. Automatic cycles controller a) Stabilized, insufficiently sharp and round peaks of maximum tubing pressure show that an excessive amount of gas has been injected a) Characteristic shops of casing pressure rise with round peaks and two typical declivities both on the rising port, and on reduction of pressure which indicates moments of the motor valve opening, as well as opening and closing of operating valve. Practically all peaks are similar what shows a regular work of the system. %,

2. Casing Pressure Curve:

Quantitative Casing & Tubing pressure Diagram Analysis Using the new Model

Date of analysis:

15.01.2001.

Model application results:

Two Pen Chart Computer Analysis GAS-LIFT VALVES OPERATING PARAMETERS No.
1

PVC
[psi]

TRO
[psi]

TVL
[F]

PTL
[psi]

667.2

667.2

210.2

317.6

Operating Valve Depth (Lov): Tubing Pressure at Operating Valve Depth (Ptl): Fluid Production Rate per Cycle (Qfcik): Initial Liquid Slug Length (hsli): Surface Liquid Slug Length (hslp): Initial Liquid Slug Volume (Vsli): Liquid Fallback (FB):

6381.2 [ft] 532.5 [psi] 2.58 [bbl/cyc] 1140.3 [in] 445.9 [in] 6.5 [bbl3] 14.8 [%]

February, 2004.

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16

As it can be seen from the shown results, the operating valve is 6381.2 ft depth, which means that the designed injection point was reached, and the injection is done through the Operating Gas lift valve The conditions of well performance have been simulated based on these data (Figure 6).

Figure 6. Operating valve depth determination and well performance conditions simulation

Solea,M., Cvetianin, S.:" POVLIFT - Computer program for designing and optimizing intermittent gas lift The sixth SPE Computer conference, June, 1991. Dallas, Proceedings, Pg. 68-88 SPE Paper No. 22296.

February, 2004.

Prepared by: Slavoljub Stojanovic

17

CONCLUSION A number of wells in the oil field MZ in which a gas lift method has been applied, are in use for more over than 20 years. Negative factors noticed in those wells: 1. Decrease of a reservoir pressure: from 3045 psi to 2030-1305 psi 2. Increase of water cut over 60-80 % Wells with an intermittent gas lift method comes into a period when specific gas consumption is high, and production becomes non efficient. In such conditions one of the possible methods to decrease specific gas consumption in wells with intermittent gas lift was a use of a Plunger lift. According to the received results of the analyzed well Mk-75, a Plunger lift method showed to be successfully carried out after which we started with a serious utilization of this method. Main characteristics of the Plunger lift use in the oil gas field MZ: 1. Specific gas consumption is much lower then in case of intermittent gas lift. 2. fall back of liquids have been decreased after the use of Plunger lift 3. A problem of paraffin deposition is permanently drawn down after the use of Plunger lift method.

The utilization of Plunger lift method is very attractive to use concerning the financial aspect, because of its simple equipment as well as maintenance. It should be expected that a development of technology and new methods would provide some new models possible to create in the nearest future. And, also find a solution if not for all existing problems than for a bigger part of them.

February, 2004.

Prepared by: Slavoljub Stojanovic

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References:
1. Beauregard, E., Ferguson P.I.:"Introduction to Plunger Lift: Applications, Advantages and Limitations", Presented at the Sauthwestern Petroleum Short Course, 1981. 2. Brown, K.E.: The Technology of Artificial Lift Methods, Vol. 2A, Tulsa, Oklahoma, 1980 3. Chacin.J. Schmidt.Z. Doty.D: Modeling and Optimization of Plunger Lift Assisted Intermittent Gas Lift Installations,SPE. 23683 4. Solea, M. - Intermittent and plunger lift optimization, Training school material, Novi Sad, 1995. 5. Solea.M. uri.S. Miljkovi.M. Iveti.Z : Analysis of Intermittent Gaslift application on Field MZ, Feasibility study, 1993. 6. Solea,M., Damjanov, J., Miljkovi, M., amber, D., uri, S.:" Work Study of the Plunger lift applied in the well Mk-125", NIS Naftagas, Novi Sad, 1999. 7. Solea,M., Cvetianin, S.:" POVLIFT - Computer program for designing and optimizing intermittent gas lift The sixth SPE Computer conference, June, 1991. Dallas, Proceedings, Pg. 68-88 SPE Paper No. 22296. 8. Slavoljub,S.: "The possibility of Plunger lift Use for Exploitation of Gas Wells with liquid loading problems", Final exam work paper at University, Belgrade, 2000. 9. Slavoljub,S.: "Optimization of Oil Production in the MZ by the use of the Plunger lift method", Kikinda, July 2001. 10. Slavoljub, S.: "Utilization of the Mechanical method in Oil Exploitation by the use of a Plunger Lift in the Wells with Intermittent Gas lifts ", Novi Sad, November 2002. 11. Technical documentation, NIS Naftagas, Serbia & Montenegro

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