Artificial Lift Design, Optimization and Cost Estimation

REPUBLIQUE TUNISIENNE Ministère de l’Enseignem l ’Enseignement ent Supérieur et de la Recherche Scientifique Université de Gabès

Ecole Nationale d’Ingénieurs de Gabès Département de Génie Chimique Procédés

GRADUATION PROJECT REPORT Presented to obtain the

National Diploma of Chemical-Process Chemical-Process Engineering degree Realized by:

JENDOUBI Riadh

Subject :

Artificial Lift System Design, Optimization and Cost Estimation Defended on July the 14th, 2018 in front of the committee:

Mr. RJEB Skandar

President

Mr. HANNACHI Ahmed

Supervisor

Mrs. BEN ALI Samia

Member

Mr. FADHEL Imed

Guest

ear: Academic Y ear:

2017/2018

GCP 2018-45 / 60 60

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Dedi Dedica cati tion on

To the sake of Allah , my Creator and my Master. To my great teacher and messenger, Mohammed (May (May Allah bless and and grant him) him) , who taught us the purpose of life. To the memory of my late father, Mr. Jendoubi , May Allah rest his noble soul, who Jendoubi Noureddine Noureddine , May always supported me, whatever path I took. To my loving mother, Mrs. Azizi Mbarka , for her encouragement and unconditional affection, whatever things I did. To my dear little brothers, Mr Jendoubi , for Jendoubi Marouane and Mr. Jendoubi Mohamed Majdi Majdi , standing by my side in times of need. To all of my friends, especially Mr. Saadi Seddik Seddik and Mrs. Mrs. Marouani Chaima I dedicate this modest work.

















Ackn Acknow owle ledg dgme ment ntss

I am extremely fortunate to be involved in an exciting and challenging project which h as enriched my life and gave me the opportunity to look at the Horizon of Technology. Sincere thanks to the members of the jury: Mr. REJEB Skander and Mrs. BEN ALI Samia for taking time out of their busy schedule and assessing my work. It is an honour to have my work evaluated by such educators. Special thanks to the School staff for their hard work as well as their professionalism supporting the student’s best interests. I would like to express my deep sense of o f gratitude and respect to my dear supervisor Mr. for his excellent guidance, suggestions and constructive criticism. I feel HANNACHI Ahmed for proud that I'm one of his engineering students. I’m also grateful for the affectionate support extended by Mr. FADHEL Imed , as my supervisor during our stay together at ETAP and for sharing his wide experience on petroleum production engineering. His support and suggestions helped me a lot to complete the project successfully. I think this opportunity to express my heartfelt gratitude to Mrs. DALHOUM Rym , for her thoughtful advice and useful discussions.

















Abst Abstra ract ct In an effort to increase oil production and guaranteeing competitive position stimulatingly, in an industry that continues to increase regulations for environmental protection, several conducted studies aimed at the exploitation of oil wells to the fullest by increasing their recovery. Multiple recovery systems have been explored, some of them have led to higher recoveries but have been super costly. other techniques have failed to reach the set objective. This study is about modelling an already set artificial lifting system which is the JET Pump. Also, the optimization of oil production by designing a new lifting system which is the ESP. Finally, an economical study is provided as a guideline for choosing the appropriate, cost-effective system. Keywords: Oil, Artificial Lifting, JET Pump, ESP, cost effective.

Résumé Afin d’augmenter la production du pétrole et garantir une position concurrentielle, dans une industrie qui continue à forcer les réglementations pour la protection de l'environnement, plusieurs études ont été menées dans le but de maximiser l’exploitation et la production des puits de pétrole en augmentant leurs récupérations. Plusieurs systèmes de récupération ont été explorés, certains d'entre eux avaient réussi à des recouvrements plus élevés mais ont été très coûteux. D’autres techniques n'avaient pas réussi à atteindre l'objectif fixé. fixé. Cette étude comporte la modélisation d'un système d’activation artificielle déjà mis en place, la JET pompe. En outre, l'optimisation de la production de pétrole en concevant un nouveau système d’activation qui est l'ESP. Enfin, une étude économique est fournie comme guide pour choisir le système approprié et rentable. Mots Clés : Pétrole, Activation Artificielle, JET Pompe, ESP, Rentable.

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Symbols Boi: Formation volume factor [m 3 /m3] Cp: Heat capacity or thermal capacity [BTU/lb/F]

 : Average reservoir pressure [psia] Pwh: Pressure at the wellhead [psia] Pwf : Flowing pressure at the bottom node [psia] Soi: Connate water salination [%] ΔPupstream: Pressure loss due to upstream components [psia] ΔPdownstream: Pressure loss due to downstream components [psia] ΔP: Total pressure drops [psia] ΔPf : frictional forces [psia] ΔPg: gravitational energy change [psia] ΔPk: kinetic energy changes [psia] φ: Porosity [%]

















Abbr Abbrev evia iati tion onss ALS: Artificial Lift System AOP: Absolute Open Flow BPD: Barile Per Day BHP: Bottom Hole Pressure CAPEX: Capital Expenditures EOR: Enhanced Oil Recovery ESP: Electrical Submersible Pump FDP: Field Development Plan GL: Gas Lift GOR: Gas Oil Ratio HP: Hydraulic Pump ID: Internal diameter IPR: Inflow Performance Relationship JP: JET Pump LSE: Laarich South East MLD: Makhrouga Laarich Debech Concession OD: Outside Diameter OOIP: Oil in Place OPEX: Operating Expenditures PVT: Pressure, Volume and Temperature PCP: Progress Cavity Pump SRP: Sucker Rod Pump or Beam Pump STB: Stock Tank Barrel SODEPS: South Permit Development and Exploitation Company



















Units Psi: Pound-force per square inch Bpd: Barrel per day Ft: feet °F: degree Fahrenheit Sm3: Standard cubic meter API: American Petroleum Institute gravity sp. Gravity: Specific gravity ppm: Parts per million °C: degree Celsius m3: Cubic meter cp: centipoise STB: Stock tank barrel MMscf : Million standard cubic feet lb: Pound Hz: Hertz $: US Dollar Bbls: Barrels M$: Million Dollars K$: Thousand Dollars

















Contents DEDICATION .................................... ....................................................... ...................................... ....................................... ....................................... ..................................... ...................................... ....................................... ...................... ... I

ACKNOWLEDGMENTS ACKNOWLEDGMENT S ..................................... ........................................................ ...................................... ....................................... ....................................... ..................................... ...................................... ......................... ..... II

ABSTRACT .................................... ....................................................... ...................................... ....................................... ....................................... ..................................... ...................................... ....................................... ....................... .... III

SYMBOLS......................... SYMBOLS............................................. ....................................... ..................................... ...................................... ....................................... ...................................... ...................................... .................................... ................. IV

ABBREVIATIONS ABBREVIATIONS ..................................... ........................................................ ...................................... ...................................... ...................................... ...................................... ...................................... .................................. ............... V

UNITS ..................................... ........................................................ ...................................... ..................................... ...................................... ....................................... ....................................... ...................................... ............................. ........... VI

CONTENTS .................................... ....................................................... ...................................... ....................................... ....................................... ..................................... ...................................... ....................................... ...................... ... VII

LIST OF FIGURES ..................................... ........................................................ ..................................... ...................................... ....................................... ...................................... ...................................... ................................. .............. IX

LIST OF TABLES ................................... ....................................................... ...................................... ...................................... ....................................... ...................................... ...................................... ..................................... .................. X

GENERAL INTRODUCTION................................................... ...................................................................... ....................................... ....................................... ..................................... ...................................... ......................... ..... 1

CHAPTER I.

I.1

I.2

LITERATURE REVIEW ..................................... ........................................................ ..................................... ...................................... ....................................... ...................................... ..................... .. 2

THE OILFIELD LIFE CYCLE ........................................................ .................................................................................. ........................................................... ............................................................ ....................................... ............ 2

I.1.1

Exploration phase ......................................................... ................................................................................... ........................................................... ................................................................ ...............................2

I.1.2

Appraisal phase: ........................... .......................................................... ................................................................ ............................................................ .......................................................... ............................... 2

I.1.3

Development planning: ......................................................... .......................................................................................... ........................................................... ................................................ ...................... 3

I.1.4

Production phase:...................................................................... ....................................................................................................... ........................................................... ............................................ .................. 3

I.1.5

Decommissioning: ........................................................ .................................................................................. ........................................................... ................................................................ ............................... 3

ARTIFICIAL LIFT .......................................................... .................................................................................... ........................................................... ........................................................... ................................................. ....................... 4

I.2.1

he n eed to the arti!icial li!t: ............................................................................. ........................................................................................................ ..................................................... .......................... 4

I.2.2

Arti!icial li!t s"stems: ............................................... ......................................................................... ........................................................... .................................................................. .................................... ... 4

















I.4.2

et *as .......................................................... .................................................................................... ........................................................... ........................................................... ........................................... ................. 1'

I.4.3

*as (ondensate............................................................................. .............................................................................................................. ............................................................ ...................................... ........... 1'

I.4.4

olatile il .......................................................... .................................................................................... ........................................................... .................................................................. ....................................... ...... 1'

I.4.5

6lac$ il ......................................................... .................................................................................... ............................................................ .................................................................. ........................................... .......... 1)

I.5

PRODUCTION AND SYSTEM ANALYSIS SOFTWARE PROSPER........................................................................ ......................................................................................................... ................................... 17

I.6

PETROLEUM PRODUCTION OPTIMIZATION: SENSITIVITY ANALYSIS PARAMETERS ................................................. ................................................................................. ................................ 1

I.7

LAARICH CONCESSION OVERVIEW ......................................................... ................................................................................... ........................................................... ....................................................... ...................... 1

I.

CHAPTER CONCLUSION: ......................................................... ................................................................................... ........................................................... ............................................................ ..................................... .......... 1!

CHAPTER II.

II.1

JET PUMP MODEL SETUP........................................... .............................................................. ....................................... ....................................... ..................................... ..........................20 ........20

WELL MODELLIN" WITHOUT ARTIFICIAL LIFT SYSTEM ........................................................ ................................................................................... ............................................................ ................................... 2#

II.1.1

Input Data.................................................. Data............................................................................. ............................................................ ........................................................... ............................................... ..................... 27

II.1.2

P data ......................................................... ................................................................................... ........................................................... ........................................................... ........................................... ................. 27

II.1.3

ell Data.............................................................................. ............................................................................................................... ........................................................... ............................................... ..................... 27

II.1.4

#etting up t he model in P%#PE% ............................................... ................................................................................ ........................................................... ......................................... ............... 21

II.2

WELL MODELLIN" WITH ARTIFICIAL LIFT SYSTEM ......................................................... .................................................................................... ............................................................ ....................................... ...... 31

II.2.1

ptions #ummar" ......................................................... ................................................................................... ........................................................... .............................................................. ............................. 31

II.2.2

#ensitivit" anal"sis ....................................................... ........................................................................................ ............................................................ ........................................................ ............................. 32

II.3

CHAPTER CONCLUSION: .......................................................... .................................................................................... ........................................................... ........................................................... ..................................... ........... 37

CHAPTER III.

III.1

ESP MODEL SETUP................................................... ...................................................................... ....................................... ....................................... ...................................... .......................38 ....38

ARTIFICIAL LIFT SELECTION CRITERIA ........................................................ ................................................................................... ............................................................ ................................................. ................ 3

III.1.1

Arti!icial li!t s"stem standards .................................. ............................................................ ........................................................... ........................................................... ................................. ....... 3,

III.1.2

Arti!icial li!t s"stem choice ......................................................... .......................................................................................... ........................................................... .......................................... ................ 3

III.2

LASE$2 WELL MODELLIN" WITH ESP .......................... .......................................................... ........................................................... ............................................................ ............................................. ............ 4#

III.3

ECONOMICAL EVALUATION .......................................................... .................................................................................... ........................................................... ............................................................ ........................... 42

III.3.1

Introduction ........................................................ ................................................................................... ............................................................ .................................................................. ...................................... ..... 42

III.3.2

E#P (ase #tud" ................................................ .......................................................................... ........................................................... ............................................................ ........................................... ................ 42

















List List of Figu Figure ress Figure 1: Surface equipment of Jet Pump .................................................. ....................................................................................... ..................................... 6 Figure 2: Subsurface Equipment of Jet Pump................................................................................. 7 Figure 3: ESP configuration.......................................................................................................... 10 Figure 4: The locations of the nodes ............................................................................................. 12 Figure 5: Inflow and outflow curve at a specific node ................................................................. 13 Figure 6: Typical tubing performance performance curve ..................................................... .......................... 15 Figure 7: Geographical G eographical location ....................................................... ............................................. 18 Figure 8: PVT Data before Matching ........................................................................................... 24 Figure 9: PVT Data After Matching ............................................................................................. 25 Figure 10: Downhole Equipment Summary ................................................................................. 27 Figure 11: Downhole Equipment Sketch .................................................. ...................................................................................... .................................... 27 Figure 12: IPR data d ata input main screen ...................................................... .................................... 29 Figure 13: IPR Curve ..................................................... ....................................................... ........ 30 Figure 14: IPR/VLP curve cu rve intersection (State zero) ..................................................................... 30 Figure 15: Water Cut Curve .................................................... ...................................................... 33 Figure 16: Water Cuts/ GOR curve .............................................................................................. 34 Figure 17: Sensitivity Analysis Results ........................................................................................ 36 Figure 18: Jet Pump Boundaries ...................................................... ............................................. 36 Figure 19: Higher Reservoir Pressures with ESP ......................................................................... 40

















List List of Table abless Table 1: Options Summary ........................................................................................................... 21 Table 2: PVT Data ........................................................................................................................ 23 Table 3: Laboratory Data ........................................................ ...................................................... 24 Table 4: Deviation Survey ............................................................................................................ 26 Table 5: Geothermal Gradient ...................................................................................................... 28 Table 6: Average Heat Capacities................................................................................................. 28 Table 7: IPR Data Input ............................................................................................... ................. 29 Table 8: JET Pump Data Entry ..................................................................................................... 32 Table 9: Sensitivity Analysis on Various Water Cuts .................................................................. 32 Table 10: Sensitivity Analysis on various Water Cuts and GOR values ...................................... 34 Table 11: Sensitivity Analysis on various pressure values ................................................... ........................................................... ........ 35 Table 12: surface considerations ...................................................... ............................................. 38 Table 13: Operating considerations .............................................................................................. 38 Table 14: ALS operating conditions ................................................ ............................................................................................. ............................................. 39 Table 15: Recapitulative Table: Reservoir Pressure/Production Press ure/Production Rate (ESP) ............................... 40 Table 16: ESP Data ....................................................................................................................... 41 Table 17: CAPEX Expenses ......................................................................................................... 43 Table 18: Reserves Estimation...................................................................................................... 44 Table 19: Recovered and Remaining Volumes ............................................................................ 44 Table 20: OPEX Expenses ...................................................... ...................................................... 45 Table 21: Economical Balance ..................................................................................................... 45



















General Introduction No one can deny the importance of oil as well as petroleum products in our daily life. Besides being the origin of multiple geopolitical conflicts, ‘Black Gold’ as it is called provides mankind it’s essential needs in energy in addition of various uses in many fields such as the medical, cosmetic and agricultural domains. But, oil production faces logical obstacles that requires an intervention to assure a continuous but yet efficient production in a leading competitive industry. Thus, comes the need to artificial lifting systems. In Tunisia, the Oil& Gas industry, controlled, operated and supervised by the "The Tunisian Company of Petroleum Activities- ETAP" which is a public enterprise created by Law 72-22 of March 10, 1972 and allowing the state to increase its control and its active and direct participation in the various activities of the oil industry by conducting all petroleum studies and managing the national oil wealth as well as supplying the country’s needs in crude oil and gas.



















Chapter I. Literature Review

I.1 I.1.1

The Oilfield Life Cycle Exploration phase

Since the late 1800’s and while looking for oil, major discoveries have been made all around the world. Although, it is likely that any an y future finds are in fact smaller, s maller, more complex fields, appraisal wells can now be sited more accurately thanks to the development of new techniques increasing the exploration's efficiency. Managing exploration assets represents a major task because, in addition of promising geological conditions presenting the existence of hydrocarbons, the host country’s political and fiscal conditions must be favourable for the rentability of the entire cycle. Among these conditions we can mention, spatial distance to future markets, the existence of an infrastructure, and availability of a talented workforce. Normally, exploration investments are made long ago before there is any opportunity of producing crude oil. Commonly, a company must work for many years on a precise location before entering the production phase. During this period and prior to spudding the first well, the geological history will be studied with carrying a working program such as field work, magnetic surveys, gravity surveys and seismic surveys (1). I.1.2

Appraisal phase:



















I.1.3

Development planning:

After formulating and executing a field development plan used as a key document to achieve required agreements on the activities of a new field, or extension to an existing one. The purpose of The field development plan is serving as conceptual project p roject specification for the field facilities, the operational and maintenance strategy to support the investment proposal. The FOP (Field Development Plan) is divided into multiple stages from which we can mention: •

Objectives of the development

•

Petroleum engineering data

•

Description of engineering facilities Cost and manpower estimates

•

Budget proposal

•

Project planning

After completing the field development plan (FOP), the next steps are: •

Facilities design

•

Procurement of the materials of construction

•

Facilities Fabrication



















Maintenance and operating costs represent the major expenditure in field life and they are related to the required staff operating hardware running the facility. As decommissioning approaches, EOR is the remaining mean after primary production. Ultimately, the field is decommissioned if it can’t sustain running costs. I.2 I.2.1

Artificial Lift The need to the artificial lift:

Lacking the needed reservoir pressure which assure producing oil up to the surface, oil wells all around the world are in fact unable to produce at economic rates without assistance. This condition may be the result of pressure depletion overtime, by reservoir mechanism, or be caused by low original reservoir pressure. So, operators equip the wells with artificial lift systems (ALS) to produce the desired economical rate (2). To achieve the lower BHP, several artificial lift systems can be used with a positive displacement downhole pump, like a beam pump, a progressive cavity pump and an electrical submersible pu mp. It could be achieved with the gas lift in which the fluid density in the tubing is lowered and expanding gas helps to lift the fluid. To realize the maximum potential from developing oil field, the optimum artificial lift method has



















I.2.3 I.2.3.1

Sucker Rod Pump system: Basic operation:

The sucker rod pumps are the most widely used form of artificial lift. A rod pump typically consists of a prime mover, gearbox, walking beam, sucker rod strings and a pump. The dominant types of rod pumping are the walking beam type or simply beam pumping. This type of artificial lift uses a positive displacement plunger pump and a surface driving unit that converts the rotary movement of the motor with mechanical linkage including a pivoted walking beam (1). The need for producing deeper and deeper wells with increased liquid volumes necessitated the evolution of long stroke beam pumping. Several different units were developed with the common features of using the same pumps and rod string as in the case of beam pump units but with substantially longer pump stroke length. The desired long strokes did not permit the use of a walking beam, and completely different driving mechanisms had to be developed. The basic types in this class are distinguished according to the type of surface drive used, as given below: • Pneumatic Drive • Hydraulic Drive





















I.2.4 I.2.4.1

Hydraulic Pump System: Basic operation:

Hydraulic pumping is a proven artificial lift method that has been used since the early 1930’s in several thousand oil wells, and the number of h ydraulic installations in increasing yearly. It offers different systems for handling a variety of well conditions, like depth, deviation surve y, tubing and casing. The Hydraulic pumping system takes liquid from the surface (known as power fluid) and puts it through a reciprocating triplex piston pump to increase its pressure, and then injects the pressurized liquid down hole through a tubing string. The downhole jet pump converts the pressurized power fluid to a high velocity jet through the nozzle that mixes directly with the









































•

PCPs are able to produce high viscous fluids.

•

As there is only moving part in PCPs, there is no sand problem in this system.

•

Existence of free gas does not reduce the efficiency of PCP. Also, gas anchor is installed in well completions.

•

Capital and operating expenses are low of this system.

•

PCPs handle very well in abrasive fluids, paraffin plugging and scaling.

•

High Overall system energy efficiency, typically in the order of 55 to 75 % range.

PCP systems, however, also have some limitations and special considerations: •

PCPs are limited in producing high volume of liquid. The available maximum limit is





















The main parts of gas lift system are; station for gas compression, injection manifold, injection chokes, surface controllers, injection valves and chamber that installed in down hole. The figure below presents view of these parts (4). I.2.6.2

Advantages & Limitations:

The major advantages of Gas Lift are: •

This method is capable of handling high volume of solids easily.

•

Production rate is very high in this method. The maximum production rate could reach 50000 bpd.

•

As it was discussed above, it could be changes from continuous gas lift to intermittent gas





















The operation of ESP is similar to any other industrial electric pump. Electric cables provide electric energy to the down-hole motor. These cables are attached on the tubing. Electric motor and pump directly connected each other by shaft. The key parameter is the outside diameter of the down hole components. Outer diameter mainly ranges between 3.5 and 10 inches. Pump length ranges is between 40 and 344 inches. ESPs are mainly applied in the wells with high productivity index. Casing and tubing sizes are also important in the design of the subsurface components. All these factors influence on the fluid flow rate. Tubing size and flow rate is used to calculate and determine the total dynamic head (TDH). The different components (Surface+ subsurface) are shown in ( figure3 figure3).























The limitations of Electric Submersible Pump are summarized below: •

Electric power availability.

•

The higher pulling costs (Hard workover and production losses)













































tool in Petroleum Engineering in order to predict future performance of wells, since, during a well’s lifespan, flow regimes are approximating the pseudo steady-state ones.























I.3.4

Vertical Lift Performance (VLP)

One of the major factors affecting the production performance of a well is the pressure loss in the tubulars. As much as 80% of the total pressure loss in a flowing well may occur in lifting the fluid







































































































































































































































































































































































































































































































































Appendix 8: Downhole Equipment Input Data

















Appendix 10: Average Heat Input Data

















































Appendix 14: Sensitivity Analysis on various pressure values



















































































Artificial Lift Design, Optimization and Cost Estimation

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