artificial lift (filling the gap @ low spm) · artificial lift (filling the gap at low spm) lebro...

Gas Well Deliquification WorkshopSheraton Hotel, Denver, Colorado

February 23 - 26, 2009

Artificial lift (Filling the Gap @ Low SPM)

Companies:BP Devon Pioneer Questar NCX Inc.

Alex Rodriguez (BP) & Colin Foust (NCX Inc.)February 24, 2009

Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado

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Pump Jack (Filling the GAP at Low SPM)


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Ways to slow down the Pump Jack


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Challenges @ Low SPM

Challenges:• Artificial lift that works at low SPM at efficient working

parameters• Cost effective Artificial lift technology • Low maintenance• Easy installation• Lift low volumes of murky fluid without pumping off• Height issues (For wells within irrigation systems)• Decrease moving parts (Safety)• Smaller footprint (Environmental issues)


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Artificial Lift (Filling the GAP at Low SPM)

LeBro Pump Actuator is an Artificial lift technology that can fill the

Gap for low SPM pumping needs.


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Comparing / Contrasting Units (with a focus on LOW SPM)

Pros:• Reliable (Good History)

• Efficient at High Strokes Per Minute (spm) (>5 spm)

Pump JackPump JackCons:

• Not good pump efficiency at low spm due to slippage

• Not very power efficient at low spm

• Need extra auxiliary equipment to slow down the pump below 5 spm.

• Cost and maintenance.

• Installation


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Comparing / Contrasting Units (with a focus on LOW SPM)

Cons:• Not efficient at high spm

(>7spm)

• New or modified technology

• Very little history (~3 yrs)

LeBro PumpLeBro PumpPros:

•High efficiency at low spm (< 5 spm)•Power efficiency greatly increased•Cost and preventive maintenance decreased•No outside moving pieces (Safety)

•Smaller footprint (Environmental)

•Height greatly reduced (Irrigation)•Installation•Stuffing box eliminated.•Able to long stroke pump (Rig less)


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Cost, Maintenance, & Power Comparison


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Cylinder Classification

32” Stroke32” Stroke

60” Stroke60” Stroke

120( + ) ” Stroke120( + ) ” Stroke


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First LeBro Pump Installation– Bywaters Estate #2-399

• Bywaters Estate #2-399 Reactivation

• Well T&A since 11/1998 (PBTD 3252’)

• Texas Hugoton Reactivation program

• Estimated for well to make about 40-50 bbls/d initially and decreases down to ~<10 bbls/d.

• Initially LeBro Pump set at 4 SPM lifting ~40 bwpd. Later on pump was adjusted to 6.5 SPM lifting ~55bwpd.


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Height Comparison

Pump Jack LeBro Pump


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Timer that controls the Upstroke and Downstroke time.

LeBro Sealing Arrangement

LeBro seal design arrangement prevents outside wellhead leaks.

• The benefit of this mechanical seal arrangement is that in case of seal leakage, ie: end gland seals damaged or worn, the hydraulic fluid would leak inside of the wellbore rather than outside the wellhead. Furthermore, a low liquid level sensor is set up in the hydraulic fluid reservoir (on skid) to shut-down the equipment when it detects a low level hydraulic fluid on the reservoir tank. Thus, the shut down of the equipment will minimize any probable hydraulic leakage.

PNR Application (Well is located in the Texas West Panhandle field. It’s a Red Cave well with a TD of 2,260’ and PERFS at 1,772’ – 1,994’.)

- 54” stroke actuator, Initial rate 38 bbls/d @ 6 SPM. Fluid production decline down to 5 bbls/d @ 1SPM. Continuous pumping.

- In May 2008 the pump got stuck due to very thick oil (~23 gravity oil) – replaced the pump


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Pump got stuck due to thick oil

MC

FD

Time

PNR Application (Well is located in the Texas West Panhandle field. It’s a Red Cave well with a TD of 2,200’ and PERFS at 1,741’ – 1,980’.)

- 54” stroke actuator, Initial rate 65 bbls/d @ 5-6 SPM. Fluid production decline down to 16 bbls/d @ 2 SPM. Continuous pumping.

- Nov. 08’ there was a problem with the temperature switch on the pump. The switch was replaced and haven’t had any problems since.


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Problems with temperature switch on pumpSwabbing on the well

before the pumping unit was installed

MC

FD

Time

CBM Application Questar


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Arkoma Basin ( 2 x Wells )

Problems: Pump losses of 6 x per day in 91 degree horizontal well.

Project Goal: Address total pump loss from coal dust

Candidacy: LeBro USDTM due to demonstrated ability to pump at lower velocity, attain continual fluid movement and long stroke (purge) the pump on demand

System Design: 2HP LeBro USDTM system with NG generator. 54” Surface stroke and 1 x stroke every 1.5 minute(s)

CBM Application – Questar (Cont.)


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Preliminary findings: 4 x pumps total have been pulled due to complete filling of the horizontal bore with coal dust. These pumps were reported to have no damage, cleaned and ran back in. 1 x well has demonstrated an increase in production. The NG generator not observed to handle application as reliable as NG engine.

Developed Ideas: New design of Coal Dust Self Purging Pump TM – No pump changes since this design installed

Design of direct NG engine / hydraulic drive power source

Arkoma Basin ( 2 x Wells )

Questar CBM Application (54” stroke actuator, current fluid production decline is 0.5 bbls/d @ 1stroke every 2 minutes. Continuous pumping.)


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Questar CBM Application( 54” stroke actuator, current fluid production decline in 0.8 bbls/d@ 1stroke every 1 ½ minutes. Continuous pumping)

Devon CBM Application


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Installed: 01/19/2009Total Cost: $35,200**AFE Total

Devon CBM Application


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2005 06 07 08 091

5

10

50

100

500

1000

Date

Dly

Gas

Rat

e ( M

cf/d

)

Dly

Wat

er R

ate

( bbl

/d )

Dly

Oil

Rat

e ( b

bl/d

)

Csg Pressure ( psig )

DENNY 1-2H Gas Cum : 464 MMcfOil Cum : 0 MbblWater Cum : 14 Mbb

Installation of LeBro UnitInstallation of LeBro Unit

Production fell off due to liquid loading Production fell off due to liquid loading

PROSCheaper than pump jack

Delivers similar results

Limited pump speed (4 SPM max)

CONSTakes longer to drain backside treated water due to low SPM (Currently set around 1.5 SPM)

Feb. 23 - 26, 2009 22

Artificial lift Comparison (Semi-Deep Application)

Compared environmental footprint

Compared environmental footprint

2009 Gas Well Deliquification Workshop Denver, Colorado

Traditional Platform

(86” Stroke)

LeBro USD platform

(86” Stroke)


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Deep well application (NCX inc.)OBSTACLES:• Weight of the rods plus hydrostatic • Weight applied to well head equipment.• Pump efficiency (possibility of slip in lower metal

plunger)• Compressibility of well fluids. • Static stretch.• Rod compression, normal loss of down hole stroke

length and over travel. • Actuator friction and heat. Well deviation at surface.• Hydraulic system shock when valves open or close at

higher fluid gpm rates.


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Deep well application(NCX inc.)SOLUTIONS:• Increase size of actuator accordingly to exceed

lifting weight.• Use x-heavy fittings and insure well head is

flange and not slip type.• Decrease plunger clearance or increase fall rate.• Allow additional hp and spm for loss of pump

displacement if high gravity oil.• LeBro pump design stroke cycle results in less

loss of static stretch.• Retaining static stretch reduces or eliminates

rod compression. • Surface controls, proximity sensors, and

replaceable wear guide to protect shaft and end glands. Adjustable soft shift hydraulic valves.


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Lifting Coupler

Polish Rod to Rod-string

Hammer Union

Wellhead Configuration

• Versatility – Currently installed on both oil and gas wells in multiple fields

• Range – Volumes of ¼ bpd to 65bpd

• Depth – 2100’ to 6000’ also pursuing deeper applications

• Incorporates Harbison Fischer Components / GasVent ™ Pump

• Interchangeable to Wellhead / existing infrastructure / SCADA

• Transportable to location by pickup

• Reduced lifting costs : Pump changes, power consumption, pump purging (long stroke), lower hp demand


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LeBro Pumping System

Optimal in lowering fluid levels with low strokes per minute

Optimal in lowering fluid levels with low strokes per minute

Applications Electric * NG * Solar

Applications Electric * NG * Solar


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Conclusion (LeBro Pump actuator)

Pros:• Artificial lift that works at low SPM at

efficient working parameters• Cost effective• Energy efficient• Low maintenance• Easy installation• Lifts low volumes of murky fluid

without pumping off.• Solves height issues (Irrigation)• Greatly decreases moving parts

(Safety)• Smaller footprint (Environmental)

Stuffing box eliminated.• Able to long stroke pump to clean up

obstruction or fill. (Rig less)

Cons:• Reliability. Not enough history

(~3 yrs)• Not efficient at high spm

(>7spm)


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Q&A


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Cylinder To Wellhead

Stuffing Box is eliminated

Hammer Union feature allows for quick installation and spacing to rod string


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Rapid Fill / Gas Vent Functions

Gas lock eliminated

Only restriction is the weight needed to lift valve ball off of seat

Non- PSI difference between compression chamber and formation fluid

HF Actuator Cylinder

Specs on the HF Cylinder:• Collapse PSI: 12,000 psi• Burst PSI: 12,000 psi (based on tensile strength)• Cylinder ID: 3.250"• Drift: 3.250"• Literal Yield Strength: 60,000 psi• Diagram for the Modified End Gland with Brass Wear Ring is

attached. Specs: 2.875" OD x 1.500" ID x 5.500" length, steel construction with brass inserted guides for wear.

Other pictures


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LeBro USD™ Pumping SystemOriginal design targeted cost effective measures associated with marginal wells

Specific focus on maximizing fluid movement in wells with low PSI and / or depleted reservoirs

Workover &Pulling

Workover &Pulling

TreatingTreating

Power ConsumptionHP Demand

Power ConsumptionHP Demand

ReplacementsPump, motor

Etc.

ReplacementsPump, motor

Etc.


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Copyright

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– Display the presentation at the Workshop.– Place it on the www.alrdc.com 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 uses of this presentation are prohibited without the expressed written permission of the company(ies) and/or author(s) who own it and the Workshop Steering Committee.


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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.

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