Cormorant Engineering

Transcription

1 Gas Well Deliquification Workshop Sheraton Hotel, Denver, Colorado February 27 March 2, 20 Selection and Validation of Hydraulic Dewatering Pumps using Predictive Performance Model and Downhole Simulator Test Rig David Bolt Engineering Manager Ken Newman PE President Cormorant Engineering

2 Presentation Summary Predictive Performance Model Hydraulic Dewatering Pump Segmentation Casing vs. Tubing Pump Single vs. Dual Acting Pump Multiple Power Stage Pump Performance model as a design tool Pump and Model Validation Above Ground Test Facility Installation data 20 Gas Well Deliquification Workshop Denver, Colorado 2

3 Hydraulic Dewatering System Hydraulic Dewatering System (HDS) Works in Deviated Wells Cost Effective 24 / 7 Operation with minimal maintenance Operates with very low bottom hole pressures Three major components: Surface Hydraulic Power Unit (HPU) Hydraulic / Water conduits Hydraulic Downhole Pump (HDP) Surface HPU HDP 20 Gas Well Deliquification Workshop Denver, Colorado 3

4 Predictive Pump Model Cormorant developed a dynamic simulation model for hydraulic dewatering pumps Model uses Finite Element Methods Coiled Tubing String into several hundred elements of 0 20 ft in length Calculates the performance for each of these elements simultaneously End conditions are the HDP and the HPU Also uses Finite Difference in time Method Entire process is repeated at time increments of approximately 0 ms. Dynamic Simulation of the pump, actuator, flow and losses in each element, hydraulic system inputs and water production output. Hydraulic Pressure Function 20 Gas Well Deliquification Workshop Denver, Colorado 4 Pump Water Pressure Function

5 Model Output Water Production and Piston Displacement 7 Piston Displacement (in/0) Water Flow Volume at Surface (gal).6 Displacement in x Water Production - Gal Time (sec) Design Results Water Flow rate From Well 29 BPD Strokes per Minute 2.7 Slippage Past Water Plunger 0.8 BPD Balance Hydraulic Pressure 2,275 psi Water Flow rate Without Slippage 30 BPD Max Pump Hydraulic Power 6 HP Water Production w/ 25% Gas Gas Well Deliquification Workshop Denver, Colorado 5 0.0

6 Model Output Hydraulic Pressures 6,000 HF Conduit Pressure at Surface (psi) HF Conduit 2 Pressure at Surface (psi) HF Conduit Pressure at Downhole Pump (psi) HF Conduit 2 Pressure at Downhole Pump (psi) 5,000 Pressure (psi) 4,000 3,000 2,000, Time (sec) 20 Gas Well Deliquification Workshop Denver, Colorado 6

7 Model as a Design Tool Model simplifies the segmentation of hydraulic pump applications Using this tool Cormorant has developed pumping solutions for: Through Casing Through Tubing Single Acting Dual Acting Each application is modeled and an optimum pump identified 20 Gas Well Deliquification Workshop Denver, Colorado 7

8 Through Casing vs. Through Tubing Pump Configurations 2 Hydraulic Conduits Hydraulic Conduit Hydraulic Water Conduits 2 Hydraulic Water Conduits Thru Tubing Dual Acting Thru Tubing Single Acting Thru Casing Single Acting Thru Casing Dual Acting 8

9 Through Casing vs. Through Tubing Water Production BPD Cormorant Hydraulic Dewatering Pumps Add 2 7/8 tt / tc pumps 3.5 tt and tc? Through Tubing Pumps Few Water and Hydraulic conduits required Lower Cost Installation Through Casing Pumps Larger Hydraulic Piston Lower Operating Pressures Greater Water Production No Sanding / Silting in concerns (solids carried to surface) Well Depth - ft 20 Gas Well Deliquification Workshop Denver, Colorado 9

10 Single Acting vs. Dual Acting Hydraulic Pumping Systems Single Acting Hydraulic driven power stroke Return stroke by pressure difference of Hydraulic fluid and Water Lower Cost Install with hydraulic conduit Lower system pressures Dual Acting Hydraulic pressure drive power piston in both directions Operates in high gas environment Operates in high solids environment Long operating life Benefits exhibited in deeper wells 20 Gas Well Deliquification Workshop Denver, Colorado 0

11 Pump Selection in High Solids Harbison Fischer water pump section designed for solids environment (Sand Pro Model) Through Casing Pumps carry solids to surface through high velocity water in Coiled Tubing Flat Pak Percent of Production Impact of Friction on Performance Single Acting with Back Pressure Dual Acting Dual Acting design more robust 0 0% 00% 200% 300% 400% 500% Pump Friction Increase 20 Gas Well Deliquification Workshop Denver, Colorado

12 Water Production Production Rate vs. Coiled Tubing Diameter Water Production vs Coiled Tubing Size 5000 Well 3.5 TC Pump Coiled Tubing Diameter - inch 3000 psi System 4000 psi System CT Size impacts performance Smaller tubing higher viscous losses Larger tubing larger impact of Bulk modulus Balance Friction losses and Tubing volume Modeling is critical to optimize application 20 Gas Well Deliquification Workshop Denver, Colorado 2

13 Model and Pump Validation A test facility was developed to simulate down hole pressure and flow conditions for hydraulic pumps Facility utilizes a Coiled Tubing Reel with ft CT strings. 2,.25, and OD A set of custom developed volume meters and intensifiers are used to measure the hydraulic flow and flow volumes, as well as the water flow and flow volumes. The model validation is a work in process, results, and discoveries will continue to be shared in future workshops and papers. 20 Gas Well Deliquification Workshop Denver, Colorado 3

14 Pump Test System Reservoir Pump Control Valve Hydraulic Fluid Volume Meter Hydraulic Dewatering Pump Coiled Tubing 5000 ft Boost Pressure Coiled Tubing Backpressure control Water Volume Meter 5000 ft Boost Pressure Pressure Intesifier Input: System Pressure (3000 psi) Output: Input pressure plus Boost Pressure Water Reservoir 20 Gas Well Deliquification Workshop Denver, Colorado 4

15 Pump Test System with Instrumentation Reservoir Pump Control Valve Hydraulic Fluid Volume Meter Hydraulic Dewatering Pump Volt Coiled Tubing 5000 ft Boost Pressure Coiled Tubing 5000 ft Volt Backpressure control Water Volume Meter Boost Pressure Pressure Intesifier Input: System Pressure (3000 psi) Output: Input pressure plus Boost Pressure Volt Water Reservoir

16 Test System for Validation of Predictive Performance Model Hydraulic and Water Intensifier Cylinders Coiled Tubing Reel 20 Gas Well Deliquification Workshop Denver, Colorado 6

17 Test Facility Instrument Dashboard

18 Test Facility for testing down hole pumps Hydraulic System A series of test have been conducted on the test system in order to validate the model results Pressure Decay from 5000 CT String Plunger Slippage Test Cycle Rate and Production Rate This is an on going effort as we continue to refine and improve the model. 20 Gas Well Deliquification Workshop Denver, Colorado 8

19 Validation of Cycle Rate on Test System Piston Displacement - in / Model Piston Position Model Water Production - gal Actual Piston Position Actual Water Production Volume - Gallons in Through Casing Pump 3000 psi System pressure 30 BPD Output 3300 ft water pressure Time (sec) 20 Gas Well Deliquification Workshop Denver, Colorado 9

20 Data From a 7000 Deviated Vertical Well 3.5 in Through Casing Pump Pressure Oscillations Correspond to Speed of Sound in Water Column Gas Well Deliquification Workshop Denver, Colorado 20

21 Data From a 7000 Deviated Vertical Well 3.5 in Through Casing Pump Gas in Water Column Reduces Bulk Modulus to 250 Kpsi

22 3 ½ Pump Through Casing 7,000 ft Near Vertical, Conventional

23 Field Experience with Generation Pumps 200 Model Well Average Gas Production Water Failure Mode Through Casing Single Acting Horizontal (CBM) 2800 TVD 35 MCF - 45 MCF w/o 90 MCF w/ Back Pressure 7 BPD Power piston seals wore due to abrasives (Coal Fines) Through Casing Single Acting Deviated Vertical 700 TVD 35 MCF 76 MCF w/o BP 5 BPD Premature Failure Due to CT Connector Through Casing Single Acting Deviated Vertical 700 TVD 5 MCF 30 MCF w/o BP BPD Premature Failure Due to CT Connector 20 Gas Well Deliquification Workshop Denver, Colorado 23

24 Coiled Tubing Pump Connection Dual CT String with alternating pressure cycle Pressurized CT string grows in length (4ft, 7000 ft well) Causes torsion due to ends being fixed Grapple Connectors used not designed for continuous dynamic rotation Well Head Pump 20 Gas Well Deliquification Workshop Denver, Colorado 24

25 Coiled Tubing Pump Connection Dual CT String with alternating pressure cycle Pressurized CT string grows in length (4ft 7000 ft well) Cause torsion due to ends being fixed Designed Connection System: Dimple Clamp isolates pump from relative torsion of the CT strings Well Head Pump 20 Gas Well Deliquification Workshop Denver, Colorado 25

26 Sealing System Generation 2 Pump Water Seal System Designed for self cleaning Redundancy (8x) Hardened wear surfaces and abrasion resistant materials Aramid Fiber / HNBR Rod Seal System Mud Pump Design 20 Gas Well Deliquification Workshop Denver, Colorado 26

27 Generation 2 Pump Design Water Section Harbison Fischer Water Pump Section Field Proven Designs Using Clearance Plunger in combination with soft seal plunger Achieve extremely low unswept volumes for gas handling Add top traveling valve to improve gas handling Silt Dam to eliminate silting in pump during shut down 20 Gas Well Deliquification Workshop Denver, Colorado 27

28 Conclusions A Finite Element based Predictive Performance model has been developed Using this model Cormorant designed 5 different pump configurations Through Tubing Through Casing Single Acting Dual Acting Multi Stage Single Acting A test system simulating downhole pressure and flow conditions has been developed to validate pump performance Each application can be modeled for optimum pump selection Generation 2 Cormorant Pumps designed for reliability and performance 20 Gas Well Deliquification Workshop Denver, Colorado 28

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