What's new in artificial lift: Part 1—twenty new systems are described for sucker rod and progressing-cavity pumping, plunger lift and gas lift

World Oil, April, 2006 by James F. Lea, Herald W. Winkler, Robert E. Snyder

The latest model, the CEO IV Plunger Lift Controller is designed to meet remote requirements by using ultralow-power electronic technology. The design incorporates all the proven SCADA and RTU functions of other wellsite intelligence products, making it a complete and advanced plunger lift controller. This state-of-the-art system is designed with a programmed on-cycle initiation calculation accounting for casing, tubing and line pressures, as well as annulus volume, fluid load and tubing frictions. It can also be used to monitor tank levels, and it offers a broad range of control mechanisms, including time-based, using system pressure inputs; pressure-based; single-, dual- and triple-valve; flowrate and differential pressure.

GAS LIFT

Three new systems are introduced by two companies to improve the efficiency of using annulus gas to lift liquid columns in the tubing.

Side pocket mandrel. Weatherford's SBRO-DVX side-pocket gas-lift mandrel, Fig. 12, features unique dual-pocket communication channels that, when equipped with external backflow check assemblies, prevents well fluids from entering the casing annulus through gas lift valves or empty pockets. The mandrel can encompass multiple barriers to protect the annulus from corrosive fluids and pressure during operation and during valve change out. The mandrel will accept existing standard gas-lift valves and latches for maximum flexibility. It is available in 2 3/8- to 7-in. sizes, in a variety of materials for high-pressure and corrosive environments.

[FIGURE 12 OMITTED]

Applications include any well completion incorporating standard side-pocket gas-lift mandrels, including deepwater, high-pressure and/or highly corrosive well environments. Dual external valves prevent tubing fluids from entering the casing annulus. The dual-valve design also eliminates need for a positive check valve within the gas-lift valve, reducing required pressure drop at gas-lift valve depth. Thus, use of higher injection pressure lowers operating depth and improves system efficiency. Industry standard pocket configuration accepts 1.0- and 1.5-in.-OD gas-lift valves and latches from other manufacturers. No additional gas-lift equipment has to be purchased for upgrading to the new mandrels.

Continuous gas pump. BST Lift Systems of Ventura, California, is seeking field test partners for two new innovative gas-lift products now in patent application. The first is a new production system which uses a downhole injection, gas-powered booster pump assembly to eliminate flow gradient back pressure on continuous-flow wells. The new system allows gas lift to compete with rod pump and ESP to produce a well from initial flow to final tertiary recovery. The new device can produce gaseous fluids, high-viscosity liquids, and those with entrained solids better than either rod pump or ESE It can be installed on coil tubing, jointed pipe or a combination of both, with wireline retrievable capability, Fig. 13.

[FIGURE 13 OMITTED]

5,000-psi high pressure valve. The second innovative development from BST Lift Systems is a 0 to 5,000-psi operating pressure gas-lift valve with an improved bellows design which prevents overpressure and over-travel in existing 1 1/2- or 1 in.-OD standard configured valves. This unique bellows design provides for long-life operation utilizing standard high-pressure mandrels and proven wireline tools.