Gas Well Deliquification Workshop

Sheraton Hotel, Denver, Colorado

February 19 – 22, 2012

Diverter Gas Separator

Jim McCoy

Lynn Rowlan, Dieter Becker, Ken Skinner

Echometer Company

Tony Podio - University of Texas – Austin

liquid in

anchor

pump

slip

gas in

anchor

Basic Principles of Downhole Separator

System

Gravity separation is the

governing principle for

downhole gas separators.

2

GAS BUBBLES FLOW UPWARD IN OIL OR WATER AT A RATE OF APPROXIMATELY

6 INCHES PER SECOND. THUS, GAS BUBBLES WILL BE RELEASED FROM A LIQUID

COLUMN IF THE DOWNWARD LIQUID VELOCITY IS LESS THAN 6 INCHES PER

SECOND.

A LIQUID COLUMN HAVING AN AREA OF 1 SQUARE INCH TRAVELLING AT A

VELOCITY OF 6 INCHES PER SECOND IS A RATE OF APPROXIMATELY 50 BPD

Gas Rise Velocity in oil and

water is approximately 6 inches

per second.

If the downward liquid velocity

is greater than 6 inches per

second, gas is drawn

downward.

Gas Separation from Liquid

Gas Separator Liquid

Capacity is based on

the principle that gas

is lighter than liquid

and tends to rise.

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 3

Natural Gas Anchor

The most efficient downhole gas separators locate the pump intake below the lowest gas entry point.

2012 Gas Well Deliquification Workshop

Denver, Colorado Feb. 19 – 22, 2012 4

Improved Natural Gas Anchor

Maximum flow

area in casing

annulus below

pump.

2012 Gas Well Deliquification Workshop

Denver, Colorado Feb. 19 – 22, 2012 5

Liquid Capacity for Various Annular Areas

Natural Gas Anchor

2012 Gas Well Deliquification Workshop

Denver, Colorado Feb. 19 – 22, 2012 6

“Poor Boy” Gas Separator above perforations

A small, long dip tube

within a small

diameter separator.

Very poor design with

a small outer tube ID

and long flow paths.

Only acceptable for

low volume wells.

7

2012 Gas Well Deliquification Workshop

Denver, Colorado

“Poor Boy” Gas Separator

Seating Nipple

Collar

Perforated Sub

Collar

Joint of Tubing

Dip Tube

Tubing Collars

prevent perforated

sub from laying

against casing wall

where liquid

accumulates

Casing

Limited Flow Area

and Small

3/8 inch holes in

perforated sub limit

gas exit flow and

liquid entry thus

reducing separation

efficiency

Feb. 19 – 22, 2012 8

“Poor Boy” Gas Separator Liquid Capacity

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 9

Collar Size Separator Increases Liquid Capacity

A good separator must

strike a balance between

annular flow area,

separator flow area, dip

tube diameter and

pressure drop.

Outer barrel OD same as collar OD.

Thin wall outer barrel and dip tube.

Short flow conduits.

Large inlet ports.

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 10

To get gas capacity of a specific installation multiply the

table value by the Pressure at the Pump Intake (psi)

and divide by 14.7 2012 Gas Well Deliquification Workshop

Denver, Colorado

11

Packer Gas Separator

• Uses gravity separation

like the “Poor Boy”

except much more

separation area and

capacity.

• Higher cost and higher

risk of mechanical and

sand problems.

2012 Gas Well Deliquification Workshop

Denver, Colorado Feb. 19 – 22, 2012 12

Concentric Packer Gas Separator

A concentric packer type gas

separator offers additional liquid

and gas capacities.

2012 Gas Well Deliquification Workshop

Denver, Colorado Feb. 19 – 22, 2012 13

Diverter Gas Separator Animation

Pump

Diverter Gas Separator Animation

Pump

Pump

Reservoir Fluid Discharge Above Diverter

Liquid Inlet Ports

The liquid falls to these

ports and is directed into

the pump inlet using large

ports and short tube to

minimize pressure drop

from inlet ports to pump

inlet.

5 Feet

Diverter Cups The diverter cups are

constructed from high

temperature, flexible,

wear-resistant, premium

elastomer.

Diverter Cups

Multiple cups can

be utilized as

desired

2012 Gas Well Deliquification Workshop

Denver, Colorado

Shear Pins

Shear pins are located below the

diverter cups. The force required to

shear the shear pins is operator

selectable. Factory setting is 4000

pounds.

If the diverter cups are not

retrievable with the gas separator,

the cups will be left in the well with

the shear pins and shear collar.

Pump

Feb. 19 – 22, 2012 20

Sand Accumulation

Sand or debris may deposit above the swab cup

flow diverter. If 5 inches of sand accumulates

over the diverter between the gas separator and

the casing wall, the flow of liquid into the gas

separator will cease and production from the

tubing will cease.

When sand or debris is blocking the gas

separator liquid inlet ports, a fluid level test will

indicate a high fluid level in the casing annulus

and a dynamometer pump card will indicate low

or no pump fillage. The well will require

servicing.

The diverter cups can be located further from the

inlet ports if desired.

Pump

2012 Gas Well Deliquification Workshop

Denver, Colorado 21

Sand Accumulation

When the pump is unseated, liquid in the tubing

will flow down the tubing and discharge out of the

gas separator through the gas separator liquid inlet

ports. The discharging liquid will be at high

pressure. This will wash the sand and debris away

from above the diverter. The discharging liquid will

flow up the casing annulus and carry the sand.

Probably ½ of the liquid and sand will flow down

through the gas separator into the lower portion of

the casing below the diverter. The discharging

liquid should carry some of the sand from above

the diverter to below the diverter.

Reseat the pump and pump the well. Perform the

liquid level test and dynamometer test to insure the

well is operating properly.

Pump

2012 Gas Well Deliquification Workshop

Denver, Colorado 22

Sand Accumulation - Shear Pin

Sand can accumulate above the gas separator

diverter and cause difficulty in removing the gas

separator and diverter from the well.

Retrieval of the gas separator and diverter may still

be a problem even after flushing sand from above

the diverter. A shear pin is located at the bottom of

the swab cup diverter on the gas separator so that

the gas separator can be removed from the diverter

and retrieved from the well. The shear pin holds the

diverter swab cups to the gas separator. When the

shear pin is sheared, the gas separator can be

separated from the diverter swab cups and

removed from the well. The shear pin will shear at

4000 # (pre-set or as desired).

Pump

2012 Gas Well Deliquification Workshop

Denver, Colorado 23

2012 Gas Well Deliquification Workshop

Denver, Colorado

Fluid Pressures

Surrounding Separator

Pump

58 psi Fluid Discharge Pressure

60.5 psi Liquid Inlet Pressure

60 psi Separator Inlet Pressure Feb. 19 – 22, 2012

24

Producing BHP Recommendation

PBHP 10% of SBHP insures producing 97% of Well’s Max Rate

25

Producing BHP Recommendation

PBHP 25% of SBHP produces 90% of Well’s Max Rate

3600 3240

SBHP PSI

0 3600

720

1080

1440

1800

2160

2520

2880

26

Echometer Test Equipment

5000 psi gas gun 15,000 psi gas gun 1500 psi Compact Gas Gun Liquid Level Tracking Pressure Transient Testing Plunger Lift Analysis Plunger Tracking Pump Animation Wireless Equipment

Insufficient Gas Separator

A good Gas Separator will separate the gas from the

liquid in the casing annulus and cause the liquid to

enter the pump if sufficient liquid exists in the casing

annulus.

If a well has a high fluid level and the pump is not full,

the separator capacity is not sufficient for the well.

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 28

Insufficient Gas Separator

• The pump is not at fault when gas is present

in the pump and liquid exists in the casing

annulus. Do not blame the pump.

• The gas separator capacity is not sufficient

for the well.

• This is a common error of many operators.

• However, the gas and liquid capacity of the

well may exceed the separation capacity of

the available space in the Casing/Tubing

combination.

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 29

High Fluid Level High Casing Gas Flow Rate

30

Fo max Fo from fluid level Fo Plunger

Feb. 19 – 22, 2012 31

Fluid Level Test and Analysis

Cobra Oil and Gas

Feb. 19 – 22, 2012 32

Stabilized Surface Dynagraphs

COBRA

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 33

Surface Dynagraphs and Pump Card

Cobra

Feb. 19 – 22, 2012 34

Diverter Gas Separator Laboratory Test System

Available for demonstration on request

On Memory Stick 2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 35

No Gas at Pump

No gas was flowing with the water

in this slide. The liquid enters the

separator and falls to the diverter

water inlet to the pump.

The rate is 600 BPD with no gas.

2012 Gas Well Deliquification Workshop

Denver, Colorado

36

Fluid Level At Separator

The top of the gaseous column at 1

to 3 feet above the top of the diverter

gas separator was used to determine

maximum gas flow rate for a certain

water rate in these tests and these

numbers were used in the calculation

of the Diverter Performance

Calculator.

The water rate was 400 BPD with a

gas rate of 45 MCF/D in this slide.

2012 Gas Well Deliquification Workshop

Denver, Colorado

37

High Fluid Level

The casing above the diverter

separator is full of gaseous liquid

column up to the top of the test

fixture. This rate is 400 BPD with

90 MCF/D

The gas rate is greater than is

used in the Performance

Calculator Spreadsheet. 2012 Gas Well Deliquification Workshop

Denver, Colorado Feb. 19 – 22, 2012

38

Pressure Across Diverter Cups

At 400 BPD

and 75 MCF/D

39

Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

40

Diverter Gas Separator Performance Calculator

Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

41

Diverter Gas Separator Performance Calculator

Diverter Calculator Input and Analysis

On Memory Stick 2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 42

Analysis at 300 BPD – 4.7 ID – 150 psig PIP

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 43

Diverter Gas Separator Configuration

Tubing String

Tubing Anchor

1 joint of tubing

Pump

Seating Nipple

Diverter Gas Separator

Diverter cups

Separator

Fluid Inlet

Fluid

Outlet

Liquid

Inlet

A 2 foot sub is needed below the seating nipple

if a short strainer nipple is run below the pump. 2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 44

Diverter Cups – After Roundtrip

The Diverter Gas Separator was run

to 7500 feet. The pump and rods

were installed. The rods unscrewed

from the pump. The tubing and

separator were pulled to retrieve the

pump. Shown are the diverter cups

in good shape.

Water was discharged at a show

rate into the casing annulus while

the separator was run into and out of

the well. The liquid level was at

3000 feet.

2012 Gas Well Deliquification Workshop

Denver, Colorado

45

Negligible free Gas at Pump

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 46

Full Pump – Limited Free Gas

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 47

Grantham 12 Fluid Level Test

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 48

Grantham 12 Casing Pressure Buildup Gas Flow 285 MCF/D in Casing Annulus and at Pump

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 49

Grantham 12 Casing Pressure Buildup Gas Flow 285 MCF/D in Casing Annulus and at Pump

Gas Flow at Pump (Volume)

285 * 15 / 491 = 8700 CF/D

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 50

Grantham 12 Dynamometer

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 51

Pump Position, Velocity and Rate

Strainer nipple (64 - 3/16 inch holes) and 2 standing valves may cause excessive pressure drop and cause free gas to be in pump

Pump Position Velocity

Maximum Rate is 1258 BPD

Upstroke

Upstroke

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 52

Pump Rate During a Stroke

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 53

Grantham 12 Fluid Level Test 02/12/2012

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 54

Grantham 12 Dynamometer 02/13/2012

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 55

Grantham 12 Fluid Level Test 02/14/2012

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 56

Grantham 12 Dynamometer 02/14/2012

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 57

Grantham 12 Dynamometer

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 58

Grantham 12 Fluid Level Test

2012 Gas Well Deliquification Workshop

Denver, Colorado

Feb. 19 – 22, 2012 59

Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

60

Use Efficient Downhole Gas Separators to

INCREASE OIL AND GAS PRODUCTION

IMPROVE EFFICIENCY OF THE LIFT SYSTEM

CORRECT ARTIFICIAL LIFT PROBLEMS

CAUSED BY INCOMPLETE PUMP FILLAGE

DUE TO GAS INTERFERENCE

REDUCE OPERATING COST

Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

61

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.

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Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Gas Well Deliquification Workshop where it was first presented.

Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

62

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.

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