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Artificial

Lift.

Are you considering all the options?

With 80 percent of the oil produced today coming from fields developed
before 1973, artificial lift systems are playing a significant role in the
modern oil and gas industry. To help maximize production from these reservoirs,
customers can choose from five artificial lift systems with distinct capabilities:
ROD LIFT, PROGRESSING CAVITY PUMPING, GAS LIFT,
HYDRAULIC LIFT OR ELECTRIC SUBMERSIBLE PUMPING.

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PERCENTAGE OF WELLS ON ARTIFICIAL LIFT

100
80
60
40
20
0

Aging Fields

/Increasing

US

Canada

Decline Rate

FSU

The difficult aspect is choosing the best

system for maximum performance, since
the proper selection requires a thorough
understanding of the types of lift and
specific reservoir conditions, including:
well depth, volume of fluid to be pumped
and the properties of those fluids, the
amount of gas produced, the pressure in
the reservoir and the presence of sand.
Other factors such as cost constraints
and equipment capabilities also must
be considered.
To eliminate some of the guesswork,
Weatherford uses a five point systematic
solution process that includes:

International

division. As the industrys only company

that provides a complete suite of artificial
lift systems, products and services,
our goal is to help customers analyze
which system is the best for maximizing
their production and ultimate reservoir
recovery.
Consider the following scenario:
What would be the best artificial lift
system to use in a low gas/oil situation
when operating at 10,800-foot depth
with a 7-inch casing, 2 7/8 -inch tubing,
with a bottomhole temperature of
260 degrees F, a bottomhole pressure of
1,700 pounds per square inch (psi), and
a wellbore deviation of 22 degrees with a
dog-leg and a required production rate
of 600 BFD?

Data collection/confirmation
Elimination process (ruling out
systems that do not meet that wells
particular criteria)

A) Reciprocating Rod Lift

B) Electric Submersible Pumping (ESP)
C) Hydraulic Lift
D) Gas Lift

Systems analysis (which system truly

is the best for that application)
Final selection (economic evaluation,
which equipment is available for the
customers timeframe)

Based on the conditions mentioned,

the reservoir is deep and wellbore is
crooked, making it an ideal hydraulic lift
candidate. Reciprocating rod lift is not the
optimum choice because of the failure rate
of rods and pumps in this environment.
ESPs are not a good choice due to the
temperature, depth, reservoir pressure and
high gas/oil ratio.

Follow-up analysis (did the system

meet expectations?)
We often find that operators repeatedly use the same artificial lift system,
regardless of the uniqueness of the
reservoir, because they are comfortable
with the familiar, said Lee Colley,
President of Weatherfords Artificial Lift

Read on for further details.

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ROD LIFT
SYSTEM

Rod Lift

Sucker Rod

Tubing Anchor
Catcher

SYSTEMS

Representing more than 80 percent of all

systems in use worldwide, reciprocating rod lift
pumping systems dominate the market for
artificial lift equipment. These systems are
primarily used to recover light and heavy oil
from land wells, since the weight, footprint,
wellbore angle and well servicing costs make it
undesirable for most offshore platform locations.
The most common form of artificial lift is the
traditional beam pump system because of its
long history, reliability and ability to reuse
components in different well applications. This
system includes a beam-pumping unit and
sucker rods attached to a downhole pump.
Powered by either gas or electricity, the
reciprocating rod lift system has the flexibility
to adjust production through stroke length,
pump size and speed.
For example, although rod lift systems are
most effective in low-to-medium volume
applications the typical range is between 201,000 barrels per day (b/d) some operators
have achieved higher lift volume requirements
by utilizing long-stroke pumping units
(RotaflexTM). Likewise, in troublesome and
high-volume wells, a type of long slow stroke
pumping system is frequently used to extend
tubing wear and eliminate gas lock problems.
The advantages of reciprocating rod lift
include high system efficiency, upgraded materials
that reduce corrosion, repairs that can be conducted while the well is in service, and a high
salvage value for surface and downhole equipment. The systems primary limitation is depth,
due to rod capability. Other considerations
include tubing and rod wear and gas-oil ratios.

Sucker Rod
Pump Assembly

USE ROD LIFT FOR:

Recovering light or heavy oil
Typical operating depth range is
2,000 feet-11,000 feet; in certain
conditions can reach 16,000 feet
Typical operating volume is 20 to
1,000 b/d; in certain conditions can
attain 3,500 b/d
Typical operating temperature
is 100 - 250F; the maximum
temperature is 550F.

Rotaflex units

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RECIPROCATING

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Case history Rotaflex

The field test ran from mid-July 1998 through the

end of November, and included a pump-off controller
system on one long-stroke and one conventional beam
pumping unit, enabling close monitoring of well
conditions and differences in operating parameters.
Test data concluded that thermal applications could
apply a cost-effective pumping system using a
mechanical long-stroke pumping unit. Primary benefits
of the long-stroke units included improved fluid
production (on average, the well test production rate
on the Rotaflex wells was 41 percent higher.)
At the same time, the average pump efficiency
increased from 46.8 percent to 67.6 percent, and lifting
costs were lowered by more than 18 percent.
Additionally, inspection on the pumps after the first
production cycle showed that on average the wear in
pumps from the Rotaflex wells was noticeably less
than in the units from the other wells.

Lowered lifting costs, improved fluid production

and increased pump efficiency were three benefits
resulting from a major oil companys controlled test
of a mechanical long-stroke pumping unit as a
possible alternative to conventional pumpjacks in
thermal applications.
The company had been using a conventional
beam unit pumping system with a variable
frequency drive for speed control on a number of
multilateral horizontal cyclic steam wells. To
optimize its system, the company field-tested the
mechanical long-stroke pumping unit (Weatherfords
Rotaflex system) for operating reliability, its ability
to lift available production, power consumption
(lifting cost) and the frequency of maintenance.

systems incorporate wireline retrievable

valves, which allows for increased lifting
flexibility and low cost well servicing.
Considerations should be given to the
following restrictions before using gas lift:
it needs a high-pressure gas source and it is
not efficient in lifting small fields or single
well leases.

Gas
Lift

SYSTEMS
Gas lift most clearly resembles the natural
flow process and is the preferred form of
artificial lift when there is an economical
supply of pressurized injection gas. These
systems are used on multiple and slim
hole completions and can handle sandy
conditions well.
With a low initial installation cost, gas lift
systems are ideally suited for offshore oil
wells because they require less platform
space and centralized gas compression.
These systems are also used to kick off wells
that will flow naturally once the heavier
completion fluids leave the production
string. An efficient form of artificial lift, gas
lift systems are used throughout the world
in a variety of locations, including the Gulf of
Mexico, Venezuela, Nigeria, Russia, Oman,
and Brunei.
Gas lift systems include gas lift valves,
mandrels and accessories, surface controls,
packoff equipment, and coiled-tubing gas lift
equipment. Advantages include good lifting
efficiencies, minimal moving parts and
flexibility in lifting from near the surface or
deep within the wellbore. Many gas lift

Colin Rae, Regional Sales Manager, Artificial Lift (left) and

Steve McLeod, Area Manager North Sea pictured with
some of the components of Weatherfords gas lift systems.
Gas lift is the most common form of artificial lift used for
North Sea reservoirs, followed by electric submersible pumping.

USE GAS LIFT FOR:

Working on offshore wells or on land
wells where a natural supply of gas
is available
Typical operating depth is 8,000 feet;
maximum is 15,000 feet
Typical operating volume is 400 b/d;
maximum is 30,000 b/d
Typical operating temperature is 180F;
maximum is 400F

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Gas Lift Valve

Application

For one major oil company, a gas lift solution

meant cost savings of an estimated $86,000.
Located in Lafayette, La., the customer had
a horizontal low-pressure well that was
operating at TVD 5,280 feet. The task was to
determine which artificial lift system would
kick off the well after the completion.
The Weatherford solution consisted of
two valves the Proportioning Differential
Valve (RPDV-1) and the Dump Kill Valve
(RDDK-1) which allow the customer to test
the packer and then unload the well without
intervention.
On the initial completion,
four-sided mandrels were spaced out at
650-foot increments from top station kickoff
depth. The top three unloading stations
were equipped with RPDV-1 valves to close
at a differential of 320 psi. The bottom
mandrel was loaded with an RDDV-1 valve
set to shear at 2,000-psi differential.
After careful testing, the casing pressure
was increased to 1,950 psi. This step closed
the RPDV-1 valves and sheared the RDDK-1
valve, causing circulaGAS LIFT
tion between the casing
SYSTEM
and the tubing. Once
equalized, the RPDV-1
differential valve
reopened, allowing the
Side Pocket
well to be unloaded
Mandrel with
Gas Lift Valve
with gas lift.
The rig was
then moved off
Side Pocket
location and the well
Mandrel with
Gas Lift Valve
was completed. This
process eliminated
well re-entry, time
Side Pocket
and associated risks.
Mandrel with
Gas Lift Valve
Upon its completion,
the procedure saved
the customer
Completion
approximately
Fluid
$86,000: $40,000 in
rig time; $6,000 in
Single
wireline charges
Production
Packer
and $40,000 in the
elimination of
nitrogen testing.

Progressing
Cavity
PUMPING SYSTEMS

Over the past 20 years, use of Progressing

Cavity Pumping (PCP) systems has grown
substantially. Initially used to produce only
high viscosity sand-laden heavy oil, PCPs
also are now a widely accepted artificial lift
method for shallow high water cut, high
volume production and de-watering coal
bed methane wells.
The growth and popularity of PCPs are
expected to continue, due to several factors.
First, todays progressing cavity pumping
systems offer a wider range of volume and
lift capacities they can operate to depths
of up to 6,000 feet and have a maximum
production rate of 4,000 b/d. Second, more
pump choices exist to suit a broader range
of producing environments. Third, several
new pump materials have been developed
for more aggressive producing environments.
Other developments include vast
improvements in the experience required
to properly apply and service the pump
systems, more comprehensive design
programs for selecting PCP systems and
specifically developed databases that track
installations and document pump run life.
Key advantages to the PCP system
include low capital costs, power
consumption and noise levels; low profile
surface equipment; high resistance to
abrasion; high overall system efficiencies;
simple installation, operation and
maintenance (no internal valves to lock or
stick); and capacity to pump a wide range
of fluid viscosity, production rates and
pressures.

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Case
history

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Components of the PCP system include

the downhole pump, continuous or
conventional sucker rod, a surface drive
and various types of torque and/or speed
limiters. All system components should be
considered to optimize each application.
Well parameters that are evaluated with
each application include the volume
of fluid and pressure required, bottom

USE PCP FOR:

All well types, including horizontal, slant,
directional and vertical reservoirs
Typical operating depth is 2,000 - 3,000 feet;
maximum is: 6,000 feet
Typical operating volume is 50-2,000 b/d;
maximum is: 4,000 b/d
Typical operating temperature is 75-110F;
maximum is 200F

Casing

Production
Tubing

Sucker
Rod

Sucker Rod
Coupling

Tubing Collar

Stator

Rotor

PCP
SYSTEM

hole temperature, producing fluid,

aromatic content, levels of carbon dioxide
or hydrogen sulfide, and the reservoirs
past history.
With a mature PCP market share already
a fact in Canada, growth is now occurring
in areas such as the United States,
Venezuela and Brazil, as well as in emerging
markets in Indonesia and Argentina.
Tubing Collar

Tag Bar Sub

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Electric
Submersible

ESP
SYSTEM

PUMPING SYSTEMS
Electric submersible pumping systems (ESP) are
typically targeted for high volume wells where gas
is not readily available for use in gas lift. Because
they require very little space on the platform and
can be installed in highly deviated wells, they are
ideally suited for offshore installations.
The U.S. (which has approximately 10,000 ESPs
in service), Russia and Indonesia currently constitute the largest markets for ESPs. Major growth
areas will include reservoirs that have lost pressure
and have increasing water cut. The North Slope
of Alaska and the former Soviet Union are good
examples of areas that are using increasing
numbers of ESP pumps.
ESP installations are considered harder to
design than other forms of artificial lift because
they require an understanding of hydraulic,
mechanical and electrical systems. Recent
advances in software programs, however, have
helped by rapidly examining design parameters
and evaluating options. Furthermore, a properly
designed ESP system providing that the correct
equipment is selected requires little or no
monitoring or daily maintenance and should have
a bottom hole life in excess of three years.
Key elements of the ESP system include the
pump, motor, protector, cable and controller.
Submersible pump assemblies are located
downhole, with only the control mechanism and
transformers above ground.
In addition to handling deviated wells, other
advantages of the ESP system include high
volume and depth capability (can reach a
maximum depth of 12,000 feet and a maximum
operation volume of 30,000 b/d) and the ability

Pump

Power
Cable

Seal
Section

Motor

to adapt to a variety of wellbore configurations.

At producing rates below 1,000 b/d, however, rod
lift systems are normally more cost-effective
than ESPs.
Considerations for ESPs include that the
system can only be operated with electric power
and high voltages. Likewise, ESP systems do not
work well for gassy fluids. Modern gas separators
available with ESP systems can remove a fair
amount of free gas and allow the pump to operate
successfully, but for a high volume well with a
high gas/oil ratio, gas lift may be a better option.

USE ESP FOR:

Handling deviated wells and adapting to
all wells with 5 1/2 -inch casing and larger
High volume and depth capability
Typical operating depth range is
1,000-10,000 feet
Typical operating volume range is
600-8,000 b/d
Typical operating temperature range is
100-250F; maximum is 325F

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Production
Tubing

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Hydraulic
LIFT
SYSTEMS

Because of their ability to

operate in high volume, high
depth requirements, hydraulic
lift systems have been gaining
popularity during the past five
years. As of 1998, approximately
1,750 wells worldwide were
using hydraulic lift systems,
with more than 1,100 operating

Production
Casing

Packer
Nose

USE HYDRAULIC LIFT FOR:

Deep, deviated wells
Typical operating depth: 10,000 feet
Piston can go to 17,000 feet;
maximum for Jet is 20,000 feet
Typical operating volume of 500 b/d,
but can go to 4,000 b/d (Piston);
Jet is 1,000 BPD, with a maximum
of approximately 15,000 b/d
Typical operating temperature for
Piston and Jet is 100 - 250F,
maximum of 500F

in North America. In the

international arena, the technology is being introduced
into new markets such as
West Africa and Mexico.
Hydraulic lift systems are
used primarily for recovering
medium to light oil. System
components include the
surface power fluid and
cleaning units, and
subsurface jet or piston
hydraulic pumps. The
jet pumps, with no
moving parts,
high alloy
construction
and abrasion
resistant

components, provide long run

times, even in sandy or highly
corrosive well environments.
Likewise, the piston hydraulic
pumps can efficiently lift from
great depths, and have the
potential to operate to almost
total well depletion.
Both types of hydraulic
pumps are commonly circulated
High Pressure
to the surface for maintenance,
Power Fluid
dramatically reducing well
down-time and eliminating
pulling unit expenses.
Additionally, both jet and
piston pumps operate very
successfully in highly deviated
Bottom Hole
wellbores.
Assembly
Produced well fluid is
pressurized by the surface
power unit and is used as the
power source to operate the
downhole pump. The surface
power installation can be
Piston or Jet
Free Pump positioned at a central location
to serve multiple wells, or as a
convenient skid-mounted unit
located at the individual
wellsite. The system has the
ability to use gas or electricity
as the power source.
Standing
Hydraulic lift systems are
Valve
one of the most versatile
types of artificial lift.
However, jet pumps
are limited by very
low bottom hole
pressure
HYDRAULIC
and piston
SYSTEM
types by high
gas-to-liquid
ratios.

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Future Plans

Unidraulic
System

In 1999, Lee Colley noted, Weatherford

will introduce new technologies that will push
the operating envelope of current artificial lift
methods in both capability and improved
system economics. These technology
initiatives include subsurface pump developments that will significantly improve the
efficiency in volumetric sweep and extend
operating life. Also included are a number of
thru-tubing technologies to save the cost of
pulling tubing and reduce lost production
while servicing the well.
Colley also noted that other areas of
focus include the continued expansion of
Weatherfords contract services, which install
and manage artificial lift systems, partnering
with clients to develop specialized and unique
artificial lift system configurations, and
further development of well site optimization
packages, which use well site information
gathering to enhance artificial lift performance.
Weatherford also is exploring opportunities to
combine different types of technologies, such
as gas lift with PCPs, or using hydraulic lift to
drive PCPs.
Weatherfords artificial lift goal is to
continue to seek initiatives and solution
strategies, which with other industry
improvements will position us as a
technology leader, said Colley.

Maximizing recovery benefits sometimes is

as simple as taking advantage of a resource
that has been underutilized, as demonstrated
by an East Texas operator whose reservoir
has continued to flow oil without a
significant increase in operating costs.
From 1950 to 1970, the reservoir used rod
pumps to supplement the reservoirs natural
energy. With time, the wells depleted,
production decreased and maintenance
problems with rod and tubing wear became
apparent. To increase efficiency, operators
began searching for an artificial lift system to
increase their total production and reduce
maintenance costs, without increasing
operating costs.
Based on the specific conditions of the
reservoir and assistance from Weatherford
experts, the operator selected a hydraulic lift
system to supplement the wells natural
energy. The system included a 60-horsepower
(hp) Unidraulic and 2-inch downhole jet
pump. A gas engine using produced gas
from a reservoir was chosen to power the
Unidraulic. An approximately 20 percent
increase in production resulted, with no real
increase in operating costs. In 1985, two
additional 100-hp Unidraulic systems were
added and the 60-hp unit was upgraded to
100 hp. The total system included a 150-hp
water injection pump that was also powered
by the natural gas engine.
Today, the reservoir operates with
basically the same equipment. It yields
approximately 2,300 b/d, costs about $0.014
per barrel of fluid to be produced and 41
cents to produce a barrel of oil, considering
only maintenance and repair costs.

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Case
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