GAS LIFT

DESIGN
 GAS LIFT DESIGN :
GAS QUANTITY REQUIREMENT AND PORT SIZE SELECTION
FOR UNLOADING VALVES

 IF THE PRESSURE AT WELL DEPTH IS

LESS THAN SBHP, FIND OUT THE RATE

FOR THAT ‘DP’ (SBHP - FBHP)

 FROM THE RATE REQUIRED, CALCULATE

GAS REQUIREMENT (RATE x IGLR)

2
 GAS LIFT DESIGN :
GAS QUANTITY REQUIREMENT AND PORT SIZE SELECTION FOR UNLOADING VALVES

 SELECT PORT SIZE USING THORNHILL

CRAVER EQUATION

 USE THE SAME PROCEDURE FOR OTHER

UNLOADING VALVES

3
 GAS LIFT DESIGN :
CALCULATION OF DOME PRESSURES

 FORCE BALANCE EQUATION TO BE USED :

Pd = Pt x R + Pc (1-R)
Pt FROM TUBING PRESSURES AT VALVE
DEPTHS
Pc FOR FIRST VALVE = PSO
FOR DEEPER VALVES:
Pso (SUBSEQUENT VALVES) = Pso - SAFE
PRESSURE DROP (10, 15, 20, 30
ACCORDING TO PORT SIZE) 4
 GAS LIFT DESIGN :
CALCULATION OF DOME PRESSURES

 HIGHER THE PORT SIZE, HIGHER DROP

REQUIRED TO CLOSE UPPER VALVES DURING
UNLOADING
 USE Ap/Ab (R) VALUES FOR CORRESPONDING
PORT SIZES SELECTED FOR EACH VALVE.
 USE TEMPERATURE CORRECTION FACTORS
TO CALCULATE DOME PRESSURES (Pd) AT
LAB TEMPERATURE (80 deg F)

5
 GAS LIFT DESIGN :
CALCULATION OF DOME PRESSURES

 TABULATE VALVE DEPTHS AND

CORRESPONDING Pc, Pd, PORT SIZE, GAS

QUANTITY, RATE, Pso, Psc, PTRO ETC.

6
 GAS LIFT DESIGN

Important parameters in Gas lift design

 Gas pressure at depth.
 Temperature effect on the bellows dome pressure.
 Volumetric gas throughput of a choke or gas lift
valve.
 Gas volume stored in a conduit.

7
 GAS LIFT DESIGN

Important parameters in Gas lift design

Gas pressure at depth

 P at depth = P at surface* (0.01877*Gas

density *Depth/ T*z)

 This equation involves trial and error solution.
 Hence Charts are developed for ready use.

8
 GAS LIFT DESIGN

Important parameters in Gas lift design

Gas pressure at depth

Example problem – 6 :
Gas pressure at Surface = 800 psi
Well depth = 8000 ft.
Average temp = 120 deg F
Gas Gravity = 0.65
Find Gas pressure at 8000 ft.
9
 GAS LIFT DESIGN

Important parameters in Gas lift design

Temperature effect on the bellows dome pressure

 Significant in Valve opening and closing pressure

calculations.
 Temp correction factor to be used from chart.
 Chart base is 60 deg F.
 If the room temp., where the valves are set, is different
from 60deg F,again correction factor is to be applied.

10
11
 GAS LIFT DESIGN

Important parameters in Gas lift design

Temperature effect on the bellows dome pressure

Example problem - 7 :
Dome pressure at valve depth = 879 psi
Temp at valve depth = 180 deg F

Calculate the dome pressure at lab temp of 80 Deg

F.

12
 GAS LIFT DESIGN

Important parameters in Gas lift design

Volumetric gas throughput of a choke or gas lift valve.

 Thornhill-Craver equation can be used.

 Again,reading from chart is the convenient way.
 Calculation of choke size for a given gas throughput.
 Calculation of gas throughput for a given choke.

13
THORNHILL – CRAVER EQUATION..

14
15
 GAS LIFT DESIGN

Important parameters in Gas lift design

Gas volume stored in Annulus.
 Useful for calculating inj.gas requirement in
intermittent gas lift wells.
 Also useful for inj.gas line sizing.
 Approximate (~5%)volume of gas stored in a
conduit between two avg. pressures is given by,

Vc*((P1-P2)/14.7)

16
 Design of G/L for a well…
Data…..
 Production rate = 1500 BPD
 Perforation interval = 5900 - 6000 ft.
 Depth = 6000 ft.
 Casing = 5 1/2" ; 17 - 20 ppf
 Tubing = 2 7/8"; N-80, 8 RD, EUE.
 Gas lift valve= J-40 (Camco Co. 1" O.D.)
 Port sizes = 3/16", 1/4", 5/16"
 Gas lift mandrel = 2 7/8"
 Injection gas quantity = Unlimited
 Specific gravity of gas = 0.65
 Gas injection pressure = 1100 psi

17
 Design of G/L for a well…
Data….
 Flowing tubing head pressure = 160 psi
 Kill fluid gradient = 0.45 psi / ft.
 Static wellhead temperature = 74 deg F
 Geothermal gradient = 0.019 deg F/ft
 Gas oil ratio (FGOR) = 300 SCF/bbl
 Gas liquid ratio (GLR) = 150 SCF/bbl
 SBHP = 2020 psi at 6000 ft.
 FBHP = 1780 psi at 6000 ft.
 Productivity Index = 4.6 b/d/psi

18
 Design of G/L for a well…

Step-1 Mark these on Depth Vs Pr…

 Well depth = 6000 ft

 Packer depth = 5800 ft.
 GL injection pressure = 1100 psi at surface
 Flowing tubing head pressure = 160 psi
 Static Bottom hole pressure = 2020 psi
 Flowing Bottom hole pressure = 1780 psi
 Static well head temperature = 74 DegF

19
 THP GIP ST F

160 1100
74

DEPTH

2020
5800 1780
6000
ft FBHP 20
SBHP
 Design of G/L for a well…

STEP – 2 Drawing temp. grad line..

 Geothermal gradient = 1.9 F / 100 ft.

 BHT at 6000 ft. = 74 F + (0.019 x 6000) F= 188 F

 Mark 188 F at 6000 ft. and draw TGL.

21
 THP GIP ST F

160 1100
74

DEPTH

188
1780 2020
5800
6000
ft FBHP SBHP22
 Design of G/L for a well…
 STEP – 3 Drawing casing pr. Line…..

  g *D 
 
53.3*Tavg * Zavg
Pd  Ps * e  

 Tavg = (74 + 188) x 1/2 = 131 = (131 + 460) R

= 591 R
 Zavg = 0.84 ( assumed )

=
 0.65*6000 
 53.3*591*.84  1274 psi at 6000
 Pd 1274
Mark Ps *e  
ft Psi point.
psi at 6000 ft line join with 1100

23
Injection pr. at diff. depths..

24
 THP GIP ST F

160 1100
74

DEPTH

188
1780 2020
5800
6000
ft 1270 FBHP SBH
25
 Design of G/L for a well…

Step – 4 Drawing Kill fluid grad line

Pr at 6000 ft = 6000 * 0.45 = 2700 psi.

Mark 2700 psi. point on 6000 ft. line

Join with (0,0) point

26
 THP GIP ST F

160 1100
74

DEPTH

KF GL

SBHP
188
1780 2020
5800
6000
ft 1270 FBHP 27 2700
 Design of G/L for a well…
Step – 5 Drawing Min grad line
Select minimum ( Gas Unlimited) grad line for water
flowing at 1500 b/d through 2 7/8" and average
temp. 140degF.

Drop line from 160 psi. point on the grad line.

Note the depth = 950 ft.

Note pressure at 6000 ft + 950 ft = 6950 ft, = 1355

Mark 1355 psi. on the graph paper at 6000 ft.

Join 160 psi. and 1355 psi. points 28

Design of G/L for a well…

29
 THP GIP ST F

160 1100
74

DEPTH MIN GL

KF GL

188
5800 1355 1780 2020
6000
ft 1270 FBHP SBHP 30 2700
 Design of G/L for a well…

Step – 5 Finding first Balance point

Draw a parallel line starting from Pwh = 160 psi. point

To the kill fluid line

The intersection point on the Casing grad line gives

the balance point

31
 THP GIP ST F

160 1100
74

DEPTH
2088 ft

KF GL

SBHP
188
1355 1780 2020
5800
6000
ft 1270 FBHP 32 2700
 Design of G/L for a well…
Step – 6 Locating First valve

The intersection point gives the first valve position-

2088 ft

Drop a horizontal line on temp grad line – note – Temp

114 Deg F

33
 THP GIP ST F

160 1100
74

DEPTH
2088 ft 114 Deg F

KF GL

SBHP
188
1350 1780 2020
5800
6000
ft 1270 FBHP 34 2700
 Design of G/L for a well…
Step – 7 Locating Second valve
•Draw a line from balance point to intersect min. grad
line
•Take reduced injection pr. by 50 psi. and draw a
parallel Line to injection line
Above this point the tubing would get aerated while the
Tubing below is full with kill fluid.
•Draw a Kill fluid grad from the intersection on the Min grad
line to intersect the available injection pr line

•The intersection point gives the position of the second

valve 3350 ft.

•Drop horizontal line form L2 to get temp. and the point on

35
the min grad line
 THP GIP ST F

160 1100
74

DEPTH
MIN
Gr.L 114 Deg F
2088 ft
Pmin 560

137 Deg F
3350 ft

KF GL

SBHP
188
1350 1780 2020
5800
6000
ft 1270 FBHP 36 2700
 Design of G/L for a well…

Step – 8: Locating subsequent valves

•Take reduced injection pressure by 50 psi and draw a

parallel Line to injection line by reducing 50 psi,
Above this point the tubing would get aerated while the
Tubing below is full with kill fluid.

The procedure is repeated till the Operating point

is reached or the deepest possible Injection point
is reached
39
 Design of G/L for a well…

Step – 9 Calculating gas requirement

From flowing gradient chart, the required GLR at L1

= 500 scf/bbl is obtained.

1500 b/d x 500 scf / b

 Q Calculated = ------------------------------- = 750 MCFD
1000
Q cal 750
Q corrected = ------------------------------------ = -------------------------------------
0.0544 S.G. x (T + 460 ) 0.0544 0.65 ( 114 + 460 )
750
= -------- = 714 MCFD
1.05

40
 Design of G/L for a well…

Pmin

Depth of Ist Valve

41
 Design of G/L for a well…

Step – 10 Calculating port size

For Pmin at L1 = 560 psi; Pinj 1 at L1 = 1160 psi

Use Thorn hill and Carver equation / chart to

determine the port size for passing 714 MSCFD of
gas for the above Injection and tubing pressure

Which comes @ 11/64 say = 3/16 inch

42
43
Step – 11 Calculating bellow charge pr.
The bellows charge pressure at well temperature (Pbt) is calculated by
using equation,

Pbt = (Pop at L) ( 1 - Av/Ab) + (Pmin at L) (Av/Ab)

Where, ( 1 - Av/Ab) and (Av/Ab) values are supplied by gas lift valve
manufacturer.

For, J-40; 3/16" valve Port : ( 1 - Av/Ab) = 0.906; (Av/Ab) = 0.094

For, J-40; 1/4" valve Port : ( 1 - Av/Ab) = 0.836; (Av/Ab) = 0.164
For, J-40; 5/16" valve Port : ( 1 - Av/Ab) = 0.745; (Av/Ab) = 0.255

Therefore,

Pbt for L1 = 1160 x 0.906 + 560 x 0.094 = 1005.66 + 52.64

44
= 1058.30 psi at 114 0F
Step – 12 Calculating bellow charge pr.
at Room temperature
The bellows charge pressure (Pb) at test bench (60
0F) is calculated from

Pb = Pbt x Ct, Where Ct values are provided by the

manufacturer

Therefore,
Pb for L1 = 1058.30 x 0.896 = 948.24 psi
Pb for L2 = 1075.82 x 0.858 = 923.05 psi
Pb for L3 = 1089.58 x 0.836 = 910.89 psi
Pb for L4 = 1093.64 x 0.826 = 903.35 psi
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Step – 13 Test rack opening pressure.
at Room temperature
The test rack opening pressure of the valve at 60 DegF (PTRO or Pvo)
is calculated

Pb
From PTRO = --------------
( 1 - Av/Ab)

Therefore,

948.24
PTRO for L1 = ----------- = 1046.62 psi; Adjusted PTRO (at 600F)
1050 psi
(at 600F) 0.906
46
Setting Test rack opening pressure.
at Room temperature

47
48 4.226
 Summary of Design

Valve Port Depth Temp. at Pmin Temp. Inject. Inject. A.T.E. Summ- Pop.
No. Size of Valve At Correction Press. Press. Less psi ation of At L psi
In inch Valve Depth L psi Factor At By 50 psi at A.T.E.psi
In ft. 0F (Ct) L Psi L psi

L1 3/16 2088 114 560 0.896 1160 1110 24 -- 1110

L2 1/4 3350 137 820 0.858 1200 1150 30 24 1126

L3 1/4 4060 151 960 0.836 1219 1169 18 54 1115

L4 5/16 4450 158 1040 0.826 1234 1184 11 72 1112

L5 5/16 4600 162 1070 0.820 1240 1190 -- 83 1107

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 Summary of Design

Valve Valve PORT SIZE DEPTH DPETH PTRO or

No. Type IN INC H (ft) (mts). Pvo psi

L1 J - 40 3/16 2088 635 1050

(1" O.D.)

L2 J - 40 1/4 3350 1019 1045

(1" O.D.)

L3 J - 40 1/4 4060 1234 1040

(1" O.D.)

L4 J - 40 5/16 4450 1353 1035

(1" O.D.)

L5 J - 40 5/16 4600 1400 1025

(1" O.D.)

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 GAS LIFT
Thumb rules for quick estimation
INTERMITTENT LIFT
• Tubing Gradient ( spacing factor ) – 0.05 to
0.075 psi/ft( depending on tubing size & rate)
• Max possible injection depth (ft) =

(Inj.Pr – THP)/Gradient
• Inj. Gas/cycle = 100 to 150 m3/cycle

(only applicable for 2 7/8” tubing,about 1250 mts of inj.depth

and THP of 8 kg/cm2,inj.pr about 35 kg/cm2)

51
 GAS LIFT
Thumb rules for quick estimation
INTERMITTENT LIFT
• Liquid Fall Back – 7% for every 1000 ft

• Inj Cycle time – not less than 3 min/1000 ft

• Inj.period/cycle – 30 sec /1000 ft

52
 GAS LIFT
Thumb rules for quick estimation
INTERMITTENT LIFT
Unloading
• Same as Cont.lift till First valve is uncovered.
• Then, adjust the time cycle controller short
duration frequent injection cycles of about 30
second injection every 3 minutes till top few
valves are uncovered.
• Then adjust the cycle time for 30sec/3min/1000
ft

53
 PRESSURE SURVEY CHART OF WELL NO. K-53
Depth of recording - 1300 mts

69
Injection
67 closes
65
63
61
Slug load
PRESSURE,KG/CM2

59
unloaded to
57 well head
55
Injection
53
starts
51

49
47 Build up
time
45
7 11 15 19 23
TIME,HRS

54
 INTERMITTENT GAS LIFT

General basis of design for required gas

calculation & no. of cycles required
- Required Inj gas calculated as the volume
required to fill the tubing volume ( for Depth of
Injection – Slug height and based on tubing area
)
- Slug height calculated based on assumption
that tubing load is approx 65 % of casing load
for good recovery.

55
 INTERMITTENT GAS LIFT
• Tubing pressure at depth – 0.65 * Pvo
• Tubing load ( Slug load in psi ) –
Slug load in psi = Tub pr at depth – (WHP

+ Gas column wt )
• Slug load in psi / well gradient = Slug ht
• Slug volume = Slug ht * Tubing area

56
 INTERMITTENT GAS LIFT
• Fall back % – 0.07 * (Inj depth /1000)
• Fall back load – Slug Ht & Fall back %
• Pressure fallback – Fall back load *
Gradient
• Avg pr – (Pr before fallback + Pr after fall
back ) /2
• FBHP = Avg Tub Pr + Pr. Below inj depth
• Flow rate as per IPR ( ie say cu ft /sec) -
per cycle rate
57
 INTERMITTENT GAS LIFT
• Depth of fill – Vol fill / Tub area ( cu ft/sec/
sq ft ) = ft /sec
• Pressure fill/sec = Depth of fill * well
gradient ( ft/sec * psi / ft = psi /sec )
• Required pressure fill = Tub pr ( 0.65 Pvo )
– Pressure after fall back )
• Time build up = Required pr fill ( psi ) /
Pressure fill ( psi/sec) ie build up in seconds

58
 INTERMITTENT GAS LIFT
• Gas volume = Required gas volume to fill tubing converted to Std
conditions by considering avg pr at depth ( (Tub.pr + Pvc) / 2 ), Std pr,
and both temperatures ( Calculated as SCFT or SCMD )

• Total time required for inj cycle – approx 3 min /1000 ft of injection
• Cycle time + build up time -Total cycle time ( sec)

• No of cycles – 24* 60 * 60 / total cycle time

• Rate of production – Rate per cycle * No of cycles

59