Artificial Lift Systems

Introduction:
Most oil wells do not have the required natural energy to bring oil to the surface on their own. Some wells may
initially have a natural flow of oil to the surface, but over time, the pressure bringing the oil to the surface
naturally depletes while the well fluid changes with increasing water. If left as is, the production life of the well
is also inefficient and short-lived.
Production wells are free flowing or lifted. A free flowing oil well has enough down-hole pressure to reach
suitable wellhead production pressure and maintain an acceptable well flow. If the formation pressure is too low,
and water or gas injection cannot maintain pressure or are not suitable, the well must be artificially lifted
Directly, the artificial lift system’s purpose is the literal “lifting” of the oil or production fluid to the surface of
the well. Indirectly, its purpose is to maximize performance and productivity, but for the latter to materialize, the
right method of artificial lifting must be implemented.
New lift systems are being developed and tested continually. The lifting of heavy viscous crude oils requires
special attention, and methods designed specifically for this purpose are being tested. Wells located offshore and
in deep water present specific problems, and surface- space limitations become important.

The purpose of any artificial lift system is to create a predetermined tubing intake pressure such that the
predetermined tubing intake pressure such that the reservoir may respond and produce the objective flow rate.
The design and analysis of any lifting system can be divided into two main components. The first is the reservoir
component (inflow performance relationship), which represents the well's ability to produce fluids.

Artificial lift is a multi-stage process using external source supplementing reservoir energy. This could be
through high-pressure gas or pumps to lift production fluids to the surface. There are different methods that serve
as the basis of artificial lift systems, that we can divided in two main methods:

 PUMPING:
 Rod-lift systems: sucker rod pumping (beam pumping)
 Progressing cavity pumps
 Electric submersible pumping,(ESP’s)
 Hydraulic lifting systems (piston pumping, Hydraulic jet pumping…)
 Plunger piston pumping, plunger (free-piston) lift,
 GAS LIFT
 AND OTHER METHODS. THIS DIFFERS ACCORDING TO FIELD, STATE, AND
COUNTRY.

Using the right artificial lift system for your oil and gas operations is key to maximum performance and
efficiency, which is imperative to your bottom line. There are multiple variables and factors to consider when
determining which artificial lift system will produce the best result for any given well. Here are some variables
and factors you should consider when determining the system best for you.

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ARTIFICIAL LIFT SYSTEM IN WORLD WIDE :

Variables to Consider :

 Economic investment
 Field-tested technology
 System reliability
 Horsepower usage
 Equipment maintenance
 Personnel capabilities
 Overall operations

Factors Specific to the Well:

 The volume of solids and/or heavy oil

 Availability of wellbore gas
 The depth of the well
 The condition of the well
 Location, i.e. offshore or onshore

Overall, you want an artificial lift system that accommodates your operations by providing solutions and not
becoming another problem that needs to be addressed and/or fixed.

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PUMPING:

Sucker rod pump(SRP):

The sucker rod pumping is the oldest, the most economical and the most commonly used method for artificial
lifting.
The sucker rod pump is a pump with reduced piston adapted to work in oil wells at greater depths.  
It is mechanically simple, it can work under a wide range of conditions and has a wide variety of available parts .

A Sucker Rod Pump is an artificial pump system used to connect the downhole pump assembly with the surface
components that facilitate a pumping motion.

The main components of a Sucker Rod Pump are a walking beam, power shaft, cranks, counter weighs,
horsehead, , Pitman arms and Samson beams, plunger , standing valve, traveling valve and pump barrel.

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  A motor and gear box runs the power shaft.
 The rotation of the motor is transformed to a vertical mouvment by the gear box
 When the horsehead and plunger are lifted up, the fluid gets lifted from the bottom to the surface. This
completes the upstroke
 On the upstrocke:

 The standing valve opens

 Reservoir fluid fill the pump barrel

 When the plunger and the horse head are lowered, it completes 1 downstroke.
 on the downstrocke:

 The standing valve closes

 The travelling valve opens
 The fluid that has been trapped in the barrel swept up through the ports into the tubing

Advantages of the sucker rod pumping system:

 Easy and simple design and selection, low replacement costs.

 Flexible, with a wide scope of operations.

 Easy to operate in the field, well-known technology.

 It can operate at low dynamic levels.

 Resistant to high temperature fluid.

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  It can be used with corrosive and/or viscous fluids.

Limitations of the sucker rod pumping system:

 Not suitable for deviated wells.

 Limited in depth due to rod and/or pumping unit elongation and/or resistance.

 Not suitable for high production volume and/or high water content.

Progressing cavity pumps(PCP):

A Progressive Cavity Pump is a type of a positive displacement pump which uses a rotor to pump fluids. It is
also known as Progg cavity pump; Progressing cavity Pump; Eccentric cavity pump or simply cavity pump. As
the rotor of this pump rotates, it transfers the fluid forward through the pump in the sequence of small fixed
shape discrete cavities. This results in making volumetric flow rate proportional to the rotational rate of the rotor
because of which fluid is pumped with low shear.

PCP Configuration:
The two key features that differentiate PCP systems from other forms of artificial lift are the downhole PC
pumps and the associated surface drive systems. Although other major components, such as the production
tubing and sucker rod strings, are found in other downhole lift systems, the design and operational requirements
typically differ for PCP applications. Also, many additional equipment components may be used in conjunction
with PCP systems to contend with specific application conditions.
The basic surface-driven PCP system configuration illustrated in the figure is the most common, although
electric and hydraulic downhole drive systems and various other hybrid PCP systems are also available
(see Alternative PCP system configurations). The downhole PC pump is a positive displacement pump that
consists of two parts:

 Helicalsteel “rotor”
 “Stator” comprised of a steel tubular housing with a bonded elastomeric sleeve formed with a multiple
internal helix matched suitably to the rotor configuration

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The rotor turns and forces the liquid through the stationary cavities, The point of the helical rotor as it’s rotating
creates sealing points and forces the liquid to pass into the next cavity and out to the discharge
Advantages:

 High overall system energy efficiency, typically in the 55 to 75% range.

 Ability to produce high concentrations of sand or other produced solids.
 Ability to tolerate high percentages of free gas.
 No valves or reciprocating parts to clog, gas lock, or wear.
 Good resistance to abrasion.
 Low internal shear rates (limits fluid emulsification through agitation).
 Relatively low power costs and continuous power demand (prime mover capacity fully utilized).
 Relatively simple installation and operation.
 Generallylow maintenance.
 Low profile surface equipment.
 Low surface noise levels.

Limitations:

 Limited production rates (maximum of 800 m3/d [5,040 B/D] in large-diameter pumps, much lower in
small-diameter pumps).
 Limited lift capacity (maximum of 3000 m [9,840 ft]). Note that the lift capacity of larger displacement
PC pumps is typically much lower.
 Limited temperature capability (routine use to 100°C [212°F], potential use to 180°C [350°F] with
special elastomers).
 Sensitivity to fluid environment (stator elastomer may swell or deteriorate on exposure to certain fluids,
including well treatment fluids).
 Subject to low volumetric efficiency in wells producing substantial quantities of gas.
 Sucker rod strings may be susceptible to fatigue failures.
 Pump stator may sustain permanent damage if pumped dry for even short periods.
 Rod-string and tubing wear can be problematic in directional and horizontal wells.
 Most systems require the tubing to be pulled to replace the pump.
 Vibration problems may occur in high-speed applications (mitigation may require the use of tubing
anchors and stabilization of the rod string).
 Paraffin control can be an issue in waxy crude applications (rotation as opposed to reciprocation of the
rod string precludes use of scrapers for effective wax removal).
 Lack of experience with system design, installation, and operation, especially in some areas.

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Electric submersible pumping:

The electrical submersible pump, typically called an ESP, is an efficient and reliable artificial-lift method for
lifting moderate to high volumes of fluids from wellbores. These volumes range from a low of 150 B/D to as
much as 150,000 B/D (24 to 24,600 m3/d). Variable-speed controllers can extend this range significantly, both on
the high and low side. Generally the pump is used when the volume is greater than 400 B/D. If the pump is
operated below this volume, it usually tends to perform with low efficiency.
About 15 to 20 percent of almost one million wells worldwide are pumped with some form of artificial lift
employing electric submersible pumps. In addition, ESP systems are the fastest growing form of artificial lift
pumping technology.
The ESP’s main components include:

 ESP centrifugal pump

 ESP seal section
 ESP motors
 ESP pump intake
 ESP power cable
 ESP surface motor-controllers
 ESP optional components

The components are normally tubing hung from the wellhead with the pump on top and the motor attached
below..
Normally, the ESP pump is installed close to perforation areas, in the production tubing string. Working
principle of the ESP pump is very similar to any other pump - a multistage centrifugal pump driven by an
electrical motor, provides a high speed rotation of impellers that in turn create centrifugal forces to lift the fluids
up.

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  ESP centrifugal pump :
The electrical submersible pump (ESP) is a multistage centrifugal type. A cross section of a typical
design is shown in the figure. The pumps function is to add lift or transfer pressure to the fluid so that it
will flow from the wellbore at the desired rate. It accomplishes this by imparting kinetic energy to the
fluid by centrifugal force and then converting that to a potential energy in the form of pressure.
Main components:
 Impeller (rotating)
Pump impeller types :
 Mixed Flow impellers :
This design develops pressure/head through centrifugal and axial forces.
Used where a High Flow – High Head installation is required
 Radial flow impellers:
This design develops pressure/head through centrifugal forces.
It is generally used where a low flow, high head installation is required.
 Diffuser
o The impellers throwing the fluid outwards
o Many of impellers are connected to a single shaft.

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o FunctionalFeatures:
 Shaft:
The shaft is connected to the seal-chamber section and motor by a spline coupling. It transmits
the rotary motion from the motor to the impellers of the pump stage. The shaft and impellers
are keyed, and the key transmits the torque load to the impeller. As was mentioned earlier, the
diameter of the shaft is minimized as much as possible because of the restrictions placed on the
pump outside diameter. Therefore, there are usually several shaft material options available,
depending on the maximum horsepower (HP) load and corrosion protection required.
 Housing:
The housing is the pressure-containing skin for the pump. It holds and aligns all the
components of the pump. There are several material options available for different application
environments. For additional corrosion protection, there are several coatings that can be
applied.
 Pump base:
Several different styles of intakes can be selected. They allow for entrance of the fluid into the
bottom of the pump and direct it into the first stage. Integral intakes can be threaded directly
into the bottom of the housing during the manufacturing assembly process, while others are
separate components, which are bolted on to the bottom pump flange.
 Flanged connection to seal-chamber section:

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 The bottom flange of the pump bolts to the flange of the seal-chamber-section head. It
maintains axial alignment of the shafts of the two units. It also allows the floating pump shaft
to engage the end of the seal-chamber-section shaft so that the axial thrust produced by the
pump is transferred to the thrust bearing in the seal-chamber section.

 Stages :

The stages of the pump are the components that impart a pressure rise to the fluid. The stage is
made up of a rotating impeller and stationary diffuser. The stages are stacked in series to
incrementally increase the pressure to that calculated for the desired flow rate.

ESP centrifugal pumps types:

 ANSI pumps (American National Standards Institute) :

They are radial centrifugal pumps that are also based on standards set by an accrediting organization
that define the dimensions of the pumps.

Some of the dimensions impacted include the hold-down bolt placement on the pump and pump
coupling height.

They are used in heavy-duty services, such as the transfer of crude oil and hydrocarbons in pipeline and
refinery processing services

 API process pumps ( American Petroleum Institute):

They are radial centrifugal pumps that are also based on standards set by an accrediting organization
that define the dimensions of the pumps.

Some of the dimensions impacted include the hold-down bolt placement on the pump and pump
coupling height.

Used in heavy-duty services, such as the transfer of crude oil and hydrocarbons in pipeline and refinery
processing services.

 ESP seal section :

The component located below the lowest pump section and directly above the motor, in a
standard electrical submersible pump (ESP) configuration, is the seal-chamber section. The seal-
chamber section is basically a set of protection chambers connected in series or, in some special cases,
in parallel.

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This component has several functions that are critical to the operation and run-life of the ESP system,
and the motor in particular:

 It protects the motor oil from contamination by the wellbore fluid. The motor is filled with a high-
dielectric mineral or synthetic oil for electrical protection and lubrication. Well fluid migrating into
the motor can potentially cause a premature electrical or mechanical failure through the reduction
of the motor dielectric or lubricating properties.
 It allows for pressure equalization between the interior of the motor and the wellbore. Its design
allows for a breathing or equalization method that compensates for pressure variances caused by
the submergence pressure encountered during the installation from surface pressure to downhole
static pressure and the thermal expansion and contraction of the motor oil because of motor heat
rise during operation.
 It also absorbs the axial thrust produced by the pump and dissipates the heat that the thrust bearing
generates.

o FunctionalFeatures:
 Shaft :
Usually, there are several shaft options available, and their selection is based on the fluid
environment and the horsepower (HP) to be transmitted. Even though a majority of the shaft is

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 exposed only to the clean, dielectric motor oil, the top end is exposed to the wellbore fluid.
Therefore, the material must be an alloy that protects the integrity and function of the shaft.
This could be the entire shaft or, at a minimum, the top section that is directly exposed to the
wellbore fluid.

 Labyrinth protection chambers :

This chamber design features a direct fluid interface between the wellbore fluid and the motor
oil.

 Positive-barrier protection chambers :

This chamber incorporates a positive barrier between the wellbore fluid and the motor oil. The
barrier is usually an elastomeric or rubber bag, which is also called a bladder.

 Mechanical face seals :

A rotating mechanical face seal is generally located at the top of each protection chamber.

 Axial thrustbearing :
This bearing carries all of the axial thrust produced by the pump and seal-chamber section.
Generally, sliding-shoe hydrodynamic types are used for this application because of their
robustness and ability to function totally immersed in lubricating fluid. It is composed of two
main components: a stationary pad and a rotating flat disk. The stationary part has pads
finished to a very close flatness tolerance, connected to a base by a thin pedestal or flexible
joint. The rotating disk is also finished to a very close flatness tolerance

 ESP motors :
The ESP motor is a two-pole, three-phase, squirrel cage, induction design.A two-pole design means that it
runs at 3,600-rpm synchronous speed at 60-Hz power or roughly 3,500-rpm actual operating speed. It
operates on three-phase power at voltages as low as 230 and as high as 5,000, with amperages between 12
and 200. Generally, the length and diameter determines the motor's horsepower (HP) rating. Because the
motor does not have the power cable running along its length, it can be manufactured in diameters slightly
larger than the pumps and seal-chamber sections and still fit in the same casing bores.
Its role is to drive the downhole pump and seal section.

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o Functional Features:
 Wound stator :
A wound stator comprises an unwound stator, electrical windings, and insulation and
encapsulation systems. The unwound stator has thousands of electrical-grade steel laminations
stacked in the housing and is compressed to hold them aligned and stationary. The laminations
are die-punched with a center bore for the rotating components to fit into and 18 winding slots
for the winding wire. Each slot is insulated with a very-high-dielectric-strength polyamide
insulation material. This slot insulation provides winding-to-stator (turn-to-ground) electrical
protection.

 Shaft :
The shaft transmits the torque produced by the rotors, keeps all the rotating components
aligned axially, and provides a path for the cooling and lubricating oil to the radial bearings
and rotors. The shaft is generally tubular material, and the hollow core allows for the motor oil
to communicate from the motor head and base areas to the hotter radial bearing and rotor areas.
Because the shaft is completely immersed in clean oil, exotic corrosion-resistant materials are
not required. Typically, the shaft material is alloyed carbon steel. Its straightness is also critical
because of its close rotating clearances and high speed.
 Rotor :
Ideally, the rotor should be one continuous component that runs the length of the stator
lamination bore. This would cause tremendous dynamic-instability problems because of the

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 very large rotor length-to-diameter ratio. Therefore, the rotors are constructed in short
segments with radial support bearings placed between them for dynamic stability. Rotors are
constructed by stacking hundreds of thin, electrical-grade laminations between two metal end
rings. Copper rotor bars are inserted into the lamination slots, the whole stack is compressed,
and the rotor bar’s ends are mechanically bonded to the end rings. This results in the "squirrel
cage" rotor. The center bore of the rotor has an axial-keyway groove for engaging the axial key
stock mounted on the motor shaft. This locks the rotor to the shaft for torque transmission but
allows axial movement for thermal growth.
 Radial bearings :
A sleeve-type-bearing system provides the alignment and radial support for the long shaft and
rotor assembly. The sleeve part of the journal is keyed to the shaft and rotates with the shaft.
The stationary part of the bearing has a bore in which the sleeve runs. It has an outside
diameter (OD) that has a small clearance with the stator-lamination inside diameter. Also, the
stator laminations at the bearing locations are made of nonmagnetic material to reduce the
rotating magnetic field and the rotational forces tending to rotate the radial bearing. In some
designs, an elastomer ring or locking key is located between the bearing OD and the stator
inside diameter (ID) to prevent or retard any relative rotation. If rotation does occur, the
bearing may start wearing into the stator until contact with the phase mag wires causes an
electrical short.
 Motorhead :
The motor head contains the electrical termination for the connection of the three-phase
windings to the electrical power cable. This connection is made in an insulated cavity either by
a male/female plug-in design or a motor-wire to power-cable-wire splice. Also, a small thrust
bearing is located in the head. It is designed to carry the weight of the shaft and rotor stack
during startup and maintains the axial position of the rotors and radial bearings relative to the
stator.

 ESP power cable :

The ESP power cable transmits the required surface power to the ESP motors. Typically, it is banded or
clamped to the production tubing from below the wellhead to the ESP unit because it is not designed to
support its own weight. It is a specially constructed three-phase power cable designed specifically for
downhole well environments.

 ESP pump intake :

As the
name

suggests “ Pump Intake ” is where the well fluid enters the Submersible Pumping System. Care should be taken
when designing a submersible pump intake because it is such a vital point in the system that when not designed
properly may create all kinds of problems.
Also it includes gas saparator
Usually, the pump intake is a separate component that bolts onto the bottom of the pump section.

 ESP surface motor-controllers :

The surface controller provides power to the ESP motors and protects the downhole ESP components.

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  ESP optional components :

Provide additional mechanical and electrical protection, monitoring, or performance enhancements in the
operation of an artificial lift system using electrical submersible pumps.

 Downhole sensors :
 Internal motor temperature
 Pump discharge pressure
 Pump discharge temperature
 Downhole flow rate
 Equipment vibration

 ESP packers
 ESP wellheads
 Centralizers/protectorilizers
 Check/drain tubing valves
 Motorshroud/recirculation systems
 Screens and filters
 Y-tool or bypass

Advantages:
The major advantage to a submersible pump is that it never has to be primed, because it is already submerged in
the fluid. Submersible pumps are also very efficient because they don’t really have to spend a lot of energy
moving fluid into the pump. Water pressure pushes the fluid into a submersible pump, thus “saving” a lot of the
pump’s energy.

Also, while the pumps themselves aren’t versatile, the selection certainly is. Some submersible pumps can easily
handle solids, while some are better for liquids only. Submersible pumps are quiet, because they are under water,
and cavitation is never an issue, because there is no “spike” in pressure as the water flows through the pump.

Limitations:
Have to do with the seal. The seals can become corroded with time. When that happens, water seeps into the
motor, rendering it useless until it is repaired. Also, that seal makes the submersible pump a bit difficult to get
into for repairs. The other main limitation is that one pump does not fit all uses. Single stage pumps are used for
most home and light industrial pumping. This includes aquarium filters, sewage pumping, or sump pumps for
drainage. Multiple stage pumps are used for anything underground, such as water wells or oil wells. Also, pumps
are made to work with thin liquids like water, or thick ones like sewage.

 Caution must be used with submersible pumps; they must be fully submerged. The water around a
submersible pump actually helps to cool the motor. If it is used out of water, it can overheat.

Hydraulic lifting systems:

Hydraulic systems uses fluid pressure to power a pump. That is done by pumping fluids down-hole using a
triplex pump designed for extremely high pressure, usually between approximately 2,000 and 5,000 psi.
Hydraulic lift pumps are flexible, and are useful for wells that are producing any volume, from low to high. In
general, hydraulic lifts have higher production volumes than mechanical lift pumps.

Hydraulic pumping is a proven artificial lift method that has been used since the early 1930s. It offers several
different systems for handling a variety of well conditions. Successful applications have included setting depths
ranging from 500 to 19,000 ft and production rates varying from less than 100 to 20,000 B/D. Surface packages

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are available using multiplex pumps ranging from 15 to 625 hp. The systems are flexible because the down-hole-
pumping rate can be regulated over a wide range with fluid controls on the surface. Chemicals to control
corrosion, paraffin, and emulsions can be injected down-hole with the power fluid, while fresh water can also be
injected to dissolve salt deposits. When pumping heavy crudes, the power fluid can serve as an effective diluent
to reduce the viscosity of the produced fluids. The power fluid also can be heated for handling heavy or low-
pour-point crudes. Hydraulic pumping systems are suitable for wells with deviated or crooked holes that can
cause problems for other types of artificial lift. The surface facilities can have a low profile and may be clustered
into a central battery to service numerous wells. This can be advantageous in urban sites, offshore locations,
areas requiring watering systems (sprinkle systems), and environmentally sensitive areas
Hydraulic pumping systems transmit power down-hole by means of pressurized power fluid that flows in
wellbore tubulars. Hydraulic transmission of power down-hole can be accomplished with reasonably good
efficiency using a reciprocating piston pump. With 30°API oil at 2,500 psi in 2 7/8-in. tubing, 100 surface
hydraulic horsepower can be transmitted to a depth of 8,000 ft with a flow rate of 2,350 B/D and a frictional
pressure drop of less than 200 psi. Even higher efficiencies can be achieved with water as the hydraulic medium
because of its lower viscosity.
The down-hole pump acts a transformer to convert the energy into pressure in the produced fluids. A common
form of a hydraulic down-hole pump consists of a set of coupled reciprocating pistons, one driven by the power
fluid and the other pumping the well fluids. Another form of a hydraulic down-hole pump that has become more
popular is the jet pump, which converts the pressurized power fluid to a high-velocity jet that mixes directly with
the well fluids. In the turbulent mixing, momentum and energy from the power fluid are added to the produced
fluids.  The operating pressures in hydraulic pumping systems usually range from 2,000 to 4,000 psi. The most
common pump used to generate this pressure on the surface is a multiplex positive displacement pump driven by
an electric motor or multi-cylinder gas or diesel engine. Multistage centrifugal pumps and horizontal electrical
submersible pumps (ESPs) have been used,  and some systems have been operated with the excess capacity in
water-injection systems.  The hydraulic fluid usually comes from the well and can be either produced oil or
water. A fluid reservoir at the surface provides surge capacity and is usually part of the cleaning system used to
condition the well fluids for use as power fluid. Appropriate control valves and piping complete the system. A
schematic of a typical hydraulic pumping system is shown in the figure

There are two primary kinds of hydraulic pumps:

 Jet pumps :
This Figure shows a jet pump arrangement. For jet pumps, high-pressure power fluid is directed down the
tubing to the nozzle where the pressure energy is converted to velocity head (kinetic energy). The high-

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velocity, low-pressure power fluid entrains the production fluid in the throat of the pump. A diffuser then
reduces the velocity and increases the pressure to allow the commingled fluids to flow to the surface.

When the power fluid and the production are combined, the system is an open power-fluid system. For a
vented open power-fluid system, the production and power fluid typically are returned separately in a
parallel tubing string with gas normally vented through the casing annulus to the surface. A non-vented
casing installation requires a pump to handle the gas and production. The power fluid plus all reservoir
fluids are produced up the annulus. Both completion types are used with positive-displacement pumps and

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 with jet pumps. In fact, many bottom-hole assemblies (BHAs) can accommodate jet or positive-
displacement pumps interchangeably.

 Reciprocating positive-displacement pumps ;

The positive-displacement pump consists of a reciprocating hydraulic engine directly coupled to a pump
piston or pump plunger. This Figure shows a reciprocating hydraulically powered pump. Power fluid (oil or
water) is directed down the tubing string to operate the engine. The pump piston or plunger draws fluid from
the wellbore through a standing valve. Exhausted power fluid and production can be returned up a separate
tubing string or up the casing.

Functional Features :

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The most outstanding feature of hydraulic pumps is the “free pump” system. This Figure shows a schematic of a
free hydraulic pump. Fig. a shows a standing valve at the bottom of the tubing, and the tubing is filled with fluid.
In Fig. b, a pump has been inserted in the tubing and power fluid is being circulated to the bottom. In Fig. c, the
pump is on bottom and pumping. When the pump is in need of repair, fluid is circulated to the surface as shown
in Fig. d. The positive-displacement pump, the jet pump, and the closed power-fluid system previously shown
are all free pumps.

Surface facilities require a power-fluid storage and cleaning system and a pump. The most common cleaning
systems are settling tanks located at the tank battery. Cyclone desanders sometimes are used in addition to
settling tanks. In the last 40 years, wellsite power plants, which are separators located at the well with cyclone
desanders to remove solids from the power fluid, have become popular.
Surface pumps are most commonly triplex plunger pumps. Other types are quintiplex plunger pumps, multistage
centrifugal pumps, and “canned” ESPs. The surface pressure required is usually in the 1,500 to 4,000 psi range.
It is important to specify 100% continuous duty for the power-fluid pump at the required rate and pressure. Low
volume (< 10,000 B/D), high-pressure installations (> 2,500 psi) typically use plunger-type pumps.

Advantages:

 Being able to circulate the pump in and out of the well is the most obvious and significant feature of
hydraulic pumps. It is especially attractive on offshore platforms, remote locations, and populated and
agricultural areas.
 Positive-displacement pumps are capable of pumping depths to 17,000 ft and deeper. Working fluid
levels for jet pumps are limited to approximately 9,000 ft.

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  By changing the power-fluid rate to the pumps, production can be varied from 10 to 100% of pump
capacity. The optimum speed range is 20 to 85% of rated speed. Operating life will be significantly
reduced if the pump is operated above the maximum-rated speed.
 Deviated wells typically present few problems to hydraulic free pumps. Jet pumps can even be used in
through flowline installations.
 Jet pumps, with hardened nozzle throats, can produce sand and other solids.
 There are methods in which positive-displacement pumps can handle viscous oils very well. The power
fluid can be heated, or it can have diluents added to further aid lifting the oil to the surface.
 Corrosion inhibitors can be injected into the power fluid for corrosion control. Added fresh water cansol
vesalt buildup problems.

Limitations:

 Removing solids from the power fluid is very important for positive-displacement pumps. Solids in the
power fluid also affect surface-plunger pumps. Jet pumps, on the other hand, are very tolerant of poor
power-fluid quality.
 Positive-displacement pumps, on average, have a shorter time between repairs than jet, sucker rod, and
ESPs. Mostly, this is a function of the quality of power fluid but, on average, the positive-displacement
pumps are operating from greater depths and at higher strokes per minute than for a beam pump system.
Jet pumps, on the other hand, have a very long pump life between repairs without solids or if not
subjected to cavitation. Jet pumps typically have lower efficiency and higher energy costs.
 Positive-displacement pumps can pump from a low BHP (< 100 psi) in the absence of gas interference
and other problems. Jet pumps cannot pump from such low intake pressures, especially when less than
the cavitation pressure. Jet pumps require approximately 1,000 psi BHP when set at 10,000 ft and
approximately 500 psi when set at 5,000 ft.
 Positive-displacement pumps generally require more maintenance than jet pumps and other types of
artificial lift because pump speed must be monitored daily and not allowed to become excessive.
Power-fluid-cleaning systems require frequent checking to keep them operating at their optimum
effectiveness. Also, well testing is more difficult.

Plunger lifting system:

A plunger lift is an artificial lift method of de-liquifying a natural gas well. A plunger is used to remove
contaminants from productive natural gas wells, such as water, sand, oil, and wax.

Plunger lift has become a widely accepted and economical artificial lift alternative, especially in high-gas/liquid-
ratio (GLR) gas and oil wells .Plunger lift uses a free piston that travels up and down in the well’s tubing string.
It minimizes liquid fallback and uses the well’s energy more efficiently than does slug or bubble flow.

The plunger lift system works with this way:

• The well is shut in and the plunger travels from the surface to the bottom of the tubing.

• Time passes allowing the casing pressure to build .

• At just the right time pressure pushes the plunger and fluid to the surface .

• The plunger lift the entire slug .

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Advantages:
 Low capital cost
 Low maintenance & operating cost 
 Low energy cost

Limitations:
 Require another lift method to deplete the well
 Optimum for low producing rate
 Require good communication between production tubing and well casing

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GAS LIFT:

This method of using a gas lift is not by any means new to the oil & gas industry. In fact, they were using this
method in the mines to help lift water out of mine shafts back in 1797. For the oil & gas industry, the gas lift was
used in Pennsylvania to help production in oil wells in 1864. The compressed air being used was an air pipe that
brought the air to the bottom of the well. Since then, we have adapted and perfected this method into the method
we use today.

The gas lift process start from injecting gas to the well in order to decrease the density of the hydrocarbon by
developing and forming a bubble gas in the tubing, after that the bubble gas push the oil inside the tube to the
surface.

Gas lift uses high pressure source at the surface to inject gas down the annulus into the tubing. The
compressed gas is injected in the production stream through gas lift valves fitted in integral mandrels.

The mandrels are installed as part of the tubing string and are positioned at prescribed depth as the gas enter
the tubing string through the valves it creates aeration or a bubbling effect, in the liquid column, the gas
bubbles expand as they rise to the surface displacing the liquid around them and reducing the density and
weight of the fluid, this decreases the flowing tubing pressure and creating a differential pressure between the
reservoir and the well bore and allowing the well to produce at its optimum rate.

Moreover, the main equipment of gas lift includes gas lift valves and the mandrels such as (Compressor
horsepower, Tubing- and wireline-retrievable equipment, Open and closed installations, Considerations for
selecting the proper installation and equipment, Bellows,

Gas lift Basic equipment:

Downhole gas lift instrumentality consists primarily of the gas lift valves and also the mandrels
within which the valves are placed.

The main equipment’s are the following:

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  Compressor horsepower
 Tubing- and wireline-retrievable equipment
 Open and closed installations
 Bellows

Compressor horse-power:

A gas compressor a mechanical device that increases the pressure of a gas by reducing its volume. Compressors
are the same as pumps: each increase the pressure on a fluid and each will transport the fluid through a pipe. As
gases are compressible, the compressor additionally reduces the volume of a gas. However, liquids are relatively
incompressible

Gas Compressor (usa compression, 2015)

Tubing and wireline-retrievable equipment:

The early and first gas lift valves were the conventional tubing-retrievable type, in which the tubing mandrel that
held the gas lift valve and reverse check valve was part of the tubing string. It was essential to pull the tubing to
replace a conventional gas lift valve.

The process of gas lift valve working could be removed or installed by wireline operations without the need to
pull the tubing. kickover tool is a primary wireline device which is used to locate the mandrel pocket and
removing or installing the gas lift valve.

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 wireline-retrievable gas lift valve and mandrel

tubing-retrievable valve and mandrel

Open and closed installations:

Most tubing flow gas lift installations include a packer to stabilize the fluid level in the casing annulus and
prevent injection gas from blowing around the lower end of the tubing in wells with a low flowing bottom hole
pressure.

 Open installations:

no packer is set in open installations. open installation is suitable for continuous flow
gas lift in wells with good fluid seal. Although this type of installation is simple, it
exposes all gas lift valves beneath the point of gas injection to severe fluid erosion due
to the dynamic changing of liquid level in the annulus. Open installation is not
recommended unless setting packer is not an option.

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  Semi closed installation:

It is identical to the open installation except that a packer is set in the annulus
(between the tubing and casing). This type of installation can be used for both
continuous and intermittent-flow gas lift operations. It avoids all the problems
associated with the open installations. However; it still does not prevent flow of well
fluids back to formation during unloading processes, which is especially important for
intermittent operating.

 closed installation:

In this method a standing valve is placed in the tubing string or can be placed below
the bottom gas lift valve. The function of this valve is to effectively prevents the gas
pressure from acting on the formation, which increases the daily production rate from
a well of the intermittent type

 An open installation is seldom recommended.

Bellows:

The advent of the unbalanced, single-element, bellows-charged gas lift valve revolutionized gas lift application
and installation design methods. Before the bellows- charged gas lift valve, there have been differential valves
and various kinds of distinctive devices used for gas lifting wells. These devices, or valves, were operated by
rotating or vertically moving the tube and by means that of a sinker bar on a wireline.

Original King unbalanced, single-element, bellows- charged gas lift valve on a tubing-installed mandrel (U.S.
Patent No. 2,339,487) Original King unbalanced, single-element, bellows- charged gas lift valve on a tubing-
installed mandrel (U.S. Patent No. 2,339,487)

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When injecting the gas down hole, it could be injected continuously or intermittently. This depends on the way
the gas lift equipment is arranged and producing characteristics. Deciding just how much gas needs to be
injected depends on the well conditions and geometries. If too much gas is injected, the economics may not be
sound but if too little, then production may not be maximized. 

For the gas to be at the appropriate pressure to be re-injected, the process requires a compressor which will raise
the pressure of the gas to the appropriate levels of re-injection. 

Types of Gas Lift :

Now day most of the wells that needs artificial lift to extract oil use continuous gas lift instate of intermediate.

there are some differences between both methods

 Continuous Flow Gas Lift:

The majority of gas lift wells are continuous flow gas lift. This type of gas lift is the most common
because it resembles the natural flow of a well. Using a continuous injection of compressed gas into the
well reduces reservoir pressure and increases production.

 Intermittent Gas Lift :

When low reservoir pressure and low production rates are present in a wellbore, intermittent gas lift can
be a better option. In this process, high-pressure gas is injected in intermittent cycles to displace liquid
slugs to the surface. This type of gas lift is only used for tubing flow. Due to high injection rates from
the compressor in intermittent gas lift, the energy in the formation gas does little to assist in lifting most
wells.

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 Dual Gas Lift :
dual gas lift, defined as the simultaneous production by gas lifting of two formations opened in the same
well, is a time-proven part of gas lift technology.

Generally, if several formations are produced from one well, the main rule is that each zone must be
produced independently from the others

Dual gas lift installations have to contain two tubing strings dedicated to the two productive formations

The schematic of the generally used dual installation is shown in Figure 8-1, with two packers isolating
the two formations. Both the short string producing the upper zone and the long string producing the
lower zone are equipped with their individual operating valves and unloading valve strings. Both
production strings share a common annulus, and this is the main source of many problems associated
with dual gas lift.

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  Annular flow:
Annular flow is a type of multi-phase flow in which the lighter fluid generally gas flows in the center of
the pipe while the heavier fluid either oil or water flows as thin film over the walls of the pipe. This
kind of flow is also called a channel flow.

The compressed gas pumped into the tubing string where it is then sent through the valves to the
anuulus. It is used in large capacity wells

Gas lift Downhole equipment:

Mandrel :
A section of pipe used in the tubing into which a gas lift valve can be inserted. The mandrel will allow
communication with the annulus gas lift supply through the valve.
There are 2 types of mandrel:
 Conventional Mandrel:
 Valves have already been set in place inside the mandrel

 Simpler to install
 Side-pocket Mandrel:
Valves can be accessed for servicing and cleaning (using through tubing wireline)
Valves can be retrieved and reinserted without pulling the entire tubing string.

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Gas Lift valves (GLV) :
Gas lift valve is the heart of a gas lift system because of controlling production rates. The GLV is a
backpressure regulator which functions based on the differential pressure between the injection gas pressure and
the production fluid pressure. The GLV regulates the pressure on its upstream side to its downstream. The
architectural design of each GLV is as important as the depth of installation and number of GLVs used in each
installation. Poor designs may result in installing dozens of GLVs to unload well that may not to be necessary

 Orifice valves :

In a well with more than one gas lift, the predicted lowest injection point is normally
completed with an orifice valve rather than a normal gas lift valve is without bellows, but has a
check valve to prevent back flow into the casing. The advantages of using an orifice valve
rather than a normal gas lift valve are as follows:

 Mechanically simple therefore less possibility of mechanical failures, which can

cause blockage.
 No throttling action and therefore a continuous rather than intermittent gas lift
flow can be achieved.
 Dummy valves:
These valves are made of solid metal, resembling a normal gas lift valve. They will provide
total isolation between the casing and the tubing. A dummy valve is used to seal an SPM(single
point mooring) when no gas lift is required to be injected at that SPM.

gas lift works in this way :

Gas is injected in stages (steps) starting from the top of the string and going deeper at varying depth until the
bottom.

Operating valve nearest the wellbore is opened and all the other unloading valves above it have been closed.

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Compressed gas at the surface is released into the annulus , the gas pushes the liquid down as the gas fills the
space.

When the gas reaches the top unloading valve ,the valve in the mandrel opens letting the gas flows into the
tubing string.

So the gas helps to lighten the load of heavier oil in the hydrostatic column.

As more compressed gas is pumped into the annulus the liquid level continous downward until it reaches the
second unloading valve, as the second valve opens the first one closes.

The gas that have been entered from the second vale flows up to meet the injected gas from the first valve, this
lighten load again allows more oil in the hydrostatic column to be pushed to the surface.

At the same time the compressed gas in the annulus continues its downward path until the last valve

So the tubing string is said to be in stady state operating condtion

When the column lightened with compressed gas the reservoir pressure should be enough to push the oil in the
tubing string through out the entire hydrostatic column to the surface.

After that the injected gas is recaptured and recycled.

Advantages of gas lift :

 Best artificial lift mechanism, can handle sand and solid materials

 Crooked holes can be lifted easily with gas lift.

 Central gas lifting system can be used to service many wells.

 Installation of gas lift is compatible with subsurface safety valves and other surface equipment.

 Deviated or crooked holes can be lifted easily with gas lift.

 Gas lift is flexible, the gas lift can be used in wide range of volume and depth.

Limitation of gas lift:

The primary limitation for gas lift operations is the lack of formation gas or an injection-gas source. Wide well
spacing and lack of space for compressors on offshore platforms may also limit the application of gas lift. Poor
compressor maintenance can increase compressor downtime and add to the cost of gas lift gas, especially with
small field units. Compressors are expensive and must be properly maintained. Generally, gas lift is not as
suitable as some other systems for single-well installations and widely spaced wells. The use of wet gas without
dehydration reduces the reliability of gas lift operations.

Conclusion:
Artificial Lift is a process of changing reservoir pressure in oil wells in order to increase the flow of oil (or
water) to the surface.  As production continues, the natural reservoir pressure declines, as such, there is no force
to push the oil out. What Artificial Lift does is provide this additional drive by increasing pressure.
Artificial Lift is used in mature fields, as well as in newer fields to make projects economics work. More than
75% of wells worldwide ( around 1million) use Artificial Lift. North America is the largest region for Artificial
Lift application, with more than 50% of the market. This is followed by Europe, Asia Pacific and Latin America.
Effective utilization of Artificial Lift requires a detailed analysis whereby almost each well feature makes a
difference. Deviation and lateral profiles, pressure and temperature, gas-to-liquid ratio, facilities footprint and
many more. Selecting the optimum lift method involves extensive planning, analysis and scenarios. Each method

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has its own pros and cons and may not be the best method during the later time of the field, although initially, it
was the optimum solution. Poor selection may result in high operating costs or deferred production, due to wells
not being at its optimum production levels. Frequent pump failures, due to sand and solids, tubing wear and
many more, result in unnecessary well work-overs.
When it comes to breaking down the market by type, it is difficult to have a very accurate segmentation, as the
numbers are conflicting, sometimes. However, as a guide (95% accuracy) the segmentation of Artificial Lift
industry looks like as below. In offshore applications, ESP and Gas Lift significantly dominate the market of
Artificial Lift, with smaller proportion of PCP and Jet Pumps

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