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Activation of A Non-Eruptive Well by Using Gas Lift Method and Step-Up of Its Productivity: Sensitivity and Economical Analysis
Activation of A Non-Eruptive Well by Using Gas Lift Method and Step-Up of Its Productivity: Sensitivity and Economical Analysis
Activation of A Non-Eruptive Well by Using Gas Lift Method and Step-Up of Its Productivity: Sensitivity and Economical Analysis
1, 2022 65
Madeleine Nitcheu*
Department of Basic Scientific Teaching,
School of Geology and Mining Engineering,
University of Ngaoundere,
P.O. Box 115 Meiganga, Cameroon
Email: nitcheumadeleine78 @gmail.com
*Corresponding author
Abstract: This paper aims to design a gas lift that not only activates a
non-eruptive well but also and above all, optimises the recovery of
hydrocarbons at the surface while using a very less and limited gas quantity per
day. The data are reservoir data, fluid data, well architecture properties, and
also injection targets. To achieve the objective, it is necessary to carry out a
nodal analysis of the non-eruptive well, and design the gas lift system by
finding the gas injection pressure in the well, the number of valves, the optimal
heights of injection, and the flow rates received by each valve. The evaluation
of the system performance, as well as the sensitivity analysis, allows the
selection of an optimal production rate. All the simulation operations and the
well diagram are carried out with PIPESIM 2017.1. The results obtained show
for the continuous injection of gas at 0.73 and 0.23 mmscf/d respectively. For
valves 1 and 2 in the well, i.e., 1 mmscf/d for the two valves and using pressure
at the head of the well of 100 psia, an optimal flow rate of 262.9 STB/d can be
produced and the payback period is one year and two months.
1 Introduction
The oil and gas industry faces many challenges in the exploration, drilling, production,
and management of hydrocarbons found beneath the earth’s subsurface (Economides and
Boney, 2000; Guo et al., 2007; John, 2018). Despite all these obstacles, the engineer must
be able to create solutions to solve different problems. Several years ago (150 years),
hydrocarbons used the natural energy of the reservoir to reach the surface. But as we
produce, the fields become mature, and the reservoir pressure decreases (Katz and
Barlow, 1995; Bellarby, 2009; Renpu, 2011). The energy in the reservoir is therefore no
longer sufficient to bring the hydrocarbons to the surface, or the pressure at the bottom of
the well becomes greater than the pressure in the reservoir, which causes considerable
reduction in the production flow, which can even lead to production stop (Gilbertson,
68 J.F. Matateyou et al.
2010; Crumpton, 2018; Guo et al., 2007). In the oil field, the literature indicates that
several artificial techniques have been adopted to activate and increase the production
rate of hydrocarbons at the surface, and certain techniques are recent: using of
progressive cavity pump (PCP), sucker rod pump, electrical submersible pump (ESP),
plunger lift, hydraulic pump and gas lift (Valchon and Bussear, 2005; Qahtani et al.,
2005; Basic ESP Sizing, 2007; Khamehchi and Mahdiani, 2017; Takacs, 1983; Ben
Amara, 2016). However, gas lift units have proven to be one of the most widely used
methods of lifting smaller oil flows and high gas-oil ratio (GOR). The global oil supply
with gas lift systems is estimated to be over 20% (Brown and Phillips, 1984). The gas lift
is an artificial lifting system, easy to install and use. It uses an external source of high gas
pressure, to supplement the formation gas to lift the fluids from the well. Its principle is
that the gas injected into the tubing reduces the density of the fluid, and the gas bubbles
have a purifying action on the fluids, causing a faster oil ascension (Laing, 1989; Shahri,
2011; Brown, 1967, 1980; Gábor, 2005). After years of production, the reservoir begins
to provide flow rates that are no longer economically profitable because of its depletion;
it is possible to go to a total stop of production (non-eruptive well), even though the
reservoir still contains the hydrocarbons (Cloud, 1937; King, 1998). For very viscous oil,
generally, it is recommended to use the gas lift to allow it to reach the surface. The
installation of a gas lift system will help reduce the bottom hole pressure in the case of a
non-eruptive well (Clegg et al., 1993). But this injection must be done optimally (inject
less gas to produce the maximum amount of oil), which is not easy. The majority of wells
using gas lift systems generally consume a lot of gas to produce commercial flows, which
is a major problem due to the high costs of gas supply (Winkler and Camp, 1987;
Schlumberger, 2020; Ayatollahi and Moshfeghian, 2001). A central question emerges
from this observation: is it possible to activate and optimise the production of a
non-eruptive well by the gas lift method while injecting less and limited gas quantity into
the production system?
This paper aims to provide an optimal analysis of a non-eruptive well named well X
(for confidential reasons) that has stopped producing after the well pressure has become
greater than the reservoir pressure. To carry out this paper, the following tasks are
performed: carry out a nodal analysis of the well before setting up the gas lift system;
design the gas lift; make a new well completion; perform a sensitivity analysis to choose
the optimal flow parameters and perform an economic analysis. To achieve these
objectives, technical and economical approaches are studied.
The synthesis of this paper is presented in three sections: The introduction is
presented in Section 1. Section 2 presents the data, tools, methodology, and results.
Section 3 gives the conclusion.
This paper aims to propose an economical gas lift design to reactivate a non-eruptive well
that has stopped producing while optimising production using as little gas as possible.
This is made possible through the nodal analysis of the non-eruptive well before the
installation of the gas lift system, the gas lift design, the drawing of the final diagram of
the well, the diagnosis of the performance of the artificial lift, the sensitivity analysis and
analysis of the payback period.
Activation of a non-eruptive well by using gas lift method 69
The well X consists of a vertical well. Its well profile starts with a 20” conductor pipe
(CP) hammered till 100 ft, followed by 13-3/8” surface casing with casing shoe at 800 ft
of grade K55; 9-5/8” intermediate casing with casing shoe at 3,500 ft of grade N80 and a
last 7” OD production casing at 8,000 ft of grade C90 with a nominal weight of
29 pounds per foot. The production tubing is 2,992” ID set at 7,500 ft with a production
packer at 7,300 ft. The PIPESIM 2017.1 software, sensitivity analysis and economical
analysis are used to attain the aims of this paper.
Figure 1 Nodal analysis for non-erupting well (see online version for colours)
Figure 2 Gas lift performance curve (see online version for colours)
The simulation results of the well’s response to a gas injection calculate the maximum
gas injection pressure CHP = 750 psia as shown in Figure 2. A minimal sensitivity
analysis is performed by utilising optimum gas injection pressure data of the gas lift
performance curve. From Figure 2 the optimal rate of gas injection is 5 mmscf/d, and this
flow requires recovering an oil flow of 266.5964 STB/d on average. However, as part of
Activation of a non-eruptive well by using gas lift method 71
this optimisation, the quantity of gas available is 1 mmscf/d, and in a normal injection of
1 mmscf/d, an oil flow rate of 174.916 STB/d is produced. It is therefore imperative to
install a system of valves that will continuously deliver a rate of gas available per day to
boost the well performance. The optimal gas injection point into the well is calculated
based on the height of the well, its pressure, its temperature, and the AOF of the well at
the moment when the pressure at the bottom of the well is greater than the pressure of the
reservoir. The results are shown in Figure 3.
Figure 4 Well gas lift design (see online version for colours)
72 J.F. Matateyou et al.
For efficient recovery, the second gas injection valve should be placed at 4,349 ft. This
valve is practically halfway up the well. And the daily injection rate is found manually by
varying the quantities of gas received by each valve until the maximum flow is obtained.
The injection rate found is 0.73 and 0.27 mmscf/d respectively for valves 1 and 2. The
injection is continuous into the well. The well design schematic is shown in Figure 5.
In Figure 5, it is essentially made up of the production casing, the production tubing, the
production packer, and their different heights; the height of the perforations and surface
elements: flowline (FL), choke (Ck), and sink (Sk). With the installation of the gas lift
equipment in the well, a depression in the well can therefore be created, until the pressure
in the reservoir, which is 1,000 psia, again becomes greater than the pressure recorded at
the bottom of the well. So, the well can deliver to the surface an oil flow that can be
managed (Hernandez, 2016). The gas lift performance results are shown in Figure 6 and
Table 3.
Activation of a non-eruptive well by using gas lift method 73
After installing the gas lift valves at defined depths, a flow rate of 166.1055 STB/d is
produced, with a pressure of 819.389 psia at the bottom of the well, less than the tank
pressure. This information is the result of the lightening of the column of fluid by the gas
introduced into the tubing. This throughput can be further optimised by performing a
sensitivity analysis on the modifiable production parameters.
Figure 7 Wellhead pressure sensitivity analysis (see online version for colours)
74 J.F. Matateyou et al.
Operating point Q at NA P at NA
Case
psia STB/d psia
1 50 286.7124 662.7323
2 100 262.9248 696.002
3 150 233.6235 735.2163
4 200 201.0188 776.8496
5 250 166.1055 919.3362
Since the wellhead pressure needs to be set according to the surface equipment, when
production stopped in field X, the wellhead pressure was 250 psia. The minimum
standard pressure of production according to the basic production equipment being 100
psia, the pressure at the head of the well can therefore be reduced to 100 psia. Therefore,
this pressure must be controlled throughout the production period, because its variation
could cause damage to surface equipment, and surface equipment is designed to receive a
relatively sweet flow. With a well head pressure of 100 psia, a flow rate of 262.9248
STB/d is obtained, and the pressure recorded at the bottom of the well is 696.002 psia.
Activation of a non-eruptive well by using gas lift method 75
For a daily gas injection of 1 Mmscf/d, the recovery rate is almost identical to that of a 5
Mmscf/d gas injection in a single injection. Figure 8 indicates the results of sensitivity
analysis with three different GOR (300, 400, and 500) scf/sbbl, with a wellhead pressure
of 100 psia.
Table 5 shows a summary of the flow rates produced according to the variation of the
GOR.
Table 5 Flow rate with GOR variation
In the worst case (GOR = 300), the product oil flow rate is 246.0471 STB/d. The results
of the water cut sensitivity analysis are shown in Figure 9 and Table 6. The selected
water cut parameters are calibrated from 60% to 85%.
Figure 9 Sensitivity analysis water cut (see online version for colours)
It is found that as the percentage of water increases in the well, the production decreases
considerably, and this decrease cannot be stopped. It is therefore this breakthrough in
water that will determine the end of the efficiency of the gas lift installed because there is
no point in producing water. From the sensitivity analysis, new production parameters
can be defined. For optimum production, it is recommended to have a maximum fluid
outlet pressure of 100 psia, so as not to damage surface equipment. The decrease in the
GOR and the increase in the water cut over time will lead to a considerable drop in
production, until the well reaches its economic limit. For this specific case, reducing the
pressure at the wellhead makes it possible to obtain a new flow rate of 262.9248 STB/d.
76 J.F. Matateyou et al.
Operating WCut Q at NA P at NA
Case
% STB/d Psia
1 60 262.9248 696.002
2 65 254.6591 707.2512
3 70 246.6856 717.9606
4 75 237.8749 729.6382
5 80 226.6224 744.3243
6 85 215.6435 758.4178
We assume $50 per barrel of crude oil, then the estimated cost for four years is tabulated
as shown in Table 9.
Table 9 Gas-lift estimated cost for four years.
From the economic analysis of Table 11, it is possible to conclude that the operating cost
of the gas lift is quite high and this justified its efficiency in the activation and
optimisation of production, while the well was not producing more hydrocarbons. The
overall performance is better with this method, especially when it comes to producing
low flow rates while having a quick return on investment. The payback time shows that,
after 1 year and 2 months, the initial investment cost is recovered.
3 Conclusions
The objective of this paper was to propose a gas lift design, allowing activating and
optimising the production of hydrocarbons of a non-eruptive well, while injecting as little
and limited gas quantity as possible into the production column. To do this, PVT data and
production data were used and their importance was mentioned in the context of this
paper. Also, to achieve the set objectives, an appropriate methodology was developed.
First, it consisted in defining and presenting the data used and presenting a nodal analysis
of the non-eruptive well. As a second step, bring out the gas lift design for optimal
recovery of the oil on the surface, a sensitivity analysis allowed to optimise surface
production. As a third step, an economic analysis was developed to determine the project
rentability. Given these procedures, it appears that the nodal analysis of the well before
the installation of the gas lift presented an absolute open flow of 555.5 STB/d. The gas
lift design for gas injection into the well allows an injection pressure of 750 and 692 psia
for each valve and a maximum height of the first gas valve set at 7,290 feet. For better
recovery of hydrocarbons at the surface, a second relay valve must be placed at 4349 ft.
and the daily injection rate is 0.73 and 0.27 mmscf/d respectively for valves 1 and 2 (for
an available quantity of gas of 1 mmscf/d). With an outlet pressure of 100 psia, the
optimum recorded production flow rate is 262.9248 STB/d. The economic analysis was
given a gross profit of $9,269,809.87 after 4 years and the payback period is 1 year and
2 months. Prospects may be: generalise this study on the other wells of the field X with
internal diameters of production tubing other than 2.992” to assess the financial potential
of all the dead wells in the field.
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