Optimization Through Downhole Gas Separation
Optimization Through Downhole Gas Separation
Optimization Through Downhole Gas Separation
JEFF RYAN
COASTAL MANAGEMENT CORPORATION
I. Abstract
Pumping efficiencies are severely affected when gas is produced through the
downhole pump. In order to maintain optimum production from a well producing free
or solution gas through the pump, pumping times or speeds must often be maximized
to compensate for reduced efficiency. As a result, surface and downhole equipment
life is drastically reduced. Accordingly, proper downhole gas separation greatly
enhances equipment performance, life and wellbore productivity. This paper will
illustrate three (3) basic methods of downhole gas separation, a method of designing
modified poor boy gas anchors and results obtained from improved downhole gas
separation in the University Waddell (Devonian) Field in Crane County, Texas.
II. Introduction
The physical mechanism which separates free or solution gas from the fluid in the
wellbore can be described as a gas separator. The basic premise of gas separation
focuses on gas and fluid velocities in the wellbore and downhole production
equipment. When oil containing solution gas crosses the perforations or slots in a
mud anchor, a pressure drop is observed resulting in the evolution of free gas bubbles.
In addition, agitation, change in direction, and sudden velocity increases result in the
evolution of free gas. Depending on the size and shape of the bubbles, fluid viscosity
and velocity, the free gas bubbles will attempt to migrate upward while the fluid
moves downward. If the downward fluid velocity exceeds the critical velocity
required for upward migration of the gas bubbles, free gas will be forced through the
production equipment. For wells producing with a water cut greater than twenty
percent (20%), the critical downward velocity of fluid is .5 ft/sec. For wells
producing with water cuts less than twenty percent (20%), the critical velocity of the
fluid is .5 ft/sec divided by the viscosity of the fluid in centipoise. Therefore,
successful gas separation may be achieved by employing gas separators that ensure
downward fluid velocities which do not exceed the aforementioned critical velocities.
Through the years many different types of gas separators have been developed and
utilized in sucker rod lift applications with varying degrees of success, However, this
paper will focus on the three most common types of gas separators utilized in sucker
SOUTHWESTEFtNPETROLEUMSHORTCOUFtSE-92 353
rod lift applications: the natural gas separator, the poor boy gas separator and the
modified poor boy gas separator. To ensure common identification with the parts
composing a gas separator, this paper will refer to the piping that attaches to the
pump or seating nipple as a gas anchor and the piping which surrounds the gas anchor
will be labeled as the mud anchor.
The natural gas separator is the simplest type of gas separation device.
Natural gas separation is achieved by placing the gas anchor or pump
intake below the casing perforations without a mud anchor attachment
(please refer to Fig. I). The gas-liquid separation capacity of the natural
gas separator is greater than the capacity of any other separation device
because the casing is utilized as the mud anchor, providing the largest
possible separation chamber which can be employed in the wellbore.
When installing a natural gas separator, the gas anchor or pump intake
should be placed at least twenty to thirty feet (20-30) below the
lowest active perforation ensuring that the gas anchor is not in the
turbulent zone of the wellbore. Employing a natural gas separator
requires the following:
354 SOUTHWESTERNPETROLEUMSHORTCOURSE-92
consists of a slotted mud anchor or perforated nipple/mud anchor
combination and a gas anchor (please refer to Fig. II). The mud anchor
is usually one to three (I-3) joints of pipe with the same outside and
inside diameters as the production string with the end orange peeled
closed. The mud anchor might be slotted at the top to allow fluid entry
if a perforated nipple is not employed in conjunction with the mud
anchor. The gas anchor is piping usually one inch (1) in diameter and
six to ten feet (6-10) in length with the end orange-peeled closed.
Fluid entry is achieved through perforations or slots placed in the bottom
of the gas anchor. During normal pumping operations, fluid enters the
perforated nipple or slots in the mud anchor, travels down the annular
space between the gas and mud anchors, and enters the pump via the
i gas anchor perforations or slots. Initial gas separation occurs at the mud
anchor or perforated nipple-openings due to the pressure drop required
to achieve entry coupled with the turbulence created as fluid flows into
the separator. Secondary gas separation occurs at the gas anchor
b
openings due to the pressure drop required to enter the pump. The
downward flow rate of the fluid inside the separator should be below the
critical velocity in order to allow the secondary gas to escape into the
casing. However, historical practices and procedures often do not
ensure that critical velocity requirements are met, therefore, the
separator does not function properly. Existing separators should be
examined to ensure that the design accounts for the critical velocity of
the produced fluid. Placement of the mud anchor or perforated nipple
openings may be above or below the casing perforations, but most often
the openings are placed above the perforations due to limited rathole.
As with the natural gas separator, the mud anchor openings should be
placed twenty to thirty feet (20-30) above or below the uppermost or
lowermost active perforation, to ensure that the openings are not in the
turbulent zone of the wellbore. In association, gas evolution inside the
gas anchor should be minimized by utilizing the largest diameter possible
in design of the gas anchor, thereby minimizing friction pressure drop.
Gas anchor size will be limited by mud anchor size which in turn is
limited by casing size. Optimizing the design will require balancing trade
offs in equipment sizes. When utilizing a poor boy gas separator, the
following design conditions should be specified:
2. The outside diameter of the mud andhor should be less than the
internal diameter of the largest overshot which might possibly be
SOUTHWESTERNPETFtOLEUMSHORTCOUFtSE-92 355
employed in fishing operations.
4. The mud anchor length should be no more than two to five feet
(2-5) longer than the gas anchor.
When rathole does not permit the installation of a natural gas separator,
availability of materials and economics makes the poor boy gas separator
the most widely utilized gas separator in sucker rod lift applications.
Before deciding on what type of gas separator is best suited for a given well,
a study of the wells history should be undertaken. The following questions
should be answered in order to facilitate selection of gas separator type, size
and placement:
After answering the above questions and selecting the type, size, and
placement of the gas separator, the actual design of separation equipment may
commence. Listed below are seven basic principles applying to the design of
poor boy gas separators:
Princiole Number One: The minimum separation area (gas anchor/mud anchor
annulus) should be large enough so the fluid velocity does not exceed the
critical velocity of .5 ft/sec. If the viscosity of the produced fluid is
significantly more viscous than water, the critical velocity should be adjusted
by dividing by the viscosity of the produced fluid. The only limitation on
separation area is casing size. The outside diameter (O.D.) of the mud anchor
should be less than the inside diameter (I.D.) of the largest overshot which can
be run in the casing in question.
Princiole Number Two: The area of the mud anchor or perforated nipple
openings should be equal to or greater than four times the minimum separation
area. The openings should be placed as close to the seating nipple as possible.
The slot area should be within one and one-half to two feet (1 l/2-2) of the
seating nipple. Recommended dimensions are one-half inch (l/2) in width and
four inches (4) in length. Never remove more than half (.5) of the mud anchor
circumference.
Principle Number Three: The area of the openings in the gas anchor should be
equal to or greater than four times the standing valve inside diameter area. If
slots are utilized, the dimensions should be one half inch (l/2) in width and
four inches (4) in length.
Princiole Number Four: The separation volume (vertical space between the
bottom of the mud anchor openings and top of the gas anchor openings) should
Princiole Number Five: The gas anchor length should be minimized to prevent
excessive pressure drops. The total length of the gas anchor is the sum of the
separation length (separation volume divided by separation area), the perforated
nipple or slot length, and the seating nipple length. The end of the gas anchor
should be orange peeled closed.
Principle Number Six: The mud anchor should be no more than two to five feet
(2-5) longer than the gas anchor with the end orange peeled closed.
Understanding and adhering to these seven basic principles will improve the
chance of success and performance of the poor boy gas separator.
As mentioned previously, the most effective type of gas separator is the natural
gas separator. However, sometimes wellbore conditions do not permit the use
of the natural gas separator. In such an event, the modified poor boy gas
separator should be utilized if casing size permits. The following is a detailed
discussion explaining the steps necessary to design a modified poor boy gas
separator:
Reauired Data
3. Pump stroke length. (If the pump stroke length is unknown, use the
polish rod stroke length.)
Desian Calculations
A. Select the gas anchor size and outside diameter area from Table I based
on total fluid production from Step 1.
B. Determine the area of the plunger and the internal diameter area of the
standing valve seat from Table II based on the plunger diameter specified
in Step 2.
350 SOUTHWESTERNPETROLEUMSHORTCOURSE-92
C. Calculate the required separation area:
(in2-ft-dav)
= .009358 set-bbl X TFP (bbl/dav)
VEL (ft/sec)
, where:
For most design applications the critical velocity will be .5 ft/sec, and the
formula is reduced to:
D. Calculate the area of the openings (flow area) in the mud anchor or
perforated nipple.
t MAFA = 4 X RSA
t where:
E. Calculate the number of slots required in the mud anchor if the slot
dimensions are one-half inch (l/2) by four inches (4):
= MAFA (in2)
2 (in2)
F. Calculate the area of the openings (flow area) in the gas anchor.
SOUTHWRSTERNPETROLEUMSHORTCOURSE- 92 359
GAFA = 4 X IDSVA (in2)
where:
G. Calculate the number of slots required in the gas anchor if the slot
dimensions are one-half inch (l/2) by four inches (4).
= GAFA (in2)
2 (in2)
where:
After determining the minimum separation area, enter column three (3)
in Table Ill and select the pipe size which has an internal diameter (I.D.)
area equal to or just larger than the minimum separation area. The
minimum separation area should be larger than the required separation
area obtained in Step C. Make sure the restrictions outlined in Principle
Number One are considered before selecting the mud anchor size.
where:
sv = 2 X PA (in2) X S (in)
SL = a (if?)
ASA (in2)
where:
where:
In association with improving equipment life and efficiency, proper gas separation will
optimize production from the wellbore. The University Waddell (Devonian) Field is
located in Crane County, Texas. Production originates from three distinct Devonian
intervals located at a depth of 8400-9200. The field is currently under secondary
recovery operations, and the average well produces 22 BOPD, 108 BWPD, and 31
MCFD. The majority of the wells employ sucker rod lift utilizing fiberglass or steel rod
strings. Prior to May 1991, gas separation was achieved by implementing the
following assembly:
B. Tailpipe with the same outside diameter as the production tubing was
installed open-ended to a depth of 8800-9000, above or in the middle
and lower sets of perforations.
The aforementioned gas separation design was actually a lethal gas trap. As a result
of the tailpipe length, placement, and configuration the majority of the free gas
entered the pump, taking the path of least resistance. The gas which broke out of
solution at the strainer nipple was forced through the pump because of the absence
of an escape path (i.e. no slots were cut in the tailpipe). As might be expected, pump
efficiencies were low and fluid levels were high due to the gas interference in the
downhole pumps. In association, several of the fiberglass rod strings were failing due
VII. Conclusions
Adhering to the basic principles of gas separator design will improve the effectiveness
and efficiency of the separator by ensuring that the critical velocity requirements are
satisfied. However, the best designed separator will not function properly unless care
is taken to ensure proper installation. Communication between engineering and field
personnel is essential to the implementation of a successful gas separation program.
As mentioned previously, extensive testing may be required to determine the optimum
separator application for a given field. Communication is essential to guarantee that
test results are interpreted accurately and corresponding modifications implemented
correctly. Regardless, the cost of testing and employing a gas separation technique
for a given field will be offset by the economic realization of reduced lifting cost and
optimum wellbore productivity.
VIII. Acknowledaements
The author would like to thank the management of Meridian Oil Company and Coastal
Management Corporation for the opportunity to publish and present this paper.
Special thanks are extended to Mr. Dick Hergenreter, Mr. Mike Miller and the
operations staff of Coastal Management Corporation in Penwell, Texas for their
assistance in development, testing and implementation of a successful gas separation
program. Concluding, the author deeply appreciates the assistance of the Coastal
Management Corporations operations staff in Midland, Texas for assistance in
preparing and publishing the paper.
References
1. Gipson, F.W., and Swaim, H. W., The Beam Pumping Design Chain, Proceedinas of the
Thirtv First Annual Meeting, Southwestern Petroleum Short Courts, April, 1984.
2. Eubanks, J. M., Franks, B. L., Lawrence D. K., Maxwell, T. E., and Merryman, C. J., Pumoing
Well Problem Analvsis, Sun Oil Company, 1958, Artificial Lift Efficiency School, Chastain,
1985.
Table II
Pump Data
Pump Pump ID
Plunger Plunger S.V. ID Area
Diameter Areas Seat S.V. Seat
* JbJy m fin)
Table IV
Lift Design - University Waddell (Devonian) Field
East Waddell Ranch
Production
Before After Incremental
BOPD m BOPD Action Taken
ADVANTAGES
t SCWMiWESl'ERNPETROLJWMSHORTCOURSE-92 366
I
__I TUDING
ADVANTAGES
DISADVANTAGES
MU0 ANCHOR
n 4~ PRODUCTION ZONE
SOUTHWRSTERN'PETROLRUMSHORTCOURSE-92
.. . -CASING
TUBING
I
t
ADVANTAGES
ilOS--
SEATING NIPPLE
t DISADVANTAGES
n
change that TUBING INTAKE
2. A fluid velocity
PORrS
could cause a gas breakout will
exist at the gas anchor inlet.
P
GAS ANCHOR
MUD ANCHOR
f
PROOUCTION ZONE
I SOUTHWESTERNPETROLEUMSHORTCOURSE-92 361
REQUIRED DATA
CALCUI ATIONS
MAFA = 4 x RSA
=4x- (in2)
Line IC)
# = MAFA! 2
= -12
Line (DI
GAFA= 4 x IDSVA
=4x (in*1
Line B (11
# = GAFA I 2 =
= -12
Line F
MSA = WA + GAODA
= -+- fin?
Line c Line A (II
sv = 2xPAxS
=2x -X- (in?
Line B Line 3
SL = SVIASA
= -I- (in)
Line J Line I
MAL = GAL + 24
= - + 24 (in)
Line L
Dia = Lgth =
Line A Line L
Dia = Lgth =
Line H (2) Line M
PBTD: 4065
SOUTHWE3TERNPETROLEUMSHORTCOURSE-92
REQUIRED DATA
CALCULATIONS
MAFA= 4 x RSA
= 4 x 5.50 22 (in2)
Line ICI
# = MAFA ! 2
= 22 I2 11
Line (Dl
GAFA= 4 x IDSVA
= 4x ,338 1.35 (in)
Line B ill
# = GAFA I 2 =
= 1.35 I2 ,676
Line F
sv = 2xPAxS
=2x1767x 120 424 (in31
-
Line B Line 3
SL = SVIASA
= 424 I 7 72 55 fin21
Line J Line
- I
MAL = GAL + 24
= 103 + 24 127 (in)
Line L
Figure VI (cont.) - Modified poor boy gas separator de$gn problem solution
372 SOUTHWJBTERNPETROLEUMSHORTCOURSE-92
1,800
r
1,600
I,
Q 1,400
:
rq 1,200
1,000
8oo5,1 5/15 6/l 6115 7/l 7115 B/l 0/15 Q/l Q/15 10/l lo/15 11/l 11/15 12/l 1205 l/l l/15 l/31
I
DATE
I