beam pumping with solids present - alrdc suc… · beam pumping with solids present by mark...

Sucker Rod Pumping WorkshopWyndham Hotel, Houston, Texas

September 11 – 14, 2007

Beam Pumping with Solids PresentBy Mark Mahoney, HF PumpsJim Lea, PLTech LLC

Sept. 11 - 14, 2007 2007 Sucker Rod Pumping Workshop 2

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• Don’t forget to possibly slow unit and pump continuously and not with POC to keep pumps from sticking….J Lea


TYPICAL SAND PROBLEMS

• STICKING OF PLUNGER DUE TO SAND TRAPPED BETWEEN THE BARREL AND PLUNGER

• PACKING-OFF CAGES AND PLUNGERS WITH SAND

• STICKING VALVES OPEN

• STICKING BOTTOM HOLD DOWN PUMPS IN TUBING

• PLUNGER / BARREL WEAR

• BALLS AND SEATS WEAR


SAND SIZETHOUSANDS OF AN INCH

• BELOW .003” SILT AND CLAY• .003-.005 VERY FINE SAND• .005-.010 FINE SAND• .010-.020 MEDIUM SAND• .020-.040 COURSE SAND• .040 AND ABOVE VERY COURSE SAND

• MICRON= .00003937”• 100 MICRONS = .0039


MESH SCREEN SIZE

• MESH SIZE GRAIN SIZE• 100 .006”• 65 .008”• 48 .012”• 35 .016”• 28 .023”• 20 .033• 14 .046


Analysis• Solids from wells are often assumed to be scale or iron sulfide.

Add xylene to the solids to remove oil, paraffin, and asphaltenes. Check the remaining solids to see if they are acid soluble. Effervescence will indicate a carbonate scale, calcite (calcium carbonate) or siderite (iron carbonate.

• Iron carbonate will not smell but will cause the acid to turn yellow. An H2S small indicates iron sulfide. If not acid soluble, try caustic. Caustic followed by acid will tell us whether calcium sulfate is present. Barium sulfate and sand will be inert to allattempts.

• If no history is available, a more complete analysis is recommended.


Analysis• When the pump and tubing is pulled, always inspect

the gas and mud anchor for solids.• The presence of solids/scale doesn’t necessarily

mean there is a problem. Evaluate these findings with respect to the current equipment life. For instance if sand , did it reduce the pump life?

• The lack of sand in an insert pump does not always indicate a "clean well". An aggressive rig operator can accelerate the rods to a high speed then slam on the brake causing the pump valves to bounce open and allow sand to fall from the pump.


Solids or scale problems can be minimized by three different approaches:

1. Prevent solids from entering the pump. Must have rathole.

2. Use a proper fit to either keep solids from the plunger/barrel interface or let them pass through without sticking the pump.

3. Use a large valve ports to allow sand to travel through the valves without packing-off.

Handling Solids with Beam Pumps


PLUNGER/BARREL CLEARANCE FOR PUMPING SAND

GENERAL RULE :• TIGHT FIT TO EXCLUDE SAND FROM BARREL/ PLUNGER

INTERFACE. WORKS WITH LARGE GRAIN SIZE (.015-.020”AND ABOVE).

• LOOSEN FIT TO ALLOW SAND TO PASS BETWEEN THE PLUNGER AND BARREL INTERFACE WHEN FINE SAND IS PRESENT .002 +.

• SAND WILL TRAVEL UP TUBING ONLY IF LIQUID RATE HIGH ENOUGH. SOMETIMES THE SAND JUST STAYS SUSPENDED ABOVE THE PUMP IF THE UPSTROKE FLOW IS NOT CAPABLE OF SURFACING THE SAND.


Continuous Operation

• If pump sticking during shut down periods then slow the unit so it runs continuously so sand will not settle on off cycle and this may prevent most of sticking problems.


Exclude sand from pump

Cavin Desanders: They are sized for the size of the particulates encountered. They use centrifugal force from a swirling motion to throw sand towards the side walls of the tail pipe while the fluid stays in the center and enters the pump. These devices have proven to be effective in many W. Texas installations. Eventually you must clean out the well or the rat hole.

Prepack Screen and Liner: These are self contained units that are most often used in unconsolidated sand formations. The prepack unit has screens and sand with resin, while the screen and linerhas only screens. Wells with scaling tendencies may present a problem with this type of device.

Installing a screen in place of the perforated nipple has not proven to be good design


Location

• Above perfs: If the reservoir pressure allows a high fluid level, consider setting the pump above the perfs to use the “rat hole” below the perfs as a natural sump. Use a properly designed gas anchor if gas reduces the pump efficiency.

• Below the perfs: With low well pressure, set below the perfs in the “rat hole”. If the solids settle in the well bore due to their size and a low production rate, the pump can be set high with only a seating nipple (if gas is not a problem). Once the fill reaches the seating nipple the tubing will have to be pulled and the casing cleaned out.


Mud Anchors and Screens

• Install a gas/mud anchor to help remove the solids from the production. Drill a ½” hole in the bottom of the bull plug to allow solids to settle out of the mud anchor. If gas is a problem, then gas anchor efficiency may be reduced by adding a drain hole and a purge valve should be used in place of the bull plug.

• Screens should only be used when the pump life is continually short due to abrasion. Many times the solids production is temporary due to stimulation or changes in the production


Some FiltersCavins Desander:

•Some success in W. Texas

•Successful in E. Texas (previous pump lasted 6-8 months…after PAP 12 months with high efficiency.

Stanley Filter:

•Successful in medium to light sand production.

•Mixed results in high sand

•FG filters have problems with sticking/breaking, especially if the assembly is tagged against fill

•Heavy oil/ high temp filter has mixed results as most filters have troubles with viscous oil

•Tagging this pump can cause damage


Cavens Desander


Filters


Tight Fit Pumps

These pumps are used to prevent solids from fitting between the plunger OD and the barrel ID. The most common types of pumps used for this are stroke-through pumps with about 0.002 inch fits. Names such as “Pampa”, “Modified Pampa”, “Sand Busters” are examples of these types of pumps.


PAMPA TUBING PUMP• RECOMMENDED FOR WELLS THAT PRODUCE

SAND OR OTHER PARTICULATES THAT HANG UP OR STICK STANDARD PLUNGERS.

• DESIGNED WITH A LONG PLUNGER AND A SHORT BARREL SECTION.

• THE PAMPA PUMP CAN BE CONFIGURED AS A TRAVELING BARREL, STAIONARY BARREL OR TUBING PUMP AS NEEDED TO MATCH WELL CONDITIONS.

• PAMPA PUMPS CAN ALSO BE USED WITH LOOSE FITS TO KEEP THE PLUNGER FRO STICKING WITH FINE SAND


Pumps & Attachments

• Short Barrel and long plunger: This is extension of the stroke through pump where the barrel seal is 3-4” and the plunger is much longer. The advantage is that the solids are not “wedged”between the plunger and barrel over the length of the stroke.


P a m p a R H B C I n s e r t P u m p

C o p y r ig h t A p r i l 2 0 0 2 H a r b is o n -F i s c h e r


Close Fit Pump : PAP Pump

PAP Pump:•Good success in some areas

•Not good for high corrosion areas (wipes the film off the barrel)

•Tubing pump: loose rings and can’t fish the SV.

•Not recommended for wells with scale problems

•PAP in combination with Stanley filter has proven successful in some areas.


Loose Fit Pumps:

These pumps can be used to allow solids to pass freely between the plunger and the barrel. This can be accomplished by using a pump with a long leak path (a three tube pump), a soft packed plunger ( a Martin plunger) or a Pressure Actuated Plunger. Large clearance require minimum of about 10 SPM.

For all of the above alternatives, California style valves can be used (i.e.., undersized balls and seats in regular size cages to reduce the possibility of sand from becoming rapped between the balls and the seats.

It is recommend to first try to exclude sand from the pump. The next recommended alternative should be a loose fit PAP pump.


Three Tube Pump: A Three Tube Pump is designed to pump solids by having a very loose fit (0.015 inches). And a very long leak path to reduce total slippage.. Additionally, they can wear very quickly.

The do reduce the maximum size pump that can be run in the tubing .

Desanders and Pressure Actuated Plungers should be considered as an alternative to a Three Tube Pump. They have almost zero compression ratio.

Three Tube Pump


3-TUBE PUMP

• RECOMMENDED FOR OPERATION IN SANDY OR DIRTY FLUID.

• DESIGNED WITH THREE LOOSE FITTING TUBES, PERMITTING PARTICULATES TO PASS THROUGH THE PUMP, MAKING IT LESS VULNERABLE TO STICKING.

• HAS THE ADVANTAGES OF BOTH A STATIONARY BARREL PUMP AND A TRAVELING BARREL PUMP.

• AVAILABLE IN CORROSION AND ABRASION RESISTANT MATERIALS.

Sept. 11 - 14, 2007 2007 Sucker Rod Pumping Workshop 29C o p yr ig h t A p r i l 2 0 0 2 H a r b i s o n - F i s c h e r


VALVES for SAND APPLICATIONS

NEW 4 -GUIDE CAGEStellite Lined

RUBBER LINED CAGE

Viton ®RubberGuides

Balland Seat

TopView

SideView

Copyright April 2002 Harbison -Fischer


Special Balls and Seats


Balls & Seats

Ceramics have not run that well. Silicon Nitride is good for corrosion but is very expensive.


Bottom discharge valves (BDV): BDV’s are devices that are normally used at the bottom of an insert bottom hold down stationary barrel application. It is designed to discharge fluid on the down stroke from between the standing and traveling valve within the barrel to the annular space between the barrel OD andtub tubing ID. This is done to protect the tubing and barrel with corrosion inhibition and to reduce the amount of solids that canpack in around the barrel above the hold down.

BDV’s are recommended only when solids problems have been identified as the reason for sticking an insert pump in the tubing and when the well depth is lower than that recommended for a top hold down.

On stationary barrel bottom holddown pumps a BDV is installed just above the holddown,. 20-25% of the production is discharged on the downstroke keeping the sand from settling between the barrel and tubing

Bottom Discharge Valves


BOTTOM DISCHARGE VALVE

• The Bottom Discharge Valve is designed to be used when sand or other particulates are produced.

• The BDV is assembled above the standing valve on a standard bottom hold-down pump.


B o tto m D is c h a r g e V a lv e

F lu idE x it toT u b in g ,d o w n s tro k e

D is c h a rg eV a lv e

P ro d u c t io n F lu id

S ta n d in gV a lv e

P ro d u c t io nF lu id th ruP u m p , u p s tro k e

C o p y rig h t A p ril 2 0 0 2 H a rb is o n -F is ch e r


BOTTOM DISCHARGE VALVESOLUTIONS

• Twenty percent of the produced fluid exits the pump through ports just above the standing valve, preventing sand from settling above the seating nipple.

• A secondary benefit is that corrosion chemicals can be circulated through this normally stagnant fluid area.


•Historically they have been used in heavy solid producing wells where sand or other materials prop the ball off the seat. Double valving may reduce the problem in this case, but other products such as desanders are generally a better solution. They prevent the sand from entering the pump where it can cause a problem. •Washing or jetting of the balls and seats can occur if a sand grain lodges and holds the ball off the seat on either the TV or the SV. By adding another valve, the chances of both being off seat at once are greatly reduced. •Remember small valves pack-off easier than large valves for the same given sand size and double valves increase the path the sand has to travel

Double Valving


Pump: Metallurgy• For a metal pump, consider the hardest surface

material for the barrel and plunger for resistance to abrasion. Chrome plated barrel and sprayed metal plunger in non corrosive environment nickel-carbide barrel in corrosive wells

• Well that produce solids should be sized to produce all the time so sand will not settle during down times.

• If properly applied metal plunger does not provide adequate pump life, consider a soft packed plunger.

• Continue pump problems with metal and soft packed plungers due to solids production warrants evaluating the use of a PCP for depths less than about 4000’.


Special Application Pumps/Attachments


TEXAS STIPPER PUMP

• DESIGNED FOR SHALLOW, LOW VOLUME WELLS THAT PRODUCE SAND AND OPERATE WITH PERIODS OF SHUTDOWN.

• BUILT AS A STATIONARY BARREL BOTTOM HOLD DOWN (RWB) PUMP WITH AN OUTER JACKET THAT SHIELDS THE DISCHARGE PORTS, PREVENTING SAND FROM ENTERING THE PUMP DURING SHUT DOWN PERIODS.


• Insert- Top Hold down: A top hold down is a first choice. Pumps discharge is close the NoGo on the seating nipple which minimizes sand accumulations. Intermittent pumping can allow sand to settle inside pump sticking the plunger.

• Insert-Bottom Hold down: A bottom hold down pump has a large annular area between the barrel and the tubing which can fill and “sand in” the pump. Sand can also settle inside the pump sticking the plunger. A top sand seal can help if the pump has to be run as a bottom hold down

Special Pumps Continued


Pumps & Attachments

• Insert-Traveling Barrel: A traveling barrel pump minimizes sand accumulation between the barrel and the tubing if properly spaced. Since the traveling valve is on top of the pump, sand cannot accumulate inside the pump. Also the fluid is discharged spread out over the stroke length minimizing erosion damage to the tubing.

• Stroke Through Pump: Both the insert top/bottom hold down pumps extensions to allow the plunger to stroke out of the barrel top/bottom on each stroke. The minimum stroke length is fixed.


Pumps & Attachments

• Pull Tube Discharge Pump: Both the insert A/B pumps can be equipped with a blind valve rod guide and a pull tube that is ported above the plunger. A pull tube traveling valve will act as a sand check. Most of the fluid is displaced through the pull tubeminimizing sand that can wedge between the plunger and the barrel. Also fluid is discharge spread over the stroke length thus minimizing the erosion damage to the tubing.

• Tubing Pump: Many of the attachments for the stationary barrel insert pump apply.


Pumps & Attachments

• Attachments:• Top Seal: For stationary barrel bottom holddown pumps another

seal bore is run I the tubing string above the seating nipple which accepts a seal assembly on the pump below the pump discharge. Issue is spacing.

• Top Slide Valve: Added to the pump below the rod guide and is available for both top and bottom holddown stationary barrels. On the downstroke, the slide valve closes which minimizes sand from settling inside the barrel.


Summary

• Fair for low viscosity (<10 cp) production. Improved performance for high (>200 cp) viscosity cases. May be able to handle up to 0.1% sand. (Hein, Bucarem, Clegg)

• Sand reduces run life but with proper choices of equipment and techniques, sand laden fluids can be produced with beam systems.

beam pumping with solids present - alrdc suc… · beam pumping with solids present by mark...

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