production engineering experiment

Production engineering experiment

Teacher ： Zhan Yongping

中国石油大学 (华东 )石油工程实验中心

contents

Vertical Pipe Flow Experiment

Pump Efficiency Experiment

Fracture Conductivity Experiment


1 Vertical Pipe Flow Experiment

(1) Observe various flow regimes in the vertical pipe and master the identification method of each flow regime;

(2) Verify the pressure drop model of multiphase flow in vertical pipe ;(3) Understand the principle of flowing well and gas lift.

(1) Observe various flow regimes in the vertical pipe and master the identification method of each flow regime;

(2) Verify the pressure drop model of multiphase flow in vertical pipe ;(3) Understand the principle of flowing well and gas lift.

Experimental PurposesExperimental Purposes

When the wellhead pressure is higher than the bubble point pressure, the flow in the well will be single-phase. When the bottomhole pressure is lower than the bubble point pressure, the flow will be two-phase in the entire pipe. During the flow, most of the total pressure losses in oil production system are consumed to overcome the elevation losses and friction losses of the mixture flow. The kinetic energy (acceleration) losses can only be considered when the flow rate of the two phase is high enough (such as spray flow). In the vertical wellbore, most of the bottomhole pressure are consumed to overcome the gravity of the liquid column.

The total pressure loss in wellbore can be expressed:

When the wellhead pressure is higher than the bubble point pressure, the flow in the well will be single-phase. When the bottomhole pressure is lower than the bubble point pressure, the flow will be two-phase in the entire pipe. During the flow, most of the total pressure losses in oil production system are consumed to overcome the elevation losses and friction losses of the mixture flow. The kinetic energy (acceleration) losses can only be considered when the flow rate of the two phase is high enough (such as spray flow). In the vertical wellbore, most of the bottomhole pressure are consumed to overcome the gravity of the liquid column.

The total pressure loss in wellbore can be expressed:

Experimental principleExperimental principle



Where: — gravity pressure drop;

— frictional pressure drop;

— acceleration pressure drop.The possible flow regime in wellbore from the bottomhole to the wellhead may include: pure oil flow, bubble flow, slug flow, circular flow and spray flow.

Where: — gravity pressure drop;

— frictional pressure drop;

— acceleration pressure drop.The possible flow regime in wellbore from the bottomhole to the wellhead may include: pure oil flow, bubble flow, slug flow, circular flow and spray flow.

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Experimental apparatusExperimental apparatus


(1) Instruments and equipment: flowing well simulator, air compressor, centrifugal pump, second counter, etc.;(2) Experimental medium: air and water;(3) Experimental process (showed in Figure 1)

(1) Instruments and equipment: flowing well simulator, air compressor, centrifugal pump, second counter, etc.;(2) Experimental medium: air and water;(3) Experimental process (showed in Figure 1)

Fig1 Schametatic of Vertical Pipe Flow ExperimentFig1 Schametatic of Vertical Pipe Flow Experiment Laboratory instruments PhotosLaboratory instruments Photos


Experimental stepsExperimental steps


(1) Check the state of the flowing well simulator’s valves and ensure that all valves are closed.Check the liquid level of the buffer tank. If the liquid level is lower than the 3/4 height of the buffer tank, the inlet valve should be opened and the tank will be filled to reach a suitable level(3/4 height of the buffer tank);

(2) Open the gas loop valve and ensure the flow path in a connected state, then open the air compressor and supply gas to the system;

(3) Adjust the valuator of buffer tank to ensure its pressure do not exceeding 0.10MPag. Open the pressure valve of buffer tank and then open the valve after the pressure stabilized, supply liquid to the system;

(4) Now, the liquid and gas are fed to the system at the same time. When the liquid level reaches to the wellhead, change the opening size of the gas valve and observe various flow regimes appeared in the pipe, then adjust to the desired flow regime and begin to measure parameters after steady ;

(5) Press the “reset” button of flow totalizer, and start the second counter at the same time, observe the indicator of bottom pressure and gas rotameter. When the time up to 10 seconds, record bottomhole flow pressure, gas flow rate, liquid flow rate and accumulated time;

(1) Check the state of the flowing well simulator’s valves and ensure that all valves are closed.Check the liquid level of the buffer tank. If the liquid level is lower than the 3/4 height of the buffer tank, the inlet valve should be opened and the tank will be filled to reach a suitable level(3/4 height of the buffer tank);

(2) Open the gas loop valve and ensure the flow path in a connected state, then open the air compressor and supply gas to the system;

(3) Adjust the valuator of buffer tank to ensure its pressure do not exceeding 0.10MPag. Open the pressure valve of buffer tank and then open the valve after the pressure stabilized, supply liquid to the system;

(4) Now, the liquid and gas are fed to the system at the same time. When the liquid level reaches to the wellhead, change the opening size of the gas valve and observe various flow regimes appeared in the pipe, then adjust to the desired flow regime and begin to measure parameters after steady ;

(5) Press the “reset” button of flow totalizer, and start the second counter at the same time, observe the indicator of bottom pressure and gas rotameter. When the time up to 10 seconds, record bottomhole flow pressure, gas flow rate, liquid flow rate and accumulated time;



(6) Change the flow rate, repeat steps 4-5 and record each data; requiring to record 5 set of data for slug flow and bubble flow.

(7) End the experiment. Close the fluid loop at first, then close the air compressor and the power supply. After the gas be evacuated completely, close all the valves on the panel. Clean the experimental devices and end the experiment.

(6) Change the flow rate, repeat steps 4-5 and record each data; requiring to record 5 set of data for slug flow and bubble flow.

(7) End the experiment. Close the fluid loop at first, then close the air compressor and the power supply. After the gas be evacuated completely, close all the valves on the panel. Clean the experimental devices and end the experiment.

AttentionsAttentions

(1) Do not step on the pipes;(2) Pay attention to the liquid levelwhen operating the flowing well simulator,do not

make it empty or overflow;(3) The recoreded value of the rotameter and pressure gauge sholud be the average value

within the measuring time;(4) Pay attention to the units of rotameter and flow totalizer.(5) Be careful to operate the reset button of the flow totalizer.

(1) Do not step on the pipes;(2) Pay attention to the liquid levelwhen operating the flowing well simulator,do not

make it empty or overflow;(3) The recoreded value of the rotameter and pressure gauge sholud be the average value

within the measuring time;(4) Pay attention to the units of rotameter and flow totalizer.(5) Be careful to operate the reset button of the flow totalizer.


2 Pump Efficiency Experiment

(1) Observe the composition and work process of the pumping unit and pump.(2) Master the measuring and calculating method of the pump efficiency.(3) Observe the realationship between pump efficiency and gas rate.(4) Observe the degasing effectiveness of the gas anchor.(5) Understand the measuring and analysising method of dynamometer diagram.

(1) Observe the composition and work process of the pumping unit and pump.(2) Master the measuring and calculating method of the pump efficiency.(3) Observe the realationship between pump efficiency and gas rate.(4) Observe the degasing effectiveness of the gas anchor.(5) Understand the measuring and analysising method of dynamometer diagram.

Experimental purposeExperimental purpose

Pump efficiency is a significant parameter for analyzing the work condition of pumping unit. According to the energy equation of gas-liquid mixture flowing through the pump and the law of coservation of energy,the pump efficiency can be analyzed.

Pump efficiency is a significant parameter for analyzing the work condition of pumping unit. According to the energy equation of gas-liquid mixture flowing through the pump and the law of coservation of energy,the pump efficiency can be analyzed.

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where, — pump’s actual displacement —pump’s theoretical displacement —pump efficiency

Where, D —pump diameter；S —stroke ； n — pumping speed



Experimental equipments and materialsExperimental equipments and materials

(1) Experimental equipments: beam pumping unit, pump, air compressor, air rate setter, rotameter, liquid bottle, second counter,etc.(2) Experimental medium: air and water.

(1) Experimental equipments: beam pumping unit, pump, air compressor, air rate setter, rotameter, liquid bottle, second counter,etc.(2) Experimental medium: air and water.

Laboratory instruments PhotosLaboratory instruments Photos



(1) Record the pump diameter(2) Move the holder to ensure the centerline of pump barrel is in alignment with the

horsehead, check the air inlet pipe and liquid inlet pipe of the pump barrel to ensure whether the flow path is unblocked or not.

(3) Turn the belt roller with hands to drive horsehead move up and down, record the plunger stroke

(4) Turn on the power supply of pumping unit and measure the plunger stroke(5) Record the actual fluid volume at the pipe outlet with volumetric cylinder and second

counter, repeated 3 times.(6) Turn on the power supply of air compressor, adjust the air rate setter and keep the

entered gas rate at 0.2L/min. When the produced fluid is in stable, then record the pump discharge for three times

(7) Turn on the power supply of air compressor, adjust the air rate setter and keep the entered gas rate at 0.8L/min. When the produced fluid is in stable, then record the pump discharge for three times


(1) Record the pump diameter(2) Move the holder to ensure the centerline of pump barrel is in alignment with the

horsehead, check the air inlet pipe and liquid inlet pipe of the pump barrel to ensure whether the flow path is unblocked or not.

(3) Turn the belt roller with hands to drive horsehead move up and down, record the plunger stroke

(4) Turn on the power supply of pumping unit and measure the plunger stroke(5) Record the actual fluid volume at the pipe outlet with volumetric cylinder and second

counter, repeated 3 times.(6) Turn on the power supply of air compressor, adjust the air rate setter and keep the

entered gas rate at 0.2L/min. When the produced fluid is in stable, then record the pump discharge for three times






(9) Turn off the power supply of pumping unit and air compressor, move the holder and then replace the pump barrel, the air inlet pipe and liquid inlet pipe

(10) Repeat step 5-9(11) End the experiment.

(9) Turn off the power supply of pumping unit and air compressor, move the holder and then replace the pump barrel, the air inlet pipe and liquid inlet pipe

(10) Repeat step 5-9(11) End the experiment.

(1) Do not touch the counterbalance and the brake of beam pumping unit in operation;(2) Ensure the centerline of pump barrel is in alignment with the horsehead;(3) Ensure the liquid and gas supply loops in unblocked state before starting beam pumping

unit;(4) Do not operate the air rate setter button endlessly;(5) Pay attention to observe the working condition of the plunger and valve during the

experiment;(6) Turn of the power supply at first in case of accident.

(1) Do not touch the counterbalance and the brake of beam pumping unit in operation;(2) Ensure the centerline of pump barrel is in alignment with the horsehead;(3) Ensure the liquid and gas supply loops in unblocked state before starting beam pumping

unit;(4) Do not operate the air rate setter button endlessly;(5) Pay attention to observe the working condition of the plunger and valve during the

experiment;(6) Turn of the power supply at first in case of accident.


AttentionsAttentions


3 Fracture Conductivity Experiment

(1) Understand the changes of the fracture conductivity with the closure stress, and the differences of the fracture conductivity between different sand layers at the same closure stress.(2) Calculate the fracture conductivity with Darcy's formula and binary formula, analyze the difference and explain the reason. (3) Be familiar with the operation of the fracture conductivity instrument and the experiment process.

(1) Understand the changes of the fracture conductivity with the closure stress, and the differences of the fracture conductivity between different sand layers at the same closure stress.(2) Calculate the fracture conductivity with Darcy's formula and binary formula, analyze the difference and explain the reason. (3) Be familiar with the operation of the fracture conductivity instrument and the experiment process.

The fracture’s permeability can be characterised by the gas flow rate.The fracture’s

conductivity can be determined with Darcy's formula of gas radial flow by measuring the

flow rate at different inlet and outlet pressure.

The fracture’s permeability can be characterised by the gas flow rate.The fracture’s

conductivity can be determined with Darcy's formula of gas radial flow by measuring the

flow rate at different inlet and outlet pressure.

Experimental purposeExperimental purpose




Experimental apparatus and materialsExperimental apparatus and materials

(1) Instrumentation: fracture conductivity instrument, including compression testing machine, air compressor, value setter, pressure gauge, float type flow meter, rock core, vernier scale, electronic balance, magnifier

(2) Materials: quartz sand and ceramsite from different place

(1) Instrumentation: fracture conductivity instrument, including compression testing machine, air compressor, value setter, pressure gauge, float type flow meter, rock core, vernier scale, electronic balance, magnifier

(2) Materials: quartz sand and ceramsite from different place

Laboratory instruments PhotosLaboratory instruments Photos



(1) Preparations ① Record the name, place and grain size of the proppant and the gas viscosity at room

temperature on the attachement I. ② Measure the outside diameter of the rock core and the internal diameter of the penetrated

hole in the rock core with vernier scale, then record them on the attachement I to calculate the area of the rock core.

③ Weigh a certain proppant (recording the grain size) and lay them on the core surface, be sure to keep them in a single layer, then observe whether the proppant’s distribution

are uniform and tight or not with magnifier. Then weigh the remaining proppant, the difference is the weight of the proppant layed on the core. Calculate the proppant concentration using the following formula.

(g/cm2)

record this data on the attachement I ④ Put the upper core (the penetrated hole should be downard) above the lower core, then

put them together to the center of the compression testing machine.

(1) Preparations ① Record the name, place and grain size of the proppant and the gas viscosity at room

temperature on the attachement I. ② Measure the outside diameter of the rock core and the internal diameter of the penetrated

hole in the rock core with vernier scale, then record them on the attachement I to calculate the area of the rock core.

③ Weigh a certain proppant (recording the grain size) and lay them on the core surface, be sure to keep them in a single layer, then observe whether the proppant’s distribution

are uniform and tight or not with magnifier. Then weigh the remaining proppant, the difference is the weight of the proppant layed on the core. Calculate the proppant concentration using the following formula.

(g/cm2)

record this data on the attachement I ④ Put the upper core (the penetrated hole should be downard) above the lower core, then

put them together to the center of the compression testing machine.


proppantwithareaCore

layersingletheofweightProppantionConcentrat



⑤ Record the load data showed on the compression testing machine panel.(2) Core Loading

① Put core on the lower bearing plate, rotate the screw with hands to clamp the upper and lower bearing plate together, then loading.

② Tighten up the scavenge valve and turn on the green button to start the machine. Loading slowly by the oil supply valve, control the loading rate by adjusting the oil supply valve’s openness. When the indicator reach to 1.5t (or 1kN), then slow down the opening operation and keep it at the current state. Open the value setter and let the gas enter into the flow meter, then adjust the value setter and let the flow meter reach to the maximum value.

③ Continue to operate the oil supply valve. When the indicator reach to the desired value, then keep it in a stable state and record the flow rate and pressure on the attachment III.

④ Load should be exerted successively, 3ton, 5ton, (7ton), 10ton, (12ton), 15ton, (18ton), 20ton, 25ton, 30ton; or 30KN, 50KN, (70KN), 100KN, (120KN),150KN, (180KN), 200KN, 250KN, 300KN;then record the flow rate and pressure at each run and calculate the results. ⑤ After the experiment, close the oil supply valve, turn off the power supply, open the scavenge valve to unload, take out of the core and observe the broken state of the proppant.

⑥ Measure the double layer proppant: lay a twice weight of proppant on the core, then following the steps (2), record the flow rate and pressure at the different load on the attachment III and II.



ReportReport

The report should include:

(1) the purposes and principles of the experiment;

(2) the experimental data

(3) the calculation formula and the calculation process

(4) the curve of versus

(5) the flow schematic

(6) Based on the pressure and flow rate data at a closure stress, calculte the result with the

binary formula( ) and draw the curve with as Y-axis and as X-

axis, then obtain the intercept value A. Then use A ( ) to calculate the and

compare it with the value obtained by Darcy's formula

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production engineering experiment

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