Tu l s a U n i v e r s i t y A r t i f i c i a l L i f t P ro j e c t s 60th Advisory Board Meeting Age nda N o v e mb e r 5 t h & 6 t h , 2 0 1 5 A l l e n C h a p ma n S t u d e n t C e n t e r – 4 4 0 S o u t h G a r y Av e T h e U n i v e r s i t y o f Tu l s a , Tu l s a , O K Thursday, November 5th , 2015 4:00pm Facilities Tour with Refreshments in Alpine House TU North Campus 6:00pm Reception Allen Chapman Student Union, Chouteau C Friday, November 6th , 2015 8:30am Registration and Breakfast Allen Chapman Student Union, Alcove Progress Report Meeting 9:00 Welcome and Review of TUALP Research Projects Holden Zhang 9:30 Experimental Study and CFD Simulation of ESP Performance under Gassy Conditions Jianjun Zhu 10:10 CFD Simulation of Oil Viscosity Effect on Multi-Stage ESP Performance Jianjun Zhu 10:30 Coffee Break 10:45 Experimental Study of Viscosity Effect and Oil/Water Flow in ESP Hattan Banjar 11:15 Modeling of Transient Operations and Instabilities in Gas Lift Fahad Al-Mudairis 12:00pm Lunch 1:00 Transient Plunger Lift Modeling Allen Chapman Student Union, Chouteau C Weiqi Fu 1:20 Downhole Gas-Liquid Separation Literature Review and Research Plan Haiwen Zhu 1:45 Eccentric Pipe-in-Pipe Downhole Gas Separator for ESP – New Designs Holden Zhang 2:10 2015 Questionnaire Results and New Project Plan Holden Zhang 2:30 Business Report and Open Discussions Holden Zhang 2:40pm Adjourn Tulsa University Artificial Lift Projects Welcome to the TUALP 60th ABM Holden Zhang McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 TUALP 60th ABM TUALP 60th Advisory Board Meeting Handout All presentations on thumb drive Will be posted on TUALP website after ABM for download by members who cannot attend (www.tualp.utulsa.edu) 60th Advisory Board Meeting November 6, 2015 Our Team Holden Zhang Director Bryan Sams Project Engineer Donna Trankley Project Assistant 60th Advisory Board Meeting November 6, 2015 Our Team… Jianjun Zhu PhD candidate Hattan Banjar PhD candidate Sponsored by Saudi Aramco Saul Gomez PhD student Sponsored by PEMEX 60th Advisory Board Meeting November 6, 2015 Our Team… Fahad Al-Mudairis PhD candidate Sponsored by Kuwait University Haiwen Zhu PhD candidate, TA Congratulations to Fahad and Haiwen for passing qualifying exams!! 60th Advisory Board Meeting November 6, 2015 Our Team… Weiqi Fu MSc student Jiecheng Zhang MSc student Yuchen Ji MSc student 60th Advisory Board Meeting November 6, 2015 Our Team… Dr. Junqi Wang Xian Petroleum University (Xian, China) Joining at end of this month Dr. Jie Liu Yangtze University (Wuhan, China) Joining at end of this year 60th Advisory Board Meeting November 6, 2015 Guests AppSmiths Larry Peacock Borets Bert McCoy Dover Paul Song eLynx Tech Ryan McDonald Summit ESP Walter Dinkins Louis Lee 60th Advisory Board Meeting November 6, 2015 2015 TUALP Members Baker Hughes Chevron GE KOC Pemex Petrobras PetroChina Petroleum Experts Schlumberger Statoil 60th Advisory Board Meeting November 6, 2015 Possible New Members Instituto Mexicano del Petroleo (IMP) eLynx Tech 60th Advisory Board Meeting November 6, 2015 Agenda Time Topic Presenter 9:00am Welcome Holden Zhang 9:10 Industry Challenges and Our Researches Holden Zhang 9:30 Experimental Study and CFD Simulation of ESP Performance under Gassy Conditions Jianjun Zhu 10:10 CFD Simulation of Oil Viscosity Effect on MultiStage ESP Performance Jianjun Zhu 10:30 Coffee Break 10:45 Experimental Study of Viscosity Effect and Oil/Water Flow in ESP Hattan Banjar 11:15 Modeling of Transient Operations and Instabilities in Production Fahad Al-Mudairis 12:00pm Luncheon All 60th Advisory Board Meeting November 6, 2015 Agenda… Time Topic Presenter 1:00 Transient Plunger Lift Modeling Weiqi Fu 1:20 Downhole Gas-Liquid Separation Literature Review and Research Plan Haiwen Zhu 1:45 Eccentric Pipe-in-Pipe Downhole Gas Separator for ESP – New Designs Holden Zhang 2:10 2015 Questionnaire Results and New Project Discussion Holden Zhang 2:30 Business Report and Open Discussions Holden Zhang 2:40pm Adjourn All 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects Industry Challenges and Our Researches Holden Zhang McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Industry Needs Efficiency and optimization Cost reduction More important at low oil price Reliability and flow assurance Best models for multiphase flow in artificial lift systems Best design and selection rely on accurate characterization 60th Advisory Board Meeting November 6, 2015 Industry Needs… New challenges High oil viscosity, HPHT, emulsions Horizontal well, slugging, fast decline… New developments Smart wells Mechanistic models of multiphase flow in pipes and artificial lift systems serve as backbone simulator for data interpretation, diagnosis, prediction and control 60th Advisory Board Meeting November 6, 2015 High Oil Viscosity and Oil/Water Emulsion in ESPs Oil viscosity affects ESP performance Significantly Oil/water emulsion rheology complicated Effective viscosity Inversion point Droplet size Stage effect 60th Advisory Board Meeting November 6, 2015 TUALP Project (PI: Hattan Banjar) Study of oil/water flow and emulsion characterization in ESPs Measure ESP stage performance Oil viscosity effect Mechanistic modeling CFD simulation Three-phase flow? 60th Advisory Board Meeting November 6, 2015 Gas Entrainment in ESP ESP performance degradation Gas lock and instabilities Poor heat transfer 60th Advisory Board Meeting November 6, 2015 TUALP Project (PI: Jianjun Zhu) Experimental study and CFD simulation of ESP performance under gassy conditions Measurements Surfactant effect CFD simulations Mechanistic modeling 60th Advisory Board Meeting November 6, 2015 High Oil Viscosity Effect on ESP Performance High-viscosity oil and oil/water flow loop to be built, 3”, 10,000 bpd 60th Advisory Board Meeting November 6, 2015 TUALP Project (PI: Holden Zhang) Mechanistic modeling of ESP performance Based on overall pump geometry, fluid viscosities, densities, interfacial tension and flow rates High oil viscosity Gas-liquid flow Oil-water flow Gas-oil-water flow 60th Advisory Board Meeting November 6, 2015 Sand Production with ESP Sand erosion Abrasion ESP performance change 60th Advisory Board Meeting November 6, 2015 TUALP Project (PI: Saul Gomez) Experiments and CFD simulation of ESP sand erosion Experimental measurement and observation CFD simulation of sand particle trajectory and accumulation Identify areas vulnerable to sand erosion 60th Advisory Board Meeting November 6, 2015 Casing Heading in Gas Lift Commonly exist in gas lift wells Reduce production rate Consume more compressed gas and power Intermittent flow 60th Advisory Board Meeting November 6, 2015 TUALP Project (PI: Fahad Al-Mudairis) Transient gas lift modeling Develop a transient model to simulate various unsteady/unstable gas lift processes Liquid unloading with gas lift Analyze gas lift instabilities 60th Advisory Board Meeting November 6, 2015 New Design – Self-Stabilizing Gas Lift Valve Self stabilized by flow Small pressure drop Can avoid damage due to high pressure drop and high shear Patent pending 60th Advisory Board Meeting November 6, 2015 Liquid Loading in Gas Well Reduce production rate Eventually kill well 60th Advisory Board Meeting November 6, 2015 TUALP Project (PI: Weiqi Fu) Plunger lift modeling and optimization Transient mechanistic model Cover all phases of plunger lift cycle Incorporate inflow and pipeline to separator 60th Advisory Board Meeting November 6, 2015 Downhole Gas Separation ESP doesn’t like gas Separation limited by space Separation affected by slugging Most current methods have limitations Low efficiency High resistance Poor slug handling High power consumption …… 60th Advisory Board Meeting November 6, 2015 TUALP Project (PI: Haiwen Zhu) Experimental study and CFD simulation of downhole gas separation Evaluate different downhole gas separation methods Select best design Performance modeling 60th Advisory Board Meeting November 6, 2015 New Design – Eccentric Pipe-inPipe Downhole Gas Separator High efficiency and low cost Low pressure drop Sufficient length for slug elimination Sand handling 60th Advisory Board Meeting November 6, 2015 Horizontal Well Challenges Liquid loading Terrain slugging (or severe slugging) Artificial lift location Rapid decline 60th Advisory Board Meeting November 6, 2015 Smart Field Development Data interpretation Problem diagnosis Sensor optimization Control algorithm 60th Advisory Board Meeting November 6, 2015 TUALP Mechanistic Models Mechanistic models for multiphase pipe flow Steady state unified model Transient unified model Mechanistic models for multiphase flows in artificial lift systems ESP SRP Valves Separators Serve as engine for online and offline simulations 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects Experiments, CFD Simulation and Modeling of ESP Performance under Gassy Conditions Jianjun Zhu McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Application Entrained gas deteriorates ESP performance and causes gas locking Mechanistic models needed to predict ESP performance under gassy flow conditions CFD simulations help better understand degradation mechanism Experimental data needed to compare with simulation results and validate model predictions 60th Advisory Board Meeting November 6, 2015 Objectives Test ESP performance under gassy condition Investigate effects of multistage, viscosity, intake GVF and pressure, interfacial tension, etc. CFD simulations of ESP performance Mesh quality and numerical accuracy Intake hydraulic parameters Develop mechanistic models for predictions of Bubble size In-situ gas void fraction (α) Initiation of gas pocket ESP two-phase performance 60th Advisory Board Meeting November 6, 2015 Outline Experimental study update Facility modification Experimental test results Mechanistic modeling update Bubble size prediction In-situ gas void fraction (α) Conclusions and discussions Near future work 60th Advisory Board Meeting November 6, 2015 Experimental Study Update Facility modification Fully closed loop has been replaced by semiclosed loop with the external supplement of compressed air Air compressor was adopted with capacity 186 cfm @ 217 psig Venturi pipe was replaced with straight pipe Fitting for bubble size measurement instrument (e.g. PVM or FBRM) 60th Advisory Board Meeting November 6, 2015 Experimental Facility Update… Schematic of new loop NI Fieldpoint Modules Computer Data Wiring Box PT Surfactant Injection P T Air Compressor VSD Coriolis Flow Meter Vent Separator Syringe Pump RFT9739 Flow Control Valve Coriolis Flow Meter RFT9739 Torque & Rotary Speed Monitor T Motor P P P DP DP ESP TE2700 GE 60th Advisory Board Meeting P T Flow Control Valve November 6, 2015 Experimental Facility Update… LabView-based DAQ (front panel) 60th Advisory Board Meeting November 6, 2015 Experimental Facility Update… Water flow rate PID control (front panel) 60th Advisory Board Meeting November 6, 2015 Experimental Facility Update… Water flow rate PID control (rear panel) 60th Advisory Board Meeting November 6, 2015 Experimental Facility Update… Air flow rate PID control (front panel) 60th Advisory Board Meeting November 6, 2015 Experimental Facility Update… Air flow rate PID control (rear panel) 60th Advisory Board Meeting November 6, 2015 Experimental Facility Update… Bubble size measurement considered Particle Vision & Measurement (PVM) Probe based instrument Visualize particles and particle behavior 60th Advisory Board Meeting November 6, 2015 Experimental Facility Update… Bubble size measurement considered Focused Beam Reflectance Measurement (FBRM) Focused laser scans Tracks individual chord lengths to acquire particle size and population information in real time In-situ measurement 60th Advisory Board Meeting November 6, 2015 Experimental Test Matrix Single phase test matrix Rotational Speed (rpm) 3500, 3000, 2400, 1800 Liquid Flow Rate (bpd) 0, 100, 200, … Two phase test matrix Surfactant Rotational Intake Pressure Concentration Speed (rpm) (psig) Liquid Flow Rate (bpd) Gas Flow Rate (lb/m) 0% 3500, 1800 50, 100, 150 0, 100, 200, … 0.01, 0.02, 0.03, …, 0.5 1% 3500, 1800 50, 100, 150 0, 100, 200, … 0.01, 0.02, 0.03, …, 0.5 2% … 3500,1800 50, 100, 150 0, 100, 200, … 0.01, 0.02, 0.03, …, 0.5 60th Advisory Board Meeting November 6, 2015 Experimental Matrix Nomenclature Qmax coefficient = Qmax/N, is a constant for ESP, but will change due to rusty condition Qmax is the open flow capacity of ESP with zero-head performance qld , qgd are dimensionless variables – ratio of actual fluid flow rates (bpd) to the maximum flow rates of single-phase water in ESP 𝒒𝒍𝒅 𝑸𝒍 = 𝑸𝐦𝐚𝐱 𝒒𝒈𝒅 60th Advisory Board Meeting 𝑸𝒈 = 𝑸𝐦𝐚𝐱 November 6, 2015 Experimental Matrix… Qmax coefficient (Qmax/N) 60th Advisory Board Meeting November 6, 2015 Air Properties Based on CIPM-81 Density pM a ZRT MV 1 xv 1 M a M a 28.9635 12.011 xCO2 0.0004 D pSV 1 exp AT 2 BT C T f p t 2 Kg/m3 g/mol Pa pSV t pSV t r xV hf p, t f p, t r p p 60th Advisory Board Meeting November 6, 2015 Air Properties… Compressibility Z p p2 2 2 Z 1 a0 a1t a2t b0 b1t xV c0 c1t xV 2 d exV2 T T Constants A 0.000012811805 a0 0.00000162419 B -0.019509874 a1 -0.000000028969 C 34.04926034 a2 0.0000000001088 D -6.3536311 b0 0.000005757 b1 -0.00000002589 α 1.00062 c0 0.00019297 β 0.0000000314 c1 -0.000002285 γ 0.00000056 d 0.0000000000173 e -0.00000001034 60th Advisory Board Meeting November 6, 2015 Isopropyl Alcohol (IPA) A surfactant that reduces interfacial tension between water and air 60th Advisory Board Meeting November 6, 2015 Single-phase Test Results 100 psig, stage 6 60th Advisory Board Meeting November 6, 2015 Single-phase Test Results 3500 rpm, 100 psig 60th Advisory Board Meeting November 6, 2015 Single-phase Test Results 3500 rpm, 150 psig 60th Advisory Board Meeting November 6, 2015 Surging Test Results 100P3500N2700QL 60th Advisory Board Meeting November 6, 2015 Surging Test Results… 50P3500N2700QL 60th Advisory Board Meeting November 6, 2015 Surging Test Results… 150P3500N2700QL 60th Advisory Board Meeting November 6, 2015 Surging Test Results… 150P3500N2700QL & 5 % isopropyl alcohol 60th Advisory Board Meeting November 6, 2015 Surging Test Results… Comparison at average stage 1 and 2 60th Advisory Board Meeting November 6, 2015 Surging Test Results… Comparison at stage 3 60th Advisory Board Meeting November 6, 2015 Constant GVF Mapping Test 100P3500N, stage 3 60th Advisory Board Meeting November 6, 2015 Constant GVF Mapping Test… 100P3500N, stage 7 60th Advisory Board Meeting November 6, 2015 Constant GVF Mapping Test… 100P3500N, stage 0-12 60th Advisory Board Meeting November 6, 2015 Constant qgd Mapping Test 100P3500N, stage 0-2 60th Advisory Board Meeting November 6, 2015 Constant qgd Mapping Test… 100P3500N, stage 7 60th Advisory Board Meeting November 6, 2015 Constant qgd Mapping Test… 150P3500N, stage 0-2 60th Advisory Board Meeting November 6, 2015 Constant qgd Mapping Test… 150P3500N, stage 3 60th Advisory Board Meeting November 6, 2015 Multiphase CFD Simulation Predicted ESP performance with modified bubble size model at BEP 1.2 0.02 mm 0.05 mm Normalized Pressure 1 0.06 mm 0.07 mm 0.1 mm 0.8 0.11 mm 0.6 0.125 mm 0.4 0.14 mm Salehi (2012) 0.2 Constant bubble size_0.1 mm 0.185 mm Modified bubble size_Drag force only Modified bubble size_Drag force+Lift force 0.19 mm 0 0 4 8 12 16 20 λG (%) 60th Advisory Board Meeting November 6, 2015 Bubble Size Modeling Existing models Murakami and Minemura (1974) N d m 21.82 6.862 3 4 0.618 4.273 Barrios (2007) d b _ surg 0.8809 1 / 4 0.0348 N l Gamboa (2008) d max 14.27 l 3/ 5 D 4 2 / 5 3/ 5 l g 1 N r 3 2 2/ 5 1 60th Advisory Board Meeting 1/ 5 1 191.7 0.2 November 6, 2015 Bubble Size Modeling… Modified bubble size prediction model Levich (1962) droplet breakup theory Wecrit by Kouba’s (2003) model Turbulent kinetic energy (e ) from Padron’s (2005) postulation d max 14.06 c 3/ 5 Pq cV 2 / 5 d 32 0.43d max 6.034 c 3/ 5 c d 1/ 5 Pq cV 60th Advisory Board Meeting 2 / 5 c d 1/ 5 November 6, 2015 Bubble Size Modeling… Model comparison with CFD simulation QL= 2700 bpd, 3500 rpm (TE2700) 0.6 Murakami & Minemura (1974) Barrios (2007) Gamboa (2008) Simulation_Drag force Simulation_Drag force+Lift force This study 0.5 db (mm) 0.4 0.3 0.2 0.1 0 0 3 6 9 12 15 18 λG (%) 60th Advisory Board Meeting November 6, 2015 Bubble Size Modeling… Model validation with CFD simulation QL= 1157 bpd, 1500 rpm (TE2700) 0.5 0.4 db (mm) 0.3 0.2 Murakami & Minemura (1974) Barrios (2007) 0.1 Gamboa (2008) This study 0 0 2 4 6 8 10 12 14 16 λG (%) 60th Advisory Board Meeting November 6, 2015 Bubble Size Modeling… Predicted ESP performance with modified bubble size model at off-design point 1 0.8 Np 0.6 0.4 0.2 Experiment_Salehi (2012) Simulation with predicted bublbe sizes 0 0 2 4 6 8 10 12 14 16 λG (%) 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling Empirical correlations Chisely (1997) 0.07 0.36 0.64 1 x g L 1 0.28 x L g Estevam (2002) Zapata (2003) 1 1 1 0.5 q q g L qmax qmax N 0 . 598 0 . 223 N 1.277 0.034N N 60th Advisory Board Meeting 1 0.921 0.068N N November 6, 2015 Gas Void Fraction (α) Modeling… Pros and cons of correlations Easy to implement Empirical Poor extrapolation Lack of interacting mechanism between gas and liquid 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… Zhang (2013) proposed mechanistic modeling of α inside ESP Centrifugal buoyancy force on a gas bubble FC d B3 6 FD L G RI 2 Drag force due to slippage 2 VSR d B2 FD C D L 2 4 FC ω dB - bubble diameter RI - impeller representative radius CD - drag coefficient VSR - bubble slip velocity in radial direction 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… From force balance on gas bubble d B3 2 2 V d L G RI 2 C D L SR B 6 2 4 Radial bubble slip velocity VSR 4d B L G RI 2 3C D L VSR in ESP impeller can be written as VSR VLR VGR Q QLK 1 2RI Z I TB YI 1 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… Equalize two expressions of VSR Q QLK 1 2RI Z I TB YI 1 4d B L G RI 2 3C D L Rearrange and denote RS 4d B L G RI 2 3C D L 2RI Z I TB YI Q QLK Then, one can get 1 Rs RS 2 1 RS 0 1 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… Solve for α and discard negative root: RS 1 1 RS 2 4 RS 2 RS Questions How to determine dB? How to calculate CD? How to validate mechanistic modeling? 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… dB ̶ bubble diameter Bubble size predicted by new model of this study d 32 6.034 c 3/ 5 Pq cV 2 / 5 c d 1/ 5 CD ̶ drag coefficient Most CD models have no consideration of rotating/shear effects Few experimental data for CD in ESP 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… Existing models for CD Clift et al. (1978) No shear effect! Mei et al. (1994) CD 24 0.42 1 0.15 Re 0.687 Re 1 4.25 104 Re 1.16 1 16 8 1 CD 1 1 3.315 Re 2 Re Re 2 1 Legendre and Magnaudet (1998) Shear effect considered 0.55 C D , sr C D ,0 1 2 Sr Sr d b U v Re 50 Rastello et al. (2011) 0.3 C D , sr C D ,0 1 2.5 Sr 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… CD ̶ drag coefficient Legendre and Magnaudet (1998) model for Re ≥ 50, and Rastello et al. (2011) model for Re < 50 are used: C D , sr 0.55 C 1 Re 50 D ,0 2 Sr C D ,0 1 0.3 Re 50 Sr 2.5 CD,0 is drag coefficient calculated without shear effect, Clift et al. (1978) model is used C D ,0 24 1 0.15 Re 0.687 Re 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… Model validation and comparison 3500 rpm, 2700 bpd & 1500 rpm, 1157 bpd 60 3500RPM_Simulaiton 3500RPM_Model 50 1500RPM_Simulaiton 1500RPM_Model αG 40 30 20 10 0 0 4 8 12 16 20 λG 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… Model validation and comparison Case I: 3500 rpm, 2700 bpd 60 Chisely (1997) +25% Estevam (2002) Zapata (2003) 50 3500RPM_This study -10% Perfect line αG,predicted 40 30 20 10 0 0 10 20 30 40 50 60 αG,simulation 60th Advisory Board Meeting November 6, 2015 Gas Void Fraction (α) Modeling… Model validation and comparison Case II: 1500 rpm, 1157 bpd 60 Chisely (1997) +25% Estevam (2002) Zapata (2003) 50 1500RPM_This study -10% Perfect line αG,predicted 40 30 20 10 0 0 10 20 30 40 50 60 αG,simulation 60th Advisory Board Meeting November 6, 2015 Conclusions and Discussions Experiments of TE2700 ESP under gassy conditions were conducted Effects of intake pressure, GVF, rotary speed, surfactants etc. were investigated Mechanistic modeling of bubble size inside ESP and local gas void fraction was validated by multiphase CFD simulation 60th Advisory Board Meeting November 6, 2015 Near Future Plan Facility modification Replace old TE2700 with the new one from GE 60th Advisory Board Meeting November 6, 2015 Near Future Work… Experimental work Run testing with different IPA concentrations Dynamic operation to observe transient phenomenon (fluctuations of flow rates and performance etc.) Mechanistic modeling Surging initiation modeling Flow pattern prediction Comprehensive model for predicting ESP twophase performance 60th Advisory Board Meeting November 6, 2015 Near Future Work… CFD simulation Unsteady state simulation of ESP dynamic phenomenon MUSIG (multiple size group), poly-dispersed phases (oil, water and gas), multi-momentumtransfer mechanisms (virtual mass force, turbulence dispersion force, wall lubrication force etc.) 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects CFD Simulation of Oil Viscosity Effect on Multi-stage ESP Performance Jianjun Zhu and Hattan Banjar McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Application Significant effects of fluid viscosity on ESP performance Only water performance available Actual flow condition very different Prediction model for ESP performance under higher fluid viscosity and multiphase flow conditions needed for production design and artificial lift integration 60th Advisory Board Meeting November 6, 2015 Outline Experimental study CFD simulation Geometry and mesh Single-phase water Viscosity effect Streamline comparison Conclusions and discussions 60th Advisory Board Meeting November 6, 2015 Experimental Study Banjar (2015) experimental facility 60th Advisory Board Meeting November 6, 2015 ESP Geometry and Mesh ESP geometry DN 1750, Schlumberger Series 400, BEP: 1750 bpd at 3500 rpm Specific speed: 2900 (mixed type) 60th Advisory Board Meeting November 6, 2015 ESP Geometry and Mesh DN1750 3D model Mesh generation Seven stage cascade assembly 60th Advisory Board Meeting November 6, 2015 Mesh Validation Wall function 𝒚+ < 𝟏𝟎, 𝒖+ =𝒚+ 𝟏 𝜿 𝟏𝟎 < 𝒚+ < 𝟏𝟎𝟎, 𝒖+ = 𝐥𝐧(𝒚+ ) + 𝑪 𝒚+ = 𝒖𝝉 𝒚 𝝂 𝒖+ = 𝒖 𝒖𝝉 500 9.2 400 8.9 300 8.6 200 𝑴𝒂𝒙 𝒚+ 8.3 100 12.00 10.00 8.00 ΔP (psi) 9.5 Y+ (blade surface) Pressure Increment (psi) Turbulence model: SST (shear-stress-transport) 6.00 4.00 2.00 𝑨𝒗𝒆 𝒚+ 8 0 200000 400000 600000 0 800000 0.00 1000 Experimental KE SST BSL KOmega RNGKE 1200 1400 1600 1800 2000 Q (bpd) Mesh Number 60th Advisory Board Meeting November 6, 2015 2200 Comparison with Catalog Curves Dimensionless group Q D 3 gH 2 D2 3 D 5 0.4 80 0.3 60 0.2 ψ Phorsepower 40 𝜺 = 𝟐𝟓𝟎𝝁𝒎 0.1 η 20 π 0.05 0 0 0.1 0.12 0.14 0.16 0.18 0.2 φ 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement 56 cp oil, overall performance of 7 stages 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… 56 cp oil, performance of stage 3 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… 220 cp oil, overall performance of 7 stages 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… 220 cp oil, performance of stage 3 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… Water +10% -10% 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… 56 cp +15% -10% 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… 98 cp +15% -10% 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… 180 cp +15% -10% 60th Advisory Board Meeting November 6, 2015 CFD Simulation vs Measurement… 220 cp +15% -10% 60th Advisory Board Meeting November 6, 2015 Streamline Comparison 3500 rpm, 0.4QBEP, 0.5 span Water 56 cp 60th Advisory Board Meeting 220 cp November 6, 2015 Streamline Comparison 2000 rpm, 0.25QBEP, 0.5 span Water 56 cp 60th Advisory Board Meeting 220 cp November 6, 2015 Conclusions and Discussions Steady state CFD simulation results of ESP performance with water are comparable to catalog curves and experimental data CFD simulation can capture trend of ESP performance with viscosity increase CFD simulation over predicts ESP performance at higher oil viscosity with up to 15% error 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects Experimental Study of Viscosity Effect and Oil/Water Flow in ESPs Hattan Banjar McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Outline Application Experimental system Experimental program Mechanistic modeling Experiment results Project schedule 60th Advisory Board Meeting November 6, 2015 Application Fluid viscosity affects ESP performance significantly Oil/water emulsion rheology depends on: Oil and water properties Water fraction Droplet characteristics (shear, mixing, etc) Prediction model for ESP performance under oil/water emulsion flow conditions needed for production design and artificial lift integration 60th Advisory Board Meeting November 6, 2015 Experimental System Improvements: Choke valve relocated Entrance length of pipe viscometer extended 60th Advisory Board Meeting November 6, 2015 Experimental System… Improvements: Pressure ports drilled horizontally to the flow Temperature probes separated from pressure measurement lines and moved from ESP to upstream and downstream 60th Advisory Board Meeting November 6, 2015 Experimental System… Current flow loop schematic 60th Advisory Board Meeting November 6, 2015 Experimental System… DAS (LabVIEW 2013) Speed control Choke valve control 60th Advisory Board Meeting November 6, 2015 Experimental System… Pipe viscometer 60th Advisory Board Meeting November 6, 2015 Experimental System… Pipe viscometer Effective viscosity of emulsion (laminar) 𝒅𝑷(𝑷𝒂) 𝝅𝑫𝟒 𝒅𝑷 𝒄𝑷 = 𝟐𝟏. 𝟕𝟐𝟏 𝝁𝒆 = ⇒ 𝝁𝒆 (𝒄𝑷) 𝟐𝟕. 𝟕𝟓𝟓 𝑸(𝑩𝑷𝑫) 𝟏𝟐𝟖𝑸 𝒅𝑳 60th Advisory Board Meeting November 6, 2015 Experimental System… Measuring emulsion droplet sizes? Particle Video Microscope (PVM) Droplet images Focused Beam Reflectance Measurement (FBRM) Reflected pulses measure droplet chord length 60th Advisory Board Meeting November 6, 2015 Experimental Program Test Fluids Tap water Mineral oil ISOPARTM V DN-20 Aquamarine-460 60th Advisory Board Meeting November 6, 2015 Experimental Program… Viscosity 60th Advisory Board Meeting November 6, 2015 Experimental Program… Test Conditions Pump inlet pressure: ~50 psig Motor speed: 3500, 3000, 2500 and 2000 rpm Heat exchanger to maintain temperature Starting from 100% water (oil) by volume, water (oil) is replaced by oil (water) step by step 60th Advisory Board Meeting November 6, 2015 Experimental Program… Oil and water ratios: Obtain mixture density from flowmeter 𝝆𝒎 = 𝝆𝒘 𝒇𝒘 + 𝝆𝒐 (𝟏 − 𝒇𝒘 ) Sampling 𝟐𝟒 𝒉𝒐𝒖𝒓𝒔 60th Advisory Board Meeting 𝑯𝒆𝒂𝒕 𝟏 𝒎𝒐𝒏𝒕𝒉 November 6, 2015 Mechanistic Modeling Develop mechanistic model for prediction of ESP performance under high viscosity and oil/water flows Based on physics Verify with experimental data Easy to use 60th Advisory Board Meeting November 6, 2015 Experimental Results 60th Advisory Board Meeting November 6, 2015 Experimental Results… 60th Advisory Board Meeting November 6, 2015 Experimental Results… 60th Advisory Board Meeting November 6, 2015 Experimental Results… 60th Advisory Board Meeting November 6, 2015 Experimental Results… 60th Advisory Board Meeting November 6, 2015 Pipe Viscometer 60th Advisory Board Meeting November 6, 2015 Pipe Viscometer… 60th Advisory Board Meeting November 6, 2015 Pipe Viscometer… 60th Advisory Board Meeting November 6, 2015 Pipe Viscometer… 60th Advisory Board Meeting November 6, 2015 Project Schedule 2014 Q1 Q2 Q3 2015 Q4 Q1 Q2 Q3 2016 Q4 Q1 Q2 Q3 2017 Q4 Q1 Q2 Q3 Q4 DAS Communication Literature Review Facility Upgrade 1 Two Phase Experiments Two Phase CFD Simulation Facility Upgrade 2 Three Phase Experiments Three Phase CFD Simulation Modeling and Model Validation 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects Modeling of Transient Operations and Instabilities in Production Operations Fahad Al-Mudairis McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Outline Objectives Unified model transient extension Transient simulator applications Graphical interface Conclusions Future works 60th Advisory Board Meeting November 6, 2015 Objectives Develop transient gas-liquid flow model for simulation and analysis of various steady and unsteady state production processes A tool for design and optimization Help estimate steady state stabilization times Compare with experiments, field data and transient simulators 16 160 Superficial Velocity (m/s) Outlet gas Bottomhole pressure 140 12 120 10 100 8 80 6 60 4 40 2 20 0 Pressure (bara) Outlet liquid 14 0 0 2 4 8 10 60th6Advisory Board Meeting t (hr) 12 14 16 November 6, 2015 Steady State Zhang et al. (2003) Unified Model 60th Advisory Board Meeting November 6, 2015 Steady State Zhang et al. (2003) Unified Model… Inputs: Pipe inner diameter Pipe roughness Inclination angle Liquid and gas densities Liquid and gas viscosities Surface tension Liquid and gas flow rates Inlet pressure Inlet temperature 60th Advisory Board Meeting November 6, 2015 Steady State Zhang et al. (2003) Unified Model… Outputs: Pressure profile Temperature profile Flow pattern Liquid holdup Local and superficial velocities Slug characteristics Wetted wall fraction …….. 60th Advisory Board Meeting November 6, 2015 Unified Model Transient Extension Mass and momentum conservations are function of time 60th Advisory Board Meeting November 6, 2015 Unified Model Transient Extension Initial conditions are calculated using the steady-state Unified Model Fluid properties are calculated at each time step Pressure and temperature profiles are estimated simultaneously 60th Advisory Board Meeting November 6, 2015 Transient Model Outputs Inputs Unified Transient 60th Advisory Board Meeting November 6, 2015 Transient Simulator Modifications and Applications Original transient simulator for single pipe Integrating heat transfer model Basic transient operations Gas-lift instabilities: Gas-injection at bottomhole Gas-lift with variable valve position Gas-lift with multiple valves Self-stabilizing valve (Zhang and Arellano, 2014) Pump intake pressure depletion for bounded reservoir 60th Advisory Board Meeting November 6, 2015 Original Transient Simulator for Single Pipe Transient Unified Model for single pipe gas-liquid flow at all inclination angles 60th Advisory Board Meeting November 6, 2015 Integrating Heat Transfer Model Need to solve the pressure and temperature dependency Get pwf for given Q Get Tbh for given temperature gradient Guess pi+1 and calculate pavg Guess Ti+1 and calculate Tavg Calculate fluid properties at pavg and Tavg Calculate Ti+1 using heat transfer model Calculate pi+1 using transient model 60th Advisory Board Meeting November 6, 2015 Example of Heat Transfer Model Predictions 60th Advisory Board Meeting November 6, 2015 Basic Transient Operations Gas or liquid flow rate change Liquid blow down 60th Advisory Board Meeting November 6, 2015 Minami 1991 60th Advisory Board Meeting November 6, 2015 Example of Basic Transient Operations Gas flow rate change 0.14 5 QG (m3/sec) 0.10 4 QG 3 0.08 0.06 2 QLout 0.04 1 0.02 0.00 QL(x10-3 m3/sec) 0.12 0 0 500 Elapsed Time (sec) 1000 1500 Liquid blow down 5 QG 0.10 4 0.08 3 0.06 2 0.04 QLout 0.02 1 0.00 0 0 500 1000 58th Advisory Board Meeting Elapsed Time (sec) 1500 October 9, 2014 QL(x10-3 m3/sec) Qg (m3/sec) 0.12 Gas-lift Instabilities Gas lift instabilities (casing heading) Tubing pressure decreases due to gas injection Gas injection becomes higher than needed due to tubing pressure decrease and gas in the annulus expands Annulus pressure is depleted followed by lower or no gas injection and tubing pressure builds up Annulus pressure builds up and new cycle repeats 1 2 3 9 8 7 6 5 4 3 2 1 0 140 120 100 80 60 40 2 1 3 20 Bottom hole pressure (bara) Outlet v SG (m/s) 4 0 1 1.5 2 2.5 3 t (hr) 3.5 60th Advisory Board Meeting 4 4.5 5 November 6, 2015 Gas-injection at Bottomhole 1: Gas injection valve: 2: Gas-lift valve: 3: Surface valve: 60th Advisory Board Meeting November 6, 2015 OLGA Hypothetical Well 60th Advisory Board Meeting November 6, 2015 Example of Gas-injection at Bottomhole 150 OLGA Simulations New Model 140 130 120 p (bara) 110 100 90 80 70 Gas injection rate = 0.6 kg/s Gas injection rate = 0.8 kg/s 60 50 40 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 t (hr) 60th Advisory Board Meeting November 6, 2015 Gas-lift with Variable Valve Position 4: Interval below gas-lift valve Get pwf for given Q Calculate pressure drop for casing interval Get pressure at tubing end Calculate pressure drop for tubing interval up to gas-lift valve Get pressure at gas-lift valve Integrate the calculated value into the previous model 60th Advisory Board Meeting November 6, 2015 Example of Variable Valve Position Maloob Field Poblano et al. (2002) 60th Advisory Board Meeting November 6, 2015 Stability Map by Poblano et al. (2002) for Maloob Field Data 60th Advisory Board Meeting November 6, 2015 Predicted Results when Switching to Point 2 in Maloob Well 10 100 Outlet liquid 9 Outlet gas Bottomhole Pressure 90 8 80 6 5 70 p (bara) vSL & vSG (m/s) 7 4 60 3 2 50 1 0 0 200 400 600 t (minutes) 60th Advisory Board Meeting 800 1000 40 1200 November 6, 2015 Predicted Results when Switching to Point 3 in Maloob Well 6 94 Outlet liquid Outlet gas Bottomhole Pressure 92 5 90 88 86 3 84 2 p (bara) vSL & vSG (m/s) 4 82 80 1 78 0 0 200 400 600 t (minutes) 60th Advisory Board Meeting 800 1000 76 1200 November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #1 Perforation interval (ft) 7622-7752 Wellhead pressure (psig) 134-166 Water cut (%) 33% Casing diameter (in) 9.625 Tubing diameter (in) 3.5 Tubing depth (ft) 7528 Gas injection specific gravity 0.884 Oil API 32.7 Reservoir pressure (psig) 2100 Productivity index (bpd/psig) 0.5 Oil flow rate (bbl/day) 1012-1602 GOR (SCF/STB) 482-757 Injection flow rate (MMSCF/day) 0.2-0.6 Valves locations (ft) 1400-7062 Wellhead temperature (F) 121-127 Gas lift valve port size (in) 0.187 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #1 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #1 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #2 (Long String) Perforation interval (ft) 7822-7956 Wellhead pressure (psig) 122-126 Water cut (%) 45% Casing diameter (in) 9.625 Tubing diameter (in) 3.5 Tubing depth (ft) 7740 Gas injection specific gravity 0.83 Oil API 32.7 Reservoir pressure (psig) 2100 Productivity index (bpd/psig) 0.5 Oil flow rate (bbl/day) 1159-1169 GOR (SCF/STB) 1351-1418 Injection flow rate (MMSCF/day) 1.8-2 Valves locations (ft) 1428-7300 Wellhead temperature (F) 125 Gas lift valve port size (in) 0.1875 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #2 (Long String) 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #2 (Long String) 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #2 (Short String) Perforation interval (ft) 7434-7672 Wellhead pressure (psig) 145-141 Water cut (%) 22% Casing diameter (in) 9.625 Tubing diameter (in) 3.5 Tubing depth (ft) 7326 Gas injection specific gravity 0.83 Oil API 32.7 Reservoir pressure (psig) 2100 Productivity index (bpd/psig) 0.5 Oil flow rate (bbl/day) 1809-1799 GOR (SCF/STB) 1255-1143 Injection flow rate (MMSCF/day) 2-1.8 Valves locations (ft) 1396-7268 Wellhead temperature (F) 124 Gas lift valve port size (in) 0.25 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #2 (Short String) 60th Advisory Board Meeting November 6, 2015 Gas-lift with Multiple Valves Kuwait Oil Company Well #2 (Short String) 60th Advisory Board Meeting November 6, 2015 Self-Stabilizing Valve (Zhang and Arellano, 2014) 1 0.9 y = -0.0022x2 + 0.1348x - 1.2169 Injection Factor 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 10 20 30 PA-PT (psia) 40 60th Advisory Board Meeting 50 60 April 17, 2015 Self-Stabilizing Valve (Zhang and Arellano, 2014) 60th Advisory Board Meeting November 6, 2015 Pump Intake Pressure Depletion for Bounded Reservoir Radial Transient Flow Radial Pseudosteady State Flow 60th Advisory Board Meeting November 6, 2015 Pump Intake Pressure Depletion for Bounded Reservoir 1: Steady state flow: 2: Pseudosteady state flow: 3: Transient flow: 4: Transient multi rate flow: 60th Advisory Board Meeting November 6, 2015 Pump Intake Pressure Depletion for Bounded Reservoir 60th Advisory Board Meeting November 6, 2015 Graphical Interface Gas-Lift Transient Simulator 60th Advisory Board Meeting November 6, 2015 Conclusions A unified transient model is developed for gas-liquid flow based on conservations of mass and momentum Two sections for heat transfer modeling – from bottom hole to gas-lift valve and from gas-lift valve to surface Black oil model is added for fluid properties 60th Advisory Board Meeting November 6, 2015 Conclusions New transient model verified with experimental results for four different transient phenomena Effects of three factors on casing heading are simulated Gas injection rate Port size of gas-lift valve Productivity index Model applied for different applications such as self-stabilizing gas-lift valve and reservoir transient response 60th Advisory Board Meeting November 6, 2015 Future Works Final version of GUI and model will be available to TUALP members by next ABM Gas-liquid transient model will be extended to three-phase (gas-oilwater) 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects Transient Plunger Lift Modeling Weiqi Fu Zhiyuan Wang McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Outline Liquid loading prediction Plunger lift modeling Future works 60th Advisory Board Meeting November 6, 2015 Application of Plunger Lift Liquid loading usually happens in gas wells and leads to production rate decrease or stop 60th Advisory Board Meeting November 6, 2015 Application of Plunger Lift… Plunger lift can be used to deliquify gas wells Liquid loading prediction is important for plunger lift simulation and optimization 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction Models Liquid loading prediction models can be classified into two groups Traditional models Mechanistic models 60th Advisory Board Meeting November 6, 2015 Traditional Models Traditional models: Turner et al. (1969) – terminal velocity 𝝈𝟏/𝟒 𝝆𝑳 − 𝝆𝑮 𝑣𝑡 = 𝟏𝟕. 𝟔 𝝆𝑮 𝟏/𝟐 Drag Force 𝟏/𝟒 𝒗𝒕 = terminal velocity, ft/s 𝝆𝑳 = density of liquid, lb mass/cu ft 𝝆𝑮 = density of gas, lb mass/cu ft 𝝈 = interfacial tension, dynes/cm Liquid Droplet Gravity Extensions of Turner et al. model, such as Guo et al. (2005) and Zhou et al. (2009) 60th Advisory Board Meeting November 6, 2015 Traditional Models… Tuner et al. model underestimates terminal velocity about 40% compared with field data Modified Turner models also give larger errors than expected 60th Advisory Board Meeting November 6, 2015 Mechanistic Models Mechanistic models: Liquid film velocity Minimum pressure gradient 60th Advisory Board Meeting November 6, 2015 Liquid Film Velocity Relationship between film velocity and liquid loading Many researchers, such as Liquid film Veeken (2009), Westenden (2008), Yuan (2011) and Gunner (2012) proposed that liquid film reversal leads to liquid loading They also conducted experiments for validation 60th Advisory Board Meeting Gas flow Tubing November 6, 2015 Liquid Film Velocity… Liquid loading determined by film velocity Film velocity > 0, unloading Film velocity < 0, loading 60th Advisory Board Meeting November 6, 2015 Minimum Pressure Gradient Relationship between the minimum pressure gradient and liquid loading Veeken (2009) suggested that, when OPR reaches the minimum pressure, liquid loading happens Yuan (2011) and Gunner (2012) had similar observations in their experiments 60th Advisory Board Meeting November 6, 2015 Minimum Pressure Gradient… Liquid Loading Boundary 60th Advisory Board Meeting November 6, 2015 Zhang et al. Unified Model Predict liquid loading with Zhang et al. (2003) Unified Model Step 1: Input: well geometry, fluid properties and flow rates Step 2: Calculation Step 3: Output: HL, vF, pressure gradient, flow pattern, etc Step 4: Use film velocity and minimum pressure gradient to determine liquid loading Step 5: Compare simulation results and experiment results 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction Pressure gradient prediction in vertical gas wells Liquid Loading Boundary 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Film velocities in vertical gas wells Liquid Loading Boundary 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Liquid loading boundary in vertical gas wells 59th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Pressure gradient prediction in 75° gas wells Liquid Loading Boundary 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Film velocities in 75° gas wells Liquid Loading Boundary 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Liquid loading boundary in 75° gas wells 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Pressure gradient prediction in 60° gas wells Liquid Loading Boundary 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Film velocities in 60° gas wells Liquid Loading Boundary 60th Advisory Board Meeting November 6, 2015 Liquid Loading Prediction… Liquid loading boundary in 60° gas wells 60th Advisory Board Meeting November 6, 2015 Comparison Result comparisons and discussions vSW, m/s vSG, exp, m/s vSG, Dp/DL, m/s vSG, Liquid film , m/s 0.01 0.05 0.1 0.01 0.05 0.1 0.01 0.05 0.1 15.1 14.9 20 17.5 20.1 25 20 27.5 27.5 10 12.6 17.4 10 12.5 12.5 10 12.5 14.9 18 15.78 22.5 21 26 24 24.96 25.84 26.16 60th Advisory Board Meeting θ 90 90 90 75 75 75 60 60 60 dP/dL, vF, Discrepancy Discrepancy 34% 15% 13% 43% 38% 50% 50% 55% 46% 19% 6% 13% 20% 29% 4% 25% 6% 5% November 6, 2015 Bubble and Film Velocities Results validation Direction of film velocity in experiment is determined by direction of bubble in liquid film There is slippage between bubble and liquid film Film velocity needs to be corrected with slippage velocity 60th Advisory Board Meeting Bubbles Tubing Liquid film November 6, 2015 Slippage 𝐯𝐬𝐥𝐢𝐩 = 𝐯𝐠𝐚𝐬 𝐛𝐮𝐛𝐛𝐥𝐞 − 𝐯𝐥𝐢𝐪𝐮𝐢𝐝 𝐟𝐢𝐥𝐦 𝐯𝐬𝐥𝐢𝐩 = 𝟏. 𝟓𝟑 𝐠𝛔𝐋 𝛒𝐋 −𝛒𝐆 𝛒𝟐𝐋 𝟏 𝟒 Slippage velocity is 0.25 m/s Input g, m/s2 ρL, kg/m3 ρG, kg/m3 σ, N/m Output 9.81 998 1.27 0.07 vslip, m/s 0.25033323 60th Advisory Board Meeting November 6, 2015 Correction 60th Advisory Board Meeting November 6, 2015 Trends of Liquid Film 60th Advisory Board Meeting November 6, 2015 Conclusions Liquid loading determined by film velocity shows smaller errors than the minimum pressure gradient method Considering slippage, film velocity value of 0.3 m/s is recommended 60th Advisory Board Meeting November 6, 2015 Transient Plunger Lift Modeling New function: Integrated all four steps Moving up Blowout Moving down Build up 60th Advisory Board Meeting November 6, 2015 Transient Plunger Lift Modeling Simulation 60th Advisory Board Meeting November 6, 2015 Transient Plunger Lift Modeling Data analysis 60th Advisory Board Meeting November 6, 2015 Future Works Case studies using TUALP Plunger Lift Simulator Simulator improvements based on case studies Thesis writing and defense 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects Downhole Gas-Liquid Separation Literature Review and Research Plan Haiwen Zhu McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Outline Application Introduction Literature review Research plan Future schedule 60th Advisory Board Meeting November 6, 2015 Application Downhole separator is used to overcome gas problem like gas lock, gas pound and gas interference in artificial lift systems More efficient and optimized geometry needed Better understanding of downhole separation mechanism and constraints 60th Advisory Board Meeting November 6, 2015 Introduction… Types of downhole separator Gravity type Advantages: simple geometry, easy to operate and cheaper Disadvantages: not capable of handling very high flow rate, larger size Rotary type Advantages: more efficient, smaller size, can handle higher flow rate Disadvantages: more expensive, higher pressure loss 60th Advisory Board Meeting November 6, 2015 Introduction… Types of downhole separator Impeller type Cyclone type Combined type 60th Advisory Board Meeting November 6, 2015 Literature Review… Rotary downhole separator Alhanati (1993) For the first time, a theoretical simplified model for downhole rotary gas separator (RGS) efficiency was developed 60th Advisory Board Meeting November 6, 2015 Literature Review… Rotary downhole separator Gernot Lackner (1997) Introduced an improved turbulence model for twophase flow Serrano (1999) Introduced empirical correlations for region in front of pump intake Harun (2000) Introduced a new mechanistic inducer model to be incorporated into Alhanati’s simplified model 60th Advisory Board Meeting November 6, 2015 Literature Review… Downhole natural separation Liu (2001) Developed a natural separation efficiency model based on bubble tracking method Marquez (2004) Presented three approaches for downhole separation efficiency One-cell simplified model Mechanistic model New two-dimensional two-phase flow model 60th Advisory Board Meeting November 6, 2015 Literature Review… Gravity type downhole separator Podio et al. (1995) Robles and Podio (1996) McCoy and Podio (1998) Lisigurski (2004) Guzman (2005) Lisigurski et al. (2005) Bohorquez et al. (2009) 60th Advisory Board Meeting November 6, 2015 Gravity Downhole Separator Natural downhole gas separator (McCoy, 1999) Prototype of gravity downhole separator Pump inlet below perforations Dip-tube 60th Advisory Board Meeting November 6, 2015 Gravity Downhole Separator… Concentric and eccentric gas anchor Above perforations Separation chamber Lopes (2002) Stewart (2001) 60th Advisory Board Meeting McCoy et al. (1997) November 6, 2015 Gravity Downhole Separator… Packer-type downhole gas separator Above perforations Packer/Diverter/Tail pipe Complex geometry Page (1990) Don-Nan (2011) 60th Advisory Board Meeting McCoy (2014) November 6, 2015 Rotary Downhole Separator… Lee et al. (1984) Impeller rotated by motor Three working regions 60th Advisory Board Meeting November 6, 2015 Rotary Downhole Separator… Two stages RGS (Morrison, 2013) 60th Advisory Board Meeting November 6, 2015 Impeller Downhole Separator… Weingarten et al. (1995) Fixed axis and impeller 60th Advisory Board Meeting November 6, 2015 Impeller Downhole Separator… Different impeller geometry Ward (1985) Shi et al. (2015) 60th Advisory Board Meeting November 6, 2015 Cyclone Downhole Separator Tangential inlet Cylindrical or conical chamber Schultz (2015) 60th Advisory Board Meeting Stevens (1978) November 6, 2015 Combined Downhole Separator The SPIRIT downhole gas separator (Raglin, 2013) Impeller on inner tubing Gravity separation in casing annulus No moving mechanical parts 60th Advisory Board Meeting November 6, 2015 Research Considerations Pressure loss Reliability Ability to handle slug flow Separation efficiency Chamber geometry effect In situ condition effect Fluid properties effect Flow rate and effect 60th Advisory Board Meeting November 6, 2015 Research Plan Simulation and modeling Conduct 3-D CFD simulation Develop a mechanistic model Experimental program 60th Advisory Board Meeting November 6, 2015 Research Plan 60th Advisory Board Meeting November 6, 2015 Schedule before Next ABM NOV DEC Primarily design Literature review, design one or more separator geometry JAN FEB Geometry generation Software study and build CFD geometry and meshing 60th Advisory Board Meeting MAR APR Simulation study Affecting factor analysis, choose optimized design and do evaluations November 6, 2015 Tulsa University Artificial Lift Projects Eccentric Pipe-in-Pipe Downhole Gas Separator Holden Zhang McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 Why Separate Gas in Downhole? Gas involvement reduces pump capacity and efficiency, even causes gas lock Gas needs to be separated upstream of pump Slugging causes separation problems, especially in horizontal wells 60th Advisory Board Meeting November 6, 2015 Previous Designs Don-Nan Pump & Supply Co. Use a ported coupling Concentric Two-phase flow in annulus Single-phase liquid flow in central pipe High resistance to flow 60th Advisory Board Meeting November 6, 2015 Previous Designs… Helical gas separator (US5,431,228) May not separate completely Liquid entrained by gas Gas entrained by liquid Not good for handling slugging 60th Advisory Board Meeting November 6, 2015 Previous Designs… Gas separator within ESP shroud For ESP application Gas may be dispersed in liquid due to small area and high velocity May not be good for handling slugging 60th Advisory Board Meeting November 6, 2015 Previous Designs… Centrifugal separator For ESP application Consumes more power More failure causes Not good for handling slugging 60th Advisory Board Meeting November 6, 2015 New Separator Design Eccentric pipe-in-pipe configuration Multiphase flow in inner pipe Gas separates from liquid after exit from inner pipe Gas flows upward Liquid flows downward slowly 60th Advisory Board Meeting November 6, 2015 New Separator Design… Single-phase liquid enters crescent area between outer tube and inner tube at bottom Free of gas, liquid flows upward in the crescent area and into pump intake Sufficient liquid volume in annulus for slug elimination 60th Advisory Board Meeting November 6, 2015 New Downhole Separator Design… Large area in annulus between separator and casing for liquid settling Inner tube cross-sectional area larger than the crescent area for multiphase flow Multiple holes on outer pipe bottom for liquid to enter the crescent area 60th Advisory Board Meeting November 6, 2015 Sand Handling Design Multiphase fluids first flow into the crescent area between the outer tube and the inner tube Gas and liquid exit from the crescent conduit at the top of the outer tube, and separate Gas flows upward Liquid flows downward slowly 60th Advisory Board Meeting November 6, 2015 Sand Handling Design… Single-phase liquid enters the inner tube through opening(s) at the bottom Free of gas liquid flows upward in the inner tube to the pump intake The crescent area is larger than the inner tube crosssectional area for multiphase flow 60th Advisory Board Meeting November 6, 2015 Sand Handling Design… Ball valve at bottom of inner tube Ball valve closed in normal operation Due to suction force At shut-in, ball valve open Ball falls to lower position in its cage due to gravity 60th Advisory Board Meeting November 6, 2015 Sand Handling Design… Sand particles in inner tube and annulus can sink through ball valve Sand plug is avoided After restart, ball valve is automatically closed by suction force 60th Advisory Board Meeting November 6, 2015 Sand Handling Design… Side view of bottom opening connecting annulus and inner tube 60th Advisory Board Meeting November 6, 2015 Advantages of New Design Simple eccentric pipe-in-pipe configuration – low cost Less resistance to flow – low pressure drop Optimized areas for low velocity and better gas bubble separation 60th Advisory Board Meeting November 6, 2015 Advantages of New Design… Sufficient length for slug elimination Sensor to monitor liquid level Valve or pump speed control to maintain liquid level Sand handling with a bottom ball valve Open at shut-in Allows sand particles to go through Automatic close after restart Provisional patent filed on Nov 3, 2015 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects TUALP 2015 Questionnaire and Project Discussions Holden Zhang McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 TUALP 2015 Questionnaire Your evaluation is important to guide the direction of TUALP research Conducted yearly Drop topics with lowest scores Add new topics Proposed by members or others Based on our understanding 60th Advisory Board Meeting November 6, 2015 Please Let Us Know Your Interest If feedback from a member is not received, the previous year’s evaluation from the same member will be used New topics are assigned as “Low interest” Please feel free to let me know of any specific topics you are interested in 60th Advisory Board Meeting November 6, 2015 Overall 15 16 9 10 18 Statoil 13 SLB 11 14 Petrochina 17 Petrobras 4 8 Petex 7 Pemex 6 3 12 KOC 5 Study of Gas/Oil/Water Flow and Emulsion Characteristics in ESPs CFD Simulation and Experiments of ESP Sand Erosion Mechanistic Modeling of ESP Performance for High-Viscosity Oil and GasLiquid Flows Experiments and CFD Simulation of ESP Performance under Gassy Conditions Effect of Liquid Viscosity on Gas/Liquid Stage Performance of ESPs Experimental Study of High Speed ESP Performance Modeling of Multiphase Flow in Horizontal Wells with Distributed Influxes for Artificial Lift Application Transient Gas Lift Modeling Downhole Gas-Liquid Separation and Slug Elimination Problematic Case Characterization and Data Interpretation for Well Surveillance Unified Modeling of Transient Multiphase Flow in Well and Pipeline ESP Testing at High Pressure and Temperature Testing ESP Performance with High-Density Gas to Simulate High-Pressure Gas-Liquid Flow Conditions Experiment and Modeling of Multiphase Heat Transfer around ESP Motor Water Assisted ESP Application to Increase Heavy Oil Production Plunger Lift Modeling and Optimization Self-Stabilizing Gas Lift Valve to Prevent Casing Heading Improve Gas Handling with Gradual Type Change in ESP GE 1 2 Research Topics Chevron No. Baker 2015 Questionnaire Results 2 3 5 4 5 4 5 3 5 5 41 5 5 5 4 5 1 4 3 5 5 2 3 4 4 3 4 5 4 3 5 41 38 5 4 4 2 3 4 4 4 1 1 5 5 4 3 4 4 4 5 5 3 2 4 3 3 5 4 4 3 4 4 1 4 5 3 2 4 5 5 4 3 38 37 36 35 Ongoing Ongoing Potential 1 3 4 5 4 3 2 1 3 3 4 5 3 5 3 5 2 5 4 1 3 5 5 5 3 4 3 3 3 3 34 32 32 Ongoing Ongoing 2 2 3 3 5 3 1 5 1 3 4 4 5 3 3 5 3 3 1 3 4 5 1 2 4 1 3 2 4 4 31 31 30 Ongoing Potential 1 4 1 4 5 3 1 1 4 4 28 2 1 3 3 2 4 5 1 1 1 1 1 4 3 2 3 4 2 3 1 3 5 2 3 3 3 3 1 2 5 4 3 3 2 2 1 4 1 2 1 28 27 27 18 Potential Potential Ongoing Ongoing Potential 60th Advisory Board Meeting Status Ongoing Ongoing Ongoing Ongoing Potential Potential November 6, 2015 No. 1 and 2 Study of Gas/Oil/Water Flow and Emulsion Characterization in ESPs Combines oil viscosity effect, oil/water flow, gas/liquid and three-phase flow Hattan Banjar (PhD Candidate) leads this project Ongoing Experiments and CFD Simulation of ESP Sand Erosion Saul Gomez (PhD student) leads this project Planning experimental setup Ongoing 60th Advisory Board Meeting November 6, 2015 No. 3 and 4 Mechanistic Modeling of ESP Performance for High-Viscosity Oil and Gas-Liquid Flows Frame work developed by Holden Zhang Collecting experimental data for verification Ongoing Experiments and CFD Simulation of ESP Performance under Gassy Conditions Jianjun Zhu (PhD candidate) leads this project Significant results obtained Ongoing 60th Advisory Board Meeting November 6, 2015 No. 5 and 6 Effect of Liquid Viscosity on Gas/Liquid Stage Performance of ESPs Ongoing project Combines with Hattan’s study Experimental Study of High Speed ESP Performance Potential project High viscosity and gas/liquid flow Can start if member provides pump unit 60th Advisory Board Meeting November 6, 2015 No. 7 and 8 Modeling of Multiphase Flow in Horizontal Wells with Distributed Influxes for Artificial Lift Application Transient gas-liquid flow model has been developed Model will be extended for horizontal well simulation Transient Gas Lift Modeling Ongoing project Fahad Al-Mudairis (PhD Candidate) leads this project Significant recent progress 60th Advisory Board Meeting November 6, 2015 No. 9 and 10 Downhole Gas Separation and Slug Elimination Ongoing project Haiwen Zhu (PhD Candidate) leads this project New designs proposed by Holden Zhang Problematic Case Characterization and Data Interpretation for Well Surveillance Potential Tailor mechanistic models for surveillance data analysis 60th Advisory Board Meeting November 6, 2015 No. 11 and 12 Unified Modeling of Transient Multiphase Flow in Well and Pipeline Serves as backbone for production and artificial lift system simulations Significant recent progress ESP Testing at High Pressure and Temperature Potential project Possible with TUALP research well High temperature through recirculation 60th Advisory Board Meeting November 6, 2015 No. 13 and 14 Testing ESP Performance with High- Density Gas to Simulate High-Pressure Gas-Liquid Flow Conditions Potential project Experiment and Modeling Multiphase Heat Transfer around ESP Motor Potential project 60th Advisory Board Meeting November 6, 2015 No. 15 and 16 Water Assisted ESP Application to Increase Heavy Oil Production Potential Plunger Lift Modeling and Optimization Weiqi Fu (MSc Student) leads this project 60th Advisory Board Meeting November 6, 2015 No. 17 and 18 Self-Stabilizing Gas Lift Valve to Prevent Casing Heading Patent applied Test with a model Seek manufacturing and application Improve Gas Handling with Gradual Type Change in ESP Potential 60th Advisory Board Meeting November 6, 2015 Tulsa University Artificial Lift Projects TUALP Budget and Open Discussions Holden Zhang McDougall School of Petroleum Engineering The University of Tulsa 60th Advisory Board Meeting November 6, 2015 2015 Budget GL with Object Code 14-2-1202136-81801 14-2-1202136-90101 14-2-1202136-90600 14-2-1202136-90601 14-2-1202136-90610 14-2-1202136-90701 14-2-1202136-91000 14-2-1202136-91800 14-2-1202136-92102 14-2-1202136-93100 14-2-1202136-93101 14-2-1202136-93102 14-2-1202136-93103 14-2-1202136-93104 14-2-1202136-93106 14-2-1202136-93150 14-2-1202136-93194 14-2-1202136-93200 14-2-1202136-93300 14-2-1202136-93400 14-2-1202136-93500 14-2-1202136-93601 14-2-1202136-93602 14-2-1202136-93701 14-2-1202136-94813 14-2-1202136-94861 14-2-1202136-95103 14-2-1202136-95200 14-2-1202136-98901 14-2-1202136-99001 14-2-1202136-99300 2016 Budget Scholarships-Graduate : Zhang-TUA Salary-Principal Investigator : Z Professional Salaries (Non-Teachi Salary-Professional 1 : Zhang-TUA Professional - Part-Time : ZhangSalary-Non Professional 1 : Zhang Students-Graduate : Zhang-TUALP-P Employee Benefits : Zhang-TUALP-P Health Ins-Externally Funded A : General Supplies and Expenses : Z Research Supplies : Zhang-TUALP-P Copier or Printer Supplies : Zhan Parts for Fabricated Equipment : Computer Software : Zhang-TUALP-P Office Supplies : Zhang-TUALP-Pri Computers $1-4999 (non cap) : Zh Improvement of Research Facilitie Postage and Shipping : Zhang-TUAL Printing and Duplicating : ZhangTelecommunication : Zhang-TUALP-P Memberships and Subscriptions : Z Travel-Domestic : Zhang-TUALP-Pri Travel-Foreign : Zhang-TUALP-Prim Public Functions : Zhang-TUALP-Pr Outside Services : Zhang-TUALP-Pr Outside Services excluded IDC : Z Equipment Rental : Zhang-TUALP-Pr Indirect Costs : Zhang-TUALP-Prim Employee Recruiting : Zhang-TUALP Equipment >=$5000 : Zhang-TUALP-P Bank Service Charges : Zhang-TUAL 60th Advisory Board Meeting $ 5,000.00 $ 61,556.00 $ 36,540.00 $ 60,000.00 $ 36,000.00 $ 50,930.00 $ 19,800.00 $ 75,249.00 $ 1,584.00 $ 1,800.00 $ 12,000.00 $ 1,200.00 $ 5,000.00 $ 1,200.00 $ 2,000.00 $ 6,000.00 $ 5,000.00 $ 500.00 $ 2,000.00 $ 1,000.00 $ 600.00 $ 5,000.00 $ 8,000.00 $ 11,144.00 $ 7,000.00 $ 12,000.00 $ 5,000.00 $160,857.00 $ 1,000.00 $ 5,000.00 $ 40.00 $ 600,000.00 November 6, 2015 2016 Budget Income 80917 Membership Fees Total Income Expenses 81801 Tuition 90101 PI - H. Zhang (25-100%) 90600 Project Coordinator - D. Trankley 90601 Post-Doc Researcher - TBD 90701 Technician - B. Sams 90610 Part-Time Professional 91000 Student Stipends 91800 Employee Benefits @ .36 92102 Student Insurance Benefits @ .08 93100 General Supplies 93101 Research Supplies & Equipment <$5K 93102 Copier/Printer Supplies 93103 Component Parts (non-IDC) 93104 Computer Software 93106 Office Supplies 93150 Computers <$5,000 93194 Improvement of Research Facilities-Supplies (non-IDC) 93200 Postage/Shipping 93300 Printing/Duplicating 93400 Telecommunications 93500 Memberships/Subscriptions 93601 Travel - Domestic 93602 Travel - Foreign 93701 Entertainment (Advisory Board Meetings) 94813 Outside Services 94861 Outside Services-Facilities Improvement (non-IDC) 95103 Equipment Rental (non-IDC) 98901 Employee Recruiting 99001 Equipment >$5,000 (non-IDC) 99300 Bank Charges Total Direct Costs MTDC 95200 Indirect Costs (40% of MTDC) 60th Advisory Board Meeting Total Expenses $ $ 480,000 480,000 $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ 5,000 61,556 30,000 60,000 50,930 36,000 19,800 72,895 1,584 1,800 12,000 1,200 5,000 1,200 2,000 6,000 5,000 500 2,000 1,000 600 5,000 8,000 11,144 7,000 12,000 5,000 1,000 5,000 40 430,248 393,248 157,299 587,548 November 6, 2015 TUALP Financial Significant saving in 2015 due to an additional CNOOC project Surplus will be spent on facility buildup Membership outlook in 2016 Member pullout due to financial constraints Possible 2-3 new members 60th Advisory Board Meeting November 6, 2015 Adjourn Next ABM In Tulsa April 29 (Friday), 2016, right before the OTC Thanks for your support! 60th Advisory Board Meeting November 6, 2015