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PETE 332

Petroleum Production Engineering II Session 6 Hydraulic Pumps 04.05.2012

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Hydraulic Pumps
Piston Pumps Jet Pumps

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References for Hydraulic Pumps


Main Text: SPE, Petroleum Engineering Handbook, Volume IV, Production Operations Engineering, Chapter 14, 2007 Additional Reference: Kermit E.Brown, The Technology of Artificial Lift Methods, Volume 2b, PennWell Books, 1984 G.V. Chilingarian et. al. , Surface Operations in Petroleum Production 1, Elsevier, 1987

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Hydraulic Pumps

Objective:
Review the basics of Hydraulic Pumping Understand the basic operating principles of Piston Pumps Jet Pumps Learn about downhole and surface equipment for hydraulic pumps

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Hydraulic Pumps

Hydraulic Pumps (Piston & Jet)


Used since 1930. Tranmits energy to bottom hole by means of pressurised power fluid (oil or water). Two types of downhole pump exists: Piston (Reciprocating) Pump Jet Pump Surface facilities require: Power fluid storage Cleaning system High pressure pump and High pressure flowlines. Pump can be circulated in and out. No rig required. Attractive for offshore and remote locations, populated areas.
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(figure from Schlumberger, Oilfield Review, Spring 1999)

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Hydraulic Pumps

Types of Hydraulic Pump Installations:


Fixed Pump Installations: (Not commonly used) Pump is attached to the end of a tubing string and run in the well. 1. Fixed Insert (Tubing Conveyed) Design 2. Fixed Casing Design Free Pump Installations: (Common Practice) Designed to allow the downhole pump to be circulated in and out of the wellbore inside the power fluid string, or it can also be installed and retrieved by wireline operations. 3. Casing Return Free Installation Design 4. Parallel Return Free Installation Design
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(figures from SPE Handbook, 2007)

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Hydraulic Pumps

Fixed Insert (Tubing Conveyed) Design:

First, a larger diameter tubing string in run with a seating shoe at the bottom.

Then pump is run in hole, attached to the end of a smaller tubing, and it lands on a seating shoe in the larger tubing.
- Power fluid is normally directed down the inner tubing string. - Produced fluid and the injected power fluid flow to surface from the annulus between two tubing strings. Free gas is produced from casing and outer tubing annulus (gas separation will work better if pump is placed below perforations). It is used mainly to fit a large diameter downhole pump into restricted casing sizes and still retain the gas venting feature. It can also be used to lift more than one zone of a well separately, with parallel strings.
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(figure from SPE Handbook, 2007)

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Hydraulic Pumps

Fixed Casing Design:

Tubing with pump attached to the bottom is seated on a packer. - Power fluid is directed down the tubing string. -Mixed power fluid and produced fluid return to surface in the tubing/casing annulus.

Because well fluids enter the pump below the packer, no gas separation takes place and pump must handle all the gas.
It is used for large diameter, high capacity pumps in wells with little free gas. If space permits, gas vent string can be run below the packer to the surface.

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(figure from SPE Handbook, 2007)

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Hydraulic Pumps

Casing Return Free Installation Design:

- Power fluid is directed down the tubing - Power fluid and the produced fluids are mixed and produced to the surface from casing/tubing annulus Low initial cost (because only one tubing string is used).

Because well fluids enter the pump below the packer, no gas separation takes place and pump must handle all the gas.
If space permits, gas vent string can be run below the packer to the surface. Disadvantages: -The produced fluids contacts the casing. If corrosive fluid is produced, casings may be damaged. -Intakes all gas, therefore the displacement efficiency is low if the free gas is high.
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(figure from SPE Handbook, 2007)

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Hydraulic Pumps

Parallel Return Free Installation Design:

Bottom hole assembly (BHA) is suspended on the power fluid string. The pump is sent down to the top of the seat in BHA. - Power fluid is directed down the tubing - Power fluid and the produced fluids are mixed and produced to the surface from a return tubing. The return tubing is either screwed into the BHA, or it is run separately with a landing spear that enters a bowl above the BHA. It normally does not require packer.

Annulus serves as a gas vent passage (gas separation will work better if pump is placed below perforations).
Packer may be used if the produced gas or liquid in the casing is corrosive, but packer prevents gas passage and lowers displacement efficiency.
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(figure from SPE Handbook, 2007)

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Hydraulic Pumps

Reverse flow systems:


In conventional systems, power fluid is injected from the tubing string. Produced fluid and returning power fluid flows to surface from casing/tubing annulus.

In reverse flow systems, the power fluid is injected through casing/tubing annulus and produced fluid flow to surface from the tubing string.
Advantage: If the produced fluids are corrosive, they dont damage the casing. Disadvantage: Casing is subject to high power fluid pressures. Stronger casing design is needed to avoid casing burst and leaks.

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Free Pump Installation :

(1/2)

It is one of the most significant advantages of hydraulic pumping system. Permits circulating the pump to the bottom to produce from the well, and circulating the pump back to the surface for repair or size change. Bottom Hole Assembly (BHA) is run on the tubing string to serve as the receptacle for the pump.

Circulating to surface takes 30 mins to 2 hrs based on depth, tbg size, flow rate.
Advantages: - Reduced downtime and ability to operate without workover unit to pull the tubing. - Pressure and Temperature recorders can be mounted on the pump to monitor downhole conditions with different pump rates. At the conclusion of the test, circulating the pump to the surface also retrieves the data recorders. -Steaming, acidizing, chemical treatment can be done without pulling the tubing out of hole.
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Free Pump Installation :

(2/2)

Pump In and Pump Out Operations for Free Pump Installation


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(figure from SPE Handbook, 2007)

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Downhole Pump:
Downhole pumps acts as a transformer to convert the power fluid energy to pressure in produced fluids. Two types of downhole pumps exist in hydraulic Pumps: Piston Pump Powered by the injected fluid, the positive displacement pump piston pushes the reservoir liquid to surface. It consists of a set of coupled reciprocating pistons, one driven by the power fluid and the other pumping well fluids. Jet Pump (More commonly used than Piston Pump) It converts the pressurized power fluid to a high velocity jet that mixes directly with the well fluids. The injected power fluid passes through a nozzle creating a venturi effect pushing the produced fluids to surface. In the turbulent mixing, momentum and energy from power fluid are added to the produced fluids.
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Hydraulic Pumps

Principles of Operation for Piston and Jet Pumps:

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Hydraulic Piston Pumps

Operating of Hydraulic Piston Pump:


There eare two pistons are connected to each other with a rod.
Engine Piston : The injected power fluid operates the Engine Piston and creates the reciprocal (up/down) motion of the rods connecting the Engine Piston to Pump Piston. Pump Piston : The rods connected to the Engine Piston moves The Pump piston up and down. At each stroke, it takes in the reservoir fluid nside the pump barrel and pushes it out for production.
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(figures from SPE Handbook, 2007)

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Hydraulic Piston Pumps

Working of the Engine Piston:

(1/2)

Downstroke: Power fluid fills the upper chamber. The power fluid in lower chamber is purged into the production stream. The piston moves down. Upstroke: Power fluid fills the lower chamber. The power fluid in the upper chamber is purged. The piston moves up.

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(figures from G.V.Chilingarian et.al., 1987)

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Hydraulic Piston Pumps

Working of the Engine Piston:

(2/2)

The Engine Valve is responsible for changing the flow channel for the power fluid (to upper chamber and to lower). Engine valve moves up and down at each stroke, because of the changes in rod diameter, which enables power fluid to push the engine valve up and down.

Engine Valve down, Upper Chamber is filled with power fluid.


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Engine Valve up, Lower Chamber is filled with power fluid.


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(figures from G.V.Chilingarian et.al., 1987)

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Hydraulic Piston Pumps

Working of the Pump Piston:

(1/2)

The working principle is very similar to sucker rod pump. Two ball valves exist on upper and lower chambers. Motion of the piston away from the intake valves lowers the pressure in the chamber and opens the intake valve, closes the exhaust valve. Reservoir fluid enters the chamber. When the plunger action is reversed, the motion of the piston towards the intake valves increases the pressure in the chamber and closes intake valve, opens the exaust valve. Reservoir fluid leaves the Chamber and produced into the production string.

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(figure from G.V.Chilingarian et.al., 1987)

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Hydraulic Piston Pumps

Working of the Pump Piston: (2/2)


At Downstroke: Reservoir fluid fills upper chamber. The reservoir fluid in the lower chamber is produced up the well (through the casing/tubing annulus). At Upstroke: Reservoir fluid fills lower chamber. The reservoir fluid in the upper chamber is produced up the well (through the casing/tubing annulus).

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(figures from G.V.Chilingarian et.al., 1987)

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Hydraulic Piston Pumps


Downstroke Power Fluid IN

Schematic Operation of Piston Pump (1/7)


Beginning of Downstroke: Engine Valve is at lower position. It is kept in this position because the power fluid pushes it down. Engine Piston: The injected power fluid enters to the top chamber of engine piston and pushes the engine piston down. The power fluid in the lower chamber is pushed out into the annulus. Pump Piston: Engine piston pushes the pump piston down. Reservoir fluid fills the top chamber of the pump piston. The reservoir fluid in the lower chamber is pushed out to the annulus to be produced.

OUT

Engine Valve Engine Piston

Pump Piston
OUT

Reservoir Fluid IN
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Hydraulic Piston Pumps


Downstroke Power Fluid IN

Schematic Operation of Piston Pump (2/7)


Continuation of Downstroke: Same as before.

OUT

OUT

Reservoir Fluid IN
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Downstroke Power Fluid IN

Schematic Operation of Piston Pump (3/7)


End of Downstroke:

Engine Piston: The injected power fluid pushed the piston down. All of the power fluid in the lower chamber is pushed out into the annulus. Pump Piston: Engine piston pushed the pump piston down. All of the top chamber is filled with reservoir fluid. All of the reservoir fluid in the lower chamber is pushed out to the annulus to be produced.

Reservoir Fluid IN
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Hydraulic Piston Pumps


Downstroke Power Fluid IN

Schematic Operation of Piston Pump (3/7)


End of Downstroke (continued): Because of the decreased diameter in the rod connecting the engine piston and pump piston, power fluid can go below the engine valve and push the engine valve up (see next slide). Power fluid moves below the engine valve to push it up.

Reservoir Fluid IN
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Hydraulic Piston Pumps


Upstroke Power Fluid IN

Schematic Operation of Piston Pump (4/7)


Beginning of Upstroke: Engine Valve is pushed up. This closes the previous path for power fluid and it opens a new path which diverts the power fluid to the bottom of the Engine piston. Engine valve is kept in upper position because the power fluid is trapped below the valve and it can not escape anywhere because the diameter of the rod is changed (increased) again. Engine Piston: The injected power fluid enters to the bottom chamber of engine piston and pushes the engine piston up. The power fluid in the upper chamber is pushed out into the annulus.

OUT The power fluid pushed the engine valve up. Power fluid is trapped below the engine valve because of rod diameter change, so the valve can not come down until the upstroke is completed.

OUT

Pump Piston: Engine piston pushes the pump piston up. Reservoir fluid begins filling the bottom chamber of the pump piston. The reservoir fluid in the upper chamber is pushed out to the annulus to be produced. Reservoir Fluid IN

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Hydraulic Piston Pumps


Upstroke Power Fluid IN

Schematic Operation of Piston Pump (5/7)


Continuation of Upstroke: Same as before.

OUT

OUT

Reservoir Fluid IN
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Hydraulic Piston Pumps


Upstroke Power Fluid IN

Schematic Operation of Piston Pump (6/7)


Continuation of Upstroke: Same as before.

OUT

OUT

Reservoir Fluid IN
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Hydraulic Piston Pumps


Upstroke Power Fluid IN

Schematic Operation of Piston Pump (7/7)


End of Upstroke: Engine Valve is at upper position. It is kept in this position because there is power fluid trapped below the engine valve. Engine Piston: The injected power fluid pushed the piston up. All of the power fluid in the upper chamber is pushed out into the annulus. Pump Piston: Engine piston pushed the pump piston up. All of the bottom chamber is filled with reservoir fluid. All of the reservoir fluid in the upper chamber is pushed out to the annulus to be produced. Reservoir Fluid IN
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Hydraulic Piston Pumps


Upstroke Power Fluid IN

Schematic Operation of Piston Pump (7/7)


End of Upstroke (continued): Because of the decreased diameter in the rod connecting the engine piston and pump, the power fluid trapped below the engine valve can escape and the injected power fluid pushes the engine valve down. Upstroke is completed and trapped power fluid can escape from the bottom of engine valve. This moves the engine valve down (see next slide).

Reservoir Fluid IN
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Downstroke Power Fluid IN

Schematic Operation of Piston Pump (1/7)


Beginning of Downstroke: Engine Valve is at lower position again. It is kept in this position because the power fluid pushes it down and the change (increase) in the rod diameter doesnt allow power fluid to go below the valve to push it up. Engine Piston: The injected power fluid enters to the top chamber of engine piston and pushes the engine piston down. The power fluid in the lower chamber is pushed out into the annulus.

OUT

OUT

Pump Piston: Engine piston pushes the pump piston down. Reservoir fluid fills the top chamber of the pump piston. The reservoir fluid in the lower chamber is pushed out to the annulus to be produced.

.. whole cycle (downstroke/upstroke) is repeated with this pattern. Reservoir Fluid IN


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Hydraulic Piston Pumps

Engine Piston and the Pump Piston is connected to each other by hollow rods. The hollow rods and fluid channels in the pistons allow for:

- Equal distribution of the force between the Pistons. - Lubricating the pistons.

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(figures from SPE Handbook, 2007)

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Relative Advantages/Disadvantages of Artificial Lift systems (1/2)

Hydraulic (Piston) Pump ADVANTAGES Not so depth limited-can lift large volumes from great depths

500 B/D (80 m3/d) from 15,000 ft. (4572 m) have been installed to 18,000 ft. (5486 m) Crooked holes present minimal problems. Unobtrusive in urban locations.

Power source can be remotely located.


Analyzable. Flexible-can usually match displacement to wells capability as well declines.

Can use gas or electricity as power source.


(from K.E.Brown, JPT, Oct 1982)
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Relative Advantages/Disadvantages of Artificial Lift systems (2/2)

Hydraulic (Piston) Pump ADVANTAGES

Downhole pumps can be circulated out in free systems.


Can pump a well down to fairly low pressure. Applicable to multiple completions. Applicable offshore. Closed system will combat corrosion. Easy to pump in cycles by time clock. Adjustable gear box for Triplex offers more flexibility. Mixing power fluid with waxy or viscous crudes can reduce viscosity.
(from K.E.Brown, JPT, Oct 1982)
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Relative Advantages/Disadvantages of Artificial Lift systems (1/2)

Hydraulic (Piston) Pump DISADVANTAGES

Power oil systems are a fire hazard.


Large oil inventory required in power oil system which detracts from profitability. High solids production is troublesome. Operating costs are sometimes higher. Usually susceptible to gas interference; usually not vented.

Vented installations are more expensive because of extra tubing required.


Treating for scale below packer is difficult. Not easy for field personnel to troubleshoot.
(from K.E.Brown, JPT, Oct 1982)
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Relative Advantages/Disadvantages of Artificial Lift systems

Hydraulic (Piston) Pump DISADVANTAGES Difficult to obtain valid well tests in low volume wells. Requires two strings of tubing for some installations. Problems in treating power water where used. Safety problem for high surface pressure power oil.

(2/2)

Lost of power oil in surface equipment failure.

(from K.E.Brown, JPT, Oct 1982)


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Hydraulic Jet Pumps

Operating of Downhole Jet Pump:


High pressure power fluid supplied from the surface passes through the nozzle. Its potential energy (pressure) is converted to kinetic energy in the form of a very high velocity jet of fluid.

Reservoir fluids surround the power fluid jet at the tip of the nozzle.
The power fluid and reservoir fluid are mixed in the throat, And momentum is transfered from the power fluid to reservoir fluid, causing its energy to rise. The mixed fluid enters an expanding area (diffuser) which converts the remaining kinetic energy to static pressure by slowing down the fluid velocity.

The resulting pressure is sufficienly high to flow the mixed fluid (power + reservoir) to the surface.
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(figure from SPE Handbook, 2007)

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Power Fluid

Characteristics of Jet Pumps:

(1/2)

Jet pumps are tolerant to corrosive and abrasive well fluids because there are no moving parts.
Produced Fluid

Nozzle and throat are usually constructed of tungsten carbide or ceramic materials for long life.
Because of high velocities, the turbulence and friction is very high in the pump. Therefore, lower horsepower efficiencies are achieved compared to positive displacement pumps. This leads to higher surface hp requirements. By changing the nozzle size, throat size, power fluid rate and pressure, jet pump can produce from less than 50 B/D to more than 15,000 B/D.

(figure from SPE Handbook, 2007)

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Power Fluid + Produced Fluid

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Characteristics of Jet Pumps:

(2/2)

Power Fluid

The ratio of nozzle area (An) to the throat area (At) determines the trade off between produced head (added DP) and flow rate. If the ratio of An/At increases, a relatively high head, but low flow rate pump will result. There will be a relatively small area around the nozzle for well fluids to enter. Therefore, flow rate will decrease. Because the energy of the power fluid is given to a smaller amount of produced fluid, high head is observed. This is suitable for deep wells requiring high lifts. If the ratio of An/At decreases, a high flow rate, but low head pump will result. A larger area is available around the nozzle for the well fluids. Therefore, higher rates are possible. Because the energy of the power fluid is given to a larger amount of produced fluid, low head will be available. This is suitable for shallow wells with low lifts.
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(figure from SPE Handbook, 2007)

Produced Fluid

Nozzle Area

Throat Area

Power Fluid + Produced Fluid

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Relative Advantages/Disadvantages of Artificial Lift systems

Hydraulic (Jet) Pump ADVANTAGES Retrievable without pulling tubing. Has no moving parts. No problems in deviated or crooked holes. Unobtrusive in urban locations.

(1/2)

Applicable offshore.
Can use water as a power source. Power fluid does not have to be so clean as for hydraulic piston pumping.
(from K.E.Brown, JPT, Oct 1982)
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Relative Advantages/Disadvantages of Artificial Lift systems

Hydraulic (Jet) Pump ADVANTAGES Corrosion scale emulsion treatment easy to perform.

(2/2)

Power source can be remotely located and can handle high volumes to 30,000 B/D (4,780 m3/d).

(from K.E.Brown, JPT, Oct 1982)


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Relative Advantages/Disadvantages of Artificial Lift systems

Hydraulic (Jet) Pump DISADVANTAGES Relatively inefficient lift method. Requires at least 20% submergence to approach best lift efficiency.

Design of system is more complex.


Pump may cavitate under certain conditions. Very sensitive to any change in back pressure. The producing of free gas through the pump causes reduction in ability to handle liquids. Power oil systems are fire hazard.

High surface power fluid pressures are required.


(from K.E.Brown, JPT, Oct 1982)
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Hydraulic Pumps

Surface Equipment:
Pump Motor Pulsation Dampener Power Fluid Vessel and flow lines

Cyclone
Manifolds Wellheads
(figure from K.Brown, 2b, 1980)

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Schematic of a single well hydraulic pumping system


(figure from SPE Handbook, 2007)

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Surface Equipment:
Surface Pumps
Surface operating pressures range from 2,000 psi to 4,000 psi. Power fluid rates range between a few hundred bbl/day to more than 3,000 bbl/day. The power needed normally ranges between 15 to 625 hp. Most common surface pump to pressurize the power fluid is multiplex positive displacement pumps (triplex and quintuplex). The multiplex pumps are driven by an electric motor or gas/diesel engine depending on the availability and cost of the power source. Each plunger pumps individually from a common intake manifold to a common discharge, and because discharge occurs only on the upstroke, there is some pulsation, for which pulsation dampener is used.
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Power Fluid
Hydraulic pump systems transmit power downhole by pressured power fluid.

The power fluid usually comes from well production. It can be either oil or water.
The power fluid is usually pressurized to 2000 to 4000 psi before being injected into wellbore.

In addition to supplying energy to the downhole pump, the Power Fluid can also be used for: - Injecting chemicals to control corrosion, paraffin, emulsions. - Diluent to reduce viscosity in heavy oils - Heating the heavy oil or low pour point reservoir fluids

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Open and Closed Power Fluid Systems:


Open Power Fluid Systems (OPS): The injected power fluid and the produced fluid is mixed together at downhole and they are returned to surface together in a common flow line. OPS is more commonly used than CPS. All jet pumps work with OPS because of their operating principle. Closed Power Fluid Systems (CPS): The injected power fluid and the produced fluid is NOT mixed together at downhole and they are returned to surface with separate flow lines. All piston pumps keep the power fluid and produced fluid separate because there is a seperate piston for each fluid. If the bottom hole assembly (BHA) has the proper arrangement to have seperate tubing strings for each fluid, they can be returned to surface separately. Advantage: Power fluid is circulated in and out of well in a closed loop. No need for processing the power fluid on the surface. Disadvantage: More initial cost for downhole equipment.
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(figure from SPE Handbook, 2007)

Central OPF hydraulic power oil treating system


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Cyclone:
The cleaning of the power fluid is accomplished with cyclone desanders that require a pressure difference accross them. Fluid enters from top tangentially and spirals downward. Rotational speed increases as radius of the cyclone decreases. The high rotaional speed cleans the fluid by centrifugal force. The clean fluid (overflow) spirals back upward through the vortex core to the vortex finder.

The dirty fluid exits downward at the apex thru the underflow nozzle.
Cones are usually constructed of cast iron with elastomer interior. Different designs for feed and underflow nozzles and cone sizes are available, changing the performance characteristics of the cyclone.
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(figure from SPE Handbook, 2007)

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Control Manifolds:
When a number of wells are to be pumped from a central pumping unit, a control manifold is used to direct the flows to and from the individual wells.
The functions of the control manifolds are: Distributing the flow of power fluid to the individual wells Regulating the flow rate of the individual wells Providing a means of measuring pressure to each individual well

Providing a means for running soluble plugs in surface lines (for cleaning the lines)
Providing a manual or automatic valve to control manifold pressure by by-passing excess power fluid
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Wellheads:
Functions: Directs power fluid down the tubing for pump in and operate Direct power fluid down the proper conduit for pump out

Shut power fluid line and provide a means to bleed pressure from the tubing
Catch and hold the pump at pump out operations Be a safety device to prevent high pressure from accidentally being applied to the casing

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End

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