tubing pump

Test Your Knowledge

Tubing Pumps Quiz

Instructions: Choose the best answer for each question.

1. What is another name for tubing pumps? a) Centrifugal pumps b) Submersible pumps c) Rotary pumps d) Jet pumps

2. Which component of a tubing pump is directly attached to the tubing string? a) Plunger b) Sucker rods c) Pump barrel d) Discharge valve

3. What is the primary function of the suction valve in a tubing pump? a) To prevent fluid from flowing back down the tubing string b) To regulate the flow rate of fluid c) To allow fluid to enter the pump chamber d) To control the pressure inside the pump chamber

4. Which of the following is NOT an advantage of tubing pumps? a) Increased production b) Lower operating costs c) Increased reliance on surface equipment d) Flexibility in installation

5. In addition to oil and gas production, tubing pumps can also be used for: a) Generating electricity b) Water injection c) Transportation of goods d) Food processing

Tubing Pumps Exercise

Scenario: You are an engineer working on a mature oil field. Production rates have been declining, and the existing surface pumping equipment is aging and inefficient. The well is equipped with a tubing string.

Task:

1. Explain why tubing pumps would be a suitable solution for this scenario, considering the advantages they offer.
2. Describe the key steps involved in installing a tubing pump system in this well.

Techniques

Chapter 1: Techniques

Tubing Pump Installation and Operation

1.1 Installation:

• Well Preparation: The well must be properly prepared for tubing pump installation. This includes running the tubing string, setting the pump at the desired depth, and ensuring the wellhead is equipped for surface operations.
• Pump Installation: The tubing pump is lowered into the wellbore on the tubing string. It's important to ensure proper seating and alignment of the pump within the tubing.
• Surface Equipment: The surface equipment includes the sucker rod string, the surface drive mechanism, and the control system. This equipment is connected to the tubing string and ensures the pump's efficient operation.

1.2 Operation:

• Surface Drive Mechanism: The surface drive mechanism provides the power to operate the sucker rods. It converts rotary motion into reciprocating motion, which drives the plunger within the pump barrel.
• Pumping Cycle: The reciprocating motion of the plunger creates suction and discharge cycles, lifting the fluid from the wellbore and pushing it up the tubing string.
• Fluid Delivery: The lifted fluid is transported through the tubing string and delivered to the surface for processing.

1.3 Optimization:

• Pump Selection: Choosing the correct size and type of tubing pump is crucial for optimal performance. Factors to consider include the well depth, fluid properties, and production requirements.
• Pump Setting: The depth at which the pump is set influences the efficiency and effectiveness of the pumping process. The optimal setting depth depends on the well configuration and fluid characteristics.
• Rod String Design: The design of the sucker rod string, including the length, diameter, and material, affects the efficiency of the pumping system. It's essential to ensure proper rod strength and minimize rod fatigue.

1.4 Maintenance:

• Regular Inspections: Frequent inspections of the surface equipment, the tubing string, and the pump itself are crucial for early detection of potential problems.
• Pump Retrievals: In some cases, the pump needs to be retrieved for inspection, repair, or replacement. This process involves carefully removing the pump from the wellbore using specialized equipment.
• Preventative Maintenance: Regular maintenance schedules, including lubrication, cleaning, and component replacement, help extend the lifespan of the tubing pump and minimize downtime.

1.5 Troubleshooting:

• Fluid Production Issues: Changes in fluid production rates or composition can signal problems within the pumping system. Troubleshooting includes checking the pump setting, fluid levels, and surface equipment operation.
• Mechanical Issues: Unusual sounds or vibrations from the surface equipment or wellhead can indicate mechanical problems. Diagnosing and addressing these issues promptly is critical.

1.6 Safety Considerations:

• Well Control: Proper well control procedures are essential during all stages of tubing pump installation, operation, and maintenance. This includes ensuring well pressure control and preventing any uncontrolled fluid release.
• Equipment Safety: Regular inspections and proper handling of equipment are crucial to minimize the risk of accidents.
• Environmental Protection: Preventing spills and leaks during operations and maintenance is vital to protecting the environment.

Chapter 2: Models

Types of Tubing Pumps

2.1 Conventional Tubing Pumps:

• Single-Acting Pumps: These pumps feature a single plunger that lifts fluid during the upward stroke. They are relatively simple and cost-effective.
• Double-Acting Pumps: These pumps have a plunger that lifts fluid during both the upward and downward strokes. They offer higher production rates and are often preferred for deeper wells.

2.2 Specialised Tubing Pumps:

• Jet Pumps: These pumps use a high-velocity jet of fluid to lift the reservoir fluids. They are often used in wells with low fluid levels or high gas production.
• Gas Lift Pumps: These pumps use compressed gas to lift the reservoir fluid. They are particularly suitable for wells with high gas-oil ratios.
• Progressive Cavity Pumps: These pumps use a rotating screw to lift the fluid. They are often used in wells with high viscosity fluids.

2.3 Downhole Motor Pumps:

• Electric Submersible Pumps: These pumps are powered by electric motors submerged in the wellbore. They offer high efficiency and are often used in wells with high production rates.
• Hydraulic Submersible Pumps: These pumps are powered by hydraulic motors submerged in the wellbore. They are suitable for remote locations with limited access to electricity.

2.4 Factors Influencing Pump Selection:

• Well Depth and Conditions: The well depth and reservoir conditions, such as fluid properties and pressure, significantly impact pump selection.
• Production Requirements: The desired production rate and the type of fluid to be produced influence pump choice.
• Cost and Maintenance: The initial cost and ongoing maintenance expenses should be considered when selecting a pump.
• Environmental Considerations: The environmental impact of the chosen pump technology should be assessed, especially in sensitive areas.

Chapter 3: Software

Tubing Pump Simulation and Optimization Software

3.1 Simulation Software:

• Reservoir Simulation: Software programs can simulate the behavior of the reservoir and predict the performance of different pumping scenarios. This helps optimize well design and production strategies.
• Pump Performance Simulation: Software packages can model the performance of tubing pumps under varying well conditions. This allows for accurate predictions of production rates and pump efficiency.

3.2 Optimization Software:

• Pump Selection and Optimization: Software tools can assist in selecting the most suitable tubing pump for a given well and optimizing its operation for maximum efficiency.
• Rod String Design Optimization: Software can analyze and optimize the sucker rod string design to minimize rod fatigue and maximize pump efficiency.

3.3 Benefits of Tubing Pump Software:

• Improved Decision Making: Simulation and optimization software provides valuable data that helps engineers make informed decisions about well design, pump selection, and production strategies.
• Increased Efficiency: Optimized pump settings and well design lead to higher production rates and reduced operating costs.
• Reduced Risk: Software analysis can help mitigate risks associated with pump failure and wellbore damage.

3.4 Examples of Tubing Pump Software:

• CMG STARS: A widely used reservoir simulation software.
• PIPESIM: Software for wellbore and surface facilities simulation.
• WellCAD: Software for tubing pump design and optimization.

Chapter 4: Best Practices

Best Practices for Tubing Pump Installation and Operation

4.1 Pre-Installation Planning:

• Thorough Well Analysis: Conduct a detailed analysis of the well to determine fluid properties, reservoir pressure, and expected production rates.
• Pump Selection and Sizing: Choose the appropriate pump type and size based on the well characteristics and production requirements.
• Rod String Design: Carefully design the sucker rod string to ensure adequate strength and durability.

4.2 Installation and Commissioning:

• Proper Installation Procedures: Follow established installation procedures to ensure correct pump seating and alignment.
• Surface Equipment Setup: Properly install and connect the surface equipment, including the drive mechanism and control system.
• Thorough Testing: Conduct thorough testing after installation to verify proper operation and performance.

4.3 Operations and Maintenance:

• Regular Monitoring and Inspection: Monitor pump performance regularly and conduct inspections to detect any potential problems.
• Preventative Maintenance: Implement a scheduled preventative maintenance program to ensure the longevity and reliability of the pump.
• Proper Lubrication: Use appropriate lubricants for all moving parts to minimize friction and wear.

4.4 Troubleshooting and Repair:

• Establish Clear Procedures: Develop clear troubleshooting procedures to diagnose and address pump failures promptly.
• Qualified Personnel: Ensure that repairs are performed by qualified personnel who are familiar with tubing pump systems.
• Accurate Record Keeping: Maintain accurate records of all maintenance and repair activities.

4.5 Environmental Considerations:

• Preventative Measures: Implement measures to prevent spills and leaks, minimizing the environmental impact of the operation.
• Proper Waste Disposal: Dispose of waste materials, including fluids and lubricants, responsibly.

4.6 Safety Procedures:

• Well Control: Maintain strict well control procedures to ensure safe operations and prevent uncontrolled fluid release.
• Equipment Safety: Implement safety measures during equipment handling and maintenance to minimize the risk of accidents.
• Emergency Response Plan: Develop and maintain an emergency response plan for dealing with accidents or incidents.

Chapter 5: Case Studies

Real-World Examples of Tubing Pump Applications

5.1 Case Study 1: Increased Production in a Mature Field

• Challenge: A mature oil field was experiencing declining production rates due to depleted reservoir pressure.
• Solution: Tubing pumps were installed to increase the lifting capacity and optimize production.
• Result: The installation of tubing pumps significantly boosted production rates, extending the field's productive life.

5.2 Case Study 2: Water Injection for Enhanced Recovery

• Challenge: A reservoir with high water content required water injection to improve oil recovery.
• Solution: Tubing pumps were used to inject water into the reservoir, increasing pressure and enhancing oil production.
• Result: The water injection program, facilitated by tubing pumps, successfully improved oil recovery and increased overall field production.

5.3 Case Study 3: Tubing Pump Optimization in a High-Gas-Oil Ratio Well

• Challenge: A well with a high gas-oil ratio experienced frequent gas locking issues, reducing pump efficiency.
• Solution: A specialized gas lift tubing pump was installed, optimizing the gas-oil separation process.
• Result: The specialized tubing pump effectively minimized gas locking, leading to increased production and improved well stability.

5.4 Case Study 4: Tubing Pump Deployment in a Remote Offshore Field

• Challenge: A remote offshore oil field required a reliable and efficient pumping system for deepwater production.
• Solution: A combination of electric submersible pumps and specialized tubing pump systems were installed, ensuring continuous production despite the challenging environment.
• Result: The deployment of tubing pumps in the remote offshore field facilitated efficient production, demonstrating their versatility and reliability in challenging conditions.

5.5 Case Study 5: Cost-Effective Tubing Pump Solution for a Low-Production Well

• Challenge: A low-production well required an economical solution for continued production.
• Solution: A single-acting tubing pump with a smaller rod string was installed, minimizing initial investment and ongoing operating costs.
• Result: The cost-effective tubing pump solution allowed for continued production from the well, demonstrating the ability of tubing pumps to be adapted to a variety of production scenarios.