ALS presentation.ppt

© 2006 Weatherford. All rights reserved.1

Artificial Lift Overview


Weatherford’s Business Purpose

Provide production-enabling technologies and superior services that maximize our customers’ drilling, completion, production and intervention operations.

2


•One of the top five global oilfield service companies (NYSE: WFT)•32,000 employees located in more than 100 countries•Market leader in many key businesses

Key Facts


Lift Differentiators

Production Systems

• Only single-source provider of all forms of artificial lift

• Wellsite and remote automation/optimization systems for maximum reservoir management recovery

• Industry leader in focused technologies and hybrid lift systems to extend the operating envelope

4


1,000,000 wells world-wide

The Lift Market

• 90 percent have some form of artificial lift

• 10 percent are automated

• Weatherford’s solutions used to optimize 40 percent of automated wells

90%


Production Systems

Electric Submersible

Pumping(ESP)

PlungerLift

Reciprocating Rod Lift

GasLift

HydraulicLift

Progressing Cavity

Pumping (PCP)

Only company offering all forms of artificial lift world-wide

Single-Source Supplier


Artificial Lift Secular Trends

• Maturing reservoirs and increasing decline rates

• Industry consolidation

• Technology mandate to optimize reservoir productivity

• Development of intelligent well systems


Production Systems

The Evolution of Lift

Product/ Manufacturing Orientation

Transformation

Products+ Service+ Expertise = Solutions

Early 1990s Mid-Late 1990s 2000

• Reciprocating lift

• Indirect distribution channels

• Largely U.S. and Canada

• Limited service capability

• All forms of lift

• Applications and service excellence

• #1 Market share

• Leveraged delivery system

• Low-cost manufacturing

• Technology focus

• From western hemisphere dominance to global scale

• All forms of lift

• Hydrocarbon transmission

• Mechanical systems asset management

• Best-in-class workforce

• Remotely operated production optimization system (ROPOS)

• Technology greenhouse

• Global supply chain management

• Exploit core competency beyond traditional markets

Value Creation


Production Systems

= strategic alliance/arrangement

The Evolution of Lift (cont’d.)

AmpscotHighland

Pump

Leamco

AxelsonGuiberson

1988 1990 1996199519941993199219911989 1997 1998

Corod

Ruthco

Geremia

Anbert

PSI

Griffin Legrand

Johnson Trico

BMW

Taro

American

1999

McMurry-Macco

Tieben

ESPI

2000

WTGPJM

Case

EVIOil Tools

WeatherfordHighland Pump

2001

CAC

RotaflexCouplingsSargent

FPP

2005

SOS


• Composite PC pump

• Constant thickness stator for PCP

• Constant volume rotating pump

• Downhole water Injection

• Hybrid lift technologies advancement

• Mixed phase Pumping

• Deepwater gas lift valves

New Technology Focus

Lift Technology Advances


Reciprocating Rod Lift Systems

• Only OEM providing completely integrated systems

• Most comprehensive suite of surface pumping capabilities

– conventional – Long-stroke– Low-profile– nitrogen-over-hydraulic

• API and specialty rod pumps and sucker rods

• Exclusive OEM supplier of COROD® continuous sucker rods

• Pumping unit service and repair (Leamco)


ESPs

• Complete system offering, including complete downhole monitoring system

• Leading developer of ESP technology for coalbed methane applications

• Technology leader in expansion of ESPs into hybrid artificial lift systems

• Turnkey project capability, including full system optimization packages

• Ability to provide ALL downhole ESP completion equipment in-house, including SSDs, valves, packers, etc.


PCPs

• Integrated system

• Broadest range of applications and designs

• World-class testing and elastomer development

• Leading R&D for extending wellbore temperature ranges

• Exclusive OEM supplier of COROD®

continuous sucker rods


Gas Lift Systems

• Complete system integration

• Full range of downhole capabilities, including waterflood and chemical injection

• Leading developer of new valve technology

• Market leader in deepwater and extreme environment solutions

• High level of experience in application design and innovation


Plunger Lift Systems

• Market leader in development of intelligent control systems

• Complete suite of downhole products

• Total systems approach

• Most experienced application resources for well optimization


Hydraulic Lift Systems

• Only OEM supplier of both downhole jet and piston pump systems

• Totally integrated system

• Broadest range of designs for widest range of applications

• Premier design application software


Sucker Rods

• Continuous COROD® sucker rods

• API-normalized sucker rods

• Ultra high-strength EL® sucker rods

• High-strength XD sucker rods

• Quenched and tempered rods

• Sucker rod couplings

17


Capillary Technologies

Conduit to Precision Production Chemical Application

• Weatherford FOAM-LIFT Application Evaluation Technology

• Weatherford CC1-ATM Chemical Injection Valve

• Weatherford CAP STACKTM BOP System

• Weatherford WCVRTM System

Artificial Lift:

Production Chemistry Applications:• Foamer “ALS” Application

• Salt Inhibition

• Paraffin Control

• H2S Scavengers

• Combinations

Regions of Operation:• USA

• Latin America

• Asia PacMillions of Feet installed. Hundreds of Satisfied Customers!


Production Chemicals

• Drilling, acidizing, cementing, fracturing and water control

• Corrosion inhibitors and foaming agents


Field Automation/ Optimization Systems


Optimizing Wells World-Wide

South America8,000

North America25,000

Middle East3,000

Far East2,000Africa and Europe

2,000


Traditional Production Optimization

Hardware

S Y S T E M I N T E G R A T O R

Software Communications

Communications

Oil and gas operators


Hardware Software Communications

WeatherfordSolutions Gas Lift

Rod Pump

Injection

EFM

SubseaPipeline Plunger ESP

OffshorePCP

Oil and gas operators

Weatherford’s Solution


West Texas Field Case Study

• Before optimization

– 36 Beam well failures average per month

• After optimization

– 15 Beam well failures average per month

• Reduced number of pulling units from 30 to 13

• Pay-off in less than six months


Flu

id L

eve

l FO

P

0

100

200

300

400

500

600

700

800

900

1000

18WC2SE36 25WC2SW36 16WC2NE01 28WC2SE36 6WC2NE01 37WC2NE01 33WC2SE36 16WC2SE36 29WC2SE36 31WC2SE36

Before RPC RPC Installed

Average 201-ft decrease in fluid level

Wells

West Texas Field Case Study (cont’d.)

Fluid Levels—Before and After RPC

Decrease Fluid Level


WEATHERFORD ALS


Breakthrough Technology

ClearWELL

Prevention of Scale and Paraffin Deposition


ClearWELL Installation

A typical installation on a low producing oil well.

Installed at the surface.

Note the ferrite ring attached to the dipole generator.

Well intervention is not necessary since the signal is induced into the piping system.


ClearWELL - What is it?

The ClearWELL device is an electronic dipole generator that induces a randomly varying, high frequency electric field throughout the entire piping system.


The ClearWELL Signal

It is the varying time between declining pulses that allows the ions to move into position under varying T and P conditions.


ClearWELL - How does it work?

• Reservoir fluids flowing into a well bore can reach a super saturation condition due to the pressure drop or change in temperature, thereby causing scale to precipitate on the piping and down hole equipment

• The electric field generated by the ClearWELL device forces homogeneous crystal formation in suspension rather than on metal surfaces

• Scale crystallizes in suspension and is carried away with the oil water mixture

• Residual carbonic acid will gradually dissolve any carbonate scale that had previously adhered to the walls of the piping system

• Any paraffin present in solution will adhere to the scale and be carried away as well


ClearWELL Results


ESP results with ClearWELL

• One esp operating with ClearWELL for 776 days in a heavy West Texas scaling environment with NO chemicals

• Second esp online with ClearWELL for 742 days in West Texas – Well was pulled in December 06 due to a failed pump and virtually no scale or paraffin was seen – 2/1/08


Natural Gas (Well Y #1)

In 2005 the operator spent $400,000 to keep this well producing. The well is plagued with severe scale, both calcium carbonate and barium sulfate. The well is 12,970 feet deep and produces nearly 1,000 mcf of gas per day and 400 bbl of water. This is a very hot well with surface temperature 200 F. Acid jobs were scheduled weekly. Chrome tubing was used. Nothing worked on a consistent basis.The ClearWELL device C160 166961 was installed on 5/23/06 and is running 638 days or 21 months trouble free . The well is not showing any scaling tendency and the maintenance savings have been substantial compared to 2005. March 1, 2008

Well Schematic

High Temp High Pressure Gas Well

Production curve showing no fall off since Clearwell deviceattached. Just prior to installation 5/23/06 the well was down for repairs. Note the decline March thru May.

ClearWELL Case Study


F #1 and F #2

F # 1 and F #2 are oil wells plagued with heavy paraffin located in shallow water off the Louisiana shore line. Any maintenance or workover results in considerable expense and presents a serious environmental hazard. The wells have to be cut every 3rd day by wireline and the flow lines are pigged repeatedly to maintain production.

ClearWELL was installed using solar power on March 9, 2006 and have been running for over 14 months or 420 days. Visual observation indicates a significant reduction in paraffin in the flow lines allowing pig runs to be cut by 2/3 to date. Cutting has been reduced by a factor of 8 from every 3 days to every 24 days.

On F#1 alone the pig runs in the flow lines have been reduced from 182 in 2005 to only 42 so far in 2006. Pig runs show minimal paraffin. Intervals continue to be lengthened as the evaluation continues. Well wireline cuts have been reduced from 184 in 2005 to 52. There have been no hot oil jobs. In 2005 there were 3 hot oil jobs at $30,000 each. On an annual basis $367,748 is saved at these 2 wells by using ClearWELL.

June 1, 2007

Platform with solar panels for Clearwell

Unit installation

Pig after flow line run showing considerably less paraffin than expected. Interval 24 days extended from 3.



Well # 1959

Well # 1959 is an oil well with an electric submersible pump. It was acidized twice in 2005 and has not required any intervention since the ClearWELL device was installed on January 9, 2006. It has logged 813 days of trouble free operation. The time line indicates ClearWELL has been more cost effective and less hazardous than repetitive acid jobs. To pull the well, run acid and refurbish the pump cost the operator approximately $14,000.

The well continues to run trouble free with the esp life extended well past mean time to failure for the region. The customer has already saved $106,000 in workover expense alone. The ClearWELL device improves company safety metrics and is an approach to well management that is also environmentally friendly.

April 12, 2008

The production curve to the right shows that gas (~75 mcfd) and oil( ~10 bbld) have held steady since 1/9/06. Water

production is ~ 500 bbld .



Well Application Parameters

• Scale

– As long as the well makes scale, ClearWELL can treat it.

– All depths, pressures and well bore sizes

– All forms of lift

– The higher the flow rate the better the performance

• Paraffin

– Must have at least 10% (scaly) water; 30% or higher is desirable

– The higher the water content and the more scaly the water, the better the performance


Power Requirements

• ClearWELL is a low power device ~ 35 watts standard unit

• Power source options:

• AC source typically 110 or 220 volts

• Generator

• Solar panels & inverter

• Power source range:

• 87 – 240 volts

• 47-63 Hz


Superior Value

8/1/06 10/1/06 12/1/06 2/1/074/1/05 6/1/0612/1/05 2/1/054/1/05 6/1/05 8/1/05 10/1/05

Test Well #9 Clearwell

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7933

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Capillary Technologies Advanced Technology and Services for Safer and More Effective Production Enhancement


Capillary Applications

• Liquid Loading

• Corrosion Control

• Scale Control

• Salt Control

• Paraffin Control

• H2S Control

• Combination Products


Capillary Solutions for Various Well Problems

Specialized design and proper chemical and alloy selections control H2S and CO2

H2S and CO2

Chemicals delivered to the precise depth just beneath where paraffin begins to form

Paraffin Build-up

Targeted, customized production chemical solutions stop salt build-up right at the perfs

Salt Build-up

Injection of precisely engineered corrosion inhibitors controls corrosion and scale at the source

Corrosion and Scale

Pinpoint delivery of foaming agents and surfactants to unload fluids

Well Loading

Capillary SolutionWell Problem


Capillary System Benefits

• Maximizes well production while protecting tubulars

• Expedites payback – average of 30 to 60 days

• Reduces workovers due to scale, paraffin, corrosion, and salting

• Requires no batch treating or shut-in time

• Reduces chemical costs with precise placement and metering of production chemicals


Capillary System Benefits cont.

• Saves on downtime with continuous chemical delivery at the perforations

• Installs easily in live wells in just 3 to 4 hours

• Provides adjustable chemical volumes for changing production rates

• Enables chemical supplier to custom blend multi-phase chemical treatments to meet specific needs


Weatherford’s State-of-the-Art Equipment

• Truck-Mounted Units allow greater freedom of movement and safety in tight locations

• 10K BOP on All Trucks ensures that each wellhead on every job is provided with an extra margin of safety

• Auxiliary Air and Tool System enables fast and easy hookup of air tools to avoid time-consuming hand tool operations

• Extended Reach Crane, with elevated fulcrum and 28-ft. mast, enables working with greater safety above even the tallest wellheads in the field

Performance and Safety Advantages

• Wellhead Washdown Kit on every cap string unit permits fast and thorough cleanup before leaving jobsite

• 5,000 PSI Hydraulic Pump facilitates service of capillary string with pressure pumping jobs (as necessary)

• Climate-Controlled Cabin provides optimum working conditions in all weather


CC1-A Chemical Injection Valve

• Used to inject chemicals or fluids into the tubing to add chemical foamers for artificial lift, control corrosion in wells, treat paraffin, salt and or hydrate formation.

• Consists of a flow barrel, seat housing, floating ball and seat, stem, lower flow barrel, spring, setting and locking screw.

• Made of corrosion-resistant materials

• When injection pressure exceeds the closing force of the valve, the spring compresses, lifting the ball and stem off the seat allowing chemicals or fluids to be injected into the tubing.

Description


CC1-A Chemical Injection Valve

• Prevents chemical siphoning

• Prevents sand plugging

• Prevents gas back-flow

• Controls rate of injection

• Delivers reliable performance

• Calibrates to well conditions

• Adjusts easily on location

• Installs easily

Benefits


Is Your Well a Capillary Application?


Classic Symptoms of Prime Candidates for Capillary Injection

• Well begins to sweep on the charts

• Tubing pressure drops below critical level

• Liquid falls back

• Well loads up, falls off production

• Well unloads when shutting in, drooping soap sticks or batch treating


COLEMAN EQUATIONCritical Flow Rates vs Tbing ID and Ftp

Liquid Phase: SG=1.08; (9 ppg) - Avg Oil Field Brine

10

100

1,000

10,000

1 10 100 1,000 10,000

Flowing Tubing Pressure (psi)

Flo

w R

ate

(M

CF

D)

1-1/4", Includes Z=0.95 and20% safety factor



1-1/4", Includes Z=0.95

2-3/8", Includes Z=0.95

2-7/8"", Includes Z=0.95

Coleman Equation Includes Z = 0.95Includes 20% Safety

…. More Useful with Ftp<1,000 psi

TURNER EQUATIONCritical Flow Rates vs Tbing ID and Ftp


10

100

1,000

10,000

1 10 100 1,000 10,000


Flo

w R

ate

(M

CF

D)




1-1/4", Includes Z=0.95

2-3/8", Includes Z=0.95

2-7/8"", Includes Z=0.95

Turner Equation Includes Z = 0.95Includes 20% Safety

…. More Useful with Ftp>1,000 psi

COLEMAN EQUATIONCritical Flow Rates vs Tbing ID and Ftp


10

100

1,000

10,000

1 10 100 1,000 10,000


Flo

w R

ate

(M

CF

D)




1-1/4", Includes Z=0.95

2-3/8", Includes Z=0.95

2-7/8"", Includes Z=0.95

Coleman Equation Includes Z = 0.95Includes 20% Safety

…. More Useful with Ftp<1,000 psi

TURNER EQUATIONCritical Flow Rates vs Tbing ID and Ftp


10

100

1,000

10,000

1 10 100 1,000 10,000


Flo

w R

ate

(M

CF

D)




1-1/4", Includes Z=0.95

2-3/8", Includes Z=0.95

2-7/8"", Includes Z=0.95

Turner Equation Includes Z = 0.95Includes 20% Safety

…. More Useful with Ftp>1,000 psi

Critical Flow Rate Calculations―Critical Decisions


Liquid Loading: Coleman EquationEffects of Proper Foamer Application

Foam Cluster Apparent Density = 6 lbm/ft3

Foam Cluster Water Surface Tension = 20 dynes/cm

Standard Assumptions that “Simplify” the Turner Equation to the Coleman Equation:

Vc = 1.593σ1/4(ρLiquid-ρGas)1/4

ρGas1/2

TurnerEquation

60 dynes/cm surface tension for water20 dynes/cm surface tension for condensate67 lbm/ft3 water density45 lbm/ft3 condensate density0.6 gas gravity120 oF gas temperature20% upward adjustment Fit his empirical data

Vc = C(ρLiquid-0.0031p)1/4

(0.0031p)1/2

SimplifiedColeman Equation

Colemaneliminates 20 percent adjustment

Lower PressuresFOAM CASE

Vc reduces by factor of +/- 2.5 at 100 PSI22.8 to 9.3 ft/sec

Note: No friction considered for additional foam viscosity

C = 4.434, waterC= 3.369,condensate,p<=1,000 PSIC = 3.369, FOAM

Gas Flow

FOAM Droplet Cluster

Gravity


Calculated PREMIN and PREMAX for Various Alloys based on Composition Limits in ASTM Specs

C-27

6 (N

1027

6)

31 (N

0803

1)

33 (R

2003

3)

625

(N06

625)

AlL-

6XN

(N08

367)

25-6

MO

/926

(N08

926

254

SMO

(S31

254)

2507

(S32

750)

Zero

n 10

0 (S

3276

0)

317L

MN

(S31

726)

904L

(N08

904)

317L

M (S

3172

5)

2205

(S32

205)

2205

(S31

803)

317L

(S31

703)

825

(N08

825)

316L

(S31

603)

2304

(S32

304)

19D

(S32

001)

304L

(S30

403)

0

10

20

30

40

50

60

70

80

90

100

Cal

cula

ted

PR

E N

umbe

r R

ange

NOTE: PRE Number is a measure of the alloys tendency to resist CORROSION in chloride solutions

Alloy 625, Inconel, PRE AVG = +/- 51

Super Duplex 2507, PRE AVG = +/- 43

Duplex 2205, PRE AVG = +/- 34

316L, Austenitic SS PRE AVG = +/- 27

$

Alloy C-276, Hastelloy PRE AVG = +/- 71


Selection GuideCorrosion Resistant Alloy Tubulars in Gas Wells

CO2, H2S, Chlorides, Temperature….Which one is most important?

From Schillmoller, 1989 … Selection of Corrosion-Resistant Alloy Tubulars for Offshore Applications

0.001

0.01

0.1

1

10

100

1000

10000

100000

0.001 0.01 0.1 1 10 100 1000 10000 100000

Alloy 625

Super Duplex 2507

Duplex 2205

Alloy 300 series

Partial Pressure of H2S psia

Par

tial P

ress

ure

of C

O2

psia



Alloy 304 2,205 625

Acidity, pHMild

EnvironmentCL

Moderate Environment

CL

Severe Environment

CL

Mild Environment

CL


CL

Severe Environment

CL

Mild Environment

CL


CL

Severe Environment

CL1 100 10 1 3,000 300 30 100,000 10,000 1,0002

3

4

5 1,000 100 10 40,000 4,000 400 1,500,000 150,000 15,0006

7

8 6,000 600 60 200,000 20,000 2,000 10,000,000 1,000,000 100,000

Severe Environment


Mild Environment< 230°F with no O2 or free sulphur(Moderate partial pressures of H2S and CO2)

< 230°F to 392°F with no O2 or free sulphur(Can have high partial pressures of CO2 but must be low pp’s of H2S))

< 347°F to 500°F with O2 or free sulphur(High partial pressures of H2S and CO2)



304 Stainless


Susceptibility of CRA to Pitting and Crevice Corrosion in Acid Brine

100

1,000

10,000

100,000

1,000,000

10,000,000

1 2 3 4 5 6 7 8

Acidity, pH

Ch

lorid

e C

on

cen

tra

tion

, p

pm

(MIL

D E

NV

IRO

NM

EN

T)

1

10

100

1,000

10,000

100,000

Ch

lorid

e C

on

cen

tra

tion

, p

pm

(SE

VE

RE

EN

VIR

ON

ME

NT

)

10

100

1,000

10,000

100,000

1,000,000

Super Duplex 2507

MOST OILFIELD

BRINES AREMILD OR

MODERATE ENVIRONMEN

T5<pH<7.5

Inconel 625

Duplex 2205


Moderate Environment – CL-, X1000 230oF>T,oF<400oF

Partial Pressure H2S, <10psi


Stainless Steel Tubing Stretch Calculator

… Make Sure You ARE SET Where You Think You ARE SET

Tubing DataTubing Material Super Duplex 2507Tubing OD 0.250 In.Tubing WT (wall thickness) 0.035 In.Tubing WGHT 80 Lbs/1,000 ft.Tubing Set Depth 18,000 Ft.Tubing Tensile Strength 120 X 103 psiTubing Yield Strength 80 X 103 psiTubing Modulus of Elasticity 29 X 106 psi

Chemical DataChemical Material WFT 97111WChemical Density 8.33 Lb/galIs string full of Chemical? Y Y/N

Pump DataPump Pressure 0 psi

Pull DataPull Force 0 lbs

Temperature DataAmbient Temperature 80 °FWell Temperature 220 °F

Weight CalculationsTubing Weight 1440 LbsChemical Weight 198 LbsPump Pressure Force 0 LbsPull Force 0 LbsTotal Force to cause 80% Yield Failure 1513 Lbs CAUTIONTotal Force to cause Yield Failure 1891 Lbs OKTotal Force to cause Tensile Failure 2837 Lbs OK

Total Tubing “Effective” Weight 1638 Lbs

X-Section Calculations CalculationsMetal X-Section Area 0.02364 In2ID X-Section Area 0.02545 In2OD X-Section Area 0.04909 In2

Elongation CalculationsTubing Elongation due to Tubing Weight 37.8 Ft.Tubing Elongation due to Chemical Weight 5.2 Ft.Tubing Elongation due to Pump Force 0.0 Ft.Tubing Elongation due to Pull Force 0.0 Ft.Tubing Elongation due to Temperature Effect 18.1 Ft.

Total Tubing Elongation 61.2 Ft.

Data Section Calculations

1. All calculations assume tubing is hanging in air with CC1-A valve in place on end of string.2. External/negating forces that would reduce stretch are ignored. This is a worst case stretch evaluation.3. If CAUTION shows up, effective weight exceeds 80% yield strength of tubing—getting close to tubing deform4. If ALARM shows up, effective weight exceeds yield strength of tubing—tubing will permanently deform5. If FAILURES shows up, effective weight exceeds tensile strength of tubing—tubing will part

NOTE:


Criteria for Selecting Foaming Agents

• Condensate ratios• Foam quality and bubble size• Lack of emulsion• Complete water analysis• Testing of live fluids• Selection and incorporation of

other components.**The other components will prevent

corrosion, scale, and salt deposition.

The key to maximizing production is the selection of the correct foaming agent

With Weatherford Engineered Chemicals’ CCT simulator, we can effectively prove your application before it is installed.

All of the following are important considerations:

58


Weatherford Engineered Chemistry (WEC)

Proven formulas including biocides used for refinery processes and well workover applications. W-Cap certified versions available.

Specialties

Dispersants, penitrants, pour point depressants, crystal modifier. W-Cap certified versions available.

Paraffin Treating

Versions available for continuous or formation squeeze. Hot/cold climate stable. W-Cap certified versions available.

Scale Inhibitors

A broad range to treat water in oil emulsions. W-Cap certified versions available.

Emulsion Breakers

Complete line of non-regeneratative scavengers. W-Cap Certified versions available.

H2S Scavengers

Oil- and water-based, continuous or batch applied Inhibitors designed for a wide range of systems and conditions. W-Cap certified versions available.

Corrosion Inhibitors

AdvantagesProduct Category


Hydraulic Lift Systems


Global Perspective

• The broadest range of quality products and services in the industry

• Fit-for-purpose

• A wealth of global experience

• A commitment to continuous improvements, bringing business benefits to our clients

• A level of service that meets or exceeds the business goals of our clients

• A desire to be partners and share in the success with our clients


Fit-For-Purpose Solutions

Solutions

• Making the right decision with quality data, effective data management and thorough preparation

• Preparation, planning and implementation of new technology to reduce the capital cost of development

• Commitment to excellence and innovation

• Proven track record of providing reliable services


Hydraulic Jet Lift System Advantages

• No moving parts

• High volume capability

• Free or wireline retrieved

• Deviated wells

• Tolerant to solids, corrosive fluids and high GORs

• Adaptable to existing BHAs and sliding sleeves

• Well site repairable

• Excellent for producing viscous crude

• Low pump maintenance/easy to repair

ProductionCasing

High PressurePower FluidPacker Nose

Bottom HoleAssembly

Piston or Jet“Free Pump ”

Standing Valve

Surface PowerFluid Package

ProductionCasing


Bottom HoleAssembly


Standing Valve



Hydraulic Jet Lift Application Considerations

Typical Range Maximum

OperatingDepth 5,000 to 10,000’ TVD 15,000’ TVD

OperatingVolume 300 to 1,000 BPD >15,000 BPD

OperatingTemperature 100° to 250° F 500° F

Wellbore 0 to 20° 0 to 90° Pump

Deviation Hole Angle Placement <24°/100’ Build Angle

Corrosion Handling Excellent

Gas Handling Good

Solids Handling Good

Fluid Gravity >8° API

Servicing Hydraulic or Wireline

Prime Mover Type Multi-Cylinder or Electric

Offshore Application Excellent

System Efficiency 10% to 30%

ProductionCasing


Bottom HoleAssembly


Standing Valve


ProductionCasing


Bottom HoleAssembly


Standing Valve



Type HHigh Volume

Bottom hole assembly

StandardCirculation

Jet Free Pump Applications

Type H

Tubing

Packer nose

“Free” Jet Pump

Nozzle

Throat

Diffuser

Bottom hole

assembly

Retrievable standing

valve

Packer

Casing

Adaptable

Equalizing check valve

ReverseCirculation

Lock


Wireline/Tubing Conveyed Applications

Wireline Set

Tubing Conveyed

Sliding Sleeve Tubing/Packer Fixed Insert Fixed Casing


Hydraulic Piston LiftSystem Advantages

• Often free or wireline retrievable

• Positive displacement—strong drawdown

• Double-acting high-volumetric efficiency

• Good depth/volume capability— +15,000 ft.

• Deviated wells

• Multi-well production from single surface package

• Horsepower efficiency


*SpecialAnalysisRequired

Hydraulic Piston LiftApplication Considerations

ProductionCasing

High PressurePower Fluid

Packer Nose

Bottom HoleAssembly


Standing Valve


ProductionCasing

High PressurePower Fluid

Packer Nose

Bottom HoleAssembly


Standing Valve


Typical Range Maximum


OperatingVolume 5 to 500 BPD 4,000 BPD

OperatingTemperature 100° to 250° F 500° F

Wellbore 0 to 20° 0 to 90° Pump

Deviation Landed Pump Placement <15°/100’ Build Angle

Corrosion Handling Good

Gas Handling Fair

Solids Handling Poor

Fluid Gravity >8° API

Servicing Hydraulic or Wireline

Prime Mover Type Multi-Cylinder or Electric

Offshore Application Good



Basic downhole installations

CasingReturn

ParallelReturn

Free Pump

CasingReturn

Tubing Conveyed

T/T AnnulusReturn

Open Power Fluid Configurations


“Free Pump”Pump In and Out Operation


Why Weatherford?

• Achievement of a unified, seamless organization through functional integration

• Promotion of the importance of quality improvement

• Recognition of processes necessary for achievement of continuous improvement

• Sharing information on successful quality strategies within the partnership

• Alignment of business strategy and objectives with those of our customers

• Establishment of performance criteria to measure process improvement


Gas Lift Systems


Weatherford Gas Lift Systems

• Only company offering all major forms of artificial lift

• Second to none technical support capabilities and field support

• State-of-the-art analysis software for installation design and sizing, individual well evaluation and troubleshooting

• Custom solutions to gas lift challenges

Enhancing production and reservoir recovery with comprehensive gas lift systems, including a complete portfolio of value-added products and services.


Weatherford Advantages

• Complete system integration

• Full range of downhole capabilities, including waterflooding, steam flooding and chemical injection

• Globally recognized leading developer of new valve technology and extensive performance testing

• Market leader in development of hybrid lift systems employing gas lift technologies

• Field-proven solutions, including deepwater and high-volume applications

• Most comprehensive suite of gas lift solution offerings, including a wide range of sizes

• A complete line of computerized engineering optimization (CEO™) electronic controllers


Gas Lift Objectives and Process

• To lift as deep as possible within constraints of production system

• Inject gas requirements through one single valve station


Gas Lift Applications

• Increase production from flowing wells

• Kick off wells that will flow naturally once heavier completion fluids are vacated from production spring

• Unload water from gas wells that would otherwise prevent gas production

1,600

1,400

1,200

1,000

800

600

400

200

0 200 300 400 500 600 700

Max

imum

Flo

w R

ate

, B

LPD

Ptf, PSI

Tubing size: 2.0” IDPI: 5.6 B/D/PSI

• Continuous or intermittent flow

• Tubing and casing flow

• Wells where pressurized injection gas is readily available

• Wells with insufficient bottom hole pressures or deep wells that cannot flow against hydrostatic head


Application Considerations

Typical Range Maximum*


OperatingVolume 100 to 10,000 BPD 30,000 BPD

OperatingTemperature 100 to 250°F 375°F

Wellbore 0 to 50° 70° Deviation Short to

mediumradius

Corrosion Handling Good to Excellent (With upgraded materials)

Gas Handling Excellent

Solids Handling Excellent

Fluid Gravity Best in >15° API

Servicing Wireline or workover rig

Prime Mover Type Compressor

Offshore Application Excellent



Gas Lift Offerings

• Valves

• Mandrels

• Latches

• Kickover tools

• Communications and isolation devices

• Downhole regulators

• Surface controls

• Special application equipment


Valves

• Injection pressure-operated

• Pilot-operated

• Production pressure-operated

• Special application valves

– Chemical injection

– Water injection

– Steam injection

A complete line of McMurry Macco™ wireline-retrievable and tubing-retrievable gas lift valves.


Mandrels

• Product families feature 1- and 1 ½-in. ID pocket profiles

• Oval and round body designs

• Several configurations and models– Forged and machined pocket– High-pressure– Solid-body– Special-clearance designs

• Injection subs

• A variety of porting options– Annular, tubing, side-string, bypass and chemical-

treating injection

An extensive range of wireline-retrievable side-pocket mandrels an tubing-retrievable mandrels.


Progressing Cavity Pumps


One Weatherford

34,000 people

710 facilities

100 countries

85 manufacturing plants

16 training and R&D facilities

More than…More than…


Weatherford PCP Manufacturing Locations

CANADAEDMONTON (Strathcona) – Manufacturing, R&D

LLOYDMINSTER – Assembly, Testing, Head Service Center

MEDICINE HAT – Assembly Center

CANADAEDMONTON (Strathcona) – Manufacturing, R&D

LLOYDMINSTER – Assembly, Testing, Head Service Center

MEDICINE HAT – Assembly Center

BRAZILSAO LEOPOLDO – Manufacturing, Assembly, Testing

BRAZILSAO LEOPOLDO – Manufacturing, Assembly, Testing

Sao Leopoldo

EdmontonEdmontonLloydminsterLloydminster

Medicine HatMedicine Hat


Weatherford PCP FacilitiesStrathcona, AB, Canada

• 108,800 square feet

• ISO-9001 certified

• Rotor and stator manufacturing

• Drivehead component manufacturing

• Extensive elastomer Lab

• Pump test benches

– 12 endurance flow loops

– 1 slurry test loop

• PCP & PDM Research and Development

• PDM relining

• Manufacturing process development

• Global technical support services

• International customer service


Weatherford Flow LoopsStrathcona FacilityWeatherford Flow LoopsStrathcona Facility

High temperature loops

Slurry loops

Endurance/fatigue loops (12)


• Automatic comparison of actual versus target dimensions

• Rapid verification of cores and complex geometry rotors

• Resolution accuracy within 0.002”

• Portable

Laser CMM Inspection

Weatherford PCP FacilitiesStrathcona, AB, Canada


Weatherford PCP FacilitiesLloydminster, AB, Canada

• 77,700 square feet

• Pump assembly and phasing

• Pump testing

• Drivehead assembly

– Direct

– Hydraulic

• Drivehead testing

• Head repair and service center

• Accessory manufacturing

• Surface transfer pumps

• Drivehead and accessory development

• Canadian technical support

• Canadian customer service


Weatherford PCP FacilitiesSao Leopoldo, RS, Brazil

• 103,490 ft2

• ISO 9001 Certified

• Downhole pump manufacturing, phasing, and assembly

• Surface Transfer Pumps

• Industrial PC Pumps

• Test benches for oil/water (6)

• Drivehead manufacturing, assembly, and testing

• Accessory manufacturing

• Extensive elastomer laboratory

• Product engineering & development

• Global technical support and customer support services


Weatherford PCP FacilitiesSao Leopoldo, RS, Brazil

PCP Test Benches

3 for downhole pumps

3 for surface/transfer pumps


Weatherford Service CenterSamara, RussiaWeatherford Service CenterSamara, Russia


Progressing Cavity Pump Technologies


Elastomer Development

• Elimination of explosive decompression

• 15% swell versus 200%

Old High Nitrile elastomer

New ED resistant elastomer

Weatherford PC Pump Technology


Tensile Strength

0

500

1000

1500

2000

2500

3000

3500

WFD 59O ArtemisNO80

GeremiaNBR-M

Kachele 366 Mono A Moyno 102 NetzschNBR01

Elongation

0

100

200

300

400

500

600

700

WFD 59O ArtemisNO80

GeremiaNBR-M


Tear Strength

0

20

40

60

80

100

120

140

WFD 59O ArtemisNO80

GeremiaNBR-M


Water Swell

0

5

10

15

20

25

30

35

WFD 59O Artemis NO80 GeremiaNBR-M


903 Oil Swell

0

2

4

6

8

10

12

14

16

WFD 59O Artemis NO80 GeremiaNBR-M


Abrasion Resistance

0

20

40

60

80

100

120

140

160

180

200

WFD 59O ArtemisNO80

GeremiaNBR-M


Abrasive Wear

W A B C D E F W A B C D E F W A B C D E F

W A B C D E F W A B C D E F W A B C D E F


Elastomer benchmarking versus the competition



Elastomer R&D



3-D Non-linear Finite Element Modeling


• Elastomer/fluid compatibility testing

• Multi-component & multiphase fluids that normally separate when heated

• 4 chambers

• 150ºC and 3000 psi

Agitating Autoclave




• Impact on heat build up and pressure distribution.

• Test variables: free gas level, liquid viscosity, pump geometry, rotor fit, and pump speeds.

Free Gas Testing


Technical Support

• Application Design

• Pump Optimization

• Problem Well Analysis

• Fluids Analysis

• Failure Analysis

• Customer services

• Logistics

• Training



PCP Strategic Partnering


Strategic Partnering

Focus on maximizing value over the life of the field:

– Evaluation collaboration

– Integrated solutions for life of the well

– Well designs for production

– Migrate technologies over time

– Management, maintenance, production optimization


Strategic Partnering CASE STUDY

200

20.1

77 jo

bs/

wm

200

30.1

55 jo

bs/

wm

200

40.1

22 jo

bs/

wm

200

5 Y

TD

1.1

8 jo

bs/

wm

200

10.1

82 jo

bs/

wm

Service Jobs perWell Source: WHE-ALS-CIO

Start of WHE-ALS-CIOMarch 2001

Slope =-0.0015

Reduced service jobs per well.

200

2

200

3

200

4

200

5 Y

TD

$28

.8 M

$19

.2 M

200

1

Total Annual Service Job Cost Flat-line Comparison

Actual

Projected, based on servicejobs per well, 2001

Reduced total service cost.


Complementary Technologies

• All forms of Artificial Lift

• Formation evaluation

• Drilling & well construction

• Completion equipment & services

• Downhole sand control

• Surface sand management

• Production automation & optimization

• Intervention

• Pipe line heating

• Produced water treatment


Progressing Cavity Pump Products


Total System Sourcing

Downhole Equipment

Belts & Sheaves

Surface Drive

Stuffing Box

Pumping Tee

Electric Motor

Polished Rod

Sucker Rodsw/ Couplings

Surface Equipment

PC Pump Stator

PC Pump Rotor

No-Turn Tool

Tubing String

Tagbar

Sucker Rodsw/ Couplings


Standard Pump Models & Geometries (1 of 2)


Standard Pump Models & Geometries (2 of 2)


Heavy Oil Rotor Geometries

60 82 88 107 140 200 500 615 820 1000 1010 1100


PC Pump Tag Bar Assemblies


Insertable PC Pumps

Tubing

Pump Seating Nipple

Extension Tube

PC Pump

Seating Mandrel

Pull Rod

Tag Bar

No-Turn Tool

• Same operating principle than conventionalconfiguration but having the complete pumprun on the rod string

• The only device attached to the tubingstring is the pump seating nipple (PSN)

• In case of failure, the complete pump can beremoved by pulling the rods

• Models available to handle up to:

– 175 Bls/day (25 m3/day) in 2⅞” tubing

– 600 Bls/day (95 m3/day) in 3½” tubing




Insert Pump


Charge / Recirculation PumpProductionPump

Pup Joint(could be perforated)

Pony Rod

Charge/RecirculationPump

• Tandem dual PC pump configuration

– A large volume/low lift pump located at the

bottom (also called charge pump)

– A lower volume/high lift pump located at the top

(known as production pump)

• In gassy applications, the charge pump compresses

the fluid to allow the primary pump operate at higher

efficiency.

• In sandy applications, a perforated nipple between the

pumps allows some fluid to recirculate to keep the

sand in solution.


PC Pump Intake Accessories

Tail Joint – Tubing extension to lower the pump intake below the perforations to aid in gas/liquid/solids separation.

Downhole Gas Separator – Passive device installed at the pump intake designed to reject gas. Internal baffles utilize fluid dynamics principles to separate free gas from liquids.


Sucker Rods

• Continuous Corod® sucker rods

• API normalized sucker rods

• Ultra high-strength EL® sucker rods

• High-strength XD™ sucker rods

• Quenched and tempered rods

• Sucker rod couplings

• Revolutionary Pro-KC™ connections


PCP Driveheads

A complete line of electric driveheads from 5 to 250 Hp.


PCP Driveheads

A complete line of standard hydraulic driveheads and power units to 99 Hp, non-std installations to 200 Hp.


PCP System Accessories

• Rod Guides / Centralizers,

rotating and non-rotating

• Tubing drain / insulated

nipple

• Rod shear coupling

• Anti-rotation devices

• Composite Pumping Tee


Motor Controllers and Downhole Gauges

• Fixed Speed Controller

– Torque limiter

– Auto-restart

• Variable Speed Controller

– Full automation and control functionality

– Accepts external analog or digital signals for additional “intelligence” (pressures, temperatures, flow, etc.)

– Configured for remote communication and control.

• Hardened downhole gauges for PCP applications

– Single & multi-point gauges for P & T

– mPOD3 vibration gauge


Weatherford Differentiation

Weatherford brand recognition and acceptance

Global service infrastructure

Engineering and technology

- Application design expertise

- Technical support including 3 elastomer labs

- Testing and verification of performance

Supply chain depth and breadth – Three PCP production facilities plus supply chain partners

Proven performance

Total system solutions: pumps, rods, drives, controls, telemetry, gauges, and accessories

Strategic partnering


© 2006 Weatherford. All rights reserved.120SPE ESP Workshop 2009 - Houston Texas

Surface Pumps Horizontal Pumping Systems (HPS)


Best solutions

• Dependable High “Uptime” percentage

• Minimal routing Maintenance

• Flexible - for changing operating conditions

• Low Capital Cost

• Low Maintenance Cost

• Low Whole Life Cost


Key advantages

• Increase production without drilling new wells

• Flooding: Water/CO2/Polymer

• Pressure maintenance

• Increase production from existing wells

• Low capital, operating and whole life cost


Applications

• Upstream Oil & Gas Applications:

– Produced Water Injection (Disposal, Waterflood, Pressure Maintenance)

– Power Fluid Pump (for downhole Jet/Hydraulic pump)

– Liquid CO2 for Transfer or Injection

– Crude Oil Transfer

– Boiler Feed for steam generators - SAGD


Available Models – Small

Up to 100hp (Patented)


Available Models – Medium

100 to 300hp “Single Beam”


Available Models – Large

350 - 1500hp “Double Beam"


HPS Configuration “side winder” Engine


HPS Configuration

API 610 / 682


HPS Configuration

Limited Available Space2 Systems - 1 Skid - Canada


HPS Configuration

Limited Available Space and belt drive for low cost speed changes


High Quality GA’s with “Bill of Material”


HPS Installation

Crude Oil Transfer - Texas


HPS Installation

Waterflood – Alberta Canada


HPS Installation

75,000BPD Disposal, Texas


HPS Installation

53’ Trailer Mounted – Rockies USA


HPS Installation

Boiler Feed Pumps SAGD – Canada


HPS Installation

Produced Water Disposal – Texas


HPS Installation

Crude Oil Transfer Pumps - Russia


HPS Installation

DNV Certified – North Sea


HPS Installation

Produced Water Disposal – Texas


HPS Installation

1250hp Power Fluid Pumps - Alaska


HPS Installation

600hp Natural Gas Engine – Mid Cont.


HPS Installation

Utilador Mounted Disposal - Manitoba


HPS Installation

70,000bpd Cavern Storage - Gulf Coast


Competition

• Split-case centrifugal pumps

– Long lead-times

– Expensive

– 2 seals

– inflexible


Competition

• Plunger (triplex/Quintuplex) positive displacement pumps

– High Routine Maintenance

– Many repairs

– Extra wearing parts

• dampers, oilers, sump pump, belts etc

– Environmental issues

• Noise, Emissions, Vibration

– Reduced “up-time”


Product Comparison

SELECTION FACTORS HPS Plunger PD SPLIT-CASE

Capital Cost Low Low High

Life Cycle Cost Low High Moderate

Maintenance Low High Low

System Efficiency 75% 90% 75%

Noise Level Low High Low

Vibration/Pulsation Low/Nil High Low/Nil

Environmental Impact Low High Low

Repair Cost Low High High

Down-Time for Repair Low Moderate High

Flexibility To Change High Moderate Low


Summary of Benefits

• Short delivery lead times

• Competitive pricing

• Reliable for 24/7 operations

• Minimal routine maintenance

• Easily replaced components (pump, TC, seal)

• Maximum “up-time”

• Flexible – for changing operating conditions

Documents

ALS presentation.ppt