Horizontal Well Downhole Dynamometer Data Acquisition: Prototype is ready!

Transcription

1 2018 Sucker Rod Pumping Workshop Cox Convention Center, September 11-13, 2018 Horizontal Well Downhole Dynamometer Data Acquisition: Prototype is ready! Project sponsored by ALRDC Chair: Victoria Pons Ph.D. Lynn Rowlan Cleon Dunham Ronda Brewer Tony Podio Ph.D. Ryan Gernentz Gabriel Guillen Walter Phillips Gregg Hurst Michael Romer Rajan Chokshi, Ph.D.

2 The Project Overview Design & build downhole dynamometer tools Generate dynamometer tool specifications Design and Test prototype Manufacture tools in sets of 6 Deploy tools in deviated & horizontal wells Generate test procedures for field data capture Design includes six tools strategically placed in each rod string Record data during pumping operation according to test schedule Retrieve and Download downhole data sets Validate & maintain data Developing visualization tools and user interface Accessible to all ALRDC members for model validation and creation Sept , Sucker Rod Pumping Workshop

3 Project Goal & Overview Gather true measured data on both deviated & horizontal rodpumped wells Actual downhole load & position: dynagraph cards Provide that measured downhole data to industry Improve our understanding of side loads, bending, friction, damping, and other factors resulting from well deviation Our industry needs downhole measurements in deviated wells that serve the same purposes that the 1990s measurements served for vertical or near vertical wells, Dr. Sam Gibbs 3

4 Historical Perspective - Sandia Gathered and published data from multiple test wells Project took place during a period of low oil prices Proved wave equation methods are sound and accurate But This only holds for vertical wells Number of well drilled since Sandia? How many of those wells are straight holes? 4

5 Rod Pump Diagnostics: Introduction Historically, the pump condition has been determined by dynamometer analysis A surface dynamometer measures position and load to generate a surface card The downhole card is calculated by solving the 1D wave equation (the surface card is projected downhole) The solution removes all dynamics in the surface card to show you the resulting work at the pump Since the rod string acts as a transmission line for the pump, any distortion in load signals result in poor downhole resolution 5

6 Example 1: Vertical Wellbore Calculations: Pump Intake Pressure Pump Efficiency Pump Displacement Rod Loading Additional observations: Well is pumped off Tubing movement is apparent Confidence in original design: Pumping conditions can be duplicated by predictive software 6

7 Example 2: Deep Deviation Calculations: Possibly Pump Intake Pressure Possibly Pump Efficiency Possibly Pump Displacement Possibly Rod Loading Additional observations: Well is close to pumped off Confidence in original design: Pumping conditions can be (relatively) duplicated by predictive software 7

8 Example 3: Shallow Deviation Calculations: No reliable downhole calculation available Both the Net Stroke and Fluid Load are distorted Additional observations: Production is the only proxy for the condition of the pump Incomplete fillage calculations will not be reliable 8

9 Rod Pump Diagnostics: Current Pitfalls The diagnostic solution to the 1D wave equation assumes all elastic deformation originates at the pump a) Shallow friction distorts both Gross Stroke and Fluid Load b) Deep deviation will tend to mostly affect Fluid Load The damping term of the wave equation is only meant to account for viscous forces, not mechanical friction Furthermore incorrect dynamometer data can give false indication of buckling anywhere in the string - Gibbs 9

10 HWDDDA Members at 2018 ALCE Walter Phillips Gregg Hurst Dr. Tony Podio Bill Lane Cleon Dunham Lynn Rowlan Dr. Victoria Pons Rob Shoup 10

11 HWDDDA Project Structure General Committee Business General Committee: Manage overall project Develop and Present to Industry Report progress to ALRDC R&D Committee Business Sub-Committee: Define/manage budget and document project Tool Design/Manufacturing/Testing Sub-Committee: Define tool specifications and tool testing requirements Select tool manufacturer Tool Deployment/Retrieval/Data Gathering Sub-Committee: Outline testing procedures and well selection criteria Gather data Data Validation/Maintenance Sub-Committee: Validate data, build and maintain database Tool Design Tool Deployment Data Validation 11

12 Test Wells All distinct categories of deviated wells Vertical (for control test) Deviated Slant Horizontal Testing Criteria Test at different SPM Anchored vs. unanchored tubing Rod guides vs. no rod guides (varying rod guides placement) Rod string configuration (steel, fiberglass, sinker bars) Depth of kick off point Fluid properties i.e. viscosity, gas, etc. 12

13 Project Overview: Test Scenarios Pump Considerations: Fluid Pound Gas Compression Operational Considerations: Vary SPM Vary Stoke Length Vary Inter-stroke Speed (proxy for pumping unit geometry testing) Valve Checks (PIP calculations) Design Considerations: Point of Initial Deviation Sinker Bar Length/OD Taper % (87, 86, etc.) Specialty Pumps Guiding 13

14 Tool Specifications Tools Placed along the rod string for collecting and storing data on-board Location of tools to be determined by deviation survey Sensors: 3 axis accelerometer position & relative gravity vector Multiple load cells linear loading, plus bending and compression Pressure, temperature, vibration, etc. Synchronized clocks for correlating data across multiple tools 14

15 Downhole Dynamometer Tool 15

16 Technical Details The ALRDC dynamometer tool is a battery powered electromechanical system used for data acquisition during artificial lift operations and can record acceleration X, Y, Z pressure - external temperature - external axial strains Footprint matching existing API 11B specifications and can easily be placed within the string 1.75 dia. and 30 inches long Has a pin/pin connection 7/8 API thread Constructed out of steel meets or exceeds artificial lift operating conditions Passed temperature and vibration downhole 16

17 Technical Specifications Software interface functions: Communicate with the tool Program data acquisition sequence, frequency, scheduling Record data in the memory, battery usage, memory allocation Validate tool status, display data, calibrate channels Calculate remaining battery life and memory space available Save data in ASCII format 17

18 Software Interface 18

19 Technical Specifications Firmware distinctive features Record high/low frequency data 9 data acquisition channels Selectable accelerometer range Power consumption (power management) optimization Memory allocation (writing to memory) optimization On-demand data acquisition Record high resolution data Recordkeeping capability for tool setup and running parameters 19

20 Current State of Software Tools Predictive Modeling Software Srod, RodStar, Qrod, LOWIS All of the current software are based on data from Sandia (vertical) The software used by the industry to design sucker rod strings is based on data collected in vertical wells. Therefore, it isn t sufficiently accurate for design and analysis of rod strings in our newer wells, Cleon Dunham, President of ALRDC It is unwise and economically risky to apply the results of such extended models without having adequate validation of their accuracy, Dr. A.L. (Tony) Podio Diagnostic Modeling Software for deviated wells does not exist 20

21 Future State of Software Tools Improve Predictive modeling Replace guess work with scientific design Precise placement of rod guides Optimal Sinker bar size and placement Etc Development of Deviated Diagnostic Models Remove mechanical friction from downhole card Enhanced well control based on deviation Extended life of artificial lift system 21

22 Benefits to Industry Improved understanding of effects of mechanical friction Data for new development of models for both predictive and diagnostic designs Improved optimization of Rod Lift Systems Provide basis for comparison of measurements i.e. deviation survey, surface data, etc Ability to isolate effects of other issues i.e. paraffin, scaling Ability to quantify effects of poor drilling practices that directly impact operations efficiency throughout the life of each well 22

23 Benefits for Participants Operational Benefits Testing various rod string designs Determine effects of deviation, pumping speed, and incomplete fillage Understand if inadequate tubing tension is a potential root cause of failures Develop more reliable intake pressure calculations Provide feedback to drilling on optimal back build profiles Reduction in CAPEX and OPEX through improved rod lift system design 23

24 Benefits for Participants Use information for making improvements to well designs and workflow tools during project period that will reduce or defer failures No more waiting until a significant number of failures have occurred before determining design success and understanding the root causes of failure: accelerate learnings from project testing to solve previously unknown failures on high visibility wells Early access to data (5 years) Customize testing procedure to address current failure issues on your wells Ownership of tools for use after project completion (if purchased) 24

25 Conclusions Improved downhole models can result in substantial reductions in operational expenses Better decisions and well designs We can t eliminate downhole friction, but we should be able to design around it, once better understood Gathering real-world data is a first & significant step 25

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