4th Annual Appalachian Basin Gas Well Deliquification Workshop. Garold Muth. President

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1 4th Annual Appalachian Basin Gas Well Deliquification Workshop Marietta College, Marietta, Ohio June 3 5, 2013 Extending Downhole Rod Pump Run Life while Dewatering Gas wells. an Garold Muth President

2 Abstract Submitted for APOGCE 2011 Extending Downhole Pump Run Life using Ingenuity Innovation and New Technology Lead to Reduced OPEX and Increased Revenue in the Duri Steam Flood (DSF), Indonesia. SPE PP In DSF, > 700 Pump Stuck (PS) jobs are performed each year which primarily caused by sand production. Annual total cost of this routine service work is multimillion dollar. In addition, with average of 3 days downtime/ps job, there is over 2,100 days of lost production associated with downtime. With currently over 5,000 active producer wells, identifying artificial lift SRP alternatives that can improve run life and reduce number of PS jobs performed would result in lower OPEX (*Operating Expense) (less PS jobs), higher production (reduced downtime), and lower risk of HES (*Health, Environment, Safety) incidents (less rig work). Three viable options were identified for a field trial after soliciting ideas and opinions from Service Suppliers, MSS (*Maintenance Supports & Services) Team, and Chevron Global Network to overcome these pump stuck issue: 0.015" fit Tubing Pump Stroke-Thru Pump 0.002" fit FARR Plunger The PMT (*Production Management Team) HOOU (*Heavy Oil Operation Unit) Artificial Lift Lean Sigma confirmed that these artificial lift options had a longer run life than the standard 0.010" fit pump. Average run life was increased by 93 days, and 70% of the time produced a longer run life. During 12 months trial period, there was an average reduction of 12 PS jobs/month compared to baseline data. Since the 0.002" fit FARR Plunger had encouraging results in low wellhead temperature wells, there was initiative to evaluate it in higher temperature by modifying the pump fit to 0.005" considering thermal expansion. In 2010, 15 units of 0.005" fit FARR plungers were tested, replacing either a Stroke-Thru or 0.015" Fit Pump that had failed. The results were encouraging and indicated that the 0.005" FARR Plunger exceeded the run life of the previous pump 71% of the time with additional incremental run life of 44 days. Author Aan Akhmad Prayoga Petroleum Engineer PT Chevron Pacific Indonesia 2

3 DURI STEAM FLOOD (DSF), INDONESIA RESULTS PROBLEM: 700 Well Pulling Jobs per year due to stuck pumps Multi-millions of dollars spent on service for those wells 3 days down time per well = 2100 days of lost production annually Estimated $2.1 Million in lost production (10bbl) SOLUTION: Identify artificial lift SRP alternatives that can improve run life 3 viable options Tubing Pump Stroke-Thru Pump FARR Plunger (non steam) FARR Plunger (Steam) RESULTS: All three combined increased average life by 93 days in 70% of the wells. Failed Tubing and Stroke Thru were replaced by FARR Plunger FARR Plunger extended run life an additional 44 days over and Stroke Thru FARR PLUNGER EXTENED OVERALL RUN LIFE AN ADDITIONAL 137 DAYS Reduced well pullings on average of 12 per month. Millions saved in Operating Expenses and increased production. 3

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6 In January 2013 a prominent Kern County Oil Company completed a Six Sigma Study of the FARR Plunger. The study found that the FARR Plunger increased run times 300% in their oil wells equipped with FARR Plungers. All of these wells had high concentrations of sand and failure rates due to sand. This study compared the FARR Plunger to other Sand Pump Plungers (Sand Pro, 3 Tube, -10 Conventional, Sand Flush, etc.) 6

7 BY MAKING ONE SMALL CHANGE TO YOUR STANDARD API DOWN HOLE ROD PUMPS, YOU WILL: MAXIMIZE PRODUCTION AND EFFICIENCY MINIMIZE HEALTH, SAFETY, & ENVIRONMENTAL RISKS INCREASE PUMP LIFE 150% TO 200% GUARANTEED BEST PART - YOU DON T HAVE TO CHANGE PUMP SHOPS! 7

8 Conventional Plunger From a Well With Sand Present 8

9 Rod Pump With Conventional API Plunger 9

10 Conventional API Plunger 10

11 Pull Rod 60 Thousandths Connector 2 Thousandths Plunger Walls 11

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15 Funnel 15

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18 The Wedge Effect Wedge When Sand or Solids are present and you are using a POC s with a conventional plunger you will likely get stuck due to the wedge effect. 18

19 Conventional FARR 19

20 From To Conventional FARR 20

21 % Reduction Conventional FARR 21

22 % Reduction Conventional FARR 22

23 Funnel Conventional FARR 23

24 Wedge Conventional FARR 24

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27 Increase Pump Life 3-6 Times Longer Studies in California, Indonesia, and Venezuela have all shown the FARR Plunger out-performs other rod pump plungers. Increasing run life an average of 3-6 times. In some cases our customers have seen run times increased times and even greater. 27

28 Reduce Environmental Spill Incidents There is an increased risk for a spill or an accident every time you have to pull a pump from a well. Sometimes when a pump is stuck you have to pull the whole tubing string to retrieve the pump and get the well operational again. This could result in costly spills or other problems. Spills could prompt a visit from the EPA. 28

29 Reduce Health & Safety Incidents Most oilfield accidents occur when you have rigs or other work over equipment on site. You have more personnel in the area and a greater risk for injury. Because the FARR Plunger will stay in the well longer there will be fewer well pulling s which reduces the risk for injury. 29

30 Copyright Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Gas Well Deliquification Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to: Display the presentation at the Workshop. Place it on the web site, with access to the site to be as directed by the Workshop Steering Committee. Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee. Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Gas Well Deliquification Workshop where it was first presented. 30

31 31 Disclaimer The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Gas Well Deliquification Web Site. The Artificial Lift Research and Development Council and its officers and trustees, and the Gas Well Deliquification Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Gas Well Deliquification Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained. The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials. The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.