SPE 104314

Economic Pumping Technology for Coalbed Methane (CBM), Stripper Oil, and Shallow
Gas Well Deliquification
Michael W. Dickey, SmithLift LLC

Copyright 2006, Society of Petroleum Engineers

(NPSH) requirement is considerably less, allowing an operator
This paper was prepared for presentation at the 2006 SPE Eastern Regional Meeting held in to drawdown fluid levels very close to the pump intake. This
Canton, Ohio, U.S.A., 11–13 October 2006.
offers potentially significant production benefits to the
This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
producer.
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to At the conclusion of the paper, readers will have a thorough
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at understanding of the function of the HDESP system, its
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
performance successes and failures, suitable target
for commercial purposes without the written consent of the Society of Petroleum Engineers is applications, deployment techniques, and the overall potential
prohibited. Permission to reproduce in print is restricted to an abstract of not more than
300 words; illustrations may not be copied. The abstract must contain conspicuous for economic benefit the system brings.
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836 U.S.A., fax 01-972-952-9435.
HDESP System Description

Abstract The HDESP is a positive displacement pump that comprises

Operators of shallow, low flow oil and gas wells have two main components:1) an oil filled submersible electric
commonly relied on conventional beam pump and other motor and, 2) twin acting diaphragm tubes. The entire system
artificial lift methods to produce these types of wells. Often, contains hydraulic oil and is sealed against intrusion by well
the use of these pumping systems results in inefficiencies, fluids. The stainless steel construction makes it resistant to
short run-life and environmental challenges that affect the corrosion. Figure 1 illustrates the internal components.
overall economics of the operation.
A hybrid artificial lift system has been developed to allow
operators of shallow, low flow oil and gas wells the
opportunity to produce the wells in a much more economical
fashion than beam lift or other conventional methods. This
paper introduces the technical aspects of the system, its
operation and deployment techniques, and the power savings it
realizes in comparison to beam lift and other traditional lift
systems.
The Hydraulic Diaphragm Electric Submersible Pump
(HDESP) uses a technology that offers a number of benefits to
operators. The system’s hybrid design advantageously
combines the beneficial features of both electric submersible
pumps (ESP) and hydraulic diaphragm pumps (HDP). Both of
these types of systems are widely accepted in their respective
industries. Figure 1
Laboratory tests and deployment of the HDESP in producing
wells confirm the systems capabilities in vertical wells up to The electric motor is supplied with 3 phase, 460 volt power by
2500 feet in depth with production rates less than 200 BFPD. a submersible power cable that is banded to the production
Ongoing design engineering has objectives of greater depths tubing and sealed at the wellhead. Since the assembly is
and higher volumes. Heat issues commonly associated with suspended by the tubing string and the prime mover is now
electric submersible motors are also being addressed. located downhole, rod strings are eliminated and mechanical
Abrasives and gas handling comparisons are made between losses minimized. Rod wear is no longer an issue.
ESPs and beam pumps. Procedures optimizing HDESP Hydraulic diaphragm pumps have excellent solids handling
reliability within adverse wellbores are also described. capabilities and the twin acting diaphragm tubes provide
Power cost studies indicate that the HDESP can reduce increased pumping efficiency even in the presence of
electrical cost by as much as 50% compared to beam pumps produced gas.
and water-well type ESPs. The net positive suction head
2 SPE 104314

Surface controls monitor and protect the motor against voltage installation economics. Figure 2 illustrates the deployment of
fluctuations, phase loss, and ground faults. The pump-off an HDESP on thermoplastic tubing.
control is built-in to the surface control panel. Variable speed
drives can be utilized however, these devices are typically
Comparison of Fixed Flow Rates and Resulting
used to convert single phase to three phase power rather than
speed control for the HDESP motor. Velocities
As environmental concerns increase for the operator, the
In 1.99” and 0.61” OD Pipes
HDESP offers a small surface profile installation that prevents
fluid leakage from stuffing boxes and packing glands. Flow 2 3/8”OD 1.0” OD Percent
Overhead irrigation concerns are not an issue, and since the Rate (1.99”ID) (0.61” ID) Increase
system is downhole, noise pollution and unsightly pump jacks
(B/D) Velocity Velocity
in sensitive areas are eliminated. By utilizing an electric
submersible motor and hydraulic diaphragm pump, the
HDESP represents a “true hybrid” system of two widely 100 0.3 ft/sec 3.2 ft/sec 1067%
accepted forms of pumping fluid.
150 0.5 ft/sec 4.8 ft/sec 960%
HDESP Pump Function
Table 1
After an HDESP pump is installed and all the electrical
connections are complete, power is supplied to the electric
motor via the starter panel or variable speed drive. The motor
is directly coupled to an internal pump that moves the
hydraulic oil from one diaphragm to another so as to
alternatively expand and contract them. Two intakes, each
dedicated to their own diaphragm tube, allow well fluid to
enter into the chamber with the collapsed diaphragm. As one
diaphragm is collapsed, the other is expanded thereby causing
the discharge of contained production fluid from the pump
into the tubing. Viewed as a process, the alternately expanding
and contracting diaphragms provide flow continuity. Surface
controls monitor downhole parameters and take the unit off
line in the event of pump-off. This eliminates the need for
downhole pressure sensors and fluid level gauges.
Since internal components are not in contact with the well
fluid and since there are no rotating parts, the HDESP is far
less susceptible to abrasive wear or gas locking than rod Figure 2
pumps and ESPs during low flow conditions and at pump-off.

Deployment Mechanisms Field Performance Results

The 3.75 inch OD HDESP allows it to be deployed in 4.50” As with most new technologies, early field testing of
and larger casing. The system can be landed below the prototype HDESPs did not meet all design goals. A number of
perforations. In such cases, a flow shroud may be necessary to test installations experienced short run failures. These were
increase fluid velocities by the motor shell for cooling shown to primarily be the result of deployment in wells with
purposes. Dimensionally, the HDESP is very easy to handle. inappropriate application windows. At the same time, field
Its length is approximately 7 feet and weight about 90 pounds. testing found a number of ways in which to improve prototype
The pump can be deployed on conventional steel tubulars or engineering designs. Initial field testing played an important
coiled tubing. As a benefit of small system dimensions, recent role in establishing a sound production product design.
deployments have been on one inch thermo-plastic tubing. An operator in Kentucky has been using the product since its
Since coal bed methane (CBM) and shallow oil and gas wells early design stage. This operator uses the pump in shallow
commonly contain formation solids and frac sand, and usually (1200 feet or less) oil stripper applications. Production is
produce at low flow rates, small diameter tubing results in typically less than 25 BPD. The company had previously used
relatively high fluid velocities. These are usually sufficient to rod pumps and had experienced failures primarily caused by
ensure reliable solids transportation to the surface. This feature wear from abrasives in their production fluid. The HDESPs
of small diameter tubing minimizes the potential for “solids achieved a six-fold increase relative to prior beam pumps in
settling” at the pump discharge or check valve. See Table 1. realized run time. This operator produces from within
environmentally sensitive areas and considers the cleaner well
Thermo-plastic tubing is corrosion resistant and can be locations associated with the HDESP an important product
installed in a matter of a few hours without need for a bonus.
workover rig. The elimination of conventional tubing and rod
strings, and their handling, is advantageous to HDESP
SPE 104314 3

Several operators in the Powder River Basin in Wyoming have Field Data
reported improvement in their CBM operations as a result of
the HDESP installations. One well was experiencing an 18 1
day run average for water well type ESPs that were installed.

KW/bbl/1000'
0.8
Five of these pumps had been replaced within 90 days because 0.6
of failures caused by gas locking and abrasive wear due to 0.4
solids in the production fluid. The HDESP replacement 0.2
system had achieved a cumulative run for 136 days. During
0
this period, an increase in gas production from 60MCF to 1 2 3
110MCF was realized. The operator grossed an additional Rod HDESP ESP
$29,500 with the increased performance. An additional
savings in pulling costs was also realized.
Since the application window for production HDESP systems Figure 3
has been clearly defined and because of engineering Based on these results, if one was to look at the case of a well
enhancements, the performance of the HDESP has, today, lifting 200BPD from 2000 feet at $0.10 per KWH, the results
exceeded the initial performance goals. indicate a 55% savings versus a rod pump and a 74% savings
versus an ESP. The resulting yearly power costs are illustrated
Comparison to Other Lift Systems in Figure 4.
The unique design of the HDESP offers several benefits that A second study was performed with the operator from
address common problems associated with rod pumps and Kentucky. The results indicated the rod pump consumed 228%
ESPs. more electricity than the HDESP. This data supported the
In comparison to typical rod pump installations for shallow, initial findings at RMOTC.
low production wells, the HDESP eliminates the use of rods Power consumption testing is currently being performed to
and mechanical wear on the tubing is eliminated. Since there determine how the HDESP compares with other methods of
are no rotating or moving parts in contact with the well fluid, artificial lift, such as progressive cavity pumps (PCPs).
abrasive wear to the pump is minimized. At pump-off
conditions, gas locking has never been observed in HDESP
Annual Costs
units in the field. Packing glands and stuffing boxes are
eliminated. The potential for leakage at the wellhead is 12000
essentially eliminated. The low surface profile of the HDESP 10000
Dollars/Yr

eliminates concerns with over-head irrigation. Lastly, studies 8000

have indicated a substantial decrease in power consumption 6000

favoring the HDESP in comparison to rod pumps. The low 4000

2000
power consumption of the HDESP is an even greater
0
advantage when compared with ESPs. 1 2 3
Rod HDESP ESP
Power Consumption Comparison
When oil prices are depressed, operators tend to place more Figure 4
emphasis on electricity costs for their artificial lift systems. It
seems, during times of higher oil prices, that emphasis is Conclusion
shifted to other areas of concern although these costs still exist
and can even become a larger percentage of production costs. The HDESP is an advantageous alternative to conventional
The HDESP is a positive displacement pump. Typically these artificial lift systems. It is specifically designed for shallow,
types of systems result in higher pumping efficiencies (60%- low volume fluid withdrawal. With its superior solids and gas
80%). A power cost study was performed at the Rocky handling capabilities, increased reliability is achieved. It can
Mountain Oilfield Test Center (RMOTC) to verify the be deployed without a workover rig, thereby reducing
HDESP’s power consumption versus rod pumps and water- deployment costs and downtime. Since there are no rod
well type ESPs. A revenue grade power meter was installed on strings, mechanical wear is virtually eliminated. The pumping
similar wells with the three different forms of lift. The data efficiency (60%-80%) of the system provides the operator
was analyzed and a formula of KW/bbl/1000’ was applied. with a reduction in electrical consumption. Finally, the low
The results of those findings are summarized in Figure 3. profile surface equipment provides a leak free, aesthetic
completion for the operator.

References
Traylor, Leland; “Comparison of the Energy Efficiency of
Various Types of Artificial Lift Systems for CBM Well
Applications”, presented at the “Gas Well Deliquification
Symposium”, Denver, CO March 2006.