RAM’s ACC2000 Cellular Batch Controller Improves Corrosion Treatment Program.
An East Texas producer was experiencing excessive corrosion problems at a rod-pumped well
site. The well was previously being truck treated with corrosion inhibitor every 2-3 weeks. The
well produces approximately 18 bpd oil and 25 bpd of water. Iron counts were typically over 100
ppm indicating a higher than normal potential for corrosion. Rod corrosion was severe and the
rod string required replacement or repair every 2-3 months.
Well specs: 8200 feet vertical 3200 feet horizontal
Casing – 7 5/8″
Tubing – 2 7/8″
Rod size – 100x 7/8″ Rods at the top.
90x 3/4″ rods on the bottom.
No sinker bars; uses 7/8″ rods
Pump located in the vertical part of the well.
Has a 1″ gas hanger pipe on the well pump that separates the gas to the casing.
Treating rates PRIOR to the mini-batch unit – the corrosion inhibitor was pumped at the same rate
(6 qts per day) continuously with an LMI chemical pump; but without the batches of flush fluid.
A continuous “trickle flush” was initially attempted but it was not delivering near enough fluid to
get the chemical downhole.
A RAM ACC2000 remote cellular chemical pump controller was installed at the well site along with a standard diaphragm style chemical pump and an actuated flush valve. Figure 1 shows the piping of the flush loop on the well head PRIOR to installation of the automated system:
(Image Left) – Flush loop piping PRIOR to installation of ACC2000)
After installation of the ACC2000 controller, the corrosion inhibitor was injected at ½ quart every 2 hours (every time the pump jack was activated by its timer); and the chemical injection was followed by a 1.25 minute flush of produced fluid, controlled by the actuated valve (see diagram below).
This process continued 24 hours a day injecting 6 quarts of chemical on a daily basis.
Essentially a “mini-truck treatment” occurred every 2 hours. The chemical injection followed by immediate flush insures that the inhibitor gets all the way down the casing to the formation and is produced back up the tubing with the normal action of the rod pump.
The 12 flushes per day of well fluids (every 2 hrs) provided by the mini-batch unit was what made the huge difference in corrosion inhibitor effectiveness. It provided a larger flush volume but for a very short interval (about a minute) 12 times per day immediately after each 1/2 quart injection of chemical. We estimated the daily flush volume to be 1-2 barrels based on pressures & pipe size.
Since the installation of the ACC2000 controller, there have been no rod failures in the past 2 years. Iron counts were reduced to less than 10. Total flush volume was reduced by using small controlled amounts throughout the day, this increased production efficiency.
Uptime was increased by reduction of rod failures from corrosion.
Most importantly, the entire system communicates remotely via the cellular network. Chemical injection rates and flush volumes can be monitored or modified. All information is recorded on the RAM data website and provides validation of chemical treatments. Chemical injection rates and flush times can be changed at any time via text message from an authorized cellular device. The complete RAM ACC2000 batch treatment system is shown in below.
Before ACC2000:———— Rod Pull $7k (2-3 months)
Tubing replacement ——– $16k
Down time ——————— $32k/month (18bpd at $60)
New rods———————– $25 – 50 each (40 this well)
Truck treating —————– $200 x2 per month
Total annual cost before: Approx… $65k
(4 rod pulls, 1 month down time, chemical)
After ACC2000: Cost of chemicals $675/month
(1.5gpd at $15/gal)
Cost of RAM equipment: $5k ( one time)
Total annual cost after: Approx… $13k
Estimated ANNUAL SAVING to Well Owner:
Over $52k per year.
Extra sales for chemical service company: $3.3k
(increase of 68% sales) 2 years and still going.
Expand the Capabilities of Solar Chemical Injection Pumps.
Many oilfield chemical injection applications have very low daily injection rates that require the use of small capacity chemical injection pumps. Some locations require less than a gallon of chemical per day. Accurate control of most chemical pumps at lower injection rates can be a significant and costly problem, especially with solar powered chemical pumps. Over – injection within the course of several months can lead to unnecessary use of excessive amounts of chemicals and serious overages on chemical budgets.
A RAM PCS chemical pump controller can drive a solar powered chemical pump much more accurately than simple on/off timers. It is high precision local pump controller that uses advanced STROKE COUNTING and motor CURRENT SENSING (patent pending). Additionally, RAM pump controllers with their STROKE BASED DELIVERY system operate with a nearly 0% delivery error, regardless of the pump motor speed or well pressure.
In addition, since this controller counts pumps strokes, the operating range of a larger capacity chemical pump can be greatly expanded—meaning it can be used for accurately delivering lower daily injection volumes.
The RAM PCS pump controllers offer unprecedented delivery, accuracy and resolution down to 0.01 QPD.
Controls single or double head pumps.
Enables the use of higher capacity pumps in lower volume applications.
Installation is easy for new installations or retrofits.
Built in RS232, RS485 and SCADA ready.