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In recent years, screw pump systems have gained popularity in oil recovery due to their low energy and metal consumption. These devices are particularly effective in extracting high-viscosity crude oil that contains significant amounts of gas and mechanical impurities. As a result, they are increasingly being adopted in various oil fields around the world.
Russia has developed a unique screw pump system that utilizes the same well injection process. This method relies on the natural sedimentation of the oil and water mixture within the wellbore, allowing for efficient oil-water separation. The produced associated water is then directly injected back into the formation, improving overall efficiency and reducing waste.
The screw pump unit is installed in the well by connecting the worm of the upper pump to the worm of the lower pump using a polished rod that passes through a sealing swivel. A cover is then installed to create an additional passage, ensuring that the injected water flows into the lower reservoir when the worm rotates.
The two screw pumps are connected via the tubing string and lowered into the well. The rotors of both pumps are driven by a rotating sucker rod. The upper pump's worm is linked to the lower one through the polished rod, which also seals the swivel. Suction devices are placed below the upper pump and another one with a short tube beneath the lower pump. Packers are installed between formation I and II to isolate different zones.
The lower pump is equipped with a concentric housing that forms a sealed chamber. As the oil and water mixture flows from formation I, it naturally separates in the wellbore. Lighter oil rises into the upper suction unit and is drawn out through the upper pump’s tubing string. Meanwhile, the upper pump’s worm drives the lower one via the polished rod, filling the space above the packer.
The water in the lower section enters the lower pump inlet through radial holes in the lower suction device. It then travels through the sealed outer cover and is injected into the second absorption layer via the slotted tube.
In 2002, Russia initiated a field test of the same-well injection system using screw pumps in the Ulusstamovsky oilfield. Before the test, the reliability of the equipment and the feasibility of in-well oil-water separation were evaluated. An oil recovery and reservoir water injection testing and calculation system was also established.
During the test, a meter was installed in the pipeline to monitor moisture content, with data transmitted to the wellhead computer. A sensor measured the fluid production rate, while a relief valve at the wellhead released annulus pressure to the outlet line. The wellhead computer ensured the system operated in manual or automatic mode, maintaining optimal performance with the lowest possible moisture content.
The system continuously recorded operating parameters such as speed, moisture content, load current, and shaft torque. These data were analyzed to optimize performance and ensure accurate readings. Laboratory analysis of the produced liquid’s moisture content was also conducted.
The test successfully separated the oil and water mixture. The optimal screw pump speed was found to be 110 revolutions per minute. To date, the pump has been operating continuously for 1,340 days, with moisture content maintained at 66%. The economic benefit for a single well reached 351,500 rubles (approximately 90,000 USD).