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In recent years, screw pump systems have gained popularity in oil recovery due to their low metal and energy consumption. These devices are particularly effective in extracting high-viscosity crude oil that contains significant amounts of gas and mechanical impurities, making them a preferred choice in challenging reservoir conditions.
Russia has pioneered the use of screw pumps with an integrated well injection process. This system utilizes the natural sedimentation of oil and water mixtures within the wellbore to achieve oil-water separation. The produced water is then directly injected back into the formation, improving overall efficiency and reducing environmental impact.
To install the screw pump unit, the upper screw pump’s worm is connected to the lower pump’s worm via a polished rod passing through a sealing swivel. A cover is then installed to create a supplementary passage, ensuring that injected water flows into the lower reservoir during rotation. The entire assembly is lowered into the well using a tubing string, connecting both pumps together.
The two pump rotors 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. An intake device is placed below the upper pump to draw formation fluid, while another suction device with a short tube is positioned below the lower pump. Packers are installed between the first and second formations to isolate different zones. Additionally, the lower pump is equipped with a concentric housing that forms a sealed chamber for controlled fluid flow.
As the oil-water mixture flows from formation I, it naturally separates within the wellbore. Lighter oil rises and is drawn into the upper suction unit, exiting the well through the upper pump’s tubing. Meanwhile, the upper pump drives the lower pump via the polished rod, filling the space above the packer. Water from the lower section enters the lower pump inlet through radial holes in the suction device, then flows through the sealed outer cover and slotted tube into the second absorbing layer.
In 2002, Russia conducted field tests of this same-well injection system in the Ulusstamovsky oilfield. Before the test, the reliability of the equipment and the feasibility of in-well oil-water separation were thoroughly evaluated, along with the development of a reservoir water injection testing and calculation system.
Throughout the pipeline, meters are installed to monitor moisture content, with data transmitted to the wellhead computer. Sensors measure the volume of produced fluid, and a relief valve at the wellhead releases annular pressure to the outlet line. The wellhead computer ensures the system operates either manually or automatically, maintaining optimal performance by minimizing liquid moisture content. It continuously records operational parameters such as speed, moisture content, load current, and shaft torque, and transmits these data for analysis. Laboratory chemical analysis of the produced liquid further validates the moisture content readings displayed on the system.
During the test, the oil-water mixture was safely separated, with the optimal screw pump speed set at 110 revolutions per minute. To date, the system has operated continuously for 1,340 days, maintaining a moisture content of 66%, with a single well generating an economic benefit of 351,500 rubles (approximately 90,000 USD).