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Liberty Lift’s Types of Production Enhancement Solutions
Liberty Lift Solutions provides a broad range of effective artificial lift techniques for the optimization of oil and gas production during the various stages of the well’s life cycle. Our standard technologies include:
- Gas lift
- Hydraulic jet pumps
- Conventional beam pumping units with high efficiency (HE) or enhanced geometry (EG) configurations
- Extra-long stroke (XL) rod pumping units
Each solution has been engineered and designed by experts with decades of oilfield artificial lift experience. All of our equipment has been manufactured in conformity with, or exceeding, defined API standards.
View our overview video on the XL
When your production might need an XL unit
Artificial lift begins after well completion. Usually the initial flows are aided by techniques to optimize early production, assisting oil recovery and handling sand production and contaminants. Our gas lift and hydraulic jet pump technologies are ideal for this production phase. Other techniques, including electric submersible pumps (ESPs) can be used effectively at this initial phase.
Once initial volumes diminish, however, especially on deep and deviated wells, producers face a dilemma to cost effectively optimize continuing flow rates while minimizing operating costs. If ESPs have been used initially, they often have to be replaced with mid-size ESP units at this point, necessitating the use of a costly workover rig to pull and replace the unit.
Additionally, ESPs have been prone to continued failure, further exacerbating the need for multiple replacement with operating costs that can approach several hundred thousand dollars.
At this well cycle stage, conventional beam pumping units do not yet have the capacity to effectively handle these moderate flow rates either.
This continually widening grey area in lifting unconventional wells is where the XL is gaining tremendous traction in answering operators artificial lift needs.
Where the XL Long Stroke Pumping Unit fits your production needs
The XL long stroke unit has proven to be the ideal solution.
It provides an earlier and cost effective transition from the high volume lift methods to longer term conventional rod pumping needed for the duration of the well’s life.
FEATURES, BENEFITS & TECHNICAL INFO
VIEW BENEFITS
VIEW FEATURES
STANDARD
- Wireless Load Cell
- High efficiency and dependable electric motor
- Wire mesh personnel safety guards
- Efficient self-contained hydraulic rollback system
- Unit Sentry operational safety monitor
- Helical involute gear design
- Safety tie-offs at all access points
- Emergency braking system
- Three sets of wind guard panels
- Wind guard wheels
- Upper proximity sensor
TOP SPROCKET
- Supported by high-capacity tapered roller bearings
- Adjustable position compensates for chain wear
- Ready accessibility from mid-tower platform
- Personnel safety tie-offs and caged ladders
- Efficient controlled oiling system
COUNTERWEIGHT BOX
- Guided by 12 roller contact points for smooth, controlled operation
- Traversing carriage for stroke transition
- Partitioned for adjustment to offset rod string weight
- Personnel platform for easy unit access
GEAR REDUCER
- Double reduction helical design
- Manufactured using a precision hobbing process
- Manufactured to API 11E specifications
- Ductile iron gears for enhanced durability
- Quenched and tempered alloy steel pinions for long life
- Course pitch design helps withstand operational load fluctuations
- Oversized anti-friction bearings for increased reliability
- Removable safety covers on braking system and reducer sheave
TOP DRUM
- Supported by two self-aligning double-row spherical roller bearings
- Heavy-duty coated woven load belt carcass
- Covered for protection from elements and contaminants
UNIT SENTRY OPERATIONAL SAFETY MONITOR
- Over speed detection
- Vibration detection
- Rod pump control (RPC) pause and fault
- VSD pause and fault
- Emergency stop
- High and low load shutdown
- Operator defined faults (2)
- Multiple restart options after power loss
- Control of structure oiling system
- Recognizes loss of load cell signal
Technical Specifications
Please click on the tabs below to view the technical specifications for that Liberty Lift product.
HOW THE XL UNIT WORKS
The XL unit is a rugged stationary vertical structure utilizing a gear reducer to operate a lower sprocket connected to a chain and an internal sliding traversing mechanism. This mechanism drives the vertical and horizontal movement of a counterweight box -- up and down inside the XL tower. The counterweight is connected to a heavy duty woven belt carcass which connects to a sucker rod positive displacement lift system.
The XL’s stroke can be as long as 366 inches, approximately 60 percent greater than the largest conventional unit stroke.
As such, it provides a longer and slower stroke that reduces pump cycles while producing higher pump fillage rates per stroke and higher volumetric efficiency that can allow direct transition from initial flow lift to conventional, bypassing intermediate ESPs.
At that stage, operators using the XL can readily achieve 700-900 bpd at depths of 6,000 feet or more. The number of strokes per minute can be fewer than one-half that of a conventional beam pumping unit.
In addition to greater production per stroke, the reduced number of cycles with the unit’s slower speed assists in decreasing rod fatigue or tubing wear.
In deviated well applications, rod wear against the tubing wall is a persistent problem. The XL effectively reduces the aggravation on wear points, making tubing less susceptible to develop holes and need replacement. This slower stroke also reduces rod buckling tendencies. By helping reduce the impact of the above issues, the XL helps dramatically reduce the need for workovers and lessen deferred production from downtime.
The XL, due to its extra long stroke, also has creates a higher compression ratio due to having more unswept area in the pump, which can provide more efficient pump fillage if there is a gas breakout at the pump.This is very advantageous to many operators today who have difficulty producing liquid in unconventional wells with high GLR’s.
UNIQUE FEATURES OF THE EXTRA LONG STROKE PUMPING UNIT
The XL utilizes several unique, cutting edge features that provide operating efficiencies, increased access, and improved safety for its users.
UNIT SENTRY
The XL relies on its Unit Sentry™ to provide cutting-edge technology measures to ensure operational safety throughout the unit's life. It monitors operating abnormalities, pausing or stopping the unit depending on the fault sensored. Among its many capabilities, the Unit Sentry, can also effectively calculate the speed and stroke position in real time.
The Unit Sentry also reads and detects real-time load, vibration, speed, and lubrication system oil pressure. There is an available history log that shows all events that occurred during operation. The Unit Sentry also allows operators to input custom defined faults to shut down the unit during any type of situation they define as critical.
Communication from the Unit Sentry can be configured to interface with rod pump controller systems, including pump off detection. This capability allows the XL to provide continuous operating surveillance and downhole diagnostics through a ‘plug and play’ connection, relaying pertinent operating information to well analysts for pump card analysis and trends.
LIBERTY XL IN CONJUNCTION WITH A VSD
The XL’s, in conjunction with a variable speed drive (VSD), enables the operator to further optimize their production capabilities. Long stroke units operate with a chain drive that circles a fixed-bottom sprocket and adjustable top sprocket in a ‘race track’ pattern.
With the Xl and a VSD the speeds can be adjusted to customize the goals of the operator using the Unit Sentry’s position and load signal. The accuracy in which the XL transmits this information allows the operator to fully utilize the XL units capabilities.
Especially important is the varying speeds necessary during the stroke ‘cornering’ position from upstroke to downstroke in order to optimize the speed changes for enhanced production. Speeds can be adjusted to help increase production and also minimize the dynamic rod loading within the sucker rod string. The combination of these two benefits allow the operator to maximize production and minimize down hole issues.
BEARINGS AND GEAR REDUCER
As with all Liberty Lift pumping units, the gear reducer is manufactured with double reduction helical involute gear design and all bearings are manufactured to exceed API 11E specifications.
SAFETY FEATURES
Personnel and asset safety features are built into all Liberty Lift artificial lift solutions. For the XL, there are multiple safety guards to prevent operator hazards.
HYDRAULIC ROLLBACK SYSTEM
A hydraulic rollback system is a standard feature on all units. This feature allows the XL to shift back as much as 10 feet from the wellhead when necessary during a workover without the use of a crane or tractor. It can be returned to its original position quickly.
LUBRICATION SYSTEM
The XL non-splash lubrication system is inside the unit tower housing and at ground level to further assist worker safety. This unique feature can provide uniform oiling of internal sprockets and chain regardless of operation speed. This oiling system greatly improves the life of the chain, traversing mechanism, and sprockets of the XL unit.
As with all field equipment provided by Liberty Lift, we offer service excellence. We understand proper unit and foundation installation techniques and removal protocol, using a fleet of appropriate trucks and rigging equipment. Our field service technicians are experienced in resolving life cycle maintenance and repair issues and regularly work with our clients to conduct predictive maintenance inspections and audits for early detection of potential problems.
Our total objective is to provide long-lasting equipment, suited for the well operating parameters, and maintained for the life of the well.
Need more information on Liberty Lift’s XL Long Stroke Pumping Units?
Call us at 713-575-2300 or email us at sales@libertylift.com
Liberty Lift operates from locations throughout the major oil and gas producing regions of the United States.