Info 3 PDF

USING REAL TIME AUTOMATED OPTIMISATION
AND DIAGNOSIS TO MANAGE AN ARTIFICALLY

LIFTED RESERVOIR
Julian Cudmore
New Technology Manager
Zenith Oilfield Technology
19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 1 of 46

KEY LEARNING OBJECTIVES
1. Understand the potential of real time digital processing when used on
artificially lifted wells
2. See how automation shortens the time to optimised production and

improves run life
3. Learn how draw down can be balanced using the lift system as a control
to obtain best production
4. Listen to case studies illustrating how proactive data management has

delivered significant profit for operators

SECTION #1
TAKING THE HARD WORK

OUT OF WELL SURVEILLANCE

MORE OUTPUT / LESS INPUT
 A single well lifted by an ESP can have 20 or more key data streams
associated with its operation which can be updating more than once per
minute resulting in a potential overload of information.
 Manual analysis of this data can take days and becomes overwhelming
with the high well counts of today’s operations.
 Automated technology can gather data from the wells’ artificial lift system
and perform automatic data analysis, diagnosis, optimisation and
protection at the well site in real-time.
 With the automated system in place, operators can instantly recognise
and prioritise wells requiring attention.

SECTION #2
ARCHITECTURE
OF THE AUTOMATED SYSTEM

WELL SITE CLIENT OFFICE ANY LOCATION
Well processor panel with Communications server Web based remote
downhole dual pressure ESP sensor for remote data access and control user interface and VSD control
Modbus interface to VSD and
remote communication

SYSTEM IMPLEMENTATION
 The intelligent surface panel is installed at the well
site to locally process instrumented data into
operational recommendations in real time
 All instrumented data, VSD data, and processed
pump operational information is available at the
well site, and transmitted to control rooms and
office personnel where remote control of the VSD
can be accessed
WELL SITE OFFICE & CONTROL ROOM

SECTION #3
SIMPLIFYING THE
OPTIMISATION PROCESS

FROM THIS
TO THIS

THE “OLD” WAY THE “NEW” WAY
1. Establish desired production rates for the reservoir 1. Establish safe target production rates for wells
2. Test each well to establish current production rates 2. Automated real time system suggests
optimum frequency & WHP for each pump
3. Production log the wells (if possible) to measure the
inflow conditions and BHFP 3. Frequency adjusted by remote control
4. Gather all the necessary data 4. Results monitored using real time calculated
well test data
5. Amalgamate the well test data with down hole
gauge, log data, and ESP controller data
6. Perform sensitivity studies in software to assess the
optimum frequency and WHP within the well draw
down and ESP capabilities
7. Notify field operations to action the changes
8. Perform further well tests to verify the new
production data
9. Analyse the new production data to ensure the ESP
and well are running optimally and safely at the new
set points
10. Continue the process to meet production targets

THE AUTOMATED REAL TIME
1. Reservoir engineers provide the desired bottom hole
flowing pressures for each well to appropriately manage
overall drawdown.
2. This data is entered into the system as the target for
optimising each well.
3. The automated optimisation calculations check if the
target BHFP is achievable on the IPR curve, then
calculate the potential rate increase.
4. The potential rate is automatically cross checked by the
system against the ESPs operational capacity and
operating limits to validate if the pumping system can
safely deliver to target without effecting run life.
5. The system provides optimum operating frequency and
well head pressure recommendations to achieve the
target rate within the boundaries of each ESPs capability.

Well Head Pressure
Tubing Gradient
Intake Pressure Discharge Pressure
Well Potential
Draw Down
19 Sept 2013
Target BHFP Current BHFP Reservoir Pressure
© 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 12 of 46
Target BHFP
Well Potential

Current Operation
ESP Maximum Rate
Well Potential
This well will benefit from a larger ESP!

THE AUTOMATED REAL TIME
 The process is simple – basic petroleum engineering
 Performing the process manually over many wells takes time and
continuous effort
 Automation of the process utilizes real time nodal analysis calibrated to
instrument data
 When deployed across the field, draw down across the reservoir can be
automatically controlled to maximize recovery

SECTION #4
MANAGING RESERVOIR DRAWDOWN

USING THE LIFT SYSTEM

WELL 1 WELL 2 WELL 3 WELL 4 WELL 5
GAS
OIL
WATER
TARGET BHFP CURRENT BHFP STATUS
WELL 1 1100psi 1500psi INCREASE ESP TO 58 HZ
WELL 4 900psi 900psi HI WATER CUT ALARM

OIL PRODUCTION: 15,835 BOPD
LOW WATER CUT WELLS WITH
POTENTIAL FOR MORE PRODUCTION HIGH WATER CUT WELLS
GAS
OIL
WATER

DECREASE TARGET DRAWDOWN
TO MANAGE WATER PRODUCTION
GAS
OIL
WATER

SYSTEM RECOMMENDS THE NEW
ESP FREQUENCIES REQUIRED
GAS
OIL
WATER
WELL 4 1000psi 900psi DECREASE ESP 59 TO 55 HZ

DECREASING DRAWDOWN TO
CONTROL WATER PRODUCTION
GAS
OIL
WATER
WELL 4 1000psi 1000psi 55 HZ – WELL OPTIMISED

OPTIMISED WELLS
GAS
OIL
WATER
WELL 4 1000psi 1000psi WELL OPTIMISED

SYSTEM RECOMMENDS INCREASE HZ
TO MEET BHFP TARGETS
OPTIMISED WELLS
GAS
OIL
WATER

HIGH WATER CUT ALARM! HIGH WATER CUT ALARM!
REDUCE THE TARGET BHFP VALUE REDUCE THE TARGET BHFP VALUE
GAS
OIL
WATER

NEW TARGET BHFP VALUES ASSIGNED:
SYSTEM RECOMMENDS THE NEW FREQUENCIES AUTOMATICALLY
GAS
OIL
WATER
WELL 2 1250psi 1200psi DECREASE ESP TO 55HZ
WELL 5 950psi 900psi DECREASE ESP TO 55HZ

OPTIMISED WELLS
GAS
OIL
WATER

SECTION #5
AUTOMATION IN THE FIELD

CASE STUDY #1:
AN ALREADY OPTIMISED WELL?

 The production of the well was previously thought to be fully optimised to
the limits of the ESP. The well was producing around 940 bfpd.
 After installation of the real time system, the automated analysis showed
that the well was not achieving the target bottom hole flowing pressure,
but was close to the upper range limit of the ESP whilst running at 55hz.
 The real time system predicted through automated sensitivity studies, that
the frequency could be increased to 61.9Hz whilst keeping the ESP within
its operational limits.

CASE STUDY #1:
AUTOMATED RECOMMENDATION
 The automated system relayed the following recommendation for the well
optimization:
AN ADDITIONAL 123 BFPD IS ACHIEVABLE

BY INCREASING FREQUENCY TO 61.9HZ
 The VSD frequency was subsequently increased manually from 55 Hz to
56 Hz and then by remote control to 61Hz
 Adjustment was performed in 1 Hz steps to verify the system’s
recommendations and enable independent well tests to verify the results

CASE STUDY #1:
REAL TIME CALCULATED WELL TEST DATA

 The real time system calculations for flow and water cut were verified
independently by well test during the optimization process:
55 HZ
Well test total liquid flow at 55 Hz 935 stb/day
Virtual total liquid flow at 55 Hz 971 stb/day (+3.8% variance from well test)
Well test water cut at 55 Hz 22%
Virtual water cut at 55 Hz 19.5% (-2.5% variance from well test)
57 HZ
Well test total liquid flow at 57 Hz 998 stb/day
Virtual total liquid flow at 57 Hz 1031 stb/day (+3.3% variance from well test)
Well test water cut at 57 Hz 22%
Virtual water cut at 57 Hz 19% (-2.5% variance from well test)

CASE STUDY #1:
RESULTS
 Oil production was increased by more than 71 bopd

 The overall increase in oil production in the 270 days since the automated
system was initiated was:
19,400 BARRELS OR $1.82M

CASE STUDY #2:
OPTIMISING A WELL WITH

EMULSION PROBLEMS
 A minimum bottom hole flowing pressure limitation of 370 psi was specified
 The ESP was running at 43 Hz but not achieving the target draw down. The
automated optimisation immediately highlighted that optimum frequency
of the ESP was 47.1Hz
 The automated pump performance diagnosis showed that the head
performance of the ESP was unstable, dropping intermittently by up to 22%
 The reduction of head performance was thought to be due to formation
of emulsions

CASE STUDY #2:
OPTIMISING WELL DRAWDOWN

USING FREQUENCY
Frequency was increased in small steps from 43Hz to 47Hz while monitoring
the effect of the emulsions on the pump head performance
The first optimisation step The final optimisation step

from 43hz to 44hz from 45hz to 47hz
CASE STUDY #2:
REDUCED HEAD DUE TO EMULSION
The pump operating point at 47Hz is shown to fall below the pump curve due
to reduced head performance of the ESP whilst emulsions were forming.
The ESP design was slightly oversized to compensate.
CASE STUDY #2:
THE OPTIMISED WELL
The gradient plot taken at 47Hz The live IPR Plot shows the
shows bottom hole flowing pressure BHFP operating point on the well
has achieved the target of 370psi inflow curve

CASE STUDY #2:
RESULTS
 The VSD frequency was increased from 43Hz to 47Hz over the course of
optimisation
 Correspondingly the production rate was increased from 570 stb/day to
671 stb/day
 With water cut averaging 73% this equated to a 27 bopd increase in
production:
APPROX $2,500 PER DAY

ADDITIONAL REVENUE
 The ESP was shown to be within range, and sized to compensate the
reduced head performance of approx 22%

CASE STUDY #3:
AN UNDERPERFORMING
& UNDERSIZED ESP
 The target BHFP was set at 1131 psi Reservoir Press
 The automated ESP diagnosis highlighted

Target BHFP Current BHFP
that the ESP was underperforming by 30%
 The system recommended that the ESP
frequency could be safely increased from
42Hz to 46.7Hz
 The system automatically showed that
46.7Hz was still not sufficient to achieve
the target draw down, because further
increases of frequency were limited by the
ESP sizing (pump range)
CASE STUDY #3:
AN UNDERPERFORMING
& UNDERSIZED ESP
 The bottom hole flowing pressure stabilised
at 1267 psi with a liquid rate of 2720 stb/day
 The target bottom hole flowing pressure
provided scope for an additional 1142 stb of
fluid (PI 8.4 stb/d/psi )
 The ESP installed was not capable of providing
this additional flow rate
 In January 2012 the ESP was resized based on
the recommendations of the real time system
and draw down was optimised to the target
bottom hole flowing pressure
 Flow rate was increased to 4027 stb/d
CASE STUDY #3:
RESULTS
 Automated diagnosis and frequency optimisation of the underperforming
ESP provided an additional 73,000 barrels of oil ($7.15 Million) in the 334
days of operation with the real time system
 The ESP under performance issue was highlighted immediately the
automated system was implemented on the well
 Further increase in rate was limited by the upper flow range of the ESP
 Resizing of the ESP in January 2012 resulted in:
562 BOPD OR $55,070 PER DAY

ADDITIONAL PRODUCTION

THANK YOU
Julian Cudmore
Zenith Oilfield Technology
www.zenithoilfield.com

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USING REAL TIME AUTOMATED OPTIMISATION

AND DIAGNOSIS TO MANAGE AN ARTIFICALLY

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 1 of 46

2. See how automation shortens the time to optimised production and

4. Listen to case studies illustrating how proactive data management has

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 2 of 46

TAKING THE HARD WORK

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 3 of 46

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 4 of 46

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 5 of 46

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 6 of 46

WELL SITE OFFICE & CONTROL ROOM

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 7 of 46

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 8 of 46

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 9 of 46

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 10 of 46

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 11 of 46

Intake Pressure Discharge Pressure

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 13 of 46

This well will benefit from a larger ESP!

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 15 of 46

MANAGING RESERVOIR DRAWDOWN

19 Sept 2013 © 2013 Zenith Oilfield Technology | www.zenithoilfield.com Slide 16 of 46

TARGET BHFP CURRENT BHFP STATUS

WELL 1 1100psi 1500psi INCREASE ESP TO 58 HZ

WELL 2 1200psi 1400psi INCREASE ESP TO 56 HZ

WELL 3 1200psi 1250psi INCREASE ESP TO 57 HZ

WELL 4 900psi 900psi HI WATER CUT ALARM

WELL 5 850psi 850psi HI WATER CUT ALARM

TARGET BHFP CURRENT BHFP STATUS

WELL 1 1100psi 1500psi INCREASE ESP TO 58 HZ

WELL 2 1200psi 1400psi INCREASE ESP TO 56 HZ

WELL 3 1200psi 1250psi INCREASE ESP TO 57 HZ

WELL 4 900psi 900psi HI WATER CUT ALARM

WELL 5 850psi 850psi HI WATER CUT ALARM

TARGET BHFP CURRENT BHFP STATUS

WELL 1 1100psi 1500psi INCREASE ESP TO 58 HZ

WELL 2 1200psi 1400psi INCREASE ESP TO 56 HZ

WELL 3 1200psi 1250psi INCREASE ESP TO 57 HZ

WELL 4 1000psi 900psi HI WATER CUT ALARM

WELL 5 900psi 850psi HI WATER CUT ALARM

TARGET BHFP CURRENT BHFP STATUS

WELL 1 1100psi 1500psi INCREASE ESP TO 58 HZ

WELL 2 1200psi 1400psi INCREASE ESP TO 56 HZ

WELL 3 1200psi 1250psi INCREASE ESP TO 57 HZ

WELL 4 1000psi 900psi DECREASE ESP 59 TO 55 HZ

WELL 5 900psi 850psi DECREASE ESP 58 TO 56 HZ

TARGET BHFP CURRENT BHFP STATUS

WELL 1 1100psi 1500psi INCREASE ESP TO 58 HZ

WELL 2 1200psi 1400psi INCREASE ESP TO 56 HZ

WELL 3 1200psi 1250psi INCREASE ESP TO 57 HZ

WELL 4 1000psi 1000psi 55 HZ – WELL OPTIMISED

WELL 5 900psi 890psi DECREASE ESP 57 TO 56 HZ

TARGET BHFP CURRENT BHFP STATUS

WELL 1 1100psi 1500psi INCREASE ESP TO 58 HZ

WELL 2 1200psi 1400psi INCREASE ESP TO 56 HZ

WELL 3 1200psi 1250psi INCREASE ESP TO 57 HZ

WELL 4 1000psi 1000psi WELL OPTIMISED

WELL 5 900psi 900psi WELL OPTIMISED

TARGET BHFP CURRENT BHFP STATUS

WELL 1 1100psi 1200psi INCREASE ESP TO 58 HZ

WELL 2 1200psi 1300psi INCREASE ESP TO 56 HZ

WELL 3 1200psi 1200psi WELL OPTIMISED