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Spe-193121-Ms - Integrated Production Optimization Workflow
Spe-193121-Ms - Integrated Production Optimization Workflow
This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 12-15 November 2018.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
This paper demonstrates the production optimization methodology being used by Kuwait Oil Company to
increase production in one of its giant and mature fields by 18% over 5.0 years.
Production optimization is a continuous iterative process to improve production, especially in mature
fields. The North Kuwait Redevelopment team has adopted an integrated enhanced and structured process
to identify opportunities for production optimization with a pro-active approach focusing on flowing wells
and rig-less interventions to tackle production challenges and achieve production targets
Typical mature-field challenges are present. These include water flooding, produced water management,
artificial lift, with more than 1000 (vertical, deviated and horizontal) active wells, coupled with high
structure complexity and stratigraphic heterogeneity, tight sandstone and carbonate reservoirs, shortage
of work-over rigs. These challenges make the field appropriate to apply the production optimization
methodology outlined here.
The Heterogeneity Index (HI) process is utilized to rapidly demonstrate production gain opportunities, for
a giant mature North Kuwait Sabria field of approximately 1000 wells produce from different reservoirs. The
HI process provided a quick screening method of identifying preliminary candidate wells with anomalous
behavior (over/under performance) for further analysis and most importantly, provided the foundation for
the overall structured production approach. The results from this screening tool were utilized to identify
the families of type productivity problems at field and well levels with solution categories for production
enhancement. Representative wells were selected for detailed diagnostics based on the relevance and size
of productivity impact and the potential of its well deliverability. Once a few "top potential" wells were
identified, production engineering workflows were implemented to assess and forecast the potential of
production increase and to determine and evaluate the best intervention action.
This production optimization workflow is done in a consistent cycled process considering the ageing
condition of the mature field, and the aforementioned challenges.
Approximately 35% of the wells have been selected for further analysis over multiple production
optimization cycles spanning approximately 5.0 years. A detailed production engineering workflow
provided recommendations of various remedial intervention solutions to improve well production potential
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Introduction to SA Field
The main field production and reservoir challenges can be summaeized as follows:
• Increasing water production and need for efficient water conformance and management in
producers and injectors using different Water Shut Off (WSO) techniques
◦ Need for WSO which add Rig Work over (RWO) cost and production deferment
• Water flood surveillance, management and conformance control of water flood surveillance
• Shortage of work over rigs (RWO) which contributes to significant production deferment due to:
◦ Delay in restoring oil production for pump (like to like) replacement which represents ~20 %
of RWO activities (ref. activities April – September 2014)
◦ Delay in execution of other required interventions (WSO, stimulation, zone transfer, etc)
• Reservoir accessibility for appropriate surveillance and intervention (PCP and ESP pumps
completion with few Y-Tool).
• Very complex multilayer reservoir structure with different depletion and different water cut
• Low Productivity issues for flank wells and need for effective stimulation techniques
◦ Production history and ESP/PCP downhole gauges and surface data trend analysis.
◦ Reviewing available PLTs and or PNC/TDT to identify production contribution and water inflow
profile along the perforated intervals / horizontal ICD's.
◦ Production Engineering: Wellbore modeling, Nodal analysis (e.g. WSO, zone transfer,
stimulation, perforation, etc), Perforation analysis, Stimulation analysis (acid or propped
hydraulic fracturing), decline curve analysis, pressure and rate transient analysis, etc
4. Solution Design and Recommendation: conceptual design of recommendaed solution (remedial
action) including any required data acquisition to support analysis (e.g. PLT, BHP, PNC, etc). Solution
could be in reservoir side (skin removal, stimulation, add and/or re-perforation, water shut off, water
injection requirements or adjusments, etc) or in the outflow/lifting side for improving artificial lift
(adjusting operating parameters "e.g. frequency, choke" or changing lifting system/type), or could be
both of reservoir and lifting sides as illustrated in (Figure 6).
5. Post job evaluation and follow up: after actions and job implementation, review the execution results
to evaluate the solution success and improve next similar analysis and executions with considering
the learning lessons.
Key success factor of implementing such work flow starting from problem understanding, conceptual
solution design and implementation of recommended intervention solution is the collabortation and
Multideciplinary Team Integration cycle between all concerned teams of Petroleum Engineering (Field
Development Group) and well intervention Operation (drilling, rig workover, rig-less operation teams) as
illustrated in (Figure 8).
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A process was put in place for fast screening and capturing oil production gain opportunities in the North
Kuwait fields of Kuwait Oil Company.
In this analysis, well performance is compared at the wellbore level. Individual well performances can
be viewed as better as or worse than average and can be easily compared to each other with scatter plots.
◦ High Oil high Water: Increasing Liquid - good / bad Water – WSO possible candidates
◦ Low Oil Low Water: Decreasing liquid – stimulation / Re-perf / add perf or any other production
improvement intervention possible candidates.
◦ High Oil Low Water: Good performers
◦ Low Oil High Water: High Water and increasing – WSO possible candidates
• Selection of candidates for further analysis and diagnostics for Production Enhancement
◦ Improve uptime time of Artificial lift and by turn minimize production deferment
The results from this screening tool were utilized to identify the families of productivity problems at
reservoir level, and additional fast screening and ranking were done at well level to identify candidates for
production enhancement. Representative Wells were selected for detailed diagnostics based on the relevance
SPE-193121-MS 9
and size of productivity impact, and the potential of its production rate or well deliverability. (Figure 11)
shows example of HI analysis on oil, water and liquid rates based on individual wells performance.
The same concept of HI has been run on Electrical Submergible PUMP (ESP) performance. The HI of
liquid production rate has been run versus ESP uptime to as a quick screening tool to identify high/low
performing ESP wells based on liquid and/or uptime performance. Example of ESP HI analysis is shown
in (Figure 12).
The Heterogeneity Index (HI) process is utilized to rapidly demonstrate production gain opportunities, for
Figure 11—HI Analysis– Oil, Water and Liquid Rates Scatter plots
Figure 10—Concept of Heterogeneity Index (HI)
SPE-193121-MS
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Table 1—Statistics of Prescreened ranked wells (H, M & L) of 1st prod. Optimization Cycle
strategy). This data must be integrated with PIP data, GOR production data, and waterflooding sectors
analysis. The selection criteria for ESP upsizing candidates are mainly as follows:
Figure 13—Increasing Production through Electrical Submergible Pumps (ESP's) Optimization Workflow
based on ESP surface electrical and downhole pressure gauges data (Amperage, pump intake and discharge
pressures and tempratures, and surface wellhead pressure), produced fluids (water cut, gas oil ratio, fluids
density), and water injection / aquifer support. The following are the main process steps (Figure 14):
1. Candidates Screening & Selection: Select all the ESP wells with run life more than 1000 days and
perform trend analysis of production Delta Qliq (e.g. Last year - this year). Ranking from the highest
to the lowest liquid rate lost and select the top wells for further analysis.
Following the workflow, out of 70 wells, the top 14 underperforming wells were selected, analyzed and
action plan recommended (e.g. Change the pump, upsize pump, choke management, VSD optimization,
and increase of wtare flood pressure support).for well optimization with estimated potential oil gain. Three
wells were executed by changing out the old deteriorated ESP's and replacing them by new same size ones,
as an elective pull in the 2nd half of 2016.
SPE-193121-MS 15
Results
The total production rate has been improved with added oil gain of ~85% more than the previous oil rate
just before changing to new ESP (Figure 15).
Forward Plan
The positive results of the analysis and recommendations supported the value of applying this structured
workflow for ESP health check evaluation during any stage of ESP run life. Moreover, this workflow is
shared and expanded to other KOC assets to maximize the benefit.
Objective
To demonstrate how fit is the Heterogeneity Index (HI) process to be utilized as part of the SAFD planning
of rig / rig-less subsurface activities.
Methodology
Compare the prescreened HI wells Vs. SAFD actual executed and planned interventions.
Input data
• HI prescreened candidates from 1st (July, 2013) and 2nd cycles (March, 2014) via OFM
• Actual / planned SA subsurface activities from Wellwork Evaluation & Planning (WEP)
• HI process screened candidates for well review contributes 53% and 38% of Actual executed and
planned activities respectively
• WC gradual increase to 75 – 80% in 1.5 years, resulted in liquid rate drop by ~50%, oil rate drop
by ~28% with wellhead pressure dropped from 700 to 250 Psig at same choke size
• Horizontal Production Log (PLT) was run after 8 months of initial production at WC 35% and
shown the following that both heal and Toe of the horizontal section contribute most of water at
WC ~50% and oil rate ~20% of total flow (Figure 19).
• Well ceased to flow naturaly in March 2014 (WHP = FLP = 80 psig, choke 32/64") at estimated
WC 75 – 80%.
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Figure 19—Well 1 PLT Results (June 2013, WC 35%) and Inflatable packer setting depth for WSO
• The horizontal section has been subdivided to 3 sections (heal, middle and toe) for simplicity based
on PLT water inflow contribution.
• Three layers Vogel IPR using the downhole PLT's SBHP and FBHP data combined with ICDs
contribution from PLT analysis, and PVT data.
SPE-193121-MS 19
• Hagedorn Brown Multiphase flow correlation has been used for vertical pressure drop calculation
and Mechanistic (Achong) correlation for choke pressure drop. The final matched inflow / outflow
without any tuning
Then the same model was used to simulate the production test results of January 2014 (WC 56%) before
ceased to flow in March 2014, and got good match without tuning which validates the initial built model
WSO Results
• WSO successfully enabled retrieval of natural flow which was confirmed by multi-rate Production
test after WSO.
• The well has retrieved its stable natural flow (NF) with restoring the deferred oil with extra oil gain
of ~20% more following reducing WC from ~80% down to 52% (-28%) confirmed by multiple
production tests over 2 months after WSO execution (Figure 18). The estimated cost pay back was
~ 7 days of production.
• The production after WSO has shown improvement of CUM oil trend by almost doubling it relative
to the last 2 months of production before ceasing to flow naturaly and WSO as shown in (Figure 21).
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The summary of applied workflow is shown below in (Figure 22). This well together with other similar
WSO application have been presented in 2015's SPE Kuwait Oil and Gas Show conference (Ref.2: S.
Al-mosaileekh and M. Abdel-Basset; Successful Rig-less WSO in Horizontal Openhole ICD Completions
Using Latest Real-time Intervention Technologies and Multidisciplinary Team Efforts - North Kuwait,
SPE-175318-MS, KOGS 2015, Kuwait).
Summary of Analysis and WSO Results.
• Execution: May 2014 using Rea-time Coil Tubing and Inflatable packer technology.
• Continued application of the structured and proactive approach of the Production Engineering
Enhancement Process enables proactive opportunity mapping, identification of production gaps,
and introduction of new technologies fit for purpose to help achieve production targets and
optimum reservoir management.
• Clearly and by using detailed and structured workflow analysis, a series of outputs and remedial
intervention solutions have been recommended such as water shut-off, conformance, stimulation,
perforations, artificial lift optimization, and other supporting recommendations to improve
production and injection strategies which is reflected in significant oil gain in tank along the process
cycles.
• To sustain and continue to achieve production optimization success, the process outlined above
needs to be embedded into the NOC's overall process and procedures, NOC leadership and
executives continuing support in the embedded said process's play also a key part in the strategic
success.
• Increased Knowledge and awareness can be gained by studying carefully the process used, it will
reinforce the message that YES, technology is important but also that the right people are even
more important, by placing both of these key ingredients into a systematic and well thought out
consistent approach you can deliver exceptional results, always of course supported by strong and
executive NOC leadership.
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Acknowledgment
The authors would like to thank the management of Kuwait Oil Company and Schlumberger Company
for their permission to publish this work. We also would like to expresse our gratitude to Hamad Al-Zaabi
(KOC NK Field Development Manager) for his continuous support for getting this integrated production
optimization workflow embedded in the KOC workflows as best bractices.
Nomenclature
References
1. Khaled Harami, Mohamed Abdel-Basset et al: Hetrogeneity Index and Fast Screening Processes
Used in a Large Mature Field Designed for Quick Production Gains (SPE 167350, KOGS 2013,
Kuwait).
2. S.R. Al-mosaileekh, D. Al-Sirri, M.M. Al-Mufarrej, M. Al-Mutawa, Kuwait Oil Company; M.
Abdel-Basset, A. Benslimani, Schlumberger; Successful Rig-less WSO in Horizontal Openhole
ICD Completions Using Latest Real-time Intervention Technologies and Multidisciplinary Team
Efforts - North Kuwait (SPE-175318-MS, KOGS 2015, Kuwait)