SPE-175205-MS

Optimizing Production & Operation through Automated Well & Network

Modeling
Mriganga Das, Zadil Hayat Bin Naharuddin, and Dhuha Al-Khalid, Kuwait Oil Company

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Kuwait Oil & Gas Show and Conference held in Mishref, Kuwait, 11–14 October 2015.

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
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Raudhatain field located in North Kuwait produces hydrocarbons from over 230 wells into Gathering
Center X with varying complex geometries, completions and downhole equipment. NK asset team is
executing a project of modeling the entire NK production system starting with wells in Raudhatain field
producing to GC-X, involving building models for the wells and the gathering surface network of flow
lines.
There are numerous challenges that the NK asset team is facing in meeting production targets,
including controlling water/gas breakthrough in horizontal wells. Mitigation measures include installation
of inflow control devices (ICDs). Since inception a decade ago this proven technology has long been used
in many oilfields around the world and is increasingly being installed in horizontal wells in Kuwait. To
date there are several horizontal wells in Raudhatain field completed with ICDs.
Reservoir modeling and simulation approach is frequently used in the industry capturing the behavior
of existing ICD wells. This approach uses conventional modeling tools that are typically more intricate
and require expert skills in capturing the dynamic behavior of the wellbore and the reservoir which is less
appealing to the operations and practicing engineers.
Limited with time and resources in this project, the NK team took a relatively simpler and fast approach
in modeling existing ICD wells in Raudhatain field with the aim of enabling the engineers to capture the
behaviour of the wells using existing production engineering tools at their disposal.
The approach can be summarized as follows:
➢ Establishing the well performance
➢ Modeling the individual ICD sections in accordance to the approximate flow distribution/geometry
along the horizontal well
➢ Matching the well with well test data
Key benefits of this approach are:
➢ Enabling the engineers to quickly model the ICD wells.
➢ Facilitated the use of existing tools to deliver engineering models fit for use in the production
system.
2 SPE-175205-MS

➢ Serves the purpose of high level modeling of complex ICD wells and in the future this exercise will
certainly be undertaken to capture wellbore hydraulic effects.
➢ ICD well models are timely added into the gathering network which would otherwise have been
delayed using a conventional method.

Background
In Phase-1, Schlumberger was contracted to undertake a ⬙Network Model⬙ building project that covers the
entire North Kuwait pipelines connecting 5 Gathering Centers. The scope of the study was to build a
calibrated & representative Network Model that starts from Wellhead (i.e.no completion or reservoir
description included) to the Production Headers at the Gathering Centre. The phase 2 activities were
closely planned to tie into those from phase 1.
In Phase-2, the work done in the phase-1 is extended to integrate well models to create production
system from sand face to manifold only for GC-X. The integrated production system model will provide
a mechanism to calculate well rate estimates based on hydraulic well models. This will allow comparison
of recent production well tests (PGOR) with expected behavior predicted from model physics. The main
objectives of the project are:
● Understand back pressure response.
● Enable ⬙what-if⬙ scenarios to be executed to investigate the impact of changes to the production
system
● Link the well models to the pre-existing surface production system to calculate three phase stock
tank rates at all points in the production system from sand face to GC process headers based on
well deliverability as defined by measured PI and reservoir pressure.
● Technology to investigate and solve production problems.

The expected benefits of the Phase-2 project are:

● Streamlining the workflow from data gathering to model update and analysis.
● Aiding Operation & Field Development team in planning and improve on the quality of analysis.
● Reducing time spent on acquiring and executing well performance analysis and decision making;
and getting data into various technical applications.
● Reducinh risk through automation associated with having data stored and managed by individuals.
● Models will form the foundation for studies and further engineering work by various stakeholders
in KOC.
● Engineers will be able to identify areas of bottlenecks in production system.
● Furthermore through modeling engineers will be able to compare allocated volumes and test rates
against model predictions and do reconciliation where necessary.
● Enhanced quality adat will be stored in FINDER database.

Model Development and Planning

The delivered production system was built by combining all the component models together and a
description of these building components follows below. A number of valid engineering assumptions were
used when data in not available or of bad quality. Field terrain is assumed flat, the elevation data is not
considered due to lack of topographical data.
Steps for model development:
1. Design of Automated Data Acquisition Workflow and Automation Workflow for Model Main-
tenance
2. Well Modeling.
3. Surface facilities modeling.
SPE-175205-MS 3

4. Surface and Subsurface model integration.

5. History matching and result extraction/ analysis.
The overall workflow to execute the project is symbolized below:

Figure 1—Project Workflow

Data Acquisition Workflow

A large quantity of data were gathered & a comprehensive process was followed to use the validate data
only for the modeling work. The objective of the integrated production system and automation system is
to provide data integration layer and mechanism to pull the required data from the KOC FINDER database
and automatically update the well and network models without having to go through information
management and data preparation hassles, and also to provide interface to run the model, extract & share
the results.
The automation system has been designed in three layesr:
1. Data Acquisition Layer: This provides integration between FINDER as main data source and
PIPESIM as simulation engine. The data include reservoir pressure, well head pressure &
temperature data, well production data (rate, GOR, water cut), choke data, well status & well
connection history.
All these data will be formatted and saved into AWM for the next step process.
2. Workflow Processing Layer: The engineering tool used here in the Avocet Workflow Manager
(AWM) which allows designing & executing the workflows.
The main AWM modules & functions used here are:
● Feed & acquired data into PIPESIM model.
● Execute the model.
● Extract the result from the simulation output file.
● Save the result back into AWM database for further reporting and output layer.
The technology that has been used to build the workflows is called OpenLink, which is a set of
API that can be called by any application to control PIPESIM GUI and the calculation engines
directly.
3. Result & Visualization Layer: This workflow is desgned to generate the report which can be saved
in different formats and send it via emails or save it in shared folders.
● The benefits of the integrated production & automation system are realized as below:
● Utilize the automation system to update the well models.
● Network model batch updating with latest data.
● Insure data quality & consistency.
● Integration with other platforms and application i.e: OFM for more analisys.
● Allow collaboration between operations and engineering team.
Below is the illustration of workflow for data acquisition, processing & storage in to the OFM project.
4 SPE-175205-MS

Figure 2—Automated Data Acquisition Workflow for Model Maintenance

Figure 3—Automation Workflow for Model Maintenance

The automated model maintenance workflow utilize existing database for data retrieval. It utilize fully
documented API called Openlink that enables integration with other software through Microsoft Excel
Macro. This saves lot of engineering time spent previously for data gathering. The automation needed for
Data uniformity across the whole network, to expedite the process of building the model, updating model
SPE-175205-MS 5

(latest WC, GOR, choke, headers) and streamlining the process. The automation template can be used for
other field network model development with reduced time to develop new network model and automation
template.

Well Modeling
The construction of the well models followed a very well established practice and during its course a
quality improvement process was defined. Broadly the well modeling exercise can be summerised as
follow:
● Perform quality check on data and information required in defining a complete well model.
● Well models construction: wells were constructed using either a semi-auto fast process or a manual
process. Complete well model consist of all the components (deviation surveys, geothermal
gradient, production/casing string, downhole equipment).
● Semi auto – fast process using the OpenLink facility in PIPESIM. This facility was used to build
vertical, natural flowing wells. This process also served as an initial diagnostic tool. Once model
were built a quick data match was performed as a first pass and the results used to identify potential
problems with data inputs.
● Manual - All other well models were constructed and tuned manually. Construct skeletal or
complete well model components (deviation surveys, geothermal gradient, production/casing
string, downhole equipment).
● Well models were matched to field conditions with a stabilized multi-rate test but in absence a
single point test was used. Modelled wells were matched to the latest PGOR well test WHP and
flow rate measurements within ⫹/- 5%.
● All ESP wells are equipped with sensor and monitored in real time using Vmonitor. ESP pressure
intake and ESP Pressure discharge were used to calibrate the model and determine the productivity
index of the wells. For wells with faulty sensors, WHP and Ql are used to calibrate the model.
● ESP downhole sensors also are utilized to monitor reservoir pressure when the ESP tripped or
manually shutdown. All the wells are modeled to the exact pump frequency but with assumption
in gas separator accuracy. Some of the pump data such as performance curve and variable
performance from new pump manufacturer is not available and had to be added in the software
database.
● All the wells are modeled with fixed choke value to match the well to the WHP. KOC requirement
that all wells must be tested with fixed choke during production test.
● Gas lift wells were models and matched to the latest GLVS result to determine injection depth.
However, gas injection rates is calculated based on reservoir initial gor and compared to maximum
rate that can pass thru orifice.
● For PCP wells, the challenges in modeling is due to the fact of the rate is too low. Unsure of pump
efficiency. But limited number of wells
● Total numbers of drilling rigs, workover rigs and pulling unit are more than 10. So, the field
always have either new production well, newly converted ESP well, newly work over well with
new producing zone, newly sidetracked wellOpenLink facility is used to monitor the new wells
and update the model.
6 SPE-175205-MS

Figure 4 —Well Model Building Workflow

ICD Modeling-Unique Approach

An increasing number of horizontal wells in North Kuwait are now being completion with Inflow Control
Devices (ICD). ICDs regulate flow between reservoir & wellbore by introducing an additional pressure
dron between them. Modelling ICD completion is not straight forward using any steady state tool like
PIPESIM. Therefore a fit for purpose approach was adopted in order to model these wells using PIPESIM.
A couple of engineering assumptions are made in order to map the ICD flow characteristics to the flow
control valve (FCV) behavior. Each ICD section is modelled separately in order to equalize flow and
enable proper control.
In Phase 2 of the project, there are 21 wells with ICDs producing to GC, giving a total of 237 ICD
sections that were modelled. The well models were matched to well test data and subsequently inserted
into the network.
The modeling approach can be summarized as below:
● A quick analysis of the data for the well bore & installaed ICD completion.
● Review of the underlying engineering assumptions.
● Establishing the well performance.
● Modeling the individual ICD sections in accordance to the approximate flow distribution /
geometry along the horizontal well.
● Matching the well with recent PGOR test data.

The key benefits realized of this approach:

● Enabling the engineers to quickly model the ICD wells.
● This facilitates use of existing tool to deliver engineering model fit for use in the production
system.
● Engineering assumptions can be reviewed and improvements can be easily added to address more
complexity and challenges.
SPE-175205-MS 7

Figure 5—ICD Completion Well Model Building Workflow

Surface Facilities Modeling

GC has 7 headers LPW, LPD, MPW, MPD, HPW, HPD & Test, in addition to one Manifold RQT
outside the GC flowing to LPW. All of the 7 headers are connected by 119 slots where the flow lines
are hooked up. RQT near GC is a manifold that is giving the option to divert the flow between GC-X
and GC-Y through 24 transit lines called RQT lines. The PIPESIM Network Model was built by
dividing the 119 slots into 4 quarters in addition to the RQT near GC MF folder, by utilizing the
subfolders option in PIPESIM. Three layers of folder are used to design the model interface. Well to
slot group, Slot group to headers & Headers to header group. Each quarter has slot connections; each
slot is connected to seven headers by a connector (which physically has zero length) just to give
option to activate / de activate connections to headers by automation code. And for each slot there
should be only single active connection to one header. All wells are created in the main network top
layer to facilitate wells diversion between different slots & folders will have connection upto the GC
headers.
In the header subfolder, each header has four connections to the four slot quarters, except the LPW has
a fifth connection from the RQT.
8 SPE-175205-MS

Figure 6 —Image of PIPESIM Network Model top layer, header slot connection & header connection

The benefit of subfolder usage in Pipesim:

● The model is neat/tidy, the workflow is easier to understand, easier to search model component for
any changes.
● Creates multi layer of network for different type of objects (well, flowlines, header, production
separators)
● Allows parts of network to be ⬙collapsed⬙ in to a sub-network of the main model. This could be
used to divide a large model into a number of smaller sections, especially for big network model.
● Each quarter has slot connections, each slot is connected to seven headers by a connector (which
physically has Zero length) just to give the option to activate and deactivate connections to headers
by the automation code, and for each slot there should be only one active connection to one header,
to avoid any communications between headers.
● All wells were created on the main network top layer to facilitate wells diversions between
different slots, and folders will have connections up to the GC headers.
● As a first step to update the network model to prepare it for simulation, the header and slot
connections should be updated according to a network update date (calibration date) that can be
at any historical time step, and the automation code will get wells’ connection status according to
this date from Finder.
Calibration, Simulation & Evaluation of Scenarios
The network was calibrated with surface pressure & rate measurements at different locations within the
surface production system. The global matching was achived by tuning a few variables such as pipeline
roughness and compared with the measuring points at the mid points & the header manifolds.
In some cases global tuning would render local impbalances of some well head pressures and flow rates
which leads to an investigation into the other uncertain parameters causing differences. Of particular
interest are the choke bean sizes which carry a high uncertainty due to human errors & old worn out
SPE-175205-MS 9

chokes, which were altered and network simulation model re-run to achieve better local and global
matching within ⫹/- 10%.
For Model Calibration, it is recommended to calibrate the network model and match the production
from a single day in which all (or nearly all) parameters affecting the well flow rates are known. It is
important to select the test date on which to match the network model such that the system has been on
steady production for a reasonable period. The flow rates, pressures and temperatures used in the network
calibration exercise would ideally be measured on a single dau and compared with model predictions,
however this is practically complex and hence data was collected over 3 days.
This calibration & matching procedure assumes that the wells are producing at steady state (not
transiaent) flow, thus steady production from the wells are required. It is desired to have as many of the
wells on production as possible and as full set of measured pressures and flow rates as possible.
After calibrating and validating the network, it was then used as a valuable tool to evaluate various
scenarios of enhancements, development strategies and production optimization.
For Simualtion and evaluation of scenarios, the online integrated production system model will
provide a mechanism to quickly evaluate potential production optimization scenarios. For example: 1- The
network routing may be altered to redirect wells from MP to LP headers to look the impact on production.
2- The impact of changes in ESP frequency and the resultant impact on well production including the
impact of system back pressure. 3- Impact of well work on system deliverability taking into account the
back pressure through the system.
The first scenario performed was a network simulation to evaluate the deliverability of the headers and
then compare the result with GC measurements. Second scenario involved changing the sink / header /
separator pressure and evaluates the impact. Then other scenarios that could be evaluated and aid in
decision making include:
● Evaluate the impact on production by altering the network routing by redirecting wells between
headers or to other GC.
● Effect of adding new wells, new flow lines, or the flow line sizes.
● Establish system / well deliverability.
● Imapct of planning Artifical Lifting.

History matching and result analysis

Once the model is ready, automation workflow for model maintenance is activated. Microsoft Excel
Macro is used to collect latest production data such as prod test result, current choke size, latest watercut
test reading, current slot and headers pressure. The result from the query will be used by the Microsoft
Excel Macro script to access and update model parameters through Openlink API.
First run result will be extracted and analyzed to fine tune the matching. For ESP wells, the first run
result will be compared to the real-time data from V-monitor especially Pi, Pd and WHP and liquid rate
from production test.
For natural flow wells, the wells with realtime WHP will be matched to the latest WHP. Overall result
liquid and oil rate will be compared to
1. Total production test
2. Total model test
3. Total daily production.
The target is to get the different ⫹- 5%. Some of the ESP well matching might be affected by the well
flowing stability.
10 SPE-175205-MS

Figure 7—Network Model Simulation Run

Production system was used to evaluate 3 scenarios and could be extended to all the others listed above.
1. Comparison of model calculated deliverability with that from measured PGOR tests.

Figure 8 —Comparision of measured and calculated rates

2. High Pressure gradient locations – identify branches/locations in the network with high pressure
gradients; wells connected to these branches will most likely experience back pressure.
SPE-175205-MS 11

Figure 9 —Pressure Gradient Screening

Acceptable pressure drop at 2.0 psi/100 ft is used as first pressure gradient screening criteria.
3. Fluid velocity ratio through the network (i.e. all flow lines) should be below the maximum value
of 1.0 (above which a flowline will be in danger of failure due to high velocities). Branches close
to the ratio of 1.0 should be monitored in the future, especially if operational conditions change
(e.g. downstream pressure).
Conclusion and Further improvement
The integrated used in phase 2 to combine the wells and network models together with the participation
of Field Development Team, Production operation Team & Information Management Team was critical
to its success. This mode of participation should further be encouraged to form an integrated part of KOC
asset management. The modeling of the production system and operating condition is a boost to the
foundation of production and operational process. Many of the on-going and future management decision
on the asset will be influenced by the quality of analysis based on the modelled production system.
The effectivemenss of the integrated system is determined not just by the result of the modeling,
accuracy of measurement and allocation process, but by also by the pragmatic implementation of such a
system in the context of operating realities of the field.