Integrated Analysis and Optimization for Progressing Cavity Pump Systems in Greater Burgan Field

Najaf, A. A. (Kuwait Oil Company) | Ramchandra, A. (Kuwait Oil Company) | Al-Yetama, M. (Kuwait Oil Company) | Ledesma, F. (Weatherford International) | Al-Salman, A. (Weatherford International) | Suleiman, N. (Weatherford International)



Progressing cavity pump (PCP) systems are widely used in the oil and gas industry. Continuously evaluating PCP performance helps to maximize and sustain fluid production and increase pump run-life. This paper focuses on integrating a real-time platform and advanced software to model, troubleshoot, and optimize PCP systems and their operation.

More than 50% of installed PCP systems located in Great Burgan Field in southeast Kuwait are connected to a real-time SCADA platform. These connected systems are monitored to support daily operations and to identify underperforming wells for troubleshooting. Special attention is given to wells exhibiting critical behaviors or wells with optimization opportunities. Before implementing any actions on these wells, real-time data history is used along with nodal analysis to predict the outcomes. This paper presents an intensive optimization analysis through the following field case studies:

Preventing sucker rod string failure

Evaluating pump submergence

Optimizing fluid production

Identifying optimum operating conditions

Software is used to perform simulations of flow under different operating conditions and to generate a full analysis report based on PCP equipment configured in the well model. The sharp-edge results are not limited to the production rate. They also extend to pump performance and other surface and downhole parameters such as pump torque, intake pressure, and discharge pressure. The outcome of these results assists with making well-informed decisions with the following benefits:

Operating conditions have been improved by estimating the production rate at different speeds.

Pump life has been improved by evaluating rod load, lift load, and efficiency.

Down-time has been reduced by preventing pump-off conditions.

The procedure serves as a proven guide for analysis and optimization of PCP systems. Improving pump efficiency, achieving the target production rate, identifying problems, and preventing potential failures all help to optimize PCP system performance.

The innovative integration of PCP analysis and optimization provides a means to increase production and reduce the load percentage of surface and subsurface equipment parameters. A real-time SCADA platform combined with the optimization software created an ideal solution to keep wells operating at peak performance levels.