Haider, Bader Y.A. (Kuwait Oil Company) | Rachapudi, Rama Rao Venkata Subba (Kuwait Oil Company) | Al-Yahya, Mohammad (Kuwait Oil Company) | Al-Mutairi, Talal (Kuwait Oil Company) | Al Deyain, Khaled Waleed (Kuwait Oil Company)
Production from Artificially lifted (ESP) well depends on the performance of ESP and reservoir inflow. Realtime monitoring of ESP performance and reservoir productivity is essential for production optimization and this in turn will help in improving the ESP run life. Realtime Workflow was developed to track the ESP performance and well productivity using Realtime ESP sensor data. This workflow was automated by using real time data server and results were made available through Desk top application.
Realtime ESP performance information was used in regular well reviews to identify the problems with ESP performance, to investigate the opportunity for increasing the production. Further ESP real time data combined with well model analysis was used in addressing well problems.
This paper describes about the workflow design, automation and real field case implementation of optimization decisions. Ultimately, this workflow helped in extending the ESP run life and created a well performance monitoring system that eliminated the manual maintenance of the data .In Future, this workflow will be part of full field Digital oil field implementation.
This paper describes the selection, design, successful application and performance monitoring of Electrical Submersible pumps in the giant Mangala oil field and Thumbli water field situated in the Barmer basin in Rajasthan, India. Mangala oil field contains approximately 1.3 billion barrels of STOIIP in high-quality fluvial reservoirs. The field was brought on production in August 2009 and is currently producing at the plateau production rate of 150,000 bopd of which approximately 40% of the oil production is from the ESP oil wells.
To support the water requirement of Mangala and other satellite oil fields, Thumbli source water field was developed with 5 water production wells with up to 4 wells operating at a time. Each of these water wells is installed with 60,000 bwpd capacity pumps and the field is currently producing up to 225,000 bwpd to meet the water requirements of Mangala and other satellite fields.
The Mangala oil field is a multilayer, multi-Darcy reservoir, has waxy viscous crude with in-situ oil viscosity up to 22 cp and wax content in the range of 18 to 26%. The field was developed using hot water flood for pressure maintenance. Significant production challenges included unfavorable mobility ratio with early water cut and hence the early requirement of artificial lift to maintain the plateau production rate. The field has 12 horizontal producers and 100 deviated producers. ESP was selected as the artificial lift mode for the high rate horizontal producers while hot water jet pumping was selected as the artificial lift mode for low rate deviated oil wells. Each horizontal well is capable of producing up to 15,000 blpd and high rate ESPs were designed and installed to deliver the production requirement. Currently 8 of the 11 horizontal producers are on ESP lift and the remaining three wells are planned for ESP installation in the near future. Apart from two early ESP failures during installation, ESPs have had a good run life; the paper also describes lessons learnt from the infant mortalities.
The Thumbli water field, located ~20 km southeast of Mangala field has been developed to meet the water requirement of Mangala and other satellite fields. Thumbli water aquifer is a shallow water field which contains water of ~ 5000 ppm salinity with dissolved CO2, oxygen, chlorides and SRB. 5 high capacity water wells were drilled in Thumbli field to meet the huge water demand from Mangala for water injection in Mangala and satellite field injector wells, hot water circulation in oil production wells and associated water requirement for boilers etc. 1000 HP water well ESPs were designed to produce up to 60,000 bwpd from each well with installed water production capacity of up to 300,000 bwpd from Thumbli field.
Over the last several years, horizontal drilling and multi-stage hydraulic fracturing have become the norm across the industry and proved crucial for economic production of natural gas from unconventional shale gas and ultra tight sandstone reservoirs, also referred to as nano-Darcy reservoirs.
Following the success of the Barnett shale, horizontal drilling and multi-stage hydraulic fracturing has spread across North America with new emerging shale gas plays such as the Eagle Ford, Woodford, Haynesville, Marcellus, Utica, Horn River
changing the industry's landscaping. In the current economic environment of high drilling and completion costs, coupled with lower commodity prices, the economic success of shale gas developments has become reservoir specific.
Evaluation of well's initial performance in a particular field and especially the ability to accurately predict the long term production behavior and EUR is critical to the efficient deployment of large capital investments. Field analogies making use
of arbitrary "type curves?? can have a significant negative impact on the project's bottom line.
With the growing number of multi-stage horizontal wells producing from shale gas reservoirs, many "unconventional?? production analysis techniques have been developed based on new concepts such as stimulated reservoir volume (SRV),
fracture contact area (FCA), or sophisticated mathematical relationships (power law decline curves, linear flow type curves, to name a few). These sophisticated engineering processes are well documented in the literature and have been presented at
numerous industry work shops and conferences. However, for the majority of these techniques there is one common reoccurring theme: performance evaluation of shale gas production cannot be analyzed using conventional methods (e.g.
This paper will demonstrate how the conventional approach of reservoir characterization, well performance evaluation and forecasting, can be implemented for all unconventional gas reservoirs, using traditional well testing and production data
analysis techniques. We will present one simple analytical model based on the solution of the pseudo steady state equation and will introduce the concept of a shale gas normalized production plot. In our view, the shale gas normalized production
plot is one type curve generally applicable to any shale gas reservoir.
Finally, pre-frac in-situ testing techniques will be reviewed and special consideration will be given to the perforation inflow diagnostic (PID) testing. We will emphasize the importance of specific reservoir parameters (pore pressure and in-situ shale
matrix permeability) and show their impact on drilling and completion strategy and design. Field case examples including well test results and production data from wells completed in several shale gas reservoirs are presented.
The Stybarrow Field is a moderately sized biodegraded 22° API oil accumulation reservoired in Early Cretaceous sandstones of the Macedon Formation in the Exmouth Sub-Basin, offshore Western Australia. The reservoir is comprised of excellent quality, poorly consolidated turbidite sandstones up to 20m thick. The field lies in approximately 800m of water and has been developed with five near-horizontal producers and three water injection wells. The Stybarrow development came online at an initial rate of 80,000BOPD in November 2007.
Due to the lack of significant aquifer support, water injection was planned from start-up for pressure maintenance. Acquisition of a variety of data types have enabled key subsurface challenges to be addressed both before and during production. Structural and stratigraphic complexities influence connectivity and therefore must be fully evaluated in order to achieve optimal sweep. A feasibility study concluded that Stybarrow would be a good candidate for 4D seismic monitoring. Two monitor surveys were acquired and, along with other reservoir surveillance techniques, have been used to refine the geological model.
The first monitor survey at Stybarrow was recorded in November 2008. The results of this survey were in agreement with prior 4D modelling and supported the drilling of a successful development well in the north of the field. A second monitor survey was recorded in May 2011, three and a half years after first oil and at 70% of expected ultimate recovery. This survey is currently being analysed to determine if sweep patterns have changed.
The 4D surveys have proven to be an important tool for understanding subsurface architecture and dynamic fluid-flow behaviour. The results of both 4D seismic surveys have provided significant contributions to understanding the dynamic behaviour within the reservoir to facilitate optimal reservoir management.
The Pyrenees Development comprises three oil and gas fields: Ravensworth, Crosby and Stickle. The fields are located in production licenses WA-42-L and WA-43-L, offshore Western Australia, in the Exmouth Sub-basin and are operated by BHP Billiton (Fig. 1). Eighteen subsea wells, including 14 horizontal producers, 3 vertical water disposal wells and 1 gas injection well have been constructed to date and additional wells are planned for infill and to develop additional resources. First oil was achieved during February 2010 and production exceeded 50 million barrels in November 2011.
The Pyrenees fields are low relief, with oil columns of approximately 40 metres within excellent quality reservoirs of the Barrow Group. The 19° API crude has moderate viscosity, low gas / oil ratio (GOR), and a strong emulsion forming tendency which makes oil/water separation and accurate well test metering difficult. Early in the project design phase it was identified that the complex subsea gathering system and the need to reduce measurement uncertainties would dictate special attention to production measurement.
Subsea multiphase flow meters (MPFMs) were specified to meet the challenges of production optimization and allocation while at the same time minimizing production deferral for separator testing. Each oil producer is monitored by a dedicated MPFM. With 14 meters, Pyrenees is among the largest subsea MPFM installations worldwide.
This paper describes the process of MPFM qualification and commissioning together with their performance over 2 years in the field. We show how close cooperation between the Operator and MPFM Vendor has enabled quality rate measurements of emulsified production despite large changes in producing gas/oil ratio and water cut.
While the primary justification for Pyrenees subsea MPFMs was production allocation and optimization, interpretation of transient water cut and GOR data proved valuable for production and reservoir engineering applications. Examples of proactive reservoir and production management including optimizing drawdown of Inflow Control Device (ICD) equipped wells, optimizing well lineup and gas lift to commingled wells are presented.
Producing and delivering North West Australia (NWA) deepwater gas reserves to LNG plants poses unique challenges. These include extreme metocean conditions, unique geotechnical conditions, long distances to infrastructure and high reliability/availability requirement of supply for LNG plants. A wet or dry tree local floating host platform will be required in most cases. Whereas semisubmersible, TLP, Spar and floating LNG (FLNG) platform designs all have the attributes to be a host facility, none has been installed in this region to date.
This paper will address important technical, commercial and regulatory factors that drive the selection of a suitable floating host platform to develop these deepwater gas fields off NWA. Linkages between key reservoir and fluid characteristics and surface facility requirements will be established. A focus will be on the unique influence of regional drivers and site characteristics including metocean and geotechnical conditions, water depths and remoteness of these fields.
There have been 17 FPSOs producing oil in Australian waters. These facilities have been chosen because of the remoteness of the fields and the lack of pipeline and process infrastructure. Storing oil on the FPSO for offloading and shipping from the fields becomes an obvious solution. Semisubmersible, TLP or Spar platforms show little advantage in such developments.
For deepwater gas developments, the product has to be processed, compressed and piped to shore for liquefaction. As host processing facilities, Semisubmersible, TLP and Spar platforms have clear advantages over FPSOs because of their superior motion performance in the harsh Australian metocean environment and other benefits such as facilitating drilling, dry tree completion and well services. FPSOs or FSOs may be applied for storage of associated oil and condensates. For marginal and remote gas field developments, an LNG FPSO (FLNG) may be an attractive option as it eliminates long pipelines and land-based liquefaction plants.
As discussed by Dorgant and Stingl (2005), a deepwater field development life cycle following discovery usually involves five distinct phases, Figure 1. The "select?? phase occurs after a discovery has been appraised sufficiently to further evaluate it for development. It consists of evaluating multiple development concepts and scenarios and selecting the one that will most likely achieve the identified commercial and strategic goals. Selecting a floating platform and its functions for a deepwater development is an important subset of the select phase and the overall field development planning.
The process of field development planning involves a complex iterative interaction of its key elements (subsurface, drilling and completions, surface facilities) subject to regional and site constraints (D'Souza, 2009). The objective is to select a development plan that satisfies an operator's commercial, risk and strategic requirements. It entails developing a robust and integrated reservoir depletion plan with compatible facility options. The selection occurs while uncertainty in critical variables that determine commercial success (well performance, reserves) is high. One of the challenges is to select a development plan that manages downside reservoir risk (considering the very large capital expense involved) while having the flexibility to capture its upside potential.
The first hydraulically operated completion was installed in Australia in 2004 (Guatelli et al 2004). Since then, a number of intelligent completions have been installed in offshore Australia. The remoteness of offshore Australia, particularly in the Timor Sea area, means intervention vessels are not readily available and well interventions are costly operations. For this reason, intelligent completion is considered to be an attractive alternative, by providing a down-hole solution to actively manage the reservoir production life and delay potential water breakthrough.
The Kitan oil field is remotely located in the Joint Petroleum Development Area (JPDA) between East Timor and Australia. The Kitan oil field production facilities consist of three vertical producing wells, subsea flowlines, risers, and one Floating Production Storage and Offloading (FPSO) facility. The wells were completed with an intelligent design and cleaned up using a rig before the FPSO arrived on location.
The intelligent completion design consists of two multi-stage hydraulic down-hole Flow Control Valves (FCVs) and three Down-Hole Gauges (DHGs) to independently control and monitor two different production zones. The FCVs have a total of 8 positions (fully opened, fully closed and 6 intermediate choke positions).
It is planned to close the lower FCV to shut off water production from the lower zone while the upper FCV remains fully opened over the field life. The different FCV choke positions were utilized during the field startup and during the early stages of production while the water cut was still low, to overcome unforeseen technical limitations in the production system, and to optimize hydrocarbon production.
This paper describes various aspects of the Kitan oil field intelligent well completion from design through installation and field startup to early stage of production operations, and includes technical problems encountered during the field startup as well as lessons learnt.
Healy, John C. (John C. Healy Jr Consulting LLC) | Sanford, John R. (ENI International Resources Ltd) | Reeves, Donald Franklin (Noble Energy Inc.) | Dufrene, Kerby John (Schlumberger) | Luyster, Mark R. (M-I Swaco) | Offenbacher, Matthew A. (MI-SWACO) | Ezeigbo, Chinyereze (M-I Swaco)
A case history from Offshore Israel is presented that describes the successful delivery of two ultra high-rate gas wells (>200 MMscf/D) completed in a depleted gas reservoir with 9??-in. production tubing and an openhole gravel pack (OHGP). Maximizing gas off-take rates from a volumetric drive gas reservoir that possesses high flow capacity (kh) requires large internal diameter (ID) tubing coupled with efficient sand face completions. When sand control is required, the OHGP offers the most efficient as well as the most reliable, long-term track record of performance. A global study of wells completed with 9??-in. production tubing ("big bore??) determined that this design concept was feasible and deliverable in a short time frame while still maintaining engineering rigor. The paper will highlight key accomplishments within various phases of a completion delivery process with particular emphasis on the sand control design, testing and execution. The completions were installed with minimal issues (NPT ˜ 9%) and have produced without incident. The two wells, Mari-B #9 and #10, achieved a peak gas rate of 223 and 246 MMscf/D, respectively.
Most offshore wells that require artificial lift are gas lifted, as gas typically is readily available and compared to other lift systems, gas lifting is relatively inexpensive and low maintenance. However, electric submersible pumps (ESPs) can
efficiently and economically increase oil production and reserves recovery under the appropriate operating conditions. This may translate to a lower abandonment pressure in the long term—possibly reducing the total number of wells required to deplete an asset.
Since few ESPs currently are installed in offshore wells, an ESP screening "Rules of Thumb" was created as a simple guide for prioritizing offshore ESP candidates. The selection criteria focus on feasibility of installation, operability conditions
and operating practices to maximize run life, and economic considerations. ExxonMobil† and industry experience from North America, South America, West Africa, Asia, Australia, the Middle East, and the North Sea provided the basis for the study.
The plans for many of the upcoming deepwater projects involve the use of highpower Electrical Submersible Pump (ESP) Systems for Artificial Lift. However,the perception in the industry is that the average run-life currentlyachievable with such high power ESP Systems is much shorter than what would bedictated by robust project economics, given that intervention costs in theseapplications can be very high, in the US$50MM - 75MM range. Therefore, theconsensus among operators is that there is a need to try and improve thereliability of these systems.
In response to this industry need, DeepStar® recently commissioned a gap studytowards identifying the barriers that may be preventing ESP Systems fromachieving the desired reliability as well as the additional R&D effort thatmay be required for the industry to close the existing gap. DeeepStar® providesa forum for deepwater technology development, while leveraging the financialand technical resources of the industry (http://www.deepstar.org/).
This paper presents a summary of the results of this study, including: a) theMean Time To Failure (MTTF) that people believe is currently achievable (i.e.with current technology); b) the biggest differences about these applications,which introduce additional uncertainty to the ability of the system to performreliably; c) the main sources of uncertainty regarding each of the major ESPSystem component's reliability; and d) the tentative plan that was outlined aspart of the project, to address the gaps that were identified.
The Gap Analysis was based on phone interviews conducted with recognizedindustry experts, on discussions that took place with members of a TechnicalCommittee (TC) that was put in place for the project, and on a broader industrysurvey conducted through the internet. The proposed go-forward plan consists oftwo follow-up projects: one focused on improved system design and operationalpractices, including system monitoring (or surveillance) and control; and onefocused on validating the design of key components of concern, for thespecifics of these applications, through laboratory testing. The proposednear-future R&D effort has the support of major operators, but still needsto be fine-tuned, with input from the industry, before the actual work canproceed with buy-in and financial support from all of the partiesinvolved.