Online Field-Wide Gas-lift Optimisation

e-petroleumservices.com

Dr Alasdair S BrownTechnical ManagerEPS Americas Inc

Presentation Structure

• Introduction• Single Well vs Field Wide• Online vs Offline• Case Studies

– Latin America– Middle East

• Conclusions• Questions

Single Well

• Single Well Gas Lift Optimisation– Valve Spacing– Injection Depth– Valve Performance– GL Injection

Pressure

– Qgaslift

– CHP

Single Well

• Conditions change– GL is inherently flexible– Design in flexibility

• Single well optimum– Well performance curve– Different for each well– Not necessary optimal

for system

Gas Lift Optimisation

Gas Lift Compressor

Equal Gradients Method

Common Pressure

Field Wide Optimisation

• Field Wide Gas Lift Optimisation– Distribution of Gas to competing wells– Pressure losses in gas lift distribution system– Pressure losses in production system– “Closing the Loop”

• Total system modellingTotal system modelling– including produced gas reinjection– Compressor performance

– Offline/Online

Why Online?

• Large Number of Wells• Complex optimisation problem• Reduce cycle time

– Optimisation-to-implementation– Engineer’s time concentrated on value adding tasks

• Goals– Automate Process– Automate Repetitive Tasks– Optimise

Sustainable Production Optimisation

Simple Manual Optimisation

Complex Manual Optimisation (Offline GLO)

Complex Automated Optimisation (Online GLO)

Automation & Optimisation• Off-line

– Data input manually into system model– Results from system model implemented manually

• Open loop– Data input automatically into model from SCADA– Results from model implemented manually

• Closed loop– Data input automatically into model from SCADA– Results from model implemented automatically via

set point controllers– Operator review may be required to ensure that

implemented results are “sensible”

Off-line Optimisation

Optimiser

OPERATOR • Advice• Approval• Implementation

Manual Data Input Data Output

Open Loop Optimisation

Optimiser

FieldOPERATOR • Advice• Approval• Implementation

Automatic Data Input Data Output

Closed Loop Optimisation

Optimiser

OPERATOR •Advice•Approval•Implementation

Automatic Data Input

Data O

SetpointControllers

Case 1: PdVSA On-Line

– SCADA data automatically loaded to give current block valve and compressor status and to constrain the optimisation to stay close to existing operating conditions

– Price/cost and equipment constraint data loaded from Corporate databases

– Gas injection well set-points sent directly to SCADA controllers (after production operator review as a block)

– Recommended pressure control valve set-points and compressor operating conditions sent to production operators in open-loop advisory messages

– Results stored in central database for access by other applications.

PdVSA Systems Overview

PROCESS CONTROL

CENTRAL CONTROL

OPTIMISATION

RTU, PLC..

ASMS, WTO, NN, OM&S, IS

CENTINELA, SIAL, SICOT..

Integration Schematic

DataReconciliation

Well ModelRecalibration

LegacyData

Systems

m.Changes

NeuralNets

System Geometry

Decoupled

One iGES Server per BU

iGES-basedapplications

OracleIntermediate

DataBase

MiddlewareTransaction Services

SCADA ServerSCU 2

Real Time History

SCADA ServerSCU 7

Real Time History

PIHistorian

Crude/WaterTreatment

&Water Injection

Dynamic LeakDetectionPI Decoupled

from PRAP

Databaseservers

MasterRecollectors

PI API

SCADA ServerSCU 1

Real TimeHistoryAverageData

Real Time

SCADA ServerSCU 6

Real TimeHistoryAverageData

ABB Simcon

KBC UpRight EPS

Valmet

Stoner

System Architecture

Process Control

Central Control

Optimisation

Corporate Systems

PdVSA Online GLO

Process Control

Central Control

Optimisation

Corporate Systems

The Online GLO Application

RTU/PLC

Optimiser

Database

Input Output

Online GLO Daily Operation

GLO is executed...

Gas lift rates andrecommendations downloadto SCADA

Gas Lift Well

MiniPlantas

Compressors

The results are evaluated...

Approval atSupervisory level

The SCADA Operatoraccepts the gas lift ratesand carries out adjustments

La Salina Online

Tuned Well ModelsGenerate Operating PtWellhead PerformanceCurveWells in FlowgroupsFlowgroup Performance

SurfacesHP Gas Lift NetworkLP Gas GatheringNetworkComplete Network

Field Implementation Results

POIS• POIS = Production Operation Information System• Northern fields of Kuwait• Performed by consortium including EPS, Aspentech, Daelim• EPS role was to provide the optimization software, software integration

and detailed engineering models for five fields in North Kuwait. • The fields included 197 wells (411 well strings)

– 33 water injectors, – 91 gas lifted producers and – 30 produced with ESPs.

• The wells and fields are connected through a complex network allowing wells to be switched between high, medium and low pressure as well as ‘wet’ and ‘dry’ separator trains

• Total production 600 Mstb/day

Design Brief

• Hydraulic model of GL Distribution System• Compressor Station behaviour and Performance

– Power turbines, compression, gearboxes, intercoolers, gas recycling

– Surge and stonewall constraints

• Multiphase Flow• Scalable to >1000 wells• Optimise non-hierarchical networks• Online Integration with

– Production Management System– DCS/SCADA System

Objectives

• Data acquisition via SCADA to MIS (Aspentech)

• GL optimisation for new GL wells– GL being installed following water injection

• Automatic acquisition of WT data • Automatic well model recalibration• Automatic online GL optimisation calculation• Manual setting of optimised setpoints

(initially)

PAS Concept

NewWellTest

WellFloWell Model

Compare with

Engineerintervention

Rerun orretune

Manual Model Retune

Automatic Model Retune

Rerun Welltest

Data Transfer

Past data

GLO Concept

ReO System Model

Network model

Wells Wells Wells Wells Wells

InitiateGLO run

GetUpdated

well models

Generatewell

performanceRun GLO

Convert tochoke

settings

New SettingsNew gas allocation

Implementation

• Well modelling of all 411 wells (WellFlo)• Construction and tuning of network Model

(ReO)• Automatic tuning of Well models• Automatic GL optimisation• Integration with Aspentech MIS• Model maintenance and development

Important Issues Identified

• Data Quality– Well data– production data– Surface network data

• Business processes– building use of POIS model into std. procedures– model maintenance– model enhancement

• Compressor optimisation• Multistage separation optimisation

Network Config Modelling

Individual fields (viz., RA, SA, RQ, AD & BH) modelled as separate sub-sheets

Each GC has 7 headers that can take inflow from any or all wells

All fields interconnected through 3 Gathering Centres: GC-15, GC-23, and GC-25

Multiple GC & MF options for all the wells made network very flexible to accommodate any future flow path definition

Optimiser easily handled this huge network - over 40,000 objects!

SCADA & POIS

Well Head PressureFrom 217 Wells

GC SCADA GC DCS

GC RTDB(POIS)

All DCS DATATRANSFERRED

RADIO LINK

PMDBALTAMEER

(POIS)

FINDER WELL INFORMATION

Business Process ExplorerGUI

WellFlo Reo&

WellFlo

Maintain Well Models(Administration of)

Hydrocarbon AccountingMaterial Balance

Top Level Network

Raudhatain-[RA]-GC15&GC25

Abdali-[AD]

Ratqa-[RQ]

Bahra-[BH]

Sabriyah-[SA]-GC23

C-GC15 C-GC25 C-GC23

Abdali:

16 Wells

to 2 GC

via 13 6in linesRatqa:

20 Wells

to 2 GC

via 36in & 10in lines

Raudhatain:

195 Wells

to 3 GC

thru’ 7 MF each

Sabriyah:

142 Wells

to 1 GC thru’ 7 MF

Bahra:

5 Wells

to 1 GC thru’ 7 MF

378 producers with choice of producing into any of 3 GCs through any of 21 MFs

RA Field Network

Lift-Gas System

5x7 Possible inputs from RQ & AD fields

9 Sub-sheets holding 20-25 wells each

7x3 MF interconnecting all 194 wells across the field

7x3 MF outlets to production terminals

Lift gas to SA field

NP & GLwells (FG)

Multi-header choice for lift-gas

at present & for future

Multi-MF choice for production

at present and for future

GL Well Performance Surface Data

Conclusions

• KOC currently producing to quota– Current capacity higher than quota

• (how much higher is unknown)

– However additional production can be allocated to NK– Cost reduction is additional benefit

• Reduction in admin overhead• Reduction in flaring• Potential reduction in new well requirement• Network reconfiguration

• Work practices need to change to extract full value from the system

POIS project

• Client - Kuwait Oil Company• Year of Contract Award – 2000• Projected Value Generated:

– $100 million - $175 million per annum (projected)

Questions?

Online Field-Wide Gas-lift Optimisation

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