Gas-lift Automation in Unconventional Fields
GAS-LIFT AUTOMATION IN
UNCONVENTIONAL FIELDS
Steve Cannon
Global Product Line Manager, GHP Automation
May 2017
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Gas-lift Automation in Unconventional Fields 1
AGENDA
1 INTRODUCTION
2 THE DECLINE
3 CUSTOMER CHALLENGES
4 THE SYSTEM
5 AUTOMATION vs. OPTIMIZATION
6 GAS LIFT OPTIMIZATION
7 THE ROADMAP FOR SUCCESS
8 SUMMARY
9 Q&A
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Gas-lift Automation in Unconventional Fields 2
INTRODUCTION
Gas Lift Traditionally, shale wells are transitioned directly to
Automation rod lift once natural flow has stopped or slowed
Delays CAPEX for
Unconventional significantly.
Production However, many operators are now choosing to delay
CAPEX by transitioning to gas lift before later
converting to rod lift.
For this reason, gas-lift optimization has become
increasingly important for customers working in shale
plays.
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Gas-lift Automation in Unconventional Fields
THE DECLINE
Jet Pump
Rod Lift
PRODUCTION
Well
Prep
Early Production
Later Production
TIME
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Gas-lift Automation in Unconventional Fields
THE DECLINE GAS LIFT
“… an artificial lift method whereby external
gas is injected into the produced flow stream
Jet Pump
at some depth in the wellbore. The additional
gas augments the formation gas and reduces
the flowing bottom hole pressure, thereby
Rod
Gas Lift increasing the inflow of produced fluids.”
Lea, James F., Nickens, Henry V., and Wells, Mike R.; Gas Well Deliquification Second
Edition; 2008 Gulf Professional Publishing.
PRODUCTION
Well
Prep
Early Production
Later Production
TIME
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Gas-lift Automation in Unconventional Fields
GAS LIFT FACTS
The artificial lift method that most closely simulates a
naturally flow well.
Gas lift will only produce what the well gives up
naturally.
Gas lift is not a positive displacement pump. More
injection gas does not mean more production.
Injected gas simply reduces the hydrostatic head of the
fluid column—reducing back pressure on the
reservoir—to keep the well flowing above its ‘critical
velocity’.
©2017 Weatherford International plc. All rights reserved.
Gas-lift Automation in Unconventional Fields
CUSTOMER CHALLENGES
Inefficiencies in GL system and/or facility.
Over/under utilization of supply gas and/or
compression.
Overcoming deficiencies in source gas or
compression
A goodfor“system”
unloading and ramping.
design is critical
Manualfor optimization
daily inspection to be effective.
and tuning.
We can only optimize to what the
wellhead
Timeliness and system
and inaccuracy are capable
of reports.
of producing.
Others
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Gas-lift Automation in Unconventional Fields
THE GAS LIFT SYSTEM
Supply Gas and Compression: High pressure source of
injection gas delivered to the wellhead.
‐ Compressor monitoring & control
‐ Meter supply gas
‐ Discharge pressure
Lift Gas Manifold: Metering, control and distribution
of the source injection gas to individual wellheads.
‐ Monitor & control of injection rate
‐ Meter gas volumes
Wellhead: Source gas is injected into the annulus,
operating a series of gas-lift valves maintaining
sufficient differential pressure to move the fluid to the
surface.
‐ Operating casing & tubing pressure
‐ Flowing temperature
‐ Flow line pressure
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Gas-lift Automation in Unconventional Fields
THE GL SYSTEM
Production Separator: Separates gas and liquids
produced from the wellhead.
– Produced gas flow meter (SP, DP, T)
– Produced liquid flow meter
– Produced liquid tank level (water, oil)
Electronic Gas Meters
– Source injection gas meter; buy back gas
meter
– Injection gas meter (wellhead and total)
– Produced gas meter (wellhead and total)
– Sales gas meter
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Gas-lift Automation in Unconventional Fields
AUTOMATION vs OPTIMIZATION
Automation Optimization
To manage the operation of a system or The systematic or continuous control of a
process with electronic, mechanical, system or process to maximize (or
hydraulic or pneumatic technology. minimize) the results.
“To operate without manual intervention” “To manage to a target or goal”
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Gas-lift Automation in Unconventional Fields
EXAMPLES
Automation Optimization
Record process values and status Allocation of production resources
Pressures, temperatures, rates, levels… Facility equipment, compression, injection
On/off, open/closed, high/low … gas, etc.
Control to setpoint Managing production
PID, open/close, shutdown… Maximize production, minimize costs
Operating sequences, unloading, ramping, Sequencing wells for start-up and shutdown
well testing… by priority
Control process to seek optimum injection
Detect events and alarms rates
Accumulate values and reporting Optimize on/off cycles (intermittent GL
– Daily production flows & volumes control)
– Runtimes
Modeling
Compare theoretical production with actual
and adjust control parameters.
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Gas-lift Automation in Unconventional Fields
GAS LIFT OPTIMIZATION
Unstable Injection Rates
GL Wells have few options for
optimization solutions.
Most options have little or no
intelligence. Typical solutions include:
– PID to control injection rate to a
setpoint
– Simple timer for on/off injection
Production changes can easily disrupt Dramatic Swings in
simple controls. Casing Pressure
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Gas-lift Automation in Unconventional Fields
GAS LIFT OPTIMIZATION – THE OPTIMUM INJECTION RATE
The well’s performance can be
Potentially Large Production Losses
described by a simple curve showing
liquids returned versus gas injected.
This curve is typically calculated from Optimum
Injection
the well model and past performance Rate
Oil (BBLs/day)
Over
data. Injection
Most often the performance curve is Under
not available in the controller, and/or Injection
periodic calculations may be
uneconomical to implement.
Too much time spent under- or over- Gas Injected (MCF/day)
injecting will result in production losses
©2017 Weatherford International plc. All rights reserved.
Gas-lift Automation in Unconventional Fields
GAS LIFT OPTIMIZATION – THE OPTIMUM INJECTION RATE
With access to real-time production data Potentially Large Production Losses
or current well test, the WellPilot DLQ will
make periodic incremental control
adjustments moving toward the optimum Optimum
injection rate. Injection
Rate
Oil (BBLs/day)
Over
Injection
What about wells with a common source
of gas and compression? Under
Injection
‐ A key feature of the controller is its ability to
manage multiple wells. Each well is given a
priority. Lower priority wells give up supply to
support the higher priority wells.
Gas Injected (MCF/day)
‐ It also has access to many other automation
devices to aid in decision-making.
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Gas-lift Automation in Unconventional Fields
GAS LIFT OPTIMIZATION – UNSTABLE INJECTION RATES
Unstable Injection rates due to changes in the well/reservoir performance and/or production
facility (e.g. high line pressure).
Automatic Choke Control. The WellPilot DLQ opens/closes the well using a motorized choke
valve with a setpoint for how far open the choke should be initially. After the valve is opened,
the “Flow Control” module adjusts the position of the valve until it meets a setpoint rate.
Here the square wave (yellow) is the
injection rate. Notice how it is self-
correcting to the 550 MCF/d target rate.
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Gas-lift Automation in Unconventional Fields
GAS LIFT OPTIMIZATION – INTERMITTENT INJECTION
Production has become less than expected (modeled/designed).
Limited gas supply/compression.
Intermittent control requires periodic analysis of surface line pressure to determine optimum
injection rate.
– When injection ON-time continues past the fluid slug arrival, the downhole pressure is maintained higher than
necessary, lowering production.
– If injection ON-time is too little, production falls dramatically.
The WellPilot DLQ intelligently changes ON-time
to changing well and surface conditions. This
well had a rising flow line pressure, requiring
more lift gas to complete the lift cycle.
©2017 Weatherford International plc. All rights reserved.
Gas-lift Automation in Unconventional Fields
GAS LIFT OPTIMIZATION – ANALYZING SLUG ARRIVAL
With intermittent GL, continuing to inject after the slug has arrived consumes more
energy than necessary. And increases bottom-hole pressure, causing less production.
Analyzing the slug for arrival and stopping injection reduces cost and increases
production. Customer Real Results:
Usage of lift gas is reduced by moving to intermit GL with the
The WellPilot DLQ’s proprietary
ability control
to optimize algorithm
beyond detectsofslug
the capabilities arrival
on/off timerand stops injection.
boxes.
The drop in lift gas being circulated through the sales line causes
a production line pressure drop. Increases in production have
been observed due to this result.
Downtime in over-stressed compressors has been reduced due
to lower gas volumes.
Normal Short or Flow Foamy Long, Fast Restriction
Low Velocity Restriction Slugs Gas Cut Cycle at Separator
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Gas-lift Automation in Unconventional Fields 17
ROADMAP FOR SUCCESS
Step 1 Step 2 Step 3
DynaLift™ is a dynamic gas-lift LOWIS™ software provides real- The WellPilot DLQ delivers
simulation software application time surveillance, analysis and remote, real-time control and
used to interactively test and well service management tools, optimization for one or multiple
fine-tune gas-lift system designs empowering producers to better gas lifted wells. It continuously
before going into the well. organize and standardize their monitors available injection gas
WellFlo lets you design, model, production workflow processes. and distributes to wells by
optimize and troubleshoot CygNet for Production™ is a fully priority. Pre-programmed
naturally flowing or artificially operational SCADA system, the controls for unloading and
lifted oil and gas wells. CygNet Enterprise Operations ramping functions are supported.
Platform provides the core Through an integrated approach
ReO provides simulation and foundation, built to adhere to to production automation, the
optimization of production common operations practices DLQ provides real-time critical
solutions for surface networks and reporting requirements. measurements, optimization, and
from wellhead to the processing control at the wellhead, meter, or
plant. production facility.
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Gas-lift Automation in Unconventional Fields 18
SUMMARY
Understand the Challenges
– What are the your problems, frustrations and
Identify, missed opportunities?
Plan, Plan for success
– “System” Design is critical (Reservoir, Well
Execute, Construction, Facility, Controls and Optimization)
and Optimize
– Select equipment that will support multiple
Review scenarios
It’s a Continuous Process
– Monitor, Analyze and Adjust
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Gas-lift Automation in Unconventional Fields
QUESTIONS
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