Front-End Integrated Production System Modelling for Production Optimization – Experience from a Niger Delta Field

Felix O. Okoro, E. Arochukwu, Segun Adomokhai, L. Dennar
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Abstract

The M001 project involved the hook-up of 12 wells (17 conduits) which were drilled and completed between year 2000 and 2005 but were closed-in for operational reasons, until year 2019 when the first seven (7) conduits on cluster MX1 were cleaned up successfully. The seven conduits (Well-A, Well-B, Well-C, Well-D, Well-E, Well-F & Well-G) were expected to flow via three 8" bulk lines. Post well open-up and handover to production, significant bulking / backing out effects were observed. An average Flow Line Pressure (FLP) of ∼22 bar was recorded on the flowlines, hence limiting the capacity to bulk the wells, [FLP increases towards Flowing Tubing Head Pressure (FTHP) hence, pushing the well out of the critical flow envelope as FTHP<<1.7FLP]. Due to this challenge, total production from Cluster MX1 was sub-optimal with only five (5) conduits out of seven (7) able to flow due to bulking and backing out effect. The sub-optimal performance from the conduits were investigated using the Integrated Production System Model (IPSM) / PIPESIM models. Four different scenarios were run in the model and the calibrated IPSM model indicated all 7 conduits should flow if there are no surface restrictions. The model identified pressure, mass and rate imbalances in the integrated system and suggested the presence of a restriction at the manifold, causing sub-optimal production from the wells. The model outcome triggered an onsite investigation / troubleshooting from the wellhead to the manifold at the facilities end where an adjustable choke was identified in the ligaments of the manifold. In line with process safety requirements, a risk assessment was carried out and a Management of Change (MOC) raised to remove the adjustable choke at the manifold. Post implementation of the intervention, all the seven (7) conduits produced without any bulking effect. Total production realized from the seven (7) conduits post execution of the recommended action is ca. 9.3 kbopd against 5.2 kbopd pre-intervention. A total of ca. 4.1 kbopd production gain was realized and 10 mln USD proposed for additional bulkline was saved.
面向生产优化的前端集成生产系统建模——来自尼日尔三角洲油田的经验
M001项目涉及连接12口井(17个管道),这些井在2000年至2005年期间钻完,但由于操作原因而关闭,直到2019年MX1簇上的前7口管道被成功清理。这7条管道(Well-A、Well-B、Well-C、Well-D、Well-E、Well-F和Well-G)预计将通过3条8英寸的散装管线输送。在开井和移交生产后,观察到显著的膨胀/倒出效果。在流线上记录的平均流线压力(FLP)为~ 22 bar,因此限制了井的膨胀能力,[FLP随着流动油管压力(FTHP)的增加而增加,因此,当FTHP<<1.7FLP时,将井推出临界流量包络线]。由于这一挑战,簇MX1的总产量不是最优的,由于膨胀和回退效应,7条管道中只有5条管道能够流动。利用综合生产系统模型(IPSM) / PIPESIM模型对管道的次优性能进行了研究。在模型中运行了四种不同的情况,校准后的IPSM模型表明,如果没有表面限制,所有7条管道都应该流动。该模型确定了综合系统中的压力、质量和速率不平衡,并表明歧管处存在限制,导致油井产量达不到最佳水平。模型结果引发了从井口到设施末端的歧管的现场调查/故障排除,在歧管的韧带中发现了一个可调节的节流器。根据工艺安全要求,进行了风险评估,并提出了变更管理(MOC),以移除歧管处的可调节阻流器。干预措施实施后,所有7条管道均未产生任何膨胀效应。在建议措施执行后,7条管道实现的总产量约为9.3万桶/天,而干预前为5.2万桶/天。实现了总计约4.1万桶/天的产量增长,并节省了1000万美元的额外储备。
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