MENU

PRODUCTION

The Case for Intelligent Artificial Lift

WEB EXCLUSIVE ISSUE
SHARE THIS PAGE

Automation and real-time analysis can

improve personnel safety and reduce
costs.
by Bill Lane

As constrained spending has slowed the development and

construction of new wells, operators are increasingly reliant
on their mature assets. The companies that will be successful
are those that can leverage their existing investments to
optimize production; reduce health, safety and
environmental (HSE) risk; and control costs. One key
method to achieve these goals is improved production
surveillance and analysis.

Thirty years ago, production monitoring consisted primarily

of surface gauges, which were present on only about 10
percent of active wells. Now, most wells have some type of
basic monitoring hardware. However, the true value of
production monitoring is not realized until monitoring
equipment is connected as part of a system for automated
control, remote surveillance and production analysis.

Empowering, Not Replacing, Personnel

It is important to understand that intelligent systems are
tools that help skilled field personnel do their jobs more
effectively. Field personnel are essential to any automated
system. To start, they are responsible for setting appropriate
parameters to achieve performance goals.

The resulting improvements can be impressive. In a 14,000-

well Texas field, automated systems reduced the number of
pump strokes by more than 1 million and cut 50,000 on-off
cycles per day to reduce wear on components and extend
equipment life. In another case, the production from 200
electric submersible pump wells in China was increased 30
percent through the use of real-time automation systems.

Real-time analysis also allows field personnel to more

effectively prevent downtime and the resulting production
delays. In Argentina, analysis software enabled personnel
CAHABA MEDIA GROUP. ALL to
RIGHTS RESERVED.

make adjustments that increased production on 190

make adjustments that increased production on 190
MENU
progressing cavity pump (PCP) wells while decreasing pump
downtime by 70 percent. In another field, lift system
downtime for problem wells was reduced by more than 50
percent.
ADVERTISEMENT

Enhancing Short- and Long-Term Performance

Automated production monitoring and analysis systems
come in two primary types: those that support real-time
control and optimization of production operations and those
that aggregate and organize large swaths of data to support
long-term planning.

Real-time automation systems can autonomously adjust

artificial lift systems in response to changing well conditions.
For example, pumping rates can be continuously adjusted to
match production inflow in order to maximize production
while preventing damaging pump-off conditions. Automated
controls can also adjust pumping cycles to match fluid
conditions. In rod-pumped wells, pumping speeds can be
adjusted within the pumping cycle to maximize production
on the upstroke without over-running the rods on the
downstroke.

Real-time automation systems also enhance HSE

performance by mitigating potentially damaging or
hazardous downhole conditions, such as rod stick-slip and
pressure kicks, before they develop into more serious risks.
In some cases, automated systems have prevented
catastrophic events by recognizing dangerous conditions and
immediately adjusting lift systems to counteract themall
without exposing personnel to additional risk. HSE is further
improved by remote surveillance, which eliminates the need
for most wellsite visits to monitor production activity and
status.

Analysis software manages and examines large amounts of

collected data to identify trends and opportunities for
planned improvements in operations. Modeling and
simulations can predict the impact of declining well pressures
CAHABA MEDIA GROUP. ALL RIGHTS RESERVED.

on production and cost, enabling operators to consider

on MENU
production and cost, enabling operators to consider
appropriate changes in production systems. Automated
analysis software can also reveal data trends that point to
water coning, water encroachment and liquid loading.

By automating certain facets of well monitoring, analysis

software improves the efficiency and effectiveness of
personnel resources so they can better manage a broader
scope of responsibilities. This has an indirect favorable HSE
impact since fewer personnel is required to manage assets
and fewer visits to the wellsites are required.
ADVERTISEMENT

Related Surface & Downhole Equipment

Whether the automation system is focused on real-time data,
long-term analysis or both, the software must be supported
by high-quality monitoring equipment installed at the
wellsite. On-site monitoring equipment commonly includes
sensors and transmitters connected to a field network that
performs system calibration and diagnoses any anomalies. In
an automated system, the network organizes and analyzes the
data, identifies areas of concern and initiates immediate
action as neededall without the need for human
interference.

For example, one type of deliquification system (DLQ) is a

remote terminal unit that automates such critical
functionality as electronic flow measurement, injection well
processes and custody transfer quality measurements. The
system can be customized for use on one or multiple wells of
various types, from flowing to injection to artificial lift.

Another related technology is variable speed drives (VSDs).

For rod pumping applications, one VSD monitors implied
pump fillage from the pump card and adjusts the rate to
maximize pump fillage. When pump fillage is below the
established parameters, the VSD reduces the pumping rate.
When pump fillage is above the established point, it increases
the rate.

CAHABA MEDIA GROUP. ALL RIGHTS RESERVED.

For PCP applications, this VSD automatically and

ForMENU
PCP applications, this VSD automatically and
continuously adjusts the pumping rate to match the well
inflow. Inflow is calculated based on downhole pressure
measurements. The system also enables operators to "soft
start" PCP systems to prevent overstressing components
when the system is initially turned on. This can be important
for preventing system damage after momentary power
interruptions.

Downhole sensors also play a role in automated production

surveillance. Automatic systems require highly accurate input
values to trigger the appropriate response. Despite
improvements in surface sensors that infer downhole
conditions, direct downhole measurements are the only way
to accurately determine downhole conditions such as
pressure, temperature and fluid phases. Measuring forces and
operating speeds at the surface cannot effectively reflect
downhole conditions that are outside of normal operating
parameters.

Electronics-based sensors provide cost-effective

measurement of downhole pressures, temperatures and
vibration, especially in moderate well conditions. They
provide feedback of real well conditions more accurately than
values that can be calculated or inferred through indirect
measurement.

Permanent fiber-optics-based systems provide more sensing

options and improved reliability. This is especially important
for high-value wells, such as those in unconventional
reservoirs, which see strong declines in pressure and
production rates soon after starting production. In these
fields, it is essential to collect direct measurements of
pressure, temperature, flow and liquid levelssomething that
can only be accomplished using permanent downhole gauges.
These values can then be automatically monitored and
analyzed using optimization software, which serves to
support both daily operations and long-term strategic
planning for maximizing production.

Intuitive Displays Enable Fast Action

The form of data presentation is equally important to data
quality. For example, software that presents an intuitive
visual interface using multiple presentation styles and colors
could be helpful. Color-coding leverages learned signals to
quickly transmit information from the eyes to the brain.
Automation software can be configured to display data in
green, yellow or red based on whether the downhole
conditions are in the normal range, of some concern or
require immediate attention. This enables decision makers to
act on the most critical items quickly and with confidence.
CAHABA MEDIA GROUP. ALL RIGHTS RESERVED.
 MENU

Figure 1. One type of software displays color-coded alarms. (Graphics courtesy of Weatherford)

Application Example: Intelligent Gas Lift

One area with room for growth is the automation of gas-lift
and gas-assisted plunger lift. Intelligent lift systems of this
type work by determining the precise amount of gas needed
to complete a lift cycle, then injecting only that amount. This
reduces the amount of gas needed to complete each lift cycle,
which substantially reduces overall lifting costs.

The technology also lowers tubing pressures to encourage

greater production inflow since less gas is circulated through
the sales-line suction system. Finally, by reducing the demand
for injection gas, intelligent gas-lift technology decreases the
strain on compression systems, extending the time between
maintenance and minimizing downtime related to system
failure.

Figure 2. The chart at the left reflects a gas lift well in which the gas injection rate is manually
controlled. The chart at the right is for the same well on automated control, which resulted in
stabilized injection pressures with 9 percent less gas usage.

Justifying the Investment in Mature Assets

While it is usually easy to justify installing sensing and
control systems on new wells as they are brought online, it
can be harder to argue for the same systems on existing wells
in mature assets. Typically, the approach is to spend as little
as possible on wells that have their best years behind them.

Although permanent fiber optic systems may be out of reach

from a cost basis, there are many lower-cost options that can
CAHABA MEDIA GROUP. ALL RIGHTS RESERVED.

provide meaningful production improvements and

 provide
MENUmeaningful production improvements and
reductions in operating costs. The automation of gas lift
systems is one example. The use of remote monitoring to
reduce wellsite visits is another obvious example.

Even lower-cost solutions must be justified. The most

effective way to prove value is to partner with an experienced
systems supplier and to start very smallperhaps with a few
pilot systems on a basic network to measure the gains. The
system can then be expanded, perhaps gradually, based on the
lessons learned from the initial successes. It is not uncommon
for operators to use the improved earnings and reduced
operating costs from the pilot projects to fund expansion of
the systems, from which they can then realize greater
benefits.

The combination of real-time and trend data with analysis

facilitated by intelligent, automated production systems has
many benefits including greater efficiency, higher production
and fewer lift-system failures. All of these are proven and
justified ways to lower costsan essential goal for all
operators at a time when capital expenditures are scarce.

ABOUT THE AUTHOR

Bill Lane is vice president of emerging technologies for Weatherford artificial lift
systems and a member of the Weatherford unconventional resources team. He
currently serves as chairman of the R&D Committee of the Artificial Lift Research
and Development Council (ALRDC).

Related Articles

Optimizing Returns for Declining Wells

Hydraulic Jet Pumps Offer Solution for High

Dogleg Severity Wells

Water Management & Safety in Offshore Oil &

Gas

Customizable Platforms Enable Automation &

Fast Decision-Making
CAHABA MEDIA GROUP. ALL RIGHTS RESERVED.

RFID-Activated Tools Allow Rathole-Reaming &

RFID-Activated
MENU Tools Allow Rathole-Reaming &
Wellbore-Cleaning During Single Run in Caspian
Sea

CAHABA MEDIA GROUP. ALL RIGHTS RESERVED.