Oilfield Production Modeling & Optimization - ALRDCalrdc.org/workshops/2016_2016GasLiftWorkshop/presentations/2-3...Oilfield Production Modeling & Optimization ... – gPROMS technology

May 16 – 20, 20162015 Gas-Lift Workshop 1

Oilfield Production Modeling & Optimization

• Kevin Wade, Lead - Oil & Gas Production System

Process Systems Enterprise (PSE), UK

39th Gas-Lift WorkshopHouston, Texas, USAMay 16 – 20, 2016

Agenda

• Overview of PSE

• Overview of PSE’s Production modeling Technology

– Focus on Oilfield Optimization Technology

• Discrete optimisation

• Case example

Private, independent company

incorporated in UK

1997

Company ‘spun out’

Acquires technology

PSE HISTORY: FROM RESEARCH TO INDUSTRY

1989 – 1997 Now

Advanced Process modeling platform

100s of person-years of

R&D with industry

Simulation & modeling,

Optimization, numerical

solutions techniques,

supply chain

London HQ Korea JapanUS NJUS TX Switzerland

Thailand Malaysia ChinaTaiwan

140+ people~60 PhDs

Background

PSE Business Sectors

Oil & Gas Chemicals &Petrochemicals

Life Sciences, Consumer & Fine Chemicals

Power & CCS

Overview of PSE’s Production modeling Technology

Overview of PSE’s Production Optimization Technology

Scope

Oilfield Production Optimization

Maximise production value from an oilfield by adjusting process and well behaviour

Decide

which wells to use

which routing to take to the surface

how much gas-lift to apply to each well

……

…within operational envelope

Scope

Well and well-network systems:

From: Sandface

To: Topside Separator

Overview of PSE’s Production Optimization Technology

Technological basis

Key elements of gPROMS Oilfield Optimizer

1. gPROMS Platform

2. gPROMS Oilfield Model Library

3. gPROMS Oilfield Optimizer

4. Interface to existing systems and data

Process flowsheeting technologies

The Sequential Modular (SM) approach

?

WATER

ETHANOL

MIXED REF-1

REF-0WGS-IN

PRODUCTS

REFORMER

HEATER COOLER

MIXER

WGS

1 2

3

4

5

67

8

9

10

f(x) = 0One large set of equations (103-106 variables)

Solved simultaneously

Process flowsheeting technologies

The Equation Oriented (EO) approach

1 2

3

4

5

67

8

9

10

Conceptually much simpler …

Complete Field Optimization

Field Optimization

• Existing tools can optimise production on

– Well level

– Manifold level and

– Field level

• Given a number of field constraints

• These focus on continuous variables

– Gas lift injection rate (0-x) MMscf/d

– Choke Delta P (0-x) psi

• We also optimise on discrete variables

– Well status (on/off)

– Well routing (pipeline A or pipeline or ….)

– Pipeline routing (riser A or riser B or …)

– Riser routing to (separator A or separator B or …)

Feb. 4 – 8. 20132013 Gas-Lift Workshop 13

Discrete Optimisation

• Traditional tools can only solve continuous optimisation

• They can be made to optimise discrete cases by:

– Brute force approach

– using GA

• Brute Force: Ok if options are small

• For I = 1 to number of wells on/off options

– For j = 1 to number of well routes

• For k = 1 to number of pipe routes

– For l = 1 to number of separators

» Call continuous solver

• Next l, k, j, i

• GA: has limitations

Feb. 4 – 8. 20132013 Gas-Lift Workshop 14

Innovate UK project

Case study performance

Solver parameter settings

RunObj Func[$m/day]

CPU [hr] Param #1 Param #2 Param #3

1 3.3467 136 1.E-04 1.E-08 1.E+062 3.2705 91 1.E-02 1.E-06 1.E+063 3.2015 66 1.E-06 1.E-09 1.E+034 3.1789 137 1.E-06 1.E-09 1.E+035 3.1742 125 1.E-03 1.E-06 1.E+066 3.1354 29 1.E-06 1.E-09 1.E+03

Best solution significantly better than

that from industry-standard tool

Quality of solution varies significantly

with solver parameter settings

Long execution times 5½ days to get best solution strongly dependent on solver settings

IS IT POSSIBLE TO DO BETTER THAN THIS ?

Best-in-Class MINLP solver

Solver parameter settings

RunObj Func[$m/day]

CPU [hr] Param #1 Param #2 Param #3

gOO 3.5071 1.6 N / A

1 3.3467 136 1.E-04 1.E-08 1.E+06

2 3.2705 91 1.E-02 1.E-06 1.E+06

3 3.2015 66 1.E-06 1.E-09 1.E+03

4 3.1789 137 1.E-06 1.E-09 1.E+03

5 3.1742 125 1.E-03 1.E-06 1.E+06

6 3.1354 29 1.E-06 1.E-09 1.E+03

Innovate UK project

Case study performance

Significantly better solution:

$58.5m/year

Significantly faster solution:

O(100) speed advantage

Performancenot dependent on

solver parameter settings

Conclusions now confirmed across a range of case studies

Best-in-Class

MINLP solver

Innovate UK project

Project outline

• Project start: 1st November 2015

• Project finish: 30th September 2016

• WP1: System scoping & specification

– Stakeholder interviews

• WP2 – Technology assessment, gap analysis & project planning

• WP3 – Development of the framework and further development of numerical solvers

• WP4 – Construction of the validation case study model

• WP5 – Industry feedback and exploitation plan

PSE is now seeking input and potential test applications from stakeholders.

Case examples

gPROMS Oilfield Optimization

Case Study 1: Optimization Onshore

• Challenge

– Optimize revenue (from both oil & gas)

– Separator: maximum gas rate constraints

– Well: Maximum liquid rate & maximum drawdown

Client: Confidential

Field type: Gas Condensate

Well count: 120

Pipeline count: 200

Separator count: 3

Routing combinations: >1 Million

Case Study 1: Optimization Onshore

Current Technology vs gPROMS results

Matched simulation results of current world-leading Optimization tool to within 0.3%.

Constraints violated

Gas rate [MMScf/day] / separatorOil rate [bbl/day]

Revenue [MM$/day]A B C

(max 1030) (max 571) (max 161)

Simulation

Current Technology

973 610 155 221,615 $ 24.08

gPROMS 974 608 161 222,235 $ 24.15

Optimization(Continuous)

Current Technology

974 555 157 215,380 $ 23.4

gPROMS 991 571 1601 224,924 $ 24.37

Optimization(Field Configuration)

Current Technology

974 555 157.2 215,380 $ 23.4

gPROMS 1030 571 161 239,570 $ 25.83

Case Study 1: Optimization Onshore

Current Technology vs gPROMS results

Increase in production of 4.4% with gPROMS ~ $1.0M/d!

Gas rate [MMScf/day] / separatorOil rate [bbl/day]

Revenue [MM$/day]A B C

(max 1030) (max 571) (max 161)

Simulation

Current Technology

973 610 155 221,615 $ 24.08

gPROMS 974 608 161 222,235 $ 24.15

Optimization(Continuous + Well

Status)

Current Technology

974 555 157 215,380 $ 23.40

gPROMS 991 571 161 224,924 $ 24.37

Optimization(Field Configuration)

Current Technology

974 555 157.2 215,380 $ 23.4

gPROMS 1030 571 161 239,570 $ 25.83

gPROMS solution into current technology

991 567 154 223,880 24.25

Case Study 1: Optimization Onshore

Current Technology vs gPROMS results

Increase in production of 11.0% with gPROMS ~ $2.5M/d!

Better utilisation of separators

Gas rate [MMScf/day] / separatorOil rate [bbl/day]

Revenue [MM$/day]A B C

(max 1030) (max 571) (max 161)

Simulation

Current Technology

973 610 155 221,615 $ 24.08

gPROMS 974 608 161 222,235 $ 24.15

Optimization(Continuous + Well

Status)

Current Technology

974 555 157 215,380 $ 23.40

gPROMS 991 571 1601 224,924 $ 24.37

Optimization(Field Configuration)

Current Technology

974 555 157.2 215,380 $ 23.40

gPROMS 1030 571 161 239,570 $ 25.83

Case Study 1: Optimization Onshore

Current Technology vs gPROMS results

Increase in production of 11.0% with gPROMS ~ $2.5M/d!

Better utilisation of separators

Gas rate [MMScf/day] / separatorOil rate [bbl/day]

Revenue [MM$/day]A B C

(max 1030) (max 571) (max 161)

Simulation

Current Technology

973 610 155 221,615 $ 24.08

gPROMS 974 608 161 222,235 $ 24.15

Optimization(Continuous)

Current Technology

974 555 157 215,380 $ 23.4

gPROMS 991 571 1601 224,924 $ 24.37

Optimization(Field Configuration)

Current Technology

974 555 157.2 215,380 $ 23.4

gPROMS 1030 571 161 239,570 $ 25.83

221,615

215,380 215,380

222,235224,924

239,570

SIMULATION OPTIMISATION (CONTINUOUS) OPTIMISATION (FIELD CONFIGURATION)

Production Rate b/d

Other gPROMS

gPROMS Oilfield Optimization

Case Study 2: Optimization Offshore

• Challenge

– Optimize Oil Production

– Riser: maximum fluid velocity speed & limited

gas lift injection gas

– Well: Maximum liquid rate & maximum drawdown

Client: Confidential

Field type: Gas Lifted Oil Field

Well count: 13

Riser count: 5

Separator count: 3

Routing combinations: > 300,000

Matched simulation results of current world-leading Optimization tool to within 1.1%.

Oil rate [bbl/day] Revenue

[MM$/day]

Simulation

Current Technology

85,254 $ 9.26

gPROMS 86,107 $ 9.36

Optimization(Continuous + Well Status)

Current Technology

90,404 $ 9.82

gPROMS 95,464 $ 10.34

Optimization(Field Configuration)

Current Technology

90,404 $ 9.82

gPROMS 105,432 $ 11.37

Case Study 2: Optimization Onshore

Current Technology vs gPROMS results

Case Study 2: Optimization Offshore

Current Technology vs gPROMS results

Increase in production of 5.6% with gPROMS ~ $0.5M/d!

Oil rate [bbl/day] Revenue

[MM$/day]

Simulation

Current Technology

85,254 $ 9.26

gPROMS 86,107 $ 9.36

Optimization(Continuous + Well Status)

Current Technology

90,404 $ 9.82

gPROMS 95,464 $ 10.34

Optimization(Field Configuration)

Current Technology

90,404 $ 9.82

gPROMS 105,432 $ 11.37

Case Study 2: Optimization Offshore

Current Technology vs gPROMS results

Increase in production of 16% with gPROMS ~ $1.5M/d!

Oil rate [bbl/day] Revenue

[MM$/day]

Simulation

Current Technology

85,254 $ 9.26

gPROMS 86,107 $ 9.36

Optimization(Continuous + Well Status)

Current Technology

90,404 $ 9.82

gPROMS 95,464 $ 10.34

Optimization(Field Configuration)

Current Technology

90,404 $ 9.82

gPROMS 105,432 $ 11.37

Case Study 2: Optimization Offshore

Current Technology vs gPROMS results

Increase in production of 16% with gPROMS ~ $1.5M/d!

Oil rate [bbl/day] Revenue

[MM$/day]

Simulation

Current Technology

85,254 $ 9.26

gPROMS 86,107 $ 9.36

Optimization(Continuous)

Current Technology

90,404 $ 9.82

gPROMS 95,464 $ 10.34

Optimization(Field Configuration)

Current Technology

90,404 $ 9.82

gPROMS 105,432 $ 11.37

Conclusions & Discussion

• Modeling

– gPROMS technology can demonstrably model the field as accurately as established production modeling tools

– Existing production system models can easily be imported

– The process and production system can be modelled in the same environment

• Optimization

– Standard gas lift / choked well (continuous Optimization)

• gPROMS Oilfield Optimization => Reliably better solutions that established production modeling tools

– Discrete Optimization (well status and routing)

• gPROMS Oilfield Optimization => Significant increase in production and/or revenue

gPROMS Oilfield Optimization

Conclusions

Equation-based modeling and Optimization

Best practice multiphase flow approaches+ validation

Thank you