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Production Engineering Overview
Production Engineering Overview Presentation Outline: Well Life Cycle Production Engineering Roles Production Engineering Duties Goals of a Production Engineer Capital Investment Programs – Artificial Lift, Completions, Recompletions, Facilities, and Pipeline
Expense (Maintenance Capital) Programs – Well maintenance, optimization, chemical, power, automation, enhanced recovery
Workover Operations
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Production Engineering Overview Presentation Outline: Well Life Cycle Production Engineering Roles Production Engineering Duties Goals of a Production Engineer Capital Investment Programs – Artificial Lift, Completions, Recompletions, Infrastructure
Expense (Maintenance Capital) Programs – Well maintenance, optimization, chemical, enhanced recovery
Workover Operations
Well Life Cycle Well Life Cycle: •
Drilling: 15 to 60 days (depending on vertical or HZ and operator)
•
Completions: a few days to a month (depends on the company)
•
Production: 0 days to 100 years (depends on reservoir and recovery)
Drilling
Completion
Production
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Production Engineering Overview Presentation Outline: Well Life Cycle Production Engineering Roles Production Engineering Duties Goals of a Production Engineer Capital Investment Programs – Artificial Lift, Completions, Recompletions, Infrastructure
Expense (Maintenance Capital) Programs – Well maintenance, optimization, chemical, enhanced recovery
Workover Operations
Production Engineering Roles
What does a Production Engineer do at Linn Energy? • Communication • Goals of a Production Engineer • Capital Program Creation and Implementation •
Artificial Lift Implementation: •
•
Completions: •
•
Selecting the artificial lift technique that optimizes production and maximizes cash flow Selection of tubing design using IPR curves and Nodal Analysis.
Recompletions: •
Work closely with Geology and Reservoir Engineers to test new zones and increase production in marginally commercial wells.
• Expense (Maintenance Capital) Program Optimization: •
Reviewing monthly operating costs for field of wells and minimize the costs required to operate wells at their peak DCF. •
Artificial lift optimization, Chemical, compression, downhole maintenance, etc…
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Production Engineering Roles
Communication for Production Engineer Regulatory Land / Legal Reservoir Well
Field Operations
Production Engineering Geology Supply Chain Accounting
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Goals of a Production Engineer
Maximize Production & Lower Cost Production
Cost
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Production Engineering Overview Presentation Outline: Well Life Cycle Production Engineering Roles Production Engineering Duties Goals of a Production Engineer Capital Investment Programs – Artificial Lift, Completions, Recompletions, Infrastructure
Expense (Maintenance Capital) Programs – Well maintenance, optimization, chemical, enhanced recovery
Workover Operations
Production Engineering Roles
Capital Investment Program Creation & Implementation • Capital Program Creation •
Yearly Budgeting Process: •
Submit a budget with project types, number of projects, capital cost, type curve (uplift), economics
•
Inventory creation through well reviews
• Capital Program Implementation •
Artificial Lift Implementation: •
•
Completions: • •
•
Flowback design and choke size considerations Selection of tubing design using IPR curves and Nodal Analysis
Recompletions: •
•
Selecting the artificial lift technique that optimizes production and maximizes cash flow
Work closely with Geology and Reservoir Engineers to test new zones and increase production in marginally commercial wells
Infrastructure (Facilities, Water Management, & Pipeline): •
Assist in the design and implementation of infrastructure projects 10
Artificial Lift Overview Why do we need artificial lift? Reservoir’s contain Gas, Oil, & Water. Initial reservoir pressure and high initial gas rates unload the fluid to surface. But overtime this pressure drop in the reservoir causes less production and a decrease in velocity inside the wellbore.
Critical rate is key to unloading fluids. (gas and fluid velocity)
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Artificial Lift Overview Critical rate: Critical rate is the flowrate necessary to remain in mist flow Primarily a function of pressure and tubing size
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Artificial Lift Overview Mandhane Flow Pattern Diagram
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Artificial Lift Overview Liquid Loading- Loss of Gas Velocity Over Time Surface Condition
Stable Flow
Initial Production
Unstable Flow
Stable Flow
RATE
Well Dead
Decreasing Gas Rate with Decreasing Reservoir Pressure Highest Velocity
Gas Velocity
TIME Lowest Velocity 14
Artificial Lift Overview Why do we need artificial lift? Weight of fluid causing back pressure. .433 lbs/ft. Approx. 2,300 ft. = 1,000 lbs.
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Artificial Lift Overview Example: @ 60#, CR = 230 MCFD
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Artificial Lift Overview Example:
Plunger Lift Install
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Artificial Lift Overview How do we prevent liquid loading? Remove the liquid – “We are in the liquids removal business” Scott Clinton
How do we remove liquids from a well to reduce flowing bottom hole pressure: Artificial Lift Rod Pumps Plunger Lift Gas Lift Wellhead Compression ESPs Jet Pumps Progressive Cavity Pumps
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Artificial Lift Overview Artificial lift Techniques: Surface and Downhole
SPE 52157 Selection of Artificial Lift James F. Lea and Henry V. Nickens--Amoco EPTG/RPM
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Artificial Lift Overview Artificial lift Techniques: Advantages and Restrictions Rod Lift
PCP
Gas Lift
Plunger Lift
Hydraulic Lift
Hydraulic Jet
ESP
Capillary Technologies
Maximum operating depth, TVD (ft/m )
16,000 4,878
12,000 3,658
18,000 4,572
19,000 5,791
17,000 5,182
15,000 4,572
15,000 4,572
22,000 6,705
Maximum operating volume (BFPD)
6,000
4,500
50,000
200
8,000
20,000
60,000
500
Maximum operating temperature (°F/°C )
550° 288°
250° 121°
450° 232°
550° 288°
550° 288°
550° 288°
400° 204 °
400° 204 °
Corrosion handling
Good to excellent
Fair
Good to excellent
Excellent
Good
Excellent
Good
Excellent
Gas handling
Fair to good
Good
Excellent
Excellent
Fair
Good
Fair
Excellent
Solids handling
Fair to good
Excellent
Good
Fair
Fair
Good
Fair
Good
>8°
<40°
>15°
>15°
>8°
>8°
>10°
>8
Workover or pulling rig
Wireline or workover rig
Wellhead catcher or wireline
Workover or pulling rig
Capillary unit
Gas or electric Gas or electric
Compressor
Well's natural energy
Form of lift
Fluid gravity (°API) Servicing Prime mover Offshore application System efficiency
Hydraulic or wireline
o
Multicylinder or Multicylinder or Well's natural Electric motor electric electric energy
Limited
Limited
Excellent
N/A
Good
Excellent
Excellent
Good
45% to 60%
50% to 75%
10% to 30%
N/A
45% to 55%
10% to 30%
35% to 60%
N/A
Values represent typical characteristics and ranges for each form of artificial lift. Parameters will vary according to well situations and requirements and must be evaluated on a well-by-well basis.
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Artificial Lift Overview Rod Pump Mechanic lift Application Down hole pump and rods lift fluid to surface through tubing Rod pump makes up 82% of the artificial lift in the United States
http:// www.youtube.com/watch?v=mezztZpaFQM&featu
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Artificial Lift Overview Down Hole Pump: There are many different types and variations of down hole pumps. But the physics behind the mechanical application are very similar.
Traveling Valve
Standing Valve 22
Artificial Lift Overview Rod Pumping Parts Rod Sizes: 1-1/8”, 1”, 7/8”, 3/4” 5/8”
Threads
Couplings
Rod String
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Artificial Lift Overview Rod Pumping Production profile: – Erratic oil production that relates to pump cycles (SPM, and POC) – Gas production is up the annulus and is fairly consistent but is related to the unloading of fluid from the annulus to increase inflow Evans, AO #10-5715 1/13/2015 10:56:10 to 4/13/2015 11:56:10 300 250 200 150 100 50 0 15 Thu 22 Thu Jan 2015
1 Sun 8 Sun 15 Sun 22 Sun 1 Sun 8 Sun 15 Sun 22 Sun
1 Wed 8 Wed 15 Wed 24
Artificial Lift Overview Rod Pumping Advantages: – Simple system design – Efficient – Low BHP (bottom hole pressure) – Transferable units – Flexible production rates – Handles high temperatures – Gas or electric power
Disadvantages: – High initial capital cost – Trouble handling solids – Friction on deviated wells – Depth limited – Large surface footprint – Limited on casing size
– Handles corrosion and scale 25
Artificial Lift Overview Plunger Lift Hydraulic lift application Reservoir and casing pressure applies the force to lift the plunger and fluid to surface
http:// www.youtube.com/watch?feature=player_embedded&
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Artificial Lift Overview Plunger Lift
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Artificial Lift Overview Plunger Lift Equipment Bottom Hole Assembly
Pad plunger
Brush plunger
Solid plunger
Bypass plunger
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Artificial Lift Overview Plunger Lift • Production profile Erratic production due to the number of plunger trips per day Casing and tubing pressure build and fall as the plunger cycles
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Artificial Lift Overview Plunger Lift Advantages: – Very inexpensive – Low operating cost – Wire line retrievable – Keeps tubing clean (combats scale) – Small surface footprint – Can be used in conjunction with gas lift
Disadvantages: – Needs high GLR (gas to liquid ratio) – Cant handle high volumes of fluid – Requires constant surveillance to adjust the shut in times, casing pressure, or after flow periods – Danger in plunger reaching to high of velocity causing surface damage
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Artificial Lift Overview Gas Lift Velocity lift application A mixture of gas velocity in the tubing and a decrease in the hydrostatic weight of your tubing column results in a decrease of your bottom hole flow pressure and an increase in production.
http:// www.youtube.com/watch?v=ryvl1jgnxDs&feature=player
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Artificial Lift Overview Gas Lift Design
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Artificial Lift Overview Gas Lift Equipment Compressor Gas Lift Mandrel
Compressor: 50 psi. to 1100 psi. 33
Linn Energy – Gas Lift Review Gas Lift Production Profile: – Fairly consistent gas and oil production based upon injection rate and casing pressure (casing pressure is important to monitor)
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Artificial Lift Overview Gas lift Advantages: – Inexpensive – Handles high volumes of fluid – Handles solids – Deviated wells – No obstruction for wire line – Small footprint
Disadvantages: – Higher operating cost – Supply gas required – Cannot produce to abandonment – Difficult to lift viscous fluids – Not as efficient as other artificial lift applications
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Artificial Lift Overview Electric Submersible Pump (ESP) Mechanical lift application Centrifugal pump Down hole electric pump supplies lift force to push fluid to the surface
http://wn.com/electrical_submersible_pump#/videos 36
Artificial Lift Overview ESP Design
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Artificial Lift Overview ESP Internal Framework Centrifugal pump – similar to a inboard boat/jet ski motor and impeller
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Artificial Lift Overview ESP Production Profile: – Consistent oil and water production – Gas production (if there is any) is dependent on the unloading of the annular space 1000
25
900 800
20
700 600
Water Production (bbls/day)
15
500
Oil Production (bbls/day)
400
10
300 200
5
100 0 1/1/2015
1/21/2015
2/10/2015
3/2/2015
3/22/2015
0
Date 39
Artificial Lift Overview ESP Advantages: – Large fluid volumes (60,000 bbl/d in shallow wells) – Small footprint – Works in deviated wells – Simple daily operations
Disadvantages: – Must have electricity on location – Solids – Gas Interference – Expensive to change application – High initial capital cost – Cables on tubing – Depth limitations
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Artificial Lift Overview Advantages
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Artificial Lift Overview Disadvantages
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Completions Overview Production Engineer Roles in Completions: Flowback design – Flowback iron, manifolds, sand separator, flowback tanks, etc…
Facilities design – Separator sizing, flow pipe sizing, tank size and quantity, etc…
Choke management: – Choke size selection: determining the rate and pressure of flowback – From experience choking the well is a good thing
Selection of tubing design using IPR curves and Nodal Analysis – From experience if you are between size always go with the smaller size (longer life application)
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Production Engineering Overview Presentation Outline: Well Life Cycle Production Engineering Roles Production Engineering Duties Goals of a Production Engineer Capital Investment Programs – Artificial Lift, Completions, Recompletions, Infrastructure
Expense (Maintenance Capital) Programs – Well maintenance, optimization, chemical, enhanced recovery
Workover Operations
Production Engineering Roles
Expense (Maintenance Capital) Program • Expense (LOE) Program Details •
Well maintenance and repairs (wellbore intervention): •
Downhole failures: tubing leak, rod part, downhole pump failure, downhole plugs, stuck plungers, failed gas lift valves, ESP cable shorts, etc…
• Expense Program Goals •
Decrease costs: •
•
Run economic sensitivities to determine if the expense capital is worth expenditure on wells
Optimization: • • • • • •
Increase efficiencies for artificial lift systems (operating at optimum) Review of chemical effectiveness and cost Ensure that the surface facilities are optimized and there are no pressure restrictions Review and evaluate methods for automation (POC’s, SCADA, etc…) Evaluate the cost and effectiveness of slickline and swab activities Always trying to enhance the recovery of hydrocarbons from the wells/reservoirs 45
Production Engineering Overview Presentation Outline: Well Life Cycle Production Engineering Roles Production Engineering Duties Goals of a Production Engineer Capital Investment Programs – Artificial Lift, Completions, Recompletions, Infrastructure
Expense (Maintenance Capital) Programs – Well maintenance, optimization, chemical, enhanced recovery
Workover Operations
Production Engineering Roles
Workover Operations • Workover Rig: •
400 to 500 HP
•
Running tubing
•
Running rods and pump
•
Drilling out plugs
•
Repair casing leaks
•
Any remediation work to a well
Derrick
Finger Boards
Traveling Blocks Engine
Pipe Racks 47
Production Engineering Roles
Workover Operations • Slickline Unit: •
Installing plunger lift equipment
•
TD check
•
Flowing gradient
•
Fish lost tools
•
Broach the tubing
•
Perforating
•
Logging
Slickline Lubricator
Wellhead
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Production Engineering Roles
Workover Operations • Swabbing Unit: •
The swabbing unit is used to remove fluids from the tubing of a well
•
Swab cups
Swab Line
Lubricator
Wellhead 49
LINN Energy’s mission is to acquire, develop and maximize cash flow from a growing portfolio of long-life oil and natural gas assets.
Questions?