35th Gas-Lift Workshop

Houston, Texas, USA

February 6 10, 2012

Honeywells On-line Gas Lift

Optimization Solution
Ravi Nath and Sanjay Sharma
Honeywell Process Solutions
Houston, TX

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

Agenda

Introduction
GLO problem definition
Traditional GLO solution
Honeywells GLO solution
Case Study
Conclusions

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

Introduction: Production Process mature field

P3

Choke

(no gas lift)

Sales Gas

P4

other
suppliers

Separator

P2

Riser
Well

Water

Oil

Other Wells

P1

Reservoir

Mature field:

P1

reservoir pressure

P2

well head pressure = P1 liquid column weight

P3

separator pressure

P4

Gas pipeline pressure

Feb. 6 - 10, 2012

lower reservoir pressure

chokes are fully open
production P

2012 Gas-Lift Workshop

Introduction: Production Process mature field

(gas lift)

Lift Gas
P4

P3

Sales Gas

Choke

Separator

P2

Riser
Well

other
suppliers

Water

Oil

Other Wells

P1

Reservoir

Lift gas lightens the liquid column

increases P2
increases P
increases production
Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

Introduction: Gas lift optimization problem definition

Lift Gas
P4

P3

Sales Gas

Choke

Separator

P2

Riser

Water

Well

other
suppliers

Oil

Other Wells

P1

Reservoir

To determine the amount of gas lift to each

well that will maximize oil production.

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

Gas lift optimization traditional solution

Assumes that the separator pressure (P3) is fixed.
Generates Gas Lift Performance Curves by well simulation.
Determines the optimum lift gas to each well and/or generates
sensitivity tables.

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

Gas lift optimization traditional solution work flow

Step

Activity

Responsibility

Frequency

Generate Gas Lift Performance Curves

Production Engineer

periodically

Generate sensitivity tables

Production Engineer

periodically

Implement gas lift optimization using Board Operator

sensitivity tables

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

hourly

Gas lift optimization traditional solution summary

Traditional gas lift optimization gives benefits, but less than estimated.
Can we do better? Yes!
How can we do it?
1. Global optimization
Consider top side constraints
Compressor constraints
Valve constraints
Water handling constraints
Consider external factors
Ambient conditions
Sales gas pipeline pressure
2. Real time implementation
How much better?

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

Honeywells on-line Gas lift optimization : HGLO

1. Global optimization
Considers top side constraints
Compressor constraints
Valve constraints
Water handling constraints
Considers external factors
Ambient conditions
Sales gas pipeline pressure
2. Real time implementation

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

HGLO top side constraints - compressor

Lift Gas
P3

P4

Sales Gas

Choke

Separator

P2

Riser

Water

Well

Compressor

other
suppliers

Oil

Other Wells

P1

Reservoir

Feb. 6 - 10, 2012

Compressor must be limiting , why?

Increase in gas lift will
increase gas flow to the compressor
increase separator pressure
tendency to reduce production
2012 Gas-Lift Workshop

10

HGLO compressor constraint trade offs

Gas
Flow

Separator
pressure

Lift gas

Oil
Flow

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

11

HGLO dynamic constraints

Top side constraints can change quickly and create short term
opportunities.
A real time optimizer is best suited to exploit such opportunities.
Examples:
A drop in gas pipeline pressure
A rain or drop in ambient temperature

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

12

HGLO change of state

As conditions change new constraint can becoming active.
Then implementing a stale optimum is not desirable; instead a reoptimization must be performed.
A real time optimizer is best suited to re-optimize.
Example:
A lift gas valve going wide open
A well comes on-line

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

13

HGLO automation
A fast executing, on-line, real time optimizer is best suited for gas
lift optimization .
The optimizer can quickly respond to changes in the operating
environment.
Maximizes production.

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

14

HGLO work flow

Step

Activity

Responsibility

Frequency

Generate Gas Lift Performance Curves

Production Engineer

Periodically

Determine global optimum solution

NOVA Optimizer

Minute
minute

by

Control process and implement gas lift Profit Controller

optimization solution

Minute
less

or

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

15

HGLO - solution
Honeywell NOVA optimizer
State of the art SQP optimizer (with integer optimization capability)
Fast execution, typically < 1 min
Layered on Real Time execution platform (URT)
Maximizes production subject to all constraints: top side and sub-sea
Determines all lift gas flows as well as compressor operation
Honeywell Profit Controller
Multivariable predictive controller
Inherently robust controller (patented)
Manages constraints in real time
Implements the optimum solution from Nova
No additional instrumentation (beyond lift gas flow controllers)
No changes to compressor controls
Manipulates the same handles as operator
Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

16

HGLO case study

8 operating wells on a platform in GOM
Lift Curves from client (generated using Prosper)
Traditional GLO
HGLO (simulation)
Benefit estimation

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

18

HGLO case study

8 operating wells on a platform in GOM.
Lift Curves from client (generated using Prosper).
Traditional GLO:

Case 3

Case 1

Case 2

9.5
55,362

12.6
55,951

6.4
55,297

9.5
55,792

12.6
56,105

Initial production increase, BPD

Initial production increase, %

343
0.6%

430
0.8%

514
0.9%

1st year CF benefit*, MM$

Project NPV benefit*, MM$

7.5
5.5

10
7.3

11.3
8.2

Total lift gas, MMSCFD

Total production, BPD

HGLO:

Total lift gas, MMSCFD

Total production, BPD

Benefit:

*assuming

Feb. 6 - 10, 2012

6.4
54,954

: 80$/bbl, 15% IRR, 4.6 productive years remaining, linear decline

2012 Gas-Lift Workshop

19

HGLO Results

HGLO
turned ON

Production
Well sensitivities, bbl/SCF

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

20

HGLO dynamic constraints

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

21

Conclusions
Honeywells on-line Gas Lift Optimization (HGLO)
Asset wide, real time optimization
Considers all constraints including the top side
Continuous constraint protection and opportunistic optimization
No new instrumentation: beyond lift gas flow controllers
Significant benefits: over and above traditional GLO
0.8% initial production increase
10 Million $ 1st year CF benefit
7 Million $ NPV benefit

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

22

Questions

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

23

Copyright
Rights to this presentation are owned by the company(ies) and/or
author(s) listed on the title page. By submitting this presentation to
the Gas-Lift Workshop, they grant to the Workshop, the Artificial Lift
Research and Development Council (ALRDC), and the American
Society of Mechanical Engineers (ASME), rights to:
Display the presentation at the Workshop.
Place it on the www.alrdc.com web site, with access to the site to be as
directed by the Workshop Steering Committee.
Place it on a CD for distribution and/or sale as directed by the Workshop
Steering Committee.

Other uses of this presentation are prohibited without the expressed

written permission of the company(ies) and/or author(s) who own it
and the Workshop Steering Committee.

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

24

Disclaimer
The following disclaimer shall be included as the last page of a Technical Presentation or Continuing
Education Course. A similar disclaimer is included on the front page of the Gas-Lift Workshop Web
Site.
The Artificial Lift Research and Development Council and its officers and trustees, and the Gas-Lift
Workshop Steering Committee members, and their supporting organizations and companies (here-inafter referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or
Continuing Education Training Course and their company(ies), provide this presentation and/or
training material at the Gas-Lift Workshop "as is" without any warranty of any kind, express or
implied, as to the accuracy of the information or the products or services referred to by any presenter
(in so far as such warranties may be excluded under any relevant law) and these members and their
companies will not be liable for unlawful actions and any losses or damage that may result from use
of any presentation as a consequence of any inaccuracies in, or any omission from, the information
which therein may be contained.
The views, opinions, and conclusions expressed in these presentations and/or training materials are
those of the author and not necessarily those of the Sponsoring Organizations. The author is solely
responsible for the content of the materials.
The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond
the source documents, although we do make every attempt to work from authoritative sources. The
Sponsoring Organizations provide these presentations and/or training materials as a service. The
Sponsoring Organizations make no representations or warranties, express or implied, with respect to
the presentations and/or training materials, or any part thereof, including any warrantees of title, noninfringement of copyright or patent rights of others, merchantability, or fitness or suitability for any
purpose.

Feb. 6 - 10, 2012

2012 Gas-Lift Workshop

25