Field Production Engineering

(Integrated Production System) Course

Mahmoud Farag Radwan

Subsurface & Integrity Op. Dept. Head
 Presenter Name:
Mahmoud Farag Radwan

Mahmoud Radwan is a Subsurface & Integrity Operations Dept. Head at AMAL

Petroleum Company (AMAPETCO) with 14 years of experience in oil & gas industry.
Mahmoud worked in Well Engineering, Intervention, Integrity & Work-over at several
Short companies, including Badr El-Din Pet. Co. (BAPETCO), Qarun Pet. Co. (QPC) and Wadi
Biography El-Sahel Petroleum Co. (WASPETCO).
Also, a freelance instructor at upstream Oil & Gas in Egypt & UAE since 2008.
Mahmoud received a BSc degree in Petroleum Engineering from Al-Azhar University in
2007.

- Evaluating Sustainable Annulus Pressure (SAP) in Sour Wells and the Possible
Causes to Avoid Recurrence to the Well Integrity Annual Middle East Conference in Abu
Dhabi; UAE in Apr 2015
- Implementing NDT methods for maintenance and inspection to the Asset Integrity
Management North Africa Conference in Cairo; Egypt in Nov 2015
- Feasibility Evaluation of Using Downhole Gas-water Separation Technology in gas
Reservoirs with Bottom Water; paper number: SPE-183739-MS to the 20th Middle East
Publications Oil & Gas Show and Conference in Mar 2017 http://dx.doi.org/10.2118/183739-MS
- Managing the Operational Challenges in Corroded Wells through Well Integrity
Management System to the Improving Brownfield Performance Technical Convention,
in Cairo; Egypt in Dec 2019
- Safe and Economic Attractive Rigless Operations Using a Digital Slickline in
Unmanned Platform with Low Structure Loads and Spacing; paper number: SPE--
202857-MS to the Abu Dhabi International Petroleum Exhibition & Conference (ADIPEC)
in Nov 2020 http://dx.doi.org/10.2118/183739-MS
 Course Contents
 Introduction

 Well Completion

 ESP & SRP Causes & Effects in One Page

 Production Optimization Using Nodal Analysis

 Field Development Operations - Flow Assurance

 Production Problems – Petroleum Cholesterol

 Corrosion in Oil & Gas Industry

 Surface Facilities Engineering

Well Completion

1
Completion Define & Justify
Key Well Objectives
Res. Exploitation Strategy
Surface Constraints Well
Lifetime Requirements
Design Well Proposal

Define Completion
Monitoring Requirements
Workover & de-completion

Process No
Objectives
Cost Model
Analogues and Field Data
Confirm Feasibility
Well Geometry Reservoir
Inflow Model Communication Reservoir
Rock Data
Yes Outflow Model Fluid Data
Feasible
Detailed Design Stimulation
Drill & Complete Sand Control
Tubing Size
Operate & Maintain
Artificial Lift
No Requirements Well Design Model
Met?
Facilities Model
No
Optimized
Solution Cost VS Benefit Analysis
 Int Segregation
3 PRODUCING ZONES

Concentric String
Multiple String
MULTIPLE
Single String
Co-Mingling Int
SINGLE
Standard
DESIGN CONSIDERATIONS

Sub-Pump
Plunger Rod
2 OUTFLOW

Gas Lift
SEC RECOVERY
WELL COMPLETION

Rod
High Rate Liner
PRI RECOVERY High Pressure
Simple, Low Cost
Tubing-less
HORIZONTAL
Internal GP
PERFORATED CASING
Standard
1 INFLOW
PERFORATED LINER
Ext GP
P//Pack Screen
UNCEMENTED LINER
WWS

VERTICAL
Slotted Pipe
OPENHOLE
 Casing Design : Basic Construction

1 1. 30” conductor
2 2. Conductor setting depth
3 3. 20” surface casing
4
4. 20” shoe
5 5. Cement
6 6. Formation open to C annulus
7
7. 13 3/8” casing
8
8. Formation open to B annulus
9
10 9. 9 5/8” production casing
10. Liner hanger
11
11. 7” Liner
12. TD – Total Depth
12
Well COMPLETION
6
COMPLETION ACCESSORY DEPTH RATIONALIZATION 1

1 DHSV 2
• HP of control line fluid
• Earth crater depth
3
2 Landing Nipple
• Below kick off point for deviation. 2
• Check well integrity 4
• Hanging depth for FCD. 5

4
3 SPM
• Hydrostatic head of hydrocarbon & communication
6
4 SSD
5
• Depth of required communication
2
5 Packer
• Determined by reservoir depths.

6 Anti-Erosion Device
• Determined by reservoirs & flow characteristics
WELLHEAD & XMAS TREE
CONVENTIONAL WELLHEAD

It’s a built up of modules. During drilling BOP is installed

above it & it must be removed each time a new module
to be installed & replaced the BOP on top of it before
commence drilling.

Features:

1 Starter Spool (Conductor Pipe)

2 Surface Casing Head
3 Surface Casing Hanger
4 Production Casing Head
5 Production Casing Hanger
6 Tubing Head
7 Tubing Hanger
WELLHEAD & XMAS TREE
XMAS TREE
Surface valves manifold to control flow of well fluids & access for well
intervention activities.
Features:
1 LMV
Manual, NOT working valve optimum conditions.
2 UMV
Emergency valve (Hyd/Pneu) & cut wire.
3 FWV
Permits passage of well fluids to CV.
4 CHOKE VALVE (CV)
Restrict, control or regulate flow of well fluids.
5 KWV
Permits entry of kill fluids into tubing or equalize.
6 SV/CV
Permits entry of well interventions.
 Xmas Tree Type
Xmas Tree type:
 Solid Block (Mono Block) Xmas Tree
- Contains fewer components (for
high pressure wells)
 Composite Block Xmas Tree
- Valves are located on separate
block & joined by API flange.
 Horizontal Xmas Tree
- New concept used for sub-sea
completion.
WELLHEAD & XMAS TREE

Wellhead Connection Types;

 Screwed type (low press <1 000psi).
 API Flanged type (high press <5 000psi).
 API Flanged type are mostly used by OPCO –
because it’s less susceptible & easier oriented.

Example of API Flange specification:

9⅛” – 5000 psi API Flange.

9⅛” is the ID of the flange & 5000 psi is the

working pressure.
Dual Solid Block Xmas Tree
Intelligent / Smart Completion
 What is an Intelligent Completion?
“An Intelligent completion is defined as one that
provides the ability to both monitor and control at
least one zone of a reservoir”
i.e.
 Completion with permanent down hole monitoring
- Pressure and Temperature
- Flow rate
- Water cut
 And surface operated down hole flow control
-Hydraulic operated flow control valves
-Electric operated flow control valves
Intelligent Completions: Business Value

Reduced well intervention costs

Accelerated production

Reduced well costs

Reduced surface facilities

Increased ultimate recovery

Real Business Value

 Monitoring Devices
Pressure Sensors Flow Measurement Electric Water cut Meter

Pressure - Flow Stations

Densitometer Formation Arrays

 Downhole Flow Control Valves
 Hydraulically actuated are most common

 Direct hydraulic valves require minimum of one

control line per valve

 Multi-drop systems share control lines but add

complexity to the system

 Valves can be On/Off, Discrete position or infinitely

variable

 Electric valve
 Control Lines & Cables
 Hydraulic lines
• Control down hole valves and other devices
 Electric cable
• Provides power and communication for down
hole gauges
 Optical fiber (Distributed Temperature Sensing)
• Can use independent line or share electric/
hydraulic line
 Multiple lines are usually combined in a flat pack
for ease of handling
 Different encapsulations available for different
down hole environments
 Multi Port Packers
 Allow passing of control lines

 Production packers

• Provide isolation and anchoring

 Isolation packers

• Provide isolation only

 Open Hole packers

• Swell or Mechanical
 Wellhead and Tubing Hanger
 Wellhead and Tubing Hanger

 Control line and cable penetrations

Production Optimization
Using Nodal Analysis
Production Optimization
Possible Pressure Losses in A Production System

p8= Pwh-Psep
gas
Pwh-Pds = p5 p6= Pds-Psep

Pwh Pds Flowline Separator

Psep
Surface choke
Tank
Pdv
Safety valve
p4= Puv-Pdv Puv
p1=Pr-Pwfs Loss in porous medium
Well p2=Pwfs-Pwf Loss across the completion
p3=Pur-Pdr ” ” restriction
p4=Puv-Pdv ” ” safety valve
RestrictionPdr p5=Pwh-Pds ” ” choke
p6=Pds-Psep ” in flow line
Pur p7=Pwf-Pwh
p3= Pur-Pdr p8=Pwh-Psep
Total loss in tubing
Total loss in flowline

Reservoir Pwf Pwfs Pr Pe

p1=Pr-Pwfs
Pwfs-Pwf = p2
Multi-phase flow upward in vertical
pipes

Bubbly Slug Churn Annular

Experiments provide ‘map’

showing where these
different flow regimes occur
(Taitel & Dukler) flow regime map
Slide 26
Multi-phase flow in horizontal pipes

Stratified smooth flow

Stratified wavy flow

Plug flow

Slug flow

Annular flow

Dispersed bubble flow

Superficical Gas Velocity (m/s)

Slide 27
 Outflow Performance Curve
Multi-phase Flow Correlations
NODAL ANALYSIS APPLICATIONS

• Selecting tubing size.

• Selecting Flowline size.
• Gravel pack design.
• Surface choke sizing.
• Analyzing an existing system for abnormal
flow restrictions (production impediments).
• Artificial lift system design.
• Well stimulation evaluation.
• Analyzing effects of perforating density.
• Predicting the effect of depletion on production
capacity.
• Allocating injection gas among gas lift wells.
• Analyzing a multiwell producing system.
 SUGGESTED PROCEDURE FOR
NODAL ANALYSIS APPLICATION
1. Determine which components in the system can be changed.

2. Select one component to be optimized.

3. Select the node location.

4. Develop expressions for the inflow and outflow.

5. Obtain required data to calculate the pressure drop versus

flow rate fall components.

6. Determine the effect of changing the characteristics of the

selected component by plotting inflow versus outflow and
reading the intersection.

7. Repeat the procedure for each component that is to be

optimized.
31
 Petroleum Cholesterol

Scaling

Asphaltene Wax Paraffin Hydrates

32
33
34
35
 Petroleum Constituents Classification

Paraffins

Naphthenes Aromatics Resins & Asphaltene

36
37
 Wax
are complex mixtures of n-alkanes, i-alkanes and cycloalkanes
with carbon numbers ranging from C18 to C65

Waxes composed primarily of normal Waxes composed primarily of

alkanes crystallized in large flat cycloalkanes and i-alkanes crystallized
plates (microcrystalline structures) as small needle structures and are
and are referred to as paraffin waxes referred to as microcrystalline waxes

38
39
40
41
42
 Hydrate Plug Prevention

Dispersants/Anti-agglomerants

Emulsifiers Slurry Flow Insulation & Heating

43
Corrosion in Oil & Gas Industry
 Downhole Corrosion Mechanisms

Electrochemical Chemical

Pitting CO2 (sweet) H2S (sour)

Galvanic

Intergranular Crevice Bacteria Acid

Mechanical
Hydrogen
Attack
Stress Erosion

Electrochemical, Chemical and mechanical corrosion occur in many forms in the oil
industry. A detailed discussion of all the corrosion mechanisms is beyond the scope
of this presentation, however some examples of these mechanisms will be presented.
Stress & Temperatures
Metals under stress are susceptible to
corrosion. High differential pressure
tensile stress and torque are common
Spent Acid
causes of stress on casing and tubing. Acids used for stimulation treatments
HCL dissolve metal.
Saline Fluids
Saline fluids act as an electrolyte
promoting electrochemical reactions. HCL
Formation and completion fluids are Poor Cement
often saline. Cement acts as a primary protective
sheath for casing. The absence of
Corrosive Annulus Fluid cement or permeable cement allows
Completion fluids, particularly heavy corrosive fluids to contact the casing.
brines can be highly corrosive. These
are in contact with casing and tubing.

Bimetallism & Odd Joints

Small differences between metals
promote galvanic corrosion. The
intensity of the reaction depends
(among other things) on the H2S
conductivity of the surrounding liquid
and the difference between metals. CO2
H2S Corrosive Gases
Metals from the same plant can show Combinations of H2S and/or CO2 with
small differences. Also, collars can be CO2 water are aggressive corrosive agents.
slightly different from the joints. This H2O + Solids flowing with produced fluids can
corrosion mechanism is used in dry-cell H2O also cause serious damage by erosion.
batteries.

Stagnant Fluids
This fluid many contain spent acid and
saline workover fluid. Corrosion also
appears at the interface between
different fluids.
Corrosion / Erosion Monitoring Equipment
weight loss coupon electrical
resistance probe
(ER probe)

linear polarisation
resistance probe
(LPR probe)

..probes or iron counts are often used for short term decision making
recent development : “CEION” probe from Cormon

..a faster version of ER probes

Corrosion / Erosion Monitoring Equipment

Ultrasonics - “UT”, flexible UT mat Field Signature Method - “FSM”

Inspection of wall thickness of pipe and choke body

downhole : finger caliper, UT tool
topsides : UT and radiography scans
pipeline : UT or magnetic flux intelligent pig

recent development : “Field Signature Method” from Corrocean

 Erosion Modelling Tools

Commonly used erosion models;

- “HeliErosion”
- API RP14E
- Salama
- Salama & Venkatesh
• Contributing factors for erosion are solid content, fluid
velocity and mixture density
• API Erosion equation and C factors used by BP

C Carbon steel 13 Cr Duplex

Vmax 
m
Liquid 250 300 450
Liquid + gas 135 300 350
Methods to Control Corrosion

There are five methods to control corrosion:

 Material selection
 Coatings
 Changing the environment
 Changing the potential
 Design
SEPARATION EQUIPMENTS
Types of Separator
Types of Separators:
Based on Shape; Based on phase;
• Horizontal • 2 Phase
• Vertical • 3 Phase
• Spherical
Based on Function; Based on operating pressure;
• Test Separator • HP Separator
• Production Separator • MP Separator
• LP Separator
 Operation of Separator
PSV Flare
SDV BDV
SDV
Effluent PCV

Inlet Gas
Outlet

Deflector Plate Demister Pad

Straightening Vane
Weir

Vortex Breakers

Coalescing Plate
SDV LCV
SDV
Oil/Condensate
Outlet
LCV
Water
Outlet
 Slug catcher
a particular separator design able to absorb
large volumes at irregular intervals.

Usually found on gas gathering system or two-

phase pipeline systems.

A slug catcher may be a single large vessel or a

manifolded system of pipes.
Slug catcher
Safety Devices in Separator
• PSHH (Pressure Swich High High)
• PSLL (Pressure Swich Low Low)
• LSHH (Level Swich High High)
• LSLL (Level Swich Low Low)
• BDV (Blowdown Valve)
• PSV (Pressure Safety Valve)
• SDV (Shut Down Valve)
OIL TREATMENT
 Problems Caused by Impure Water
Water Oil Emulsion
Emulsion – Suspension of liquid droplets (dispersed phase) of
certain size within a second immiscible liquid (continuous
phase).
Theory of emulsion:
 Dispersed phase.
 Continuous phase.
Type of emulsion:
 Water in oil emulsion.
 Oil in water emulsion.
Based on size of liquid droplets:
Stability of emulsions may be engineered to vary from seconds to
years depending on application.
 Emulsifying Agents
Stable suspensions of liquids constituting the dispersed
phase, in an immiscible liquid constituting the continuous
phase is brought about using emulsifying agents such as
surfactants .

Surfactants must exhibit the following characteristics to be

effective as emulsifiers:-
Good surface activity.
Should be able to form a condensed interfacial film.
Diffusion rates to interface comparable to emulsion
forming time.
 Tridair Hydraulic( Induced Gas Flotation System)
Applications:-

Oilfield produced water, offshore and onshore.

Refining/Petrochemical waste water.

– Recycle/Reuse.
– Discharge.

Boiler feed water treatment.

Hydraulic Tridair Induced Gas Flotation
Tripacktm Corrugated Plate Interceptor (CPI)
Tripacktm Corrugated Plate Interceptor (CPI)
Water Treatment (Treating Equipment)

Precipitators:
Excelsior subject to plugging and not manufactured any more
COMPRESSORS
 COMPRESSORS CLASSIFICATION
Volumetric (Positive Displacement)
• Reciprocating
• Rotating (Screws, Sliding Vanes, …)
Dynamic (Variable Head)
• Centrifugal
• Axial
Thermal
• Ejectors
• Axial