Real Time Intelligent Alarm and Surveillance System in Heavy Oil Project- North Kuwait Illustrated Through Case Examples

Abstract

Instrumentation of sucker-rod pumping systems in a large scale thermal pilot was an essential requirement for steam-injection projects. The manuscript focuses on the setup of a real-time smart alarming suite, and the benefits realized in terms of identifying surface and downhole equipment issues and wells requiring critical actions.

Two levels of alarms have been set after reviewing well performance with well-surveillance and field-development teams using real time data gathered through a SCADA system for each parameter for each well individually. The capability in the real-time smart alarming system to set both warning and critical alarm criteria for minimum and maximum values allowed deeper supervision of abnormal conditions, highlighting assets in need of preventive actions. The pre-configured controller alarms have been integrated with software smart alarms to be available in one screen in real time, to immediately take the necessary actions.

The alarm system identified wells with:

Surface equipment problems related to load cell and position sensor issues

Down hole equipment issues related to standing and travelling leaks

Surface network issues related to flow line pressure increases due to back pressure

The presence of such an alarm system prevented major issues that sucker rod pump systems typically experience in terms of high load exerted on the gearbox, high stress applied on rods/sinker bars, and forces applied on surface unit structure. The implementation of such a preventive approach reduced the amount of well trips and downtime, avoiding unwanted incidents, reducing the response action time and unnecessary workover costs

Setting limits for essential parameters that are being reviewed in a fixed period helped in identifying wells far from critical zones to be addressed as candidates for further investigation for production/asset optimization. The real-time intelligent alarming and smart notification system is considered the backbone for production optimization and asset management in the oil and gas industry.

Achieving such a level of effective surveillance/alarming allowed better asset management, prevented equipment failures, prolonged equipment life time, and reduced unnecessary costs. Successful deployment of the smart field approach in the North Large Scale Thermal Pilot for sucker rod lifted pumps helped in utilizing the performance of the equipment, increased oil production and assured smooth operational activities.