By-Anand VadlamaniAarthy RamanEngineer- Production Optimization

Components of The projectWell Site (Owned by ONGC): Load Cell installed on polished rod Position Sensor installed on the walking beam RPC installed on well site GPRS modem Cables: Load & Position sensors to RPC and RPC to Electrical Control Panel Conduits for cables: Well head to RPC and RPC to Electrical Control Panel Protective Cage installed around RPC

Control Room (Owned by ONGC) GPRS Server (For Communication) LOWIS Server (For data capturing and analysis) Two Desktops, One Printer and Two monitors

Control Room (Weatherford) Router Switch One Desktop, Laser Printer Furniture and Fixtures Manpower for 24 x 7 monitoring

HSEWell Site ComponentsLoad Cell : FM approved for Class I, II, III and Division 1, 2, Groups C through G approvedPosition Sensor is ATEX Directive CE II3G & EN 5002121: 1999 EEx mA II T4 compliantRPC installed at Wellhead is fully NEMA compliant.All Wellhead equipment are fit to be used in Zone-IIAdditional safety barriers are installed in RPC to close out any chance of accident whatsoever.

Load Cell

Position Sensor

RPC

GPRS Modem

Overall Wellhead

RPC Display

Resource SourcingCommunicationEquipment(Indonesia)Wellhead Equipment(USA)Knowledge Base(USA)Installation Expertize(UAE)QA(UK)

Difficulty LevelAdverse crude chemistrySevere gas lockingSand incursion problemUnreliable Power Connection Depleting reservoir

Project Deliverables Fully configured desktop wells replicating field conditions Continuous scanning of wells for electrical shut-down Scanning of wells in every 15 minutes for collecting operating parameters Automatic collection of various cards minimum twice in a dayGeneration of Detailed Daily Progress Report at 9 am along with relevant recommendations Monthly Report Live inspection on field Valve leakage testing as and when envisaged Expert advise from WFT Mumbai and Houston team on critical issues Proactive and Reactive troubleshooting suggestions Participation in job planning process

Project ObjectivesMonitor and identify any fault in the well with an eye to reduce downtime specially related to electrical faultReduce Runtime of wells based on wellbore fillage keeping the production level same or betterReduced runtime will help saving power cost and prevent dry run Preventing dry run and reduced run time brings down maintenance costProactive troubleshooting which may save rod parting by taking timely actionAppropriate job planning by diagnosing exact problems.

Global knowledge SharingCOMMUNICATION PROVIDERS NETWORKWEATHERFORDCOMMUNICATIONS CENTERANALYSIS TEAM (Houston) Current Well Status Weekly Snapshot Reports Download Monthly Data Callout System

Experienced Analysts Industry Leading Software Detailed Analysis Reports Recommendations Trouble-shootingLocal Control RoomMumbaiTeamIndonesianTeam

Progress So FarReduction of downtime of the wells due to electrical fault. During monsoon, on an average we are identifying and intimating about well shutdown 10 times a day. Prevention of possible Rod parting at least in three casesIdentification of valve leakage/ tubing leakage in several cases through diagnostic analysisPredicting inferred production through diagnostic analysisAverage dry runtime reduction by 1.5 hours a day Identification and specific suggestion on SPM increase for 7 wells which is likely to enhance productionAppropriate job planning (scheduling HOC jobs etc.) by diagnosing exact problems and in-situ monitoring of the job.

Monitoring Details

ActionsBenefitsMonitoring of well on-off conditions (Electrical/ mechanical problems). Follow up on actions takenReduction in down time. Monitoring of loads/ stress on rodsPrevention of sucker rod parting by taking timely actions like HOC/ HWCMonitoring of Inferred productionAnalysis of well behaviorDaily well analysis report of each wells along with recommendationsOptimising production

Monitoring Details

ActionsBenefitsPlanning for HOC/HWC jobs as and when requiredTo sustain / improve productivity of well. Also, optimization is done on job frequenciesReduction of well dry run timeBrings down maintenance frequency and also prevents unnecessary wear and tear of equipmentCollection of well cards- Dyna card, pump-off cards, failure cards etc.Helps in well analysisGeneration of downhole cardsHelps in well analysis

Monitoring Details

ActionsBenefitsValve Leakage TestsValve leakage tests are conducted independently by WFTGeneration of daily detailed well analysis reportsAll relevant cards and analysis are highlighted in these reportsFrequent independent field visits to confirm the health of equipment and wellsAccess the well health and provides redundancy to ONGC well assessment team.

IMPLEMENTATION RESULTS

Major Recommendations

Well#RecommendationDate of RecommendationAction taken onOutcomeRemarksSK-004Substantial drag and friction observed. HOC recommended9-Jun-1016-Jun-10HOC done. Peak load reduced by more than 1000 lbsPrevention of Mechanical failureSK-057High rod stress observed. HOC recommended8-Jul-1010-Jul-10HOC done. Rod stress reduced. Prevention of Rod snappingSK-066Tubing leakage confirmed9-Jul-109-Jul-10Tubing leakage confirmed by ONGCWork over planned.SK-093High rod stress observed. HOC recommended2-Jul-106-Jul-10Peak load reduced by 3000 lbs. Prevention of Rod snapping

Major Recommendations

Well#RecommendationDate of RecommendationAction taken onOutcomeRemarksSK-121High rod stress observed. HOC recommanded4-Jul-104-Jul-10Peak load reduced by 3000 lbs. TV leakage not rectified. Prevention of Rod snappingSK-136Bottom tagging observed5-Jul-105-Jul-10Bottom tagging corrected. Possible prevention of pump failurePrevention of possibility of pump failureSK-057Distorted Dynamometer Card. Valve reseating followed by HOC, if required5-Aug-1016-Aug-10Surface unit balancing done. Dynacard is coming alright. HOC will be done subsequentlyPrevention of Mechanical failure

Major Recommendations

Well#RecommendationDate of RecommendationAction taken onOutcomeRemarksSK-093Distorted Dynamometer Card. Valve reseating followed by HOC, if required5-Aug-1028-Aug-10HOC done. Load reduced by 5000 lbs. Prevention of Rod snappingSK-078Increase of SPM26-Jul-102-Aug-10Substantial liquid increaseProduction IncreaseSK-073Increase of SPM26-Jul-105-Aug-10Minor increase of liquidProduction IncreaseSK-079Increase of SPM26-Jul-1014-Aug-10Substantial liquid increaseProduction IncreaseSK-122Change of Surface unit & Increase of SPM26-Jul-1012-Aug-10Substantial liquid increaseProduction IncreaseSk-63Unit stopped because of high loads , high stress values and odd card shapes.

Informed tudu sir. they visited the well and it was found that the flow arm was closed. the well was allowed to24/9/1024/9/10Avoided stuffing box damage. and leakage at the well head.Avoided production loss, stuffing box damage avoided,

Implementation Results

Benefits No. of WellsSavingsPrevention of Mechanical Failure02Work over job 02 nos.Prevention of possibility of Rod snapping04Work over job 04 nos.Sucker rods Prevention of possibility of pump Failure01Work over job 01 no.Sub Surface Pump Production enhancement04Additional Gain 10 tpd

SK-04: Before and After HOC cardsPeak Load 13000 lbsPeak Load 12000 lbs

SK-57: Before and After HOC cardsHigh Load span indicates heavy frictionAnd high stress on roadsLoad span and stress deceasedsubstantially

SK-66: Tubing leakageLow load span, High FAP, tubing and casing pressures wereAnalyzed together to conclude about tubing leakage.The same was confirmed by pressure testing. Well is currently under workover.

SK-93: Before and After HOC cardsPeak Load 17500 lbsPeak Load 12500 lbs

SK-121: Travelling Valve LeakageTypical card shape with Travelling valve leakage.It was confirmed by ONGC from pressure testing

SK-121: Rod parting preventedPeak Load 18000 lbsPeak Load 12500 lbs

SK-136: Bottom TaggingBottom Tagging observed which hasPotential to create severe pump damage

SK-93: Prevention of rod partingPeak Load 16000 lbsPeak Load 9200 lbs

SK-73: Production enhancement after SPM increaseSPM Increase

SK-78: Production enhancement after SPM increaseSPM Increase

SK-79: Production enhancement after SPM increaseSPM Increase

SK-122: Production enhancement after SPM increaseSPM Increase

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