Integrated Solutions

Here are some examples of how our technology can be combined to create complete production optimization solutions.

Software/Consulting - Several years have gone into delivering production gains through the implementation of optimization technology (ReO^® software) interfaced to online systems. This has proven successful in Central and South Lake Maracaibo and is now being rolled out to all other production districts in the region. One aspect of this is the use of ReO software as an off-line application. The operator’s production management team recognized the opportunity for quick gains in production through this approach and applied ReO software to one of the area’s production platforms.

A comprehensive model of the wells and production network was built in one month with the help of Weatherford consultants. A production gain of 800 barrels of oil per day was achieved solely through the application of the ReO gas lift optimization approach. This translated to an immediate “quick win” and ongoing improved field performance. Subsequent experience in further assets achieved similar gains between 3% and 7%. Moreover, optimization identified and achieved reductions in lift gas requirements of 2% to 6% on the same assets.

Training/Consulting - Weatherford’s trainer/consultant taught field personnel rod pump controller (RPC) operation, surveillance/optimization software, pumping system design, electric submersible pump (ESP) optimization, well-testing equipment, rig crew operations, pump shop practices and chemical treatment practices. Some of the actions resulted in immediate results while others will have long-term benefits. Deviated wells experienced an increase of 315 STB/D (50 M3D) net oil from changes put in place while changes to ESP well operations resulted in two wells increasing over 315 STB/D (50 M3D) each and two wells increasing 189 STB/D (30 M3D) net oil.

Multiphase Metering - A major US oil company needed automated three-phase metering systems for satellite well-testing in recently developed oilfields located in West Africa. The company was looking for a compact, efficient, highly accurate, cost effective alternative to traditional metering systems or complicated nuclear multiphase meters.

Weatherford’s multiphase metering units were designed to meet the customers specific needs. Some were configured with dual meters and to give accurate measurements over a wide flow range. The skid mounted flow computer monitors all signals, calculates oil/water/gas flow rates, controls system valves and offers several communication options.

Complex Control System - This platform control system is installed on an offshore, unmanned production platform located in the Mediterranean Sea near Egypt, Africa. The electro-hydraulic control system is designed for automatic controlling and monitoring of critical operating functions of the production platform.

The platform control system operates in a Zone 2, Group IIA area. The system consists of a hydraulic control panel integrated with a CS7X™ controller. The control system monitors and controls all aspects of the platform operation including process shutdowns; emergency shutdowns; pressure, temperature and corrosion measurement; AGA3 flow calculations; variable frequency drive (VFD) motor control; valve control; operational status; flow measurement; hydraulic injection pump control; electric load shedding; wax inhibitor pump control; glycol injection pump control and corrosion injection pump control.

Optical Monitoring Solution - An operator for one of the largest field developments in the North Sea in the past decade has selected and integrated solutions consisting of Weatherford’s optical permanent monitoring system and production analysis software. The optical production monitoring solution incorporates pressure/temperature, multiphase flow meter and distributed temperature systems to provide the required level of data to support detailed analysis of each well’s production performance. Asset optimization software provides well performance data interpretation and offline analysis for the field. Weatherford supports the deployment of the integrated system with a dedicated project engineering team to sustain well and platform production monitoring system design, planning, custom development, risk assessment, logistics, installation, technical support, commissioning, production analysis reporting and maintenance.

Rod Pumping - An East Texas operator replaced his timers with Weatherford’s Model 2000 RPCs. This reduced the amount of time that the pumpers needed to stay in the field and significantly cut the electricity costs as well as the rod and tubing repairs. Over two years, the controllers reduced rod and tubing repair costs by 31% and electrical costs by 40%. This resulted in operating cost savings of approximately $50,000 per year.

Real-time Production Optimization
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Integrated Solutions
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