Special Report: Wellhead efficiency improvements

In the most recent shift in prices, we have seen another significant change in mind-set. Our world is becoming ever more inter-connected. With the advance of the Internet-of-Things, the oil and gas industry too is embracing this interconnectedness, not only with data, but also with people and solutions through collaboration and innovation. 

Exploration and production companies are looking for smarter and simpler solutions to their challenges and there is a huge drive to make the industry safer, more efficient and more productive. These solutions must present opportunity now, along with sustainable results that support through the lower-for-longer ‘norm’ we are experiencing. 

An area where we see opportunities for this is at the wellhead. The integrated wellhead system comprises the following sub-components: wellhead, christmas tree, wellhead control panel, chemical injection skids, permanent downhole gauge and cathodic protection system.

The wellhead and christmas tree themselves are designed strictly in accordance to API 6A standards. These systems have not undergone any major technology changes and have undergone only small modifications to comply with standards. However, the control and monitoring equipment installed on and around the wellhead and christmas tree have made significant advances, bringing better visibility and accurate data to decision-makers.

With over 20,000 producing wells in the region, the scale at which operators need to manage the daily output has become increasingly complex. With many wells initially commissioned decades ago, with limited or no integrated communications systems, the complexity has become even more challenging. 

When wellhead systems were installed, prior to digital technology being adopted, the requirements to monitor well data, adjust production flow and maintain or repair systems was a manual endeavour. Operators would have to physically go to site to take details or analyse the recording to have data to make decisions. This was often a slow, laborious and occasionally risky activity. Although the new wells today are equipped with digital control systems (RTU/PLC/ICSS) to capture data in real time, the older wells, of which there are thousands, still fall into the former category. 

From a well integrity point this presents some gaps when trying to identify exactly how conditions are at the wellhead. Crucial control and monitoring features are not available, leaving these wells off the ‘connected’ network of newer and digitally connected fields. Data is available but only through visiting the well site. 

In the current climate where budgets are increasingly scrutinised to explore more viable alternatives, solutions are now developed to bring the older wells ‘online’ and integrate the vital statistics into the operators’ connected oilfield. Simple and smart solutions are available that do not require a huge investment from the operators, nor are they restrictive due to wireless security reasons.

Now, SMARTBOX systems can be installed on older wells that can remotely notify key well parameters to operations and maintenance personnel. This prompts them to take corrective actions on an exceptional basis rather than following a site visit schedule. This also allows maintenance teams to prioritise wells that require immediate attention, rather than redundant visits to less troublesome wells that are flowing as expected. 

Time and cost

Another shift in the area of wellhead systems is the focus on reducing the installation and commissioning time at each well. In the past decade, we saw end users in the region outsource the complete wellsite scopes to engineering, procurement and construction contractors to consolidate the responsibility and liabilities under a single point of contact. For less complex situations and tie-in wells, this is still a timely and costly option as most of the equipment is common across wells.

Several major firms are adopting modular skid components wherein wellhead control panels, chemical injection skids, downstream wellhead valves and automation systems are installed on an integrated skid. These can halve installation time and alleviate site related delays due to multiple vendor complications. 

As exploration in remote areas increases, the logistics and infrastructure required to complete the wells and bring production on-line is more challenging. It involves the coordination of multiple suppliers’ equipment, movement of heavy construction machinery to conduct civil works and facilities put in place during the well pad construction, as well as site integration and testing before starting to flow the well. Time saved here can have an enormous impact to the bottom line. 

Looking to the future, we see continued focus on digital integration of older wells. Established and mature fields are where we see a lot of opportunity to increase productivity. We foresee increased investment in a ‘collaborative work environment’ wherein different departments can work in real time for faster and well-informed tactical decisions. 

Collaboration among different departments is fundamental to finding the best solutions that maximise the return on investment and ensure safe practices. We also foresee industry adopting advanced process control techniques to optimise artificial lift mechanisms. This will enhance well efficiency and improve the longevity of the well.

In addition, an advanced wellhead monitoring and control system ensures that production machinery and other critical equipment downtime is minimised, reducing operating and maintenance costs while increasing production revenue.

An advanced wellhead monitoring and control system provides production assurance, so it can identify events with enough lead time to properly schedule maintenance and avoid production disruptions. Further, this reduces the frequency of physical visits by operators. Leveraging the analytics on an embedded platform provides an inherent safety advantage because operators are taken out of situations in which they need to interface directly with the equipment.

The industry continues to evolve, finding more preferred innovative solutions to improve well efficiency, Integrity and safety.  Now, the oil and gas industry is also working towards reducing its carbon footprint through the utilisation of green technologies.