Integrated Field Control: An Autonomous and Real-Time Field Operation

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Abstract This paper describes a system that autonomously minimizes production losses caused by upset events at the central processing facility (CPF) by restricting well production using automated choke valves and/or at the central gas-lift compressor (CGL) facilities by adjusting surface gas-lift injection control valves. The system provides a real-time, automated, autonomous operation that improves operational efficiency, increases production by reducing unplanned downtime, simplifies the decision-making process, increases process safety, and enhances general HSE performance. The system has three main components: Gas Lift Optimizer (GLO), Auto-choke (AC), and Choke Optimizer (CO). The GLO delivers a real-time optimum gas-lift rate per well based on well and surface network models, optimization and regression solvers, and a disturbance adaptation model. The AC, based on a set of simple control rules programmed into the local programmable logic controller (PLC) at the CPF, prevents conditions that could impact equipment and operations. The CO uses the same GLO data architecture and Internet of Things (IoT) technology to send operating and business data to an optimization algorithm that identifies the best combination of wells and required backpressure to reduce produced fluids into the CPF and avoid reaching upset conditions that could trigger the AC. This novel system has been successfully developed, piloted, and implemented to manage operational upset conditions effectively at CPFs and CGLs in Occidental's gas-lift fields in the Permian Basin. This cutting-edge system employs a closed-loop configuration driven by both physical and data-based models, enabling remote, real-time, and optimized control. Post-implementation results revealed a remarkable 3 to 5% reduction in downtime per field and saving 500 to 750 man-hours per year per facility. The integration of IoT devices has proven to be an exceptionally successful hardware and software solution, facilitating seamless wired and wireless connectivity, business and automation data integration, and rapid and reliable data transmission.

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