Multiphase flow metering is considered one of the most essential technologies in well testing. Since the mid 1990's, Multiphase Flow Meters (MPFM) have evolved from a revolutionary new technology into a consolidated solution widely adopted by the major operators worldwide. This evolution has taken place thanks to the high quality of measurements, low operational cost and the capability of enabling remote monitoring of wells' performance with ease. The meters have proven to be durable for testing oil wells of Saudi Aramco's (SA) fields. The installed MPFMs in Northern fields of Saudi Aramco have contributed effectively to enhancing the semi-real time measurements' quality as well as improving reservoir characterization. However, MPFMs are prone to mechanical and firmware failures. To keep the general health of the installed systems, various preventive and ad-hoc services are needed. The MPFM technology largely seems to be performing as expected and delivering high quality data. So far, 58% of the systems have been in service for more than 8 years and continuing to operate efficiently. Thorough analysis of the routine maintenance and checkups conducted during the past 10 years revealed the following: The MPFMs Mean Time between Failure (MTBF) and Mean Time to Repair (MTTR) indicated that the MPFMs have been available 97% of the time.The use of a probabilistic approach (Monte-Carlo™ Simulation) to study the P10, P50 and P90 values of the maintained MPFMs indicated that the variance between these values is small, demonstrating the reliability of these equipment.The classification of the diverse types of problems faced while operating the MPFMs highlighted the dominant cause of failures and enabled the initiation of a surveillance and subsequent failure mitigation program. The latter program resulted in fewer failures and higher equipment efficiency. This paper discusses the lessons learnt and experience gained from operating 168 MPFMs provided by different vendors in different environments during a 10-year period, along with the appropriate solutions that were implemented to mitigate the challenges faced and subsequently improve the efficiency and data quality of the MPFM.
Multiphase flow metering is considered one of the most essential technologies in well testing. Since the mid 1990's, Multiphase Flow Meters (MPFM) have evolved from a revolutionary new technology into a consolidated solution widely adopted by the major operators worldwide. This evolution has taken place thanks to the high quality of measurements, low operational cost and the capability of enabling remote monitoring of wells' performance and testing with ease. The installed MPFMs in Northern fields of Saudi Aramco have contributed effectively to enhancing the semi-real time measurements' quality as well as improving reservoir characterization. Though, MPFMs are prone to mechanical and firmware failures. The MPFM technology largely seems to be performing as expected and delivering high quality data. So far, 58% of the systems have been in service for more than 8 years and continuing to operate efficiently. Thorough analysis of the routine maintenance and checkups conducted during the past 10 years revealed the following: The MPFMs Mean Time between Failure (MTBF) and Mean Time to Repair (MTTR) indicated that the MPFMs have been available 97% of the time. The use of a probabilistic approach (Monte-Carlo™ Simulation) to study the P10, P50 and P90 values of the maintained MPFMs indicated that the variance between these values is small, demonstrating the reliability of these equipment. The classification of the diverse types of problems faced while operating the MPFMs highlighted the dominant cause of failures and enabled the initiation of a surveillance and subsequent failure mitigation program. This paper discusses the lessons learnt and experience gained from operating 168 MPFMs provided by different vendors in different environments during a 10-year period, along with the appropriate solutions that were implemented to mitigate the challenges faced and subsequently improve the efficiency and data quality of the MPFM.
There are well-known correlations and technologies which estimate the flow rate in dry gas wells. Measuring the surface rate is challenging, especially when there is no measuring equipment. Nevertheless, the choke equation and some well-known correlations can provide an estimate of the flow rate whether the gas at the surface is single-phase or multi-phase but with a certain accuracy and basic assumptions. Another tool to estimate flow rate is the surface venturi meter, which is being used for dry gas wells. In this paper, a new method was established to calculate and verify measured gas flow rates. An empirical correlation was developed to calculate the real-time flow rate in dry gas wells at the surface utilizing the most appropriate parameters: upstream flowing wellhead pressure, downstream flowing wellhead pressure, upstream flowing wellhead temperature, and choke size. The proposed equation consists of a coefficient for each individual parameter which is fine-tuned in the equation using an advanced non-linear regression method. Moreover, a comparison between calculated rate using the new method and measured gas rate shows accurate values with an average absolute error of 11%. A comparison between the measured rate, Beggs equation, and Gilbert's correlation showed highly deviated values, with an average absolute error of 60% for Beggs's and more for Gilbert's. It is worth highlighting that there is a major difference between the new correlation and Beggs' equation or any other that the new correlation is customized for the selected field. Another difference that the new correlation uses real and field data whereas the Beggs's equation and Gilbert's correlation used experimental data which might not be applicable to the selected field. Hence, this correlation provides a matching trend to the measured flow rate from venturi readings in dry gas wells. The new correlation would enable production engineers to enhance their rate validity and furthermore it might replace the meter readings when the meter device become defective. Also, this correlation is aimed at calculating the gas flow rate in real-time measurements of wellhead parameters which enhances the monitoring of the well's performance on a real-time basis.
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