This paper presents the recent developments that have been achieved to improve the Karachaganak Integrated Asset Model (IAM). In 2014, SPE-172330 showed a step change in the application of integrated modelling techniques to this complex field and demonstrated the significant value of integration compared to standalone techniques. The complexity of modelling and integration is driven by more than 120 operating wells (production and injection), a complex gathering system, multiple processing facilities and multiple export lines, combined with gas reinjection for reservoir pressure support. To correctly capture real operations, the model requires layers of constraints at well, facility and export levels and an appropriate line-up of wells to maximise field oil and gas production. The model has been used to evaluate multiple field development projects with intensive capital investment worth several billions of US dollars. Hence, it is critical to ensure that the model is robust and replicates the reality. The latest improvements presented in this paper include a description of a more enhanced field optimisation approach that fulfills oil and gas export as well as gas reinjection targets whilst respecting all of the field constraints. Optimising such a complex problem is a challenging task considering the number of variables and constraints in the system. Production well ranking for line-up selection has also been improved. Rather than following a single approach of well prioritisation, for example by well Gas/Oil ratio to maximise liquid production, in the new methodology wells are smartly picked to fulfill all export and gas injection targets. Another improvement in the model was converting the optimisation logic, which was previously based on scripts, into open and transparent workflows using Visual Workflows in Resolve (application for connecting and running integrated models). This approach made it possible for Engineers to read, modify and extend the logic without having programming skills, bringing flexibility and sustainability into the model. Several case studies of actual project evaluations using the improved Integrated Asset Model will also be discussed. These studies highlight the key results, the importance of the implemented improvements for decision-making and how these affect the bottom line of projects.
Karachaganak is one of the world's largest oil and gas condensate fields in a deep heterogeneous carbonate reservoir with complex sour fluid system located in Western Kazakhstan. Karachaganak's estimated reserves are over 2.4 Bln bbls of condensate and 16 tcf of gas. The asset is co-operated by Shell and Eni through Karachaganak Petroleum Operating (KPO) b.v. Joint Venture. KPO successfully deployed a new KUAT operating center with aim to maximize production and improve collaboration among key functional groups managing day-to-day field activities. Maximizing oil production means getting the most condensate liquids to surface at a given gas (or other) constraints by routing producer wells through the network to arrive at the lowest field GOR. Experience showed that the key success factor was to establish a collaboration between Subsurface and Production departments built upon common understanding of field data. Physical embodiment of this collaboration is the Karachaganak Unified Action Team – KUAT, which means "power" in Kazakh. This center was established in 2020 with physical placement of Petroleum Engineers together with Production, Process and Planning Engineers in one Operating Center at the field site. The objectives of KUAT team include the following short-term integrated activities: Daily well line-up optimization as per integrated limit diagram views Integrated activity planning – e.g. optimized start-up of the new wells and projects Well surveillance planning and execution – from reference plans, EBS and opportunity-based GOR management Flow assurance KUAT team utilizes the industry standard digital solutions like PI and PI vision and Petex type of solvers as well as custom-made integrators like Data Integrator and Network Optimizer (DINO). In order to ensure that production is always maximized and potential downtime is minimized a robust understanding of the limit diagrams and well potentials is required. This information is provided by live integrated dashboards which include the real-time data from subsurface to export routes. The overall contribution from KUAT is estimated at ~7,000 BOPD or 3% of incremental field production. This paper will cover the overview of KUAT journey from early concept development to current state explaining how this center operates today. Workflows and improvements are included in the discussion as well as challenges faced throughout the implementation of newly developed team within the organization
Minimising or eliminating completely the flaring of hydrocarbons during well clean-up and early production testing is an increasing challenge for the oil and gas industry and an important issue for Karachaganak Petroleum Operating b.v. (KPO). KPO operates the giant Karachaganak gas-condensate carbonate reservoir located in north-western Kazakhstan. To improve reservoir management and field recovery, KPO drills long horizontal wells and then stimulates them with acid. KPO has used a variety of different acid stimulation techniques, progressing from simple acid washes to high rate matrix acid treatments and hydraulic fracturing with gelled acid. With the advent of mechanical downhole diversion equipment, KPO can now perform Multi-Stage Selective Acid Stimulation treatments. However, as the complexity of the stimulation techniques has increased, so has the volume of fluid injected into the wells, most of which is recovered to surface during the subsequent clean-up and well testing. The processing facilities at Karachaganak are not designed to handle large quantities of water. A traditional approach to dealing with this problem would be to flare all the produced fluids from the wells until an acceptable water-cut of 1% is achieved. KPO recognised that it had to adopt a different methodology in order to reduce the volume of hydrocarbons flared during well clean-ups and testing. A new approach to well clean-ups was sought that would be capable of efficiently separating the fluids and measuring the flow-rates from high productivity wells and would: Reduce or eliminate flaring. Reduce the environmental impact of well clean-up operations. Dispose of unwanted fluids in a safe and environmentally friendly manner. Recover additional hydrocarbons that would otherwise be flared. This paper describes the evolution and application of a new approach to performing well testing, clean-up and water separation and treatment in the Karachaganak field. It describes the methodology, challenges and strategies that were adopted to manage the liquids produced during the clean-up and early testing of new Karachaganak wells. It focuses on the value brought to both the environment and the field by the deployment of an advanced, integrated 3 Phase High Pressure Separator (3P-HPS) spread with associated water treatment concept.
Сокращение выбросов углеводородов в атмосферу: применение комплексного решения по сепарации технологической жидкости и пластовой воды из скважинного флюида при освоении скважин на месторождении Карачаганак, Республика Казахстан Индира Казиева (КПО), Тамер Саада, Питер Хатсон (SPE/КПО/Би Джи Групп), Симоне Андреа Фрау, Энцо Вильянте (КПО/Эни), Лео Донохью, Разия Шектебаева, Арман Избассов (КПО) Авторское право 2014 г., Общество инженеров нефтегазовой промышленности Этот доклад был подготовлен для презентации на Ежегодной Каспийской технической конференции и выставке SPE, 12 -14 ноября, 2014, Астана, Казахстан.Данный доклад был выбран для проведения презентации Программным комитетом SPE по результатам экспертизы информации, содержащейся в представленном авторами реферате. Экспертиза содержания доклада Обществом инженеров нефтегазовой промышленности не выполнялась, и внесение исправлений и изменений является обязанностью авторов. Материал в том виде, в котором он представлен, не обязательно отражает точку зрения SPE, его должностных лиц или участников. Электронное копирование, распространение или хранение любой части данного доклада без предварительного письменного согласия SPE запрещается. Разрешение на воспроизведение в печатном виде распространяется только на реферат объемом не более 300 слов; при этом копировать иллюстрации не разрешается. Реферат должен содержать явно выраженную ссылку на авторское право SPE.
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