Primary funding is provided by

The SPE Foundation through member donations

and a contribution from Offshore Europe

The Society is grateful to those companies that allow their

professionals to serve as lecturers.

Additional support provided by AIME.

Society of Petroleum Engineers

Distinguished Lecturer Program www.spe.org/dl

Hani AlKhalifa

Saudi Aramco

Society of Petroleum Engineers

Distinguished Lecturer Program www.spe.org/dl

2

Produced Water Re-injection:

Your Recipe for Improvement

How much water was produced worldwide in

2012?

3

Produced Water Forecast (MMB/D)

E X P L O R A T I O N & P R O D U C T I O N O I L & G A S R E V I E W 2 0 0 7 O T C E D I T I O N

4

Problems with Produced Water

5

Avoid it ...

6

Dealing with Produced Water

Avoid it

Process it

Dump it

7

Treatment Cost

38%

62%

Power Requirement

Water Re-injection

Others

8

Current System Efficiency

9

0.700.630.560.490.420.350.280.21

LSL USL

LSL 0.3

Target *

USL 0.7

Sample Mean 0.260474

Sample N 359

StDev (Within) 0.0215691

StDev (O v erall) 0.0353599

Process Data

Z.Bench -1.83

Z.LSL -1.83

Z.USL 20.38

C pk -0.61

Z.Bench -1.12

Z.LSL -1.12

Z.USL 12.43

Ppk -0.37

C pm *

O v erall C apability

Potential (Within) C apability

% < LSL 89.14

% > USL 0.00

% Total 89.14

O bserv ed Performance

% < LSL 96.66

% > USL 0.00

% Total 96.66

Exp. Within Performance

% < LSL 86.82

% > USL 0.00

% Total 86.82

Exp. O v erall Performance

Within

Overall

Process Capability of before

10

Quality

Capacity

Efficiency

Produced Water Re-injection System

Produced Water Quality:

Regulations ...

11

Quality Specifications:100 ppm - 10 ppm

Produced Water Quality:

What do we Know?

13

Available Instrumentation:

Different Technologies

Side Stream

Partial Reading

Available Oil in Water Online

Analyzers Technologies

14

Side Stream Nondirect

Measurement

Maintenance Accuracy

Available Oil in Water

Analyzers Technologies

15

Produced Water Treatment

16

17

Quality

Capacity

Efficiency

Produced Water Re-injection System

Fundamentals: Off Plot

P3

0

1000

2000

3000

4000

0 5000 10000 15000P

SIG

GPM

Performance Curves

18

Pipeline Size

No. of Wells

Centrifugal Pumps Fundamentals

Flow Rate (gpm)

Head a

t pum

p o

utlet

Steady-state flow

rate at given

conditions.

liquid Pump Curve

System Curve

P1

P2 P3

Q1 Q2

Q

19

21

The Recipe ... 1st

Challenges

Reservoir Factor

Market Demand

Operations Requirement

22

Actual Flow Rates

23

The Recipe 2nd

24

Which is More Important?

25

Case A, Plant 1: Excess Power

0

500

1000

1500

2000

2500

3000

3500

4000

0 2000 4000 6000 8000 10000 12000 14000

PS

IG

GPM

Performance Curves

Discharge Pres-3 Sys Curve

Discharge Pres-1 Discharge Pres-2

26

Efficiency Improvement

27

28

Case B, Plant 2: System Limitation

0

500

1000

1500

2000

2500

0 2000 4000 6000 8000 10000 12000 14000

PS

IG

GPM

Performance Curves

Sys Curve Min Max

29

Case C, Plant 2: System Limitation

0

500

1000

1500

2000

2500

0 2000 4000 6000 8000 10000 12000 14000

PS

IG

GPM

Performance Curves

Sys Curve Min MaxDischarge Pres-1 Discharge Pres-2 Discharge Pres-3

30

Case D, Plant 2: System Limitation

0

500

1000

1500

2000

2500

0 2000 4000 6000 8000 10000 12000 14000

PS

IG

GPM

Performance Curves

Sys Curve Min Max

Discharge Pres-1 Discharge Pres-2 Discharge Pres-3

Where to Focus ...

System Capacity:

Short-term

Long-term

Economic Evaluation:

Capital cost

Operational cost

31

System Analyzer: Input

32

System Analyzer: Output

33

Right Tools: Accurate

User-friendly

The system as a whole

Economics

34

The Recipe 3rd

Potential Problem Causes

% Low

Eff.

Process

Fluctuation in

Input Flow

dP Across

LCV-3033

Malfunction of

LCV-3033

Process and

Control Delays

Control

Untuned Control

System

Recycling FCV-3025

Instrumentation

Untuned

Instruments Bad Readings

Lack of Individual

Eff. Index

Design

Oversized Motor

Sizing of LCV-3033

Low Eff. Pump Design

Overrated Pump

Size of WOSEP

Fixed Speed Pump

Size of Pipes

Maintenance

Aging of Pump

Aging of Motor

FCV-3025 Leaking

Pump Internal Leak

Centrifugal Pumps

Flow Rate (gpm)

Head a

t pum

p o

utlet

Steady-state flow

rate at given

conditions.

liquid Pump Curve

System Curve

P1

P2 P3

Q1 Q2

Q

36

Plant A1: Improvement

37

2012

2013

Outcome ...

Adequate Capacity

Efficient Operation

Save Power and $

30% 60%

38

The Recipe ... 4th

39

Concluding Thoughts

40

Society of Petroleum Engineers

Distinguished Lecturer Program www.spe.org/dl 41

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