Gas Well Deliquification Workshop
Sheraton Hotel, Denver, Colorado
February 17 – 20, 2013
Automatic Plunger Lift Adjustment Pilot
Using Lean Methodology
Kelli Poppenhagen, Production Engineer
Encana Oil & Gas (USA) Inc.
Presentation Outline
• Lean approach overview
• Problem definition
• Baseline measurement
• Data analysis
• Improvement implementation
• Control plan / propagation
• Conclusions
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado 2
Background
• Encana Piceance field
located near Parachute,
Colorado
• >1900 S-shaped wells
producing from tight gas
Williams Fork formation
• ~90% of wells on plunger lift
3 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
Lean Methodology
• Eliminate waste, improve business processes
and enhance bottom-line results
• Structured problem solving approach to identify
highest priority issue(s), determine the best
solution, achieve a robust implementation and
deliver sustainable results
• DMAIC phased approach – Define, Measure,
Analyze, Improve, Control
4 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
First Things First- Project Charter
• Sets resource
requirements up front
• Reduces rework related to
poor scope definition
• Improves team member
and stakeholder buy-in
• Is customer driven –
customer requirements are
captured at the beginning
5
Charter Process Owner
Project Lead
Business Case
Problem Statement
Objective
Voice of Customer
Scope
Team Members
Stakeholders
Timeline
Add’l Support Required
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
DMAIC
Define: Problem Statement
• ~1700 plunger wells to optimize
• Pumpers are burdened with many
responsibilities – less and less time to devote to
“pumping”
• Lacking standard optimization approach
• Impossible to watch every well every second and
react to every changing condition
• Keep the lights on – important to maximize base
production
6 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
DMAIC
Additional Charter Details
• Objective:
– Improvement in place by 4/1/12
– Improve production of pilot wells by 5%
– Achieve 10% reduction in pumper man-hours
• Team Members:
– Project Lead
– Pumper
– Lead Pumper
– Automation Technician
– Production Engineer
7 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
DMAIC
Determine Key Inputs (Production Output)
8 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
DMAIC
Scope – Pilot Area Selection
• Hypothesis Test – Control Group and Test Group:
– Wells in close proximity
– Plungers already running
– High (99+ mcfd) and low (<=98 mcfd) producers
– Include wireless
– Coin toss:
• Group A - test (24 wells) Group B - control (24 wells)
9 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
DMAIC
Baseline Output Data
10 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
Gas Production
DMAIC
MC
FD
Production Statistics
11 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
MCFD
Rate
Category High High Low Low
Group A B A B
Count 3105 3312 1863 1656
Mean 326 356 82 79
Stdev 115 166 25 21
Range 978 1105 245 163
Minimum 0 0 0 0
Maximum 978 1105 245 163 A B-100
100
300
500
700
900
1100
GA
S
Group - Rate Category: High
Median
25th
75th
Mean
Outliers
ExtremeOutliers A B-100
100
300
500
700
900
1100
GA
S
Group - Rate Category: Low
Median
25th
75th
Mean
Outliers
ExtremeOutliers
DMAIC
Potential Failure ModePotential Failure
EffectsPotential Causes Current Controls Actions Recommended Resp.
In what ways does the
Key Input go wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes the Key Input to go wrong?
What are the existing
controls and
procedures (inspection
and test) that prevent
either the cause or the
Failure Mode?
What are the actions for
reducing the occurrence of the
cause, or improving
detection?
Who is
responsible for
the
recommended
action?
Settings (optimization
process) not optimal
Well is not
producing at
maximum daily
volume
7 Optimial settings not known 8 No detection available 8 448Utilize AutoAdjust, monitor
flow-time and gas productionTeam
Plunger stops arriving
Lower gas
production, pumper
time to unload well
8
Loaded up - inhibitor loaded it up, loaded
up due to high line pressure, bad opt
settings, worn out plunger, etc.
4Detect visually on
Cygnet8 256
Utilize AutoRecovery, 2
missed arrival alarms, use tbg-
line pressure dp open setting
Team, Auto
Tech
Plunger arriving but not
being measured
Lower gas
production, pumper
time to unload well
7Arrival sensor fails, goes to max lift time
(ignores opt settings)5
No regular
maintenance, upfront
test to make sure it's
working
7 245
Set up report to ID two
consecutive non-arrivals, send
alarm to email. Fix it right
away.
Auto Tech
Plunger stops arriving
Lower gas
production,
slickline retrieval
cost, pumper time
to surface plunger
8 Downhole problem - sand, scale (stuck) 2Detect visually on
Cygnet8 128
Set up report to ID two
consecutive non-arrivals, send
alarm to email. Fix it right
away.
Auto Tech
Well not building
pressure - valve unable
to seal, well loads up
Lower gas
production, pumper
time to fix problem
and unload well
8
Stem and seat leaking, happens about
every 6 months, happens faster with more
plunger arrivals
3
Detect with missed
plunger arrivals,
equalized tbg/line
pressures
3 72
Set up report to ID two
consecutive non-arrivals, send
alarm to email. Fix it right
away.
Auto Tech
S
E
V
E
R
I
T
Y
O
C
C
U
R
R
E
N
C
E
D
E
T
E
C
T
I
O
N
RPN
Determine Best Solution
Failure Modes and Effects Analysis (FMEA)
12 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
DMAIC
Potential Failure ModePotential Failure
EffectsPotential Causes Current Controls Actions Recommended
In what ways does the
Key Input go wrong?
What is the impact
on the Key Output
Variables
(Customer
Requirements)?
What causes the Key Input to go wrong?
What are the existing
controls and
procedures (inspection
and test) that prevent
either the cause or the
Failure Mode?
What are the actions for
reducing the occurrence of the
cause, or improving
detection?
Settings (optimization
process) not optimal
Well is not
producing at
maximum daily
volume
7 Optimial settings not known 8 No detection available 8 448Utilize AutoAdjust, monitor
flow-time and gas production
Plunger stops arriving
Lower gas
production, pumper
time to unload well
8 Loaded up - inhibitor loaded it up, loaded up due to high
line pressure, bad opt settings, worn out plunger, etc.4
Detect visually on
Cygnet8 256
Utilize AutoRecovery, 2
missed arrival alarms, use tbg-
line pressure dp open setting
Plunger arriving but not
being measured
Lower gas
production, pumper
time to unload well
7Arrival sensor fails, goes to max lift time (ignores opt
settings)5
No regular
maintenance, upfront
test to make sure it's
working
7 245
Set up report to ID two
consecutive non-arrivals, send
alarm to email. Fix it right
away.
Plunger stops arriving
Lower gas
production,
slickline retrieval
cost, pumper time
to surface plunger
8 Downhole problem - sand, scale (stuck) 2Detect visually on
Cygnet8 128
Set up report to ID two
consecutive non-arrivals, send
alarm to email. Fix it right
away.
Well not building
pressure - valve unable
to seal, well loads up
Lower gas
production, pumper
time to fix problem
and unload well
8Stem and seat leaking, happens about every 6 months,
happens faster with more plunger arrivals3
Detect with missed
plunger arrivals,
equalized tbg/line
pressures
3 72
Set up report to ID two
consecutive non-arrivals, send
alarm to email. Fix it right
away.
S
E
V
E
R
I
T
Y
O
C
C
U
R
R
E
N
C
E
D
E
T
E
C
T
I
O
N
RPN
Automatic Adjustment
• K-3512 RTU AutoAdjustTM - optimize plunger lift wells
– Controller adjusts well operation based on plunger
arrival time
– Open conditions (psi): tbg, csg, line, csg-tbg, tbg-
line, csg-line
– Close conditions (psi): tbg, csg, line, csg-tbg, tbg-
line, csg-line, orifice diff and flow rate
• K-3512 RTU AutoRecovery - react to missed plunger
arrivals
– Unique open condition or shut-in time
Feb. 17 – 20, 2013
2013 Gas Well Deliquification Workshop
Denver, Colorado
13
DMAIC
Automatic Adjustment
• Literature Search
– SPE 24296 Increasing Production Using
Microprocessors and Tracking Plunger-Lift
Velocity, 1992
– SPE 124911 Optimizing Mature Gas Wells in South
Texas – A Team Approach, 2009
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
14
DMAIC
Pilot Process Flow Diagram – “Future State Map”
15 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
15
Plunger Arrives Plunger Does Not Arrive
Multiple
consecutive failed
arrivals
Outside time
band
Single failed arrival: failed
trip adjustment: open
&/or close, larger
increment Full
adjustment:
open &/or
close
Proportional
adjustment:
open &/or
close
SI well for set time
period &/or use AR
increment (only on
open settings)
AR value is inserted
as new open setting
Within time
band
Prepare Well for Plunger Lift
Begin Plunger Lift (drop plunger, initial AA/AR* set-up)
Pumper, Production Engineer monitor results and adjust /
troubleshoot as needed
Arrives
Does not
arrive
Arrives
Does not arrive
*AA/AR: AutoAdjust
/ AutoRecovery
Hu
ma
n
Inte
rve
ntio
n
Hu
ma
n
Inte
rve
ntio
n
Au
tom
atic
Inte
rve
ntio
n
DMAIC
Determining Adjustment Windows
16 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
Tbg Line DP Open starting minimum of 80 psi. Not low enough, decreased to
60 psi which was too low (multiple failed trip adjustments) -> increased to 70
psi.
DMAIC
Flow Rate AutoAdjust Example
17 Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
Small adjustments: Target arrival
time is 11:34 +/- 60 sec (750 fpm).
DMAIC
Results Summary
• Total production for the 23* Group A wells increased 2.5% with
the improvement
– Low rate wells responded better than high rate wells
– Group A daily production StDev (variability) decreased by 30
mcfd vs Group B decrease of 13 mcfd
• Daily plunger non-arrivals:
– Both groups maintained 0 non-arrivals as the median, however Group A variability decreased from 6 to 0 vs Group B decrease from 8 to 3
– Group A maximum decreased from 83 to 4 non-arrivals, Group B decreased from 98 to 26
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
18
DMAIC
Results - Total Production
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
19
Group A: 2.5%
increase
Group B: 0.2% increase
MC
FD
DMAIC
Results – Median Uplift
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
20
0.07% chance of being
wrong about the
median difference
Mood's Median Test: Prod Variance
Test Information
H0: Median 1 = Median 2 = ... = Median k
Ha: At least one pair Median i ≠ Median j
MISC3 Group A Group B High Low Group A Group B Group A Group B
Count (N <= Overall Median) 494 713 410 191 359 431 138 279
Count (N > Overall Median) 707 500 353 247 404 386 300 117
Median 11 6 10 13 10 8 13 3
UC Median (2-sided, 95%) 12 6 11 15 11 9 15 4
LC Median (2-sided, 95%) 10 5 8 11 8 7 11 2
Overall Median
Chi-Square
DF
p-value (2-sided)
Low Wells
0.0235
1
5
8
High Wells
0.0000
1
126
6
1
0.0000 0.0007
1
Overall Group A
8
75 11
11
DMAIC
Results – Well Production Examples
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
21
We
ll 1
W
ell 2
PILOT START
Mean CL: 0.10
-0.06
0.27
-2
0
2
4
6
8
Ind
ivid
ua
ls:
Pu
mp
er
hrs
by P
eri
od
Results – Pumper Time Burden
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
22
Group A Control Chart
Before
Improvement
Transition After
Improvement
• The pumper’s time was reduced by ~1 hr/day for the Group A wells
• Less time spent trying to optimize settings
• Fewer unloading events and minimal troubleshooting required
• More time available to focus on other issues / wells
DMAIC
• Less manual unloading due to AutoRecovery - wells
do not continue to load with each missed arrival
• More consistent liquid production (more oil) - helps
with hauling and more revenue
• Increased measurement accuracy due to consistent
operation
• Less equipment wear and tear due to more
consistent arrivals
Results – Other Benefits
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
23
DMAIC
• Preparation
– Prepare wells ahead of time and allow stabilization including choke changes, setting standing valves and changing plunger type
– Functioning arrival sensors are critical – ensure placement is correct
• AA/AR Set-up
– Start with 750-800 fpm target arrival speed
– Set Flow Rate Close AutoAdjust Condition on all wells at minimum off-time (plunger drop)
– If using AutoAdjust Open Condition, use Tbg/Line DP
– Accurate line pressure is important – install transducers ahead of time
– Start small on AutoRecovery shut-in time
– Set adjustment windows wide to allow adjustment and limit determination
Lessons Learned
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
24
DMAIC
Control Plan
• Definition
– The Control Plan documents the knowledge, control points,
and corrective measures needed to maintain the benefits of
the solution discovered during the improvement effort
• Benefits
– Provides the recipients of the solution – many of whom were
not on the project team - the documentation required to
control the improved / changed process
– The Control Plan provides guidance after the team has
dispersed to other assignments
– It formalizes the change in process ownership to the Site
Lead from the project team
Feb. 17 – 20, 2013
2013 Gas Well Deliquification Workshop
Denver, Colorado
25
DMAIC
Process RACI
• Maintain Group A Results
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
26
DMAIC
Action ItemSite Lead
Prod
Coordinator
Lead
Pumper Pumper
Automation
Tech
Prod
Engineer Green Belt
PE Group
LeadDate Due
Review AA/AR settings and
adjust as neededA C, A R R C Quarterly
Investigate alarms (two
consecutive missed arrivals)C, A R C C, I C
Upon
Occurance
Check plungers and replace as
neededA R
Every 3
months
Run variance report (actual vs
forecast) to identify under-
performing wells
I R C A Monthly
Update production
charts/statistics and report
results
A, I I I I I R C I Monthly
Maintain Change Tracking
SpreadsheetA R R C
Upon
Occurance
Maintain Results in Insights I I I I I C, I R I Quarterly
Complete Audit Plan Tasks A, I I I C C R C, I A Quarterly
R - Responsible
A - Accountable
C- Consulted
I - Informed
Propagation Plan
• Q4 2012: Conduct second automatic adjustment pilot
– Different area, different team
– Utilize DMAIC Process
• 2013 – 2014: Implement automatic adjustment throughout South Piceance
– Risks-
• Can Automation meet this schedule?
• Budget constraints (hardware including arrival sensors, expansion boards)
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
27
DMAIC
Conclusions
• Lean DMAIC methodology resulted in robust implementation
with statistically significant results
• Production from AutoAdjust / AutoRecovery wells improved
compared to existing optimization process
– AutoAdjust makes optimization adjustments on every cycle,
reacting to continuously changing surface pressures and
liquid loads
– AutoRecovery returns wells to normal production faster
without human intervention and manual unloading
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
28
Acknowledgements
• Encana
• Lean Coach – Brent Chance
• Project Team – Travis Preble, Ty Tanner, Karl
Biermann, Paul Schroeder, Will Trump
• NRG Services LLC – Troy Malone
• Weatherford – Tom Held, Annette
Ausseresses, Jeb Bucher
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
29
Copyright
Rights to this presentation are owned by Encana Oil & Gas (USA) Inc. (“Encana”) listed on the title page. By submitting this presentation to the Gas Well Deliquification Workshop, Encana grants to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), only the following limited rights to:
– Display the presentation at the Workshop.
– Place it on the www.alrdc.com web site, with access to the site to be as directed by the Workshop Steering Committee.
– Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee.
Any other use of this presentation or any modification of the same is prohibited without the expressed written permission of Encana. Encana may publish this material in other journals or magazines if they refer to the Gas Well Deliquification Workshop where it was first presented. No right, title, or interest in or to any of Encana’s or its affiliates’ trade mark included in this presentation and any goodwill associated therewith is granted to ALRDC, SWPSC or the Workshop Steering Committee by the submission of this presentation by Encana.
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
30
Disclaimer
The Artificial Lift Research and Development Council and its officers and trustees, and the Gas Well Deliquification Workshop Steering Committee members, and their supporting organizations and companies (hereinafter referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Gas Well Deliquification Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.
The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials.
The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.
Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop
Denver, Colorado
31