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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