Thinking Differently – Energy Optimization and Flaring Reduction Approach Improvising Sustainable Production
Authors: Ahmed S. M. , Al Ketbi A. , Al Katheiri G. , Al Mazrouei M. K. , Aslam M. , Alhammadi Y. , Haider F. 
Published: September 2024

This paper presents the innovative practice and tactical initiative adapted by ADNOC-Onshore Asset to ensure sustainable production from the facility by thinking differently and avoiding standby pump startup with mindset of optimizing energy and avoiding flaring gas volumes.

As per operational conditions and to meet production mandate, the deem necessity of 2nd pump startup reevaluated and avoided by implementing this innovative approach and resulted in energy consumption optimization and avoided huge volume of gas flaring.

The alternate approach adapted due to following main challenges: MPP High energy consumption at flowing wells extra loadHigh water flow envisaged the requirement of operating two pumps specially in summer when MPP suction temperature rises.Suction pressure increases upon MPP trip. To re start pump with minimum suction pressure permissive it requires to depressurize suction header.

Consequently, list of high potential wells developed, MPPs turndown capacities analyzed. Hence high potential wells operated through MPP bypass and low potential wells kept flowing through MPP. It resulted in not only reducing load on running MPP but also 2nd MPP operation avoided.

This strategic resolution was implemented in house without extra cost. Following benefits were obtained from this exercise and will remain beneficial in future also: Energy conservation due to less load on running MPP and hence avoiding the operation of 2nd MPP – daily use of extra 1000kW (18k USD per annum considering power cost 190 AED/1000kwh) was saved. 3000 Metric Ton CO2 Saved due to Green Power saving.Less corrective maintenance due to single MPP operationSuction strainer maintenance and also new strainer cost was avoided - 20k AEDMeeting monthly targets without compromising production allowableMin GHG emissions (54 tons eq CO2) while draining/depressurization during MPP trip – suction pressure increases due to MPP trip because of non-smart wells. In order to re start pump and to obtain min suction pressure start up permissive it was required to depressurize header.No extra cost in this project but cost saving with continuous production.Continuous ¬4000 BOPD production in case of MPP trip over the night or daytime - considering 2 trips per annum.

This in-house completed strategic solution resulted in ensuring continuous production from the station and thus avoiding flaring. The implemented pilot solution is highly effective in ensuring continuous production, optimizing energy consumption and can be replicated to other existing facilities in the company. This implementation will enhance the availability of facility with Standby equipment and also proved helpful in contributing under the pillar of Sustainability – Reduction in flaring/optimizing energy.

The characteristics and sustainable production of the high potential wells were evaluated and listed down. The effect of back pressure on the flow of the wells assessed. MPP operation at low throughput provided confidence to reduce the suction flow. Following the minimum flow requirement of MPP, potential of the wells to be taken on MPP bypass and mindset to reduce GHG emissions through any opportunity assisted to finalize the mode of remote field operation. Taking the advantage of production cushion, MPP was further utilized to divert more flow from future wells.

Due to high water cut and increase in suction temperature of MPP, it was required to curtail the production through certain wells to overcome temperature issue. High water flow envisaged the requirement of operating two pumps specially in summer when MPP suction temperature was rising up.

Diverting the high potential wells, avoided the start-up of 2nd pump hence reducing the extra power consumption of 1000kwh. Resulted in optimizing the energy from running MPP also.

In case of pump of any running pump tripping, suction pressure goes up due to connectivity of non smart wells with the suction header. MPP constitutes certain suction pressure permissive. In order to achieve suction pressure, it is envisaged to depressurize suction pressure to relief/close drain system which lead to flaring / GHG emissions.