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Comparison of Flow Control Automation on Gas Lift Wells: South American Facility Case Study

This study compares conventional and automated gas lift well control methods at a production facility in South America. The evaluation includes the use of electric-actuated choke valves, orifice plate flow measurement, and flow computers to optimize production. The advantages and disadvantages of each system, including StarPac integrated control, are analyzed based on system characteristics, installation, response speed, and gas reduction potential. The results of using StarPac system show improved production rates, reduced gas usage, and quicker system payback, with emphasis on response speed and stability at varying flow rates.

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Comparison of Flow Control Automation on Gas Lift Wells: South American Facility Case Study

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  1. Automating Flow Control on Gas Lift Wells Comparison of Alternative Methods

  2. South American Production Facility

  3. Conventional Automation • Electric Actuated Choke Valve • Orifice Plate Flow Measurement • Flow Computer

  4. Conventional System Schematic

  5. Flow Meter

  6. Well Optimization Curve

  7. System Problems • At lower injection rates (below 2.5 MMSCFD) the well produced intermittent flow

  8. Production Data with Conventional Automated System

  9. Advantages Simple Installation Uses Existing Hardware Inexpensive No Gas Emitted Operates at Last Set Point on Loss of Power Disadvantages Requires Piping Modifications Slow Actuator Speed of Response Deviations from Set Point Actuator Moves in Discrete Increments (2% typical) Very Small Movements Not Possible Conventional System Characteristics

  10. StarPac Integrated Control System

  11. Installation Schematic

  12. Fail in Place Lockup SystemActivates on loss of power or gas supply pressure

  13. System Communication Schematic

  14. Connecting StarPac to Bristol Babcock RTU

  15. RTU to Radio Connection

  16. Operator Interface

  17. StarPac System Installation

  18. Advantages Simple Installation No Piping Modifications No Deviation from Set Point Fast Speed of Response PID loop runs 16 times/sec Actuator can move in small increments (.1% typical) Simple System Integration Operates at Last Set Point on Loss of Power Disadvantages Requires Regulated Gas for Supply Gas Emitted StarPac Characteristics

  19. Production with StarPac

  20. Production Comparison(based on $25/bbl)

  21. Production Comparison

  22. Results • Crude Production Increase = 4.3% • Gas Usage Reduction = 3.3% • System Payback = 12 days • Potential Gas Reduction = 24% • (Change avg. rate from 2.9 to 2.2)

  23. Why the Improvement? • Speed of Response & Repeatability • StarPac holds closer to flow set point when system instabilities occur • Changing gas supply pressure • Changing flow line or tubing pressure • Stability becomes more critical as flow rate decreases • System is more likely to get upset/unstable at minimal flow rates • Smaller deviations can cause instability

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