Shifting Field Operation Regimen from a Reactive to Proactive Approach through Digital Twins and Flow Assurance Workflows

Abstract The oil and gas industry confronts formidable challenges in optimizing production and ensuring the secure and efficient transportation of hydrocarbons while minimizing production downtime and intervention costs. These challenges are particularly dramatic in offshore and subsea environments, where harsh environmental conditions intensify flow assurance issues. The lack of instrumentation and the potential malfunctioning of existing instruments in severe conditions contribute to operational uncertainties. In response, this paper presents a comprehensive approach employing digital twins and transient flow simulators to address these challenges and enhance operational excellence. The focal point of this study is dynamic production surveillance and management that leverages digital twins and predictive workflows to predict and optimize the production efficiently. At the core of this approach is the online flow assurance (OFA) solution, centered around digital twin that is powered by robust dynamic multiphase flow simulators together with live production data to predict the real-time multiphase flow behavior of the wells and pipeline network. The application accurately computes and reports production data, even those not directly available from the field. The innovative way in the digital twin concept is to create multiple instances of this same core to allow it to run for various operational scenarios, in different timescale, all at the same time. This web-based solution allows users to gain flow assurance and operational insights from any location and at any time. Integration with reservoir and process systems ensures the holistic use of its potential. This integration extends beyond complementing production or reservoir systems to enhancing the complete digital oil field system. Furthermore, the results produced by the OFA serve as essential inputs into the process simulator, amplifying overall process efficiency, operator training, and reducing operational risks. The study underscores the industry's ongoing shift towards digitalization, citing McKinsey & Co.'s report that effective digital technology use could lead to significant reductions in capital expenditures and operating costs across upstream and downstream operations (Martinotti & Jim Nolten, 2014). This paper discusses the integration of digital twins into the flow assurance framework, highlighting their role in providing a comprehensive understanding of the production system. The digital twin's ability to simulate and predict the behavior of the physical system allows for proactive decision-making, ensuring safety, reliability, and economic viability in oil and gas production. In summary, as industry navigates the complexities of subsea environments and endeavors to meet carbon-neutral aspirations, integrating digital twin technology into flow assurance strategies emerges as a pivotal solution. This paper unravels the potential of digital twins in revolutionizing flow assurance practices, offering a paradigm shift from reactive to proactive operational management in the oil and gas sector.