Real-Time Edge Intelligence and Remote Smart Completion for Oil and Gas Producers

Abstract Intelligent Completions integrate permanent downhole sensors and surface-controlled flow control valves (FCVs), empowering users to monitor and manage production without the need for manual interventions. However, optimizing production presents a significant challenge, as FCV actuation is typically performed manually on-site following instructions issued from a central location. This manual process, particularly on unmanned platforms, adds operational complexity and drives up operating costs. To enable fully compliant remotely-controlled Intelligent Completions with advanced edge-computation capabilities, interfaces must be carefully managed from design to execution to ensure a tailored solution. System Integration Testing (SIT) is crucial to ensure seamless execution, with a focus on improving the productivity interface panel for visualizing zonal rate measurements. Downhole equipment includes Permanent Downhole Gauges (PDG) and Flow Control Valves (FCV), while surface equipment can be situated on both manned and unmanned platforms. On unmanned platforms, a hydraulic pump system with engineered rate calculation logic is connected to the measurements of downhole flow control valves, while Surface Acquisition Units (SAUs) are linked to PDGs. Data from PDGs, DTS SAUs, and Hydraulic Control Systems (HCS) is accessible from the Central Processing Platform (CPP) via fiber-optic telecommunication between manned and unmanned platforms. A unified software solution has been developed to enable real-time data monitoring and control remotely from the CPP. The automated system has empowered end-users to confidently actuate FCVs on unmanned platforms with a simple click of a button located on the CPP. Processes that previously took months, from receiving information to making decisions and taking action, can now be completed in minutes. This facilitates production optimization by maximizing oil recovery and minimizing unwanted fluid production. Additionally, the automated system digitalizes on-site production rate computation equivalent to edge computing capabilities, facilitating direct monitoring of rate profiling from site acquisition capabilities. This includes rate computation algorithms to assist users in estimating zonal production rates and back allocation when the flow is combined from multiple zones through FCVs. The algorithm leverages real-time data acquired through PDGs, pressure drops across the FCV, FCV position, and reservoir properties. Subsequently, the estimated zonal flow rate is used to calculate the productivity index to address challenges such as uneven zonal production and high water or gas production. Intelligent Completions are selected for wells due to their potential for production optimization. However, operational complexity, cost, and resource challenges pose barriers to realizing their full potential. The integration of engineered real-time data monitoring and control has proven to streamline operations, reduce operating expenses, and minimize Health, Safety, and Environmental (HSE) risks. The adoption of these technologies has accelerated digital transformation initiatives, delivering enhanced well and resource productivity, efficiency, safety, and performance.