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Abstract Enhanced oil recovery technology become one of the key players in oil and gas applications targeting a high production value with a minimum cost. However, this necessitates the need for high reliable and efficient steam generators to recover the heavy oil. Thus, this paper followed a novel integrated approach to improve the availability of the OTSGs using both regression statistical analysis and failure-modes analysis. This was validated using actual data and the steam system availability has been compared before and after the trial. Furthermore, the second part of this study involved a sensitivity study at design and off-design conditions to identify the dominant factors with the highest impact on the reliability of steam system and its interaction with the hydrocarbons recovery. This can help to obtain the optimum operating point considering efficiency, cost, and CO2 emissions of OTSGs. The data show an average yearly availability of steam generators by about 74% with an average steam loss of about 673 ton/day and a potential of 218 m3/d of oil. This has caused approximately 24.4 MUSD as annual deferment cost. Finally, a new method has been also developed to assess the possibility of scaling formation in the steam generators and it has been also validated using actual pigging data. One of the main features of this approach is that it can be used to identify the optimum required cleaning frequency with less downtime and maintenance cost. Moreover, the upward trend of stack temperature data shows a degradation in the absorbed heat ratio by around 2.0% with an increase of about 6020 sm3/d in the fuel consumption. This also indicates the need for routine washing of the convection section finned and bare tubes. Environmentally, the high fuel rate leads to increase CO2 emission by 8164.8 ton per year. Additionally, the CO2 trend shows a sharp increase in the emission rate between 95% and 100% steam output by roughly 9.1% driven by a dramatic increase in the fuel consumption comparing with estimated additional hydrocarbons recovery revenue rate of around 6.9%.
Waleed Al Busaidi (Mon,) studied this question.