Abstract In mature oil fields, operational excellence is generally defined by the ability to sustain production, reduce intervention, and extract more value with existing inventory. This case study presents a mature exploratory well, completed in 1994, that faced intermittent flow losses despite a high production rate of 100 KLPD at 50% BS&W. With operational constraints including back- pressure sensitivity and open-hole completion, traditional approaches were ineffective or cost- prohibitive. Detailed well study revealed increased fluid column density caused by emulsion blockages and water segregation-symptoms of inadequate aeration in the vertical conduit. An initial manual bean-up strategy, though partially effective, demanded high human effort and lacked long-term sustainability. To overcome these challenges and drive performance continuity, a tailored, automated tubing purging system was implemented. Designed for autonomous operation, the system initiates bean-up cycles based on realtime flow conditions and reverts to normal operation once stabilized-eliminating manual intervention and enabling consistent, optimized lift performance. Key operational outcomes included better vertical lift performance in the well, increase in flowing tubing head pressure from 1718 kg/cm2 to 63-64 kg/cm2, 10% increase in daily crude oil production, 400% increase in daily natural gas production, zero additional CAPEX, utilizing minimal in-house inventory. This solution exemplifies how automation, data-driven intervention, and lean operational strategies can unlock value from aging wells. It enhances production efficiency, reduces downtime, and minimizes operational risk. It further demonstrates how scalable, field-proven solutions can optimize aging wells while aligning with longterm performance and sustainability goals in upstream operations. This paper presents a low-complexity, field-deployable automation approach that delivered measurable production gains in a mature, back-pressure-sensitive well- without requiring high-end digital infrastructure or capital investment. By showcasing how simple, scalable modifications can achieve autonomous operation and unlock significant value, the paper offers a replicable model for brownfield optimization. The solution has since been successfully implemented in three additional wells, further validating its adaptability and impact. It fills a critical gap between costly digital overhauls and traditional manual interventions-providing a realistic path to operational excellence for aging wells.
Nair et al. (Mon,) studied this question.