Abstract In mature oil reservoirs with rising Gas-Oil Ratios (GOR), surplus associated gas poses a growing challenge for gas handling facilities, particularly when gas volumes exceed the design capacities for reinjection and export. This paper presents a case study from a high- GOR onshore field where daily gas production has outpaced system constraints, creating a bottleneck that threatens oil production sustainability. Leveraging a structured approach combining historical production analysis, simulation using Aspen HYSYS, and technoeconomic screening, five strategic options were evaluated to mitigate the surplus gas issue. Key solutions included new compressor trains, compressor reconfiguration, rental compressor units, existing MP compressor enhancements, and high-pressure letdown strategy. A multi-criteria decision matrix evaluated each option's feasibility, cost, schedule, risk, and production impact. The letdown of HP discharge to the export network emerged as the most viable short-term solution due to its low capital cost, minimal modifications, and short implementation timeline. A phased implementation strategy was recommended, combining immediate mitigation with a scalable long-term new compression facility solution for the upcoming project. The findings demonstrate how fit-for-purpose facility modifications can ensure production continuity, environmental compliance, and operational efficiency. The proposed methodology offers a practical and transferable model for brownfield facilities confronting similar gas-handling constraints in the context of energy transition and sustainable operations. This work also aligns with UAE's Net Zero 2050 commitments, emphasizing the role of efficient gas management in energy transition. In addition to production security, the mitigation of surplus gas avoids significant deferred oil revenues.
Haider et al. (Mon,) studied this question.
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