PETROLEUM SOCIETY

PAPER 2003-006

CANADIAN INSTITUTE OF MINING, METALLURGY & PETROLEUM

Application of Intelligent System (DES PCP) for Monitoring Progressing Cavity Pumps
A.J. Szladow, D. Mills, D. Yong
REDUCT & Lobbe Technologies
This paper is to be presented at the Petroleum Societys Canadian International Petroleum Conference 2003, Calgary, Alberta, Canada, June 10 12, 2003. Discussion of this paper is invited and may be presented at the meeting if filed in writing with the technical program chairman prior to the conclusion of the meeting. This paper and any discussion filed will be considered for publication in Petroleum Society journals. Publication rights are reserved. This is a pre-print and subject to correction.

ABSTRACT In March 2002 REDUCT & Lobbe completed a comprehensive field research project for the Saskatchewan Petroleum Technology Research Center (SPTRC). This research project addressed the potential application of intelligent systems for heavy oil production in Western Canada. The objectives of the tests were to: 1) assess the opportunities and identify application areas for intelligent systems; 2) develop and demonstrate a specialized, site-specific intelligent system; and 3) assess the performance and potential benefits of the implemented system. Six applications were identified as candidates for AI systems, and Progressing Cavity Pumps (PCPs) monitoring, diagnosis and control was selected for demonstration tests. The overall conclusions from the tests were that intelligent systems have the ability to: 1) diagnose well instabilities that a SCADA system alone cannot recognize; 2) notify operators about wells that

require closer scrutiny (review); 3) provide decision support with respect to recovery from different types of failures. These benefits are critical in terms of optimizing PCP operations and retaining and making available the knowledge of experienced staff. The value of the potential benefits of a PCP intelligent system was estimated at up to $ 4,000 per well per year, or several million dollars per year for a mid-size PCP operation. Given that the cost of the software represents only a fraction of SCADA infrastructure expenditures, the implemented intelligent system could significantly leverage the SCADA system in management and operations of PCP wells. INTRODUCTION Conventional control and automation helps prevent costly shutdowns, increases yield and quality, and results in more effective and efficient operation of the process equipment. However, automation of some production

aspects is often not easy because oil-producing operations exhibit complex interactions. To derive better performance and to supplement conventional control technologies with more advanced features, the oil industry has turned, therefore, to advanced IT technologies that can facilitate the management of information, knowledge and production decisions. The majority of intelligent systems in the petroleum sector have been applied for control and monitoring of crude upgrading processes (1). These applications improved plant operations through better control and scheduling of production, and by reducing work disruptions. The benefits accrued included reduced energy consumption, improved product recovery, reduced variation in throughput capacity, increased throughput, and improved plant optimization. The following references summarize selected applications of intelligent systems in oil production and exploration: Pumparound controls (2) Smart oil recovery (3) Scheduling/planning of production (4) UNIK-CPS (5) Slurry minder (6) AcidMan (7) Gas dehydration (8)

heavy-oil production and oil treatment operations; The demonstration of an AI system leading to improved productivity, equipment maintenance and safety.

The project was carried out in four phases: Phase 1: Based on consultation with the industry and technology scoping work, six potential intelligent systems applications were identified, namely: PCP Well Monitoring, Trouble Shooting PCP Wells, Well Optimization, Pump-off Control, Battery Facilities Optimization, and Field Trucking Scheduling. Phase II: Two intelligent system applications were studied. These included PCP well monitoring and optimization, and the use of surface measurements in support of the optimization and diagnosis of Progressing Cavity Pumps. The potential benefits and costs of the PCP optimization and diagnosis were evaluated and an intelligent system prototype for monitoring PCP wells (DES PCP) was developed. Phase III: The software prototype, DecisionExpert System for Progressing Cavity Pumps (DES PCP), was tested based on historical examples of PCP breakdowns provided by industry. Also, implementation issues of DES PCP, including training, were addressed. This formed the basis for more extensive field tests over a 6 month period. Phase IV: The field tests were implemented from October 2001 to March 2002. The objectives of the fi0eld tests were to: 1) develop a specialized, sitespecific knowledge base for PCP diagnosis; and 2) assess the performance and potential benefits of the system. Application Selection Based on discussions with heavy oil producers, six potential applications were identified: 1) Single Well Monitoring; 2) Trouble Shooting Process for PCP Wells; 3) Well Optimization; 4) Pump Off Control Process; 5) Battery Facilities Optimization; 6) Field Trucking

Project Rational and Implementation In order to take advantage of Artificial Intelligence technologies in Saskatchewans heavy oil industry, a project was undertaken to identify and demonstrate the potential for artificial intelligence in Saskatchewan oil fields. This project was conducted under a SPTRC program developed to assist the Saskatchewan petroleum industry in identifying opportunities for implementation of advanced technologies, and was cofunded by the Industry Group of CANMET, Natural Resources Canada plus Husky Energy and Petrovera. The overall objectives of this project were to assist Saskatchewan petroleum producers in: The identification of suitable advanced AIbased methods for improved optimization of

Scheduling. Each of the potential applications was assessed in terms of the following criteria: Degree of importance to the participating companies. Applicability to the oil industry as a whole. Technical feasibility of solving the problem using Artificial Intelligence methods including expert systems, intelligent agents, neural networks, data mining, etc. Technical requirements for demonstrating developed AI systems including key features/operations and availability of data, information, etc. Costs and benefits to be accrued by applying AI methods.

During the early analysis of PCP historical data it became apparent that torque is one of the key indicators of well behavior. Analysis of the relationship between torque and pump speed revealed two distinct operating states for PCP wells. The first one, referred here as Quasi Steady-State, occurs when the pump is operating within one power setting, the torque and speed vary inversely so that as torque increases, pump speed decrease and vice versa (Figure 1, Lines A and B). However, when the power on the pump is increased, both pump speed and torque will increase (Figure 1, changed from form Line A to B, here referred to as a transition state). The existence of these two distinct operating states makes the modeling of PCP behavior complex and difficult. The control model describing PCP well behavior needs, therefore, to differentiate between these two concurrently occurring states. In addition, it has to account for how the transition and quasi steady-state dependencies vary as the fluid properties, well design, and other factors change. Given that the only continuous (real-time) measurements available for most PCP wells were surface measurements (torque, pump speed, tank level, and tubing or casing pressure), the first objective of the project was to determine if and what kind of PCP diagnosis may be feasible using surface measurements and intelligent systems technologies. The approach taken was to start by reviewing the feasibility of monitoring PCP well surface measurements in order to alert the operator about any changes in SCADA data that would proactively diagnose an early development of the sand-off, and thus recommend actions such as flush-by. At the same time we had to consider that although well failures do not occur frequently, they can develop quickly with little warning and no corresponding evidence in operating data. Because of this complexity, REDUCT decided to implement data mining for analysis of well behavior patterns and an expert system, DecisionExpert System (DES, Figure 2) for on-line diagnoses using the mined patterns/rules. The objective of DES was to advise the

After assessing all six potential applications, and consulting with the industry, the work focused on monitoring and control of PCP operations using surface measurements. These applications were recommended because they have the greatest impact for Saskatchewans heavy oil industry. This paper summarizes the tests completed and results obtained. It discusses the key conclusions and recommendations based on the field tests. PCP WELLS DIAGNOSIS Progressing Cavity Pumps have been established as the first choice for pump equipment for production of heavy oil. They offer a number of benefits such as the capability to: 1) handle co-production of oil, sand, water and gas; 2) pump high viscosity fluids; 3) deliver high pumping efficiency with relatively simple installation and low capital cost. The key operational issues in the application of PCPs for heavy oil production are slugging sand, plugged perforation or pump intake, stator swelling due to dry pump and heat generation. All of these problems result in expensive and time consuming repair work. The objective of this project was, therefore, to address these issues through better monitoring and control of the pump.

operators when pump behavior became abnormal, or unsteady, as well as to explain possible causes of the problem. This was to be based solely on the operating data available from the SCADA system. As indicated, REDUCT approached this problem by identifying patterns in the operating data that signified potential pump problems such as a rapid sand-off caused by: Operating practices such as varying pump speed and torque level. Changes in casing pressure such as well loading or casing gas blowdown. Large changes in pump speed caused by changing fluid dynamics in the pump well cavity. Changes in fluid properties such as increased sand cuts (sand slaggs).

discusses some of PCP wells events, associated data patterns and DES performance. DES demonstrated an ability to recognize the relative importance and sequencing of different events (hierarchy of warnings) and it provided early warnings of potential well problems with a confidence factor of 70 to 80 percent (i.e., DES correctly identified well problems 7 or 8 times out of 10). However, in more complex situations, where changes of torque and casing pressure are more erratic (noisy), the accuracy of the system deteriorated to less than 70 percent. Figure 3 depicts a typical pattern of well breakdown incidents where spiking casing pressure precedes high torque due to sand-off, which consequently results in the wells break down. Both the casing pressure spike and increased torque were recognized as a unique sand-off signature by the data mining software used, DataLogic (9), and later identified in the SCADA real-time data by the DES system. In cases where wells were characterized by significant changes in torque over a period of several hours, DES was able to recognize these situations and alert the operators of the impending risks due to well instabilities (Figure 4). DES PCP also could qualify (explain) well instabilities in terms of dependencies between torque, pump speed, casing and tubing pressure. For example, Figure 5 shows the actions of the operator (reduction of pump speed) in response to high torque alarms from the SCADA system. For the same instabilities, DES PCP qualified that the alarms were significant only if tubing pressure were also high. Further investigation of the first group of alarms depicted in Figure 5 (oval black circle) showed that there were some changes in pump speed associated with high torque, but the tank volume was increasing in a regular manner. This suggested that the system was still in a quasi steady-state and the alarm was not serious. What the analysis pointed to was that adjustment of the pump speed was not necessary and that using only SCADA torque alarms may lead to frequent adjustment of pump operations that are detrimental to long-term well production.

The patterns derived were then implemented in DES in order to advise operators about current and potential future well problems. DES PERFORMANCE TESTS The first step in the DES pilot was to test and modify, as needed, the DES knowledge base. This required implementation of: 1) rules/patterns derived using data mining techniques and based on historical data; and 2) rules describing PCP operating conditions associated with plugged tubing, loss of communication, etc. The key challenge was compensating for the fact that data describing faulty well operating failures are rare and, therefore, the DES knowledge base was incomplete. Therefore, steps implemented during the field tests were to: Monitor DES PCP field performance. Analyze DES PCP logs weekly. Upgrade/modify the knowledge base.

Five poor performing PCP wells were originally monitored by DES PCP, but two of them were shut down shortly after the tests started. The text below

CONCLUSIONS AND RECOMMENDATIONS The first conclusion from the tests performed was that because SCADA data contain only a part of the knowledge related to PCP operations, more active participation of users in the development of the knowledge base for PCP diagnosis is essential. The approach taken by REDUCT was to start DES with the knowledge base developed from limited historical data, and later to improve the knowledge of the system by analysis of test logs. It was also planned to incorporate pumpers and production engineers knowledge in DES decision support capabilities. There were, however, difficulties in soliciting this knowledge. The second conclusion from the tests was that DES correctly identifies instabilities in PCP operations. By instabilities we mean not just an increase of torque, or a change of pump speed, casing or tubing pressure alone, but interactions between operating variables that often precede PCP pump failures such as high sand- off, pump malfunction or wear, plugged pump intake or tubing, stator swelling, or a worn or damaged pump. Therefore, given the above limitations in augmenting the knowledge base with the pumpers knowledge, the major benefit of DES during the tests was to alert operators about serious instabilities of the PCPs. The tests also indicated that building the knowledge base is very important if the benefits that DES offers are to be fully realized. If DES is to provide highly reliable recommendations in addition to diagnosing instabilities, it needs to capture the knowledge of the best operators and embed it in the knowledge base. Doing so would allow the knowledge to be made accessible to inexperienced operators and hence would improve their diagnostic decisions as well as their problem-solving actions. The management and retention of the experienced operators knowledge can be of significant benefit to the industry by preserving the best operators knowledge. As demonstrated, DES could support SCADA systems by providing additional information on the performance of wells and providing guidance to less experienced operators on how to identify and address PCP problems.

The key benefits to be accrued from the implementation of intelligent systems like DES are to: Monitor PCP wells in order to detect problems early and reduce breakdowns by early detection and prevention. Diagnose the root cause of problems, suggest solutions and guide operators through recovery by prioritizing corrective actions. Improve inexperienced operators performance by making the knowledge of experienced operators available to them.

Given the complexities of PCP operations, REDUCT recommended that DES be used as partner software to SCADA systems. Such integrated SCADA-DES systems would perform the following functions. The SCADA system can inform operators about breakdowns and high torque problems of the pump. As a result, operators can be directed to the well as soon as possible rather than waiting until the next scheduled inspection. DES can inform operators about instabilities of the pumps, often before high torque alarms are observed by the SCADA system. Considering that operators monitor hundreds of wells, such capabilities are very helpful in directing engineers/operators to inspect the SCADA data and to make decisions regarding the need for corrective actions. DES can inform operators about the best ways of addressing well problems. This must be based on the experience and knowledge of the best operators as proposed to be incorporated in DES PCP knowledge base.

SUMMARY DES software performed as designed and expected without any breakdowns, crashes or other software problems. The key roadblocks to success experienced during the field tests and DES installation and tests related not to the software, but to the need for support from field staff. The maintenance of the knowledge

base was also essential for proper operation of DES or any other intelligent system. Where both management and field staffs support was in place the tests were successful and informative. DES PCP knowledge base, as developed and edited during the tests, could correctly identify serious PCP well instabilities and bring them to the attention of the operators. It could explain the reason for the instability and provide a probability assessment of the need to perform a flush-by or change the wells operating setpoints. It did require, however, the incorporation of more site/field specific information and knowledge for the wells monitored. The tests conducted provided valuable information and experience as to the issues that have to be addressed in implementing intelligent systems at oil company operations. Although applications of intelligent systems have some common underlying issues across the oil and gas industry, production of heavy oil using PCPs has many unique characteristics and the tests provided valuable information for all involved as to the requirements and challenges in implementation of intelligent systems like DES PCP. The field test demonstrated that DES PCP software can monitor PCP wells reliably, and can identify anomalous events relating to torque; pump speed and casing pressure or tubing pressure patterns. In general, DES PCP is a less costly and more effective way to capture and use operational knowledge. Specific advantages of DES are: Separating diagnostic logic from application codes increases the ease and clarity of the development and maintenance of the knowledge base. DES operational rule components are reusable and can be easily maintained and edited through easy-to-understand text files. DES allows an engineer/operator to concentrate on diagnostic or optimization knowledge and not on the vagaries of a programming language, i.e., rules have English-like syntax instead of programming language syntax.

When changes are implemented to PCP systems configuration or operations, only the knowledge base has to be edited. This means that knowledge can be maintained and changed rapidly and inexpensively. The knowledge base can be decentralized, distributed or centralized leaving a flexible architecture and the freedom to choose different deployment strategies.

There are also differences between how a SCADA system uses alarms and the DES PCP system alerts the operator about possible instabilities of a well. DES will recognize the majority of SCADA alarms; however, because DES looks for instabilities defined by interactions of torque, pump speed and casing or tubing pressure, in some situations DES will recognize critical situations before the SCADA system could. Also, DES could identify some problems, which the SCADA system could not. Therefore, it could add capabilities to SCADA by providing additional monitoring and ranking the instabilities of different wells. ACKNOWLEDGEMENT The authors like to acknowledge the support and contributions made to this project by Mr. Roland Moberg of the Saskatchewan Petroleum Research Centre, and Mr. Richard Fry of Energy Mines and Resources, Canada. REFERENCES
1. REDUCT & Lobbe Technologies, Advances in the application of intelligent systems in heavy industry, CANMET, 1997. 2. Bullerdiek, E.A. et. al., Advanced controls pay out in 6 weeks at Texas refinery, Oil and Gas Journal, pp 48-52, June 1995. 3. Armando, F., et. al., Smart oil recovery, IEEE Spectrum, vol. 33, no. 7, pp. 48-51, 1996. 4. Numao, M, An integrated scheduling/planning environment for petrochemical production processes, Expert Systems with Applications, vol. 8, no.2, pp. 263273, April-June 1995.

5. Lee, J. K. et. al., UNIK-CPS an expert system for scheduling crude oil delivery to refineries, in Operational Expert systems in the Far East, Pargamon Press, pp.109121, 1991. 6. Kelly, E.B., et.al., SlurryMinder an expert system for design of cement slurry for the well casing, in Innovative Applications of Artificial Intelligence 4, The AAAI Press, pp. 193-215, 1991.

7. ACIDMAN an expert system to assist the acid treatment of damaged or clogged wells, Atlantic Richfield company, US. 8. Gas dehydration system for offshore platform wells, SPE Petroleum Computer Conference, Dallas, 1991, pp.167-179. 9. Adam Szladow, DataLogic/R: Mining the Knowledge in Databases, PC AI, p. 25, 1993.

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Figure 1. DEPENDENCY BETWEEN TORQUE AND PUMP SPEED (lines represent Quasi Steady-State for different pump settings)

Figure 2. DECISION EXPERT SYSTEM (DES)

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Figure 3. DES DIAGNOSIS OF WELL BREAKDOWN (arrow)

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Figure 4. DES DIAGNOSIS OF WELL INSTABILITY (dotted lines)

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Figure 5. DES DIAGNOSIS OF WELL INSTABILITY (no DES alerts)

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