Production Optimization: Unlock More Production | Deliver Cost Efficiency | Maximize Asset Value

PetroOptima helps operators unlock greater value from existing assets by improving production efficiency, optimizing well performance, and extending asset life through integrated production surveillance, targeted well intervention, and practical engineering solutions.

ESP Well Flowline Cost & Schedule Optimization

Summary
Successful oil & gas operations require more than simply completing a project safely—they require timely execution, accelerated production, cost efficiency, and uncompromised safety and asset integrity. This case demonstrates how an engineering-driven approach to flowline construction enabled earlier production while delivering significant cost savings without compromising safety standards or asset integrity.

Challenge

An ESP well was required to be brought online five days earlier than originally planned, creating the need to accelerate flowline construction while maintaining the required safety standards and protecting asset integrity.

Solution

The flowline construction approach was reviewed and optimized by evaluating practical engineering alternatives and utilizing available field resources to accelerate execution. The selected approach maintained the required safety, quality, and asset-integrity standards while avoiding unnecessary expenditure.

Result

  • $92,000 in cost savings
  • Supported bringing the well online five days earlier
  • Maintained required safety standards
  • Maintained asset integrity
  • Demonstrated that schedule acceleration and cost optimization can be achieved without compromising operational standards

Flowline Corrosion & Well Uptime Optimization

Summary
Maintaining reliable production requires controlling recurring integrity issues that can cause unplanned shutdowns, production losses, and unnecessary operating costs. This case demonstrates how addressing severe flowline corrosion improved well uptime, operational reliability, and cost efficiency, while maintaining safe production with no further flowline failures.

Challenge

The well was experiencing frequent production interruptions due to holes developing in the flowline, requiring the well to be shut in while repairs were carried out before returning it to production. Despite continuous corrosion inhibitor injection, the severe corrosion rate resulted in recurring flowline failures and reduced well uptime.

Solution

The severely corroded carbon-steel flowline section between the wellhead and manifold was addressed using GRE-lined tubing (TBG) as a more corrosion-resistant flowline solution, providing improved resistance to the prevailing corrosive conditions and enhancing the reliability of the production path.

Result

  • Improved well uptime by eliminating recurring flowline failures.
  • Achieved $25,000 in cost savings.
  • The well is operating safely and reliably with no further flowline holes.
  • Reduced recurring production interruptions and associated maintenance requirements.

Accelerating Production Through Engineering Solutions

Summary
In oil & gas operations, the ability to accelerate production when field conditions change can have a significant impact on overall company performance. This case demonstrates how proactive engineering and close coordination enabled a high-rate ESP well to be brought online 10 days ahead of schedule, adding significant incremental production during a period of unexpected production decline—all while maintaining the required safety standards and asset integrity.

Challenge

A high-rate well with an expected production of 5,000 BOPD was originally scheduled to come online according to the Projects team’s flowline delivery schedule. However, the company experienced a sudden production decline following downhole issues that caused several ESP wells to go offline, creating an urgent need to accelerate the startup of alternative production.

Solution

Engineering solutions were developed to accelerate the flowline readiness and bring the high-rate well online ahead of the original schedule, while ensuring that the required technical, operational, safety, and asset-integrity standards were maintained.

Result

  • The well was successfully brought online 10 days ahead of schedule.
  • Delivered approximately 5,000 BOPD during the accelerated production period.
  • Added approximately 50,000 barrels of incremental production to company output during those 10 days.
  • Helped mitigate the impact of unexpected ESP-related production losses.
  • Achieved the accelerated production without compromising safety standards or asset integrity.

SRP Well Flow Assurance & Production Uptime Optimization

Summary
Maintaining stable production from high-PPT oil wells requires effective management of flow assurance challenges and sustained production uptime. This case demonstrates how an engineering solution addressed recurring high flowline pressure, significantly improved well uptime, and recovered otherwise lost production while maintaining the required safety standards and asset integrity.

Challenge

A group of SRP wells producing approximately 3,000 BOPD in total and handling high-PPT oil were experiencing frequent production downtime due to elevated flowline pressure. Despite continuous PPD chemical injection, the wells were going down almost every day for at least 12 hours, even under the best operating conditions, resulting in significant production losses and reduced well uptime.

Solution

An engineering solution was developed to address the underlying high-flowline-pressure issue and restore stable flow conditions. The solution was implemented while maintaining the required operational controls and ensuring that safety standards and asset integrity were not compromised.

Result

  • Significantly increased well uptime.
  • Recovered approximately 1,500 BOPD of production for the company.
  • Eliminated the recurring production interruptions associated with the high flowline pressure.
  • Improved the reliability and continuity of production.
  • Achieved the production improvement without compromising safety standards or asset integrity.

EPF Asset Optimization & Cost Reduction

Summary
Optimizing existing company assets can deliver significant and sustainable cost savings without compromising production performance or operational standards. This case demonstrates how an engineering-driven approach enabled a rental EPF handling 2,000 BFPD gross production to be replaced with a solution based on available company assets, generating substantial recurring savings while maintaining safe and efficient production.

Challenge

The operation was relying on a rental Early Production Facility (EPF) handling approximately:

  • Gross production: 2,000 BFPD
  • Water cut: 52%
  • Oil production: 960 BOPD
  • Gas production: 1.8 MMSCFD

The rental arrangement represented a significant recurring operating cost, despite the availability of suitable company-owned assets.

Solution

An engineering and operational assessment was conducted to utilize available company assets as an alternative EPF solution. The solution was implemented with careful consideration of production requirements, facility performance, operational reliability, safety, asset integrity, and long-term production sustainability.

Result

  • Achieved $53,000/month in recurring cost savings.
  • Optimized the utilization of existing company assets.
  • Maintained production efficiency and sustainability.
  • Maintained the required safety standards and asset integrity.
  • Reduced dependence on the rental EPF while continuing to handle approximately 2,000 BFPD gross production.

ESP Plugging Diagnosis & Rigless Well Recovery

Summary
Partial ESP plugging can significantly restrict well performance and contribute to substantial production losses. This case demonstrates how a structured diagnostic and rigless intervention approach was used to identify the plugging mechanism, restore ESP performance, and progressively return affected wells to their designed production rates without requiring a rig intervention.

Challenge

Several ESP wells were experiencing partial plugging, resulting in a considerable decline in company production. The plugging mechanism varied between wells and required proper diagnosis before selecting an effective treatment approach.

Solution

Each affected ESP well was investigated, and fluid analysis was conducted to identify the type and nature of the plugging and determine the appropriate method for removing it.

Based on the analysis, a rigless ESP backwash operation was performed for each well using coiled tubing and a fluid pump. Following each successful backwash operation, the wells were progressively returned to production one by one, with operating conditions restored in line with the respective ESP pump design.

Result

  • Successfully addressed partial ESP plugging across the affected wells.
  • Restored the wells back online progressively following the backwash operations.
  • Returned the wells to their normal production rates according to their respective ESP pump designs.
  • Utilized a rigless intervention approach, avoiding the need for a conventional rig operation.
  • Recovered production while maintaining the required operational and asset-integrity standards.