Weatherford smart rod-lift program redefines production strategy for 200-well field

HOUSTON – Weatherford International announced its smart rod-lift solution, comprised of production optimization software, automation, and skilled engineers, boosted uptime 42 percent and increased production 37 percent for 40 reciprocating rod-lift wells in Sumatra, Indonesia. The solution redefined the production strategy for the field, and the operator is currently installing the smart rod-lift solutions on the remaining 160 wells.

The operator objectives were two-fold: First, optimize production in horizontal wells throughout a mature, 200-well, reciprocating-rod-lift asset. Second, reduce downtime caused by premature equipment wear; the pump failure rate was averaging 15 days of downtime.

“Weatherford helped our client to redefine production strategy for this 200-well field,” said Manoj Nimbalkar, Global Vice President, Production Automation and Software, Weatherford.  “Production optimization software helped the operator monitor and remotely respond to dynamic well conditions, resulting in a 42 percent increase in uptime by preventing rod failures. Add to that the installation of variable speed drives at each of the 200 wellsites in tandem with a rod-string controller to alleviate existing rod-string problems.”

Weatherford production-optimization experts assessed production in the asset along with its failure history. To combat ongoing fluid-pound issues, the team recommended upgrading the automation systems from fixed speed to variable speed. In addition, the Weatherford team recommended a WellPilot® variable-speed drive and rod-pump controller unit to regulate the pump speed throughout each stroke. As a final piece of the solution, the team recommended the Weatherford production optimization software platform to enable the operator to monitor real-time well performance.

“The smart rod-lift solution, featuring WellPilot variable speed drives and rod-string controllers, empowered this operator to optimize production by automatically adjusting lift parameters,” said Nimbalkar. “The Weatherford production optimization software platform enabled remote monitoring and management, which enabled a faster response to dynamic well conditions. The success in meeting and exceeding all operator objectives has placed Weatherford and its field-proven solutions at the top of the production plans for the field’s remaining 160 wells.”