Publications

This paper provides an overview of recent efforts to address the "Hidden Loss" phenomenon caused by ambient temperature drops in one of the world’s largest steam flood operations in Indonesia. By applying a comprehensive end-to-end simulation framework, this study integrates surface and subsurface methodologies to tackle production inefficiencies and ensure operational optimization. The study addressed the "Hidden Loss" phenomenon through an integrated simulation framework conducted in four phases. Phase 1 analyzed production testing systems to identify discrepancies, aligning field data with actual production performance. Phase 2 developed a detailed network model to analyze production declines caused by temperature fluctuations using multiphase flow simulations. Phase 3 optimized artificial lift systems by examining backpressure impacts and improving sucker rod pump (SRP) and electrical submersible pump (ESP) configurations to stabilize subsurface flow. Phase 4 modeled gathering station performance under fluctuating temperatures, incorporating advanced interface control and separation technologies. Key findings revealed that ambient temperature drops significantly increased backpressure in both casing and tubing, correlate artificial lift performance, subsurface flow conditions, and surface flow assurance. A 10°C temperature drop caused condensation in the Casing Vapor Recovery (CVR) line, increasing backpressure led to a reduction in production by approximately 2% per 1 psig increase, or 10% for a 5 psig increase. For SRP systems, a 1 psig increase in tubing pressure led to a production decline of approximately 1.3%, while ESP systems experienced a lower decline of 0.5%. Practical interventions, including pump recalibration, casing pressure adjustments, and insulation measures, mitigated significant losses and enhanced resilience across all operational stages. This framework offers a scalable and adaptable solution to address temperature-related challenges in oil production fields, providing valuable insights for diverse operational environments.