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Developing and producing remote fields in a hilly terrain environment economically and effectively poses a great challenge to oil operators1. Transporting hydrocarbon fluids in these fields from the wells to the processing facilities and then to shipping terminals requires a detailed assessment of the flow hydraulics of the entire production network2–6. Moreover, a viable optimizing flow option needs to be considered and thoroughly evaluated prior to implementation for cost optimization, effectiveness and long-term impact on reservoir sweep7. Saudi Aramco has recently embarked on the development of several fields, including remote fields, such as Shaybah, which is located in a remote, hilly terrain desert area in the Empty Quarter of the Arabian Peninsula. The crude from Shaybah oil producing wells must travel a long distance from wellheads located in Sabkhah (flat terrain) to the Gas-Oil Separation Plant (GOSP), passing across high sand dunes rising up to 200 meters, and then through a 638 km cross- country pipeline to reach a final stabilization facility. Due to the aberrant topography of the area, high back pressure and changes of flow regime leading to huge slugs have been observed, affecting the overall performance of the wells and the operation of the processing facilities. Consequently, three innovative technologies: Horizontal Thrust Boring (HTB), Multiphase Pumps, and Drag Reducing Agents, have been evaluated and implemented to circumvent these problems. This paper will discuss in detail the realized benefits from these three technologies where results have shown a reduction in the flow and pipeline pressure drops of 230 psig and 300 psig from the application of HTB and drag reducing agents, respectively. Moreover, an overall production increase of about 50 thousand barrels of oil per day (MBOD) was realized from the utilization of HTB technology and an incremental increase of 250 MBOD in the capacity of the 638 km cross- country pipeline from the utilization of the drag reducing agent. On the other hand, the results of the trial test of the multiphase pump have indicated unsatisfactory performance due to the frequent maintenance needs and pump failures. |
