Multivariate Optimization of Production Systems
Multivariate Optimization of Production Systems
of Production Systems
James A. Carroll III, * SPE, and Roland N. Horne, SPE, Stanford U.
Summary. Traditional analysis of Introduction not adopted by the petroleum industry until
production systems treats individual Mathematically, optimization involves find- the early 1950's. The bulk of the literature
ing the extreme values of a function. Given since then discusses linear programming
nodes one at a time, calculating a techniques applied to reservoir management
a function of several variables,
feasible, but not necessarily optimal, on a macrolevel. Aronofsky 2 provides a
Z=f(xt ,Xi,X;,· .. ,.t;:), .......... (1) detailed treatment of optimization methods
solution. Multivariate optimization
an optimization scheme will find the com- in petroleum engineering.
enables determination of the most
bination of these variables that produces an Aronofsky and Lee 3 developed a linear
profitable configuration, including all extreme value in the function, whether it is programming model to maximize profit by
variables simultaneously. The optimi- a minimum or a maximum value. Many ex- scheduling production from multiple single-
zation can also find the optimal re- amples of optimization exist. For instance, well reservoirs. Aronofsky and Williams 4
if a function gives an investor's expected extended that model to investigate the prob-
covery over a period of time, rather lems of scheduling production for a fixed
return on the basis of different investments,
than just at a single instant, as in tradi- numerical optimization of the function will drilling program and scheduling drilling for
tional methods. determine the mix of investments that will a fixed production schedule. Charnes and
yield the maximum expected return. This is Cooper 5 used linear programming to devel-
the basis of modem portfolio theory. If a op a reservoir model that minimized the cost
function gives the difference between a set of wells and facilities subject to a constant
of data and a model of the data, numerical production schedule. Attra et al. 6 devel-
optimization of the function will produce the oped a linear programming model to max-
best fit of the model to the data. This is the imize flow rate subject to several production
basis for nonlinear parameter estimation. constraints. All these models used linear
Similar examples can be given for network reservoir models that were based on mate-
analysis, queueing theory, decision analy- rial-balance considerations, and the reser-
sis, etc. voirs generally were assumed to be uniform
Historically, the petroleum industry has and single phase.
used optimization to allocate production Rowan and Warren 7 demonstrated how
through pipeline networks, to schedule to formulate the reservoir management prob-
transoceanic shipments of petroleum from lem in terms of optimal control theory.
supply sites to demand sites, to model Bohannon 8 used a mixed-integer linear
refinery throughput, and to determine the programming model to optimize a pipeline
best use of limited capital. Lasdon et al. 1 network. O'Dell et al. 9 developed a linear
point out that the production sector of the programming model to optimize production
petroleum industry has seen few successful scheduling from a multireservoir system.
applications of optimization methods. Huppler 10 developed a dynamic program-
The objective of this study is to demon- ming model to optimize well and facility de-
strate the effectiveness of multivariate op- sign, given the delivery schedule and using
timization techniques applied to the a material-balance reservoir model. Kuller
performance of hydrocarbon wells. The and Cummings 11 developed an economic
study consists of two primary phases: the linear programming model of production
development of a well model that determines and investment for petroleum reservoirs.
the economic benefit of a well and the op- Several investigators attempted to couple
timization of a well's economic benefit with numerical reservoir simulation with linear
multivariate optimization techniques. programming models. The idea is to use the
reservoir simulator to generate a linearized
Optimization Studies unit-response matrix to use with linear
In Petroleum Engineering programming models . Wattenbarger 12
Optimization methodologies are the focus of used this technique to develop a linear
operations research, a field that began in the programming model to schedule production
1940's. Operations-research concepts were from a gas storage reservoir. Rosenwald and
Green 13 used influence functions in a
• Now with Conoco Inc. mixed-integer linear programming model to
Copyright 1992 Society of Petroleum Engineers optimize well placement. Gajdica et al. 14
Upstream!
Downstream
Pressure Pressure
at ~ Differential o
If:
,,
Solution at
Node Solution
Node Root of,'
Function
used aquifer influence functions to model tion that causes the pressure differential at jective function that uses all the decision
performance of gas reservoirs with water in- the solution node to vanish. This root will variables as input and determines the objec-
flux. Murray and Edgar 15 used influence be the stabilized flow rate that the well will tive variable. Examples of different objec-
functions in a mixed-integer linear program- achieve for the given well conditions. The tive functions are numerous: to maximize
ming model to optimize well placement and confusion with production optimization the present value of the production stream,
production scheduling. Extending previous arises because people typically combine no- to maximize the net present value of the
work, 16,17 See and Home, 18 demonstrated dal analysis with univariate optimization. well, to maximize the cumulative recovery
how to refine the unit-response matrix with For example, by holding all other parame- on an equivalent barrel basis, to minimize
nonlinear regression techniques. Lang and ters constant, a single parameter (e.g., tub- the cumulative GOR, to minimize the cu-
Home 19 expanded this work to consider ing diameter) is varied to see where the mulative WOR, to minimize the total invest-
dynamic programming techniques. extreme value of the objective function ment per equivalent barrel produced, to
Asheim 20 studied petroleum develop- (e.g., maximum stabilized flow rate) will maximize the rate of return of the well, etc.
ments in the North Sea by coupling reservoir occur. Having found the extreme value in
simulation and optimization. McFarland et the objective function, the parameter of Model Development
aPl used multivariate optimization to op- interest is optimized. Several investiga-
The first step of this study was to develop
timize reservoir production scheduling. tors 22 -27 provide more information on no-
a model of well performance. The model is
Note that virtually all previous research dal analysis, also known as production
systems optimization. composed of several major components,
attempted to model reservoir performance briefly described here. Carro1l 28 gives
by linearizing the reservoir performance and To optimize a function of a single varia-
ble, simply plot the variable vs. the objec- more details on the various components.
entering these data into some variation of
linear programming. The main focus in tive criterion and take the extreme value.
Only a single performance curve is required. The Reservoir Component. To replicate
every case was to model the reservoir per- the reservoir dynamics and inflow perform-
formance. None of the models endeavored Complications arise if a function of several
variables is to be optimized, particularly if ance in the well model, this study adopted
to optimize the well performance. a reservoir model developed by Borthne. 29
the variables are interrelated. To optimize
a function of two variables, a performance This model was originally designed to pro-
Modeling Well Performance vide a simple but functional reservoir com-
With Multivariate Optimization curve ofthe first variable plotted vs. the ob-
jective criterion is required for every dis- ponent for inclusion in a larger model. The
In the current literature, the terms "nodal crete value of the second variable. The model provides an accurate representation
analysis" and "production optimization" single performance curve required to op- of constrained reservoir performance that re-
are sometimes used interchangeably. This timize one variable balloons into a family quires minimal computer processing.
terminology can be somewhat confusing un- of performance curves when two variables Borthne's model is a black-oil model that
til one understands the distinction: nodal are optimized. If three variables are op- performs a generalized material-balance cal-
analysis finds the root of a function that timized, a family of performance curves is culation in concert with an inflow perform-
yields the stabilized flow rate of a well (Fig. required for every discrete value of the third ance relationship that is based on pseudo-
1); production optimization finds the root of variable. This manner of optimization rapid- pressure. The reservoir model is constrained
the gradient of a function that yields the ly becomes intractable because it suffers by both pressure and flow rate. In addition
maximum or minimum value the function from the curse of dimensionality-the work to specifying a minimum flowing well pres-
can achieve. To restate this important dis- involved increases rapidly as additional di- sure, two flow rates must be specified: a
tinction, nodal analysis finds a solution by mensions are added. It is at this point, when minimum flow rate and a maximum target
locating the root of a function; optimization the practical limits to sequential univariate flow rate. The model attempts to satisfy the
finds the optimal solution by locating the optimization are encountered, that the vigor target flow rate without violating the mini-
root of the gradient of a function. and potency of multivariate optimization can mum flowing well pressure.
The mathematical basis for nodal analysis be fully appreciated.
is relatively straightforward. Several sub- With multivariate optimization tech- The Tubing Component. The next stage in
models are coupled to provide a working niques, there is no limit to the number of the model development was to design and
model of a well (Fig. 2). The procedure of decision variables that can be optimized con- develop a component to model the mul-
nodal analysis is to find the root of the func- currently. The only requirement is an ob- tiphase flow through the vertical flowstring.
Three multiphase flow correlations were the recommended flow map superimposed. ary. Because the well model was for itera-
selected for the model: the modified Note that the map appears to be continuous tive use, the surface-choke component had
Hagedorn and Brown 30 correlation, the everywhere except at the boundary between to be applicable to both critical and sub-
Orkiszewski 31 correlation, and the Aziz et bubble flow and slug flow. Fig. 5 shows the critical flow conditions. Unfortunately, al-
al. 32 correlation. All three correlations are Orkiszewski gradient map. Here, the bound- though good correlations are available for
used extensively in the petroleum industry. aries between all four flow regions are very single-phase flow across chokes, good cor-
The Hagedorn and Brown 30 correlation is distinct. relations for multiphase flow across chokes
one of the most empirical correlations avail- are rare. Most of the available correlations
able; the Aziz et al. 32 correlation has the The Choke Component. After the reser- are strictly for critical flow.
strongest theoretical basis. voir and flowstring components were com- Nodal analysis handles the surface-choke
Figs. 3 through 5 show gradient maps of pleted, work began on a component to model discontinuity by avoiding it. In nodal anal-
the three correlations. Fig 3 shows the gra- the surface choke. We encountered a sur- ysis, the separator pressure is specified and
dient surface generated by the modified prising degree of difficulty at this stage. A then related to the pressure downstream of
Hagedorn and Brown correlation. The tran- surface choke is a binary device that oper- the choke by a horizontal flow correlation.
sition from the original Hagedorn and ates in either critical or subcritical flow. Then the pressure drop across the choke is
Brown correlation, representing slug flow, Also recall that, in critical flow, the flow obtained with the assumption that the choke
to the Griffith and Wallis 33 correlation, rate through the choke is independent of the is always in critical flow and with an em-
representing bubble flow, is very distinct. downstream pressure. Thus, a discontinuity pirical correlation. Note that by specifying
Fig. 4 shows the Aziz et al. correlation with occurs at the critical/subcritical flow bound- the downstream pressure and then calculat-
ing the upstream pressure, this procedure
manages to determine both the upstream and
downstream pressures in critical flow. If the
upstream pressure is specified in an attempt
to determine the downstream pressure dur-
ing critical flow, the most that can be deter-
mined is the maximum downstream
pressure. This is because flow rate through
the choke is independent of downstream
0'9
pressure during critical flow.
We rejected the common assumption that
0" the choke is always in critical flow as an op-
L;: tion for this well model and tried to devise
'S- 03 3
a method to handle both critical and subcrit-
Q'
ical flow. The Sachdeva et al. 34 choke
0.<<1.
model is one of the few correlations that at-
tempts to model both critical and subcriti-
cal flow. With a few modifications to the
algorithm, we incorporated this model 34
into our well model. During critical flow
through the choke, the downstream pressure
was determined by assuming that the choke
was at the critical/subcritical boundary. This
assumption enabled the critical pressure ratio
to determine the downstream pressure.
The Sachdeva et al. 34 model was devel-
oped and tested with the other well-model
components. Fig. 6 shows the present-value
surface generated by the Sachdeva et al.
Fig. 3-Hagedorn and Brown 30 gradient map. model as a function of choke and tubing di-
ameters. Note that the criticallsubcritical duction profile for a given time step and a ent value of the revenue stream generated
flow boundary occurs at a choke diameter given project life. In all examples cited here, over the life of the project. The present value
of about 10 cm. Below this critical size, the we used a 6-month timestep and a IS-year of the revenue stream is obtained by dis-
surface is completely a function of the choke project life. counting the revenue stream over the life of
diameter. Above the critical choke diameter, the project back to the present. The discount-
the surface is completely a function of the Optimization of the ing scheme used in this model is relatively
tubing diameter. However, a physical con- Objective Function simple and easy to follow. The model ac-
straint is required: the choke diameter can- counts for both the company's cost of capi-
To perform optimization on the well model,
not be allowed to exceed the tubing
the production profile had to be transformed tal and the expected inflation rate. Both these
diameter. The line superimposed on the sur-
into an objective criterion. The objective parameters are assumed to be constant over
face in Fig. 6 represents this constraint.
Although a choke component that criterion used in this research was the pres- the life of the project.
modeled both critical and subcritical flows
was successfully incorporated into the well
model, the success was at great computa-
tional expense. In addition, several assump-
tions in the choke model (e.g., no mass
transfer occurring between phases) were
considered to be highly suspect. For these
reasons, we decided not to include a choke
component in the well model.
A company has two primary means of At the end of each time step , the well may include capital expenditure, tax pay-
securing capital from outside sources: the model gives the cumulative production that ments, royalty payments, labor cost, and
issuance of equity in the company and the occurred during a timestep. Specifically, the corporate overhead contribution. Because
assumption of debt. A company's cost of well model will yield a stream of n produc- the purpose of our research was to demon-
capital is typically determined as a weighted tion quantities, C 1 C2 , . .. ,Cn> where n is strate the effective application of optimiza-
average of the company's cost of debt and the number of timesteps occurring over the tion techniques and not to concoct an
cost of equity, expressed as life of the project. These production quan- elaborate economic model, we made pres-
tities are discounted back to the present by ent value the objective criterion. To use this
D E assuming constant production over the technique to design or analyze an actual well
C e =i D (1-TR ) - - + r E - - ,
D+E D+E timestep and discounting from the midpoint system, however, the objective criterion
of the timestep (Fig. 7). should be made to reflect the financial
................. (2)
For instance, if the timestep is 1 year, then ramifications as accurately as possible;
where iD = interest rate of debt, rE = return the cumulative production produced over the therefore, a criterion of net present value
on equity expected by shareholders, d= first year will be discounted as if it were sold should be used.
amount of long-term debt, E=amount of in one discrete quanitity at 6 months. Thus,
outstanding equity, and TR = corporate tax the present value of the production stream Results
rate. for n timesteps of length llt is
Typically, a company's executive man- Surface of the Well Model. Once the well
agement specifies the weighted-average cost
of capital to use in financial calculations.
v
P
= E\" CjPj
j=1 ((1+R)[(2j-I)/2]JlI
J, ... (4)
model was completed and the objective
criterion was decided upon, we generated
Knowing the cost of capital, C e , and the a surface map of the objective criterion as
inflation rate, i, we can express the discount where Pj is the real price of the production a function of two decision variables. Spe-
rate in real terms as at the j th timestep. cifically, the present value of the produc-
The present-value calculation determines tion stream was plotted as a function of the
(1+ Cd only the positive effects of the decision vari- separator pressure and the tubing diameter
R= -1. ............... (3) (Fig. 8). The surface appears to be a text-
(1+i) ables, namely the revenue stream. The con-
cept of present value is easy to conceptualize book example of an optimization surface:
Thus, the effects of both the cost of capital because it is simply the gross value of the smooth, elliptical contour lines bounding the
and inflation have been coupled into one dis- revenue stream. To change the objective extreme value (the bull's eye). Closer in-
count factor. Note that this discount factor, criterion from present value to net present spection of the surface, however, reveals a
the real discount factor R, may be used only value, the negative effects of the decision different story. As Fig. 9 shows, the view
with cash flows expressed in real terms. variables must be included. Negative effects at a closer level reveals a surface that is very
t=O t=T
at at at
Cl C2 C3 Cn-l Cn
1. 80
6.0
0'
IL
2- 5.0
~
~
" . . the well model
VJ
VJ
~
4.0 consists of a reservoir
IL
c
component, a
.8
~ 3.0 production-string
0
""
U1
component, and
2.0 a surface phase-
separation component."
1.0
5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.':
rough. The noisy data were masked by the shows, significant improvement was ical to the performance of both methods.
graphics software in Fig. 8 but are plainly achieved in the convergence to the maxi- With relatively large finite-difference inter-
visible in Fig. 9. mum value. Even when the starting points vals, the adverse effects of the noisy sur-
A better understanding of the surface is were not near the solution, the method al- face diminish. We conclude that finite dif-
obtained by examination of several uni- ways converged to the optimum solution. ferences one-tenth the size of the decision
dimensional profiles. Figs. 10 and 11 show Because analytic derivatives were unavail- variables produce good results.
two different profiles ofthe surface. Fig. 10 able, both the Newton-based methods deter- As an alternative to derivative-based
shows a constant separator pressure with mined the gradient and Hessian matrix with methods, we investigated the performance
varied tubing diameters. Clearly, the sur- finite-difference approximations. Because of the polytope method. The polytope al-
face is very rough and discontinuous along the surface of the function is noisy, obtain- gorithm is a direct-search method that uses
this dimension, and noise is present at the ing meaningful derivatives was difficult. The function comparisons instead of derivative
surface maximum. Fig. 11 is a profile of the size of the finite-difference interval was crit- information. Fig. 13 shows the performance
other dimension, obtained by holding the
tubing diameter constant and varying the
separator pressure. Fig. 11 shows that, in
this dimension, the surface is a very smooth
and continuous function. Thus, the surface
is noisy as a function of tubing diameter and
smooth as a function of separator pressure.
Conclusions
~ The authors hope to impress on the reader
< 2.029
-
o
~
that multivariate optimization techniques can
be successfully applied to optimize produc-
tion systems and that multivariate optimi-
i5: 2.028 zation is an enlightened alternative to
Z sequential univariate optimization.
Optimization of hydrocarbon production
systems has several useful features.
2.027 1. Optimization may be used to optimize
various objective criteria, including max-
imizing the present value of the production
2.026 stream, the net present value of the well, the
cumulative recovery on an equivalent bar-
rel basis, and the rate of return of the well
and minimizing the cumulative GOR, the
cumulative WOR, and the total investment
7.4 7.6 7.8 8.0 per equivalent barrel produced.
Tubing Diameter (em) 2. Optimization facilitates the analysis of
parameters that vary in time. This is best
described by considering an example. For
a lO-year time span, multivariate optimiza-
Fig. i0-Closeup of present value vs. tubing diameter at optimum. Separator pres- tion will determine the optimal tubing di-
sure kept constant at 2921.11 kPa.
ameter to use each year-simply add 10
decision variables, one for each tubing size
for each year. As another example, if only
three tubing changes are allowed over the
lO-year span, multivariate optimization will
determine when the changes should be made
and what size the tubing should be. Attempt-
ing this with sequential univariate optimi-
2.0
zation is ill-advised.
Use of multivariate optimization in lieu
of sequential univariate optimization has sig-
nificant advantages.
~ 1.9 1. Multivariate optimization is not limit-
<
0 ed by the number of decision variables. An
...... unlimited number of decision variables may
iI"7
....... be optimized simultaneously. Sequential
CI)
:I 1.8 univariate optimization is effectively limit-
C; ed to one or two decision variables and be-
>... comes intractable when three or more
=
~
variables are optimized, especially when the
variables are interrelated.
~
t:l-. 1.7 2. Multivariate optimization converges to
the optimal values extremely quickly, ap-
proaching quadratic convergence.
3. Multivariate optimization avoids the
1.6 human input required by sequential univar-
iate optimization.
This study investigated several different
multivariate optimization methods. The sig-
nificant findings are below.
2 345 6 7 1. The unmodified Newton's method is
Separator Pressure (MPa) not viable. This technique is highly sensi-
tive to the initial guess of the decision vari-
ables. Instead, Newton's method should be
used in conjunction with a line-search proce-
Fig. ii-Present value vs. separator pressure for constant tubing diameter of 7.55226 dure and a modification to ensure a direc-
cm. tion of descent.
788 July 1992 • JPT
2. For noisy functions, the polytope al-
gorithm provides an effective alternative to
7.0
derivative-based methods.
3. For noisy functions, the finite-differ-
ence approximations are greatly affected by 6.0
the size of the finite-difference interval. We
found a finite-difference interval of one- 0'
(L
~
:J
Nomenclature '"'"
Q) 4.0
Cc = cost of capital, fraction G:
Ci = production quantities .sE' 3.0
D = long-term debt, dollars 0
"-
E = outstanding equity Q)
(f)
f = function 2.0
i = inflation rate, fraction
iD = interest rate of debt, fraction
1.0
j = timestep
n = number of timesteps 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0