Ten + One Tips for Oil and Gas Production Foreman and Lease Operators

1. Install Surface Casing and Casing Blowdown Manifolds

During my time as a lease operator, I encountered a few frustrating situations with maladaptively minimal construction methods that provided major impediments to day-to-day operations and mechanical failure intervention. One example I recall well was when the casing wing valve grease Zerk of a gas lift well broke and began to release gas. Unfortunately, the well's plumbing was kept to a minimum to save costs on fittings, making the blowdown process challenging. Seeking assistance from my foreman, I was advised to perform the blowdown in any way possible and contact a wellhead valve service for valve maintenance. It took me five hours to safely blow down the casing pressure from 900 psi to zero, using a needle valve that couldn't be removed to access the 1/4" port because the casing valve was leaking by too! Adding to the frustration, the wellhead service crew arrived three hours after my call, wasting two hours of charged time to wait.

Another safety concern arose regarding surface casings in the same field. Whenever pressure built up in the surface casings, we were required to blow them down and document the type of fluid expelled. However, the blowdown process involved an unsafe setup, with the line simply venting into the air without a ball valve, but only collar with a bushing and a pressure gauge. This meant that we had to crawl into the 20'-30' deep well cellar to close and open the surface casing wing valves and bleed the pressure off by backing off the threads of the gauge, which posed significant risks when working alone.

Years later, as a production foreman, I had the opportunity to address similarly ineffective and costly measures, prioritizing safety and efficiency centric creativity and long term frugality by implementing a few additional fittings.

For casings, it is advisable to install a jumper between the casing and tubing using 1" tubing. Ensure that 1" ball valves are installed both at the casing and tubing outlets. It is crucial to position the 1" line upstream of the check valve in the production flowline for a specific reason that will be explained in the next step. Finally, include a tee with a ball valve to allow future access for hot oiling. The ball valve on the casing side can be easily closed to facilitate hot oil treatment through the tubing. This provides a place to blow the casing down into the tubing quickly if well work or wing valve work is scheduled that day, selling the gas instead of venting it to atmosphere. The tee giving you access to flow into either the tubing or casing gives you the option to hotoil, conduct mechanical integrity tests, shoot fluid levels, or even use a pressure washer to address chemical gumming up the well tree.

When dealing with surface casings, always use fittings rated for just higher than the maximum expected pressure in the case of a surface casing leak. Use a 2" line out of your surface casing wing valve that extends about 3" above ground level then install a ball valve on top. From that ball valve, connect a 2"x1" swage followed by a tee positioned horizontally. On the upper side of the tee, attach a 1"x1/2" bushing, a needle valve, and a gauge. On the side port of the tee, connect a short nipple and a 1" ball valve. Utilize 90° elbows and a nipple to guide the line coming out of the 1" ball valve towards the top of the ground or cellar grate, and then run a 1" line across the gap between the well tree and the edge of the cellar. Use a 45° elbow, a 24" nipple, and a downward-facing 90° elbow, placing a small chemical containment below the 90° elbow opening. To secure the line, add dry cement bags on top of the line or U-bolts clamped around the grate for weight. Depending on local laws or company policies, you may need to install a plug at the end of the line. Remember to have a vacuum truck pull down the containments after each blowdown, if necessary.

2. Meter Bypasses

Across the United States, many wells have impressive downhole pressures and in West Texas wells make thousands of barrels of fluid a day, reflected in their ambitious tubing and casing sizes. However, these wells posed a challenge when it came to unloading, being thousands of feet deep. Some wells, if they became loaded, would either push the flowline's pressure safety limits to unload or take an extended period of time, ranging from two days to a week, to properly unload. This situation created significant contention for meter technicians who needed to request well shut-ins for vessel meter calibration, as it practically guaranteed that the well would become loaded and expensively cease production.

The question arose: Why did we have to shut down and halt production for calibration? The decision was made to exclude a 20-foot length of 3" bypass line due to its perceived high cost, to instead subject the wells to weeks of unnecessary downtime each year, despite their substantial daily revenue generation.

To address this issue, it is highly recommended to install bypasses for each gas, oil, and water meter, particularly when a well is newly established. While this incurs an additional initial expense, it proves to be a profitable redundancy in the medium to long term projections of the well's financial health.

3. Think In The 3 Dimensions That Pipe Can Flow

At a field I was a foreman over recently, we had a dead well with a frac wellhead on it with no connected flowlines. I often joked that our implementation of Bluetooth flowlines were not going so well. But how cool would Bluetooth flowlines be if they were real? No trip hazards, your tank battery bus lines would be leaner, and you would have a better lease road view of your production equipment. But sending production electronically through the air is not our only option to utilize the skies for moving production.

When it comes to building pipes, most supervisors focus on getting them underground or to the ground quickly. While this is usually the best and safest method, it's important to consider other options that go beyond the usual ground-level installations when tank batteries start experiencing significant congestion.

Let's imagine a situation where we have a sales line for a separator that needs to go from the containment area to the sales meter on the side of the site. If the vessel is at the back of the containment and the gas line needs to move forward to reach the sales meter, we have a couple of choices. One option is to bring the gas line back above the separator and carry it to or over the bus line, which includes supply gas, flowlines, oil, and water dump lines. Another option is to route the line straight ahead and over the walking area in front of the vessels and bring it down just outside the front of the containment. This way, the operator can move around the containment area freely without the risk of getting hurt or causing accidents.

However, it's crucial to make sure the installation is done properly to avoid the pipe tilting from side to side and falling over. As long as one side of the pipe is higher than the other, stability should not be a problem. On the other hand, if we create a flat line using 90° bends and extra pipe that looks like a suspended door frame with no bracing, eventually the pipe will topple over using the bottom bends as a hinge. Practice using Lego sets or straws to develop a structural understanding before you attempt constructing an elevated pipe lateral.

When making decisions about pipe installation, it's important to use good judgment and prioritize safety, practicality, and cost-effectiveness. By considering a three-dimensional perspective and carefully assessing the risks involved, you can find the best approach for your construction needs.

4. Consider the Benefits of Pneumatic Pumps

A significant portion of our work revolves around the transportation of various fluids from one location to another. We regularly handle fluids such as oil, saltwater, chemicals, and rainwater. One particular application that proves cost-effective is the utilization of pneumatic diaphragm pumps to inject glycol into the reboiler of a dehydration unit.

In a specific scenario, the height of the glycol tank did not allow for gravity feeding through the top, and using conventional glycol pumps took up to an hour to fill the tank. However, by installing a pneumatic diaphragm pump directly connected from the day tank to the reboiler of the dehydrator, we were able to reduce the fill time to a mere few minutes. Surprisingly, the rapid injection of a high volume of cool glycol did not lead to any significant temperature shock issues, nor did we encounter any new long-term operational problems by operating in this manner.

Pneumatic pumps offer versatility and can serve as effective containment sumps for tank batteries, buried sump tanks in compressor skids, and even recirculation pumps for the bottoms of tanks, directing the flow into a gun barrel.

By considering the use of pneumatic pumps in various applications, we can streamline operations, reduce labor costs, and achieve efficient fluid management within our systems.

5. Ensure Proper Suction and Makeup Hookups

In different operational scenarios, it is essential to find suitable solutions that effectively address the specific requirements and challenges at hand. While there may be differing opinions on this matter, the solution I implemented has consistently proven effective, irrespective of the pressure conditions.

In a field that I assumed responsibility for, I encountered a situation where each compressor suction line was fitted with suction and makeup control valves directly teed opposing each other just upstream of the suction intake of the compressor. The suction valve regulated the line at 30psi, while the makeup valve was set to pull from a high-pressure source at 1,000psi with a gas regulation target of 25psi. However, a significant issue arose when even a slight opening of the makeup valve caused a rush of high velocity gas, overwhelming the suction valve and resulting in the simultaneous closure of both valves once the suction bottle surged to 40 psi. This created a frustrating cycle of synchronized openings and closures between the makeup and suction valves. Ultimately, the makeup valve would gain the upper hand, remaining barely open, while the suction control valve would remain closed due to the makeup valve's higher pressure, effectively keeping the compressor running but pressuring up the field flowlines because the suction valve was closed. This was because the higher pressure rated valve spring reacts much more delayed than one that is rated for lower pressures, predisposing it to bully out it's lower pressure counterpart if teed into each other.

To rectify this problem, I implemented a solution wherein every compressor station had their makeup valves replaced by one makeup valve located significantly upstream of the suction control valves and just downstream of a check valve. This strategic adjustment ensured that the suction control valves maintained control over the gas intake by the compressor, while the makeup control valve had sufficient buffer distance to open and close at a pace that prevented overpressurization or starvation of the line, and it is cheaper to initially set up a compressor station this way than the other faulty method by reducing the number of expensive pressure regulator valves.

By properly configuring the makeup and suction hookups in this manner, we can optimize the control and operation of the compressor system, mitigating issues arising from pressure differentials and ensuring a more reliable and efficient process overall.

6. Protecting Tickets from the Elements: DIY Mailbox Solution

Here's a straightforward and easy method to keep your tickets safe and dry. With just a few materials and basic tools, you can construct a reliable mailbox yourself. Here's what you'll need: a plastic 5-gallon bucket, concrete bags, a 4-foot 4"x4" post, a standard domestic mailbox, screws, a small electric drill, and a shovel. Follow these steps:

1. Position the 4"x4" post straight and centered inside the plastic bucket.
2. Add the concrete powder to the bucket, ensuring it is evenly distributed.
3. Wet the concrete according to the instructions provided and allow it to set.
4. Once the concrete has hardened, securely attach the bottom of the mailbox to the top of the post using screws and a small electric drill.
5. Choose a suitable location for your mailbox and install it. It can be placed wherever it is most convenient for your needs.
6. Use a shovel to level or dig the spot down for secure placement.

I have personally used this mailbox design and found that it remains stable, even in strong winds, unless faced with extreme weather conditions like tornadoes. The durable plastic material of the bucket holds up well, unless excessive movement occurs. To prevent movement, consider burying the mailbox at a depth of just 6 inches. For optimal placement, consider situating the mailbox near the stairs leading up to your tanks or somewhere close enough to the battery that truck drivers will use it but accessible by pickup to grab them from your open window.

By implementing this DIY solution, you can safeguard your tickets from the elements, ensuring they remain protected and accessible when needed.

7. Avoid Shutting Down Wells for Vessel Maintenance on Multi-Well Pads: Upstream Vessel Manifolds

Many modern multi-well pads are intelligently designed with upstream crossover manifolds, allowing for periodic vessel maintenance without the need to shut down wells. In case your pad lacks an upstream manifold, constructing one is relatively straightforward. The optimal time to install such a manifold is during the fracking of a new well on the pad. At this time, an Authorization for Expenditure of the new well (AFE) can be utilized to install the manifold while the offset wells, typically the wells that occupy the neighboring vessels needing the upstream crossover manifold, are shut in during fracking operations.

To build an upstream crossover manifold, ensure that your inlet entering the separators is equipped with a valve for isolation purposes. Depending on company and local regulations, you may need two valves for double blocking, especially if confined space entry work is involved to periodically clean them out for severe sanding issues. Alternatively, you can use double hammer unions to provide the option to remove a section of pipe and replace it with plugs to properly isolate the vessel, saving the expense of an extra valve. Upstream of the main inlet valves, a nipple, a tee, and the flowlines from each of the respective wells leading back to the well pads will suffice. From the top or bottom of the tees, whichever is the safest and easiest direction, install another valve that connects to a common manifold line, which links all the other separators on the pad. If there is space for future separators on the pad, install a valve and a blind flange or plug facing the direction of the next anticipated expansion, demonstrating a frugal and modular approach. When it is time to isolate a vessel, choose another vessel to comingle it with, open both of the manifold valves to establish the new flow path, close the inlet valve(s) to the vessel scheduled for maintenance, and, if installed, blow down the vessel and take out the bridge spool and install your isolation plugs.

Investing in this relatively small expense will undoubtedly save significant costs in the future, particularly for wells that produce substantial amounts of sand, necessitating regular vessel cleanouts. Take note, Wolfcamp and Bone Springs operators!

By incorporating upstream vessel manifolds into multi-well pads, you can avoid well shutdowns for maintenance, enhance operational efficiency, and minimize downtime and expenses associated with vessel cleaning and upkeep.

8. Addressing Pigging Limitations: Installing Blowdowns in Valleys

In situations where you need to install a gas flowline across a valley without the availability of a pig launcher and receiver due to budget constraints or lack of foresight, there are measures you can take to mitigate the absence of pigging capabilities. Specifically, it is essential to incorporate a tee and a blowdown at the bottom of the valley during installation.

Furthermore, if there is a nearby tank, you have the option to run a 1" line to connect it, enabling the recovery of condensate that is blown out during blowdown operations. Another alternative is to install a quick connect access point to facilitate blowing down the line into a vacuum truck. It is important to ensure that the vacuum truck uses their high-pressure hoses and that the hatch on their trailer is opened before connecting to a high-pressure system.

By implementing a valley blowdown point, you can compensate for the lack of pigging infrastructure and still maintain low line pressure across the valley. This allows for easy maintenance and debris removal from the gas flowline, ensuring optimal performance and minimizing potential disruptions in the system.

9. Maintain a Printed Wellbore Diagram Folder for Enhanced Organization

Efficient organization plays a vital role in providing prompt and informed answers. In a perfect world, the perfect foreman possesses memorized knowledge of production rates, depths of tubings and casings of all wells, as well as the complete workover history for each well. However, even an almost perfect foreman may occasionally rely on the words, "Wait a minute, I have that with me... aha! Here is the answer to your question." To bolster your troubleshooting capabilities and deepen your down-hole competency during workovers, it is highly beneficial to possess physical printouts of the most recent wellbore diagrams, in addition to digital well files.

By maintaining a folder of printed wellbore diagrams, you become a formidable force in addressing production issues swiftly. This tangible resource provides you with easy access to critical information, enabling efficient troubleshooting and effective communication with your company man. Moreover, it facilitates the development of your expertise in down-hole operations, leading to increased proficiency and a higher level of confidence in your decision-making.

Investing the time and effort to organize and keep a comprehensive collection of printed wellbore diagrams demonstrates your commitment to excellence as a foreman. It empowers you to navigate challenges more effectively, enhances communication with upper management, and positions you as a reliable and knowledgeable professional in your field.

10. Maintain a Location-Specific Equipment Tag Information Folder for Enhanced Organization

In the pursuit of enhanced organization through paper records, I propose taking your game to the next level. Rather than leaving the fate of every moving part on location to chance and relying solely on the location knowledge of your lease operators, consider keeping a folder of papers dedicated to each location. These papers should contain a comprehensive list of equipment along with relevant model numbers, specifications, and sizes. This proactive approach ensures that you have crucial information readily available in person or over the phone when needed.

By maintaining a folder of location-specific equipment tag information, you gain valuable insights into the equipment at each site. For instance, if you observe a water dump leaking on SCADA, having the specific type of dump and the corresponding rebuild kit identified in advance allows you and your operator to procure the necessary supplies on the way to the location. Additionally, this organized approach enables you to plan ahead for quarterly maintenance activities, ensuring that you purchase the correct quantity and type of oil and filters required for servicing the equipment.

While SCADA can tell you that a problem has occurred, having reference access to detailed equipment information ahead of time offers a significant time advantage. It allows you to inform contractors promptly about specific equipment failures, such as a failed electric engine at what horsepower with corresponding fuse sizes, a malfunctioning tank sensor with its model number and brand, an unresponsive Total Flow system with its generation and IP address, or whatever contractor reliant equipment prone to failure may entail. This level of preparedness facilitates efficient troubleshooting, reduces downtime, and streamlines the coordination of repairs and maintenance activities.

By maintaining a folder of location-specific equipment tag information, you exhibit a proactive and organized approach to equipment management. It empowers you to make informed decisions, collaborate effectively with upper management and field personnel, and minimize disruptions, ultimately enhancing operational efficiency on your sites.

Plus 1. Optimize File Storage with a Hanging File Box

Here is your plus one tip as it ties tips nine and ten together. As your paperwork accumulates in your truck, it becomes essential to establish a convenient method for file storage. Two practical options to consider are a plastic tote-style banker's box or an open-top milk crate with a hanging file lip, both readily available at retailers such as Wal-Mart (not a sponsor). The choice between the two depends on the nature of your files and your specific requirements.

Currently, I store circle charts and need to preserve 12 months' worth of them, so for me an open-top milk crate is my current choice. Due to the larger size of circle charts, using a lid will just squish the tops of the files down and my preferences would not tolerate that. Therefore, an open-top milk crate offers easy access and ample room for storing and organizing blended sizes of documents. On the other hand, if you have a diverse range of files that do not require extra space, a closable bankers tote box can be a suitable solution. It offers the advantage of portability like the milk crate, allowing you to carry it in your truck or keep it in your office. Additionally, the tote box lid serves as a convenient surface for stacking small toolboxes, maximizing efficiency, saving space when not in use, and providing better protection for your documents.

By utilizing a hanging file box, you optimize your file storage system, ensuring that your documents are well-organized, easily accessible, and protected. This practical approach enables you to maintain a tidy workspace, efficiently manage your paperwork, and seamlessly transition between on-site and office tasks. I have additional files to store JSAs, MITs, notes, invoices, and more.

Conclusion

In conclusion, having little tricks and implementing smart solutions in your job can not only make your work easier but also contribute to saving money, which can stereotypically be seen as mutually exclusive endeavors. The examples discussed in this article highlight the importance of finding creative and cost-effective methods to address common challenges in multiple operational domains a foreman or lease operator may find themselves in. From improving blowdown processes to implementing bypasses for meters, taking a three-dimensional approach to pipe construction, utilizing pneumatic pumps, ensuring proper suction and makeup hookups, protecting tickets from the elements, avoiding well shutdowns for vessel maintenance, and addressing pigging limitations, these practical tips can lead to increased safety, efficiency, and financial savings.

By thinking outside the box and implementing these strategies, professionals can optimize their operations, reduce costs, and achieve better results in their respective fields. It's crucial to continuously seek innovative solutions and share knowledge to improve work practices. Thank you for taking the time to explore this article and considering these valuable insights.