Look Ahead: Optimization of Well Operations Using Real Time Digital Twin for Well Integrity

Abstract This study introduces a digital twin forecasting tool for well operations, combining a transient multiphase flow model and a structural model to predict safety factors (SF) for casing, tubing, equipment, and wellhead seal assembly. By utilizing historical and real-time data, the tool constructs dynamic envelopes for future operations (lookahead), optimizing parameters for well shut-in, restart, and bullheading when SFs are unsatisfactory. Real-time pressure and temperature profiles are calculated using a transient multiphase flow simulator, with updates every 20 minutes from gauge readings on the Wet X-mas tree and pressure gauges in tubing for model calibration. Safety factors are determined through a deterministic approach based on load conditions and API strength guidelines, with validation against commercial software confirming the tool's reliability. The tool's unique capability to simulate lookahead conditions, such as production casing and tubing evacuation, tubing leak and bullheading. Based on real-time well sensor data, the methodology ensures accurate diagnostics and well integrity management, even when standard limits are breached. Future implementations will include additional lookahead operations, facilitating the transition to dynamic range (maximum and minimum) of allowable wellhead operating pressure (AWOP) in tubing and A annulus and enhancing safety and cost efficiency in well operations. This paper highlights the tool's potential to provide practicing engineers with a precise and reliable asset integrity management solution, promoting the adoption of dynamic AWOP range.