Fast-Track Rigless Gas Lift Retrofit Using Non-Hazardous Kinley Perforator Technology and Advanced Production Analytics: A Case Study from Offshore Oman

Abstract This paper presents a detailed case study of a fast-track, rigless gas lift retrofit using the non-hazardous Perforator system—a non-hazardous, globally deployable solution—integrated with advanced production analytics to optimize gas lift performance in offshore oil wells. The retrofit was implemented in response to Electrical Submersible Pump (ESP) failures in two offshore Oman wells, eliminating the need for traditional jack-up rigs and hazardous materials. This case study outlines a comprehensive five-day performance analysis phase, utilizing state-of-the-art simulation techniques to model well dynamics, gas lift injection parameters, and the optimal orifice valve sizes for both wells. The combination of simulation-based optimization with the rapid deployment of the non-hazardous Perforator system resulted in system mobilization within 14 days, restoring fluid production to stable rates of over 3,000 BPD for both Well 1 and Well 2, respectively. The study emphasizes the significant role of simulation-based production analytics, specifically in optimizing gas lift performance under challenging offshore conditions. By evaluating the well dynamics, including reservoir pressure, fluid properties, and wellbore geometry, the simulation model was able to predict the ideal gas lift injection rates, lift point depths, and orifice valve sizes, which are crucial for ensuring stable production post-ESP failure. A comprehensive analysis of the Inflow Performance Relationship (IPR) and Vertical Lift Performance (VLP) curves was conducted, guiding the gas lift system design to avoid issues like zero production or unstable production. Additionally, the integration of mobile compression technology for gas injection played a pivotal role in optimizing the system's efficiency by providing a flexible, on-demand source of compressed gas at the wellsite, without relying on the well's natural reservoir pressure or traditional ESP systems. This non-hazardous technology offered numerous economic and operational benefits, such as cost reduction through the elimination of rig mobilization and hazardous material handling, minimal downtime, and rapid deployment. Furthermore, the overall intervention cost was significantly reduced by bypassing traditional workover procedures, achieving a more efficient and effective production restoration. The findings of this case study demonstrate that advanced production analytics and the non-hazardous Perforator system can significantly enhance the restoration of production in offshore wells after ESP failures as temporary measure. Simulation results, including gas injection rates, injection pressures, and orifice valve sizing, closely aligned with actual operational outcomes, confirming the accuracy of the simulation models. The successful deployment of the gas lift retrofit not only restored production in the short term but also provided a scalable, cost-effective, and safe solution for future offshore interventions