Digital Wellsite Prognostic Health Monitoring

Transcription

1 Digital Wellsite Prognostic Health Monitoring

2 Digital Wellsite Prognostic Health Monitoring It has been suggested that asset digitization could cut operational costs by 10 15% and potentially boost production by 5% or more. Asset digitization can address operators need to deal with aging assets and declining production, water production issues, containment of operational costs, reduce manpower requirements on dangerous sites and remote areas, and counter the lack of experienced personnel. The overriding benefit of these intelligent technologies is that, they can enable the operator to identify risky operating conditions, identify changes in equipment performance, share specific information to subject matter experts and appropriate parties, and remotely monitor assets in real-time to determine maintenance requirements. At the organizational level, an intelligent digitized field can help maximize production system throughput, recover from and reduce unplanned events, and remove personnel from hazardous operations. We have built an entire performance optimization solution around condition based surveillance and active response mechanisms called Digital Wellsite* prognostic health monitoring. We have alert capability through wireless transmitters and communication with flow computers. Automation capability such as the safety shutdown valve (SSV) control system also exists within the Digital Wellsite monitoring offering to control critical equipment should an event occur. We go a step further to provide predictive analytics such as our proprietary choke erosion monitoring software. The Digital Wellsite prognostic health monitoring solution comprises integrated sensor systems that monitor wellhead, temperature, and flow inputs proprietary software for choke erosion monitoring flow computers and flowmeters wireless transmitters data analysis and reporting software SCADA host software. Tubing SY SSV Production choke TSH TSH OleumTech Temp Two contacts 4 levels One contact LAH ssv TT TSH Casing 3100 Indirect heater Liquid storage tanks FT Intermediate ZSO ZSO PSV Pressure FI PI TI FC FE TE Wellhead and production tree ZSC ZSC TI FC FE FIT LACT model 2100 flow computer TT TW HIPPS Sand separator HP/LP separator data manager SCADA host software A typical Digital Wellsite monitoring configuration for an unconventional field. TT model 3100 flow computer Data concentrator Wired and wireless comm. OleumTech DH2 2

3 Swab Sensor 2: production Kill LMV Sensor 5: Gate valve hydraulic actuator Sensor 3: Gate valve displacement UMV Sensor 4: Gate valve force Sensor 1: annulus (VR Plug) Actuated gate valve and sensors Sensors help operators to uncover unexpected issues in time to rectify the problem. Condition-based surveillance We are taking a dual approach to sensors, providing sensors to monitor both greenfields and brownfields. Condition surveillance based on real-time data is an integral part of the operational support we provide with our products and systems. These systems monitor and apprise the operator of critical equipment status critical valves, actuators, and chokes have the ability to communicate equipment health through condition-based surveillance. The operator can uncover unexpected issues in time to most efficiently rectify the problem. Use of condition-based surveillance can improve maintenance agility and responsiveness, increase operational availability, reduce life cycle total ownership costs, and minimize HSE risks. We employ stringent design criteria. For example, thorough testing of 20 parameters for the five critical integrated sensor packages that we recommend for greenfields assets includes repeatability, reliability, durability, mechanical and electrical complexity, and the ability to be maintained in the field. For greenfields, we offer a sensor package that includes: Sensor 1: annulus (VR plug) Sensor 2: production Sensor 3: gate valve displacement Sensor 4: gate valve force Sensor 5: gate valve hydraulic actuator The cost of maintaining a brownfield can be lowered by increasing operational efficiency through digitization of the field. We can leverage its expertise to provide a custom solution specific to each unique brownfield. Our standard sensors can be retrofitted to equipment in service to optimize your field. 3

4 Communication of alerts We offer a comprehensive line of transmitters for wirelessly monitoring various conditions, including liquid level,, flow, temperature, and triggering alarm. Our wireless transmitters are self-contained and battery-powered, eliminating the need for external power. Additionally, these devices are intrinsically safe for use in Class 1, Division 1 locations, while providing seamless integration with our devices and sensors. The new transmitter product series features a local LCD display, which enables configuring the device on site without cables; allowing instant readings without connecting to a PC. Automation By measuring equipment performance and then comparing to baseline data, it is possible to identify undesirable trends and inefficiencies. The * model 3100 flow computer has the ability to shut down operations should an event occur. In addition, the SSV control system delivers reliable safety and protection for wells and flowlines. Advantages of predictive analytics include: 1. Safety: Avoidance of catastrophic failure 2. Environment: Avoidance of fluid release into the environment 3. Efficiency: Ensuring equipment is in adequate condition 4. Cost Saving: Lower cost of maintenance vs. cost of purchasing new equipment 5. Time Saving: Lead time of equipment delivery 6. Maintenance: Ability to stock parts for planned shutdowns as needed 7. Production: Minimizing downtime arising from equipment issues series flow computers create and store data that supports the needs of various business segments within an organization. A SCADA host software facilitates this process by copying data from the field to the office and providing the tools to validate and apply the data. The SCADA host software is designed specifically for managing the real-time and historical data required in the oil and gas industry. Our automation solution integrates automation products from multiple manufacturers to help companies maintain their legacy investments without compromising compliance with accounting and measurement standards. Solutions include automated data collection, validation, editing, real-time analysis, reporting exports, and record management. Predictive analytics Predictive analytics goes beyond simply collecting data to a capability that offers the next level of intelligence, delivering information that can turn uncertainty into opportunity. Operators who are able to act on real-time insight possess a significant advantage. As the number of wells increases, the amount of real-time data streaming from wells and production equipment is becoming overwhelming. It has become increasingly harder to derive full value solely from the incoming data. Predictive analytics allows you to anticipate failures, plan and schedule maintenance in advance, eliminate emergencies and even catastrophes, plus optimize your assets. Applying analytic capabilities to critical production assets means you can reduce nonproductive time and increase profits. Timely decisions can be made from incoming data when augmented with Cameron experience/expertise and digital prediction capability. 4

5 Model 3100 Flow Computer The flow computers measure standard volume, mass, and energy flows of gases, saturated steam and many types of liquids with custody transfer precision utilizing ISO, API, AGA, and ASME standards. Amongst diverse applications s often measure gas, oil, and water flow from a two- or three-phase separator or compute the precise flow from an ultrasonic gas flow meter, all with a complete audit trail suitable for fiscal trade. The 3100, our most advanced flow computer, offers the advantage of two integral flow runs and the ability to coalesce up to 20 remote flow runs in a local network. It operates wireless or wired, supports gas chromatographs, and offers GERG-08 calculations for improved accuracy associated with many gas compositions. The computer has the ability to collect, apply and share up to 128 data points from other Modbus devices and can be accessed from the web browser of a laptop, tablet, or smart phone. With a 3100 flow computer, we include an all-in-one PC software tool for data assessment, exporting and reporting. The data assessment tool is a full-color graphical display and a spreadsheet view which identifies select operational anomalies. To support enterprise wide utilization data exports are offered in Excel, Flow-Cal or PGAS formats. For convenience user customized reports or graphical data images can be distributed by print, PDF or pasted into an model A Versatile, Scalable, Measurement Network. Within a multi-flow measurement facility the 3100 flow computer delivers integrity and cost savings 2200 model Fault tolerant wired or wireless communication couple 22 flow runs Auto-integration of devices reduces engineering and support costs by typically more than 50% Other Modbus devices Offered in association with OleumTech Corporation SCADA processing, engineering, operations, accounting, marketing 2000 model OleumTech wireless transmitter Web-browser interface, data-reporting software Facility wide automation by the ability to collect, apply and share up to 128 data points from other automation device Access from a web browser via laptop, tablet, or smart phones 5

6 Choke Erosion Monitoring Program The ability to assess degrees of erosion in plug and cage control chokes operating in high sand producing wells is required to meet operators need to proactively plan for equipment maintenance and avoid catastrophic choke failure. We recently developed and fielded the choke erosion monitoring program, a software system that adds the element of analytics to choke data capture. The program monitors the state of control choke deterioration from erosion in the field and reduces unplanned downtime. It allows the operator to make timely, proactive decisions. In a recent field trial, a major operator observed the benefits of the erosion monitoring program on their most prolific wells. The collected data also identified other problems such as restrictions within the operator s system and erratic function of the multiphase flowmeter. The choke erosion monitoring program uses a traffic light display in which choke status is intuitively communicated through the level of deviation between actual and calculated C v values categorized either as acceptable, warning, or high risk. The system is made up of position,, and flow sensors that route data through a distributed control system/master control station to generate a real-time curve and software analysis. Algorithms have been generated based on years of experience sizing chokes and utilizing ISAS75-02 equations. We reviewed field data from our large installed base of chokes and generated acceptable operating criteria and implemented these requirements within the algorithms. Cv Percent of travel, % In-field As-new, field calibrated Factory Valve condition monitoring Cameron algorithms Flow dynamics for plug and cage and external sleeve trim chokes 6

7 Digital Wellsite cameron.slb.com/digitalwellsite *Mark of Schlumberger Other company, product, and service names are the properties of their respective owners. Copyright 2016 Schlumberger. All rights reserved. SUR-