Digital Wellsite
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 pressure, temperature,
and flow inputs
■ proprietary software for choke erosion monitoring ■ flow computers and flowmeters
■ wireless transmitters
■ data analysis and reporting software ■ SCADA host software.
Digital Wellsite Prognostic Health Monitoring
Liquid storage tanks Indirect heater LACT HP/LP separator Sand separator HIPPS
Scanner data manager SCADA host software
Scanner model 3100 flow computer
•Data concentrator
•Wired and wireless comm.
•OleumTech DH2 Scanner 3100 OleumTech •Temp •Two contacts •4 levels •One contact Wellhead and production tree Intermediate pressure Tubing pressure Casing pressure Production choke ssv Pressure Scanner model 2100 flow computer TT FI FT PT PT PT PT SY PI TI LAH TSH ZSO ZSC ZSO ZSC LSH TSH PSV PSHL PSHL PSHL PT PT PT SSV TT LSH LSH TSH PT TT PSHL TW TI LSH FE FC FE FIT FC TE
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
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■ Sensor 1: annulus pressure (VR plug) ■
■ Sensor 2: production pressure ■
■ Sensor 3: gate valve displacement ■
■ Sensor 4: gate valve force ■
■ Sensor 5: gate valve hydraulic actuator pressure
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.
Actuated gate valve and sensors
Sensors help operators to uncover unexpected issues in time to rectify the problem.
Sensor 5:
Gate valve hydraulic actuator pressure Sensor 1: annulus pressure (VR Plug) Sensor 2: production pressure Swab Kill UMV LMV Sensor 3: Gate valve displacement Sensor 4:
Communication of alerts
We offer a comprehensive line of transmitters for wirelessly monitoring various conditions, including liquid level, pressure, 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 Scanner* 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. Scanner 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.
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
shut-downs as needed
7. Production: Minimizing downtime arising from equipment issues
A Versatile,
Scalable,
Measurement
Network.
The Scanner 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
Scanners 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 Scanner 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 Scanner 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 areScanner Model 3100 Flow Computer
Within a multi-flow measurement facility the Scanner 3100 flow computer delivers integrity and cost savings
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■ Fault tolerant wired or wireless
communication couple 22 flow runs
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■ Auto-integration of devices reduces
engineering and support costs by typically more than 50%
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■ Facility wide automation by the
ability to collect, apply and share up to 128 data points from other automation device
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■ Access from a web browser via laptop,
tablet, or smart phones Scanner 2200 model Scanner 2100 model SCADA processing, engineering, operations, accounting, marketing
† Offered in association with OleumTech Corporation
Web-browser interface, data-reporting software Scanner 2000 model OleumTech† wireless transmitter Other Modbus devices
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 Cv values categorized either as acceptable,
warning, or high risk. The system is made up of position, pressure, 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.
Choke Erosion Monitoring Program
Flow dynamics for plug and cage and external sleeve trim chokes Valve condition monitoring
In-field As-new, field calibrated Factory
Cv Percent of travel, % 0 20 40 60 80 100 100 80 60 40 20 0 Cameron algorithms
