— Baldor-Reliance® explosion proof motors Certified safe solutions
When you specify a Baldor-Reliance explosion proof motor, you can trust it’s the right solution for hazardous locations. We are committed to making reliable motors that are readily available and perform efficiently throughout their entire lifecycle, without ever compromising safety. Reliable. Flexible. Performance.
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High-quality build, elegant design: Multi-touch panels for Ex Zone 2 Robust: all CPX models have a high-quality, resistant aluminum housing. Intuitive: all CPX models offer the advantages of Beckhoff multi-touch technology.
Adaptable: all CPX models impress with a wide variety of mounting concepts.
www.beckhoff.us/process By systematically integrating advanced multi-touch technologies into the company‘s Control Panel and Panel PC display portfolio, Beckhoff has provided machine builders, manufacturers and other industries with forward-looking operator interface concepts for years. With the new CPX Control Panel series, applications in hazardous areas, classified Zone 2/22, can now also benefit. The high build quality and robust aluminum enclosures ensure reliability and durability in harsh and potentially explosive environmental conditions. These panels – along with the compact, intrinsically safe EtherCAT Terminals from the ELX series classified for Zone 0/20 – deliver significant advantages to process industry applications.
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6 • JUNE 2020 OIL&GAS ENGINEERING
A slim glimmer of optimism
O
n May 19, oil held near a two-month high of $35 a barrel as supply curbs tightened the market and demand rebounded in the world’s largest consuming countries, according to the Houston Chronicle. It would seem the situation may be stabilizing. Oil & gas companies involved in exploration and production spent an average of $89 billion a year on maintenance between 2015 and 2019. Companies, already facing huge debts, are slashing all but the most essential work, either because of lack of capital, fears of having contract workers on job sites or supply chain challenges, according to a recent piece in Energy World.
Fall and rise Exploration and production companies and oilfield service companies saw stock price declines ranging from 30% to 75% or more through the end of 2019. Over the same time, the S&P 500 was up over 60%, according to a post written by Michael J. Blankenship and J. Eric Johnson of Winston & Strawn LLP. Investors were prioritizing the need for capital discipline. What was needed was for oil & gas supply to tighten and demand to grow. It didn’t happen. “The one-two punch of the COVID-19 pandemic and the Saudi-Russian oil price war generated the exact opposite result — concurrently destroying global demand and oversupplying the markets, both at unprecedented levels,” said the piece, published by Lexology, the legal news feed. The International Energy Agency reports project that energy demand will fall 6% in 2020 – seven times the decline after the 2008 global financial crisis. The unprecedented decline is the equivalent of losing the entire energy demand of India, the world’s third largest energy consumer. Advanced economies are expected to see the biggest declines, with demand
KEVIN PARKER EDITOR
set to fall by 9% in the United States and by 11% in the European Union. The impact of the crisis on energy demand is heavily dependent on the duration and stringency of measures to curb the spread of the virus. For instance, the IEA found that each month of worldwide lockdown at the levels seen in early April reduces annual global energy demand by about 1.5%. The longer term According to the U.S. Energy Information Administration (EIA), as mitigation efforts to contain the pandemic continue to lead to rapid declines in petroleum consumption around the world, the production of liquid fuels globally has changed more slowly, leading to record increases in the amount of crude oil and other petroleum liquids placed into storage in recent months. In its May Short-Term Energy Outlook, the EIA expects global inventory builds will be largest in the first half of 2020. EIA estimates that inventory builds rose at a rate of 6.6 million barrels per day (b/d) in the first quarter and will increase by 11.5 million b/d in the second quarter because of widespread travel limitations and sharp reductions in economic activity. After the first half of 2020, the EIA expects global liquid fuels consumption to increase, leading to inventory draws for at least six consecutive quarters and ultimately putting upward pressure on crude oil prices that are currently at their lowest levels in 20 years. Longer term, many are urging that the pandemic is an opportunity for an oil & gas industry sea change. The digital transformation of the industry must be accelerated by the crisis, rather than retarded. It is, in fact, a nascent opportunity. OG
OIL & GAS INFRASTRUCTURE
Blockchain establishes truth Why blockchain should be a part of any new well build By Andrew Bruce
W
ith tangible proof of blockchain’s capabilities and benefits, the energy ecosystem is pivoting to swift adoption to maximize opportunities that the innovative technology affords, including reducing costs and increasing visibility into life cycle tracking and real-time project management. Blockchain’s overall market size will exceed $23.3 billion by 2023 according to Markets and Markets. With considerable cost variability between wells dependent on type, location, conditions, productivity and regulations, blockchain provides a technological backbone that overcomes industry challenges and enables transparency into unambiguous records, a critical step toward a new model of drilling and production. Life-cycle tracking Blockchain’s inherent immutable nature makes one of its benefits that of establishing a record of neutral, verifiable truth shared among counterparties and project stakeholders. Blockchain is uniquely suited to track well life cycles with accompanying well integrity files including both plans for the well and the “as built” form. Daily structured reports — such as the IADC Daily Drilling Report (DDR), operator’s OpenWells or WellView files — are a key record of what happened and when. Electronic drilling recording (EDR) data and surveys that enable the 4D reconstruction of a well’s path is critical data that needs to pass from drilling to production in a consistent, standardized and searchable way. Additionally, the provenance of every piece of steel can be traced back to original mill certifications with the provenance capture capabilities of blockchain technology. By deploying blockchain as part of well construction and completion processes, errors and data gaps can be caught as they occur. Once a well is in production, additional data such as wellhead flow meter volumes, flaring temperatures, workovers and additional information
provide a complete life cycle picture of a well from design to decommissioning. The same data stored on the blocks to track the progress of a well — be it a $5 million land well or $85 million offshore well — can also be used to track the performance of service providers and automate contract execution, invoicing and payments. Whether a straight day-rate paid off a drilling report or footage contracts for rental tools, the data necessary for automating contract execution is the same data already being pulled to track the life cycle of the well itself. Smart contracts enable drilling participants to agree to terms and tolerances up front, then observe operating field data to ensure obligations are met. Once a smart contract is issued, invoicing and payments can be automated. Rendering paper invoices obsolete will streamline transactions and empower parties to prioritize high-quality data to ensure that vendors are paid at speed without dispute and buyers pay only for the services delivered. Complete transparency Blockchain’s innate capability to maintain unalterable records that drive visibility into all aspects of well creation and management can be applied to service providers and vendors, in royalty payments scenarios, joint industry billings (JIB) or in due diligence with acquiring/ selling assets. As the oil & gas industry evolves, reducing inefficiencies, streamlining operations and capturing and managing full life cycles of assets will become the new standard. Whether needed for performance measurement, government reporting, packaging and selling of an asset, or just knowing what’s in the hole and what the actual wellpath is, blockchain provides a single source of truth for the entire history from design to plug and abandon. It provides complete transparency into field data on a well asset and that’s why it needs to be part of any new well build. OG Andrew Bruce is CEO and founder, Data Gumbo. OIL&GAS ENGINEERING JUNE 2020 • 7
THE SUBSEA ENVIRONMENT
Remote monitoring of blowout preventers improves operations BOP system tester uses analytics software to help its oil & gas clients avoid downtime and incident By Michael Fry
Figure 1: This blowout preventer is installed and ready for use. All images courtesy: Deepwater Subsea
I
n April 2010, the malfunction of a blowout preventer (BOP) contributed to the Deepwater Horizon disaster in the Gulf of Mexico, leading to the loss of life of 11 crew members and one of the worst oil spills in U.S. history. Since then, a movie was made about the incident, with an unsurprisingly Hollywood take. In addition, there has been a not-so-surprising emphasis on comprehensive BOP monitoring throughout the oil & gas industry. BOPs are assemblies of valves, hydraulics, and electrical devices used to seal, control, and monitor wells to prevent the uncontrolled release of oil or gas (See figure 1). They are deployed on both land and ocean drilling rigs, and they are secured to the wellhead at the top of the wellbore. To comply with regulations instituted in 2019, BOP system testing must be handled by thirdparty companies, such as Deepwater Subsea, headquartered in Katy, Texas. Deepwater Subsea provides these services to its clients by streaming data from BOP systems located anywhere in the world to their monitoring center for analysis and reporting. In addition to BOP testing, Deepwater Subsea provides subsea operational support and training with its team of subject matter experts (SMEs), all of whom are highly trained specialists, to provide downtime reduction and operational performance improvements. To provide these services, the SMEs make extensive use of Seeq advanced analytics software to create insights from the streamed data. Searching for a better solution Initial Deepwater Subsea projects reinforced the need for an improved solution in an industry where many operators and service companies
8 • JUNE 2020 OIL&GAS ENGINEERING
were set in their own established, and often inefficient, procedures. Like most operators, Deepwater Subsea was using general purpose tools such as Excel to analyze data, making it difficult to predict and troubleshoot problems, and to help its customers meet regulatory requirements. As part of BOP regulatory compliance, reports must be sent to the Bureau of Safety and Environmental Enforcement, which often requires customized reports going back months or even years. These must be created quickly and efficiently, a task not well suited to spreadsheets. Achieving operational excellence for operators requires analyzing rig data, producing compliance reports, generating failure reports, and conducting regular inspections. The information generated by these activities provides operators with historical lessons, key performance indicators, operational logs, and inspection reports — which they use to improve their operations and comply with regulations. Delivery of these services is complicated by geography, as most BOPs are installed thousands of feet below water or land surface. Another issue is the sheer volume of data, with up to forty thousand data tags coming into the Deepwater Subsea monitoring center daily, streaming in real-time 24/7/365. This data must be quickly and accurately analyzed, with any problems immediately brought to the attention of the operator. The main goal is preventing failure of a BOP system, but an important secondary goal is keeping a system in operation, if a problem is found that does not jeopardize BOP operation. To attain the required level of certainty, Deepwater Subsea switched from spreadsheets to Seeq for interacting with the data of interest, creating insights and producing customized reports.
Figure 2: Deepwater Subsea’s monitoring center is staffed with personnel to analyze data from its oil and gas customers.
Deployment details Deepwater Subsea uses the OSIsoft PI data historian to collect and store time-series data from its clients’ wells and BOP systems. This data is primarily pressure measurements from the hydraulic system that controls different aspects of BOP operation, and the method of communication from a rig to the monitoring center (See figure 2) is typically via a VSAT satellite communication system. In addition to real-time data streamed from wells regarding BOP system operation, the historian also contains BOP asset information such as make, model, serial number, date of manufacture, date of installation, date of last maintenance, historical failure and leak data, and the like. A Seeq system reliability engineer initially worked with Deepwater Subsea SMEs to install the software, which took less than two hours. Upon installation, Seeq automatically detected, connected to, and indexed the PI system data. When new data sets need to be analyzed, the data extraction process is quick and easy, in contrast to spreadsheets where data must be manually copied from the historian and pasted into the spreadsheet. Multiple PI systems can be connected to provide data comparison across different sites. Tight integration between Seeq and OSIsoft PI’s asset framework is used for analytics and asset-relative displays. Seeq also offers integration with Event Frames and PI Notifications to enable the reuse of existing investments in software and analytical configurations. The combination of Seeq and OSIsoft PI also provides integration with other tools such as Microsoft Excel and Power BI for pivot tables, graphing, and business analysis. Deepwater Subsea runs Seeq as a SaaS application on Microsoft’s Azure cloud service platform. Cloudhosting provides several advantages as compared to an
on-premises installation. Local server hardware and support is not required; scalability is quick, easy, and nearly infinite; and security, backups and other features are provided by the cloud-hosting company. Offloading these activities allows Deepwater Subsea to focus on its core mission. Focus on the BOP Using the software’s unique analytics capabilities, SMEs at the monitoring center apply their domain expertise to help detect BOP system anomalies. SMEs can now accurately quantify changes in BOP control system performance, pressure leaks and more, and quickly share this information with rig personnel. Data tags can be pulled in, captured and overlaid on historical data to analyze asset performance, such as the results of pressure tests (Figure 3). The data in the historian is not disturbed by these activities, and full fidelity PI data is cached and always ready for quick access. The ability to overlay the previous test results for comparison allows Deepwater Subsea monitoring personnel to ensure that the mechanical integrity of the equipment has not changed. BOP systems can have over one hundred functions associated with a single hydraulic circuit, and pinpointing a problem, often due to a leaking component, is extremely challenging. Using Seeq, SMEs can look at a signal (for example, a manifold regulator pressure trend), and compare it to other signals over any desired time. These signals can be overlaid on top of each other, allowing quick identification of which component is leaking or causing some other type of problem. An example result would be an upper outer choke in a BOP system that leaks when a valve is closed. Further analysis can reveal whether
Figure 3: SMEs use Seeq to perform overlay pressure tests.
Figure 4: Leaking BOP control system prior to deployment.
OIL&GAS ENGINEERING JUNE 2020 • 9
THE SUBSEA ENVIRONMENT
Figure 5: Analyzing a BOP system leak with Seeq allowed regulatory approval for continued safe operation.
this is a problem which must be addressed immediately, or if repair can safely be deferred to allow proactive instead of reactive maintenance. During a recent monitoring inspection, Deepwater Subsea was able to identify 22 control system leaks by utilizing the various tools and features of Seeq (Figure 4). Each of these items could have resulted in a non-productive time event, resulting in millions in lost revenue. Increasing uptime Deepwater Subsea’s monitoring services have resulted in significant improvements for its oil & gas operator clients. Some of the operators seeking approvals from the Bureau of Safety and Environmental Enforcement (BSEE) have been able to extend BOP testing intervals from
14 to 21 days, saving them approximately $10 million annually per rig. SMEs were able to accurately quantify the rate of change in a small pressure leak in one of their customer’s BOP systems (Figure 5). They submitted a report to the BSEE showing the leak would not impact BOP performance, and approval of this report allowed the operator to keep the BOP system in operation. The subsequent return on investment associated with a week of avoiding non-productive time for pulling and servicing the BOP was approximately $2.5 million. Deepwater Subsea has recently expanded its deployment to include Seeq Data Lab, which provides an environment optimized for developing, training and deploying machine language models and enhanced visualizations. OG Michael Fry is the president and CEO of Deepwater Subsea, a company specializing in subsea operations, compliance inspections, real-time monitoring, and competency development training.
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FASTENING TECHNOLOGY
The basics of API 20E and API 20F bolting standards Standard specifies requirements for alloy and carbon steel bolting By Tom Goin
T
hroughout development of the industrialized economy, bolts, screws, studs, nuts and other miscellaneous fasteners, known collectively as bolting, have largely been deemed commodity items. In most commercial applications, a bolting failure bore limited consequences. Typically, a failed fastener was simply removed, and its replacement installed. There were limited implications to bolting failures, typically a few minutes or hours of downtime while a replacement part was installed so the machinery could resume operating. This scenario was true of most bolting used in oil & gas applications as well. As the O&G industry has expanded, however, continuously moving into harsher and more unforgiving environments, we’ve seen that the consequences of bolting failures in these applications present infinitely greater risks. When drilling offshore for oil & gas in water depths in excess of 12,000 feet or for producing oil & gas in a land-based fracking development adjacent to a suburban neighborhood, where rig hands can see and hear children playing in their backyards, a catastrophic bolting failure presents safety hazards of a completely different nature. In either scenario, there is potential for the loss of human life, extreme environmental impact and financial ruin. After weathering these risks for years, the O&G Industry addressed the challenge of bolting-related issues head-on. One of the most important components of this bolting initiative was the creation and publication of API Specification 20E and Specification 20F. Management of bolting in critical applications is complex. In addition to the need for bolting to be manufactured to the highest of quality and integrity standards, it is crucial that the bolting design is correct. Management of strength levels and applied plating and coating are necessary to reduce the propensity for environmentally induced embrittlement stress failure. If the
material strength is too high, the bolting will likely fail catastrophically. Certain coatings are known to cause fastener failure in marine environments. Also important is the control of applied preload as the bolting is installed. Too much preload stress can lead to failure, as can too little stress. Historically, there has been relatively little attention paid to the installation processes. This is rapidly changing. Specifications’ history For the past 100 years, the American Petroleum Institute (API) has published specifications and standards for every type of pressure boundary product used in the exploration, drilling, production, refining, transportation and distribution of petroleum products. The manufacturing process control, testing and inspection of pipe, valves, fittings, flanges, gaskets, O-rings and seals have been addressed in API standards, which regulate production of those products. Product and equipment producers that were evaluated and found to be compliant with those API Specifications could be awarded an API monogram and licensed to mark their product with the monogram. In the arena of pressure boundary products, bolting was the sole component category with no such control. The Association of Wellhead Equipment Manufacturers (AWHEM) is a trade association providing value-added support to the O&G service manufacturing industry. This organization provides technical support to the industry by evaluating and certifying component designs and technical support to API, aligning industry standards. In response to multiple O&G operators and original equipment manufacturers, with each initiating its own enhanced-quality bolting specifications, AWHEM chose to create an industry document to standardize the specifications. A committee of AWHEM subject matter experts convened to write a high integrity bolting technical guide. This document was published as AWHEM TR1001 (now obsolete). API OIL&GAS ENGINEERING JUNE 2020 • 11
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FASTENING TECHNOLOGY sub-committee 20 on supply chain soon became aware of this document and created a committee to use the document as a basis to develop its own specification. In August 2012, API published specification 20E, Alloy and Carbon Steel Bolting for Use in the Petroleum and Natural Gas Industries. This standard specifies the requirements for the qualification, production and documentation of alloy and carbon steel bolting used in the petroleum and natural gas industries. The companion specification covering corrosion resistant bolting, API 20F, was published a couple of years later. API 20E services levels The API 20E specification establishes three bolting specification levels (BSL-1, BSL-2 and BSL-3). These BSLs define ascending levels of technical, quality and qualification requirements. Increasing levels of severity reflect increased consequence of bolting failure. The highest level of criticality, BSL-3, is expected to be reserved
for those applications in which bolting failure is not an acceptable option. A common definition for BSL-3 application is a “critical application; one through which a bolt failure would result in release of hydrocarbons into the atmosphere.” The specification has no design responsibility and does not identify specific applications that would require BSL; that is the obligation of the designer, user, or API product committee, who has a full understanding of the application service demands and consequences of product failure. Note that it’s important to understand that this specification is designed to control the manufacturing of purpose-built critical components. It is not expected that post-manufacturing testing and inspection of any commercially produced product would comply with 20E or 20F. Compliance to these specifications cannot be “inspected in;” the product must be manufactured with the specific intent of full compliance. OG Tom Goin is CEO, WN Global, and president, US Bolt Manufacturing.
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A DV E R T I S E M E N T
ABB provides solutions. ABB provides solutions for efficient production, safe and reliable operations, and digital remote condition monitoring for many oil and gas applications across most industries.
Air Gap Inspector ABB’s Air Gap Inspector is a super-slim robotic crawler, equipped with five cameras, which moves in the air gap between the rotor and stator, covering the entire length of a synchronous motor or generator core. Video feeds allow the maintenance team to inspect inner surfaces not normally accessible without removing the rotor.
AXR The requirements of operating in hazardous locations and environments are many. That’s why ABB’s new AXR large AC NEMA motors are designed to meet API 541 and 547 standards with a more powerful and compact design. They provide more horsepower per pound than conventional TEFC motors with but a smaller frame size in some ratings, enabling compact installations in remote locations.
Explosion Proof Motors When you need the safest solution for hazardous locations, you can trust Baldor-Reliance ® explosion proof motors. They are reliable and readily available, and they perform efficiently throughout their entire lifecycle, without ever compromising safety.
ABB is the leading US marketer, designer, manufacturer and service provider of ABB and Baldor-Reliance® industrial electric motors and Dodge® mechanical power transmission products. With a long rich history dating back to 1878, the US ABB business is supported with manufacturing, R&D and support offices in more than 15 locations in Arkansas, Oklahoma, Missouri, Mississippi, Tennessee, Georgia, North Carolina and South Carolina.
baldor.abb.com 479.646.4711
A DV E R T I S E M E N T
XTS Delivers on Promise of Linear Transport Systems and Mechatronics The EtherCAT-enabled eXtended Transport System (XTS) offers paradigm-shifting capabilities for motion control and mechatronics by combining the advantages of proven rotary and linear motion principles into a new modular platform. With its compact and flexible design, the advanced mechatronic system can reduce machine footprint up to 50%. The XTS revolutionizes drive technology and promotes innovative, globally competitive machine concepts. XTS contains all functions necessary to support efficient integration for motion control applications in many industries. With attached mechanical guide rails, XTS motor modules feature directly integrated power electronics, EtherCAT communication and position measurement. An unlimited number of wireless XTS movers can be controlled with high dynamics at up to 4 m/s on extremely customizable paths. By harnessing the flexibility and scalability of EtherCAT, PC-based control and TwinCAT 3 automation software from Beckhoff, XTS enables flexible mass production down to lot size 1 for the smart factories of today. “Through the capabilities of XTS, Beckhoff once again empowers engineers and machine builders to take leading-edge machine designs to the next step,” said Kevin Barker, president of Beckhoff Automation LLC. “The launch of XTS in the United States will provide significant opportunities for customers in numerous industries to boost throughput, shrink machine footprint and increase flexibility while eliminating timeconsuming mechanical changeovers. This mechatronic system will be a key innovation driver for all companies that use it.”
Beckhoff establishes the new linear motion principle The application possibilities of XTS are virtually limitless: Movers can accelerate, brake, position and synchronize themselves on the fly with automatic collision avoidance provided by TwinCAT 3 software. They can take up absolute positions and positions relative to each other; they can group themselves and accumulate; they can create clamping forces in motion, drive through curves and along straights, recover energy through regenerative braking and use both the return and outward paths for transport purposes.
(952) 890-0000 | beckhoff.usa@beckhoff.com | www.beckhoff.us/xts
A DV E R T I S E M E N T
Instrumentation improves control of the water removal process from natural gas built-in relay, and the second is via the digital communication link. The flowmeter provides much of the data and computations supplied by a dedicated flow computer, making it much easier for process engineers to understand separator performance and control it more efficiently.
Prosonic Flow G ultrasonic flowmeter
Endress+Hauser has developed an ultrasonic flowmeter to measure the flow of natural gas and other process media. The Prosonic Flow G 300/500 has built-in pressure and temperature sensors. The input from these sensors is combined with measured sound velocities to calculate the compensated flow, and the pressure and temperature measurements can be transmitted separately via one of two digital communication links: HART imposed on the flowmeter’s 4-20 mA output or Modbus RS485. The flowmeter is offered with an “Advanced Gas Analysis” software package option to calculate additional parameters and process variables. Some examples are volume flow, corrected volume flow, energy flow, calorific value, Wobbe index, gas type, molar mass, methane content (%), density, and viscosity. The software can also detect water carryover through the analysis of sensor test points such as signal strength, flow asymmetry, and acceptance rate. Once detected, this condition can alert operators in one of two ways. The first is via a
The flowmeter measures both dry and wet gases with ±0.5% accuracy, even when process and ambient conditions fluctuate significantly. Its measuring system has been developed in accordance with IEC 61508 (SIL), and it is also preferred for use in safety-related applications. Endress+Hauser’s Heartbeat Technology is integrated into the flowmeter, which enables permanent self-diagnostics. It also enables device verification certified by TÜV in accordance with DIN EN ISO 9001:2008 without process interruption.
The Prosonic Flow G has built-in pressure and temperature sensors
The flowmeter’s transmitter includes a web server as a standard, enabling direct data access in the field from any device capable of hosting a web browser.
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Promass Q – for increased plant productivity • Error-free flow measurement in custody transfer applications in mass or volume units due to unmatched accuracy for density determination • Ideal for hydrocarbons with entrained gas thanks to the patented Multi Frequency Technology (MFT) • Patented “Heartbeat Technology” for device verification during operation and permanent self-diagnostics
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