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IT/OT CONVERGENCE
Upstream and midstream operations pivot to meet new realties World events are imposing changes on upstream and midstream oil & gas operations, but IT/OT convergence and digitalization helps users adapt By Denka Wangdi and Darrell Halterman
Figure 1: Remote oil and gas assets can be operated better and remotely when automated using converged IT/OT technologies such as edge controllers. Courtesy: Emerson
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s the impacts of COVID-19 and other world events propagate through global industries, many types of companies are looking even more closely at how to best optimize the operations and maintenance of their assets. Reduced oil and gas demand have caused upstream well operations, midstream pipeline and storage facilities, and downstream refineries to significantly reduce production. Unfortunately, this is not as simple as turning off a water hose. In particular, midstream and upstream elements are often operated remotely, introducing logistical challenges for adjusting their operation (Figure 1). Ideally, centrally-located users would be able to effectively operate and maintain these remote assets, saving the expense of worker travel and also improving safety, but traditional automation platforms may limit these possibilities.
One answer can be found as users begin a digital transformation journey and incorporate industrial internet of things (IIoT) devices and methods. The convergence of the latest IT capabilities with traditional operational technology (OT) automation delivers economic, social, and environmental advantages. Here is how a shifting emphasis towards more remote access to local automation systems makes it possible to realize these and other benefits. Measurable improvements Any operation is defined by various elements throughout the value chain. To prioritize and quantify efforts to improve operations, it becomes necessary to establish key performance indicators (KPIs) related to issues such as the following: • Economic • Social • Environmental At the most basic level, producers want to optimize operations and therefore profits. This requires comprehensive data from field assets and business units, which can then be analyzed to determine current conditions, diagnose problems, and develop operational insights. With the right information in hand, users can act to improve efficiency and optimize operations, leading to many benefits. Efficient producers can deliver quality products to end user consumers at a cost savings. Better operating practices make it safer and easier for operations and maintenance workers to perform their tasks, especially those who
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DECEMBER 2020
OIL&GAS ENGINEERING
can work more effectively from protected locations, a goal especially relevant considering COVID-19. This improved way of life for workers is an example of delivering social benefits while cutting costs. From an environmental standpoint, closely monitoring and optimizing upstream and midstream processes is necessary to identify and account for any environmental concerns. In some cases, this can require the addition of sensors and other devices over and above what is strictly necessary for nominal control. Preventing environmental incidents avoids penalties for non-compliance. Industry agencies are now enforcing stringent requirements for operators to meet lower emissions. However, there are usually technical changes to obtaining the source data required to create these KPIs. A shift is necessary In the past, many upstream and midstream automation projects have relied upon local instruments and control devices with only limited remote connectivity. The current need to dramatically shift operational priorities has exposed the fact that an even greater integration of remote assets with supervisory control and higher-level analytical systems is necessary to deliver safe and optimal operation under all conditions. Converging IT-type supervisory and analytical systems with typical OT digital assets has been possible in the past but not easily accomplished. Transferring the right data, reliably and in a timely manner, has often required extensive configuration efforts and expensive communication methods. A new class of industrial edge controllers is now available and specifically emphasizes converging IT and OT capabilities (Figure 2). This edge computing technology combines the realtime deterministic control functionality of traditional programmable logic controllers (PLCs) with modern general-purpose computing made possible by a Linux operating system. This type of edge controller platform is crucial to facilitate integration of IT-type analytics with OT-type scalable industrial systems within the oil and gas industries. Edge controllers facilitate digital transformation by helping end users operate their equipment at peak efficiency, giving them new remote access options, and providing improved monitoring of environmental conditions.
Figure 2: A new class of industrial edge technology, such as this Emerson edge controller, is a key platform needed to converge IT and OT automation and data handling. Courtesy: Emerson
Data, analytics, and scalability Digital transformation requires data, which is generally sourced from field locations at the operational edge. This data must by analyzed at the edge, on site, in the cloud, or in some combination of these locations. Results and insights can be used automatically by control systems or after review by operators to improve operations. A scalable solution spanning from the edge up to the cloud is needed to make this possible. Edge controllers fill this role by providing the required functionality in these areas: • Data: The necessary data is available in the field, but it is often trapped at the edge. Edge controllers can easily access hardwired inputs/outputs, along with networked data available using standard industrial protocols like HART, OPC UA, and PROFINET. • Edge computing: However, the massive quantity of collected data is often not readily transmitted in bulk to higher-level systems without expense and delays. Edge computing can pre-process this data so only refined results need be transmitted. • Cloud computing: Cloud-based IT solutions for more extensive analytics and remote visibility are available but require connectivity to deliver the right data at the right time. Edge controllers are optimized for cloud communications using protocols such as MQTT, and OPC UA can also be used in this role.
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Greater integration of remote assets with supervisory control and higher-level analytical systems is necessary to deliver safe and optimal operation under all conditions.
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IT/OT CONVERGENCE • Predictive analytics: Whether performed at the edge, in the cloud, or as a hybrid of both, analysis is necessary for users to unlock an understanding of operations and gain insights for improvements. • Closing the loop: An edge controller can be informed by user actions, edge-located analytics, or cloudbased analytics, to adjust parameters and operations for increased efficiency or production planning needs. Each of these tasks have been possible, but relatively difficult to implement, using traditional automation methods. Edge controllers provide a far more comprehensive solution to perform these tasks, with much of the work carried out on a consolidated platform. Oil and gas facilities are especially good candidates for edge control implementations due to the massive amounts of collected data, remote locations of many assets, and potential substantial gains from even minor operational improvements. Upstream/midstream considerations The oil and gas industries have experienced many boom-and-bust
Figure 3: Edge controllers are easily retrofit into existing control systems to add IIoT capabilities, because they can handle real-time control, a multitude of communication protocols, and offer IT-type computing and networking features. Courtesy: Emerson
cycles, and this trend is expected to continue. In response, better coordination of assets with regards to automation, remote accessibility, and detailed monitoring realized through converged IT/OT technology will enable users to manage production costs at the well and through the pipeline. New projects can incorporate this technology, but it is equally important that existing systems can be easily upgraded (Figure 3). Wellhead automation advancements can lead to improved bore hole productivity, but only if uptime is maintained. Therefore, this type of automation should be accompanied by designs for higher availability, improved communications, and better diagnostics. Edge controllers offer exactly this, with redundant processors and networking. Similar automation efficiencies apply to other processes like hydrofracking, separation, treatment, transport, and storage. Improved productivity of these elements justifies upgrading portions of the operation, such as transitioning a trucking line to a pipeline. As pipeline companies upgrade existing assets or build new systems, edge controllers enable them to realize better data access and improved coordination among all units. This includes the easy addition of environmental monitoring points which are important but not directly related to control. Edge controllers include oil and gas industry-specific features, such as native AGA calculations, making it easier for users to determine product grades, qualities, and flow rates. They support all popular industrial protocols typically found in the field, meaning edge controllers are readily integrated with upstream and midstream systems. Another consideration is that automation can help decrease production when necessary, as well as increasing it. For example, during an operational slowdown it may become necessary to shut off or “kill” a well if production cannot be slowed enough to maintain acceptable flow rates. Killing a well is a drastic measure, and it may be very
expensive to restart the well in the future. If operators can effectively slow production and avoid killing a well while reducing fixed costs, they are able to keep more wells in service, even those operating at low production rates. Convergence yields flexibility Industries worldwide are currently facing unexpected operational challenges. While some manufacturing industries may be working overtime, many oil and gas upstream, midstream, and downstream operations are struggling with how to slow production and safely deploy personnel. For the oil and gas industries, setting economic, social, and environmental goals are a way to drive progress in these areas, but improved automation is needed to overcome production and quality control challenges. Moving to a converged IT/OT approach based on edge control platforms is a way to achieve all these goals. Edge control preserves the robust automation needed for oil and gas processes and adds the ability to implement redundancy. Easy access to data and remote connectivity supports analytics in the field, in the cloud, or both—empowering maintenance teams to respond rapidly, and even proactively in some cases. Operations can use this data to fine-tune production and optimize operations systemwide, and ensure environmental responsibility. The technology step change offered by edge controllers and IIoT technologies leveraging IT/OT convergence helps skilled workers be as effective as possible, and supports companies as they proceed on the digital transformation journey. OG Denka Wangdi is a marketing leader for Emerson’s machine automation solutions business. Darrell Halterman is a senior product manager of PACSystems controllers at Emerson’s machine automation solutions business. OIL&GAS ENGINEERING DECEMBER 2020
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Casing accessories
Standardization and modularity to drive operations efficiency Mitigate the financial risk of ordering back-up float equipment By Amy Farrar
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il & gas operators look for opportunities to make operations more efficient by standardizing casing accessory designs, and thus standardizing the accessories that attach or make up the casing. However, this proves difficult when well requirements and casing availability dictate what combination of casing weights, grades, and connections are used to construct a well. Along with the variations in casing, operators are compelled to make use of casing accessories that are customized to their casing requirements. It can be challenging to use this equipment across multiple wellbores. Reducing the costs associated with casing accessory inventory is also a major initiative for many industry operators. This focus on cost containment extends to the practice of keeping customized casing accessories on consignment. A consignment arrangement allows the operator to have casing accessories available as needed without having to maintain and hold backup or contingency inventory. This inventory can sit unused for years after a drilling campaign since casing programs change based on the requirements of different well profiles. Frank’s International’s Caseless Insertable float system (CIFS) is an “off the shelf” versatile float system that allows operators to standardize equipment, and reduce costs and lead time by eliminating the need to pre-order float equipment for planned contingency strings or to acquire float equipment for an unplanned casing string. The CIFS also mitigates the financial risk of ordering back-up float equipment that cannot be used or has minimum usage on upcoming wells.
OIL&GAS ENGINEERING
Frank’s International’s float system is a revolutionary adaptation of composite technology created to allow the operator to install a float valve and plug landing system directly into a casing, removing the requirement for customization to match casing grade and connections. All of this is accomplished while maintaining the ability to easily drill-out the casing shoe track. With its modular design, the system can be configured to various operational requirements, accommodating multiple configurations for plug landing surfaces, float valves and shoes. When provided as a float assembly, the system can be set up for conventional or auto-fill with ball-drop or ball-contained options along with varying flow conversion parameters. Installation concerns The CIFS is simple to install in the customer’s existing casing string at either the pipe yard or rig site. Since it is installed directly into the casing, there is no need to source a bucking crew to make up the float equipment. The installation takes less than 30 minutes. Once installed, the anchor can be vacuum tested to verify sealing and anchor integrity, ensuring the qualification ratings can be achieved. Cement is susceptible to shrinking as it cures, which can lead to micro annuluses that can go undetected, causing seepage through the cement downhole. The CIFS uses an elastomeric seal versus traditional float equipment that relies on cement, that cannot be vacuum tested, to create the seal between the valve and body. Tested and qualified to the API 10F standard, the CIFS system was run for the first time in deepwater with a 9-7/8” liner in the GOM on behalf of an independent operator
Float system allows float valve or guide shoe directly into a casing. The off-the-shelf solution reduces lead times. Image courtesy: Frank’s International
on February 9, 2019. Running three float systems for true float valve redundancy, the assemblies were configured with the auto-fill float module. The top assembly had a ball contained float and was set to convert at 2-4 BPM. At 3 BPM the circulation pressure dropped from 1,398 psi to 240 psi indicating the proper float conversion. After conversion, the ball was expelled to the subsequent lower floats for conversion. The large ID of the float system (>12.8in2 Flow Area) allowed the operator to run a 9-7/8” liner to TD while minimizing the surge on the formation. After successfully converting the auto-fill float equipment, the primary cement job was performed, and the plugs were bumped on the top CIFS assembly to 1,500 psi. The floats were then checked, and the job was completed successfully. Once through the SSR plugs, the drill-out of the float assemblies took less than 30 minutes, each with a PDC bit. This performance was consistent with the quick drill-out times that operators have come to expect from typical composite constructed float equipment, with the added benefit of flexible configuration and reduced inventory requirements.
and reduce costs and lead time by eliminating the need to pre-order float equipment.
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float equipment converted, and the ball was expelled to the subsequent float assemblies. The cement job was completed successfully, and the floats held after the job. In addition to minimizing the quantity of customized casing accessories that the operator must store and maintain, the float system gives operators flexibility in their operations to acquire float equipment without manufacturing lead times. This is advantageous when looking at unplanned casing strings for sidetrack operations or low likelihood contingency strings. When these unplanned operations arise, they often leave the operator scrambling to find equipment to match their casing specifications. This accrues additional costs for expediting fees or having to machine crossovers to adapt available equipment with their casing string. Additionally, traditional float equipment operators must order equipment for wells three to four months in advance. Should market conditions change and a well is cancelled, they are left with equipment that might not be used elsewhere. The CIFS option takes this risk away from the operator. With the oil and gas industry focused on optimization, efficiencies, and cost reduction, the CIFS offers a step change improvement by replacing traditional float equipment. It is positioned to establish a new standard when it comes to casing accessories. OG Amy Farrar is applications engineering manager, Frank’s International.
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More success Following the success of the first run, the same operator was looking for a short lead time solution to minimize their customer owned inventory while maintaining a primary and backup option for float equipment on a 7-3/4” liner. The float system was determined to be the right solution for the operation. For this job, it was again decided to run three float systems in the auto-fill float module. The top assembly had a ball contained float and was set to convert at 2-4 BPM. At 3 BPM the
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2020 PRODUCT OF THE YEAR
Award winners recognized Oil & Gas Engineering announces winners of the 2020 Product of the Year awards
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he Oil & Gas Engineering’s annual Product of the Year awards recognize significant innovation and advancement in technologies and best practices. Below we announce the 2020 award winners. To any observer, what first impresses is the sheer scale and scope of the oil & gas industries, entailing more information than anyone could absorb in a lifetime. The selections below demonstrate how incremental but telling innovation in automation and information technology is being applied to processes or equipment categories that have been with us for quite some time.
These innovations include a new generation of machinery management software for proactive monitoring of equipment, especially the rotating kind; digital twins for use in risk evaluation management; advances in pressure pumping and in portable data collection; and incorporation of machine learning into a wide range of applications, functions and processes. While what matters most is the efficacy of the soluOil & Gas Engineering tions in the real world of dollars and cents, of the satisfying our collective curiosity about how these technologies are unfolding in the oil & gas industries today pays for itself.
2020
Product Year
Data & Analytics GOLD AWARD Asset performance management software APM 360 is a cloud-based asset performance management solution that covers overall asset health, real-time condition monitoring and predictive maintenance — accurately recommending specific actions. APM 360 leverages the Industrial Internet of Things (IIoT), artificial intelligence (AI) and failure mode and effects analysis (FMEA) to account for complex, dynamic behavioral machinery patterns and contextual data relating to the manufacturing process at large. The APM 360 AI-based anomaly engine looks for irregularities while the FMEA engine and Symphony AzimaAI’s propriety scoring know-how acts as a double filter to ensure no false anomalies. Symphony AzimaAI, https://symphonyazimaai.com
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Data & Analytics SILVER AWARD Machinery protection, condition monitoring system The Orbit 60 is a next-generation platform that collects and processes data, equipping operators with the right data and analytics to determine the health of their machines. It is an intrinsically cyber-secure machinery monitoring system with a built-in data diode, which enables secure one-way data transfer from the device to Bently Nevada’s flagship machinery management software System 1 for proactive monitoring and diagnostics. Bently Nevada, a Baker Hughes Business, www.bently.com
BRONZE AWARD Advanced analytics software Seeq R22 enables users to quickly investigate and share analyses from operations and manufacturing data sources to find insights and answer questions. Designed specifically for analyzing process data, Seeq R22 works across all verticals with time-series data in historians or other storage platforms. The R22 release includes item-level permissions, significant processing speed increases, and additional collaborative features. Seeq Corp., www.seeq.com
IIoT & Process Control GOLD AWARD Process performance management application Performance 360 is a process performance and optimization solution for the process industries including petrochemical, pharmaceuticals, food and beverage, power generation and discrete manufacturing. It combines process condition insights, performance metrics and process history. Performance 360 uses IIoT and carefully curated artificial intelligence and deep learning technologies to predict how a process will perform in the future and identify potential process disruptions, quality issues and trip conditions. Symphony AzimaAI, https://symphonyazimaai.com
SILVER AWARD Integrated HMI, SCADA platform Developed for plant, telemetry or hosted systems of any size, VTScada’s unique design integrates all core SCADA components into one easyto-use package. It replaces third-party add-ons with integrated features like Enterprise historian, security, reporting, alarming, alarm notification, version control and thin clients. This removes risk and stress from every stage of the software lifecycle; from pricing and licensing to development and support. Since versions are never retired, VTScada applications can be scaled and updated indefinitely. Trihedral, www.vtscada.com
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2020 | PRODUCT OF THE YEAR
IIoT & Process Control BRONZE AWARD Safety I/O module The Allen-Bradley FLEX 5000 safety input/output (I/O) module can meet the needs of producers in process and heavy industries that require fixed field-wiring terminations or both vertical and horizontal I/O mounting in distributed safety applications. The FLEX 5000 I/O module provides distributed safety I/O for the Allen-Bradley Compact GuardLogix 5380 and 5580 controllers. The safety module can be combined with FLEX 5000 standard I/O modules to achieve integrated safety and control in one distributed I/O platform. Rockwell Automation, www.rockwellautomation.com
Machines & Equipment GOLD AWARD Frac valve seat The SPM EdgeX Valve and Carbide Seat increases seat life 6X and doubles valve life compared to conventional offerings to provide substantial cost savings and reduction of NPT. Valves, seats and packing are the most significant maintenance expenses on a frac site, making operators focus on reducing costs related to fluid end maintenance and downtime. The SPM EdgeX Valve and Carbide Seat employs tungsten carbide strategically in key wear areas to deliver dramatically longer life than existing valve seats, including environments with large particles, which means less time spent pulling seats Weir Oil & Gas, www.global.weir
SILVER AWARD Virtual reality training software For oil and gas manufacturers, the Mimic Field 3D virtual reality (VR) simulator makes training safer and more cost effective. The simulation software uses a site’s CAD drawings and digital twin architecture to create a three-dimensional model of the operating environment. In the virtual environment, operators can use VR equipment to perform the same tasks they would in the real world, gaining familiarity with assets and controls, such as pumps and compressors, without the risk or interrupting production to practice on live equipment. Emerson Automation, www.emerson.com
BRONZE AWARD Ultrasonic gas flowmeter The Proline Prosonic Flow G 300/500 ultrasonic gas flowmeter is ideal for demanding applications, measuring both dry and wet gases with high precision (±0.5%), unmatched repeatability and high reliability — even when process and ambient conditions fluctuate significantly. The robust industrial design makes it possible to operate the flowmeter long term without maintenance, saving time and money. The meter operates at process temperatures up to 150°C and pressures up to 100 bar and can be ordered with built-in pressure and temperature sensors. Endress+Hauser, http://us.endress.com
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