VOL.14 | ISSUE 4 |
OFFSHORE WORLD
INSIGHT INTO UPSTREAM & DOWNSTREAM HYDROCARBON INDUSTRY
JUNE-JULY 2017
Leveraging Digitization & IIoT for Hydrocarbon Industry
VOL. 14 ISSUE 4 MUMBAI US $ 10 ` 150
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CONTENTS
GUEST COLUMN Industrie 4.0: Doing It Differently -Mr Ashish M Gaikwad, Managing Director, Honeywell Automation India Limited (HAIL) & Country Leader, Honeywell Process Solutions (HPS) India
06
Artificial Intelligence: The Next Big Thing in Supply Chain Management -Mr Anuj Kapuria, Founder & CEO, Hi-Tech Robotic Systemz Ltd & Co-chair- Robotics Society of India
08
Drones – Oil & Gas Assets are not Remote Anymore -Dr Arunkumar Ranganathan, AVP & Head DCG, Energy Utilities & Services, Infosys Ltd
12
Savvy Separators: Introduction to Computational Fluid Dynamics (CFD) for Separator Design -Alex Read
16
Maximising the opportunity with FTG Gravity -Colm A Murphy
22
Embracing Digital- Realizing unfulfilled potential in Oil and Gas Industry -Divjot Singh
26
Concerns over rising oil production in U.S., Libya pulls oil prices down -Niteen Jain & Nazir Ahmed Moulvi
30
Remote Monitoring Services Offer Users Competitive Advantage -Mark Sen Gupta The IoT Effect: How Technology is Modernising Traditional Industries -Martin Phillips The Next Generation Manufacturing Execution Systems (MES) -Robert Golightly & Dr Warren Becraft
32
Making Industrial IoT a Reality for the Energy Industry -Steve Sponseller
40
VOL. 14 | NO. 4 | JUNE-JULY 2017 | MUMBAI | US $ 10 | ` 150 OFFSHORE WORLD R.NO. MAH ENG/ 2003/13269 Chairman Publisher & Printer Chief Executive Officer
EDITORIAL
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Offshore World | 4 | June-July 2017
2nd
PIPELINE INTEGRITY MANAGEMENT SYSTEM Conference Cum Exhibition on 24th & 25th August, 2017 Holiday Inn, Mayur Vihar Phase I, New Delhi, India
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GUEST COLUMN
Industrie 4.0: Doing It Differently
Mr Ashish M Gaikwad Managing Director, Honeywell Automation India Limited (HAIL) Country Leader, Honeywell Process Solutions (HPS) India
T h e I n d u s t r i a l I n t e r n e t o f T h i n g s ( I I oT ) i s a p o t e n t i a l g a m e - c h a n g e r a n d the future of manufacturing in India. If India is to achieve its goals of increasing manufacturing output to 25 per cent of GDP and create up to 90 million domestic jobs by 2025, we have to go fur ther and drive innovation in t h e f i e l d o f i n d u s t r i a l a u t o m a t i o n . To a c c e l e r a t e e f f i c i e n c y a n d p r o d u c t i v i t y, manufacturers will need to invest in energy efficient technologies and automation solutions and processes.
A
profound digital transformation is now under way in the world’s leading industrial companies. Companies realize today that the role of digital technology is rapidly shifting – from being merely a driver of efficiency to an enabler of fundamental innovation. India is no exception. The countr y’s manufacturing sector is on a high growth trajector y. The Prime Minister’s Office launched the Make in India program to place India on the global map as a manufacturing hub. The sector has the potential to touch $ 1 trillion by 2025. If India is to achieve its goals of increasing manufacturing output to 25 per cent of GDP and create up to 90 million domestic jobs by 2025, we have to go fur ther and drive innovation in the field of industrial automation. To accelerate efficiency and productivity, manufacturers will need to invest in energy efficient technologies and automation solutions and processes. It is imperative for the sector therefore, to re -imagine the work place and the entire ecosystem – with computing inside.
needs – which implies, making the production process flexible without taking excess time. IIoT differs from the more generic concept of the Internet of Things (IoT). A fundamental difference is that IIoT aims to enhance the operation and management of industrial production processes, many of which involve exothermic reactions for which safety is a primar y concern. Security of IIoT-based systems is also of paramount impor tance not just from a safety perspective, but also in cases of the production of essential and strategically impor tant goods and ser vices. A n o t h e r f u n d a m e n t a l d i f f e r e n c e b e t w e e n I I oT a n d h u m a n a n d consumer applications of IoT is that an industria l plant is a ver y l o n g - l i ve d, c a p i t a l - i n t e n s i ve a s s e t re q u i r i n g l o n g - t e r m s u p p o r t in the face of rapid technological advances. In contrast, other applications of IoT involve shor t produc t lifec ycles that are of ten driven by whims of fashion and budget.
INDUSTRIE 4.0 Industrial Internet of Things (IIoT) – sometimes used interchangeably with other terms such as Smart Manufacturing, Industry 4.0, Digitization and Connec ted Enterprise are the industrial revolution of the 21st centur y. IIoT focuses on the end-to-end digitization of all physical assets and their integration into digital ecosystems with value chain par tners and exchange of information in real time. This revolution will transform the manufacturing processes in sync with the speed of change in customer www.oswindia.com
The Promise of Greater Produc tivit y, Efficienc y and Security The cornerstone of IIoT is productivity. In the world of oil and gas, for instance, where plant owners have one eye on capital expenditure (CAPEX), and another on falling oil prices, the biggest driver of IIoT technology is the promise of greater output. Running applications on premise may offer information technology (IT) teams the illusion of control, but, in reality, the task of deploying
Offshore World | 6 | June-July 2017
GUEST COLUMN
OFFSHORE WORLD DECEMBER 2015 - JANUARY 2016 VOL. 13 ISSUE 1 Mumbai ` 150
In many ways, IIoT represents an “undiscovered countr y ” – full of promise, but waiting to be explored and mapped out. The resulting vision is a new form of automation system architec ture that balances the computational and lifec ycle benefits of cloud computing with the requisite on premise, appliance -hosted capabilities necessar y to p rov i d e s a f e, s e c u re a n d l o n g - l a s t i n g a u to m at i o n f o r co m p l ex m a n u f a c t u r i n g s y s te m s a n d p ro ce s s e s. Th e re i n l i e s t h e f u t u re o f industrial automation.
` 150
Almost hand-in-hand with Make in India, the government also launched the Skill India campaign. IIoT will drive growth in produc tivit y by presenting new oppor tunities for people to upgrade skills and new high skilled jobs will be created. The growing use of digital labour will transform the skills mix and focus of tomorrow’s workforce. This is even more impor tant today, as the sector is seeing significant increases in labour costs, which mean that productivity, must be improved in order to maintain a competitive cost position.
Mumbai
What is in it for India?
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VOL. 13 ISSUE 1
That closed systems offer a greater chance of protection from cyberattack is a view that has been proven false. Manufacturers are now waking up to the fact that many older products were designed largely without any cybersecurity measures at all. As hackers become more sophisticated, the safest systems are now connected ones.
INSIGHT INTO UPSTREAM & DOWNSTREAM HYDROCARBON INDUSTRY
DECEMBER 2015 - JANUARY 2016
The IIoT approach also provides a level of supply chain efficiency and decision suppor t not possible with conventional methods. The ability to collect more data from uncorrelated sources provides oppor tunities for applying data analytics, modelling and machine learning techniques to gain better insights into the current and future state of the enterprise.
VOL.13 | ISSUE 2 | FEBRUARY MARCH 2016 | US $ 10 | ` 150
VOL.13 | ISSUE 1 | DECEMBER 2015 - JANUARY 2016 | US $ 10 | ` 150
OFFSHORE WORLD
and maintaining applications locally is becoming increasingly complex and costly. Cloud applications are quicker, cheaper and easier to deploy, but the greatest value comes from integrating data across a portfolio of plants. In a distributed organization, IIoT can help business leaders see unadulterated, clean data taken from across the entire business before they make big decisions. Cloud-hosted applications eliminate the politics of local reporting, self-serving key performance indicators (KPIs) and incomplete data sets, producing a meaningful, global view of what is happening and allowing big decisions to be taken at a lower risk to the business.
INSIGHT INTO UPSTREAM & DOWNSTREAM HYDROCARBON INDUSTRY
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Advancements in Oil & Gas Industry
Dear Readers, Offshore World (OSW), a bimonthly publication of Jasubhai Media & CHEMTECH Foundation, disseminates into the entire hydrocarbon industry from upstream to midstream to downstream. The endeavour of OSW is to become a vehicle in making “Hydrocarbon Vision 2025” a reality in terms of technologies, markets and new directions, and to stand as a medium of reflection of the achievements and aspirations of Indian hydrocarbon industry. OSW, the niche bi-monthly publication, covers insights into Exploration & Production, EPC/M in Oil & Gas Industry, Hydrocarbon Infrastructure viz; Oil & Gas Logistics, Transportation and Pipelines; Hydrocarbon Processing & Refining; Natural Gas and LNG through articles and features by industry Leaders and Dignitaries. The publication also carries inputs and views of Policy & Regulations; latest trends and technology from Policy Makers and Experts from Hydrocarbon Industry. You can share technical articles, case studies, and product write-ups in OSW. • Article length should around 1500-2000 words, along with maximum three illustrations, images, graphs, charts, etc. • All images should high resolution (300 DPI) and attached separately in JPEG or JPG format. • Product write-up length should be around 150-200 words, along with image of the product and contact details. Have a look at Editorial calnder of OSW - www.oswindia.com To know more about Chemtech Foundation, Jasubhai Media and other publication and events, please our website – www.chemtech-online.com Thank you, Regards, Nidhi Agrawal (Sub- Editor) Jasubhai Media Pvt Ltd Tel: +91 22 4037 3636 ( Dir: 40373678) | E-mail: nidhi_agrawal@jasubhai.com
Offshore World | 7 | June-July 2017
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GUEST COLUMN
Artificial Intelligence: The Next Big Thing in Supply Chain Management
Mr Anuj Kapuria Founder & CEO Hi-Tech Robotic Systemz Ltd Co-chair: Robotics Society of India
AI is transforming the dynamics of SCM by deploying smart devices and p r o c e s s e s t h a t c r u n c h b i g d a t a s p e e d i l y, i n f e r r i n g t h e r i g h t a n d r e l e v a n t c o n c l u s i o n s f a s t e r t h a n h u m a n m i n d s . I n e n d - t o - e n d l o g i s t i c s t o o, t h e benefits are immense. From mobile robots and self-driving forklifts to other autonomous vehicles, the big benefits of AI are ensuring greater e f f i c i e n c y, c o s t a n d t i m e s a v i n g s , m i n i m a l a c c i d e n t s a n d f a s t e r d e l i v e r i e s , among others.
I
n recent years, drones have attracted public attention due to their impact on supply chains. More than drones, however, another digital age innovation is making a dramatic impact on SCM – Ar tificial Intelligence (AI). I n u n d e r s t a n d i n g i t s i m p a c t, o n e n e e d s to f i r s t u n d e r s t a n d w h at AI denotes. Also termed ‘machine learning’, AI relates to the use of computers in imitating human intelligence. This includes acquiring information, decoding data, classifying the same and then reasoning or deducing insights from the data. Unlike human minds, AI packs the ability to speedily distinguish the 3V patterns – volume, velocity and variety – embedded in big data and discover relevant connections even in varied data. Increasing Benefits AI is now present in chatbots, robots, speech recognition software, drones, machines and other devices that use some form of reasoning.
While the latter concerns may be premature and misplaced, those on employment oppor tunities seem more relevant, though these too may be overstated. Any activity or function that needs to collate and comprehend data of all kinds could gain by using AI in driving swift, smar t decisions. Supply chains typically fall into this categor y and could, therefore, benefit greatly from AI. Deciding inventor y levels, network designs for transpor tation, purchase and supply management, forecasting and demand planning, etc. can all garner productive gains from AI. For example, AI’s cognitive tools can track and predict disruptions in supply chains by gathering and analysing ex ternal data available from social media, news repor ts, weather forecasts and even historical information. Globally, although most supply chains are automated to some ex tent, numerous mandator y manual chores continue to slow operations. If humans could overcome their reservations about job losses and delegate these tasks to AI, there would be tremendous time and cost advantages.
Besides accuracy in operations and speed in decision-making, AI has
After all, robots don’t need to eat, sleep, take a break or spend time on
other capabilities that humans cannot even contemplate. Naturally, AI
morning ablutions and whatnot. Best of all, robots don’t even demand a salar y or better working conditions. In shor t, the reliability of a robot simply cannot be matched by even the best human employees.
has triggered global concerns and debates about its implications on employment oppor tunities and the ver y existence of the human race.
A s p e r P w C e s t i m a t e s , a b o u t 4 5 % o f p re s e n t w o r k f o rc e a c t i v i t i e s c o u l d b e d o n e b y s e l f a u t o m a t e d m a c h i n e s , s a v i n g a ro u n d $ 2 t r i l l i o n a n n u a l l y f o r t h e c o m p a n i e s i n q u e s t i o n . www.oswindia.com
Offshore World | 8 | June-July 2017
GUEST COLUMN Robots and drones are not the only heroes taking supply chains to new levels – self- driving vehicles are the new stars on the block. But a flashback is required to put matters in perspective and clarify how AI benefits humanity, rather than being perceived as an inherent threat that could soon enslave the human race, as some analysts fear.
for the companies in question. Besides cost savings and efficienc y improvements, PwC adds that RPA could drive businesses to their nex t level of optimal production. This is already evident in Amazon’s operations where robots manage daily operations. Boosting End-to-End Logistics
During the past t wo - odd centuries, men and machines have been working in tandem, seeking to boost the comfor ts and conveniences of the human race. Yet, the first form of genuine mass produc tion o n l y o cc u r re d w h e n H e n r y Fo rd i nt ro d u ce d t h e a s s e m b l y l i n e i n 1913. Thereafter, the first moves towards greater mechanization and automation began gathering pace, although ‘automation’ as a term only emerged in 1946. In its formative years, though, automation was primarily allied with manufacturing. The advent of the digital age, however, has impar ted a new dimension to this term. The widespread use of computers has led to the creation of integrated circuits and a shift towards miniaturisation in almost all domains. S m a l l i s n o w b i g. N a n o t e c h n o l o g y h a s t a ke n t h i s to n e w o r b i t s altogether. Consequently, automation received a boost because even as per formance and production grew exponentially, timeframes and costs dropped. Calculations and deductions that may have taken humans hours, months or years are now being done by ar tificially intelligent computers within seconds.
R obotics apar t, the other big advantage of AI lies in end-to - end logistics, which includes autonomous or driverless vehicles. Using AI, online orders placed hours earlier could be delivered the same day. AI oversees and connects the dots between suppliers, manufacturers, wholesalers, retailers and end customers. In India and abroad, there are companies that specialise in offering endto-end logistics solutions for SCM. Such companies design, assemble and market autonomous and driver assistance software and systems for commercial automotive and industrial applications. To enhance automotive applications, there are devices that boost driver awareness, apar t from providing par tial, conditional and full autonomy. To promote industrial applications, such companies provide autonomous mobile robots for end-to-end warehouse logistics. As e -commerce and digitalisation gain pace worldwide, the rise of AI in manufacturing, warehousing and logistics will keep growing by the day. Industr y estimates indicate that by 2025, there will be a $185 billion market for Advanced Driver Assistance Systems (ADAS) and Industrial Logistics Robotics, growing at 21%+ CAGR from $39 billion
What automation had done to speed up repetitive tasks is now playing out in the analysis of big data via the use of ar tificial intelligence. Human hands had been replaced long ago. But not many would have f o re s e e n h u m a n m i n d s b e i n g re p l a ce d. We l co m e to t h e wo r l d o f ar tificial intelligence! Presently, AI in SCM also manifests as robotics process automation or RPA. Here, software robots manage “clerical process automation technology”. This is not restricted to physical systems alone but integrates various
in 2017. The benefits of using AI in logistics include an increase in asset utilisation; preser vation of natural resources; risk reduction; time and cost efficiencies; and a decrease in pollution, among others. ADAS and AV (Autonomous Vehicle) systems include features such as co-pilot warning system, driver profiling, predictive analytics, for ward collision/lane departure warning, vulnerable user detection, emergency brake assist, lane keep assist, adaptive cruise control with automatic steering, HD (high-definition) maps and 3D reconstruction.
ones dealing with overseeing and implementing orders. RPA automates end-to-end supply chains, facilitating management of varied tasks and domains in the proper cycle. With RPA, managers can devote minimal time to daily ac tivities and processes that are frequent but of low value, spending the ex tra time on high-value tasks garnering greater revenues for the business. As per PwC estimates, about 45% of present workforce activities could be done by self-automated machines, saving around $2 trillion annually
Driverless vehicles would be the norm in supply chains of the f u t u re, w h i c h w i l l b e s u p p o r te d by t h e I nte r n e t o f Th i n g s ( I oT ) , Cl o u d Co m p u t i n g a n d B i g D at a A n a l y t i c s. Th e i nte g rate d s u p p l y chain journey will begin from the cluster of suppliers, connec ted with integrated manufac turing systems in the manufac turer’s plants through the IoT. O nce orders are received online, supplies will be moved seamlessly via driverless vehicles to the plant. Here, mobile robots will under take tasks.
Offshore World | 9 | June-July 2017
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GUEST COLUMN Th e f i n i s h e d g o o d s w i l l t h e n b e l o a d e d o nto d r i ve r l e s s ve h i c l e s b y ro b o t s a n d t r a n s p o r te d to s m a r t w a re h o u s e s. Th e re a f te r, t h e consignments will be categorised and shipped to retailers through d r i ve r l e s s ve h i c l e s o r s e nt d i re c t l y t o t h e c l i e nt s. Th e l a s t - m i l e co n n e c t i v i t y to c u s to m e r s wo u l d a l s o b e t h ro u g h a u to n o m o u s o r driverless vehicles but with a deliver y executive on board for handing over the ordered parcel to the customer. The entire details of the integrated supply chain transac tion would be stored in the Cloud, available for future reference when required. In almost the entire transaction, AI would manifest in some form or the other – computers crunching supply data, driverless vehicles shipping t h e co n s i g n m e nt f ro m s u p p l i e r to m a n u f a c t u re r to wa re h o u s e to customer, mobile robots then transferring the consignment from plant to driverless vehicle, which would then be transpor ted across the last mile to the customer’s address. AI will also be seen in autonomous mobile robots and self- driving forklifts and pallet jacks for material flow in manufac turing plants and warehouses. The GPS- enabled driverless vehicles would permit n o n s to p t ra c ki n g o f t h e s h i p m e nt i n re a l - t i m e, p re - e m p t i n g a ny chances of pilferage and idling or wastage of time that is common with human drivers. In this end-to- end logistics supply chain, multiple benefits abound for end users. Par tial or complete autonomy of vehicles will ensure a reduced number of accidents and higher driver safety. There will be cost savings related to eliminating or minimising accidents, coupled with enhancement in the driver’s wellbeing. Fuel savings and enhanced efficiency will comprise the additional benefits. The final benefits would include the ability of the company to run lean operations at minimal labour cost, thereby prolonging the life of its assets.
others. Such L4 shuttles are capable of autonomous route planning, autonomous emergency braking and reactive manoeuvres, Cloud-based fleet management and on-demand ride calling using a mobile app. Till full autonomy arrives, it is imperative that par tially-autonomous vehicles are allowed to operate on the roads since this can potentially save many lives that would other wise be lost due to driver error or unsafe driving. The safet y quotient is enhanced by features such as for ward collision and lane depar ture warnings, parking assistance with rear camera and lane -keep assist, highway and cit y autopilot modes, among others. In this stage too, AI has a role to play through the Co-Pilot System whereby the driver’s aler tness and drowsiness levels are monitored, including distrac ted driving, even while the vehicle is cruising on Autopilot. The system also offers complete driver profiling and predictive analysis, enabling safe driving behaviour by predicting unsafe habits. M o re ove r, 3 D L I DA R ( L i g ht D e te c t i o n a n d R a n g i n g ) m o n i to r s t h e surroundings. A remote -sensing system, LIDAR’s computer-vision technology checks to ensure there are no objects or obstructions that can pose a threat. The data is then transmitted to the onboard computer, which helps it decide whether to continue cruising or to accelerate, brake or switch lanes to the right or left. A s A I t e c h n o l o g y a d v a n c e s i n t h e f u t u re , i t w i l l b e p o s s i b l e t o conver t existing vehicles to self- driving ones. B esides the benefits already mentioned above, safet y aspec ts and low maintenance are the other advantages. All this should drive faster, timely deliveries and complete customer satisfac tion – precisely what supply chain management is all about.
Path to Full Automation The levels of automated driving range from L1 to L5. L1 offers driver assistance. L2 has par tial driver assistance. L3 refers to conditional automation. And L4 denotes high automation while L5 is full automation. At this juncture, autonomous vehicles up to L4 are deployed in India. Currently, completely autonomous vehicles have not yet come on the roads, except for test drives. Nor do present road regulations permit L5 driverless vehicles in India. Nonetheless, L4 autonomous shuttles are allowed within gated precincts where the regular road or pedestrian traffic is not present. These include large office campuses, elderly care communities, Smar t Cities, trade fair and theme parks, among www.oswindia.com
Offshore World | 10 | June-July 2017
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GUEST COLUMN
Drones – Oil & Gas Assets are not Remote Anymore.
Drones have given the engineers the technologists to explore the unexplored. We no longer need to risk human life or need to depend on predic tion without unsuppor ted data to arrive at critical decisions. Dr Arunkumar Ranganathan AVP & Head DCG, Energy Utilities & Services, Infosys Ltd
D
rones – Most commonly known as Unmanned Aerial Vehicles/ Systems. They are the subset of Robots with Unmanned flight capabilities. They can fly autonomously, controlled by embedded software or can be remotely operated by controller on the ground. Drones have given the engineers and technologists to explore the unexplored. We no longer need to risk human life or need to depend on prediction without unsupported data to
Mobility: Speed, ease of use and efficiency of drones will provide the oil and gas companies with the oppor tunity to collect data at large scale and analyze it in real time Cost: Drones replace on the field crews, Helicopters and other transport mode, thereby bringing down inspection costs drastically.
arrive at critical decisions. Drones offer inexpensive visibility without risking human safety performing tasks ranging from surreal (ex: Volcano Monitoring,
Oil & Gas and Drones
Oil & Gas Pipeline inspection during accidents Integrating Drones with IoT sensors have elevated the effectiveness and now Drones can play a critical role in Remote sensing, visibility, critical data acquisition.
Oil & Gas industr y has begun its tr yst with Drones primarily to Inspect the Assets. One of the French Oil Major has piloted Asset Inspection using Drones, replacing the traditional manned inspec tions. In the
Why Drones
search for hydrocarbons, drones are becoming a highly useful resource, cheaper than helicopters or light aircraf t to map the seabed and
Drone bring in multiple advantages and some of the key advantages are
other hard to reach locations. Researchers from the CIPR (Centre for
Remote Access: They have the ability to reach locations where humans
Integrated Petroleum Research) of the University of Bergen in Nor way
cannot. Challenges could be limited space, rough terrain, and hostile environment or associated risks
are already using unmanned aerial vehicles carr ying laser scanners to
Frequency: They are por table and can be used for frequent inspections without inter fering with operations. Safety: By programming the flight path along the target, the operator can easily and safely inspect the target area or infrastructure from a safe distance
create 3-D maps of the terrain, providing highly valuable information for the exploration of new fields. UAVs are helping a large Europe based Operators exploration team to produce cost- effec tive 3D models of onshore outcrops in Azerbaijan. The combined use of drones and autonomous under water or terrestrial vehicles is another field being ex tensively developed. The Universidad
Th e f i xe d g a s d e te c t i o n s y s te m s u s e s e n s o r s m a n u f a c t u re d s p e c i f i ca l l y to d e te c t H yd ro g e n S u l f i d e l e ve l s i n ra n g e s f ro m 0 - 2 5 to 0 - 5 0 0 0 p p m . www.oswindia.com
Offshore World | 12 | June-July 2017
GUEST COLUMN Politécnica de Car tagena (UPTC) is leading the European projec t Urready4Os, Under water Robotics ready for Oil Spills, to create a joint fleet of drones and under water vehicles so as to increase the safety of installations, while terrestrial robots similar to those used on space missions could ser ve to super vise industrial installations or pipelines. Some trials are being done using Unmanned Arial Vehicles to deduct leaks from long Pipeline installations.
Oil Refiner y facilities & Storage tank inspections:
Inspec tions can be per formed simultaneously collec ting and delivering both digital photography and thermal imagery remotely
Identifying water accumulation and surrounding environment that are potentially susceptible to rust and corrosion.
Asset Monitoring using Drones
M o n t h l y, A n n u a l a n d 5 y e a r l y Vi s u a l i n s p e c t i o n o f t a n k s are mandated. Drones are usually able to collec t drone
Global technology major has estimated the amount of inspection time can be cut by half by using drones and other robots c, depending on the assets being inspected. Challenges in the inspection process through conventional means like for example: Flare Stacks require regular inspec tions for regulator y and operational purposes, this requires inspectors to get close enough to discover what are often tiny traces of wear that can lead to gas leaks and per formance issues with related systems. It’s a dangerous, time -consuming and ultimately expensive
inspec tions data from across an entire tank farm in few h o u r s’ t i m e .
Chimney Inspections
Drones minimize conventional ways of using ropes and scaffolding to identify cracks and anomalies.
Inspecting safety railings and stairs on chimneys, flare stacks and tanks before crews carr y out maintenance work.
A co m m e rc i a l u n m a n n e d ve h i c l e w i t h a h e a t - s e n s i n g ca m e ra co s t s a b o u t $ 8 5 , 0 0 0 , w h i l e a h e l i co p te r co s t s $ 3 , 0 0 0 p e r f l i g h t h o u r. task. These assets can be inspected only when it cools down after the
Drilling Facilities inspection:
asset and related systems are shut down, this process is slow and
often involving scaffolding, rope inspection teams and visual analysis. Use of Drones will address all these issues.
The data from the drone after the flight data capture is used to create a 3D model of the asset and changes over time through subsequent inspec tions are tracked. For example, they can see if a piece of metal is star ting to expand or buckle or if a miniscule crack is growing.
Robotic inspections most of the instances does not inter fere with operations and hence shut down requirements are minimized. This facilitates more frequent monitoring, leading to earlier detection of potential problems.
S i n c e t h e i n s p e c t i o n i n f o r m a t i o n i s re c o rd e d a n d a rc h i ve d, t h e y ca n b e a l o t m o re i n s i g ht f u l a n d t h o ro u g h . Te c h n o l o g y facilitates multiple stake holders to per form inspection remotely at the same time.
Other areas where Drones can play significant part in asset Inspection are
Highly- sensitive Gas sensors can deduct gas accumulation and leakages while drilling gaseous wells. Periodic sur vey to deduct anomalies can be conducted on the rig and while flaring gas. Drones can be used to continuously record impact on environment, through periodic data collection, compare current deviation. The data can be used for immediate remedial actions.
Pipeline inspections: Pipeline systems are often located underground or run for many kilometers where access roads are restricted, the surrounding nature is not attained and access to pipelines is incredibly difficult or impossible. Reliability of the pipelines suffer due to poor design, defective material or construction or from hostile conditions when in the operation. The damage can be reflected as weakening of the cladding on the external insulation and leaks of heating energy, as well as breaks in the piping and the loss of the transported medium. The internal corrosion results in the wear on the thickness during the transport of aggressive liquids or mechanical stressing in the case of the transport of non-homogeneous materials with solid particles.
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GUEST COLUMN
To resolve the problem of inspecting long-distance pipelines, an elegant and simple solution is available at first sight. UAV with a camera record and display the capture in real time by flying above the entire pipeline, a thermal camera can detec t such defec ts and record the thermal radiation of objec ts. The difference to the sur face of the pipeline and the experience of the operator in monitoring such variations can reveal hidden defects. It is easy to identify where the insulation is damaged and heat losses occur (during the transpor t of heating media). A commercial unmanned vehicle with a heat-sensing camera costs about $85,000, while a helicopter costs $3,000 per flight hour Drones uses high-resolution digital, infrared and thermal imaging to detect and document possible leaks in the pipeline. If suspect areas are found, the locations are precisely mapped with GPS. D epending on the gas pipeline inspec tion needs, drones with high-resolution digital imaging uses either a CH4 (Methane) or a C2H6 (Ethane) gas analyzer.
Optical gas imaging cameras from FLIR can be deployed to visualize and pinpoint gas leaks that are invisible to the naked eye. Drones make it ex tremely easy and affordable to continuously scan installations that are in remote areas or in zones that are difficult to access. Similar Sensor equipped Drones can be deployed to monitor and deduct other noxious gases. NASA has successfully flight-tested a miniature methane gas sensor similar to one developed by JPL for use on Mars, to improve safety in the energy pipeline industr y. A global technology major’s methane detecting Drone successfully found gas leaking from a couple of oil wells in Arkansas . Though Drones can play an efficient role in detecting noxious gases in large assets, UAV and Sensor researchers are working over time to address the following issues
The gas analyzers are designed to detect elevated levels of either methane or ethane in the air above a pipeline. The drone inspection flight repor t, shows the exact flight path, along with GPS coordinates and levels of gas detected.
Drones use high-resolution digital cameras or LIDAR for or thophotography for production of a 3D model of the pipeline corridor, and detects and documents Erosion, Exposed Pipe, Vegetation Over growth & Encroachments.
Noxious inspections: H2S is ex tremely Poisonous, Corrosive & Flammable. Sour Gas fields are required to comply to strict HES policies and provision continuous monitoring for H2S. Fixed Gas Detection systems are used for ambient area monitoring and detection of unsafe levels of Hydrogen Sulfide. These fixed gas detection systems use sensors manufactured specifically to detect Hydrogen Sulfide levels in ranges from 0-25 to 0-5000 ppm. Most drilling companies continuously monitor for Hydrogen Sulfide as the gas can come up to the sur face of the well at any time at levels that are dangerous to any personnel in the immediate area. An H2S Sensor used in a fixed gas detection system requires periodic replacement after several years of continuous use. Smar t Sensors having digital data in an on board circuit, which when connected to a gas detection transmitter is automatically uploaded into the transmitter for ease of use and continuous, maintenance-free operation. Gas fields and plants are large inland areas and UAV solutions can periodically monitor ver y efficiently.
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Issue of heavy gas sensors that are too much for the UAV to fly The issue of air displacement caused by “prop wash” from the rotors of the UAV would need to be addressed when taking actual gas measurements. Some monitors were not able to intake gas at a high enough volume in order to detect the gas unless the emission source was directly applied into the gas sensor Lack of sensitivity at long ranges
Drones are destined to transform the Asset management in Oil & Gas, it’s ex tremely relevant in the current price regime helping companies to improve efficiencies at lower costs. They are up to 85% faster and cheaper than the conventional techniques. They facilitate thorough inspec tions even at ex treme working conditions and environment, improving the safety and predictability of the operations. Use of Drones help companies continue inspection without having a need to shutdown, saving millions of dollars globally.
Offshore World | 14 | June-July 2017
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FEATURES
Savvy Separators: Introduction to Computational Fluid Dynamics (CFD) for Separator Design If yo u wor k i n the f ie ld of proce s s a nd separation, chances are you have come across comput at i o nal f lu i d d y n a m i c s (C F D). CF D produce s a wide ra nge of emotions ranging from abjec t fear, of ten invol vin g f las hbacks to a l on g forgotte n unive rs it y c la s s a nd a dizz ying array of par tial - differential equations, to c u r i o s i t y and e ve n e nt h u s i as m. The purpos e of this a r ticl e is to al l ay those fears, answer some questions and he lp yo u b e com e a n e d uc ate d cons ume r of CF D.
CFD for separators Many would start by asking the “so what” question: Why and when should CFD be cared about? This question will be answered, followed by a brief introduction to CFD including the major multiphase models, answering some frequently asked questions (FAQs) and ending with a short case study example of CFD and automated design exploration being applied to a cyclone separator, all of which will be achieved without recourse to a single equation! So why should CFD be part of the separator design? In today’s “lower for longer” market, cost reduction is front and centre for all. CFD helps in all the phases of a project: from reducing the initial project costs (CAPEX) and operating costs (OPEX) to helping manage project extensions, such as tying in additional wells to an existing facility. A subsea separator’s job is to separate gases and liquid prior to pumping. Ensuring the separator meets its process requirements is important. The pump or compressor downstream will not perform as desired if there is carry-over or under (liquid in the gas stream and gas in the liquid stream). Should this occur, operations will have a very expensive problem to resolve. In addition to meeting the minimum process requirements, there are other design considerations. There may be a need to reduce its weight to ease installation, understand how changes in upstream piping impact performance to provide a standardized design able to connect with many Subsea Processing Systems (SPS) configurations, minimize its size to reduce the amount of real estate used, minimize the pressure drop and the use and cost of internals. Hand calculations, such as Stokes law, can be used to estimate the required residence time, but this involves assumptions about the flow (for example, www.oswindia.com
no short-circuiting or even distribution across the flow area). Physical tests can be run, however these present their own challenges: cost and time, difficulty visualizing the complex multiphase flow, testing with process fluids and high pressures and temperatures introducing significant additional cost and safety concerns. Using CFD, the flow patterns in upstream piping, inlet devices and within the separator can be predicted to ensure adequate residence time. Each separation mechanism can be studied such as estimating the tendency for liquid droplet re-entrainment due to high gas velocities and improving the performance of internals by increasing the uniformity of the flow to the demisters. CFD achieves this with relative ease and speed, using actual process fluids, temperatures and pressures. After simulating the initial design, we can run “what-if ” design studies to see how the design can be improved. In short, successful use of CFD results in discovering better designs, faster and at a lower cost. This is predicated on the assumption that the CFD study was conducted co r re c t l y, a n d t h e re f o re t h e re s u l t s c a n b e t r u s te d. M a ny o f t h e uncertainties of CFD can be systematically tested for (such as a mesh refinement study), or can be interrogated by an engineer who understands the relevant physics at hand (and not CFD). A common concern is that results must be “tuned” to be accurate. This is not necessarily the case as accuracy can be obtained through systematic testing, quantification and minimization of uncertainty and error, and by ensuring the problem is adequately posed and modelling assumptions are appropriate for the problem at hand. The first step in interrogating a CFD solution is to use good engineering judgment. Does the flow field make sense, and if not, why? How does it compare with hand calculations, prior designs that have validation data and simpler analysis methods? In the early stages, CFD mistakes are often
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FEATURES typos, so if it looks like the code solved a different problem to the one being investigated, there’s a good chance it did! Next, it takes a deeper explanation to understand the major steps in the simulation process and the potential impact of these on the results. CFD attempts to solve the Navier-Stokes equations which describe the behavior of fluids. Unfortunately, solving the Navier-Stokes equations is computationally intractable, so for all practical problems, the Reynolds Averaged Navier-Stokes (RANS) form is used. These suffer from the “closure problem” as they have more unknowns due to averaging which are resolved through the use of turbulence models. Models are also used to incorporate more advanced physics, such as multiphase flow dynamics. Setting up a CFD study involves four steps: 1. 2.
3. 4.
Defining the domain of interest, geometr y, flow entr y and exit and boundary conditions (for example, velocity at the inlet) Discretizing or meshing the domain: Rather than solving for the fluid behavior (velocity, pressure etc.) at every point in space, we segment the volume using a mesh, then solve the equations only at the center of each cell in the mesh - think of a separator filled with Lego bricks. CFD will tell you what the velocity, pressure, temperature and so on, is at the center of each brick. For completeness, in time-varying problems, time is discretized by solving for time increments, such as every 0.1 seconds. Selecting the physics to simulate, whether the flow is single phase or multiphase, thermal or isothermal. The CFD program then iteratively solves the equations to convergence.
These steps also represent the four areas of uncer tainty and where attention should be focused. If a 3D CAD model or drawings of the geometry exist and are available, defining the domain typically is not an issue. Defining the flow conditions at the inlet and outlet is more challenging. In separator simulations it is typical to prescribe a droplet size distribution at the inlet, which requires
knowing or estimating this. Typically, boundary condition information is available from other analysis methods – for example, from a 1D model of the system, from CFD by extending the domain of interest upstream to some point where there is less uncertainty or by hand calculations, for example, to estimate minimum droplet sizes. The engineer who performed the CFD study should be able to explain what conditions were used, what these mean physically and why they are appropriate. Nex t, the domain (geometr y) needs to be discretized or meshed. This is an impor tant and potentially time - consuming par t of the analysis. A good mesh begets good CFD. The mesh (number, size, and type of cells used) can influence the answer. As an example, if a CFD simulation is trying to simulate a vortex using one cell, the solver only has one point at which it calculates the velocity and pressure to represent the vortex. As the number of cells is increased, decreasing the size of each cell, the resolution and therefore accuracy of the representation of the vortex improves. A similar approach is used to ensure or minimize the influence of the mesh over the solution, the mesh is progressively refined (reducing cell size) until quantities of interest, such as pressure drop, stop changing. A short note on a well-established method for grid convergence studies can be found at1. There are also different cell types: hexahedral (six sides), polyhedral (many sided, but typically soccer ball shaped with 12-14 sides) or tetrahedral (four sides). Historically, tetrahedral meshes were often used, since building hexahedral meshes was difficult and time consuming, par ticularly for complex geometries. This is undesirable as tetrahedral cells have poor numerical properties; they artificially make the fluid behave as if it is more viscous. As a consequence, many more tetrahedral cells are required to attain the same level of accuracy as when using hexahedral or polyhedral meshes. Fortunately, meshing packages have improved significantly in the last decade, so it is now possible to build polyhedral or hexahedral meshes, even on complex geometries, without significant overhead.
Figure 1 : Different cell types: tetrahedral (blue), hexahedral (green), polyhedral (red) Offshore World | 17 | June-July 2017
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FEATURES After building the mesh, the engineer must select the physics to consider. One benefit of CFD is the ability to simplify problems to consider only the physics of interest, making it easier to interrogate and understand results and trends. This is also a double-edged sword as over simplifying can miss important effects. As with boundary condition selection, the engineer performing the analysis should be able to explain the models used, their physical meaning and appropriateness for the problem at hand. In the separator world multiphase modeling is key. There are three main multiphase models used in CFD: Free-surface or Volume Of Fluid (VOF) Eulerian-Lagrangian Multiphase often shor tened to Lagrangian Multiphase or LMP Eulerian Multiphase (EMP) In the VOF approach, the interface between the phases is resolved with the mesh. As in Figure 2, if droplets of water fall under gravity through air, CFD can capture the motion of the droplet using the VOF model if there is adequate mesh resolution to capture the shape and motion of the droplet in the mesh.
Consequently, this model is well suited for flows with a well-defined interface between the phases, such as stratified flow, where the mesh can be refined locally to capture the interface. A common application of VOF is to model the sea and its behavior around ships - there is a clear interface between the sea and the air. VOF can be used to model flows other than stratified but the mesh needs to be refined to capture the multiphase effects at the interface between the phases, such as entrainment of fine droplets into the gas phase. However,
in an Eulerian framework with a fixed mesh and the flow motion relative to the mesh. The full name for LMP is Eulerian-Lagrangian multiphase, but the Eulerian is dropped for expediency. For the dispersed phase, the trajectory of each particle or droplet is solved for using Newton’s second law of motion. The calculation of the droplet or particle motion is performed from the reference frame of the moving droplet, rather than the fixed mesh, which is known as a Lagrangian method. In order to reduce the computational cost and make it applicable to scenarios with a large number of droplets, each droplet represents an ensemble of droplets. Inputs to the motion calculation include submodels for the drag force and dispersion of droplets or particles due to turbulence. Additional sub-models can be introduced to include breakup and coalescence of droplets. The interaction between the phases can be either one- or two-way. One-way is where the motion of the droplets is influenced by the continuous phase but the continuous phase does not “see” the droplets; two-way is where both phases influence each other. The one-way coupling is often applied. This method is an efficient and accurate way to model droplet or particle flow but is less applicable when the volume fraction of droplets or particles is high. Opinions on the volume fraction cut-off vary but are usually in the 5-10 percent range, at which point the model accuracy and stability deteriorate. For particle flows, more advanced models can be used to address this, such as Discrete Element Method (DEM) or Multiphase Particle-in-cell (MP-PIC). In the separator world, LMP is often used to study the motion of droplets in the gas stream. For Eulerian multiphase, the full RANS equations are solved for each phase. Using the concept of “interpenetrating continua,” the continuous and dispersed phases interact through source terms for drag, lift, virtual mass and turbulent dispersion. This makes it an immensely flexible model, able to simultaneously handle any number of phases and any range of volume fractions. Sub-models can be included to account for additional physics such as breakup and coalescence of droplets or bubbles, or heat and mass transfer.
Figure 2 : Droplets modelled using VOF this increases the computational cost of the analysis. In the separation world, VOF is often used to evaluate the bulk flow properties of the vessel. When the flow is dispersed, either Lagrangian Multiphase (LMP) or Eulerian Multiphase (EMP) is typically used. In LMP, the continuous flow field is solved using the RANS CFD approach. In the example of droplets falling through air, the air is the continuous phase and the droplets are the dispersed phase. The continuous phase is solved www.oswindia.com
The disadvantages of EMP are that each set of RANS equations comes at a cost (studying many particle sizes or phases becomes computationally expensive) and the user needs to understand, and choose, appropriate sub-models and settings. The downside of EMP’s flexibility is that it can be applied to a wide range of multiphase flows, which results in multiple sub-models to be understood and applied. For analysis of separators, EMP can be used to model the full vessel, but is particularly effective in mixing regions where volume fractions exceed the limitations of LMP and in tracking small droplets or bubbles with VOF is computationally expensive. Having built the mesh, specified boundar y conditions and chosen appropriate modelling assumptions, the solver uses iterative techniques
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FEATURES to successively improve the solution until “convergence” is attained . Mathematically, convergence describes the limiting behaviour, particularly of a series towards its limit. In CFD, the series is the flow field (values for velocity, pressures etc.). The flow field reaches its limit when the values for velocity, pressure and so on, stop changing from iteration to iteration. Convergence is often judged by monitoring residuals. Residuals measure the amount by which the discretized equations are not satisfied. A typical rule of thumb is that residual values should have dropped by three orders of magnitude. If the residual values do not drop and the flow field continues to change, this may indicate that the steady-state assumption does not work due to inherent unstable phenomena like turbulence. Alternatively, it may indicate problems such as poor quality cells in the mesh or an ill-posed problem such as the location or values of boundary conditions.
Figure 3 : Geometry and flow visualization for baseline design the engineer to provide: Design objective(s): There can be more than one and these can be competing. In this case, the objective is to maximize the separation efficiency of the cyclone.
Case study: Design space exploration of a gas-solid cyclone separator to improve separation efficiency Having described the steps in setting up a CFD study and building confidence in the result, the following is an example of how CFD should be used to understand and improve the design and performance of a gas-solid cyclone separator.
Constraints to be applied: In this case, the pressure drop across the separator cannot exceed a certain value or else the design will be deemed infeasible.
The CFD simulations were run using STAR-CCM+®, a Siemens PLM software. Figure 3 shows the geometr y of the separator, streamlines through the device with an iso-surface showing areas of low pressure, volume rendering of pressure contours and a comparison between CFD using multiple methods and experimental data for mean axial velocity at two locations in the cyclone. The purpose of these simulations was model verification, which is why multiple methods were used for the same case. The baseline geometry for the design study is from an European Research Communit y On Flow, Turbulence and Combustion (ERCOFTAC) paper where the geometry and experimental data - Laser Doppler Velocimetry (LDV) - of the mean velocity profiles across the cyclone are available. Having validated the base model, CFD allows us to explore design alternatives quickly and easily. It can also be used in conjunction with tools that will automate the simulation process and efficiently explore the design space. In this case, the HEEDS multidisciplinary design exploration software from Siemens PLM, in conjunction with STAR-CCM+, was used. For the design space exploration study, a constant gas velocity of 25 m/s was applied at the inlet. Sand particles with a diameter of 1.2 µm were introduced at the inlet, such that they accounted for one percent of the volume fraction of the flow. LMP with a one-way coupling to the continuous phase was used, along with the Reynolds Stress Turbulence model (RSM). The automation and design space exploration tool HEEDS uses algorithms to predict the next exploration point in the design space. HEEDS requires
Figure 4 : Baseline cyclone geometry
Different load cases to be evaluated, for example if the separation performance is different at different particle loadings. Design variables: Their extents and sensible increments are to be defined. In this case, we vary the radius of the cyclone, the length of the constriction and parallel wall sections.
Many different approaches have been developed to help explore the design space efficiently. These are often referred to as optimization algorithms and include among others Design of Experiments (DOE), genetic algorithm,
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FEATURES
Figure 6 : Correlation plot efficiency and pressure drop (correlation of 0.74 and 0.71 respectively). Summary To the non-specialist engineer, CFD can be initially daunting, particularly in more advanced areas such as multiphase flow and separation. While detailed knowledge of sub-models will remain with the specialist, non-specialist engineers can critique CFD results by evaluating whether the physical meaning of the results be explained and asking about the modeling decisions taken and their anticipated influence on the results and quantities of interest. By introducing the main multiphase models used, this article aims to help in this process. Figure 5 : Geometry of improved design, velocity magnitude along a plane section through the center of the cyclone and design study history showing the progressive improvement in separation efficiency downhill simplex and particle swarm. Optimization is often a misnomer since for most industrial applications no single optimal solution or design exists. However, these techniques can be highly effective in identifying better designs. An impediment to the application of these methods is their multitude: Users must understand which method to use for any given scenario. HEEDS uses a hybrid and adaptive algorithm called SHERPA, which will switch between different exploration methods (DOE, genetic algorithm and so on) depending on the information it has about the analysis such as the number of variables and time and resources available. The benefit of using these methods is that they find better designs in less iteration than an engineer on their own or other optimization methods.
CFD compliments other analysis methods (analytical or experimental). Its successful application can have a significant, positive financial impact on projects: by reducing the cost of design, improving and validating equipment per formance and mitigating problems before they occur. Linking CFD with automated design space exploration tools can further the understanding and improvement of separator designs. References 1. http://journaltool.asme.org/templates/jfenumaccuracy.pdf 2. https://www.nafems.org/join/resources/cfdconvergence/Page0/ 3. http://www.ercoftac.org/
The correlation plot shows the relationship and degree of correlation between two variables, such as the radius of the cyclone and the cyclone separation efficiency. The numbers on the top right-hand side show the correlation between the two variables represented in the square (1.0 indicates perfect correlation). The correlation plot helps the engineer to interrogate large amounts of data (100-plus designs), and to understand quickly what influences the design. In this case, the cyclone radius has a significant impact on its www.oswindia.com
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Alex Read Direc tor, Industr y Sec tor Management Siemens PLM Soft ware Email: alex.read@siemens.com
NEXT ISSUE FOCUS: LNG The August- September 2017 issue of Offshore World publication, themed around LNG is also the ADIPEC Special issue. As the relevance of Natural Gas in the Hydrocarbon Sector continues to increase internationally, Offshore World aims to cover the opinions and latest technical insights of the stakeholders from the entire value chain of the natural gas industry. 350 300
Power
250
Fertilizer
200
City Gas
150
Industrial
100
Refineries & Petrochemicals
50
Sponge/ Iron/ Steel
0 2016-17
2019-20
2026-27
Source: BP Statistical Review June 2016 & Vision 2030, Natural Gas Infrastructure in Indiammscmd- million metric standard cubic meter per day
Some of the topics, the issue targets•
Recent developments in FLNG
•
Near-shore LNG producing projects
•
Regasification FLNG concepts
•
LNG competitiveness in the energy market
•
Enhancing LNG facility
•
and fleet development •
Innovative storage units
•
Reconfiguration of receiving ter minals
•
Latest developments in small scale LNG
For editorial submission in Offshore World, please contact: Nidhi Agrawal- Sub- Editor, Offshore World, Email: nidhi_agrawal@jasubhai.com
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LNG marine carriers- vessel technologies
and associated value chain
FEATURES
Maximising the Opportunity with FTG Gravity Th e c u r re nt l ow ris k , low price e nv ironme nt efficiencies to maintain best prac tices for oil and gas explo rat i o n. Ch e a p oi l a n d ga s m e a ns com pa nie s a re faced w ith increasing chal l enges to honour l icense co mmi t me nt s f ro m ex p l oration, to a ppra is a l, to f iel d devel opment. G overnment l icensing authorities, exp lo rat i o n co m p a n i e s, co ntra c tors a nd cons ulta nts are al l faced w ith chal l enging decisions and work prac t i ce s to me e t ex p e c t at i o n s. Howe ve r, if a ny thing ha s been l earned from the recent boom years it ’s that new te chno lo gi e s, of fe r i n g i m p rove d re s olution a nd s ucce s sful returns, continue to be devel oped and ex pl oited.
N
ew technologies offer advanced capabilities to maximise opportunities.
exploration industry since its ground-breaking work in the Albertine Basin
Their increased resolving power allows for a more far-reaching
with Tullow Oil in Uganda back in 2009 where 26 out of 27 successful
capability to detect, delineate and map prospects with incredible
wells drilled were FTG anomalies.
resolution. These technology advances have been largely in seismic and drilling capabilities and benefit enormously with increased computing power through design, implementation and processing know-how. However, many of these also involve increased expense leading to challenging decisions for exploration managers in the current climate. Do we continue to spend, do we reduce capability, and do we reduce the work program? How does one promote new acreage using these new technologies in a low price environment? How does one streamline prospects with limited funds to optimise their holdings? These are just a handful of questions facing such managers.
The Full Tensor and 3D Gravity field FTG comprises 12 gravity measuring devices arranged in 6 pairs with 2 pairs on each of three separate spinning discs. Each spinning disc ensures the field is measured in all directions of the 3D field and all at the same time on any single survey. The technology detects density contrasts lying both directly beneath and in between survey lines, a feat unmatched by any other gravity measuring technology. The combined output measures the rate of change of the gravity field as detected in
Many companies have looked to alternative technologies to help mitigate
sub-surface geology at an unprecedented resolution. The stark difference
against this imposition and to maintain their work programs. Airborne
with conventional gravity measuring devices is that unwanted signal, in
geophysics has seen increased uptake in recent times and rapid advances
the form of platform contributions to the signal, is cancelled out. This
have been made, with increased resolution now the norm. Airborne
facilitates measurement of the gravity effect of subtle density contrasts
magnetics, airborne EM and airborne gravity gradiometry have all made a
sourced by subtle geological changes in the shallow section.
break through with their ability to detect, delineate and map prospectively The different outputs are transformed into a Gravity Gradient Tensor
at an unprecedented scale in recent years.
field that allows direct detection of complex geological body shapes as Airborne gravity gradiometry is arguably the most successful of these new
they present themselves in a typical geological setting. Such features
technologies. Gravity gradiometry maps the gravity field as recorded by
include closed fault blocks, anticlinal closures, salt bodies, carbonate
sub-surface geology and presents an order of magnitude greater resolving
mounds from many intra-basinal settings, but also include mapping
power over its conventional counterpart, Gravity.
primar y basin forming trends and regional tec tonic settings from strike -slip, normal and reverse faults. This combined high accuracy,
Airborne Full Tensor Gradiometer (FTG) goes one step further in mapping
high resolution output facilitates mapping of the 3D subsurface geology
the 3D Gravity field and has witnessed a rapid uptake by the Oil & Gas
on any given sur vey.
www.oswindia.com
Offshore World | 22 | June-July 2017
FEATURES F TG d a t a i s a c q u i re d f ro m b o t h s e a - g o i n g ve s s e l s a n d f i xe d w i n g
FTG for the ages
a i r c r a f t . A i r b o r n e a c q u i s i t i o n i s c h a l l e n g i n g, b u t s u r v e y w o r k co n d u c te d o n s t a b l e, s l ow m ov i n g p l at f o rm s s u c h a s a B a s l e r Tu r b o
The key focus for FTG since then has been in delineating intra-basinal
a i rc r a f t ( Fi g u re 1 ) o f f e r i m m e n s e v a l u e. Th e l o n g w i n g s p a n a n d
structuring in many play model environments: from Carbonates and
h i g h e n d u r a n c e c a p a b i l i t y e n s u re s a c q u i s i t i o n o f h i g h l y a c c u r a te, h i g h re s o l u t i o n d a t a i n a t i m e l y f a s h i o n . B e l l G e o s p a c e o p e r a te s t h re e s u c h a i rc r a f t wo r l d w i d e, o f t e n c i t i n g t h e a i rc r a f t ’s u n i q u e o f f e r i n g a s a ke y d r i ve r i n t h e i r a b i l i t y t o d e l i ve r h i g h q u a l i t y F TG d a t a o ve r t h e ye a r s.
Thrust-Fold belts in SE Asia and India, to back-arc and fore-arc basins in the Americas, southern Europe, and the Middle East, to Rift Basins in Europe and Australia to fault mapping in unconventionals exploration in the US and Australia. FTG’s unique ability to simultaneously measure all components of the gravity field means it is best suited to mapping the 3D shape of geological structures generating density contrasts. Tullow Oil’s success in 2009 with FTG is remarkable. The target geological structures were a series of tilted faulted blocks. Cored by basement rock and overlain by lacustrine sediments and shales, their density contrast is ideal for detection. Conventional gravity data acquired initially established the concept model, but as much of the acreage is over difficult to reach parts, an airborne solution was sought. The 26 out of 27 successful wells drilled by 2009 are underpinned by positive FTG anomalies (Fig2) with the only duster being associated with a negative anomaly. FTG’s success in Uganda lead to extensive survey work elsewhere along the East African Rift from Ethiopia to Kenya, from Malawi to Mozambique and
Figure 1: Basler Turbo 67 aircraft used for acquisition of FTG data by Bell Geospace Early successes with FTG
activity is still ongoing with recent surveys just completed in Tanzania and Zambia. The uptake since 2009 has been immense, with Petronas, Repsol, Sasol, and BG, to name a few, adopting the technology in their exploration workflows. Delineation of key rifted segments and their complex structuring
Some of the first FTG projects were offshore in the Gulf of Mexico, Nor th
are confirmed by sparse seismic coverage where available and used to steer
Sea, and Nor way’s Barents Sea in the 1990’s and early 2000’s where salt
planning of new seismic acquisition, both 2D and 3D. The value is efficient
models were defined for seismic workflows.
use of exploration budget at a time when costs are everything.
FTG helped depict accurate depth and body shapes of complex salt bodies, including overhang development and connectivity with deeper mother salt. Density-depth models proved to be of immense use for early stage PSDM workflows that served to advance seismic imaging exercises. Sub-basalt imaging with FTG was also achieved offshore in the Faroe Islands at the turn of the centur y. Largescale basaltic lava flows are characterised by a laterally homogenous density expression making them blind to gravity sur veying methodologies. The impact is that high resolution gravity sur veys image sub-basalt geology accurately. High resolution FTG established depth to tops of the key Mesozoic fault blocks underpinning trapped hydrocarbon occurrences and were confirmed by drilling on Statoil’s Brugdan prospect in 2006.
Figure 2: FTG mapping hydrocarbon bearing structures in the Albertine Basin, Uganda. Image reproduced from joint Africa Oil and Tullow Oil presentation at UBS Global Oil & Gas Conference, 2012.
Offshore World | 23 | June-July 2017
www.oswindia.com
FEATURES Petronas in Malaysia committed in 2012 to FTG survey work over large areas both onshore and offshore Peninsular Malaysia, Sarawak and Sabah. 4 years and 162,000 sq kms of FTG data later, the data coverage represents the largest single holding of FTG by any operator. The diverse and complex array of anomaly patterns is testament to the technologies’ ability to resolve some of the complex geological exploration challenges in these parts. The Sarawak Basin is well established as an oil producer with many producing fields from the carbonate platform since the 1970’s. The current focus is to now image sub-carbonate to identify and delineate new plays. The carbonate properties and body shapes are a challenge for conventional seismic workflows leading to long processing times. FTG does image sub-carbonate, identifying basins and migratory pathways that feed the productive reservoirs within the carbonate itself. Figure 3
Figure 3: Depth Map from FTG data in Malaysia – cold colours map basins lying directly beneath the Luconia Carbonate Platform
shows a depth to top Pre-Cycle Basement generated from FTG data over
conventional rift basin with the development of a series of half-grabens.
the Luconia platform offshore Sarawak. The FTG Depth Imaging workflow
Plays have been successfully drilled with two oil accumulations from well
establishes a variable depth to the dominant metasedimentary basement
NNG-1 (Jabber et al, 2015). The deeper of the two pools resides at Top
and predicts the presence of pre-Carbonate basins reaching 4km depths
Basement defined by a tilted fault block structure. Corresponding FTG
(cold colours). The additional benefit is direct mapping of key structural
data facilitates direct mapping of the structure (Figure 4) away from that
lineaments interpreted as faults predicting both transfer and normal fault
depicted in the seismic. The negative anomaly pattern coincides perfectly
activity. These serve as migratory pathways for generated hydrocarbons
with the basinal troughs where the source rocks reside.
from depth into the overlying Carbonate hosted reservoirs. Th r u s t a n d f o l d - b e l t s e t t i n g s a re i d e a l h u nt i n g g ro u n d s f o r F TG West of Luconia in what is known as the Half-Grabens of the Tatau
applications. The nor th-western shores and onshore Sabah, Malaysia,
region, the geology changes from dominant carbonate platform to more
has received much interest with regional 2D seismic and geological map
Figure 4: FTG response over a successfully drilled half-graben structure offshore Malaysia (seismic from Jabber, 2015) www.oswindia.com
Offshore World | 24 | June-July 2017
FEATURES data being the primar y technologies used to delineate thrust faults,
FTG signal is transformed to a conventional gravity field and combined
anticlines, and synclines. FTG data acquired in 2015 confirms the
with legacy gravity data to produce a Full Spectrum Gravity product
published interpretations of Cullen (2010) with positive anomalies
making it ideal for resource and play modelling concepts. Innovative
t ra c ki n g t h e t h ru s t / re ve r s e f a u l t p at te rn s a n d co l d co l o u r s t h e
analysis methodologies of the Tensor data facilitate detailed 3D imaging
known synclines. Figure 5 shows the one - on- one correlation with
and accurate depic tion of target struc tures. Combined with depth
corresponding fault picks made from 2D seismic data. The availability
information accessed from seismic and other technologies, the data is
of the FTG data now ensures confident mapping of the syncline’s extent
transformed into a 3D density model. Results from joint work with industry
previously only predicted from the seismic.
leaders demonstrate the true value of FTG and represents a future direction for FTG technology.
The recent shale - gas exploration successes across the US required innovative solutions for traditional geophysics, with the source and
Driving exploration with FTG
reservoir being the same target, presenting a challenge for cost effective detection. FTG’s usage in such projects has been to map fault patterns
FTG fast-tracks exploration through its unique ability to not only locate basins and basement settings but also directly identify and delineate intra-basinal structuring leading to informed play model mapping. The technology is proving to be of immense value in driving exploration activity in both mature and frontier areas alike. The recent work offshore Malaysia identifies sub-carbonate basins and new play concepts leading to improved exploration in this long established producing region. Continued work along the East Africa Rift identifies new plays along Lake Malawi and detailed mapping of pertinent strike slip fault patterns impacting shale-gas exploration in the Utica of Ohio, USA. Collective decision making by the industry’s leading players, both NOCs
Figure 5: FTG response over a previously mapped thrust fault and syncline. Grey lines locate composite seismic section with white fault lines coinciding with picks shown on the seismic. Seismic line and geological interpretation on FTG data reproduced from Cullen (2010). both on the regional and prospec t scale to assist with drill planning exercises. Mapping such struc tures is critical to minimise risk due to potential leakage from source and potential contamination of ground
and IOCs is now leading to ambitious plans to roll out FTG on largescale basin wide surveys that will build the new base maps that will serve to re-define known opportunities but equally important help open up new basins and play concepts. This cost-effective exploration technology maximises opportunity helping maintain exploration strategies in the current low price environment.
water supplied. FTG data was acquired in SE Ohio over the Utica play in 2014 for this purpose and identifies the regional strike -slip fault pattern impac ting the distribution of targeted shale horizons. Continued development FTG development continues at pace. 3D depth imaging workflows that involve seamless combination of FTG signal with conventional gravity, ability to image geology in between survey lines, extraction of geological signal and prediction of a density field are now proven and widely revered that direct usage in challenging seismic imaging projects is truly viable. Offshore World | 25 | June-July 2017
Colm A. Murphy Chief Geoscientist B ell Geospace Limited, Edinburgh, UK Email: cmurphy@bellgeo.com
www.oswindia.com
FEATURES
Embracing Digital- Realizing Unfulfilled Potential in Oil and Gas Industry Not l o n g a g o, the c ruc ia l rule of the game was foc used on l arge produc tion. The rul es then s hi f te d - to b e t te r m a rg i ns be c a us e of a s ignif ic a nt imbal ance in demand and suppl y, geo -pol itic al decisi o ns, and low c ru d e p r i ce s. In the c urre nt e conomy, e fficiencies in operations is the name of the game and t he i ndu s t r y s e e m s to h ave f ixe d the ir e ye s on one major frontier: digitization
D
igitization, which can be described as collecting, monitoring,
from smar ter exploration, easy capturing of data, robust reser voir
and analyzing huge amount of data, can bring a dawn of new
modelling applications, safer operations, and interoperabilit y of data
operational efficiencies using sensors, increased computational
across exploration ac tivities. This helps not only in reducing costs
power, automation, remote configuration and optimization, control
and better utilization of labor, but also, if done well, in transforming
systems, and even ar tificial intelligence. Analyzing big data is not new
the planning process with predic tive analytics. This provides E&P
for an industr y that has relied on data for decades to understand the
companies with a better shot at anticipating and responding to ever-
potential of reser voirs that hold billions and trillions cubic feet of oil
changing market scenarios.
and gas. Yet the industr y, par ticularly upstream, has been struggling to become “more digital.” Many companies are now giving their digital strategies a new lease of life to curb the menace of a rather painful downturn and position themselves for nex t growth cycle.
Payment Process An often neglected area for exploration and production companies is the ability to speed up the ever daunting and slow process of payments in this industry. Some E&P companies are trying auto-executable contracts
Although the potential benefits of automation in the entire upstream value chain is evident, some of the biggest and impactful oppor tunities exist in production operations. With oil and gas companies looking to deeper seas for resources, any downtime will become costlier than it was at any time before. Automation may create several benefits for operator to that end: asset utilization and integrit y and increased field recover y. There is another oppor tunit y lying ahead, not just for oil and gas producers, but also for drilling operators and oilfield ser vices companies.
and quick payments transfer by using blockchain technology that removes the requirement of a mediator to validate transactions. By accelerating the industry’s slow payments process, technology can free up cash for exploration, lower a company’s operating expenses, and contribute to higher margins per barrel. Drilling Contractors Asset Strategy Since the downturn, many drilling operators had either cancelled new orders or refurbished their old rigs to continue working with aging
Digitization is not just about much needed efficiencies; it is also about
assets. Many companies may have to reassess their portfolios, and make sure that they capable of supporting increased activity and new drilling environments. Most will need to redefine their fleets to match those opportunities—and likely will have to expedite retirement of some older rigs. Operators and drillers should collaborate in developing scenarios for balancing the supply and demand of rigs over the long term to reduce
enabling E&P companies to develop power ful capabilities to benefit
the risk of fleet investments.
Digital approach of major upstream stakeholders Exploration and Production companies Smart Exploration
www.oswindia.com
Offshore World | 26 | June-July 2017
FEATURES
Figure 1 : Impact of digitization on Upstream Value chain Technology
assistant can provide a technician clear instructions in the field when a
All three upstream stakeholders, operators, drilling contractors, and
safety valve stops functioning. The idea of virtual assistant may seem
oilfield services providers have to work together to transform the entire
futuristic, but already a major oilfield services company is trying an AI
end-to-end technology solution by introducing more automated drilling,
based virtual assistant providing assistance to its field engineers for its
data-centric approach, and condition-based maintenance. This requires
logging operations.
acceptance from all the stakeholders about challenges and opportunities new technology brings to the sector.
Key themes of digitization across oil and gas Industry
Oilfield Services
Predictive Analytics and Asset Management
Connected Oilfield
Asset management has been a much talked about topic in the industry,
Th e co n n e c te d o i l f i e l d i s a b o u t a n i nte g rate d a p p ro a c h to w a rd s
but it is only now that oil and gas companies are warming up to utilize
operations: using IT to change processes for better decision making,
its full potential. Coupling asset management with predictive analytics
remotely access, monitor and control equipment, and to move more
has ushered in a new age of out of the box solution to reduce costs of
func tions and personnel onshore. This approach ensures that not
operating an asset. Asset maintenance, in many industries, is moving
only risks associated with business, health, safety, and environment
from a time bound inspection towards a risk based assessment of assets.
are reduced but also the objectives of going digital are achieved. A
This ensures minimum downtime and reduced costs and occurrences of
connec ted oilfield works on a vir tual environment where effec tive
emergency repairs.
communication and collaboration among experts can occur, regardless of where the exper ts are physically located or to which organizations they
Artificial Reality and Wearables
belong. For example, a basic ability to remotely recalibrate a pressure
Many te chnol ogy co mmentators have al re ady written a lot about
gauge makes sure that relevant data can be shared and incorporated in
applications of ar tificial realit y / vir tual realit y in our daily lives.
the decision-making process quickly, avoiding delays and saving safety
Imagine this: a field engineer is wearing a smart glass that shows him 3D
risk, time, and money. A lot of visualization tools are being developed
schematics, guidelines, and video instructions to repair a critical failure
that will aid in ensuring seamless integration of data, thus making
in an offshore gas turbine that powers the operations of a huge process
interpretation of data easier and availability of data transparent.
platform. Or a wearable that guides you to the nearest evacuation points in case of emergency. This kind of over-the-shoulder coaching will not only
Use of Virtual Assistants
reduce downtimes drastically, it will also reduce HSE risks and expedite
With the advent of chatbots, it is not difficult to imagine that a virtual
on-the-job training for new employees.
Offshore World | 27 | June-July 2017
www.oswindia.com
FEATURES •
Look for significant trends that dominate the industry with focus on identified areas of the value chain, and take a decision to either innovate or adopt tested technologies and processes.
•
Define the links between a company’s most critical decisions and digital applications, and show how these applications improve efficiencies of existing processes.
•
Most companies falter by considering digital strategies as a one-time approach. Evaluate the investment to digitize identified processes and activities and support with a multi-year budget and roadmap.
•
Acce p t a n d a s s e s s t h e g a p b e t we e n c u r re n t p e r s o n n e l capabilities and capabilities required to implement new technologies,
Figure 2 : Oil and Gas Industry is slowly bracing automation
and plan an upgrade of existing talent or leverage a partner.
Internet of Things, Data analytics, and Process Efficiencies Big data has been talk of the town for the past five years, and rightly so. Rich data that had been lying unused for decades suddenly became useful and helped companies in shaping their strategies to iron out efficiencies in their operations. All this has been possible by ensuring that companies collect right data using sensors that feed continuous data to the cloud. As we look to expand scope and
Way Forward The journeys of this digital transformation will not always be rosy, and they will differ depending on maturity on the digital ladder, ambitions, and financial provisions. Digital leadership is not always the best strategy, and it can be expensive. Although at a time when companies are reducing their capex extensively year on year, this strategy might look
applications of Internet of Things, oil and gas companies are finding newer ways
odd. However, with the ever-decreasing cost of digital transformation,
to collect more data and devise strategies to improve efficiencies further. It is
rapidly improving tools, and potential reduction in operating costs, this
an unavoidable truth that many oil and gas companies either have made a new
area should have enough bandwidth in terms of focus and budget. It is
CXO position of Chief Data Officer or are in the process of hiring one.
no coincidence that all the major themes on digital transformation lead on to some degree of automation, and it is anybody’s guess that the
Overcoming Human Resource Crisis using Artificial Intelligence
industry is indeed headed towards automation. While en route on this
and Machine Learning
digital transformation, it should not be forgotten that any strategy should aim to create a competitive advantage over the next three to five years.
O i l a n d g a s i n d u s t r y i s u n d e rg o i n g o n e o f t h e b i g g e s t “f o rc e d ”
All of these propositions should include initiatives that offer short-term
transformations at this time: Human Capital management. There is
gains and ensure that the companies develop long-term competitive
widespread unknown of losing many experienced professionals, as many
advantage to reap the benefits of digitization.
tenured employees are going to retire in next 3-4 years or have switched to other professions to weather the downturn. Many players across the industr y are tr ying to digitize the knowledge and experience these professionals possess. As the age of AI and high computational power dawns on us, we can use these tools to create an intelligent database of all these experiences. A database that not only grows, but also learns. Strategy to Plan for the Digital Future •
Divjot Singh
Identify key areas of value chain that has the highest impact on financial and operating parameters, and treat them as opportunities to improve delivery through digital approach.
www.oswindia.com
Offshore World | 28 | June-July 2017
Business D evelopment Manager Energy and Natural Resources Cyient
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FEATURES
Concerns over Rising Oil Production in U.S., Libya Pulls Oil Prices Down In t h e t wo - m o nth pe riod of M ay-J une 201 7, worries that grow ing crude oil produc tion in U. S. and Li bya may of f s e t O P EC ’s e f for ts to conta in globa l oil suppl y pushed MC X crude oil futures prices dow n. Howe ve r, Hi nt s on a p o s s i b l e ex te ns ion of OPE C c uts during mid-May did briefl y suppor ted oil prices. The o t he r e ne rg y co m m od i t y M C X natura l ga s f uture s prices too fel l in the t wo -month period.
Rising U.S. crude production push oil prices down
cuts. However EIA repor t hinting rise in U.S. shale oil production and an International Energy Agency repor t warning that an ex tension to
MCX ac tive crude oil futures contrac t star ted the month of May at
the OPEC-led production cut agreement won’t be enough to rebalance
Rs. 3,277 per barrel; down by 0.21 per cent from previous month’s
the global crude market, denied a major rise in oil prices. Oil prices
c l o s e a s o n co n ce r n s t h at r i s i n g U. S . c r u d e o u t p u t wo u l d o f f s e t
later moved up as EIA repor ted a six th straight weekly decline in U.S.
effor ts by OPEC and other large crude producers to cap a nagging
crude inventories. Fur ther market par ticipants expressing optimism
global oil glut.
about possible price -suppor tive outcomes from a closely watched OPEC meeting at the fag-end of the month of May helped MCX crude
Additionally rising output in Libya and a sur vey showing a fall last
oil futures register its two-month (May-June 2017) high of Rs. 3,370
month in compliance with the OPEC’s production cuts added to the fall
on May 24. Internationally too, NYMEX crude oil futures registered its
in oil prices. Fur ther, data release showed that the number of active
month high of US$ 52.00 per barrel around same period.
U.S. oil rigs climbed for 16th week in a row—suggesting fur ther rise in production ahead.
Disappointment from OPEC meet pulls oil prices down
Hints on a possible extension of OPEC oil output
Oil prices then moved down as market par ticipant were disappointed
cuts lift oil prices
with the OPEC’s decision to ex tend produc tion cuts by nine months. Whi l e a n ex te ns io n wa s w id ely exp ec ted, ex p ec t at io ns were t hat
Later, oil prices recovered as comments from major OPEC oil producers
OPEC would make deeper reduc tions to output or ex tend the out-
hinted at a possible ex tension in crude -output cuts beyond this year.
limit deal by 12 months. Later af ter brief price recover y, oil prices
Saudi Arabia’s oil minister said a deal to cut produc tion could be
a g a i n f e l l o n b e l i e f t h at t h e ex te n d e d - p ro d u c t i o n ca p s by m a j o r
extended into 2018. The election of Emmanuel Macron, a pro-free trade
p ro d u c e r s a n d t h e s u m m e r - d r i v i n g s e a s o n i n t h e U. S . wo n’t d o
centrist, as France’s nex t president also helped to assuage concerns
enough to reduce global supplies.
that the European economy may see fur ther headwinds. Oil prices were fur ther helped by Energy Information Administration (EIA) weekly data
Overall, oil prices continued to steadily move down almost through the
release that revealed the biggest weekly decline in U.S. crude supplies
month of June. Apar t from rising U.S. oil production, U.S. President
so far this year. By mid of the month of May, oil prices were suppor ted
Trump’s withdrawal from the Paris Climate Accord added to fears of a
as energy ministers from Saudi Arabia and Russia released a joint
persistent supply glut. Fur ther data showing unexpected rise in U.S.
statement backing a nine -month ex tension of OPEC-led production
crude stockpiles, increase in U.S. gasoline stockpiles and continuing
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Offshore World | 30 | June-July 2017
FEATURES MCX crude oil futures prices (Rs./barrel) - May-June 2017 3,340 3,180 3,020 2,860 2,700
Source: MCX
weekly rise in the number of active U.S. oil rigs, kept oil prices on
Weather forecasts, especially in May showing mild weather in U.S.,
downtrend. Eventually fears that rising produc tion from the U.S.,
dampening demand sentiments for gas as a power-plant fuel, pushed
Libya, and Nigeria, as well as stubbornly high stockpiles world-wide,
natural gas prices down. Additionally, a consistent rise in U.S. natural
undermining views that the continuing production cuts led by OPEC
gas inventor y levels repor ted weekly, kept gas prices under pressure.
and Russia will lift prices, pushed MCX crude oil futures to two-month (May-June 2017) low of Rs. 2,732 on June 21. Internationally too,
Authors are Managers with Multi Commodity Exchange of India Ltd., Mumbai. Views
NYMEX crude oil futures registered its month low of US$ 52.00 per
expressed here are personal.
barrel around same period. M ild recover y at fag- end of t wo -month period Fo l l o w i n g t h e re g i s t e r i n g o f t w o - m o n t h l o w, o i l p r i c e s re c o v e re d a s s o m e o f t h e w o r l d ’s l a rg e s t p ro d u c e r s e x p re s s e d w i l l i n g n e s s t o s t i c k t o o u t p u t c u t s . F u r t h e r, a m o n i t o r i n g c o m m i t t e e m a d e up of OPEC members and producers outside the group said c o m p l i a n c e t o t h e d e a l re a c h e d 1 0 6 % i n M a y, t h e h i g h e s t s i n c e
Niteen M Jain Manager, Department of Research & Planning Multi Commodity Exchange of India Ltd E-mail: niteen.jain@mcxindia.com
t h e d e a l w a s f i r s t c l i n c h e d l a t e l a s t y e a r. L a t e r, o i l p r i c e s w e re a l s o s u p p o r t e d i n t h e w a k e o f t e m p o r a r y p ro d u c t i o n d i s r u p t i o n s c a u s e d b y a t ro p i c a l s t o r m i n t h e G u l f o f M e x i c o a n d a s i z a b l e w e e k l y d e c l i n e i n U. S . c r u d e p ro d u c t i o n . F i n a l l y, M C X c r u d e o i l f u t u re s c l o s e d t h e m o n t h o f J u n e a t R s . 2 , 9 6 8 , d o w n b y 6 . 4 9 p e r c e n t o v e r t w o - m o n t h p e r i o d o f M a y -J u n e . The other major energy commodity, NYMEX natural gas futures prices
Nazir Ahmed Moulvi Manager, Department of Research & Planning Multi Commodity Exchange of India Ltd E-mail: nazir.moulvi@mcxindia.com
fell by 6.20 per cent in May-June, with a close at Rs. 193.8 per mmBtu. Offshore World | 31 | June-July 2017
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FEATURES
Remote Monitoring Ser vices Offer Users Competitive Advantage
M
arket demand for remote monitoring of automation systems, especially in industries such as oil and gas, continues to increase as revenue pressures and even demographics force end users to seek new ways to address costs. Some end users have concluded that they are not in the automation business, much like an individual relies on a mechanic to maintain their vehicle, and they should consider relying on entities whose business is automation. Many plants have reduced headcounts, forcing them to operate with fewer resources. Remote monitoring ser vices offer a viable solution for owner- operators to improve reliabilit y, improve per formance, and reduce risks, especially when operating with limited internal resources. Most automation suppliers offer some form of remote monitoring – either continuous or on-demand - for their control systems. In fact, suppliers have begun to grow their remote monitoring portfolios to better meet their customers’ needs. In all cases, users can be alerted automatically when corrective actions are required. If the end user needs assistance with a work function or repair, the automation supplier can provide remote or on-site support, as needed. At larger installations, the automation supplier might dedicate specialists to monitor that site remotely, or even staff service personnel on site on a permanent basis. Generally, the user will allow the supplier remote, read-only access to their systems as needed to collect and analyze data, per form system health checks, evaluate control and optimization schemes, and troubleshoot issues. End users will usually only give the supplier authorization to make changes to the system in a closely supervised environment. However, this is beginning to change. There are a select few end users that have opted to give the supplier full responsibility for the maintenance of the automation system. The supplier, in this case, work with the end user to ensure there are no surprises to operations during any work performed.
can reduce or eliminate the often-significant costs that would otherwise be incurred if the supplier’s experts had to travel to their facilities. Limiting Risks with Remote Condition Monitoring R emote monitoring will not replace hands- on work per formed on t h e p l a nt f l o o r o r i n t h e f i e l d. I t c a n re d u ce re s p o n s e, a n a l y s i s, and remediation times. The most costly incident in a plant is unscheduled downtime. Exposure to this risk can be reduced through a combination of predic tive and preventive maintenance ac tivities. Information is gathered from the plant floor via m obile hand-held, wired, or wireless condition monitoring instrumentation. System health can be measured on a continuous or near- continuous basis. Whether collected remotely, on-site, or via a combination of the two, the plant floor data can be used to create predictive maintenance programs to help prevent asset failures, with maintenance ac tivities scheduled to minimize production interruptions. The plant floor data collec ted via remote monitoring can also be used to help evaluate loop per formance, production quality, and throughput against targets and known process and asset constraints. Some manufac turers have s t a r te d d e p l o y i n g p re d i c t i ve a n a l y t i c s w h i c h h ave i n c re a s e d t h e amount of time to remedy these potential problems.
Remote monitoring often provides a cost-effective vehicle for end users to supplement their in-house maintenance functions. It can help prevent asset failures, quickly resolve any failures that may occur, and help prolong asset life. In addition, remote monitoring increases the overall system reliability, availability, and operational performance by reducing the risks of asset failure and unscheduled downtime. Through remote monitoring, users have quicker access to their control system supplier’s experts and www.oswindia.com
Offshore World | 32 | June-July 2017
FEATURES with 24-hour remote access to their installed control systems. Corporate IT policies and physical firewalls remain major obstacles, but are being overcome as end users understand the risks and rewards. While end users remain cautious about providing significant access to their systems, automation suppliers are taking proactive measures to ensure the integrity of data. These include authentication, encryption, registered users with limited privileges, secure control rooms, and secure VPNs. Some suppliers include cybersecurity monitoring as part of their services which can also mitigate vulnerabilities. In many cases, these supplier-provided cybersecurity services create a more secure environment because end users lack the resources to actively monitor the control system infrastructure. Summing up
Enhancing Support and Maintenance Functions Over the past five years, manufacturing industries shed thousands of jobs. This resulted in a skill and knowledge gap, which is now being exacerbated by retiring baby-boomers. In response, many facilities have begun to implement advanced predictive maintenance practices to supplement their existing preventive maintenance. In this environment, remote monitoring services can provide around-the-clock monitoring capabilities, as well as provide the expert analysis needed to perform predictive maintenance and optimization functions. In cases where the knowledge does exist in house, the expertise from the supplier can serve as a valuable second opinion and assist plant personnel identify, analyze, and resolve problems. Cybersecurity Concerns As hackers continue to increase their sophistication across the globe, many industrial end users are reluctant to provide even trusted suppliers
In a world where even the slightest competitive edge can make or break an operation, remote monitoring services in the oil and gas industry can offer considerable value by helping to minimize unplanned downtime and improving asset performance. Not only does it allow end users to augment their depleted and often under-skilled staff, as well as bolster the knowledge that is available on demand, but it also has the ability to unlock the potential the large amount of data that control systems are already collecting from both process and condition monitoring instruments and applications. Generally speaking, the ability for end users to hire and maintain personnel capable of maintaining automation systems is quite limited when compared with the suppliers of those systems. The best way to secure and maintain the automation systems in peak performance is to have the best personnel dedicated to that task. Recognizing this will be key for owner operators, especially as automation systems increase in complexity. By outsourcing these tasks, end users can use their limited resources to focus on how best to control the process, a task that actually affects revenue. While remote monitoring is especially appropriate during lean periods due to the significant potential benefits, ARC believes that all industrial organizations will incorporate remote monitoring into their operating and maintenance strategies to some degree as a matter of necessity.
Mark Sen Gupta Research Direc tor ARC Advisor y Group
Offshore World | 33 | June-July 2017
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FEATURES
The IoT Effect: How Technology is Modernising Traditional Industries Th e Inte r n e t o f Things (IoT ) re fe rs to physic al devices embedded w ith el ec tronics, sof t ware, s e ns o r s and n e t wo r k con ne c tiv it y whic h e na ble objec ts to col l ec t and exchange data. To date consumer ap p li c at i o ns h ave i n c l u d e d the a c tive monitoring of wel l being through wearabl e hear t monitors and sma r t co nne c te d a p p l i a n ce s i n the hom e. Howe ve r, the re al benefit is l ikel y to be fel t by industries w here remote mo ni to r i ng a n d m e a s u re me nt c a n va s tly re duce cos t and improve efficiencies. Traditional industries, such as o i l and g a s, a re n ow p ois e d to a dopt m ore IoT a nd cl oud technol ogies, using a net work of devices and s o f t ware to m o n i tor a n d me a s ure a n a lmos t unlimited number of tasks.
A breakdown in communication For the Oil & Gas Industr y to effec tively supply its consumers around t h e w o r l d, i t i s e s s e n t i a l t h a t o p e r a t i o n s r u n s m o o t h l y. S h o u l d e q u i p m e nt b re a kd o w n o r a s s e t s f a i l, t h e e co n o m i c i m p a c t o f a n unplanned shutdown can be severe. For example, in 2014 Indonesia experienced a reduc tion in its crude oil sales, largely caused by the 122 unplanned shutdowns from the operator BPMigas, which created 6,860 bpd in lost produc tion. For oil and gas companies, upholding regular maintenance and calibration schedules can be difficult and expensive. However, cloud technology and the availability of internet connectivity has driven significant progress in remote asset management – enabling assets to be remotely and securely monitored and managed offsite. Cloud technology and internet everywhere Cloud technology and the availabilit y of internet connec tivit y have d r i v e n s i g n i f i c a n t c h a n g e i n re m o t e a s s e t m a n a g e m e n t. C l o u d infrastructure enables the constant monitoring and storage of data on remote ser vers any where in the world in real time via IoT. Monitoring equipment installed on local assets transmits information to software
Providing they are connected to the internet, businesses can access CEMS data and analyse it using a variety of devices. With internet connectivity available almost anywhere, businesses can access the real-time data feeds of remote assets from multiple sites anywhere in the world. It is not necessary to store and run the software on a machine on-site, which reduces cost and removes the need to have on-site staff. Additionally, the data is stored securely on multiple remote servers with back up and is not dependent on the health and reliability of an on-site machine. R e m o te a c t i o n c a n b e t a ke n to u p d ate s o f t wa re, s h u t d o w n f a i l i n g o r f a u l t y s y s te m s, a n d i f t h e re i s a d a n g e r o f e x p l o s i o n , e x t r a c t o n - s i t e p e r s o n n e l i m m e d i a te l y. E m p l o ye e s wo r k i n g f o r o f f s h o re o i l a n d g a s o p e r a t i o n s we re f o u n d to b e s e ve n t i m e s m o re l i ke l y t o d i e o n t h e j o b t h a n t h e a v e r a g e U. S . w o r ke r, a c c o rd i n g t o a s t u d y re l e a s e d b y t h e Ce n t re s f o r D i s e a s e Co n t ro l a n d P re ve n t i o n (C D C ) . Th e C D C t ra c ke d f at a l i t i e s f ro m 2 0 0 3 to 2 0 1 0 a n d f o u n d t h at 1 2 8 p e o p l e h a d d i e d w h i l e wo r k i n g a t o f f s h o re o p e r a t i o n s. Wi t h advances in remote monitoring technologies, fewer engineers w i l l n e e d to wo r k i n h o s t i l e o r d a n g e ro u s e n v i ro n m e n t s s u c h a s o f f s h o re r i g l o c a t i o n s. CBM
that is stored on central ser vers, rather than physically on an oil and
Condition based maintenance (CBM) – enabled by remote monitoring
gas site. When real-time data is fed into software such as a continuous emission monitoring system (CEMS), organisations can collec t record and repor t data remotely –this method has several benefits.
- reduces the risk of major equipment failure by identifying potential
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problems before they come to fruition. CBM involves continuously monitoring the condition of an asset – including its components – so
Offshore World | 34 | June-July 2017
FEATURES
maintenance can be carried out as soon as there is an indication that a device or its components may not be func tioning effec tively. CBM compares ac tual per formance with average per formance, or with a pre -programmed range. When device parameters move beyond what
Historically, these checks were the responsibility of personnel. People would need to confirm whether assets were working or not. Not only does remote measurement and polling of these assets reduce cost – it helps eliminate human risk.
is acceptable, it signals the need for maintenance. In late 2015 dozens of oil workers were killed in a fire aboard a rig in the In addition to component failure, CBM data feeds can aler t management if soft ware needs to be changed or updated, if sensors
Caspian Sea. This was caused by a gas pipeline that was damaged in high
n e e d c l e a n i n g b e c a u s e o f i ce o r d i r t, o r w h e n e q u i p m e nt n e e d s
the impact of extreme weather on oil rigs and implement procedures to
calibrating for accurac y.
reduce the risk of a similar incident. Had the owners of the rig been more aware of the likelihood of such an incident happening, the site could have been evacuated earlier.
Data can be collected from on-site equipment and streamed to a central location for analysis via the internet. This helps to reduce cost and minimise the requirement for on-site engineers, but can also improve the efficiency and accuracy of emissions reporting.
winds. By recording critical data to the cloud, companies can understand
A greener, more connected future
Oil and gas operations can be dangerous. Although rare, there is a risk of on-site explosions. The Hydrocarbon Releases (HCRs) that cause explosions like these are, in simple terms, leaks. It is inevitable that
Outside of running an efficient and safe operation, emissions reduction is another key consideration for the Oil & Gas Industry. An International Energy Agency (IEA) report, “CO2 Emissions from Fuel Combustion Highlights,” estimated that the energy sector is responsible for more than 40% of global carbon dioxide (CO2) emissions. Gas flaring is one of the primary contributors to industrial emissions. Based on satellite data, it is estimated
leaks will happen during operations, and while significant effor ts
more than 150 billion cubic metres (or 5.3 trillion cubic feet) of natural gas is
have been made to reduce these, innovations in remote monitoring
released into the atmosphere each year through natural gas flaring and cold
technology can drastically reduce risk. Regular repor ts of asset well-
flaring (venting) operations. While gas is often flared for safety reasons, a
being and asset monitoring will aler t operators when an asset is malfunc tioning – or is about to do so – reducing the risk of a leak.
large proportion is still flared as the main method of disposal - for facilities
Safety first
that do not have the infrastructure to capture, transport and monetise it.
Offshore World | 35 | June-July 2017
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FEATURES Real-time data can also be used to create a competitive advantage. Data retrieved from different sites can be compared to more effectively manage processes – site to site, country to country, or process to process – enabling continuous improvement over time. Best practice can be taken from top performing sites and implemented across the entire business operation. Conclusion
In November 2015, the COP21 climate change conference in Paris saw a number of oil and gas companies sign a pledge to reduce routine gas flaring to zero by the year 2030. This means an increased focus on emissions being recorded and shared with regulators. The Oil & Gas Industry has come a long way in its recognition and reduction of emissions. However, under increased regulatory scrutiny, it is crucial that the flaring of natural resources is strictly limited and only takes place when absolutely necessary. It is connected technologies that are now helping to measure and manage these processes more effectively. In the last five years the industr y has made significant moves to re d u c e e m i s s i o n s , i m p l e m e n t i n g I oT a n d c l o u d t e c h n o l o g i e s t o accurately collec t emissions information and provide insight that will streamline emissions heav y processes. Measuring emissions
Flaring may be largely used for the safe disposal of excess natural gas, but the burning process is damaging. Measuring flare gas is important for reducing environmental impact but is one of the most challenging types of gas flow measurement. Connected technologies are helping to refine maintenance procedures, deliver more accurate emissions information and provide insightful data to advance on-site emissions strategies through the cloud. IoT connectivity enables organisations to accurately report pollutants from gas flaring and manage gas flaring processes more effectively in offshore locations. While traditional industries have been slow to realise the potential in technology, oil and gas companies are finally considering its transformational role. It is important for the Oil & Gas Industry to sustain production and ensure its internal processes continue to operate efficiently and safely. One way to do this is through regular asset monitoring, maintenance and servicing. IoT innovation has transformed how these processes can be completed. Connected technologies can greatly reduce the risk of accident or injury in oil and gas operations, improve emissions monitoring, and provide insightful data to advance on-site operations through cloud technologies and internet everywhere.
Historically, recording and sharing emissions data would have involved recording the volume of gas flared locally and sharing data on a periodic basis. However, connected measurement technology means that now this information can be monitored and measured in real time through secure hosting in the cloud. By using cloud technology to record gas flaring, companies can build a better picture of trends over time and use this insight to drive emissions strategies. For example, on an oil rig where flaring only happens after cer tain maintenance procedures, real-time data can provide insight to more effectively manage the flaring process – reducing the amount of wasted gas. Over an extended period of time organisations may begin to see patterns emerging that enable them to more effectively predict which rigs will flare more gas than others. www.oswindia.com
Offshore World | 36 | June-July 2017
Mar tin Phillips Produc t Manager Fluenta
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The Next Generation Manufacturing Execution Systems (MES). In t h e s c i e n ce f ic tion mov ie “ B a c k to the Future”, the protagonist M ichael J Fox goes back to the f u t u re. The m a n u f a c t u r i ng indus tr y ne e ds to go ba c k to the future too. A s t h e d e c a d e s rolle d by, this once illustrious industr y watched the I T sec tor take the informat i o n s u p e r h i g hway, l e aving the re s t of the indus t r y in the dust. Now, manufac turers have no time to was te i n t he a d o p t i on of i nnovation to a cce le rate into the future. According to LN S Research, the future M anu f ac t u r i ng Exe c u t i o n Sy ste ms (M E S ) s olution will be interconnec ted w ith mul tipl e pl atforms and come eq u i p p e d wi t h s op h i s t i c ate d f unc tiona litie s that c a n handl e adverse situations in the shop fl oor in real time.
Taking hold of what tomorrow promises
standard captures the migration process from paper-based production management to EBR. It contains models and terminology on controlling
Before hur tling into the future, manufacturers need to identify and remove baggage from the past. This clearly alludes to the general lack of interoperability across Manufacturing Operations Management (MOM) software infrastructure, creating a problem in both batch and continuous processing. Today, customers want a seamless working experience with a global, unified MES solution. Bulk chemical manufacturers and refiners need to
batch processes. These models provide a hierarchical and modular categorization process to manufac ture the produc tion by executing the process. This forms the basis of standardization within batch process automation. In an ideal world of execution, the Research & Development (R&D) depar tment will develop the ISA-88 General and Site recipes. The information is fur ther communicated to Production and Engineering before being translated into ISA-88 Master Recipes, which are equipment-specific.
redefine unified solutions. This includes reference to batch operations and trends, such as the Industrial Internet of Things (IIoT), Smart Manufacturing
O ve ra l l, d i gi t a l m a n u f a c t u ri n g a cce l e rate s ra m p u p a n d t i m e - to -
– being factored into MES architectures and functionalities. Truly, there
market. Effective EBR takes hours off the production process to reduce
is no escaping the rise of enterprise MES for smart manufacturers facing
time -to-market and inventor y turns. It also accelerates operational
fierce competition in this virtually borderless world.
excellence and the New Product Development and Introduction (NPDI) process. These metrics table a strong case for management to adopt
Say no to paper-based production management
the concept of digital manufacturing, as it literally telepor ts the plant into the nex t era of growth.
A thing of the past – historic paper-based systems require a lot of time and effor t. It slows down work in the process, costing companies’ excessive time, money and reduces agility in production. Th i s b r i n g s i n t h e c o n c e p t o f El e c t ro n i c B a t c h R e c o rd s ( E B R ) to eliminate paper work. Beyond capturing workflow activity, EBR literally replaces paper logbooks to track information holistically. The ISA-88 www.oswindia.com
Smart Manufacturing is here to stay With high stakes to capture the future of process manufacturing, we can borrow a leaf of thought from Charles Dar win’s thinking on human evolution. He said, “It is not the strongest species that sur vive, nor the most intelligent, but the ones most responsive to change.”
Offshore World | 38 | June-July 2017
FEATURES S m a r t M a n u f a c t u r i n g i s a p l a t f o r m f o r a p p l i ca t i o n s to m a ke b e t te r a n d f a s te r d e c i s i o n s .” “ Th e a ve ra g e a g e o f a s s e t s co n t i n u e s to i n c re a s e, re q u i r i n g i m p ro ve d a s s e t m a n a g e m e n t to o p e ra te a s d e s i g n e d, w h i l e e x te n d i n g t h e s e r v i ce l i f e o f t h e a s s e t. In fac t, the Manufac turing Enterprise Solutions Association (MESA)
MOM will get us back to the future
clearly spells out, “The nex t generation Smar t Factor y feeds real-time information to a more empowered workforce through a combination of smar t facilities, machines and equipment with built-in sensors, self- diagnostics and connec tion to other smar t systems. Produc tion p ro ce s s e s i n t h e S m a r t Fa c to r y ca n b e o p t i m i ze d f o r b e s t u s e o f m a n p o we r, e q u i p m e nt a n d e n e rg y re s o u rc e s t h ro u g h s i m u l at i o n w i t h d i g i t a l re p re s e n t a t i o n s a n d m o d e l s . S m a r t M a n u f a c t u r i n g encompasses and goes beyond smar t machines, IIoT and the Smar t Factor y, recognizing that manufacturing processes in the 21st centur y go beyond the plant floor and must integrate the entire value chain that creates the final produc t.” Smart Manufacturing goes beyond models. It is a platform for applications to make better and faster decisions. With the next generation MES system, predictive analytics is an evolved form of machine learning. According to ARC’s Peter Reynolds, “Three things make machine learning different from predictive analytics. Machine learning algorithms are designed to adapt continuously and improve their performance with minimal human intervention. Process workflow also embeds Machine learning algorithms. That is, they become seamlessly integrated into the process to the point
MOM, or the Manufacturing Operations Management, is well positioned to deliver insights on production assets via advanced analytics and d e e p m a c h i n e l e a rn i n g. Th i s e n a b l e s t h e o rg a n i z at i o n to a c h i e ve stronger operational excellence and accelerate informed decisions wholehear tedly. The Smar t Manufacturing Leadership Coalition (SMLC) advocates an open, shared platform for developing, deploying, managing analytics and intelligence. The convergence of this shared platform meeting the rise of IIoT will disrupt business models for asset management and subject matter assistance. The move towards prescriptive analytics will drive a consolidation cycle in a crowded vendor landscape. Sur vivors include those who combine analytics, machine learning and domain exper tise to drive greater value and reduce the risk of program failure. Procedural automation is of strategic impor tance in bridging the gap between system and operator, as the industr y pushes for ward towards autonomous decision-making and action. Indeed – just like Michael J Fox, we are surely leaving the lack of interoperability in the past behind to capture an envisioned future with the nex t generation MES system.
where they are invisible to the user or operator.” The future belongs to analytic providers, who can combine domain exper tise with technology. These providers can develop more insightful analytics for asset per formance, while advanced analytics make its way into the area of asset management. ARC’s Ralph R io analyzes, “A modern Enterprise Asset Management (EAM) system provides the needed visibilit y, planning and execution to achieve the key goals
Rober t Golightly Produc t Marketing AspenTech Email: Rober t.Golightly@aspentech.com
for assets, which are uptime, asset longevit y, cost control, and safet y a l o n g w i t h t h e exe c u t i ve n e e d s f o r h i g h re t u rn o n a s s e t s ( R OA) . These goals direc tly affec t C-suite objec tives in the P&L statement and balance sheet for revenue, cash conser vation, profitabilit y and risk management. The average age of assets continues to increase, requiring improved asset management to operate as designed, while
Dr Warren Becraf t Senior Principal Business Consultant AspenTech Email: Warren.B ecraft@aspentech.com
ex tending the ser vice life of the asset.” Offshore World | 39 | June-July 2017
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FEATURES
Making Industrial IoT a Reality for the Energy Industry Th e i n d u s t r i a l I n t e r n e t o f Th i n g s ( I oT ) h a s a r r i ve d — a n d i s h e re t o s t ay. To d ay ’s I oT i s p e r h a p s b e s t d e f i n e d b y i n t e rc o n n e c t i v i t y. I t e n a b l e s b e t t e r m o n i t o r i n g, i n f o r m a t i o n g a t h e r i n g, ro l e - b a s e d i n f o r m a t i o n p re s e n t a t i o n , a n d o p e r a t o r s i t u a t i o n a l aw a re n e s s — a n d u l t i m a t e l y l e a d s t o i m p ro ve d d e c i s i o n - m a k i n g, i n c re a s e d o p t i m i z a t i o n , i m p ro ve d s a f e t y, a n d l o we re d c o s t s. Wi t h i t s a b u n d a n c e o f re m o t e a s s e t s, c o m p l e x i n t e rc o n n e c t i v i t y a c ro s s S C A DA d e v i c e s a n d e n t e r p r i s e s y s t e m s, a n d f o c u s o n s a f e a n d e f f i c i e n t p ro c e s s e s, t o d ay ’s E n e rg y I n d u s t r y i s o n e s e c t o r t h a t i s p a r t i c u l a r l y we l l - p o s i t i o n e d t o t a ke a d v a n t a g e o f t h e m a n y b e n e f i t s t h a t t h e i n d u s t r i a l I oT h a s t o o f f e r. H o we ve r, d e s p i t e t h e p o t e n t i a l b e n e f i t s, c o n c e r n s w i t h I oT s o l u t i o n s ’ i m p l e m e n t a t i o n , c o s t, a n d re l i a b i l i t y re m a i n .
Why Industrial IoT?
areas of the industr y want to increase efficiencies and switch from preventative maintenance to less costly predic tive and condition-
T h e i n d u s t r i a l i z e d w o r l d n e e d s e n e r g y, a n d t h e d e m a n d f o r
based maintenance.
hydrocarbons will not diminish in our lifetimes. With the price of oil hovering around $50/barrel, companies need to reduce costs to
Common Challenges of the Industrial IoT
be profitable. An unproduc tive day in a liquefied natural gas (LNG) facilit y could cost millions of dollars in unplanned downtime. The
D e s p i t e i t s p o t e n t i a l b e n e f i t s , c o n c e r n s w i t h I oT i m p l e m e n t a t i o n
IoT could ver y well alleviate these kinds of problems, as it enables
a r e s t i l l o f t e n t o p - o f - m i n d . I n t o d a y ’s w o r l d o f c y b e r - a t t a c k s ,
enterprise -wide visibilit y into operations. By implementing analytics
security is always at the forefront of any new technology
and machine learning technologies, companies can detect and aler t of
discussion. Given the volatile nature of its products and the
process and equipment anomalies to proac tively prevent unexpec ted
catastrophic impact that security breaches could have on
downtime or out- of-spec produc ts.
critical infrastructure —and society at large —the Energy Industr y is already a target for exploitation. Industrial
In addition, more producers are tr ying to streamline data sharing
equipment is typically designed to last for decades and the
in real-time across many disparate enterprise systems—from
majority of connected devices today (and for the foreseeable
geoscience to accounting, marketing, and compliance —as well as
future) will be from legacy equipment already operating
improve visibilit y of SCADA and measurement data from the field. All
i n t h e p l a n t o r f i e l d . M a n y o f t h e protocols for industrial
Cisco estimates that an offshore oil platform generates between 1 TB and 2 T B o f t i m e - s e n s i t i v e d a t a p e r d a y. www.oswindia.com
Offshore World | 40 | June-July 2017
FEATURES c o m m u n i c a t i o n s t o t h i s e q u i p m e n t a r e n o t s e c u r e b y t o d a y ’s
Alleviating These Challenges with Edge Computing
s t a n d a rd s ; s o m e we re s p e c i f i c a l l y s t r i p p e d d o w n a n d d e s i g n e d f o r l ow b a n dw i d t h n e t wo r k s b a c k i n a t i m e o f s i m p l e r s e c u ri t y t h re at s.
In the traditional SCADA data collec tion architec ture, all data sources in the field are polled from a centralized host. This requires all raw
A d d i t i o n a l l y, m a n y o f t o d a y ’s e n e r g y c o m p a n i e s a r e a l r e a d y
data to be requested and provided across the net work so that it can
s t r u g g l i n g t o s u p p o r t t h e n u m b e r o f c o n n e c t e d S C A DA d e v i c e s,
be stored, monitored, and analysed back in the enterprise (SCADA,
because existing telemetr y networks often have bandwidth
Historian, analytics, and so for th). However, industr y leaders are
limitations for th ese remote assets. For example, an industrial oil and gas operator could have 20,000 legac y devices located remotely across multiple produc tion sites with limited connec tivit y, power,
increasingly moving IoT data collec tion— and some analytics—to “the edge” as a potential solution to alleviate net work bandwidth limitations and securit y concerns. The edge is the net work entr y points or data sources that are in the field on the opposite end of
a n d n e t wo r k b a n dw i d t h . D e p e n d i n g o n t h e a s s e t, t h e re co u l d b e
the net work from the centralized host. Edge devices are the remote
g i g a b y t e s o f d a t a b e i n g p ro d u c e d a n d u p d a t e d i n m i l l i s e c o n d s.
equipment in the field, machiner y on a plant floor across the world,
As more devices come online, data produc tion will only increase
or any other asset that provides data in a location far from where data
exponentially and consume new levels of required bandwidth.
is ac ted upon. This includes routers, routing switches, integrated a cce s s d e v i ce s, m u l t i p l exe r s, a n d a va ri e t y o f l o ca l a re a n e t wo r k
Th e d a t a s c i e n t i s t t h a t u s e s t h e a n a l y t i c s a n d m a c h i n e l e a r n i n g
(LAN) and wide area net work ( WAN) access devices. D evices and
applications requires high frequenc y data to truly understand
sensors built for the industrial IoT with access to the net work are
a p ro c e s s o r m a c h i n e . N o t s a m p l i n g t h e d a t a a t a h i g h e n o u g h
also considered edge devices.
frequenc y could result in a completely different analysis or m o d e l l e d b e h av i o u r — a n d p o te nt i a l l y m i s s p e a k s t h at co u l d b e o f
Here are three benefits of implementing edge computing as par t of
s i g n i f i c a n ce. A s s u c h , t h e b a n d w i d t h a n d l ate n c y o f t h e i n d u s t r y ’s
an IoT initiative.
co m m u n i cat i o n n e t wo r k s i s a l s o a co n ce r n w h e n i m p l e m e nt i n g I oT s o l u t i o n s. D at a i s t y p i c a l l y m o s t va l u a b l e w h e n i t c a n b e a cce s s e d a n d a c te d u p o n q u i c k l y, e f f i c i e nt l y, a n d s a f e l y. Fo r e x a m p l e, Ci s co e s t i m a te s t h a t a n o f f s h o re o i l p l a t f o r m g e n e r a t e s b e t we e n 1 T B a n d 2 T B o f t i m e - s e n s i t i ve d a t a p e r d a y. Wi t h s a t e l l i te, t h e m o s t co m m o n o f f s h o re co m m u n i c at i o n l i n k , t h e d at a s p e e d s ra n g e f ro m 6 4 k b p s to 2 M b p s. Th i s re s u l t s i n 1 2 d a y s t o t r a n s m i t o n e d a y ’s
1. Generates cost-savings and alleviates network bandwidth limitations A t y p i ca l a rc h i te c t u re f o r a n a n a ly t i c s s o l u t i o n i s to t ra n s f e r t h e required large data sets from the field and back to the enterprise for analysis. The issue with this is that it of ten results in ser vice degradation, data latenc y, and securit y concerns— on top of new
wo r t h o f d a t a b a c k t o a c e n t r a l s i t e f o r p ro c e s s i n g — a n d 1 2 d a y s
expensive levels of required bandwidth for the needed high frequency
i s f a r f ro m “re a l - t i m e.” Th i s t y p e o f l a t e n c y c o u l d h a ve s i g n i f i c a n t
data. Edge computing reduces the need for costly bandwidth additions.
o p e r a t i o n a l a n d s a f e t y i m p l i c a t i o n s.
Lo w - c o s t e d g e g a t e w a y s, w i t h t h e i r e ve r - i n c re a s i n g c o m p u t i n g
Instead of performing centralized data analytics to determine what caused downtime after it happens, the Energy Industry could see an undesired state or accident before it happens, and prevent it entirely with real-time predictive analysis. Offshore World | 41 | June-July 2017
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FEATURES capacity, are designed to keep computing and data storage on the edge
predic t cer tain outcomes before they happen. This could be done
while hosting localized and task-specific actions to analyse edge data
locally at the edge with periodic updates on predic ted outcomes,
in near real-time. This means much less data needs to be transmitted
or through aler ts if undesirable trends are predic ted. The abilit y to
back to the host ser ver—where enterprise -level applications reside —
make decisions locally and quickly based on collec ted and analysed
saving on bandwidth requirements. On top of that, data transmission
data can significantly improve an organization’s efficienc y and safety.
is not free, so reducing the amount of data transmitted across the
Instead of per forming centralized data analytics to determine what
net work is a potential cost savings benefit overall.
caused downtime after it happens, the Energy Industr y could see an undesired state or accident before it happens, and prevent it entirely
2. Increases security
with real-time predic tive analysis.
Collec ting and analysing data at the edge increases securit y because
Conclusion
information is kept within a local network. As price and form factors of processors keep decreasing, unnecessar y computing and data storage
Edge -based data collec tion and analytics are solving some of the
can be moved away from the centralized ser ver where enterprise -
challenges of implementing the industrial IoT in the Energy Industr y.
level applications reside. This enables companies to distribute their
Collecting data locally and directly from a data source in the field can
computing to the edge of the network through gateways and industrial
reduce securit y concerns while improving data reliabilit y. Per forming
PCs that can host localized and task-specific actions in near real-time
analytics—ranging from data reduction and consolidation to machine
and transmit much less required data back to the enterprise. This data
learning and condition-based monitoring—at the edge can reduce
can be transmitted with more modern protocols— such as MQTT, OPC
the required volume of data transmission across limited bandwidth
UA, AMQP, and CoAP— which are specifically designed for secure and
n e t wo r k s a n d e n a b l e re a l - t i m e a n a ly s i s a n d d e c i s i o n - m a ki n g f o r
efficient net work communications and can deploy encr yption and
optimal operational excellence and safet y. With vendors across the
security cer tificates to strengthen access controls and prevent man-inthe -middle attacks. Locating the edge gateway in the field and on-site and connec ting it direc tly to the data sources helps alleviate many securit y concerns of communicating direc tly with the data sources in
industr y coming together to provide comprehensive solutions that make edge -based data collec tion and analysis possible, the Energy Industr y will benefit from improved safety, efficiency, and productivity at ever y level across the enterprise.
the field over a wide area net work with an unsecure protocol. 3. More precise and predic tive analytics By storing the data locally, models can be developed and patterns recognized by analytic applications running on the local gateway or industrial PC. Descriptive analytics can turn data into more meaningful information. The key performance indicators (KPI) used to determine how a machine is running might be just a few data points that are computed from several different sensor readings, which could be done locally with just the KPI information transmitted from the edge to the enterprise.
Steve Sponseller Market Insight & Solutions, Oil & Gas
Eve n m o re a dva n ce d a re p re d i c t i ve a n a ly t i c s o n t h e e d g e, w h e re
PTC
m a c h i n e l e a r n i n g te c h n i q u e s a n d a p p l i cat i o n s ca n b e a p p l i e d to
Email: steve.sponseller@kepware.com
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Offshore World | 42 | June-July 2017
A
s a leading supplier of Pumps, Valves and related systems, KSB in India is committed to provide its customers high quality, energy efficient and safe products and services. In India, KSB manufacturers a large variety of centrifugal pumps for industrial applications. Under the environment labelling program by TUV India, KSB’s pumps series like Etanorm, Etabloc, Movitec B & Amarex IN are certified as “Green Mark Products”. “Green Mark” for a product indicates its contribution to reduction in the environment impacts associated with products, through the identification and achieving of specific criteria for the products for overall environmental profitability.Selected pumps are analyzed from cradle to grave, considering energy efficiency as primary criteria i.e. from Product design→ Raw materials → manufacturing process → Product performance during use →Recycling & Disposal. These pumps are assessed according to the evaluation criteria of TUV India’s Environment Labelling Program with reference to Indian Standard Environmental Labels & Declarations-Type I Environmental Labelling-Principles & Procedures (IS/ISO 14024:1999 -Reaffirmed 2004). With Green Marking its products, KSB will benefit demonstrating transparency, improving regulatory compliances, strengthening risk awareness, encouraging innovation, and its concern for environment apart from establishing competitive positioning and market differentiation.
K
SB Pumps Ltd. launched “Magnochem” pumps in India. These Standardized Chemical Pump with Magnetic Coupling are suitable for handling aggressive, toxic, explosive, valuable, flammable, malodorous or harmful fluids in the chemical, petrochemical and general industries. Magnochem - Horizontal, seal-less volute casing pumps in back pullout design with magnetic drive confirms to ISO 2858 / ISO 5199. Magnochem pumps are Atex compliant also. Its broad range of variants offers excellent flexibility. Pumps are optimally designed for excellent energy efficiency and offers maintenance free long life. Magnochem pumps are available in 26 different sizes and are designed for 40 bar operating pressure and have capacity to pump liquid up to 300 cu. mtrs. per hour at head of 150 mtrs. To cater to wide range of applications; hydraulic components of Magnochem are available in different grades of Stainless Steel and it can withstand fluid temperature between -90 and +300 deg. Centigrade. Th e s e p u m p s a re a v a i l a b l e i n I n d i a t h ro u g h K S B ’s w i d e s p re a d authorized dealer net work.
About KSB Pumps Ltd.: KSB Pumps Ltd. founded in 1960 in India is a part of KSB AG., - one of the world’s leading suppliers of pumps, valves and systems. Combining innovative technology and excellent service to provide intelligent solutions, the company has been offering innovative and sturdy solutions to cater to the myriad needs of the Indian Customer may it be in power, oil, building services, process engineering, water treatment, water transport, etc. The activities of KSB’s in-house research center focus on the areas of hydraulics, sealing technology, materials, production technology and automation. Today the KSB group has a presence on all the continents with its own sales and marketing companies, manufacturing facilities and service operations. More than 14,500 employees generate annual consolidated sales revenue of over Two billion Euros.
Mr. Abhay Virkar DGM (PM&PS) KSB Pumps Ltd., Mumbai-Pune Road, Pimpri, Pune 411018. Tel. : +91 20 2710 1132. Email – abhay.virkar@ksb.com Website : www.ksbindia.co.in
Mr. Bipin Kode, Head (TSS Standard Pumps) KSB Pumps Limited Mumbai-Pune Road, Pimpri, Pune – 411018. Tel: +91 20-2710 1241 Email: bipin.kode@ksb.com Website: www.ksbindia.co.in
Offshore World | 43 | June-July 2017
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MARKETING INITIATIVE
KSB in India receives Green Mark Magnochem - Standardized Chemical certification for its pumps! Pump with Magnetic Coupling
MARKETING INITIATIVE
FLIR Launches Intrinsically Safe FLIR GFx320 Gas Detection Thermal Camera for Oil and Gas Industry
F
L I R G Fx 3 2 0 D e t e c t s H y d r o ca r b o n G a s e s a n d i s C o m p l i a n t t o S t a n d a r d s f o r U s e i n Po t e n t i a l l y Explosive Atmospheres
FLIR Systems, Inc. (NASDAQ: FLIR) announced the FLIR GFx320, an optical gas imaging (OGI) camera for the oil and gas industr y that is
Like FLIR’s existing GF320 model, the FLIR GFx320 is calibrated to m e a s u re te m p e rat u re, a l l ow i n g u s e r s to a c h i e ve o p t i m a l t h e rm a l contrast between the gas compound and the background scene. The camera is also verified to meet sensitivity standards defined in the U.S. Environmental Protection Agency’s (EPA) OOOOa methane rule, and tags each recording with
designed for use in potentially explosive atmospheres. The FLIR GFx320 detec ts and visualizes invisible hydrocarbon gas emissions, such as
GPS data to meet additional regulator y requirements for repor ting.
methane, and common volatile organic compounds (VOCs) found at oil and natural gas facilities. It carries cer tifications to global standards and is recognized as Intrinsically Safe, explosion-protected equipment by the International Elec tro-technical Commission. As a cer tified Intrinsically Safe OGI camera, the FLIR GFx320 re p re s e nt s g ro u n d b re a k i n g te c h n o l o g y f o r s u r ve y i n g c r i t i c a l a n d potentially dangerous work zones. Instead of scann ing for fugitive and non-fugitive gas emissions from outside hazardous areas, with the FLIR GFx320 workers can assess potential risks from
“ Wi t h t h e re c e nt t i g hte n i n g o f m e t h a n e re g u l at i o n s b o t h i n t h e United States and globally, oil and gas producers need a fast and safe way to find and image gas emissions,” said Andy Teich, President and CEO at FLIR. “With the abilit y to keep workers safe and identify greenhouse gases such as methane, the GFx320 represents another critical example of FLIR’s technology helping to protec t lives and preser ve the environment.” About FLIR Systems
afar and, once the area is deemed safe, enter with the camera to continue scanning. The first FLIR camera with the Intrinsically Safe designation, the GFx320 allows sur veyors to improve their safet y and work with more confidence on the job site.
FLIR Systems, Inc. is a world leader in the design, manufac ture, and marketing of sensor systems that enhance perception and awareness. FLIR’s advanced thermal imaging and threat detec tion systems are u s e d f o r a w i d e v a r i e t y o f i m a g i n g, t h e r m o g r a p h y, a n d s e c u r i t y a p p l i c at i o n s, i n c l u d i n g a i r b o r n e a n d g ro u n d - b a s e d s u r ve i l l a n ce, co n d i t i o n m o n i to r i n g, re s e a rc h a n d d e ve l o p m e nt, m a n u f a c t u r i n g process control, search and rescue, drug interdic tion, navigation, t ra n s p o r t at i o n s a f e t y, b o rd e r a n d m a ri t i m e p at ro l, e nv i ro n m e nt a l m o n i to r i n g, a n d c h e m i c a l, b i o l o g i c a l, r a d i o l o g i c a l, n u c l e a r, a n d explosives (CBRNE) detec tion.
FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Tel: 011 – 4560 3555 E mail: flirindia@flir.com.hk Website: www.FLIR.in
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Offshore World | 44 | June-July 2017
H
MS Industrial Networks introduces a new, upgraded version of their popular Anybus Wireless Bridge. The Anybus Wireless Bridge II supports up to 400 meters of reliable wireless communication, and can communicate via both Bluetooth and WLAN. It is ideal for replacing Ethernet cabling in hard-to-reach or hazardous locations. Cable replacement or access point By using the Anybus Wireless Bridge II, automation engineers can achieve new and smarter network infrastructures. Often used as an Ethernet cable replacement (point-to-point communication), the Wireless Bridge II can also be used as an access point for several WLAN/Bluetooth nodes such as smartphones or tablets within range. In the process, savings are achieved thanks to the reduced amount of Ethernet cabling. The new Anybus Wireless Bridge II suppor ts a longer wireless range (400 meters, 437 yards) and an even more powerful integrated wireless antenna. It is easily set up via push-button configuration or via the new integrated web interface. Anybus Wireless Bridge II is built on the same wireless technology as the family member Anybus® Wireless Bolt™, a connection point for on-machine mounting which HMS released in 2016, making them able to communicate seamlessly, opening up for even more innovative wireless system solutions.
Solving network problems for system integrators
By connecting industrial devices and networks over a wireless link, the Anybus Wireless Bridge II makes life easier for system integrators and automation engineers needing to create connections through e.g. hazardous areas, hard-to-reach locations, or moving installations where
Figure: Cable replacement or access point
cables are not desirable. The Anybus Wireless Bridge II is a proven solution to bridge popular industrial Ethernet standards such as PROFINET, EtherNet/IP, BACnet/IP and Modbus TCP and provides users with a robust and maintenance-free wireless connection. The product comes with two M12 connectors for power and network connectivity and is an IP65 protection class rating. Industrial quality
“We see a clear trend that wireless communication is gaining more and more acceptance in the conservative industrial market,” comments Martin Falkman, Product Manager at HMS. There are many wireless connectivity solutions on the market today, but few can offer the reliable and sturdy connections required for industrial use. The Anybus Wireless products for Ethernet have been very popular on the market for several years, and with Anybus Wireless Bridge II, we are now excited to be able to offer connectivity over a longer range, more reliable wireless communication links as well as easier set-up procedures. About HMS
H M S I n d u s t r i a l N e t wo r k s i s t h e l e a d i n g i n d e p e n d e nt s u p p l i e r o f products for industrial communication including remote management. HMS develops and manufactures solutions for connecting automation devices and systems to industrial networks under the Anybus, IXXAT and eWON brands. D evelopment and manufac turing take place at the headquar ters in Halmstad, Sweden and in Ravensburg, Germany. Local sales and support are handled by offices in Belgium, China, Denmark, France, Germany, India, Italy, Japan, UK, and USA. HMS employs over 500 people and reported sales of 101 million EUR in 2016. HMS is listed on the NASDAQ OMX in Stockholm.
HMS Industrial Networks “Corporate Plaza”, Unit 1A & 1B, Ground Floor, Senapati Bapat Road, Near Chaturshrungi Temple, Pune – 411016 (M.S.). INDIA. Tel: +91 20 2563 0211 Email: in-sales@hms.se
Offshore World | 45 | June-July 2017
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MARKETING INITIATIVE
New Possibilities for Industrial Wireless Solutions
PRODUCTS Petal Valve Gall Thomson offers an enhanced version of its Petal Valve MBC (Marine Breakaway Coupling) for the offshore hydrocarbon transfer market.The robust design features CNC manufactured precision Petals and improved low pressure metal seals for reliability and reduced risk of leakage on activation. The Petal mechanism has no axles, shafts, hubs or bearings to seize and is totally failsafe. Petal17 fits standard flanges at any recommended location in the hose assembly.A number of options are also available which include Locking Petals to further reduce the risk of post-activation leakage when low pressure coincides with a harsh environment; and Unit Status Indicators (USI) which allow the operator to conduct quantifiable visual integrity inspections of the MBC upon installation and during service without removing the device from the system. For easier handling during installation and post activation, lifting lugs can also be provided as an option. Gall Thomson MBCs provide an identified safe parting point in marine hose transfer systems and automatically shut-off product flow and prevent system damage in the event of an extreme pressure surge or undue significant tensile load on the hose system. For details contact: Gall Thomson Environmental Ltd Technology Centre, Suffling Road, Great Yarmouth Norfolk, NR30 3QP, U.K. Tel: +44 1493 857936 E-mail: sales@gall-thomson.co.uk
Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. Excel Metal & Engg Industries offers manifold valves in SS, brass, CS, alloys ,etc; pressure rating up to 6,000 psi (413 bar) at 100oF (38°C); temperature rating: -65oF to 973oF (-54°C to 523°C) with Grafoil packing; 2 V, 3 V and 5 V as standard; remote or direct mounting; non-rotating globe stem tip.
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Sauer Compressors has enhanced its already extensive portfolio with a broad range of oil-free and gas-tight piston compressors for compression of air and a variety of gases. With the enhanced product range, Sauer is opening up a variety of new markets and applications, including compression of SF6, oxygen, CO 2 , H 2 and various special gases such as refrigerants, Argon, ammonia and more. The HAUG Sauer range includes entirely oil-free and completely dry running compressors. Oil-free compressors are suitable for processes and applications with high demands on gas purity and process quality. Since gas treatment and filtration after the compressor is simple or not required at all, oil-free compressors can reduce operating costs and risks significantly. HAUG compressors grant high reliability, both in continuous operation and operations with long standstills, frequent interruptions and cold starts. The compressors remain gas-tight even at maximum suction pressures of up to 20 bar, practically eliminating the risk of environmental contamination due to leakage. The air-tight design of HAUG compressors with its magnetic coupling includes a builtin overload protection. If the compressor is running with too high a load or discharge pressure, the magnetic coupling “slips” and the compressor is safely shut down and stopped. For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de
Manifold Valves
For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004, Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in
Oil-free and Gas-tight Piston Compressors
Remote Data Logger RDL-904 remote monitoring solution is a rugged hardware platform, battery powered, meant for logging data from very low power pressure transmitter and monitors pulses from an external flow meter. The solution is ideal for monitoring flow along water pipes. The solution includes a controller and GSM/GPRS modem, and two additional digital inputs for monitoring. Data is sent to centrally located server through GPRS/GSM at programmed frequency through HTTP/SMTP/CSV format. The data collected can be used to monitor flow and pressure to detect leakages, if any. For details contact: Sun Indl Automation & Solutions Plot No: 95, Developed Electronics Indl Estate Perungudi, Chennai 600 096 Tel: 044-30788900
Offshore World | 46 | June-July 2017
PRODUCTS Sami Wedge Plug Valves Rasaii Flow Lines Pvt Ltd has established as specialist valve manufacturer for corrosive and erosive applications in oil and gas plants, petroleum refiner y, petrochemical plants, pharma, heavy water plants, mining industr y. The valves have proven per formance in handling erosive and clogging area. Rasaii offers the wedge plug valves to ser ve as good replacement of metal seated globe and ball valves. Sami wedge plug valves are specifically designed to handle Liquid with sludge. dir ty liquids, acetic acid, liquids clogged with solid par ticles. The wedge plug claves per form in a superior way compound to metal to metal seated ball valves with their nil cavity possibility for suspension of flowing liquids and as well by avoiding any secondar y replacement flexible soft sealing materials as primar y isolation material. No scratch actions by embedded par ticles due to scrapping and cleaning of plug avoiding any metals embedding on to seats. The valves shall be operated with fully lubricated gearbox as well as can be operated with the linear electrical actuators of internationally proven makes. The gearbox will lift the plug and reseat for lower torque operation during open and close position. Wedge Plug Valves are more reliable, easy to maintain by flushing on regular inter val without removing the valves from pipeline. Valve can handle stem, catalyst effluent, hard materials, and hard liquids like high viscosity clogging media and sticking media. It is easy to operate. It has the lowest torque resulting smallest actuator and best per formance in sealing. It finds application in toluene diisocyanate, polyester terephthalate, pure terephthalic acid, propane dehydrogenation, and styrene polystyrene, CTG. For details contact: Rasaii Flow Lines Pvt Ltd TS No: 93/3, Poonamalle Road Ekkatuthangal Chennai 600 032 Tel: 044-22252021, 22252022 E-mail: admin@rflvalves.com
Oil-lubricated Vacuum Pumps Toshniwal supplies oil-lubricated vacuum pumps.These oil lubricated vacuum pumps of the TMS Series are single stage, oil-lubricated rotary vane vacuum pumps with oil re-circulation system. The lubricant system is rated for continuous operation of high intake pressures so that the pump may be used in a versatile manner in most rough vacuum applications. The pumps are used for suction of air also in presence of water vapour and for continuous industrial use. TMS Series pumps are made from high quality materials, has economical features which matches together to achieve: high pumping speed over the range of absolute pressure 1000 mbar-0.5 mbar; high water vapour tolerance and low noise level; no pollution; air cooled: built-in anti-suck-back system. The pumping capacities available are:17 m 3/hr,35 m 3/hr, 65 m 3/hr, 100 m 3/hr and 150 m 3/hr. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net
Leak Detector Edwards offers the new ELD500 precision leak detector. It is designed for fast, accurate leak detection and is customisable for any application. Edwards’ ELD500 is ready to go in under two minutes from power On. Users can benefit from simple pass/ fail readings through to detailed analysis via the easy to read control interface, and due to the low weight and integrated carry handles it is mobile enough to be bench top or trolley mounted. At the push of a button the ELD500 can easily be set to work in either vacuum mode for precise measurement of leak rate or sniffer mode for identifying the leak location. The proven design of Edwards’ ELD500 leak detector, combined with low energy consumption, extended warranty and even longer life ion source, ensures exceptional low cost of ownership with no compromise on performance. Edwards’ ELD500 achieves excellent repeatable accuracy through calibration with the integrated test leak source and high quality mass spectrometer, so it could be used on a production line, where consistent measurement repeatability is critical or in a laboratory environment where typically the measurement of extremely low leak rates is needed. The ELD500 has three variants, the FLEX, WET and DRY plus an extensive catalogue of accessories. For details contact: Edwards Ltd Innovation Drive, Burgess Hill West Sussex RH15 9TW, U.K. Tel: +44 (0) 1293 52 88 44 E-mail: rebecca.walder@edwardsvacuum.com / pr@edwardsvacuum.com
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PRODUCTS Compressor Control
Level indicators Visual level indicators combine up to three functions in one instrument: level indicator, level switch and level transmitter. The display that can be read even over large distances works without energy and automatically as a result of the physical law of liquids in communicating vessels. The WEKA visual level indicators are characterized by their compact design and the wide range of applications. Operating pressures can range from a vacuum up to 500 bar as well as calculation pressures for the float standpipe up to the nominal pressure PN 630. Liquid densities >0.27 g/cm3 as well as a temperature range from 77 K to 673 K (-196°C to 400°C) allow use in applications for cryogenic liquid gases as well as in water hydraulics and steam boilers. Hermetically sealed floats for condensing media are available up to a max operating pressure of 320 bar. Flexibility through choice of suitable materials - standard materials: 316/316L 1.4435/1.4404, Group A4 stainless austenitic steel. Other possible stainless austenitic steels: 304/304L 1.4301/1.4306, 1.4571, 321, 1.4541. The WEKA visual level indicator is ideal for the commissioning of systems. The display works without energy and automatically as a result of the physical law of liquids in communicating vessels. Independent of a controller - and thus also independent in the event of a power supply failure - visual level indication on site is ensured. The wide, red- and silver-colored flag indicator system is easily and clearly readable, even from over large distances. The fully transparent flag indicator system made of polycarbonate (PC) also ensures readability from the side. The liquids, which are not always unproblematic and sometimes also hazardous, are safely enclosed in the dense and pressuretight float standpipe and separated from the indicator.
Sauer Compressors offers a new range of controls for fully automated monitoring and control of compressor functions. The first model is the Sauer ecc 4.0 – a control for universal use in all compressor Series for applications in the naval, shipping, offshore and industrial fields . The design of the Sauer ecc 4.0 follows an intelligent modular principle tailored to the compressor type and version. The modular system can be configured over various expansion levels - from the economical basic version through to complete monitoring of all measured values in the fullyfeatured version. The Sauer ecc 4.0 can connect up to twelve compressors, communicating via all standard interfaces. In terms of Industry 4.0, the control can be integrated into higher-level systems. The new control is operated using a 7” colour touch screen display. Users benefit from the user-friendly intuitive menu system and step-by-step instructions in 30 languages. All relevant parameters are visible at a glance, represented visually by pressure gauges and texts. In case of faults, the control provides detailed alarm and fault messages including remedial suggestions. A numerical keypad allows easy adjustment of values. Operator login is based on direct code entry. For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de
Digital Mass Flow Meters/Controllers
It finds application in explosion-proof plants; mechanical engineering and plant engineering; water management; ship building; energy; space and research.
Metal seal gas mass flow meters and controllers are characterised by their unique, patented metal-to-metal seal construction with excellent resealing capability. Further more, they distinguish themselves by a high surface quality and are therefore especially suitable for meeting the semiconductor and solar industry requirements as well as other high purity gas applications.Today’s instruments are equipped with a digital PC-board, offering high-accuracy, excellent temperature stability and fast response (settling time t98 down to 500 msec). The latest EL-FLOW design features multi-gas / multi-range functionality, providing (OEM) customers with optimal flexibility and process efficiency. Features low pressure drop and contamination risk; longer lifetime when used on corrosive gases; electro-polished stainless steel wetted parts and is easy to clean.It is available with control valve to constitute a complete, compact control loop and with industrial (IP65 weather-proof) housing.
For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044 26445626, 26448983 E-mail: sales@toshniwal.net
For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044 26445626, 26448983 E-mail: sales@toshniwal.net
As described, WEKA visual level indicators offer the ideal solution for almost all operating conditions. For most applications, you will find a suitable device from their standard program. Again and again, however, customized solutions are also required for special operating conditions. Many designs can, for example, also be used in hazardous areas according to ATEX or IECEx. (ATEX is a widely used synonym for the ATEX guidelines of the European Union). The designation ATEX is derived from the french abbreviation for atmosphere explosibles. Their instruments can thus also be used in potentially explosive atmospheres.
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NEWS
Press Release Journey towards the Digital Enterprise ARC Advisor y Group’s fifteenth India Forum for the process and discrete industries, titled Industr y in Transition: Realizing the Digital Enterprise from July 6-7, 2017, Bangalore, India attrac ted close to 280 delegates. Today, companies are digitizing business processes and exploiting the increasing convergence between operational technology (OT) and information technology (IT) on the plant floor. And these emerging business models allow manufacturers to collaborate more effectively. Intelligent connected products, along with network communications, software, and analytics now enable manufacturers to improve uptime and optimize operating per formance. The Digital Enterprise benefits from smar ter products, new ser vice and operating models, new production techniques, and new approaches to design and sourcing. This two-day forum was structured to disseminate information and technology effectively and provide end users, solution providers and decision makers an oppor tunity to network and get an overall view of the market and its requirements. The industrial world is getting increasingly connected as the volume, variety and velocity of information continue to accelerate. Information-driven companies are moving to a culture and business model where decisions are made based on analysis of plant data and business processes. Companies are equipped to adapt new technologies because connected enterprises are a reality today and early adopters have realized the benefits. The first step in this direction would cer tainly be to realize that the industrial internet of things (IIoT) is connecting, collaborating, and transforming how businesses are conducted globally. As technologies keep on evolving it is essential to keep on upgrading in terms of knowledge and skillsets – both for Greenfield and brownfield projects. When you zero in on a par ticular strategy or technology it would be useful if you can find someone who has already implemented this successfully – thereby, validating your decision. The well attended two-day forum made it clear that organizations must have a collaborative approach and adopt breakthrough technologies to enhance business per formance. Never before has there been such a deluge of information; but this information needs to be channelized and available at the right time for the required process/operation.
A n d y C h a t h a , P re s i d e n t , A R C A d v i s o r y G ro u p
IoT, Cloud, B ig Data, mobilit y, and analytics are creating a new industrial ecosystem and companies which integrate with agilit y will emerge successful. The days of expensive trial and error are over; vir tualization has transformed the way businesses are conducted. Vir tual commissioning involves the creation of a vir tual model that represents an accurate and realistic 3D simulation of mechanical, electrical, and control systems to validate the physical functions of a production system prior to actual physical implementation. The session topics were about moving towards the digital enterprise; automation trends and c ybersecurit y; evolving technology trends; and end user experiences on the digital journey. On both days there were t wo lively and thought provoking question and answer sessions with the speakers. Forum Sponsors The success of our forum is largely due to the tremendous suppor t we received from our Sponsors: Global Sponsors: Bentley Systems, Siemens; Gold Sponsors: Emerson, Infor; Silver Sponsors – Belden, Mitsubishi Electric, IBM, and Steag. Industry Association Sponsors - AIA, CIO Forum, and CSIA Media Sponsors – A&C Today, A&D, Chemical Industr y Digest, Chemical Engineering, Control Engineering Asia, DEW Journal, IED Communications, Industrial Products Finder, OffshoreWorld, Reliability Web.com, The Record, Uptime, and World of Chemicals.
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NEWS
Press Release Simmons Edeco Joins Forces with Cordax™ Evaluation Technologies to Offer “Logging while Tripping™” Services Formation Evaluation Technique Provides Open-hole Logs in any Well Trajectory, Reducing Costs & Risks SIMMONS EDECO, a leading global oilfield service provider, announced it has joined forces with Cordax™ Evaluation Technologies to provide highly cost-effective “Logging While Tripping™” (LWT) open-hole formation evaluation services. The Cordax patented formation evaluation technique is a low risk, very economical way of collecting industry-proven open-hole formation logging measurements. It is the only open-hole logging service that gathers downhole data without requiring a dedicated logging trip. Because measurements are taken from within the LWT drill collars during the regular tripping process, the open hole logging operation is considerably more efficient and cost-effective than traditional logging processes. The technology is capable of capturing quality evaluation from vertical, highly deviated and horizontal well bores. Now in its 55th year of serving the global oil and gas industry, SIMMONS EDECO made the decision to invest in Cordax in direct response to customer demand for a more efficient, cost-effective logging solution. With Cordax’s field-proven LWT technology and hands-on experience derived from hundreds of successful LWT runs, SIMMONS EDECO customers can now obtain critical high-quality downhole data from all wellbores, even those that were previously deemed to be inaccessible or uneconomic. “Standard logging practices - such as logging-while-drilling, wirelineand drill pipe-conveyed - require that drilling activity be restricted or come to a complete standstill while logging equipment is run downhole,” says Tyler Longeau, Cordax Manager – Canadian Operations. “As a result, expensive-to-rent rigs and drilling crews must stand by during every logging run. However, because the LWT sources and sensors are pumped into specially designed collars, the LWT tools are retrieved along with the drill pipe as rig operations trip to surface. Being inside the drill pipe and fully retrievable greatly reduces any risk of losing expensive logging equipment downhole and eliminates separate pipe trips. It’s all carried out in one simple operation.” The Cordax LWT method generates industry-accepted triple combo logs, including conventional and spectral gamma, compensated neutron, and formation density. It also features a choice of three types of resistivity measurements, namely induction, propagation and laterolog, based on project requirements. The Cordax log uses these measurements to clearly www.oswindia.com
define the presence of water, oil and gas, and identify the rock type and basic rock properties, such as porosity and permeability. Advanced properties, including stress brittleness, actually “grade” the reservoir, identifying the best producing sections while avoiding sections that are prone to sanding off or other completion issues. Since 2011, Cordax has logged over 700 wells without a single “lost in hole” incident. Wells in the USA, Canada, Cuba, Australia and Indonesia have been logged under many - often hazardous - conditions. From underbalanced to long multilateral horizontal and deviated wellbores, the typical logging run requires very little rig time and has minimal impact upon rig operations. By working Looking ahead, customers of both SIMMONS EDECO and Cordax will benefit, as they now have access to a wider range of services and support provided by the companies’ combined network of bases. Already, the two companies have received expressions of interest in their mutual services, and are in active discussions with operators and service companies in Argentina and Mexico.
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To ps o e to h e l p H M EL m e e t BS -VI Fuel S pecif ic atio n on Fast Trac k
integrated solution in a ver y shor t time,” says Mor ten S chaldemose, Executive Vice President, R efiner y B usiness Unit, Haldor Topsoe.
•
Engineers India Limited (EIL) is engaged to provide EPCM (Engineering, Procurement, and Construc tion Management) ser vices on the BS-VI Fuel Q ualit y Projec t. EIL have considerable experience from the Indian hydrocarbon sec tor and carr y vast experience in executing projec ts on a fast track basis.
Topsoe delivers a bundled technology solu tion of diesel hydro -treater unit and revamp of hydrogen generation facilit y • HMEL refiner y will be revamped to deliver BS VI (equivalent Euro VI) fuel specifications under BS-VI Fuel Q ualit y Projec t • BS-VI Fuel Q ualit y Projec t is planned to be commissioned within just 36 months I n d i a n re f i n e r y c o m p a n y H P C L- M i t t a l E n e rg y Ltd ( H M E L ) h a s c h o s e n To p s o e’s d i e s e l h yd ro t re a te r u n i t a n d h yd ro g e n generation facilities to meet t h e i r u p g r a d i n g re q u i re m e n t s. Th e re v a m p e d re f i n e r y i n B a t h i n d a , Pu n j a b w i l l m e e t t h e B S V I (e q u i v a l e n t t o Eu ro V I ) f u e l s p e c i f i c a t i o n s, w h e n c o m p l e te d i n t h e l a s t q u a r t e r of 2019. Image: The hydrogen generation facility is revamped using two of Haldor Topsoe’s Heat Exchange Reformers (HTER)
TechnipFMC Signs Agreement with Pall to Supply Slurry Oil Filtration Systems for Fluid Catalytic Cracking Units TechnipFMC (NYSE and Euronex t: FTI) announced that it has signed a cooperation agreement with Pall Corporation to market, design and supply proprietar y Slurr y Oil Filtration Systems for Fluid Catalytic Cracking (FCC) Units. Based on Pall technology, the filtration systems are used by refiners to remove catalyst fines from slurr y oil, an FCC main fractionator bottoms product. The clarified oil can be blended into fuel oils that must meet stringent par ticulate requirements. It can also be used as a feedstock
Topsoe’s bundled technology solution and the fast projec t implementation will make it I m a g e : T h e h y d ro g e n g e n e ra t i o n possible for HMEL to meet the BS f a c i l i t y i s re v a m p e d u s i n g VI fuel specificati on deadline. This t w o o f H a l d o r To p s o e’s H e a t solution requires less investment than competing solutions along E x c h a n g e R e f o r m e r s ( H T E R ) with shor ter projec t implementation time, while providing optimal feed flexibilit y to meet processing objec tives. The solution offers substantial projec t cost savings using a new diesel hydro -treater unit supplemented by revamp of the existing hydrogen generation facilit y with t wo of Topsoe’s proprietar y heat exchange reformers (HTER). The compac t HTERs are always individually customized for each plant to provide capacit y increases up to 30% with a ver y small footprint.
for plants that produce premium products such as carbon black and
The diesel hydro-treater unit will be optimized to take full advantage of Topsoe’s HyBRIMTM TK-611 ultra-low sulphur diesel catalyst that deliver 25% improved ac tivit y for both nitrogen and sulphur removal and longer c ycle lengths while processing complex feeds.
technology experience. The center is part of a global network of centers
“HMEL has chosen this solution based on Topsoe’s insight into processes, hardware, and catalysts for ultra-low sulfur diesel. We are ver y satisfied to be able to deliver such a highly effec tive
anode grade coke. The agreement combines TechnipFMC’s global strength in FCC technology [1] with Pall’s expertise in the development of specialty filtration systems and fabrication of advanced filter media. "As a major licensor of FCC technology, TechnipFMC is pleased to offer filtration systems which will help refiners meet increasing environmental regulations and improve the value of their supply chain," said Stan Knez, Senior Vice President, Onshore Process Technology for TechnipFMC. The associated activities will be managed by TechnipFMC Process Technology’s center in Houston, Texas (USA), which has significant refining which look after the company’s expanding portfolio of onshore process technologies in petrochemicals, refining, hydrogen and syngas, polymers and gas monetization. [1] With its FCC alliance partner, Axens, TechnipFMC has licensed 61 grassroot FCC units and performed more than 250 revamp projects.
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NEWS
Press Release
NEWS
Press Release Mr Milind Khadilkar took over the responsibilities as Director – Finance of KSB in India with effect from 6th June, 2017
manuals of delegation of authorit y, and also suppor t to procurement and sales development and growth. He has conduc ted Management and Audit Committee and B oard of Direc tors and Shareholders Meetings. He has also overseen and completed all the formalities in respec t of setting up of a Wholly Owned Subsidiar y in USA; during one of his past assignments.
Stress Engineering Ser vices Joins with Deepmar Consulting to Expand Ser vices Stress Engineering Ser vices, Inc., (SES) the global leader in consulting engineering ser vices, has teamed up with D eepMar Consulting to expand its existing upstream ser vice offerings. The integrated team will work alongside clients to increase assurance of successful projec ts in regards to health, safet y and environment (HSE), reliabilit y and efficienc y. Mr Milind Khadilkar
A qualified Char tered Accountant and armed with a Master’s D egree
Leveraging combined experience in the oil and gas industr y, the
in Commerce from Pune Universit y, Milind has a vast experience
par tnership is focused on providing ‘end-to-end’ solutions that address
spanning over 3 decades.
the entire life of field across all disciplines: drilling/completion, production/asset and various inter vention solutions.
53 year old Milind’s career graph has always been on the rise since his first assignment with AF Fergusson in 1987. Ever since then his experience and success with organizations such as Tata Motors, Fujitsu ICIM, UB Engineering; Apollo Tires; Virgo Engineers; Godrej GE Appliances; Rohan Builders; UMW D ongshin Motech Pvt. Ltd.; and also a 6 years international assignment with Ali & Abdul Karim Group of Companies, Muscat has got him to where he is, today! Prior to joining KSB, since April, 2012 he worked with Wilo Mather and Platt Pumps Pvt. Ltd. as Vice President - repor ting to the Managing Direc tor and leading a team of 40 members.
A seamless integration of verification and validation processes can be provided by using core competencies of companies, including analysis, testing, materials, real-time health monitoring, predictive forecasting, efficient work flow processes and operational guidance. Chuck Miller, vice president of Stress Engineering, said, “By teaming DeepMar’s 35 years of experience in subsea oil and gas systems with the sheer breadth of SES’s engineering ser vices, we are bridging the gap between analysis results and operational decision-making. DeepMar offers valuable hands-on experience from the operator’s perspective and the people in the field.”
and ORION, Formulation of Group Administrative, Financial and
Brian Saucier, president, D eepMar Consulting, said, “In its 40 year track record, SES has demonstrated a broad range of capabilities alongside innovative physics-based models for design and assessment. We are looking for ward to working with the team at SES in offering a broader range of integrated solutions to provide significant value and cost-savings through enhanced design and
Control Policies, HR Administration and Procedures including
operational assurance.”
During his over 30 long years of Industr y experience, Milind has handled myriad func tions including Finance and Accounts, Controlling and Budgeting, Audits, Legal & Secretarial Compliances, IT Systems, Corporate Restruc turing, Fund Raising, ERP Implementation – SAP
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EVENTS DIARY
events diary ADIPEC 2017
The Oil & Gas Conference 2017
Date: November 13-16, 2017
Date: August 13-17, 2017
Venue: Abu Dhabi
Venue: Denver, Colorado Event: EnerCom’s The Oil & Gas Conference® offers investment professionals the oppor tunity to listen to the world’s key senior management teams present their growth plans and provides industr y professionals a venue to learn about impor tant energy
Event: The Abu Dhabi International Petroleum Exhibition and Conference (ADIPEC) is one of the world’s most influential events for the oil and gas industry. As a premium exhibition platform ADIPEC enables professionals from around the world to do business and grow.
topics effecting the global oil and gas industr y. The 2016 edition of EnerCom’s The Oil & Gas Conference® hosted 100+ presenting
Each year, ADIPEC provides one of the most important channels to
companies with operations spanning more than 40 countries and six continents.
do business and exchange information, attracting Energy Ministers, discussions and knowledge exchange.
Contact details: EnerCom, Inc. 800 18th Street Suite 200 Denver, CO 80202 Tel: 303-296-8834 Email: Bandrus@enercominc.com Website: www.theoilandgasconference.com
2nd
Pipeline
Integrity
Management
global CEO’s and leading decision makers across the 4 days of business
Contact details: Nour Soliman DMG Events Tel: +971 2 697 0515 Email: noursoliman@dmgeventsme.com
System
Oil & Gas World Expo 2018
Conference cum Exhibition
Venue: Mumbai
Date: August 24-25, 2017
Event: CHEMTECH Foundation will organise the 8th edition of Oil & Gas World Expo 2018 from March 1-3, 2018 in Mumbai, India. The international exhibition and conference aims to connect, discuss and comprehend the views of leaders, policy makers, regulatory authorities, and service providers of the Indian and Global hydrocarbon industry.
Venue: New Delhi, India Event: PIMS not only extends the life of existing pipelines, but also helps to prevent the damages to assets, human life and the environment during design, construction and to address these issues, Resonance Energy is organizing 2nd edition of PIMS Conference & Exhibition which will provide ideal platform to all stakeholders including experts and technocrats in Pipeline design, construction, operation and maintenance. The conference offers excellent opportunity for all, the experienced personnel’s as well as new incumbents in the business. The exhibition also offers an excellent opportunity to showcase their products and services to the pipeline industry.
Contact details: Resonance Energy Pvt Ltd Ms Abha Chaturvedi Mobile no: +91-9599375151 Email: abha@energyworld.biz Ms Sonal Thapliyal Mobile no: +91-9311195151 Email: sonal@energyworld.biz
The expo will provide a platform to showcase innovative technologies and services, encompassing current and future trends in the entire value chain of hydrocarbon industry ranging from upstream to midstream and downstream. For details contact: Jasubhai Media PVt Ltd 3rd floor, Taj building, 210 D. N. road, Fort Mumbai- 400001, Maharashtra India Tel: 022-40373636 Fax: 022-40373535 Email: conferences@jasubhai.com Web: www.chemtech-online.com
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BOOKSHELF
Petroleum Refining V.5: Refinery Operations and Management Author: Jean-Pierre Favennec Publisher: Editions Technips Hardcover: 591 pages About Book: The refiner y operations and management is the fif th book in the series, which covers the entire range of technologies used in the petrochemicals and refining industr y. The book presents an analysis of the current environment and economics of the refining industr y and reviews the tools available for optimizing and controlling the operations. It proves to be a wor thy handbook for students, engineers, and technicians across the hydrocarbon sec tor
Nonlinear Model-based Process Control: Applications in Petroleum Refining Authors: Rashid M. Ansari, Moses O. Tade Publisher: Springer Hardcover: 232 pages About Book: The book presents the control applications found in refinery processes. It uses no-linear model based control architecture for the processes. The mathematics used in the book is easy to understand with straightforward applications. There are other books in the series of Non-linear model based process control; the present revolves around facts and applications in the refining industry.
Analysis and Control of Oilwell Drilling Vibrations Authors: Martha Belem Saldivar Mรกrquez, Islam Boussaada, Hugues Mounier, Silviu-Iulian Niculescu Publisher: Springer Nature Hardcover: 282 pages About Book: From the back cover The book is focused on the analysis of the system-dynamic response and the elimination of the most damaging drill string vibration modes affecting overall perforation performance: stick-slip (torsional vibration) and bit-bounce (axial vibration). This self-contained book provides operational guidelines to avoid drilling vibrations. Furthermore, since the modelling and control techniques presented here can be generalized to treat diverse engineering problems, it constitutes a useful resource to researchers working on control and its engineering application in oil well drilling.
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