Performance Data: Essential vs Non-Essential Data Insights

Scott Mease Vice-President, Vinson Process Controls

Emerson Local Business Partner Lewisville, Texas

Unlock the Most Valuable Performance Insights to Streamline Facility Maintenance and Operations

Introduction

• Understand how to make best use of PLCs, RTUs And SCADA Systems to collect comprehensive, valuable sets of data to drive strategic decision-making. With so many instruments to choose from, the key to success is knowing how to separate the value-leading data from arbitrary numbers. Learn how to: –  Drive improved decision making using valuable data, discarding and de-prioritizing collection of

useless performance data –  Design an effective onsite data gathering system to inform strategic rationalization and

performance management decisions –  Understand the benefits of using holistic data-management, wireless and mobile solutions to

improve data collection at relevant points across your facilities

Provide sample cases or general proofs of LOE cost reduction, production revenue improvement

AND impact to CAPEX and project schedule

Corporate IT Buzzword Bingo

Digital Transformation

RAID/Blade Servers

Different Architectures But Similar Data Management Constraints

Challenges • Bandwidth/Throughput • Relevance over time • Complex data structures (not

SCADA compliant)

• Can’t get all data from the field into SCADA? From iOps Center to Enterprise?

• Do you need to or want to? • Access and Store the data

where it is most relevant for decision making and control

• Periodic access, upload, and backup of data as needed

Mobile  User

Web  User

Historian

3RD  PartySites

Coorporate  Network

Subscription  rules,Big  Data,

VisualizationAnd

Analytics

Firewall

Enterprise  Data  Center

Process  Control  Network  (PCN)

Shared  Zone(DMZ)

Corporate  Network

Enterprise

WirelessHARTISA100

MODBUS  TCP

4-­‐20MA

Marshalling  Cabinet

DCS Historian

HistorianCitrix

Firewall

HistorianCorporate  Users

Firewall

Firewall

3rd  PartySites

Operator  Board

LLD (Lotsa Local Data)

Data Types and Strategies for Leveraging Data

• Surveillance –  Instrumentation & real-time data

• Analyze (and Act) – Real-time information & data validation – Actionable information

• Optimization – Real-time intervention & integrated

workflows • Transformation

–  Innovative business solutions & processes Data  Access  and  Visualiza0on  by  

Company  Role  and  Responsibility  

U0lize  the  Capabili0es  of  Today’s  RTUs  as  Field  Data  Servers    

Connect  Field  Data  Servers  To  Transform  Opera0onal  Results  

Leverage  Instrumenta0on  Diagnos0cs  as  

Process  Analy0cs  

Your Wellsite Facility Data Strategy Should

Consider Solutions that …

Problem: (1) Mist in the gas stream off separator,

(2) gas carryunder in liquid leg, (3) oil carryunder in

water leg

How Detected: Change in the meter drive gain voltage and density

Solution: (1) Change size of the mist extractor, (2, 3) fix dump valve or upgrade to throttling valve and/or

check level control

Example: Leverage Instrumentation Device Diagnostics to Process Analytics

Coriolis Technology Flow Meter Detects Gas/Liquid Emulsion

6

Problems: Build-up on probe, emulsion on

surface, foaming

How Detected: Change in Signal Quality (SQ) & Surface/Noise Margin

(SNM)

Solution: Clean the probe (build-up), control separator residence, change rate of

de-foaming injection

Example: Transforming Instrumentation Device Diagnostics to Process Analytics

Guided Wave Radar Level on Tank

7

Leverage the Power of your RTU as a Field Data Server to Provide Insights

• Gas and Liquids Fiscal Metering and Volume Balance capabilities

• Advanced/Complex Control – Economic and Efficiency based Gas Lift

Optimization – Cycle logging for long term analysis

• Fast Data Logging (1 second) – Sensing tubing perforation in plunger lift

• Transactional Logging – API Haul Logs and Pipeline Batching

• API class-based maintenance bypass management and reporting

Which Two Have The Same Computing Power?

Challenging the Facility Engineering Norms About RTUs and Facilities

Automation

There’s An App for That!

•  Artificial Lift Control and Optimization

•  Automated Well Test •  Tank Management • Heater-Treater

Optimization •  Surface Equipment

Control & Maintenance • Chemical Management •  LACT/Truck and Rail

Loadout •  EOR: Steam, WAG, and

CO2 Injection

•  Fiscal Reports •  Alarm and Event Lists •  Plunger Lift Cycle Logs • Gas Lift Cycle Logs • Well Test Reports • Haul Ticketing and

Summary Reports •  First Out Indication of

Shutdowns •  Various History/Trends • Report By Exception of

Abnormal Conditions •  Equipment Maintenance

Status: In/Out of Service

Many RTUs offer configurable applications

Examples of Data Available from these applications

Utilize the Capabilities of Today’s RTUs: Gas Lift Optimization Example

• Daily manual adjustment by field operator

• Daily adjustment by production engineer via SCADA

• PID Control to maintain backpressure

• Supplement with Buyback Gas

• Optimize based on desired result: volume or revenue

Value to asset: 5-35% improvement in production rate or net revenue

Current State

Ideal State

0 Hrs 8 Hrs 16 Hrs 24 Hrs 32 Hrs 40 Hrs

Injection Flowrate

Optimization PV, (Could be Volume, $,

or Efficiency)

Averaging Cycle

Connecting the Field Data Servers: Chemical Management

• Stand-Alone Injection Pump System (Non-communicating) • Surveillance of usage via SCADA • Integrated data from fiscal and allocation measurement devices

• Integration with artificial lift systems • Integration with site shutdown controller

Value to asset: 5-20% chemical expense reduction at same production rate and same site reliability

Achieving ideal state for chemical management as integral part of facility design plan has lower CAPEX than when an afterthought

Current State

Ideal State

Connecting the Field Data Server Functions: Produced Fluid Management

• Manual hauling of liquids per API 18.1 (tickets in mason jar) • Automating the data collection from manual hauling • Tank inventory management data with “auto-hauling” •  Integration with well test and allocation measurement data to

provide GAAP compliance of allocating costs to revenue • Hauling of liquids per API 18.2 w/transaction logging and/or

hauling of liquids via LACT • Vapor recovery and/or flaring volume data collection

Value to asset: Reduction of unaccounted for produced liquids below <1-2%

Holistic approach provides better accounting of overall volume balance and ability to find/eliminate shrinkage/unaccounted for volume

Current State

Ideal State

And as a Bonus for the Facilities Engineer…Capital efficiency ….

24 oil tanks reduced to 19 $70,151 capital and installation savings

per well pad

Tracking comingled allocation 20% - 55% fewer tanks

~$3,699 installation savings per tank

Eliminated grounding complications resulting in 1%-10% non-production time

World Oil Sept. 2015 Major NA Producer

Wireless reductions in installation costs and time

Thoughts on Modular Construction, OEMs, Modbus, and Wireless Networking

• Most OEMs/process skid suppliers offer a standard controller often promoted as “talks Modbus”

• Serial “Modbus Hell” across a site adds complexity and often strands data

• As the customer, don’t settle for the standard controller-specify your requirements and collaborate w/your suppliers

• Specify wireless and networkable automation to reduce CAPEX, time to first oil, and improve data access

“Drive up SCADA” Data Insights Access and Visualization

• Role specific access to: – Data from Company –  Internet access – Secure local access

• Data relevance enhanced by first hand observation, inspection and diagnosis

• Secure Enabling Technologies – HART (Wired and Wireless) – Paired BlueTooth – Site wifi Network – Virtual Network Connection (VNC) – Site HMI or PC/Tablet

Mobile  User

Web  User

Historian

3RD  PartySites

Coorporate  Network

Subscription  rules,Big  Data,

VisualizationAnd

Analytics

Firewall

Enterprise  Data  Center

Process  Control  Network  (PCN)

Shared  Zone(DMZ)

Corporate  Network

Enterprise

WirelessHARTISA100

MODBUS  TCP

4-­‐20MA

Marshalling  Cabinet

DCS Historian

HistorianCitrix

Firewall

HistorianCorporate  Users

Firewall

Firewall

3rd  PartySites

Operator  Board

Site Data

Enterprise Data

Internet Data

Integrated Operations Center – The Central Nervous System

• 

‘Human Centered Design’ Is A Key Enabler

How much of our work processes should we automate?

Do I need to connect my applications digitally?

Balance people, process, and technology

How do our people interact?

What does this workspace look

like?

What goes here?

Data Visualization: Do What Makes Sense For Each Role

Presentation of the same data in the same format in DIFFERENT applications for collaboration

between the field operator and production engineer

Presentation of similar data in different formats for collaboration between the field operator and

production engineer

Summary • As Facilities Engineers, your automation selection and design can have a substantial impact to maintenance and operations (and accounting too…)

•  Adoption of the certain data management strategies and workflows can provide CAPEX and Schedule benefits to Facilities Engineers’ projects

Data  Access  and  Visualiza0on  by  

Company  Role  and  Responsibility  

U0lize  the  Capabili0es  of  Today’s  RTUs  as  Field  Data  Servers    

Connect  Field  Data  Servers  To  Transform  Opera0onal  Results  

Leverage  Instrumenta0on  Diagnos0cs  as  

Process  Analy0cs  

Your Wellsite Facility Data Strategy Should

Consider Solutions that …