performance optimization for oil and gas · pump motor avoidable revenue losses on downtime 1.2...
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W H A T I S T H E C O S T O F B E I N G R E A C T I V E V S . P R O A C T I V E ?
AVERAGE RUN LIFE OF AN ESP OPTIMAL RUN LIFE OF AN ESP
AVERAGE DOWNTIME AVOIDABLEOR EARLY FAILURES
PUMP MOTOR
AVOIDABLE REVENUE LOSSESON DOWNTIME
1.2years 5years
30%1week
$10.9BYEARLY
40% 22%
C U R R E NT G L O B A L O I L P R O D U C T I ON
60% 4 4 . 4 M B P D
7 4 MBPD
E S P L I F T
O F T O T A L P R O D U C T I O N
!
t ASSET MANAGEMENT
= = =
L E G A C Y T E C H N O L O G Y P O S E S C H A L L E N G E S F O R I o TW i t h i n O i l a n d G a s
RTU’s / MODBUS COMMUNICATIONS SCADA / HISTORIANS
Low to No Data Storage Capabilities
Limited Standardized Communication Protocols
Modbus is Primary Standard But Has Weaknesses:• Master / Slave Arch. (Polling
vs. Streaming)• Registered Values Not Std.• Master has limits on # of
Devices They Can Poll• Limited # of Data Types
Allowed• Security Concerns
Data Has Not Been Viewed as Primary Driver to Decision Making.
Comms Design: When and If Avaialbe vs Master Data Plan.
Varying Infrastructure Exists:• No Connectivity• Hard Wired,• Radio• Broadband• 3rd Party Data Services
Data Structure Not Architected for Analytics
• Low Fidelity Data Capture (Completeness)
• Manual Mapping of Registered Values (Accuracy)
• Data Accessibility:• Partitioning• Archiving
• Basic Thresholding & Alerts• No Calculated Sensors• No Statistical Classifiers• No Machine Learning
Broken Underlying Processes Fuel Outdated Information
• Poorly Integrated with Procurement Systems
• Assets Moves / Adds / Changes Frequently Not Captured
• Maintenance and Tear Down Data Frequently Not Captured
• Out of System Data in Excel is Primary System for Field Engineers.
P R E D I C T S K E Y P R O B L E M S
E S P P U M P
· GAS LOCK
·WORN PUMP
·SHEARED SHAFT
·WORN BEARINGS
·RECYCLING
·ERODED/CORRODED HOUSING
·SEIZED PUMPSand, scale, corrosion, pump failure
M O T O R
· OVERHEATING
Operator error, scaling, motor fault, wellbore fluids
· REDUCED EARTH RESISTANCEIngress of wellbore fluids, motor fault, motor wear,
cable fault
· FAULTWear, loss of radial stability, vibration,
manufacturing error, operator abuse
· SEIZURE
Debris, internal damage
F L U I D
· CHANGING OIL /WATER RATIO
·UNEXPECTED FLUID DENSITY
·EXCESSIVE GAS
·SLUGGING
·SAND FORMATION
·SCALING
·PARAFFIN WAX DEPOSITS
P O W E R
· VOLTAGE SUPPLY DIP
·HARMONICS
·VSD ISSUES
·CABLE LENGTH ISSUES
S E N S O R
· DOWNHOLE SENSOR DATA LOSS
·SENSOR CALIBRATION PROBLEMS
· INCORRECT SENSOR ADDRESS
I N F L O W
· PRODUCTIVITY INDEX (P . I . )
·RESERVOIR PRESSURE LOSS
·WELLBORE OBSTRUCTION
O U T F L O W
· CLOSED VALVE
·OBSTRUCTED TUBING
·SAND BRIDGE
·TUBING LEAK
Partial list of problems the OspreyData system has predicted for clients
D E R I V E1P h y s i c a l S y s t e m s
I n t e l l i g e n c e m a k e s
s e n s o r d a t a
v a l u a b l e
G A S L O C KC A N B E I D E N T I F I E D I N M I N U T E SO n t h e O s p r e y D a t a G r a p h , l o w
a m p s a n d a s a w t o o t h - l i k e
p a t t e r n i n i n t a k e p r e s s u r e
i n d i c a t e t h e o n s e t o f g a s l o c k .
H O W I T W O R K S
R E C O G N I Z E2 P R E D I C T3 A C T4E s c a l a tes event s t o f i e l d op er a torsi n r ea l - t ime
C o n d u c t s
E n g i n e e r i n g A n a l y t i c s
t o i d e n t i f y f a i l u r e
m o d e s e a r l y
C o n d u c t s D a t a
A n a l y t i c s t o
d o c u m e n t + i d e n t i f y
f a i l u r e m o d e s
P H Y S I C A L S Y S T E M S I N T E L L I G E N C EUse sensor data to understand the behavior of assets and components in real time.
-
ELECTRONIC HORSEPOWER
HYDRAULIC HORSEPOWER
FLOW
TOTAL DYNAMIC HEAD
EFFICIENCY
C A L C U L A T E D S E N S O R SIN THE O SPREYD A TA L IBRA RY(Sam ples)
-
C A L C U L A T E D S E N S O R SM A K E A S E A O F S E N S O R D A T A V A L U A B L E
P ot ent ia l E SP p r ob l ems c a n b e r ea d i l y
i d ent i f ied us i ng t he Os p r eyDa ta G r a p h :
SCALE
EROSION
IRON SULFATE
TEMPERATURE EFFICIENCY
EFFICIENCY
VIBRATION EFFICIENCY
D A T A + E N G I N E E R I N G A N A L Y T I C SOspreyData’s Classifiers & Models identify failure and operational modes.
-
C L A S S I F I E R SIN THE O SPREYD A TA L IBRA RY
CLOSED VALVE
TUBING LEAK
GAS LOCK
UPTHRUST
Osp re yDa t a ’ s C a l c u l a t e d S e n s o r s
o f H e a d a n d F l o w c a n b e i n t e g r a t e d i n t o
a n o p e r a t i o n a l g r a p h . I n t h i s g r a p h , w e c a n
r e a d i l y e n s u r e a p u m p i s o p e r a t i n g s a f e l y
a n d a v o i d i n g t h e u p t h r u s t s t a t e .
E S C A L A T E S A C T I O N S W I F T L Y
S M S E S C A L A T I O N SA L E R T F I E L D O P E R A T O R SI N R E A L - T I M E
F i e l d O p e r a t o r s r e c e i v e a l e r t s
a b o u t e v e n t s a s s o o n a s t h e y
b e g i n . I m m e d i a t e a c t i o n c a n b e
t a k e n t o p r e v e n t s e r i o u s f a i l u r e .
Osp r e yDa t a ’ s e s c a l a t i o n s y s t e m
a l l o w s o p e r a t o r s t o m o d e l a n d
t e s t k e y d e c i s i o n p r o c e s s e s i n
d a i l y o p e r a t i o n .
P L A Y B O O K SP U T B E S T P R A C T I C E SA T O P E R A T O R S ’ F I N G E R T I P S
ENHANCED OIL RECOVERY
DRILLING& COMPLETION
ESP
ROD PUMPS
GAS LIFT
COMPRESSORS(NATURAL GAS)
ESP
STEAM INJECTION
WATER FLOOD
FRACKING
DRILLING DYSFUNCTION
ARTIFICIAL LIFT
U S E C A S E S
A R T I F I C I A L L I F T I S J U S T T H E B E G I N N I N G .