Monitoring World Class Oil and Gas Assets - cdn.osisoft.com · Monitoring World Class Oil and Gas...

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© Copyr i gh t 2012 OSIso f t , LLC.

Modeling and

Monitoring World

Class Oil

and Gas Assets

Ken Startz

Adv. Sr. Business Analyst


Marathon Oil Facts & Figures - 2011

• Established in 1887

• Market Cap: ~ $21 billion (as of 10/1/12)

• Revenues: $14.7 billion

• Income from Continuing Operations*: $1.7 billion

• Net Income*: $2.95 billion

• Capital Expenditures**: $3.4 billion

• Net Oil Production Sold: 219,000 BPD

• Net Natural Gas Production Sold: 866 million CFD

• Net Synthetic Crude Oil Sold: 43,000 BPD

• Net Proved Liquid Hydrocarbon, Natural Gas and Synthetic Crude Oil Reserves: 1.8 billion BOE

• Employees: ~3,300

• Headquartered in Houston, Texas *Marathon’s downstream business was spun-off on June 30, 2011, and has been reported as discontinued operations.

**Includes accruals.

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Background

• Oil and gas exploration and / or production in ten countries.

• PI System installations: – Four in upstream (Houston, MEGPL, EGLNG, and

Norway)

• My first PI System implementation was at Robinson, Illinois Refinery in 1988.

• First OSIsoft Salesman was Pat Kennedy

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Business Challenges

• No method to retrieve time-series data for upstream assets

• Requirements to gather data from six different control systems (including system with no existing interface)

• Embrace standards such as thin client using SharePoint

• Integrate with Digital Oilfield initiatives such as Viewpoint (Mash-ups from different Upstream Sources)

• Retrieve data from JV partners

• Advanced computation capability to highlight problem areas and prioritize workflows

• Provide knowledge management and knowledge transfer to newer technical professionals

• Integration with modeling applications such as Kappa Diamant, Kappa Saphir, HYSYS, ECLIPSE.

4


Contents

• Modeling: Equatorial Guinea

• Modeling: Droshky (Gulf of Mexico)

• Monitoring and Alerting: Mimm’s Creek Plunger

Lift Well Diagnostic Tools

5


Real-Time Data Infrastructure for Production Operations

6

WonderWare

DCS

Industrial SQL

OPC Interface

Intellution iFix

SCADA

iHistorian

PI Data Publisher

Aker Solutions

MCS

OPC Interface

North Dakota

Wyoming

Colorado

Oklahoma

Gulf of Mexico Texas Gulf of Mexico

NAPO IPO - EG

Experion DCS

PhD

PI PhD interface

DeltaV DCS

PI

PI to PI

MEGPL Alba B2

MEGPL Gas PlantEG LNG

Outside Operated IPO - Norway

Alvheim

Kongsberg/Rapid

PI

PI Central

Historian

RTWebParts

Server

(MOSS 2007)

ACE Server

`

HES

RTWebParts

DataLink

`

Reliability

RTWebParts

DataLink

`

Wells/Reservoir

RTWebParts

DataLink

PI ProcessBook

Kappa Diamant

Industrial

Evolution

PI

PI to PI


Marathon Equatorial Guinea

• Ownership in Alba Block

– Marathon 63.25% (65.21% W.I.)

– Noble 33.75% (34.79% W.I.)

– GEPetrol 3.00% (Carry)

• Ownership in Alba LPG Plant:

– Marathon 52.17% (65.21% W.I.)

– Noble 27.83% (34.79% W.I.)

– SONAGAS 20.00% (Repaid Carry) • Alba Field is located 18 miles NW of Bioko Island,

Equatorial Guinea in Rio Del Ray Basin.

• Water Depth ~250 ft

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Alba Field – Is all about the scale

8

29,600 acres

~ 14,923 soccer fields!

Alba 9 Well and Marathon Oil Tower Houston, Texas

Marathon Oil Tower

Alba – 9

564 ’

© Copyr i gh t 2012 OSIso f t , LLC. 9

Bioko Island – Equatorial Guinea 2007


Finished Platforms

10

B2 Platform

C Platform Pipelines Landfall

B2 Platform


MEGPL Gas Plant


Housing Complex

12


E G DCS Network

Offshore

Platform A

Honeywell

Experion

Offshore

Platform C

Honeywell

Experion

Offshore

Platform B-B2

Honeywell

Experion

Gas Plant

Control System

Honeywell

Experion

Honeywell PhD Honeywell PhD

One PC Worldwide

PHD Access

Equatorial Guinea – Before

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Equatorial Guinea – After

14

E G DCS Network GE Turbine Compressors ( 2 exist for MEGPL )

GE Power Generators ( 2 exist for MEGPL )

Offshore Platform B *

Offshore Platform A *

Offshore Platform C *

Gas Plant Control Room *

Honeywell PhD Honeywell PhD

PI API Node

PI API Node

PI System “Echo” “Echo”

MEGPL PI DMZ Network Segment

MEGPL PI System

- DataLink - ProcessBook

US Based Central PI System ( Plano , TX ) Business Network

Central PI System DataLink (Excel) PI WebParts (SharePoint)

PI to PI Interface PI to PI Interface

HYSYS Simulation Software

Kappa Diamant / Saphir Modelling

Package

PI System


Equatorial Guinea - Benefits

• Worldwide viewing of EG data

• Interface to HYSYS simulation package

• Interface to Kappa modeling packages

• Exports to GE and other service companies

• Time stamp matching of offshore and on-shore data

• This data is being used extensively by Engineers in EG and in the US to de-bottleneck process problems in the Gas Plant

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Droshky - Background

• The field is 100 percent Marathon (WI). The sub-sea wells tie back to DOR’s Bullwinkle Platform, Gulf of Mexico. The tie back is through an 18-mile pipeline.

• The majority of the data is being acquired from Aker Solutions sub-sea control system.

• Topsides data is extracted from DOR’s PI system, coming from Industrial Evolution.

• First production was July, 2010.

• Downhole calculations by Baker-Hughes DHTP Calibration server on the platform.

• Re-calibrations performed monthly by Baker-Hughes in Houston office.

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Subsea Facilities

17

Well Control Umbilical

4 Subsea Wells

w/ 10 completions

Flowline

Manifolds

DOR Bullwinkle Host Platform

Dual 8” Insulated Flowlines

75,000 BPD Design Rate


Bullwinkle

Rocky Angus

Noble Lorien

Manatee

Nexen Aspen

Brutus

Troika

Droshky

GC244GC243

GC199GC200

GC158

GC113GC110

GC65

GC155

GC201

Eagle


Communication

Spare

Electrical Power

Annulus

Monitoring

Asphaltene /

Paraffin Inhibitor

LP Hydraulic

Power

Methanol

HP Hydraulic

Power

Chemical / Scale

Inhibitor

Umbilical

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18.5-mile “extension cord” that connects the

tree control pods to host platform

Allows monitoring and control of the wells


Droshky PI WebParts Graphic

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Droshky – Before

2

1

Aker Solutions MCS (sub-sea data)

Baker Hughes Flow-Calculator DHFM

Remote Monitoring

VIC Client

Lafayette and Houston


2

Production Analysis

Saphir / Topaze

Kappa Diamant Database

(high frequency pressure

and rate data)

PI System (MOC)

Real time Collection

and Reporting

(Plano, TX)

TOW Database

Production Allocation

and Reporting

(Houston, TX)

PI System (DOR)

MMS Production

Reporting

SAP Entry (IBM)

Production Accounting

(Tulsa, OK)

SPL Incorporated

Monthly Production Allocations

(Pearland, TX)

Monthly Allocations (IBM

Manually enters into SAP)

Baker -Hughes

SDA Flow-calculator

DHFM

Aker Solutions

MCS

(subsea controls)

Bullwinkle Control

System

(Intellution)

Offshore

Raw Data Subsea

Controls

Shell Provides Daily

Allocations (MOC Operators

Manually enter into TOW)

Water Depth ~ 3,000 ft

Facility

Tags 87

Subsea

Tags 788

Calculated

Tags 150

DOR Controlled MOC Controlled

Remote Monitoring

Vic Client

(Lafayette and Houston)

Neptune Gas Plant

Monthly Gas Sales

Allocations

Droshky – After (Heavily Integrated!!)

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Droshky - Benefits

• Savings of $5K per user for displays vs. VIC client

• Daily input deck for Eclipse models saving vs. hand-typing by engineers.

• Automatic daily entry into production allocation system (TOW)

• One source of the truth using PI OLEDB COM connectors into TOW.

• Monthly updates for re-calibration of Baker-Hughes downhole data using PI Universal File Loader (UFL). PI System is considered “Gold Database”.

• Sub-surface modeling with automatic channel created to Kappa Modeling Suite.

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PI WebParts Home Page

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Typical PI WebPart Trends

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Engineering Models Used

• ECLIPSE: Sub-surface reservoir modeling for multi-phase flow through porous media. (Entire Field)

• Kappa Diamant/Saphir: Pressure transient analysis. Used in the early stages of a well to evaluate properties in the close vicinity to the well. (One well at a time)

• HYSYS: Topsides modeling. Usually used for offshore platforms. Maximize fluid recovery to optimize surface production facilities.

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Data Collection & Interpretation Data Integration & Geologic

Modelling

Upscaling & Reservoir Simulation

Fine scale static

3D model(s)

Errors, inconsistencies,

uncertainty?

Mathematical model(s) for dynamic

flow behaviour

Reservoir Simulation

Simulation Using Eclipse

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Benefits (Modeling)

• Project value estimates were based on 0.1% of

worldwide production, based on greater well

equipment reliability, and well characterization

for future wells.

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Reservoir Engineer Quote

“A new well drilled and completed in Deepwater Gulf of Mexico can cost up to $125 million. Proper reservoir characterization includes flow and pressure build-up data down to the six-second level, in order to avoid wasting capital on unproductive wells. The PI System will be instrumental in capturing this data.”

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Executive Management Quote

“The Droshky project’s execution and delivery was outstanding, and our teams working with our partners in IT advanced our capabilities in the use of real time surveillance techniques with their application,” said Dave Roberts, Chief Operating Officer (COO), Marathon Oil. “We have set the future course for better and faster data collection and interpretation for our producing assets with this success.”

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Mimm’s Creek Plunger Lift Diagnostic Tool

• Operators are overwhelmed with tasks (operate

by exception)

• Requested by the Technology Services group (R

& D function)

• Result of a six-month study to optimize

production

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Mimms Creek POC

• Over 500 Natural Gas

• Wells spread out

across East Texas

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Plunger Lift Basics

• Plunger is dropped through fluid in

production tubing with bypass valve open

• Flow control valve (FCV) is opened and

gas is injected below the plunger. This

forces the bypass valve to close and the

plunger to rise, carrying with it any fluid.

• Plunger is caught at top while fluid is

produced.

• After a designated amount of time, FCV

is closed, the plunger is dropped and the

cycle repeats.

• Controller at surface orchestrates all of

this.

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7-Day Status of All Wells

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7-Day Status Individual Well

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Well Status at Time of Error

3

8


Exporting Well Errors to Excel

3

9


Resulting Spreadsheet

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Error Detection Pilot

• A new well-state tag needed to be added for each well. The states are: Well Shut-In, Well Transition, Well Flowing.

• PI ACE kicks off the Well State Determination process every time a new value is written to the Valve Position Indicator tag.

• The remaining PI ACE calculations run based on the value of the Well-State tag.

• A new digital state tag was also added for each well to store current and historical error flags.

Current Design: Errors go to Report or PI WebParts Display

Future Design: PI Notifications

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Architecture

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PI ACE Server

Proficy

Server AutoSOL

SCADA

Server

PI

Pub. ROC

Link

ROC

PI Server

SharePoint

Server


Benefits

• Reduce Lost Production

• Reduce Maintenance

• Opportunity to focus on higher value items

• Operators are better able to prioritize their daily routine

• Fewer problems “slip through the cracks”

• Conservative Estimate

43


Conclusions

Utilizing OSIsoft’s Real-Time PI System Infrastructure

• Standardize Operational Data

• Separation of Consumers

• Application Platform

Utilizing Microsoft’s SharePoint Platform

• Visibility to Anyone

• Easily Configured / Flexibility

• One Version of the Truth

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