BCP Group: Optimizing Oilfield Production with Intelligent Artificial Lift Solutions

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

Tweet About It Using #PSUG

Optimizing Oilfield Production with Intelligent Artificial Lift Solutions

Alexander Mendoza

CEO & President

BCP Group

Juan Camilo Mosquera

R&D Automation Engineer

BCP Group


#PSUG

Agenda

Next developments

Innovation and technology as a solution for each challenge

Automation equipment necessary to make intelligent solutions

Conventional Well Pads / Challenges

BCP Group as holding company


#PSUG

BCP Group Worldwide

United States Canada Mexico

Venezuela

Colombia Ecuador

Peru

Brazil

Argentina

BCPVEN: Created in 2002 to tend to

Venezuelan market with two factories:

west Venezuela (CIBOC), Venezuelan

headquarters, financial and R&D

department. East Venezuela (CIBOR),

WOS factory, high tech. bench test

and Orinoco belt services base

SLACOL: Created in 2005 to tend to

markets for Colombia, Ecuador and

Peru, with a factory located in Bogotá

and special services facilities in Pacific

Rubiales oil field


#PSUG

BCP Group Worldwide

BCPBRA: Created in 2012 to tend to

Brazilian market and create global solutions in

Oil & Gas applications with NETZSCH.

Factory located in Pomerode, Santa Catarina,

and building the CITE do Brasil, “Complexo

Industrial e Tecnologico do Brasil”

ESP International: Created in 2005 to develop

the North American and Caribbean market,

also responsible for developing corporate

policies of each company belonging to BCP

Group companies. With Projection of new

facilities in Houston

United States Canada Mexico

Venezuela

Colombia Ecuador

Peru

Brazil

Argentina


#PSUG

Agenda

Next developments



Traditional Well pads / Challenges



#PSUG

Key Challenges for production

PRODUCTION OPTIMIZATION

TECHNOLOGY STANDARDIZATION

INCREASE RUNLIFE

ENERGY QUALITY

FACILITIES INFRASTRUCTURE

PRODUCTION

CHALLENGES

• Optimization algorithms (Well, Well pad & Oilfield) • Production measurements

• Massification of ALS technology plant wide • Equipment supply on time (Stock)

• Quick diagnostics for failures • Traceability of process variables

• Electrical protection of assets: surface and downhole • Control algorithms to optimize energy consumption

• Low commissioning time

• Easy integration with subsystems on well pad


#PSUG

Well Pads (Downhole)

PCP Control

(Tubular, insertable,

Evenwall.)

Intelligent torque

control for rods

Different types

of drive heads

Backspin control

Interaction with

different brands of

downhole sensors

Motor control

(Induction, PMM)

Electrical

Submersible

Pump

Tubing head

temperature

Tubing head

pressure

ESP COMPLETION

PCP COMPLETION

G.E Smartguard SLB UniConn G.E Scout Zenith Phoenix Centinel

General

Electric Schlumberger Baker Hughes Novomet Borets Alkhorayef

Netzsch TDA Weatherford


#PSUG

Well Pads (Surface)

PCP WELLHEAD ESP WELLHEADS

SEVERAL PROVIDERS FOR DRIVES

STEP UP TRANSFORMERS FOR ESP

Wellhead Wireless hart

Instrumentation

Manifold Wireless hart

Instrumentation

Serial Comm. For each drive


#PSUG

Production Challenges Working with Traditional Well Pads

All disciplines involved in the oil production process need to be synergic to be optimal

Electrical Engineering

Artificial lift Engineering

Civil Engineering

Petroleum Engineering / Artificial lift (Completion) / Optimization

Automation and Control Engineering

Production Management

Artificial lift systems must be designed with innovative features that allow the customer to

measure the production and maintain their assets

The Artificial lift process needs to be optimal: from the construction of facilities to the equipment operation, monitoring, control and optimization.

“The Artificial lift process needs to be automated to provide intelligent online solutions to optimize oilfields”


#PSUG

Agenda

Next developments



Traditional Well Pads / Challenges



#PSUG

Rockwell Automation Technology in BCP Group’s Solutions

BCP Group as standard,

demands the best technology

that allows for growth

The stability of Rockwell

Automation products,

integrated with our dedicated

engineering, help us create

innovative solutions

The simplicity of integration is

valuable for our developments


#PSUG

The Ideal Components to Develop Integrated Solutions Plant Wide

We realized that the capability of control systems solved integrity needs

the customer required. Power electronics, Artificial lift knowledge, control

strategies, automation and the simplicity of a friendly, operative interface

were our strengths

ControlLogix® technology

(More than 15 high-level O&G

algorithms in our applications)

VFD technology

(Drives solutions for a variety of

power ratings according to the

Artificial lift system)

Power quality

(Online electrical analysis to help

ensure equipment’s performance)

Interface

(Intuitive operation developments.

Functional operative interface)


#PSUG

Selection Criteria

Our customer implemented the PlantPAx® concept plant wide, and our technology was

exactly the solution to grow up with them in this process

Team work made us a distinctive company for them, because the market was just

providing them drives. We innovated with the automation technology to supply the perfect

Artificial lift controller and give them what they most needed: Optimization applications.

When Rockwell Automation realized its vision of the integrated architecture, we knew we were capable of developing competitive

solutions

“Rockwell Automation provided us all equipment necessary to make the equipment they needed in an efficient way and on time”


#PSUG

Agenda

Next developments

Innovation and technology as a solution for all challenges





#PSUG

Extensive knowledge in Artificial lift systems

Extensive knowledge in Artificial lift systems

The best control technology and power

systems

A leader in control technology and power

systems

The synergic integration of both created the CILA2S

CILA2S: Intelligent Controller for Artificial lift, Sub/surface


#PSUG

Pump speed control (RPM, HZ, SPM)

Surface instrumentation Control and monitoring

Monitor complete surface and down hole variables to

feed the optimization, control and protection

algorithm

Total Integration with surface instrumentation and down hole sensors

CILA2S: Intelligent Controller for Artificial lift, Sub/surface


#PSUG

Previous Installed Base

“An experience of more than 1500

CILA2S installed”


#PSUG

CILA2S Architecture

POWER SUPPLY

(480V AC)

LOAD (SUT/PUMP)

(PUMP)

SINE WAVE FILTER

HARMONICS FILTER

SPD FUSES BREAKER

0 to 480VAC 0 to 300Hz

PROTECTION MODULE POWER QUALITY VSD MODULE

CONTROL MODULE

ETHERNET TCP / IP

DOWNHOLE SENSOR

SCADA POWER MONITOR

MODBUS TCP IP

CONTROLLER

FIELD INSTRUMENTATION

HART I/O ANA- DIG I/O

HMI MODBUS RTU


#PSUG

Applications Designed for Artificial lift Methods

Online operative data Multilanguage applications

Power quality VSD control Optimization Algorithms


#PSUG

Well Diagnostics That Are Based in Graph Charts

Nomographic chart. Digital circular chart

Dinagraph chart Well productivity chart


#PSUG

CILA2S as the Solution for a Standalone Artificial Lift System

The CILA2S as an integrator of engineering multidiscipline is designed for different

Artificial lift methods according to the customer fields

ESP: Electrical submersible pumps

PCP: Progressive cavity pumping

BP: Beam pump

MPP: Multiphase pumping

MSP: Multiscrew pumping

The constant developments in optimization applications, applied automation engineering and the “know how” in Artificial lift methods, brought the solution to an experienced customer in the Oil & Gas area

“From 2010 to present time, 302 CILA2S have been delivered to this

customer, and we continue manufacture under new contracts”


#PSUG

WOS: Well Optimization System


#PSUG


Clean agent

extinction system Indoor downhole

surface panel

mount for each well Field

Instrumentation

access

Well controller

systems for different

Artificial lift methods

(ESP, PCP, BP, MPP, MSP)

Access control system


#PSUG


Power distribution

center

Controlled

environment

air conditioning

Central control

system

Emergency shutdown

system Energy quality systems

(Harmonics / Sine wave Filters)

(Electrical protections)

Auxiliary services

center


#PSUG

Central Control System

Online production measurement

Centralized operative data Field instrumentation

WOS Electrical consumption

Intelligent Well Optimization Control


#PSUG

WOS Control Architecture

Well control system

(Cila2s concept)

Well control system #1 Well control system #2 Well control system #N

. . . Ascii

Access control system

Emergency shutdown system

Ethernet TCP / IP

Central control system

SCADA connectivity


#PSUG

Previous Installed Base

“An experience of more than 8

WOS installed”


#PSUG

WOS Technology to Optimize Production

Implementation benefits of WOS solution:

One solution for complete well pad control with all equipment integrated

Manufacture and start-up time is less than 45 days

Optimum analysis of all operative variables through historical data

Drives and control systems installed under a clean, controlled environment

High reliability and speed in communications to measure production

Security compliance with the access control system

Single contract for maintenance

Easy transport from one well pad to another

Costs and construction time to develop a well pad decrease

The centralized concept of the WOS technology allows the customer to optimize the production, optimizing the well pad construction

“From year 2010 to present time, 77 WOS were delivered to the customer,

with more than 400 single well controller systems”


#PSUG

WOS SCADA


#PSUG

WOS Scada as a Solution for the Field

The well optimization concept

was taken to the whole field

optimization

A Scada that connected more

than 1100 Wells across the

customer’s field were now

capable to be optimized just

from an operations control

center


#PSUG

Field Navigation and Quick Information

Tree view to search and explore the desired well

Field map with well pad immediate status

Navigation menu with easy access to most important displays Scada developed

in FactoryTalk® View

PlantPAx ® guidelines followed


#PSUG

Easy Access to Well Status

Well pad summary visualization

Direct link to each well information detail

Well status view of the complete field, based in color codes

Direct link to an alarmed well with just one click


#PSUG

All Information of the Well in Just One Display

• Remote control of the well: Start and stop commands • Speed increments and protection configurations

• Drive status • Spin direction • Speed reference

• Sub/surface operative data

• Alarms and events

• Electrical data • Tree view and

browsing for well pads/wells


#PSUG

Remote Online FIELD Optimization

• Downhole information + Well Characterization

• Constant protection of the wellbore

• Constant protection of motor/pump

• Speed increments/decrements suggestions, based on CILA2S’ intelligent well

control analysis


#PSUG

The Solution for the Intelligent Oilfield

The SCADA was developed under PlantPAx® guidelines to adhere to customer standards

The advantage of our “know how” in oil production allowed us to develop a dedicated

SCADA for well production

The information in SCADA has multidisciplinary data to demonstrate smart integration of

operations and prove that production is the daily matter in these oilfields

The WOS SCADA solution collects online information from all standalone solutions, WOS well pads, and brings the optimization to the hand of customer’s Optimization Engineers gaining time to increment production

“The Scada brings efficiency to the oilfield, optimizing not just on site but in

operations control centers. The connectivity and dedicated information was

a sure help for our customer”


#PSUG

Agenda

Next developments






#PSUG

Knowledge through

Optimization tools

Optimization Coaching & Machine Learning

Interactivity of the machine analysis with Optimization

Engineering

Continuous coaching based in the machine

learning

Advanced Process Control Fuzzy Logic


Tweet About It Using #PSUG

Questions

Alexander Mendoza

CEO & President

BCP Group

Juan Camilo Mosquera

R&D Automation Engineer

BCP Group

www.bcpgrp.com

BCP Group: Optimizing Oilfield Production with Intelligent Artificial Lift Solutions

Technology

Transcript of BCP Group: Optimizing Oilfield Production with Intelligent Artificial Lift Solutions