Efficiency Gains Related to Chemical Treatments in ...
Transcript of Efficiency Gains Related to Chemical Treatments in ...
Efficiency Gains Related to Chemical Treatments in Oilfield Production - Resulting from Applying Systems Architecture
Complex Systems Design & Management 2013 Conference Page #1 of 15
Alan F. Krauss
Schneider Electric
� Introduction� Oilfield Production Scenario� Production Expenses� Rod Pump Controllers and Drives
� Stakeholders & Expected Feature Analysis� Needs� Requirements
Agenda
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� Requirements� Operational Analysis
� Use Case, Response Scenario� Functional Analysis
� Requirements Revisitation, I/O Diagram� Constructional Analysis
� Requirements Revisitation, Interfaces� Conclusion
Where is the Oil?
surface
anticline(impervious shale or limestone)
300-8000m
paraffinsand
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shale seal or cap rock
gas in permeable rock
oil in permeable rock
water in sandstone
sandsalt
Rod Pump Controller (RPC) Environment
Main Mission (for Producer) :
Extract resource (oil and/or gas) out of the ground with
sales $ € ¥ > cost $ € ¥
Oil Producer Issues :
1. Maintenance and downtime costs associated with equipment
2. Producing the most oil when running3. Minimizing expenses when running
(energy, byproduct generation)
rod pump
PCPESP
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(energy, byproduct generation)4. Too many wells, not enough people
ESPplunger lift
RPC Solution Components
Telemetry/Radioinstalled in enclosure
HMI Systemserver or standalone
Wireless/Wired Sensors
installed on pipes, tanks, etc.
Drive Enclosuremounted near well
Beam Pumpa.k.a. Rod Pump,
Pumpjack
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Proximity Sensormounted behind crank arm
Load Cell Sensorinstalled on bridle
Integrated Machine Controller
for ATV71 Drive
installed in enclosure
Motor
Stakeholders
Pumper
ProductionSuperintendent
ProductionManager
ProductionEngineer
ElectricalContractor
PanelBuilder
OSHA
SafetyRepresentative
EPA
VicePresident, etc.
DomesticSales
GlobalSales
SafetyCoordinator
OfferCreation
Sensor
CableSupplier
MachineShop
MiscSupplier
Competitor
RancherLease Owner
LocalOfficial
USARegulatory
System
Reservoir
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RPC System
Contractor
MechanicalContractor
ChemicalContractor
Builder
Integrator
Engineer andOffer Mgt
Tech Pubs Manufacturing
OrderAdmin
Shipping
SensorManufacturer
SensorManufacturer
Third PartySoftware
PartsManufacturer
ElectricUtility
Reservoir
Drive (Motor) Pump Jack
In this paper, we focus on two Stakeholders in part icular...
� General Needs Analysis
Expected Feature Analysis (1 of 3)
Operate Safely and in Compliance
Provide Financial Benefit
Operate Reliably
Handle Data Robustly and
Securely
Fit Into the Oilfield
Enable Oil and Gas Pumping
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Sensor Hazard Rating
Wiring Practices
Warning Labels
System Safety Peak Energy Savings
Maintenance Reduction
Production Increase
Energy Savings
Maintenance Response
Maintenance Duration
System Reliability
Survive Lightning Strike
Communication Reset
Data Security
Remote Data Access
Third Party Integration
Data Ease of Use
Data Transferability
System Expandibility
System Ease of Use
No Loud Sounds
Complete Feature Set
Efficiency Improvement
In this paper, we focus on three Needs in particula r...
� Needs Analysis
Expected Feature Analysis (2 of 3)
The Production Superintendent shall be able to:1. take corrective action to prevent loss of production within
48 hours of the onset of excessive paraffin buildupduring normal operation.
2. minimize chemical treatment production expensesduring normal operation.
3. save time in daily routines by 10% in order to be able to manage more wells in normal operation.
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The Chemical Contractor shall be able to:4. supply chemical treatment when requested within 24
hours of a request being made during normal operation.5. save time in daily routines by 10% in order to be able
to service more wells in normal operation.
Normal Operation = well is operational (not down for maintenance), there
is no emergency at another well consuming Prod. Superintendent's time,
daily duties are being performed, requests are being made and received.
� Requirements Analysis
Expected Feature Analysis (3 of 3)
The RPC System shall:1. display a trend chart of the power it takes to drive the rod
string with 1% resolution in collective and offline modes.2. enable the user to view a trend chart within 30 seconds of
engaging the HMI (Human Machine Interface) client in collective and offline modes.
3. The RPC Controller shall locate power data from (a) the drive's electrical power meter sub-system (b) the surface card
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drive's electrical power meter sub-system (b) the surface card and (c) the downhole card in data type REAL registers with resolution of at least 0.1% of the full horsepower/kilowatt range of the drive, in any installed configuration.
4. The HMI System shall store and display trend informationfor REAL data types with samples up to every 1 second and duration 12 months or more, in any networked configuration.
5. The HMI System shall contain an interface that allows zooming on trend charts, on both axes, with no more than 15 seconds retrieve, zoom and seek time, in any networked configuration.
Operational Analysis: Response Scenario (1 of 2)
ProductionSuperintendent
ChemicalContractor
RPC System
Perform Daily Duties(check RPC data)
GenerateTrendPlot
Evaluate and Decide Action
Command to See RPC Data
Visible Trend (showing increasing trend in power)
Request for Service (phone call)
Drive to Well, Add
(10 min)
(2 min)
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Ticket for Service (paper)
GenerateTrendPlot
Command to See RPC Data
Visible Trend (flat trend in or reduced level of po wer)
Chemicals, Write and Transmit Ticket
Perform Daily Duties (file paper)
Perform Daily Duties(check RPC data)
Evaluate and Decide Action
There are too many functions for the Production Superintendent to do!
(5 min)
(10 min next day)
(2 min next day)
(total 17 min one day)
Operational Analysis: Response Scenario (1 of 2)
ProductionSuperintendent
ChemicalContractor
RPC System
Analyze Power TrendsReview Info and
Approve Treatment (confirmation button)
Trend Info (increase in power) and Recommendation f or Action
Approval for Recommended Action
Electronic Ticket
Wait for Request, Drive to Well, Add Chemicals, Log Activity or
Create Ticket
(1 min) Generate RequestRequest for Treatment
Log
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Trend Info (flat trend in or reduced power) and Rec ommendation
Now the RPC System performs more functions and the Production Superintendent has a more efficient day!
(total 1 min one day)
Log Tickets
Analyze Power Trends
Review Info(1 min next day)
� Requirements Analysis
Functional Analysis: Requirements Revisitation
The RPC System shall:1. display a trend chart of the power it takes to drive the rod
string with 1% resolution in collective and offline modes.2. enable the user to view a trend chart within 30 seconds of
engaging the HMI client in collective and offline modes.
The RPC System shall:1. provide analysis of trends in the power it takes to drive the
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1. provide analysis of trends in the power it takes to drive the rod string with 95% success rate in collective and offline modes (with > 50% collective mode over time period).
2. notify the user with results and a summary of the power analysis every day in collective and offline modes.
Functional Modes
HMI ServerActive
HMI ServerInactive
RPC Active Collective Autonomous
RPC Inactive Offline Inactive
replace or add to
requirements list
(depends on the
needs)
� Requirements Analysis
Constructional Architecture: Requirements Revisitation
4. The HMI System shall store and display trend informationfor REAL data types with samples up to every 1 second and duration 12 months or more, in any networked configuration.
5. The HMI System shall contain an interface that allows zooming on trend charts, on both axes, with no more than 15 seconds retrieve, zoom and seek time, in any networked configuration.
6. The HMI System shall analyze trend information for changes
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6. The HMI System shall analyze trend information for changes in power with sensitivity of at least 1% relative to daily, weekly and monthly averages, in any installed configuration.
7. The HMI System shall contain an interface that allows SMS, email and PC notification of trend analysis, such that a user (or set of users) using a client device (or client devices) will receive a clear, concise analysis report at a configured time each day, in any networked configuration.
new requirements
to add to the list
(possibly remove
"and display" from
first requirement
depending on
functional
requirements)
Operational Architecture: Interfaces & System Construction
SMS email PC notification
Motor power has increased 7% since yesterday and 11% since last week.Reply with text 'CHEM' to approve chemical treatment.
30.032.034.036.038.040.042.044.046.048.050.0
Ave
rage
Po
we
r (k
W)
Date
Motor power has increased 7% since yesterday and 11% since last week.
Would you like to send a request for
30.032.034.036.038.040.042.044.046.048.050.0
Ave
rage
Po
we
r (k
W)
Date
Motor power has increased 7% since yesterday and 11% since last week .
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treatment.
YesClick 'Yes' or reply with 'CHEM' in the body of the email.
Would you like to send a request for treatment now?
Yes
yesterday and 11% since last week .
Would you like to send a request for chemical treatment now?
No
SMSModule
EmailModule
DisplayModule
� Stakeholder Analysis� A main issue (need) is efficiency of personnel
� Operational Analysis� Initial system design requires a lot of effort by oil producer
personnel� Reworking the response scenario relieved time on the order of
15 minutes (3% of daily activity)
Conclusion
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15 minutes (3% of daily activity)� Functional & Constructional Analysis
� The system was redesigned to incorporate the efficiency gains� Components and their relation to the environment were
specified� Result
� By applying systems architecture, a more robust and customer-centric system design was realized