Performance Data: Essential vs

Non-Essential Data Insights

Unlock the Most Valuable Performance Insights to
Streamline Facility Maintenance and Operations
Scott Mease
Vice-President, Vinson Process Controls
Emerson Local Business Partner
Lewisville, Texas
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

RAID/Blade Servers

Digital Transformation
 Different Architectures But Similar Data Management Constraints

Challenges 3RD  Party

Sites

•  Bandwidth/Throughput Historian Mobile  User

•  Relevance over time Firewall

•  Complex data structures (not Coorporate  

Network

SCADA compliant) Web  User

3rd  Party
Sites
Enterprise Subscription  rules,
Big  Data,
Visualization
Corporate  
Firewall And
Users Historian Corporate   Analytics
Network
Enterprise  Data  
Center

Firewall •  Can’t get all data from the field

Citrix Historian Shared  Zone into SCADA? From iOps
Center to Enterprise?
(DMZ)

Firewall •  Do you need to or want to?

DCS
Historian
Process  Control   •  Access and Store the data
where it is most relevant for
Network  (PCN)

MODBUS  TCP Operator  Board

LLD (Lotsa decision making and control

4-­‐20MA
Marshalling  Cabinet
W
ire
le
ISA ssH
10 AR
Local Data) •  Periodic access, upload, and
backup of data as needed
0 T
 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
Your Wellsite Facility
workflows
Data Strategy Should
Consider Solutions that … • Transformation
– Innovative business solutions & processes
Leverage   U0lize  the   Data  Access  and  
Connect  Field  Data  
Instrumenta0on   Capabili0es  of   Visualiza0on  by  
Servers  To  Transform  
Diagnos0cs  as   Today’s  RTUs  as   Company  Role  and  
Opera0onal  Results  
Process  Analy0cs   Field  Data  Servers     Responsibility  
 Example: Leverage Instrumentation Device
Diagnostics to Process Analytics
Problem: (1) Mist in the Coriolis Technology Flow Meter
gas stream off separator, Detects Gas/Liquid Emulsion
(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 6
 Example: Transforming Instrumentation Device
Diagnostics to Process Analytics

Problems: Build-up on Guided Wave Radar Level on Tank

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
7
Leverage the Power of your RTU as a Field Data Server to Provide Insights
Which Two Have The Same
Computing Power?
Challenging the Facility Engineering
Norms About RTUs and Facilities
Automation
•  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
 There’s An App for That!
Many RTUs offer
configurable applications
•  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
Examples of Data Available
from these applications
•  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
 Utilize the Capabilities of Today’s RTUs: Gas Lift Optimization Example
•  Daily manual adjustment
Current by field operator
State •  Daily adjustment by
production engineer via
SCADA
•  PID Control to maintain Injection Flowrate

Optimization PV,

backpressure
(Could be Volume, $,
or Efficiency)

•  Supplement with Buyback

Gas
Ideal
•  Optimize based on desired
State result: volume or revenue
0 Hrs 8 Hrs 16 Hrs 24 Hrs 32 Hrs 40 Hrs
Averaging Cycle

Value to asset: 5-35%

improvement in production
rate or net revenue
 Connecting the Field Data Servers: Chemical Management

Current • Stand-Alone Injection Pump System (Non-communicating)

State • Surveillance of usage via SCADA
• Integrated data from fiscal and allocation measurement
devices
• Integration with artificial lift systems
• Integration with site shutdown controller
Ideal
State 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
 Connecting the Field Data Server Functions: Produced Fluid Management

Current • Manual hauling of liquids per API 18.1 (tickets in mason jar)
State • 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
Ideal
State 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
And as a Bonus for the Facilities Engineer…Capital efficiency ….
Tracking comingled allocation
20% - 55% fewer tanks
24 oil tanks reduced to 19
$70,151 capital and installation savings
per well pad

Wireless reductions in installation

costs and time

~$3,699 installation savings per tank

Eliminated grounding complications resulting in

Major NA Producer
1%-10% non-production time
World Oil Sept. 2015
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: Site Data
– Data from Company
– Internet access Internet Data
– Secure local access
3RD  Party
Sites
Historian Mobile  User

Firewall

• Data relevance enhanced by first

Coorporate  
Network
Web  User

hand observation, inspection and

Subscription  rules,
Big  Data,
Visualization
And
Analytics

Enterprise  Data  

diagnosis
Center

• Secure Enabling Technologies

3rd  Party
Sites
Enterprise

Firewall
Corporate  
Users Historian Corporate  

– HART (Wired and Wireless)

Network

Firewall

– Paired BlueTooth
Citrix Historian Shared  Zone
(DMZ)

Firewall

– Site wifi Network DCS

MODBUS  TCP
Historian

Operator  Board
Process  Control  
Network  (PCN)

– Virtual Network Connection (VNC) 4-­‐20MA

Marshalling  Cabinet
W
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le
ISA ssH
10 AR
0 T

– Site HMI or PC/Tablet Enterprise Data

Integrated Operations Center – The Central Nervous System

• 
‘Human Centered Design’ Is A Key Enabler
What goes here?

What does this Balance people, process, and Do I need to connect my

workspace look technology applications digitally?
like?

How much of our work processes

How do our people should we automate?
interact?
 Data Visualization: Do What Makes Sense For Each Role

Presentation of the same data in the

same format in DIFFERENT Presentation of similar data in
applications for collaboration different formats for collaboration
between the field operator and between the field operator and
production engineer 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
Your Wellsite Facility can provide CAPEX and Schedule
Data Strategy Should benefits to Facilities Engineers’
Consider Solutions that … projects
Leverage   U0lize  the   Data  Access  and  
Connect  Field  Data  
Instrumenta0on   Capabili0es  of   Visualiza0on  by  
Servers  To  Transform  
Diagnos0cs  as   Today’s  RTUs  as   Company  Role  and  
Opera0onal  Results  
Process  Analy0cs   Field  Data  Servers     Responsibility