© copyright 2013 osisoft, llc....electrical power annulus monitoring asphaltene / paraffin...

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© Copyr i gh t 2013 OSIso f t , LLC.

Using New OSIsoft Tools

for High ROI Projects at

Marathon Oil

Ken Startz

Project Manager, Marathon Oil Company


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 (in enough detail) for Production Operations or Drilling

• Requirements to gather data from 7 different control systems (including systems with no existing interface)

• Embrace standards such as thin client using SharePoint

• 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.

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Contents

• Production Operations: Droshky (Gulf of Mexico)

• MaraDrill™ (Drilling Proof of Concept)

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Real-Time Infrastructure for Production Operations

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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


Droshky

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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

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Well Control Umbilical

4 Subsea Wells

w/ 10 completions

Flowline

Manifolds

DOR Bullwinkle Host Platform

Dual 8” Insulated Flowlines

75,000 BPD Design Rate

© Copyr i gh t 2013 OSIso f t , LLC. 11

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

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Aker Solutions MCS (sub-sea data)

Baker Hughes Flow-Calculator DHFM

Remote Monitoring

VIC Client

Lafayette and Houston


Droshky – After (Heavily Integrated!!)

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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

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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 $200 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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Typical MaraDrill™ Rig

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MaraDrill™ Background

• Land-Based Drilling Rigs in EagleFord and Bakken.

• Primarily Oil, Horizontal Drilling Wells.

• Factory-based Drilling Model.

• Rigs Operated by Helmerich & Payne (H & P).

• Data extracted from OMRON Control System and aggregated with

3rd party vendor data, using PI OPC_HDA Interface.

• POC started January, 2012.

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MaraDrill™ Doghouse

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Drillers Console

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Common Drilling Data Tags Engineering Units

ROP = Rate of Penetration – Feet / Hour

WOB = Weight on Bit – K Pounds

RPM = Revolutions per Minute - RPM

Mud Flow Rate – GPM

Torque - kFt*Lbs

Need 1 second time stamp resolution!

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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.

PI System

Server

Data Workflow

H&P 463 Eagle Ford

H&P 256 Bakken

H&P 458 Eagle Ford

MaraDrill

™

PI Tags

Historized

values

Houston Tower

PI CoreSight

Mobile Rig-site

Network Architecture

PI DataLink

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MaraDrill™ – Data Acquisition: PI DataLink

Collect MaraDrill™ data from PI DataLink

Functions that retrieve a single value:

•Current value

• Value at a specific time

• Tag attributes

Functions that retrieve series of values •Evenly spaced (sampled) data;

• Compressed (archived) data.;

• Sampled data for a user specified

array of timestamps

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Pre-MaraDrill™ vs MaraDrill™ Technology

Intermediary Application

Tool for Advanced Analytics

Future Plans

Pason Data Calculator Spreadsheet

PI DataLink

Pre-MaraDrill™

MaraDrill™ Technology

PI Server

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Days vs Depth: H&P 256 - Aisenbrey 21-25H

Post-Well Analyses with SpotFire

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Post-Well Analyses with SpotFire Rock Strength

Modeling the rock strength &

predicting ROP’s on

subsequent wells in the area

to improve logistics and

planning

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PI Coresight – Stick-Slip

• Stick-Slip Identification: H&P 463

“Perfect” drilling

Stick-slip

Stick-slip: Non-uniform rotation of the bit/BHA

Sticking phase → bit stops

Slipping phase → bit “breaks” free

Drillstring torsional oscillations

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PI Coresight - Stick-Slip Advisory in Real Time Stick-Slip Prevention

“Acceptable” Moderate Stick-slip

Severe Stick-slip

H&P 463- 2012 South Texas Well

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PI Coresight/SpotFire – Stick-Slip Analyses Advisory in Real Time

• Importance 1 second data

Other vendors

Rig Display

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PI Coresight - Stick-Slip Advisory in Real Time

Stick-Slip is Expensive

• Increased bit cost due to number of runs, repair/replacement charges

• Increased hourly cost due to motor usage

• Increased drilling time due to accelerated dulling (low ROP)

• Increased trip time due to number of runs

• Increased costs associated with downhole tool damage (MWD, LWD)

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MaraDrill™ Benefits

• Possibly replaces expensive third party real time data aggregation software.

• Provides accessible real time data at the rig-site and to remote employees, enabling more efficient decision making.

• Data is consistent and easy to access. More eyes on the data.

• Reduces drilling time and capital well costs:

- Potential reduction of $ 1 MM per rig per year for every 5% reduction in drill time.

- Large ROI

• Reduces vibration and damage to downhole tools:

• Continuous optimization onsite and retroactive post-well analysis

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PI System Helps Drillers Too!

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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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