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


� 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


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


(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


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


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


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


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.


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


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


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)


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)


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)


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


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)


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


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)


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


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 .


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


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

efficiency gains related to chemical treatments in

Documents