InduSoft and Genesis RTS - Evolution of Real-Time Operations in the Energy Sector


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"Evolution of Real-Time Operations in the Energy Sector" was presented at the OPC Technology Summit 2012

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InduSoft and Genesis RTS - Evolution of Real-Time Operations in the Energy Sector

  1. 1. OPC Technology Summit 2012 Scott A. Kortier and Jeffery CardenasOPC Technology Summit 2012
  2. 2.  Mr. Scott A. Kortier – InduSoft, Inc. ◦ Over 24 years in Industrial Automation ◦ Hardware and software applications for Oil and Gas, Automotive, Plastic, Water/Waste, Packaging, and others  Mr. Jeffery Cardenas ◦ Over 20 years experience in the development, delivery, and execution of critical real-time mission operations centers ◦ Focused on business-value to government and commercial customers, including direct support to aerospace/defense, veterans health, and energy sectors 2OPC Technology Summit 2012
  3. 3. HMI/SCADA Software - Established in US in 1997Pioneer in industry: First HMI/SCADA package for Microsoft Windows CE Web solution and XML integration in HMI/SCADA Patent for database connectivityCertifications:Awards: 3OPC Technology Summit 2012
  4. 4. VxWorks  Interoperability XP Embedded Linux  Ease of use Windows Mac  Gateway to other devices Java  Secure 4OPC Technology Summit 2012
  5. 5.  Multi-Platform ◦ PC platform, Windows Embedded/CE, and others  How to install and ensure all dependencies are met  Deploy for various processors  Interoperability sessions by OPC foundation  Compliance program 5OPC Technology Summit 2012
  6. 6.  Name and configure a connection  Browse item names 6OPC Technology Summit 2012
  7. 7.  Compliment other communication technologies  Use as a gateway to other PLC communication standards Temperature Controller  Keep existing infrastructure Protocol XYZ Other OPC Device Server Defined Standard Remote access iPad, Android, phones SQL Database ERP/MES Systems Other DriversOPC Technology Summit 2012
  8. 8. 8OPC Technology Summit 2012
  9. 9.  Our Experience Base  Our Vision  Current State of the Industry  Target End-State  Summary/Conclusion 9OPC Technology Summit 2012
  10. 10.  Genesis RTS specializes in delivering state-of-the-art real-time technologies for remote operations monitoring, command, and control to the oil & gas industry. It is a collaboration between ex- NASA engineers, knowledge management experts, and experienced Energy scientists and engineers  Eric van Oort, Ph.D. ◦ 20+ years experience in oilfield industry with Shell International E&P, with 15+ years experience in land/offshore exploration and development wells. ◦ Publication of 50+ oilfield papers and 15+ non-oilfield papers ◦ Experienced technical manager and scientist, specializing in wells- related performance improvement, drilling performance optimization, Real-Time Operations Center Activities  Engineering Team ◦ Led by John Lutteringer, Senior System Engineer ◦ Over 100 years cumulative experience in technical project management, systems engineering and integration, software development, especially focused on real-time operations optimization and knowledge management 10OPC Technology Summit 2012
  11. 11.  The opportunities for exploration and discovery below the surface of the Earth are just as exciting and wonderful as those above it !  Aggressive, robust implementation of optimized drilling and completion planning and operations in the energy sector  Leverage current data/information management methods, techniques, and tools  Analyze challenges as opportunities - Object Linking and Embedding for Process Control (OPC) Unified architecture (UA) is slowly being embraced by the Energy/Oil and Gas Drilling Industry 11OPC Technology Summit 2012
  12. 12. Hoisting System Mast/Derrick Well Monitoring System Drawworks surface & downhole sensors Crown Block Traveling Block Hook Power System Engines/Generators Solids Control System Shale Shakers Mud / Process Pits Rotary System Hydrocyclones Topdrive or Rotary Table Centrifuges Drillstring/Drillpipe Waste Pits Mixing / Hoppers BHA & Bit Well Control System MUX/Piloted Control BOPs Circulating System Accumulators Mud pumps Choke/Kill Manifold Stand Pipe, Rotary Hose, Swivel Bell Nipple Mud 12OPC Technology Summit 2012
  13. 13. Drilling Oil Company Drilling Contractor (Well Services Operator) Companies Accounting Rig Design and Department Maintenance Accounting Reservoir Land Drilling Department Engineering Department Drilling Drilling Superintendent Fluids Cements Formation Production Operations Evaluation Engineering Well Formation Monitoring Evaluation Drilling Superintendent Directional Well Drilling Casing Drilling Engineering Geology Well- Drilling completion Bits Equipment Company Tool Representative Pusher BlowoutOther rigs under Miscellaneous Prevention contract Other wells in progress Driller Rig Crew Field Representatives Rotary Rig Derrickman Helpers Mechanics 13OPC Technology Summit 2012
  14. 14.  Most major oil companies contract out the drilling of a well to drilling companies; e.g., Transocean, Noble Drilling, Parker Drilling  The drilling companies have fleet of rigs that may be contracted out to operators  Once a rig is built and added to the fleet there is little to no incentive to refurbish/migrate the instrumentation and data collection systems to alternate architectures or standards 14OPC Technology Summit 2012
  15. 15.  The legacy has been to provide customized, tightly coupled solutions to the oil and gas industry, particularly in the areas of… ◦ Data acquisition systems ◦ WITSML rig servers ◦ Integrated communications ◦ WITSML data historians ◦ Applications for the drilling full life cycle  Large client bases currently in existence  Reluctant/hesitant to change without proven business-value 15OPC Technology Summit 2012
  16. 16.  Functions: ◦ Hoisting (moving drillstring & casing up and down) ◦ Rotating (drillstring & casing) ◦ Circulating (fluids in & out of the well) ◦ Maintain Well Control (controlling downhole pressures, preventing blow- outs)  Operations ◦ Drilling ◦ Tripping ◦ Running Casing ◦ Cementing ◦ Formation Evaluation (Logging, Coring, Testing) ◦ (Re-)Completion ◦ Workover ◦ Abandonment 16OPC Technology Summit 2012
  17. 17.  Surface Sensors/Parameters  Downhole telemetry - MWD/LWD  Historically done through serial transfer of ASCII data  Establishment of… ◦ Wellsite Information Transfer Specialization (WITS) ◦ Wellsite Information Transfer Standard Markup Language (WITSML) – 2002  Data Interface ◦ Serial or IP-based ◦ WITS Level 0/1 or WITSML  Various instrument/service providers 17OPC Technology Summit 2012
  18. 18.  Data acquisition at the well site ◦ No direct access to instrumentation ◦ Rig data interface provides data acquisition, conversion to WITS/WITSML, and storage to server  WITSML Server ◦ Transmits processed data to WITSML data ‘historian’ (repository) ◦ Storage/forward capabilities ◦ Direct application support at rigsite 18OPC Technology Summit 2012
  19. 19. Communication Data Historian DATA COMMUNICATION Rig Picture Rig Components Drilling Applications 19OPC Technology Summit 2012
  20. 20.  WITSML server  Captures and stores all real-time well drilling data  Maintains a history of all wells drilled  Supports applications requiring data  Data historian can be located within the company’s IT infrastructure  Data historian can be provided as ‘software-as-service… ◦ Application access via internet or leased communication line 20OPC Technology Summit 2012
  21. 21.  Applications available to support the full drilling and completions lifecycle ◦ Well Planning ◦ Well Drilling ◦ Well Completion  Applications utilize WITSML and application-specific data base information 21OPC Technology Summit 2012
  22. 22.  WITSML Limitations ◦ Data standard for drilling data only ◦ Data model for drilling data only  Requirements ◦ Interface directly with rig instrumentation for data capture ◦ Ensure data quality component for each data point ◦ Command/control capability ◦ Alarms and events ◦ Security ◦ Standardized data transfer across systems  Limited Opportunities for Performance Excellence, based on… ◦ Improved well planning ◦ Optimized drilling and completions performance ◦ Well data/knowledge management ◦ Drilling process workflows ◦ Benchmarking ◦ Real-Time (remote) operations and support 22OPC Technology Summit 2012
  23. 23.  Deepwater Horizon/Macando Well  Increased competition in the industry  Environment, Health, Safety challenges and regulations  Better utilization/leverage of SME’s  Improved Risk Management  Minimize exploratory and operational costs  Maximize opportunities for project management and control 23OPC Technology Summit 2012
  24. 24.  OPC UA integration from the corporate office to the rig instrumentation and rig subsystems Communication Data Historian OPC UA Data Flow Rig Drilling Components Applications 24OPC Technology Summit 2012
  25. 25.  OPC UA creates opportunities for improved, optimized performance ◦ Increased automation ◦ Opportunities for remote command/control ◦ Increased ‘awareness’ and knowledge in decision process ◦ Knowledge management/sharing ◦ Benchmarking  Benefits are known - new drilling rigs are being OPC UA certified  Downhole equipment being OPC UA certified  Increased opportunities for unmanned drilling remotely controlled  Implement challenges can be addressed in straightforward manner 25OPC Technology Summit 2012
  26. 26.  The Oil & Gas industry is at a critical point in the development and implementation of a ‘digital oil field’ environment ◦ Real-time data structure as has evolved with little overall design and structure to the underlying data management requirements ◦ Current data standards based on a combination of proprietary vendor standards ◦ Ever growing volumes of data required to facilitate decision-making; drivers for more efficient operations and data management support  Conclusion ◦ OPC Unified Architecture (UA) combines the functionality of the existing OPC interfaces with new technologies such as XML and Web Services to deliver higher levels of operational support ◦ It provides an integrated data foundation capable of handling increased data volumes while providing optimized and accurate information required for critical decision-making 26OPC Technology Summit 2012
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