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

OPC Technology Summit 2012

Scott A. Kortier
and Jeffery Cardenas


 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, veteran's health, and energy sectors
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HMI/SCADA Software - Established in US in 1997

Pioneer in industry:
First HMI/SCADA package for Microsoft Windows CE
Web solution and XML integration in HMI/SCADA
Patent for database connectivity

Certifications:

Awards:

3


VxWorks
 Interoperability
XP
Embedded

Linux
 Ease of use Windows

Mac
 Gateway to other devices
Java

 Secure

4


 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

5


 Name and configure a connection
 Browse item names

6


 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 Drivers

 Our Experience Base
 Our Vision
 Current State of the Industry
 Target End-State
 Summary/Conclusion

9


 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

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 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

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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
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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
Blowout
Other rigs under Miscellaneous
Prevention
contract Other wells in progress
Driller

Rig Crew Field
Representatives
Rotary Rig
Derrickman
Helpers Mechanics

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 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

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 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

15


 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

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 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

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 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

18


Communication Data Historian

DATA COMMUNICATION

Rig Picture

Rig Components Drilling Applications

19


 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

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 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

21


 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

22


 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

23


 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

24


 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

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 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

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