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© Copyr i gh t 2013 OSIso f t , LLC. 1
Presented by
© 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
© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
Contents
• Production Operations: Droshky (Gulf of Mexico)
• MaraDrill™ (Drilling Proof of Concept)
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© Copyr i gh t 2013 OSIso f t , LLC.
Real-Time Infrastructure for Production Operations
7
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
© Copyr i gh t 2013 OSIso f t , LLC.
Droshky
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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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
© Copyr i gh t 2013 OSIso f t , LLC.
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
© Copyr i gh t 2013 OSIso f t , LLC.
Droshky PI WebParts Graphic
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© Copyr i gh t 2013 OSIso f t , LLC.
Droshky – Before
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Aker Solutions MCS (sub-sea data)
Baker Hughes Flow-Calculator DHFM
Remote Monitoring
VIC Client
Lafayette and Houston
© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
PI WebParts Home Page
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© Copyr i gh t 2013 OSIso f t , LLC.
Typical PI WebPart Trends
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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
Typical MaraDrill™ Rig
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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
MaraDrill™ Doghouse
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© Copyr i gh t 2013 OSIso f t , LLC.
Drillers Console
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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
Days vs Depth: H&P 256 - Aisenbrey 21-25H
Post-Well Analyses with SpotFire
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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
PI Coresight/SpotFire – Stick-Slip Analyses Advisory in Real Time
• Importance 1 second data
Other vendors
Rig Display
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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC. © Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
PI System Helps Drillers Too!
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© Copyr i gh t 2013 OSIso f t , LLC.
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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© Copyr i gh t 2013 OSIso f t , LLC.
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