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Are All of Your Sensors Oil Field Tough? How the Right Pressure Transmitter Can Enhance Production



Top Two Business Drivers For Power and Energy Companies

Need to reduce OpEx

Constrained Capex

Aging assets (plant and equipment)

Heightened regulatory compliance

Corporate sustainability initiatives

Percentage of Respondents, n=83Source: Aberdeen Group, October 2010

All Respondents

0 10 20 30 40 50

53%

50%

40%

22%

17%

60

Your job is to bring new supplies on line, on time, and at acceptable cost. All while dealing with increased regulatory activity and environmental concerns, skilled worker shortages, remote locations, and geological complexity.

And today the industry is no longer operating XQGHU�D�%RRP�7RZQ�PHQWDOLW\³LW·V�FORVHU�WR�D�“factory” business model. That means dealing with tighter margins and less room for error. Also, the expansion of gas supply may mean that the price of natural gas will be in the low-to-modest range for years to come. That makes shaving costs of drilling and well completion operations even more critical.

The Product Must Flow... But at Minimal Cost



The key to maximizing the return on oil and gas development projects rests with the maintenance and safety of your—sometimes—aging equipment.

While most upstream organizations today use traditional maintenance models (see Fig 1.), companies using condition-based monitoring have experienced:• Production increases in the range of 5% overall• Increased reservoir life• Lowered cost of production��6LJQLÀFDQW�LPSURYHPHQWV�LQ�RSHUDWLRQV�� maintenance and decision making.1

Are You In Control?

Approach Technique Needed Human Body Parallel

Reactive Maintenance

Large budget Unplanned loss of production

Stroke or heart attack

Preventive Maintenance

Periodic component replacement Bypass or transplant

Condition-Based Monitoring

Monitoring of pressure and other indicators

Detection with regular check-ups, EKG or other monitoring

1. http://www.epmag.com/EP-Magazine/archive/Monitoring-upstream-assets_4225

Fig 1.



Condition-based monitoring means detecting equipment problems before they lead to lost production. Companies employing this approach use “alarms” such as pressure transmitters to identify faults and spot patterns—and correct them before they affect production.

The next section will discuss how to select a pressure transmitter that can help ensure productive, cost-effective operations.

Why Condition-Based Monitoring?



(OHFWURQLF�WUDQVPLWWHUV�SOD\�DQ�LPSRUWDQW�UROH�LQ�WKH�VDIH�DQG�HIÀFLHQW�RSHUDWLRQ�RI�D�ZLGH�UDQJH�RI�RLO�DQG�JDV�extraction equipment. They monitor a variety of functions, from well performance to vapor recovery.

SEPARATORSPressure

OIL WELL / GAS WELLPressure

TANKPressure and Vapor Recovery

FIELD DEHYDRATION

.POJUPSJOH��4BGF�BOE�&GmDJFOU�0QFSBUJPO

Areas in oil and gas extraction that need electronic transmitters.



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Monitoring allows you and your team to identify and resolve issues quickly—while also performing regular maintenance to keep small issues from EHFRPLQJ�SURÀW�GUDLQLQJ�IDLOXUHV�

Monitoring tubing and casing pressure can not only help you maintain a constant production output, it can also help:• Assure stability and integrity of the wellbore��3UHYHQW�RLO��JDV��DQG�IUDFWXULQJ�ÁXLGV�IURP� migrating into fresh water zones or other unintended strata

Identifying Issues QuicklyMany wells have issues that lead to gas migrationand sustained casing pressure, even newer wells.

Well age, years

Perc

ent o

f wel

ls a

ffect

ed b

y SC

PSource: Schlumberger, Oilfield Review

10

20

30

40

50

60

00

4 8 12 16 20 24 28



/Well performance monitoring allows you to focus on the problem wells that may be showing signs of performance issues such as:• Scaling and water breakthrough • Compression plant constraints • Unplanned shutdowns • Hydrate formation and gas lift equipment faults

With the right information, you can analyze and GLDJQRVH�SUREOHPV�LQ�D�SULRULWL]HG�DQG�WLPH�HIÀFLHQW�manner.

Similarly, level and pressure measurement in storage tanks can help maximize productivity and avoid clean up costs for a collapsed tank or (3$�ÀQHV�IURP�D�WDQN�EDWWHU\�ZLWK�KLJK�IXJLWLYH�emissions.

Well Performance Monitoring

Hear how monitoring can help maximize output.



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Monitoring helps boost reservoir recovery. With shale gas wells, production can decline 70% RU�PRUH�GXULQJ�WKH�ÀUVW�\HDU�RI�RSHUDWLRQ�1 As production falls, liquid collects in the well bore, ZKLFK�IXUWKHU�LPSHGHV�JDV�ÁRZ�

$UWLÀFLDO�OLIW�V\VWHPV��$/6��LQFUHDVH�SUHVVXUH�ZLWKLQ�the reservoir and encourage product to the surface. 7KRVH�FRPSDQLHV�WKDW�PDLQWDLQ�JDV�ÁRZ�E\�UHPRYLQJ�DFFXPXODWHG�ÁXLGV�WKURXJK�DQ�$/6�VXFK�as a plunger lift receive:• Revenue from increased production• Revenue from avoided emissions• Avoided costs—well treatment costs, reduced electricity costs, workover costs• Salvage value

1 http://www.epmag.com/Production-Drilling/Plunger-lift-technology-improves-shale-gas-production_62594 2 http://hfoptimiser.com/FAQ.php#

1VNQ�6Q�3FTFSWPJS� 3FDPWFSZ

More thanPG�UIF�QSPEVDJOH�HBT�XFMMT�JO�UIF�6�4��IBWF�MJRVJE�JO�UIF�UVCJOH�2

90%



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2QH�IRUP�RI�DUWLÀFLDO�OLIW�V\VWHP³D�SOXQJHU�OLIW³�reduces the cost of operating a well compared to RWKHU�DUWLÀFLDO�OLIW�PHWKRGV�EHFDXVH�WKH�IRUPDWLRQ�pressure supplies the energy used to lift the liquids.

An average plunger lift installation will cost approximately $3,500 compared to $28,000 for a pumping unit or $32,000 for a small compressor.1

In this system, users monitor casing and tubing pressures via pressure transmitters to optimize the plunger lift cycle—minimizing back pressure and PD[LPL]LQJ�JDV�RXWSXW��,Q�IDFW��WKLV�V\VWHP�ZRQ·W�work without pressure transmitters.

1 http://www.fergusonbeauregard.com/downloads/introduction-to-plunger-lift.pdf2 EPA

Need an extra �� QFS�XFMM

*ODSFBTFE�HBT�QSPEVDUJPO�GPMMPXJOH�QMVOHFS�MJGU�JOTUBMMBUJPO�IBT�ZJFMEFE�UPUBM�HBT�CFOFmUT�PG�VQ�UP�� .DG�QFS�XFMM �XPSUI�an estimated

$127,7502



A well down for 2 days a month

reduces production by 6.5% annually.

For a single 350 mcf/d (thousand

cubic feet per day) well, lost revenue

equates to $25,200 per year at $3/mcf.

)RU�D�ÀHOG�RI��wells, lost revenue is more than $2.5 million per year.

Source: http://www.shaletec.com/faq/troubleshooting-plunger-lift-wells/

True Cost of Failure:Unplanned downtime is a constant, costly menace



-BCPS�*OFGmDJFODZThe cost of failure may be more than loss RI�SURGXFWLRQ�RU�(3$�ÀQHV

/You also have to think about the “soft” cost of having your e-tech spending the day at the well to check on a performance issue.



/

,I�D�SUHVVXUH�WUDQVPLWWHU�IDLOV��WKHQ�\RX�GRQ·W�NQRZ�ZKDW·V�JRLQJ�RQ�LQ�WKH�ZHOO��<RX�FRXOG�KDYH�]HUR�production. You could have a problem down hole. Without that transmitter and continuous monitoring, you have almost lost control of the well.

The same could be said of a storage tank—without a pressure transmitter you risk a collapsed tank.

Availability Is the transmitter you need available as soon as you need it?

Durability and Longevity

Will it handle the heat in Texas?

Will it handle the cold in North Dakota?

Can you install the transmitter and then forget about it for years?

/P�%FWJDF�4IPVME�,FFQ� You From Producing

Our expert explains the cost of failure for a failed pressure sensor.



/The environment can be a durability killer. Whether you have wells installed in North Dakota with LWV��Ý)�ZLQWHUV�RU�\RXU�ZHOOV�DUH�LQ�7H[DV� ZLWK��Ý)�VXPPHUV��\RX�QHHG�D�WUDQVPLWWHU� that will handle the most extreme cold and the extreme heat.

Your pressure transmitter must also handle:• Rain• Snow and icing• Dust and dirt• Corona discharge from lightning• Electromagnetic interference (EMI)

Pressure transmitters face many challenges under these operating conditions. You must carefully select the right pressure transmitter to operate successfully while providing long-term, precise measurements.

From Sun to Snow

Pressure transmitters are not all the same.



How did WIKA become the standard in stick transmitters? Because we listened to our customers.

7KH\�WROG�XV�WR�PDNH�D�SURGXFW�WKDW�LV�´RLO�ÀHOG�tough.” To do so, we asked them about the FRQGLWLRQV�WKH\�IDFH�LQ�WKH�ÀHOG��%DVHG�RQ�WKHLU�insights, we designed long-term environmental testing to establish when, how and which electrical and mechanical components would break under severe, adverse conditions. Then, we used the best materials and welds to withstand the various UXJJHG�RLO�ÀHOG�HQYLURQPHQWV�

Our pressure transmitter has an all-welded steel case that is built to last. The steel case keeps elements such as rain, snow, wind, and dust away from electrical components.

/HW�XV�EULQJ�RXU�´RLO�ÀHOG�WRXJKµ�VROXWLRQ�WR�\RXU�application, so you can focus on cost-effective, non-stop performance.

8*,"�JT�0JM�'JFME�5PVHI

Hear how WIKA ensures it has a product that it is “Oil Field Tough.”

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10 years.



Case Study: 8*,"�JT�0JM�'JFME�5PVHI

Challenge• A large E&P company needed to � ÀQG�D�SUHVVXUH�WUDQVPLWWHU�WKDW�ZDV� � ´RLO�ÀHOG�WRXJK�µ

Solution • The company tested three competing pressure transmitters and chose WIKA due to its durability.

Results • “Real-world” results have mirrored the test results—the customer now has standardized to WIKA because our � WUDQVPLWWHUV�KDYH�VXUYLYHG�RLO�ÀHOG� conditions for years.

*Source: Actual WIKA customer and case study



0HDVXUHPHQW�LV�D�KXJH�IDFWRU�LQ�PDNLQJ�VXUH�\RX�JHW�WKH�EHQHÀWV�RI�YDSRU�UHFRYHU\��LQFOXGLQJ�OLTXLG�OHYHO�monitoring in shallow tanks, and proper pressure measurement for venting and monitoring systems for salt ZDWHU�GLVSRVDO��7KH�UHWXUQ�RQ�LQYHVWPHQW�FDQ�EH�VLJQLÀFDQW�HYHQ�LQ�D�VKRUW�SHULRG�RI�WLPH�

Installation and Capital Cost1

Operating and Maintenance

($/year)Value of Gas2

($/year) Payback (Months)(Mcf/day) ($)

25 35,738 7,367 39,000 1450 46,073 8,419 79,000 8100 55,524 10,103 158,000 5200 74,425 11,787 317,000 3500 103,959 16,839 793,000 2

7BQPS�3FDPWFSZ�&RVBMT�.PSF�1SPmUT�� But Starts with Measurement

'JOBODJBM�"OBMZTJT�GPS�B�$POWFOUJPOBM�7BQPS�3FDPWFSZ�6OJU

1: Unit cost of the entire recovery unit plus estimated installation at 75% of unit cost2: $9.15/Mcf x 1/2 capacity x 365 x 95% Mcf = thousand cubic feet“Reducing Methane Emission with Vapor Recovery on Storage Tanks,” March 23, 2010, epa.gov/ga

Internal Rate of Return

(%)84%152%266%410%747%



A storage tank battery can vent 5,000 to 500,000 Mcf of natural gas and light hydrocarbons to the atmosphere HDFK�\HDU��7KH�K\GURFDUERQV�PD\�EH�YHQWHG�WR�DWPRVSKHUH��ÁDUHG�RII��RU�FROOHFWHG�E\�D�YDSRU�UHFRYHU\�system. The EPA is now employing infrared detection from helicopters to try and identify potential areas of high hydrocarbon emissions, such as what can occur with venting.

4JODF�� 6�4��0JM�BOE�HBT�DPNQBOJFT�IBWF�JOWFTUFE�NPSF�UIBOJO�DPOUSPM�UFDIOPMPHJFT�BOE�QBJE�DJWJM�QFOBMUJFT�PG�NPSF�UIBO

��CJMMJPO$93 million1

1: http://www.epa.gov/enforcement/air/oil.html

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EPA infrared video of hydrocarbons venting from storage tank



Protecting the life your assets can be a daunting task, especially when something as simple as a drop in pressure can cause such chaos. In the case of storage tanks, under-pressure needs to be combatted by DGGLQJ�ÁXLG�RU�DLU�WR�SUHYHQW�D�YDFXXP�IURP�IRUPLQJ�EHFDXVH�WKLV�YDFXXP�FDQ�EH�VWURQJ�HQRXJK�WR�FDXVH� a storage tank to collapse.

-PTU�1SPmUT�$BO�)BQQFO�8IFO�:PV�-FBTU�&YQFDU�*U

3FQMBDJOH�B�TUPSBHF�UBOL�DBO�DPTU�CFUXFFO

EFQFOEJOH�PO�TJ[F �OPU�UP�NFOUJPO�UIF�QPUFOUJBM�MPTU�QSPEVDUJWJUZ�PS�DMFBO�VQ�DPTUT�UIBU�DBO�SFTVMU�

$10,000 to $35,000



/

The oil & gas industry engages in what some have called: “Managed chaos.” Managing leaseholds and optimizing rigs across multiple basins is a major challenge. Changes in rig availability, rig rates, permit approvals, site access, and availability of consumables and services can happen overnight.

Sometimes you have to wait, wait, wait... GO!

You may want to use the best—most durable— WUDQVPLWWHU��EXW�\RX·UH�QRW�JRLQJ�WR�KROG�XS�ÁRZLQJ�a well on a $300 transmitter, so you need a supplier that can meet your demands in a timely manner.

From Managed Chaos...

“Your company needs to drill a thousand or more ZHOOV�WKLV�\HDU��<RX�GRQ·W�NQRZ�H[DFWO\�ZKHUH�\HW��<RX�GRQ·W�NQRZ�ZKHQ�\HW��%XW�\RX·UH�JRLQJ�WR�GULOO�WKHP��$QG�ZKHQ�LW·V�WLPH�WR�GULOO�WKHP��\RX�GRQ·W�want to wait for equipment.”

Chris Smith, WIKA Electronic Solutions Expert



WIKA employs a 21st Century just-in-time supply chain. We have stock in Atlanta in our main warehouse. We have several distributors located in the local shale plays that also have stock. In short, we have what you need.

We sit down with our customers on an annual or TXDUWHUO\�EDVLV�WR�GHWHUPLQH�ZKDW�WKH\·UH�JRLQJ�WR�need for their production. We also keep emergency stock on hand for short-notice orders.

We understand that if you have a lease that is just UHOHDVHG�LQ�RUGHU�WR�GULOO�RU�LI�\RX·UH�JRLQJ�WR�FRQYHUW�VRPH�ROG�ZHOOV�RYHU�WR�DUWLÀFLDO�OLIW�V\VWHPV��WKHQ�ZH�need to supply transmitters immediately.

To What You Need When You Need It

Our expert explains how WIKA can help manage the chaos of short lead times.

/



8*,"�1SPEVDUTDesigned for Your Industry



Pressure TransmitterThese pressure transmitters are designed to contain, control and vent any possible ignition, without igniting WKH�VXUURXQGLQJ�ÁDPPDEOH�JDVHV�RU�YDSRUV��7KH\�UHTXLUH�LQVWDOODWLRQ�ZLWK�FRQGXLW�DQG�FRQGXLW�VHDOV�WR�maintain the explosion proof rating.

E-10

Available with 4 ... 20 mA, 2-wire or 1 ... 5 V, 3-wire low power output signals

NACE MR-01-75 compliant, which provides additional protection against VXOÀGH�VWUHVV�FUDFNLQJ�ZKHQ�H[SRVHG�to media containing sulphur

Engineered to withstand harsh environments

FM-approved explosion-proof for Class I Division 1 hazardous locations

Piezoresistive sensor and WKLQ�ÀOP�VHQVRU�WHFKQRORJ\

Temperature compensated to assure accuracy and long-term stability when exposed to severe ambient temperature variations



Pressure TransmitterNon-incendive explosion-proof pressure transmitters are preferred when potential hazards are only occasionally present. They are designed to work in Class 1, Division II hazardous areas and require less stringent installation procedures than explosion-proof pressure transmitters.

N-10

Engineered to meet the harsh demands of gas compressor applications

NACE MR-01-75 compliant

Does not require the use of intrinsically safe barriers

FM approved Non-incendive for Class I Division 2 hazardous locations

Piezoresistive sensor and WKLQ�ÀOP�VHQVRU�WHFKQRORJ\

4-20 mA or low power 1-5 V output signals available



Pressure TransmitterIntrinsically safe explosion-proof pressure transmitters are designed to limit the thermal and electrical energy to a point where ignition is not possible. Intrinsically safe pressure transmitters require the use of an intrinsically safe barrier installed in the safe area. They do not require the use of conduit and conduit seals or need a “hot permit” if servicing of the instrument loop is required.

IS-20

Non-linearity of up to 0.125 % B.F.S.L.

Industry standard electrical connections including DIN 175301-803A L- connector, cables, housings andmany others

IP 69K high pressure steam wash-down protection available

Available output signals include 4 ... 20 mA, 0 ... 10 VDC, 1 ... 5 VDC and many others

Compact stainless steel case that is available with environmental protection ratings up to NEMA 6 (IP 68)

No internal soft-sealing materials that may react with the media or deteriorate over time



For a company in a mature, industrial environment, WIKA is very progressive. We embrace change, and we love a good challenge. We like to say, “Give us your worst.”

:H�DUH�FRQÀGHQW�ZH�FDQ�PHHW�WKLV�FKDOOHQJH�EHFDXVH�we are the largest, most experienced company in the world for pressure measurement instruments. :,.$�KDV�PRUH�WKDQ��RIÀFHV�ZRUOGZLGH�DQG�employs more than 7,000 people. When you need

our expertise, we can tap into a worldwide network of engineers to help. Someone in our network has probably already seen a problem that is new to you. $QG��WKH�ÀQDQFLDO�EDFNLQJ�RI�D�JOREDO�FRPSDQ\�PHDQV�we stand behind our products and services.

8*,"�$BO�)FMQ�:PV�3FBDI�:PVS�(PBMT

WIKA® is a registered trademark of WIKA Alexander Wiegand SE & Co. KG., used under license by WIKA Instrument Corporation. Copyright 2013 WIKA Instrument Corporation. All Rights Reserved.

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Are your sensors oil field tough?