Smart Field Systems to Create Value in Process Industries

Author photo: Tim Shea
By Tim Shea

 Summary

A session at the recent ARC Industry Forum in Orlando, Florida focused on leveraging smart field systems to create value in process industries.  Several presentations provided end user perspectives on employing smart sensors to conduct multiphase flow smart field systems to create value in process industriesmeasurement, provide safe wireless gas detection, and leverage IIoT-enabled solutions to enhance operational performance in upstream oil & gas.

ARC Advisory Group analysts provided a brief overview on leveraging smart field solutions, both wired and unwired. ARC discussed how smart connected devices relate to the emerging Industrial Internet of Things (IIoT) and the increasing impact made by solutions such as multiphase flowmeters and leak detection systems in oil & gas operations across the world.  We also briefly discussed some of the reasons for stranded diagnostics from smart devices and how Intelligent Device Management (IDM) and the ISA 108 standard could help resolve this issue.

A New Approach for More Accurate Multiphase Flow Measurements

Paolo Andreussi, Professor of Chemical Engineering, University of Pisa, presented an interesting and informative presentation on developing an intelligent (and accurate) multiphase flowmeter (MFM) using more cost-effective conventional sensing solutions.  Professor Andreussi provided some background on the University and how the Department of Chemical Engineering has been active in the field of multiphase flow since the 1970s. He also discussed his work at TEA Sistemi, a research spin-off of the University of Pisa, and its development of its Multiphase Flow Laboratory of TEA Sistemi, which was designed to study multiphase pipe flow and to test process equipment such as separators and multiphase flowmeters at actual field conditions.

According to Andreussi, most multiphase flowmeters on the market today consist of a combination of different instruments, typically, a gamma-densitometer, a water-cut meter and a Venturi meter, which do not directly measure the flow rates.  Flow rates are predicted using empirical equations of limited validity.  The combined effects of measuring errors of individual instruments and poor correlations explain the low accuracy of most conventional MFMs.  Andreussi indicated that a MFM can be calibrated if a test separator is present to verify its accuracy.    

smart field systemsAndreussi indicated that currently available MFM models based on the concept of isokinetic sampling do not require calibration and directly measure flow rates using standard field instruments.  In principle, direct measurements are much more accurate than indirect ones, but of course, the accuracy of these MFMs depends on the sampling method.  He also discussed a multiphase flow metering approach based on the analysis of process signals. He indicated that while the cost of these software-based flowmeters systems, known as “virtual flowmeters” (VFM), can be very low; their accuracy can also be very low unless calibrated with a test separator.

In 1998, TEA Sistemi started developing a wet gas flowmeter based on the isokinetic sampling concept.  Sampling is followed by phase separation and metering of individual phase flow rates.  With isokinetic sampling, the gas and liquid flow rates are immediately obtained from the measurements.  Field calibration or empirical equations are not required.  According to Professor Andreussi, in 2002 this metering solution was deployed in the Gulf of Mexico where it was able to detect liquid volume fractions as low as 0.2 percent. In a successive installation, this limit has been 0.00002 percent.

In light of the recent decline in oil prices, TEA Sistemi worked with suppliers to study alternative solutions to the expensive equipment typically deployed to exploit subsea fields.  For multiphase metering, the obvious choice would be some type of VFM, since the hardware cost for this type of metering system is close to zero.  However, VFMs typically have low accuracy, plus other problems. For instance, it can be extremely difficult to derive both the water-cut and low liquid volume fractions from the available process signals.  These limitations led to the development of a more complex configuration using an orifice plate rather than Venturi, but still based on the VFM approach.

According to Andreussi, in a MFM based on isokinetic sampling, the water-cut can be easily measured after gas separation, considering that the meter control system can guarantee the time required for liquid-liquid separation.  MFMs produce a great amount of data but, in practice, only part of these data is used.  In the present project, the time-varying signals of differential pressure have been used to detect flow regime transitions. A careful analysis of these signals allowed the team to develop physically based models.

Professor Andreussi’s conclusions included:

  • A MFM can be made of five/six conventional pressure transmitters, rather than using expensive and cumbersome instruments, such as a gamma-densitometer.
  • With this essential setup, the quality of single phase flow rate measurements does not necessarily deteriorate: this strictly depends on the quality of the data (field and/or laboratory calibrations) and the correlations adopted.
  • This MFM using isokinetic sampling presents numerous advantages in terms of ease of maintenance, commissioning, shipping, no radioactive sources and, of course, lower cost. In its gas-liquid mode, you do not need much more than a flow computer, like a VFM. In effect, this would be a VFM integrated with a liquid sampling system.

Professor Andreussi concluded his presentation by throwing out a hypothetical question to the audience: “Is it better to invest in the development of expensive equipment or in a deeper knowledge of multiphase flow?”

Wireless Gas Detectors Save Time, Space While Helping Ensure Safety

Sharul Rashid, Principal Engineer, I&C, from Petronas, discussed how the company successfully deployed wireless gas detectors to address fire & gas requirements in its refinery remote tank farm operations in Malaysia.  

Mr. Rashid discussed some of the challenges that the project faced:

  • Scarcity of spare junction boxes at site
  • High risk involved when laying new cables for detectors, especially when excavation is involved
  • Installation and commissioning of new detectors have to be done online while plant is running
  • Remote location such as tank farms makes it difficult for cable routing with bund walls and road crossings
  • More than two kilometers of homerun and branch cables required for conventional wired solution
  • Large capital expenditure required using conventional approaches

After reviewing its options, Petronas decided to deploy wireless gas detectors supplied by Yokogawa.  Some of the reasons included:

  • Solution was proven in use
  • Product maturity established
  • Compliance to ISA100.11a wireless communication standard
  • Satisfies IEC60079-29-1 performance requirements
  • Interoperability with existing wireless network and host DCS – tested by supplier and witnessed by end user
  • Used for monitoring purposes only

Rashid discussed some of the benefits of the wireless gas detector deployment.  These included:

  • Reduction in overall project risk. No cables; hence no excavation and working at height
  • Installation can be done quickly, safely, and seamlessly while plant is online
  • Simplifies engineering and drawing updates
  • Significant reduction in overall project cost

He also discussed some of the lessons learned for future consideration:

  • Good stakeholder management is necessary: having client, principal, local business partner and vendors all involved right from the beginning
  • A good and clear communication plan among all stakeholders
  • Good support and collaboration between all parties involved ensures the system was tested successfully to the client’s requirements
  • Need to pay attention on future upgrades of hardware that may affect the network

IIoT in Upstream Oil & Gas Impacts Operational Excellence

Dave Lafferty, President of Scientific Technical Services (retired from BP and now an ARC Associate) presented an interesting presentation on the enormous potential the Industrial Internet of Things (IIoT) offers for exploration and production, and particularly in unconventional oil & gas reservoirs.  Lafferty highlighted some of the issues and challenges:

  • Need to operate in large basins such as the Permian, Bakken and Eagle Ford, among others
  • Need to enhance oil recovery for wells still producing at low prices
  • Impact of the “Great Crew Change”
  • Increasing shareholder activism, among other issues  

IIoT can enhance upstream operations in a number of different areas.  These include:

  • Reduced operating costs: well monitoring enables management by exception, task-specific trips to the well, and reduced driving resulting in less labor and improved safety
  • Increased production: better data results in more informed decisions on in-field drilling and well interventions
  • Improved reliability: equipment health monitoring reduces unplanned outages
  • Production chemical treatment ensures correct dosing and helps prevent “out of stock” resulting in well shut-in

Other operational areas include asset integrity such as ensuring long-term performance of the field; capturing corrosion, well integrity, and equipment reliability information; increased estimated ultimate recovery (EUR) by optimizing enhanced recovery devices (e.g., pumps jacks and ESPs) or determining well intervention performance.

Lafferty highlighted some of the following benefits of IIoT including:

  • Ensures an end-to-end solution – no stranded data
  • Shortens time to first oil with common, pre-built infrastructure
  • Scales cost effectively for large, remote areas
  • Improves safety by reducing driving through remote monitoring
  • Supports the new wave of monitoring requirements
  • Accommodates new sensor technology
  • Ideal for the new workforce with easy-to-use HMI

Recommendations

Users should evaluate the full range of intelligent field devices and systems now available to determine if any could help solve current and future challenges.  Ultimately, the decisions should be based on business value, rather than just whether the solutions rely on the “latest and greatest” technology.  End user adoption of wireless sensing continues to grow as more applications are successfully served and the performance is adequately validated.  ARC is a strong proponent of IIoT-enabled solutions and the value they can provide through lower costs, increased productivity, enhanced collaboration, and the ability to capture previously “stranded” asset information.

ARC also recommends that users work closely with suppliers and other stakeholders to better understand how to measure ROI and share best practices for intelligent device management.  Users should always seek opportunities to leverage industry standards such as ISA 108 to improve their own plants’ operational performance and help promote application of smart field systems and intelligent device management in their respective industries.

 

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Keywords: Smart Sensors, Multiphase Flow Meter, Wireless Gas Detector, IIoT, Upstream Oil & Gas, ARC Advisory Group.

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