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Using New OSIsoft Tools
for High ROI Projects at
Marathon Oil
Presented by Ken Startz
Project Manager, Marathon Oil Company
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Marathon Oil Facts & Figures - 2011
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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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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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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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Contents
• Production Operations: Droshky (Gulf of Mexico)
• MaraDrill™ (Drilling Proof of Concept)
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Real-Time Infrastructure for Production Operations
NAPO
IPO - EG
North Dakota
Wyoming
Colorado
Oklahoma
Gulf of Mexico
Texas
Gulf of Mexico
WonderWare
DCS
Intellution iFix
SCADA
Industrial SQL
iHistorian
OPC Interface
PI Data Publisher
Aker Solutions
MCS
OPC Interface
MEGPL Alba B2
MEGPL Gas Plant
Outside Operated
EG LNG
Experion DCS
DeltaV DCS
Industrial
Evolution
Alvheim
PhD
PI
PI
Kongsberg/Rapid
PI PhD interface
PI to PI
PI to PI
PI
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PI Central
Historian
RTWebParts
Server
(MOSS 2007)
ACE Server
IPO - Norway
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HES
Reliability
Wells/Reservoir
RTWebParts
DataLink
RTWebParts
DataLink
RTWebParts
DataLink
PI ProcessBook
Kappa Diamant
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Droshky
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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 subsea 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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Subsea Facilities
DOR Bullwinkle Host Platform
Well Control
Umbilical
Dual 8” Insulated Flowlines
75,000 BPD Design Rate
4 Subsea Wells
w/ 10 completions
Flowline
Manifolds
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GC65
Bullwinkle
GC110
GC113
Angus
Rocky
GC155
GC158
Manatee
Brutus
GC199
Noble Lorien
GC200
GC201
Eagle
Troika
GC243
GC244
Droshky
Nexen Aspen
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Umbilical
Methanol
Chemical / Scale
Inhibitor
HP Hydraulic
Power
Spare
Electrical Power
Annulus
Monitoring
LP Hydraulic
Power
Asphaltene /
Paraffin Inhibitor
Communication
 18.5-mile “extension cord” that connects the
tree control pods to host platform
 Allows monitoring and control of the wells
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Droshky PI WebParts Graphic
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Droshky – Before
Aker Solutions MCS
(sub-sea data)
Baker Hughes
Flow-Calculator DHFM
Remote Monitoring
VIC Client
Lafayette and Houston
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Droshky – After (Heavily Integrated!!)
Neptune Gas Plant
Monthly Gas Sales
Allocations
Monthly Allocations (IBM
Manually enters into SAP)
MMS Production
Reporting
SPL Incorporated
Monthly Production Allocations
(Pearland, TX)
SAP Entry (IBM)
Production Accounting
(Tulsa, OK)
Bullwinkle Control
System
(Intellution)
PI System (DOR)
Facility
Tags 87
TOW Database
Production Allocation
and Reporting
(Houston, TX)
PI System (MOC)
Real time Collection
and Reporting
(Plano, TX)
Shell Provides Daily
Allocations (MOC Operators
Manually enter into TOW)
Subsea
Tags 788
Aker Solutions
MCS
(subsea controls)
Water Depth ~ 3,000 ft
Raw Data Subsea
Controls
Baker -Hughes
SDA Flow-calculator
DHFM
Offshore
Calculated
Tags 150
Production Analysis
Saphir / Topaze
Kappa Diamant Database
(high frequency pressure
and rate data)
DOR Controlled
Remote Monitoring
Vic Client
(Lafayette and Houston)
MOC Controlled
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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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PI WebParts Home Page
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Typical PI WebPart Trends
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Engineering Models Used
• ECLIPSE: Sub-surface reservoir modeling for multiphase 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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Simulation Using Eclipse
Reservoir Simulation
Data Collection & Interpretation
Errors, inconsistencies,
uncertainty?
Data Integration & Geologic
Modelling
Fine scale static
3D model(s)
Upscaling & Reservoir Simulation
Mathematical model(s) for dynamic
flow behaviour
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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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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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Typical MaraDrill™ Rig
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MaraDrill™ Background
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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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MaraDrill™ Doghouse
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Drillers Console
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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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Data Workflow
PI CoreSight
H&P 463 Eagle Ford
PI System
Server
H&P 256 Bakken
Historized
values
H&P 458 Eagle Ford
Mobile Rig-site
Network Architecture
MaraDrill
™
PI Tags
Houston Tower
PI DataLink
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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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Pre-MaraDrill™ vs MaraDrill™ Technology
 Pre-MaraDrill™
Pason Data Calculator Spreadsheet
 MaraDrill™ Technology
Intermediary Application
PI Server
PI DataLink
Future Plans
Tool for Advanced Analytics
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Post-Well Analyses with SpotFire
 Days vs Depth: H&P 256 - Aisenbrey 21-25H
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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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PI Coresight – Stick-Slip
• Stick-Slip Identification: H&P 463
“Perfect” drilling
Stick-slip: Non-uniform rotation of the bit/BHA
Sticking phase → bit stops
Slipping phase → bit “breaks” free
Drillstring torsional oscillations
Stick-slip
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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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PI Coresight/SpotFire – Stick-Slip Analyses
Advisory in Real Time
• Importance 1 second data
Other vendors
Rig Display
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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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MaraDrill™ Benefits
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Possibly replaces expensive third party real time data aggregation software.
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Provides accessible real time data at the rig-site and to remote employees,
enabling more efficient decision making.
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Data is consistent and easy to access. More eyes on the data.
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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
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Reduces vibration and damage to downhole tools:
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Continuous optimization onsite and retroactive post-well analysis
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PI System Helps Drillers Too!
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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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