From a Tactical Historian to a Strategic Enterprise Integration and Applications Infrastructure

Transcription

1 From a Tactical Historian to a Strategic Enterprise Integration and Applications Infrastructure Supporting Marathon Oil s Sustainability Strategy with the PI System Presented by Ken Startz Marathon Oil Company

2 Agenda Marathon Oil at a Glance The PI System - From Tactical to Strategic The PI System and Sustainability Illustrative Case Studies Equatorial Guinea Offshore Remote Operations Monitoring Droshky (GoM) Offshore Integration, Modeling, SME Collaboration, and Data Sharing Piceance (Colorado) - OnShore production Operations Maradrill TM Onshore Remote Drilling Monitoring and Optimization Closing Remarks 2

3 A Global E&P Company- Production in 11 Countries Established in 1887 Market Cap: ~ $26 billion (as of 7/26/13) Revenues: $15.7 billion Net Income: $1.6 billion Capital Expenditures*: $5.1 billion Net Liquid Hydrocarbon Sales: 282,000 BPD Net Natural Gas Sales: 902 million CFD Net Synthetic Crude Oil Sales: 47,000 BPD Net Proved Liquid Hydrocarbon, Natural Gas and Synthetic Crude Oil Reserves: 2.0 billion BOE Employees: ~3,400 Headquartered in Houston, Texas *Excludes acquisitions and includes accruals. Unless otherwise stated, financial and operating statistics noted are as of 12/31/12 3

4 Sustainability Adapting to Change Building a more sustainable business requires wise investment, advanced technology and stewardship of the environment - Ultimately, sustainability means adapting to change. Marathon Oil 2012 Annual Report Information Management 4

5 The Journey of the PI System at Marathon Oil Tactical Historian Strategic Infrastructure PI System selected in Refining as standard real-time data historian My First PI System Install Robinson, Ill Refinery PI System selected as integration and applications infrastructure in Upstream for Equatorial Guinea PI System Installed in Norway to Integrate and enable remote monitoring and collaboration; Droshky Gulf of Mexico PI System used for remote Drilling monitoring and optimization Separation of Marathon into Marathon Petroleum (Downstream) & Marathon Oil (Upstream)

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7 Business Challenges for 2012 / 2013 Develop infrastructure for high frequency data needed for Drilling. Embrace new web-based tools like PI WebParts and PI Coresight. Leverage PI System investment in the new unconventional resource plays. Transfer knowledge to newer professionals (Great Crew change). Provide easy self-service visualization for engineers. Deliver mobility solutions on ipad. 7

8 Agenda Marathon Oil at a Glance The PI System - From Tactical to Strategic The PI System and Sustainability Illustrative Case Studies Equatorial Guinea Offshore Remote Operations Monitoring Droshky (GoM) Offshore Integration, Modeling, SME Collaboration, and Data Sharing Piceance (Colorado) - OnShore production Operations Maradrill TM Onshore Remote Drilling Monitoring and Optimization Closing Remarks 8

9 Equatorial Guinea A Long Ways from Houston. Estrella Bococo Sierra Madre BLOCK D Estaurolita Ligero Apatito Agate Alba Deep Discovery Alba 18 Begonia Gardenia Discovery Violeta Gardenia ALBA BLOCK Magnolia 9

10 Alba Field Is all about the scale! Alba 9 Well and Marathon Oil Tower Houston, Texas Alba 9 Marathon Oil Tower ,600 acres ~ 14,923 soccer fields! 10

11 Alba Field Development Economic Value Chain Alba Offshore Wells Alba Gas Plant AMPCO EG LNG Long-life assets with diverse product and revenue streams Partners Marathon OIl Noble Energy GEPetrol Marathon Oil Noble Energy SONAGAS Marathon Oil Noble Energy SONAGAS Marathon Oil Mitsui Marabeni Gross Production ~ 220,000 boepd Products CONDENSATE NATURAL GAS PROPANE BUTANE METHANOL LNG Operator 11

12 Finished Platforms B Platform B2 Platform Pipelines Landfall C Platform 12

13 MEGPL Gas Plant 13

14 Equatorial Guinea Before the PI System E G DCS Network Offshore Platform A Honeywell Experion Offshore Platform B-B2 Honeywell Experion Offshore Platform C Honeywell Experion Gas Plant Control System Honeywell Experion Honeywell PhD Honeywell PhD One PC Worldwide PHD Access 14

15 Equatorial Guinea After the PI System Honeywell Offshore PhD Honeywell Gas Plant PhD Energy Components for Production Allocation MEGPL PI System Emerson Delta V Offshore All Employees Emerson Delta V Gas Plant 15

16 Conversion from Honeywell to Emerson 16

17 Equatorial Guinea - Benefits Interface to HYSYS simulation package Worldwide viewing of EG data Exports to GE and other service companies Time stamp matching of offshore and on-shore data Interface to Production Allocation System (Energy Components) Easy to Convert to New Control System 17

18 Agenda Marathon Oil at a Glance The PI System - From Tactical to Strategic The PI System and Sustainability Illustrative Case Studies Equatorial Guinea Offshore Remote Operations Monitoring Droshky (GoM) Offshore Integration, Modeling, SME Collaboration, and Data Sharing Piceance (Colorado) - OnShore production Operations Maradrill TM Onshore Remote Drilling Monitoring and Optimization Closing Remarks 18

19 Droshky - Background The field is 100 percent Marathon (WI). The sub-sea wells tie back to Dynamic Offshore Resources Bullwinkle Platform, Gulf of Mexico. The tie back is through an 18-mile pipeline. The majority of the data is acquired from Aker Solutions sub-sea control system. Some data is extracted from Dynamic Offshore Resources PI System, coming from Industrial Evolution. First production was July Downhole calculations by Baker-Hughes DHTP Calibration server on the platform. Re-calibrations performed monthly by Baker-Hughes in Houston office. 19

20 Overview of Off Shore Production Facilities Shell Bullwinkle Host Platform Well Control Umbilical Dual 8 Insulated Flowlines 75,000 BPD Design Rate 4 Subsea Wells w/ 10 completions Flowline Manifolds 20

21 GC65 Bullwinkle GC110 GC113 Rocky Angus GC155 Manatee GC158 Brutus GC199 Noble Lorien GC243 Nexen Aspen GC200 Eagle Troika GC244 Droshky GC201 21

22 Umbilical Methanol HP Hydraulic Power Electrical Power Asphaltene / Paraffin Inhibitor Chemical / Scale Inhibitor Spare Annulus Monitoring LP Hydraulic Power Communication 18.5-mile extension cord that connects the tree control pods to host platform Allows monitoring and control of the wells 22

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24 Droshky Without the PI System Aker Solutions MCS (sub-sea data) Baker Hughes Flow-Calculator DHFM Remote Monitoring VIC Client Lafayette and Houston 24

25 Droshky With the PI System MMS Production Reporting SAP Entry (IBM) Production Accounting (Tulsa, OK) Monthly Allocations (IBM Manually enters into SAP) Neptune Gas Plant Monthly Gas Sales Allocations SPL Incorporated Monthly Production Allocations (Pearland, TX) PI Database (Shell) Real time Collection and Reporting Bullwinkle Control System (Intellution) Water Depth ~ 3,000 ft Industrial Evolution Contract Facility Tags 87 Shell Provides Daily Allocations (MOC Operators Manually enter into TOW) Raw Data Subsea Controls TOW Database Production Allocation and Reporting (Houston, TX) PI Database (MOC) Real time Collection and Reporting (Plano, TX) Calculated Tags 150 Subsea Tags 788 Aker Solutions MCS (subsea controls) Baker -Hughes SDA Flow-calculator DHFM Offshore Production Analysis Saphir / Topaze Kappa Diamant Database (high frequency pressure and rate data) Remote Monitoring Vic Client (Lafayette and Houston) Shell (DOR) Controlled MOC Controlled 25

26 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). The PI System is considered Gold Database. Sub-surface modeling with automatic channel created to Kappa Modeling Suite. 26

27 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. 27

28 Reservoir Engineer Quote A new well drilled and completed in Deepwater Gulf of Mexico or Equatorial Guinea can cost up to $125 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. 28

29 Agenda Marathon Oil at a Glance The PI System - From Tactical to Strategic The PI System and Sustainability Illustrative Case Studies Equatorial Guinea Offshore Remote Operations Monitoring Droshky (GoM) Offshore Integration, Modeling, SME Collaboration, and Data Sharing Piceance (Colorado) - OnShore production Operations Maradrill TM Onshore Remote Drilling Monitoring and Optimization Closing Remarks 29

30 Piceance Asset: Garden Gulch Cliff Road 30

31 Piceance Field Overview Pad 20C 8,260 Pad 31C 8,520 Laydown Yard 8,250 Pad 35D 8,150 Valley Pump Station 5,790 CDP 8,300 Garden Gulch Rd 77 Production Wells 22 Pads: 1-10 wells per pad Piceance avg well:190 mcfpd, 5 bwpd, 0.5 bcpd 100% WI; 82% NRI 18A 8,100 31

32 Pad 1C (10 well pad) 32

33 Entire Pad including Facilities Piceance Operations 33

34 Piceance Background Mesas in Western Colorado. Began production operations in wells based on 27 pads. Primarily gas. Data collected in PI Server (From the beginning of the Asset). New engineer from another company with better visualization than Wonderware Active Factory. Visualization developed by operations engineer in one half day! 34

35 Control Network Wonderware InSQL Active Factory Business Network PI System 2010 CITRIX PI Coresight No More VPN!!! 35

36 PAD 28-C on PI Coresight 36

37 Piceance - Benefits of PI Coresight Benefit = 0.5 hours day $60 1 hour 5 days 1 week 48 weeks 1 year = $7200 /year Gets operators out of office and on-route quicker. Reduces contract labor. Provides look back at 1 year of production history vs. 1 month. 37

38 Agenda Marathon Oil at a Glance The PI System - From Tactical to Strategic The PI System and Sustainability Illustrative Case Studies Equatorial Guinea Offshore Remote Operations Monitoring Droshky (GoM) Offshore Integration, Modeling, SME Collaboration, and Data Sharing Piceance (Colorado) - OnShore production Operations Maradrill TM Onshore Remote Drilling Monitoring and Optimization Closing Remarks 38

39 MaraDrill Background Land-based drilling rigs in Eagle Ford and Bakken. Primarily oil. Horizontal wells. Factory drilling. Rigs operated by Helmerich & Payne (H & P). Data extracted from OMRON Control System and aggregated with 3 rd party vendor data, using PI Interface for OPC HDA. POC started January

40 MaraDrill Doghouse 40

41 Common Drilling Data Tags Engineering Units ROP = Rate of Penetration Ft / Hr WOB = Weight on Bit K Pounds RPM = Revolutions per Minute RPM Mud Flow Rate GPM Torque kft*lbs Need 1 second time stamp resolution! 41

42 Data Workflow H&P 463 Eagle Ford PI Server PI Coresight H&P 256 Bakken H&P 458 Eagle Ford Historized values Mobile Rig Network Architecture MaraDrill PI System Tags Houston Tower PI DataLink 42

43 MaraDrill Data Acquisition: PI DataLink Collect MaraDrill data from PI DataLink Functions that retrieve 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 43

44 Pre-MaraDrill vs. MaraDrill Technology Pre-MaraDrill Pason Data Calculator Spreadsheet MaraDrill Technology Intermediary Application PI Server PI DataLink PI JDBC 2010 Provider Tool for Advanced Analytics 44

45 PI Coresight 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 45

46 Real-Time Optimization PI Coresight 46 Stick-Slip Identification few stands later Stick-Slip Mitigation 40% Sustained Increase in Rate of Penetration Avg. ROP for stand is 144 ft/hr Avg. ROP for stand is 201 ft/hr Driller has taken suggestion Acceptable Moderate Severe

47 PI Coresight/SpotFire Stick-Slip Analyses Advisory in Real Time Importance of 1 second data Other vendors Rig Display 47

48 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) 48

49 CoreSight View with XML Data Export Enables integration with WellView data Enables integration with Spotfire visualization 49

50 Custom Spotfire Interface Import from CoreSight Data or Manual Selection Enables integration with PI System data from Coresight Guided analytics 50

51 Guided Analysis Time Based or Depth Based 51

52 Post-Well Science Using MaraDrill Data in SpotFire Modeling the rock strength & predicting ROP s on subsequent wells in the area to improve logistics and planning 52

53 Days vs Depth Curves for MaraDrill Rigs Black = MD, Teal = No MD 53

54 Post-Well Science Using MaraDrill Data in SpotFire Formation Sweet-Spot Analysis 54

55 MaraDrill Benefits May replace third party real-time data aggregation software. Accessible real-time data at the rig and to remote employees, enabling more efficient decision making. Consistent and easy-to-access data. More eyes on the data. Drilling time and capital well cost savings: Potential $ 1 MM / rig / yr for every 5% reduction in drill time. Reduced vibration and damage to downhole tools Continuous optimization onsite and retrospective post-well analysis 55

56 PI System Helps Drillers Too! 56

57 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 57

58 Summary 1. Use and value of the PI System has evolved over the last 25 years and has become strategic to our information infrastructure 2. Integral to our sustainability vision 3. Significant benefits in model integration and SME enablement 4. PI System has value in drilling also.. 5. PI Coresight offers significant improvement in visualizing PI Data 58

59 Please don t forget to Complete the Online Survey for this session Share what you saw with friends on Twitter, Facebook or Linkedin! #UC2013 Eventmobi.com/emeauc13 59

60 Ken Startz Advanced Senior Business Analyst Marathon Oil Company 60