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input #100 at www.controleng.com/information

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baldor.com 479-646-4711
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input #101 at www.controleng.com/information

 On the cover: This image illustrates a digital oilfield: all of the machines

I NSIDE
and equipment on the wellpad are interconnected, talking to each
other, and relaying real-time information back to the control room.
Image courtesy: ABB

06 DEVELOPMENTS TO WATCH
Cyclone separators
Real-time 3D printing enhances the viability of using cyclone separators in oil and gas applications.

07 COVER STORY
Integrated HMI/SCADA systems enable smarter data acquisition 07
Open platform development tools enable more effective, affordable approaches to SCADA.

10 CASE STUDY: GAMIFICATION SIMULATION

Real-world impact of simulation
Disruptive simulation technologies enabled a large oil pipeline company to maximize profits.
Twenty percent savings in capital projects were realized, amounting to $85 million. An additional
$24 million in savings was achieved in annual, recurring revenue.

13 CASE STUDY: PROACTIVE MAINTENANCE

Use EAM and APM techniques to achieve better maintenance planning
Enterprise asset management (EAM) software can ensure asset uptime, while an asset performance
management (APM) approach can ensure optimal levels of cost reduction and reliability.

16 CASE STUDY: ARC FLASH

Protecting FPSOs from arc flash
At a large floating production storage and offloading (FPSO) unit, managers have found a way to protect workers and
equipment from electrical arc flash and reduce the risk of downtime.

19 REGULATORY MEASURES
Electric actuator technology prospers in production fields
President Obama’s Climate Action Plan has a goal to cut methane emissions from the oil and gas industry by 40% to
45% from 2012 levels by 2025. This has led to new regulations that require widescale pump retrofitting.

21 CASE STUDY: FLOWMETERS

Solar-powered thermal mass flowmeters operate
in flare-gas monitoring system
How can new gas flowmeters operate at an oilfield without utility power service in the remote southern Bakken forma-
tion region of North Dakota? That was the challenge facing Legacy Reserves at remote sites at the Williston Basin, N.D.

23 CODES AND STANDARDS

IECEx certification makes safe safer
21
Is the European standard of IECEx for harsh environment computers right for design engineers? How
does this European standard impact U.S.-based operations?

26 WORKPLACE SAFETY
De-risk by design: Maintaining safety at heights
A major challenge facing oil and gas facilities is inadequate lighting and the need for workers to climb
to elevated heights to repair or replace lights.

28 NEW PRODUCTS
A selection of oil- and gas-related products engineers will find useful

2 • FEBRUARY 2016 OIL&GAS ENGINEERING

1111 W. 22ND ST., STE. 250, OAK BROOK, IL 60523
630-571-4070, FAX 630-214-4504 COMMENT
CONTENT SPECIALISTS/EDITORIAL
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L
ast year was Oil & Gas
Engineering’s first year as a print
edition. Here are the top five arti-
cles from last year based on data
from our partners websites, Control
Engineering and Plant Engineering.
1. Hacking oil and gas control
systems: Understanding the cyber risk
Cyber attacks are growing in num-
ber and intensity over the past decade.
Companies in the oil and gas industry are
high-profile targets and must take mea-
sures to protect themselves from hackers.
2. Black October on the horizon
The price of oil may not have hit the
bottom yet, supply is almost double that
of demand, and the Iran deal may slash oil
prices to new lows.
3. Thirty years later, the industry is
losing its best and brightest, again
In the 1980s, the oil and gas industry
was going through the same crew change
as it is now. Highly educated workers were
laid off and the cycle is repeating itself. Will
the industry learn its lesson this time?
4. Dirty pipelines decrease flow,
production—pig your line
Allen Pennington, president of Pigs
Unlimited International located in Tomball,
Texas, shared his industry insights about
the challenges related to pipeline cleaning.
5. Predictive analytics hit the
midstream
Model-based, predictive analytics lends
itself to crunching multiple data sources to
pinpoint risks for pipeline integrity manage-
ment, while analytics for process monitor-
ing and measurement evolve to better
discover crucial variances.
Based on these top five articles from
2015, proved to be that cyber security,
career development, big data and predic-
tive analytics, and pipeline maintenance
and pigging were the highest ranked
topics of the year based on our readers’
clicks.
We’ll be interested to see what our
readers choose as hot topics for 2016. As
this was our first year, we don’t have any
previous data to compare to, but you as
the reader have the power to determine
our editorial path based on what you
read and your feedback.
Wishing you all a great start to a suc-
cessful New Year and, of course saying,
thank you for reading!
-Eric R. Eissler,
Editor-in-Chief

OIL&GAS ENGINEERING FEBRUARY 2016 • 3

More throughput,
less downtime.
Another way Siemens is fueling efficiency.

With global gas prices dropping rapidly, you can’t afford
to be on the defensive when it comes to downtime.
To keep oil and gas applications up and running at all
times, a proactive approach is essential.
Siemens automation solutions allow you to
continuously monitor your operations — on-site or
remotely — so you can identify potential issues and
correct them quickly. The data gathered through
ongoing monitoring can also help your operators make
better-informed decisions to improve asset utilization
and boost production.
The best path to greater productivity is a proven
automation strategy. And the best defense against
downtime is Siemens. Visit usa.siemens.com/oil-gas
today to learn more.

usa.siemens.com/oil-gas
input #102 at www.controleng.com/information
 Advertorial

Efficiency,Visibility and Reliability:

Keys to Lower Costs and Greater
Profitability in Oil and Gas Operations
By Jeff Jensen, Application Engineer, Siemens Industry, Inc.

F
alling oil prices and collapsing profit margins are driving the industry to lower costs any way
possible. While reducing labor costs and gaining supplier concessions can help, output must
continue if not increase, especially on completed wells, to meet commitments to buyers. Some
in the industry may persist in using time-tested manual methods and localized automation, but
the economics of continuing to do so just don’t add up. Nor do they scale, as new drilling and comple-
tion techniques increase service densities along with operating complexities.

The drive to retain (or regain) profitability has never been stronger or more urgent. The fact is, oil and
gas industry professionals – especially those involved in asset management, automation and controls,
and production, transmission or plant management – can accelerate the development and deployment of
technology solutions to lower the breakeven points of their operations. This paper provides ways to think
about how automation can increase operating efficiency, visibility and reliability to help lower costs and
boost profitability.

The paper also highlights four automation design principles that can help oil and gas companies acceler-
ate putting more automation to work in their operations or those of their industry customers:
• Eliminate
• Simplify
• Standardize
• Virtualize

As oil and gas industry veterans know, the current downturn may be painful, but prices will rebound. In
the meantime, highly leveraged or undercapitalized companies may close or consolidate with larger, better-
capitalized firms. But when the rebound occurs, the capital
investments made today by companies willing to carefully
consider and deploy automation solutions will still be generat- Check out usa.siemens.com/oilgas-
ing substantial returns through greater operational efficiency, resources for more Oil & Gas White
visibility and reliability. For those companies, their competitive- Papers on:
ness and profitability will never be greater.
• How to Develop Cost-Effective, Rugge-
dized Skid-Based Applications for Remote
For more details about Today’s drive for greater Deployments. Lessons from the Design and
profitability: Never stronger — or more urgent that Engineering of an Oil-Mixing System.
every oil and gas industry executive needs to know visit • Topic Paper: From Drill Bit to Boardroom:
www.usa.siemens.com/reliable-oil-gas-operations Four Ways to Accelerate Automation’s
Deployment Across Oil and Gas Enterprises.
• Topic Paper: Rethinking Automation: A
Revolution in the Oil and Gas Industry.

OIL&GAS ENGINEERING FEBRUARY 2016 • 5

DEVELOPMENTS TO WATCH
Cyclone separators
By Don Yates
Figure 1: An example of how
a cyclone separator works.
All images courtesy: Colum-
bus Group
6 • FEBRUARY 2016 OIL&GAS ENGINEERING
T
he use of cyclones as separators would the incom-
be very popular if unwanted particles ing physical
in oil and gas applications were consis- mix to be
tent in size and would stay away from separated.
the walls of the cyclone. Unfortunately, This can be
the particles that need to be removed used to trap
in oil and gas feeds can vary in size, and when particles in
they come in contact with the walls of cyclone suspension,
separators, abrasive wear occurs. so reducing
the wearing
Enter enhanced 3D printing exposed area
One solution to this problem is the evolution of and promot-
3D printing technologies which has seen myriad ing an order-
flexible setups become possible. There is no ly downward
need for just one print head to be in use at the flow of the
same time. Indeed, many 3D print heads can be unwanted
assembled together, side by side, to dramatically separated
increase the material placement volumes particles to Figure 2: Software controlled 3D print-
and speeds, so the outcome can resemble a removal ed particulate flow changing internal
an extrusion machine. Like a smart extrusion point at the profiles.
process, the output can have almost any 2D bottom of
profile, but with the added features of varying the the device.
physical and chemical composition of the print The centrifugal parameters that aid the removal
material, in real time, and of differing specification, of certain particles can be changed in real time to
depending on the task. target their extraction for a cleaner output of oil or
In the indicative cyclone separator, the internal gas, as desired. The process exploits a world of
flow control wall profiles of the cyclone can be new Internet of Things monitoring points, micro-
continuously replaced by feeding in the “just-in- electromechanical sensors and smart logic to
time” 3D printed materials, but with connect the dots.
the additional feature that the feed A benefit of 3D printers is the ability to output
in profiles can be varied to form and different materials from the same printing pack-
composition to become appropriate age. Depending on the physical characteristics
cyclone surface materials, includ- of the particles to be removed, the separating
ing hard deflecting and super soft cyclone wall also can be continuously regener-
absorbing surfaces (see Figures 1 ated in a mix of magnetic materials with varying
and 2). attractive strengths to ensure that the extracted
As part of the continuous online unwanted materials are removed from the oil or
rebuild process, the 3D surface gas flow. OG
materials are injected in the same
direction as the induced oil or gas Don Yates is the CEO of Columbus Group where
flow to replace the internal wearing he heads up the R&D
contact surfaces caused by con- activities: a pursuit of
tinuous impact of the different size more than 30 years
particles. With this system in place, and 1,700 projects in
downtime is effectively eliminated. automated safer min-
The profile can also include a ing, smarter oil and gas
surface treatment to encourage extraction and other
a “spiral down” enhancement of industrial projects.
INTELLIGENT OILFIELDS
Integrated HMI/SCADA
systems enable smarter
data acquisition
Open platform development tools enable more effective, affordable approaches to SCADA.
H
arnessing the power of data has
By Martin Rudloff driven substantial change in the
oil and gas industry. As embed-
ded technologies have fast-tracked
and expanded data collection and
analysis, the impact is global, and
operators worldwide are able to develop fuel
sources that were once thought inaccessible
at any cost. High-performance, HMI-based
systems are at the center of this technology
expansion, handling diverse and demanding
physical computing environments while exe-
cuting sophisticated SCADA
applications. It’s a successful
PROBLEM: Developing ad- combination of hardware and
vanced SCADA applications is software capabilities that has
a challenging and time- broadened horizons for oil
and gas operations, setting
consuming process for oil and
the stage for intelligent oil-
gas system developers. fields where people, equip-
ment, and assets are con-
SOLUTION: While pre-inte- nected for the highest qual-
grated HMI/SCADA technolo- ity production and safety.
gies are breaking new ground Conversely, SCADA appli-
to solve the challenge, not all cations are complex and
systems meet the ideal re- time-consuming to develop,
quirements for rugged perfor- increasing the challenge
of seamless integration
mance, intuitive HMI controls,
with new and existing
interoperability and long-life HMI systems. Deployment
systems. becomes even more com-
plex as designers and OEMs
ACTION TO TAKE: OEMs must reduce development
should follow a careful best resources to ensure compet-
practices checklist to ensure itive value in unique oilfield
long-term performance is op- settings, but must not sac-
timized from both a hardware rifice proven rugged perfor-
mance, system consistency,
and software perspective.
and long-term supply in the
process.
Integration simplifies development
HMI/SCADA systems are deployed in some of
the most dangerous, remote, and technically
sophisticated environments on the planet.
It is no small value to ensure compatibility
and simplify development, as these systems
are integral to ensuring nonstop oil and gas
exploration and production. They must be able
to meet a range of environmental extremes,
including resistance to shock, vibration,
temperature, and dust. Incorporating SCADA
software at the manufacturing level is a new
trend that ensures customized performance
and prevents the runaway integration
challenges that can occur when systems are
dropped in—either for new deployment or
refreshing existing systems in the field.
Open platforms make all the difference
Open platform SCADA development tools are
the most important factors protecting cost,
flexibility, and more importantly, longevity of
integrated HMI/SCADA applications. An open,
nonproprietary alternative to costly in-house
design supports oil technology companies
facing pressure to reduce costs or quickly
introduce new features in connected embedded
designs. An open platform ensures an efficient
path to meet application requirements without
incurring large, upfront development costs,
compounded by lengthy time-to-market.
A common mistake is to expect an expen-
sive licensing requirement as a stumbling
block. However, OEM licensing models con-
trast favorably to the expense of retaining an in-
house development team creating applications
from the ground up. Existing software modules
help developers avoid time-consuming, low-
level processes, and instead, remain focused
on customization to distinguish their application
OIL&GAS ENGINEERING FEBRUARY 2016 • 7
INTELLIGENT OILFIELDS
and get to market faster. For increased long-
term value, the open platform ensures applica-
tions can be maintained or used by any system
integrator.
Flexible deployment options based on
price vs. performance
Oil rigs or mining platforms may be operated
by PLCs from different manufacturers.
Supporting these various product families is
a costly challenge, requiring OEM support of
HMI development packages from each PLC
vendor. In contrast, an open HMI/SCADA
platform is compatible with most types
of PLC families; with fully open platform
communications and connectivity, the system
can communicate with PLCs and controllers
from nearly any manufacturer.
As a result, OEMs minimize integration
issues that can add up over time in terms of
cost and overall resources. It’s important to
note that without this ability, an oil producer
might be faced with choosing all products
related to a single PLC family.
This potentially increases costs by eliminat-
ing the ability to evaluate each piece of an
integrated system on its own merits of price
vs. performance. For example, a panel PC
running recognized HMI software could be as
much as several thousand dollars more per
installation, compared to a bundled hardware/
software HMI and SCADA system.
Transforming oil and gas
with better data
Integrated HMI/SCADA systems acknowledge
that reliability feeds profitability. The top priority
for these streamlined systems is to deliver real-
time data to help produce gas more efficiently
and safely. Best practices for SCADA software
include database connectivity that simplifies
the linking of multiple data sources, both to
record information and to use data to develop
analytic dashboards. This allows operators to
read information at a glance, and make quick
decisions that improve safety, productivity, and
efficiency.
Notably, as systems grow less isolated and
begin to take advantage of Internet and cloud-
based capabilities, the ongoing need to mobilize
oil and gas data is driving many operators to
seek SCADA applications that provide mobile and
remote-monitoring capabilities. OEMs should
8 • FEBRUARY 2016 OIL&GAS ENGINEERING
consider the software’s ability to easily view data,
remotely control operations, or communicate
with multiple sites from a central control facility.
Next-generation systems offer these features
from a thin-client application accessible on por-
table devices, such as tablets or smartphones.
Ensuring reduced costs for long-term
software migration
Open platforms also can bridge the gap
between customized features and faster, more
fluid integration. In addition, long-term software
migrations are protected with the forward and
backward compatibility maintained in a licensed
development tool. Oil OEMs are assured a path
to the newest development platforms without
extensive re-engineering costs.
In an optimal licensed software development
product, support is added routinely, enabling
OEMs to capitalize on new operating systems;
technology standards, such as HTML5 for web
access; and other valuable communications
protocol development—but without assign-
ing resources of their own to develop these
improvements. Planning ahead also includes
embracing mobile access or cloud-ready
options.
Pre-integration reduces on-site
deployment challenges
OEMs must pay attention to how simply the
application can be deployed on-site. Add-ons
can present common problems because
systems suddenly need a raft of new interfaces
or features to connect to existing systems.
Several oil technology partners offer the option
of shipping an HMI/SCADA system as a fully
tested, turnkey system. It is a best practice
to determine the ideal level of partnership
between OEM and technology supplier
or developer because a more synergistic
relationship can save valuable time and
resources in deploying the end-user application.
With a partnership approach, manufacturers
can integrate customers’ intellectual prop-
erty as part of system development, creating
compatible plug-and-play options that refresh
systems, streamline part numbers, reduce
development time, and ensure simple on-site
integration. Expertise in applications, such as
chemical analysis, fracking data collection,
undersea robotic equipment, subsea systems,
and onshore/offshore surface logging adds
value here, helping reduce
development time and
costs and minimize inte-
gration headaches.
Longevity as a
business practice
Continued updates
to both hardware and
software are essential
for keeping oil and gas
systems fielded for
long-term deployment.
Working closely with the
forward and backward
compatibility of the
software development
platform, the hardware
side of the equation
requires consistent, high-
quality components and
flexible materials planning.
Creative and proactive programs add value,
helping to protect investments in long-term
product lifecycles. Oil OEMs should expect
technology investments backed by a focus on
longevity by design with extended support
programs readily available.
Best-practices checklist
Request details on oil and gas experience
as well as familiarity with other ultra-rugged
industry segments. Increased insight here
will have an impact on product performance.
Are environmental concerns addressed for
hardware performance, including differentiators
such as IP ratings, ruggedness validated for
extended temperature and designs incorporating
processors on a long-term embedded roadmap?
What reliability and compatibility tests are
performed and are they continually evolving with
industry needs?
Before making a technology investment, ask
for specific planning commitments that ensure
the HMI software’s forward and backward
compatibility. Does that include assurances for
hardware/software compatibility moving forward
for new operating systems, drivers, and firm-
ware? Can the system be accessed via mobile
and cloud-ready platforms? These are essential
questions that establish future flexibility of the
SCADA application. It may be worthwhile to
choose a flexible tool that offers both options.
Can the vendor further minimize OEM Blending rugged HMI hard-
costs by delivering not only hardware and ware with open platform
software, but also the OEM’s custom appli- SCADA development tools
cation, pre-installed, tested, and ready for reduces costs and simpli-
fies support of multiple
deployment? Ask for assurances that costs
PLC families, often found in
are firm and committed. This applies to con-
complex oil, gas and refinery
tract services as well as software customiza-
systems. Image courtesy:
tion, technical support, and product availabil- Corvalent
ity for the long term. Lastly, for remote oil-
field deployments, it may be critical to work
with a manufacturer offering training, such as
webinars or on- and off-site classes that can
help operators avoid unknown challenges or
unexpected delays in the field.
A new era of data-driven oil and gas
development
Asking the right questions can help determine
your best options for advanced HMI/SCADA
platforms that are driving the oil and gas era
of access to data anytime, anywhere. These
high-availability, open-platform systems are
capitalizing on long-term product development
roadmaps, commitment to longevity
and reduction of costs while optimizing
performance all the way from wellhead to
corporate offices. In the field, integration is
seamless, customized, and protected from
runaway costs. OG
Martin Rudloff is the chief technology officer at
Corvalent.
OIL&GAS ENGINEERING FEBRUARY 2016 • 9
CASE STUDY: GAMIFICATION SIMULATION
Real-world impact
of simulation
Disruptive simulation technologies enabled a large oil pipeline company to maximize profits.
Twenty percent savings in capital projects were realized, amounting to $85 million. An additional
$24 million in savings was achieved in additional annual, recurring revenue.
S
By Allan Chegus imulation is a disruptive technol-
ogy that changes the nature of the
decision-making game. The oil and
gas industry faces the challenge of
optimizing large capital assets and
extracting maximum value from
investments. But the difficulty to do this is in
analyzing the components acting in an inte-
grated system (network), rather than silos.
A large transnational crude oil pipeline
experienced this dilemma. The company
managing this asset understood that tra-
ditional modeling methods were unable to
resolve the problem because of the system
constraints moved and changed across the
network as operating conditions changed.
In addition, the combination of variables
became exponential con-
sidering the high system
complexity. The system
PROBLEM: Ineffeciencies and
contains:
lost revenue are major problems • Five major terminals
in the oil and gas industry due • 73 storage tanks
to not maximizing potential or • 47 commodity types
optomizing the entire system. • 16 commodity pools
• 20 default routes
SOLUTION: Modeling and • 37 business rules
simulation based on real-time • 1,200 connections
• 26,000 km of pipe-
operational data can provide
lines.
the the best system operational
scenarios. In addition, the system
processes 14 million bar-
ACTION TO TAKE: Talk to data rels of oil daily in 400 con-
scientists about how to get current batches.
started using real-time data in In light of these con-
simulations to determine the straints, management
best strategies for optimizing a decided to try simulation
modeling to maximize
system or process.
profits and optimize
scheduling.
10 • FEBRUARY 2016 OIL&GAS ENGINEERING
A disruptive technology
Simulation replicates the key elements of a
problem or opportunity to mimic reality in a
controlled, virtual environment. In this way,
a reasonable representation of the problem
is created, and any number of variable
inputs and outputs can be manipulated.
Decisions that would otherwise be avoided
or ignored can be tested for feasibility
because players—from technical staff to
executives—are operating in a risk-free,
virtual environment.
These gamification principles make simu-
lation effective and fun at the same time.
Users are able to drag-and-drop various
components and events—such as economic,
regulatory, and taxation—and run simula-
tions to obtain real-world output potentials.
By running the simulation multiple times,
optimal decisions can be determined for the
short- (1-to-3 month) and long-term (10-year)
horizons.
Innovative real-world results
This oil pipeline company was growing
quickly. However, it continued to
experience a chronic shortfall in its
throughput and revenue performance.
In addition, a structural change in the
regulatory environment forced the
company to increase throughput while
pushing for cost savings and capital
efficiency.
After deciding to move forward with
simulation, a multi-commodity terminal
located in the U.S. Midwest was chosen
as a candidate for modeling. The terminal
consisted of more than 40 medium- and
large-diameter oil storage tanks with many
interconnecting manifolds, associated
meters, and instrumentation.
 The first step in the process was to deter-
mine the data available within the organiza-
tion. Data were collected from the analytics
team, which served as the umbrella group
for collecting operational information for
the company. In addition, batch data were
collected from the scheduling department.
Prior to this, the operations and batch
departments had worked in isolation. The
simulation exercise facilitated collabora-
tion between the two groups and created
departmental integration.
After collecting and analyzing the data, an
assessment of operating performance rela-
tive to industry benchmarks was performed.
Over the course of this assessment, operat- model existed at first, but it gained Figure 1: Typical terminal
ing gaps and areas for improvement were increasing acceptance as analysts model. All images courtesy:
identified. The objectives of the modeling obtained working experience with the Stream Systems
exercise were to: model.
• Determine whether existing tankage at Finally, the organization did not have
the upstream terminal would be ade- robust analytical capabilities or underly-
quate to store deferred batches without ing support systems for a comprehensive
shutdowns. data management strategy. Furthermore,
• Quantify the impact of customer out- operating data were scattered and incom-
ages on the overall system volume plete. This mentality changed after the
throughput. importance of comprehensive data collec-
• Determine whether planned expansion tion was realized.
would be adequate to mitigate future
outages. Significant savings
As a result of the modeling, the organization
With the data collected and objectives determined that it was possible to eliminate
identified, an initial high-level model was one large storage tank, numerous piping
created. Working with the operations and manifolds, and associated valves and
batch departments, features and functional- instrumentation.
ities were developed to gain greater fidelity A year after implementing the simulation
and alignment with real-world operations. findings, there was a 20% savings in capital Figure 2: Typical user inter-
After a working model was confirmed, simu- projects, which amounted to $85 million. An face.
lations were implemented accounting for
real-world variables.

Overcoming implementation
challenges
The simulation implementation was not
without its challenges. First, learning
statistical methods and moving away from
reliance on spreadsheets were required
to implement the models. With no prior
experience using whole-terminal models
or large complex network simulations,
analysts looked at the problem in a micro
rather than macro sense. In addition, a
distrust in the validity of the simulation
OIL&GAS ENGINEERING FEBRUARY 2016 • 11
CASE STUDY: GAMIFICATION SIMULATION

Figures 3 and 4: Typical simu- additional $24 million in annual, recurring by MIT Sloan Management Review, top
lation outputs. revenue was achieved. Besides this exam- corporate performers in more than 30
ple, companies typically realize an average major industries indicated they were
of between 10% and 20% capital savings twice as likely to use simulation and
after implementation of simulation recom- advanced technologies to guide their
mendations. decisions compared to their competitors
(see “Five simulation effectiveness
What makes simulation effective? criteria.”)
These results are not specific to this
particular case or industry. In a study Simulation is here to stay
Maximizing efficiency in the oil and gas
industry is difficult due to the scale and
Five simulation effectiveness criteria integrated nature of operations across
There are many ways that simulation can transform complex and departments; problems do not exist in
dynamic decision-making in the oil and gas industry. Here are five of silos. In addition, system considerations,
them: such as the economy, changing regulatory
1. Asset planning tool: Simulation is an asset planning tool, not a environments, and taxation framework
scheduling application tool. It optimizes large capital assets and extracts impact the effectiveness of potential
maximum return from those investments. Therefore, the outcomes are
decisions. This is why simulation is
comprehensive in scope, taking into consideration the most important ele-
innovative in its ability to create disruptive
ments of the problem.
2. Forward looking: Simulations are validated using actual real-time and material change.
data, but the data are not extrapolated into the future to make decisions. Moreover, it will continue to be adopted
With simulation, data patterns are determined from past behaviors, and by organizations that seek to decrease
the simulations are run taking into consideration the possibility of and overhead costs and increase efficiency.
complexity of future activities and events. Simulation accounts for big-picture issues
3. Time: Whereas models of this complexity typically take 4 to 6 and allows for testing in a risk-free environ-
months to configure using conventional software, simulations typically ment. It is through this creative, out-of-the-
take between 4 and 6 weeks. This is possible because of proprietary soft- box thinking, that change can occur. OG
ware, algorithms, and because the model is fit-for-purpose with the appro-
priate level of details to solve the problem. It is also possible because of
Allan Chegus is president and cofounder of
the processing power of today’s computers. Gut-based decision making is
Stream Systems, a product and multidisciplinary
eliminated because real-world answers become evident in a short period
consulting firm specializing in business simula-
of time.
4. Collaboration: Collaboration across disciplines is required to achieve tions, advanced optimization, and predictive analyt-
optimal decision making. Departments no longer operate in silos, and ics serving the oil and gas industry. Chegus has
they become interdisciplinary as data are shared. This collaboration extensive project and
results in robust outcomes as the entire system is considered. program experience in
5. Team advantage: The team behind the simulation is crucial. Data business simulations and
scientists draw patterns from past data and determine the most important advanced decision-making
variables to include and manipulate in the simulation. It is important that systems including feasi-
the team have experience, not only running traditional simulations, but bility and business case
also working on the core operating activities in the oil and gas industry. It
development for multi-
also is important to find a balance between individuals with strong techni-
million-dollar energy-
cal skills and those who are systems thinkers.
related business projects.

12 • FEBRUARY 2016 OIL&GAS ENGINEERING

CASE STUDY: PROACTIVE MAINTENANCE
Use EAM and APM
techniques to achieve better
maintenance planning
Enterprise asset management (EAM) software can ensure asset uptime, while an asset performance
management (APM) approach can ensure optimal levels of cost reduction and reliability.
I
By Roberto Michel n these cost-constrained times driven by
low oil prices, the goals behind asset reli-
ability initiatives shift somewhat. While
asset uptime will always be the central
focus when it comes to asset perfor-
mance, in a down market, having the
insights to let noncritical parts run to failure
to save on maintenance costs and to help
right-size spares inventory becomes more
important.
A full year and a half into the oil price plunge,
which began in mid-2014, few would argue
with the notion that oil and gas industry man-
agers need to do everything they can to curb
costs, including re-examining maintenance
strategies. Part of the challenge, however,
is that enterprise asset management (EAM)
systems excel at executing maintenance pro-
cesses, but do not necessarily contain the type
of analytical functions and improvement work-
flows that help a company establish and follow
through on maintenance strategies.
Inventories of spare parts and other main-
tenance, repair, and operations (MRO) sup-
plies must be further tightened in this down
market. In 2013, research firm IHS high-
lighted the problem of “toxic MRO catalogs”
that plague asset-intensive industries. IHS
reported that MRO stockpiles were growing
by 9% per year, and that up to 30% of MRO
inventory will never be used.
To optimize MRO inventories and ensure
that the most critical assets stay produc-
tive, the trick is to assess which assets are
the most business-critical, which are less
critical, and rethink maintenance strategies
accordingly. As part of that, more companies
are examining asset performance manage-
ment (APM) strategies.
Toward APM
More companies in the oil and gas industry
are putting in place APM technologies, which
use analytical tools and functionality for
managing recommendations to improve asset
effectiveness. Reliability technologies are
essential to APM in that they help companies
establish maintenance strategies, according
to Ralph Rio, research director with ARC
Advisory Group.
“Reliability technologies determine which
assets are most critical to APM, and what
kind of maintenance plan you should apply
to a particular asset,” said Rio. “The end goal
for APM is to improve return on assets and it
tends to place emphasis on maintenance plan-
ning, whereas EAM is more about executing
maintenance processes.”
APM software solutions, according to Rio,
can have different types of applications, but
reliability centered maintenance (RCM) is
the key type of APM application. Such soft-
ware usually has an analytical component to
assess factors, such as safety or downtime
risks. However, added Rio, APM is more than
business intelligence layered on top of EAM
history in that these technologies typically
have workflows to manage recommendations,
and their analytics can take in many types of
asset-related data, not just EAM history.
The APM vendor landscape is still emerg-
ing, with plenty of overlap among companies
OIL&GAS ENGINEERING FEBRUARY 2016 • 13
Case study: proaCtive maintenanCe
involved. The market includes a handful
of vendors that specialize in APM or RCM
applications, EAM vendors with RCM tech-
nologies, major enterprise system vendors
who have manufacturing execution system
(MES) technology with plant intelligence
software that addresses equipment reli-
ability, and major control system vendors
‘
who have plant intelligence software that
A full year into addresses reliability and asset health.
Additionally, some end-user companies
the oil price have custom-built technologies for functions
plunge, which such as RCM. “ARC views APM as a devel-
oping space that for the most part, has been
began in user-driven, with many customized technolo-
mid-2014, few gies that have been created to maximize
return on assets,” said Rio.
would argue Simply deploying APM software, how-
ever, is no guarantee of improved reliability,
with the notion
warned Rio. One major hurdle is organiza-
that oil and tional: The people in a company analyzing
asset reliability might be disconnected with
gas industry groups in charge of maintenance, those in
managers charge of production, and those in charge
of IT. “Organizational hurdles are real, and
need to do they can, and often do, lead to problems,”
Rio said.
everything they
The organizations that have learned to
can to curb excel at APM have created asset reliabil-
ity groups with participation from leaders
costs, including across disciplines, reporting up to one chain
re-examining of command. Other organizational changes
that can help is to have a manufacturing IT
maintenance group that is separate from corporate IT. A
strategies.
’ manufacturing IT group can help users of
APM technologies collaborate with users of
EAM and control systems. In some instanc-
es, it may be possible to build links between
APM and EAM technologies so that a
recommended action from APM analysis
gets passed into the EAM technologies for
execution.
“Some integration between asset reliabil-
ity and EAM application can be important
and necessary, but it may not suffice to
actually improve performance if the right
information isn’t also provided to the main-
tenance organization, or it isn’t deemed
credible enough from their viewpoint,” said
Rio. “So you have to layer some organi-
zational change on top of any application
integration.”
14 • FEBRUARY 2016 OIL&GAS ENGINEERING
Another key concern in getting APM and
EAM processes in sync is master data man-
agement. Tools within APM and EAM solu-
tions that manage master data over assets
can help, but ultimately, the user organiza-
tion must decide which technology will be
the system of record for asset information.
“Getting to a state of consistent master
data can take years,” said Rio, “and may be
best pursued as companies perform major
upgrades to a plant, rig, or other key asset.”
APM in action
In practice, APM initiatives typically involve
applications that pinpoint failures to critical
equipment and also set maintenance plans
for different classes of equipment. These
implementations typically tie into EAM
technologies to follow through on changes
to maintenance procedures, and to verify
improvements.
For Super Octanos, C.A., a Venezuelan
manufacturer of gasoline additives, such
as methyl tertiary butyl ether (MTBE), an
APM program and supporting software has
improved equipment reliability and uptime.
Back in 2007, the company decided to pur-
sue an APM initiative after seeing the gap
between its asset availability plan and actual
performance reach 27%.
Super Octanos wanted to increase avail-
ability by eliminating or reducing failures,
thus improving its “on-stream factor,” which
is a percentage measure of the time that a
process unit is operating. The initiative was
successful in improving the plant’s on-stream
factor, in part, by analyzing and recommending
fixes to a recurring failure in a critical motor.
The short-circuit ring electric motor (11
MW), part of an Italian design compression
system for an MTBE plant, failed six times
between 2008 and 2012. Images of the asset
revealed physical failure of the circuit’s con-
tacts due to melted copper. The motor was
one of five in existence worldwide, limiting
available support. Each repair to the short-
circuit ring electric motor could result in lost
production of 1,692 metric tons of MTBE, or
more than $1.4 million in revenue.
Super Octanos needed to monitor this
asset’s performance and complete the APM
implementation to identify the root cause of
failure and determine the best action to resolve the prob-
lem. The project’s objectives included:
• Designing and implementing APM continuous
improvement processes
• Undergoing APM best practice knowledge transfer
• Improving availability
• Reducing cost
• Managing risk
• Training and establishing industrial systems reliability
specialists.
Super Octanos chose APM software from Meridium as
its APM foundation and to support failure elimination pro-
cesses. The APM software includes asset taxonomy, which
is a hierarchy and classification of asset structure, and an
event history with a standard process to capture and inte-
grate performance history and condition data. The company
integrated the APM software with data from its Oracle
EAM system, as well as other asset-related data, to support
analysis and identify assets experiencing the highest failure
rates, thus helping to develop mitigation strategies.
Using APM-failure-elimination technology and work pro-
cesses, the company used standardized asset taxonomy
to understand where its asset failures were occurring and
enact recommendation management to implement repairs
and monitor success in reducing failures. The company
also instituted event-reporting work processes, work-order
reporting processes, and lost-production opportunities
analysis.
components, updated work instructions for maintenance
personnel, a new training plan, and use of a quality voltage-
monitoring system. These steps have been successful
in nearly eliminating downtime from the motor. Overall,
through the implementation of Meridium’s APM and failure
elimination applications, Super Octanos’ gap between its
on-stream plan and actual data has decreased significantly,
down from 27% in 2007 to 2% in 2014.
To overcome the cultural challenges initiated in the APM
transformation, Super Octanos worked with Meridium to
assign key resources as functional leaders, communicated
new information policies to all employees, and built reliability
into the company’s framework and
mission. As Garcia summarizes, “We
established a reliability focused culture
and eliminated failures with the help
of Meridium’s knowledge and leader-
ship expertise.” OG
Roberto Michel is a freelance writer and
editor with more than 20 years of experi-
ence with business-to-business publications.
Electrical Solutions
for Hazardous Locations

Change management
According Juan Garcia, technical manager for Super
Octanos, the APM initiative boils down to a structured
“find it, fix it” process for identifying equipment and/
or procedures prone to failure, and then instituting the
fixes and follow-ups. “To say ‘find it, fix it,’ sounds simple,
but there are many work processes and cultural changes
involved in doing this successfully,” said Garcia.
Using the APM technology for failure elimination involves:

• Event reporting work process Enclosures • Control Stations • Lighting

• A work order reporting process
• Pareto analysis to identify lost production opportunities
and bad actors
• Analysis of resources and responsible assignations
within the reliability team
• Recommendation management.

With the short-circuit ring electric motor, the APM pro-

cess came up with recommendations that included work- ® technor.com
ing with the supplier to ensure dimensional control of key A company of MARECHAL ELECTRIC GROUP 888.729.9274

OIL&GAS ENGINEERING FEBRUARY 2016 • 15 input #103 at www.controleng.com/information

CASE STUDY: ARC FLASH
Protecting FPSOs
from arc flash
At a large floating production storage and offloading (FPSO) unit, managers have found a way
to protect workers and equipment from electrical arc flash and reduce the risk of downtime.
F
By Dr. Jay Prigmore PSO operations require electrical
power, which must be distributed
safely and reliably. That’s why man-
agers at a large floating production
storage and offloading (FPSO) took a
proactive electrical safety role. This
floating structure is located 10 miles offshore
in the Atlantic Ocean. It processes more than
250,000 barrels of oil per day and is capable
of storing more than 2 million barrels of oil.
On-site power generation is required
on FPSOs to power onboard equipment.
Many protection schemes and methods
are investigated to determine the most
effective safeguards for the FPSO. These
inspections include, but are not limited to
short-circuit current, arc flash, and system
stability studies. The engineering firm per-
forming the studies discussed the impor-
tance of arc flash mitigation on the FPSO
in addition to addressing the short-circuit
current. An electrical accident, such as
an arc flash, in the presence of explosive
gases, could be catastrophic to the opera-
tion and personnel.
The perfect storm for arc flash
At sea, humid salty air and water from
extreme weather can increase the risk
of electrical tracking and electrical arcs.
Electrical tracking or sometimes referred
to as electrical treeing or dry banding
is a breakdown phenomenon in solid
insulation caused by partial discharges
‘An electrical accident, such as an arc flash, in the presence of explosive
gases, could be catastrophic to the operation and personnel.
’
16 • FEBRUARY 2016 OIL&GAS ENGINEERING
over time, which “track” to the nearest
electrode causing a short-circuit or arcing
fault. Electrical tracking may occur in any
energized piece of equipment including
cables and switchgear.
Therefore, it is a common practice in the
electrical system to deliberately float or
employ high-resistance grounding. These
measures help mitigate the risk of phase-to-
ground faults, which are responsible for the
vast majority of arc flash events. Another
advantage of this system design is the ben-
efit of allowing operations the ability to ride
through the fault.
However, a chance remains for phase-to-
phase or 3-phase arc flash events, which
research shows are more likely to occur
in the presence of maintenance workers
due to movement in the area, and some-
times caused by a dropped tool, according
to the NFPA’s “Occupational Injuries from
Electrical Shock and Arc Events.” The dan-
ger to workers has made arc flash mitiga-
tion a priority.
Five types of arc flash mitigation
The managers and a consulting firm reviewed
the available arc flash mitigation approaches,
and categorized them into five groups:
1. Fault interrupting technologies include
current limiting fuses, expulsion fuses, and
circuit breakers. In the presence of fault
current, these devices open the circuit by
means of a fuse or a breaker. These devic-
es are part of the normal infrastructure of
any electrical system, and they work well
at protecting equipment and personnel
against overcurrents.
Unfortunately, an emerging arc may not
draw enough current at first to trigger an
immediate operation. These devices may
be designed or sized to ignore temporary
and normal current spikes, such as inrush
currents when a motor starts. In addition
to triggering time, these devices require a
finite time to operate, which may allow the
arc to escalate into an arc flash.
2. Arc diversion technologies include
3-phase grounding switches. A ground-
ing switch responds to an arc flash using
a light sensor to detect an arc and intro-
ducing a bolted 3-phase fault, typically
upstream in the system.
3. An arc flash relay uses the strategy
of fast arc detection. Light sensors detect
the light from an arc and within a few
milliseconds, the relay signals the circuit
breaker to open. The reaction time of an
arc flash relay is limited by the time it
takes the circuit breaker to open, which is
up to 50 msec for a typical molded case
circuit breaker at continuous currents
greater than 1,200 A.
4. Current reduction technologies
include current limiting reactors and high-
resistance grounding. These devices reduce
the amount of current in a fault by a spe-
cific percentage, which in turn reduces the
available energy during an arc flash event.
High-resistance grounding places a large
resistor on the path to ground, which limits
the current that can flow to ground to a
low value, typically around 5 A. The high-
resistance ground addresses single-phase
arc flash but does not mitigate a phase-to-
phase or 3-phase arc flash.
5. Triggered current limiter, also called
a current-limiting protector, is an elec-
tronically controlled and sensed device
that consists of a main continuous current
Arc flash explained
An arc flash occurs when electricity crosses an air gap to find a path
to ground or another phase in the circuit. The arc starts small, but as
it grows, the heated metal conductors vaporize and create a cloud of
ionized gas that conducts all the current available to that circuit. The
results of high current and expanding gas are intense heat and an
explosion—extremely dangerous to workers and destructive to equip-
ment. In addition, the costs of downtime at sea likely would be higher
than for land-based refineries due to the difficulty and delays of deliv-
ering replacement gear offshore.
conductor with a parallel-mounted, low con-
tinuous-current-rated current-limiting fuse.
The current limiting protector interrupts
the circuit within 0.25 to 0.50 of a cycle.
The trigger threshold level can be adjusted
if the electrical system is upgraded over
the life of the triggered current limiter to
ensure proper protection.
Selection considerations
Each strategy has its advantages and
disadvantages. Engineers know that
fuses and circuit breakers are essential
for overcurrent protection but cannot
react to arcs quickly enough in every
situation. For example, a typical high-
speed current-limiting fuse (4,000-A
rating) would operate quickly at less than
10 milliseconds during a high value fault
(typically around 100,000 A), but would
require more than 1 second to operate
during a moderate value (30,000 A,
typically) fault.
When operated, the grounding switch
would subject associated equipment to
electrical stress, possibly shortening equip-
ment service life and potentially damaging
the upstream equipment.
To provide effective arc flash mitigation
to an FPSO, reactors require vast imped-
ance that is not practical as they have a
regulating voltage drop and consistent
losses due to the copper windings.
The current limiting protector was not a
well-known technology. Originally, it was
OIL&GAS ENGINEERING FEBRUARY 2016 • 17
CASE STUDY: ARC FLASH

best solution that

‘ To provide effective arc flash mitigation to an FPSO, reactors managers expect

require vast impedance that is not practical as they have
will maintain critical
uptime and safety.
After a care-
a regulating voltage drop and consistent losses due to the ful review of the
copper windings.
’ options, the engi-
neers recommended
a current-limiting
protector, which
protects a bus tie,
designed for use by electric power the maximum available short-circuit a typical application on an FPSO. If
utilities for medium-voltage applica- current and include a triggered fault- there is an arc flash event, the cur-
tions. It was designed to operate current limiter to assist in managing rent limiter will reduce the energy,
the fastest of any of the arc flash the high levels of short-circuit current. eliminating or greatly reducing the
mitigation technologies under con- damage. Applying the current-limiting
sideration. Current-limiting protector protector at other strategic locations
It could be used on upstream fits the bill in the system, such as directly on a
medium-voltage equipment, extend- FPSOs need technologies for arc transformer/generator, the energy
ing protection to many electrical pan- flash protection that keeps workers may be reduced to 1% of its poten-
els downstream. A common theme safe, prevents equipment damage, tial value. Having this protection also
among FPSOs is to specify circuit and reduces liability. In this case, a enabled managers to use lower rated
breakers with an interrupt rating below lesser-known technology provided the switchgear, which saved on weight,
space, and costs.
In this case, the consultant rec-
ommended the setpoint at 21 kA,
above the expected inrush current

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levels. Because this was applied at
the bus tie between numerous gen-
erators, operation of the protector
would cut overcurrent to within the
breaker ratings and approximately
lower the arc flash energy to 25%
of its peak value. This was enough
to protect the equipment and to
mitigate arc flash at that location.
In cases where the setpoint is rela-
tively high, secondary arc flash pro-
tection, such as arc flash relays may
be applied at downstream electrical
panels. But in this case it was not
necessary. OG
Jay Prigmore, P.E., is a product devel-
opment engineer
with G&W Electric,
a supplier of elec-
trical power equip-
Oil & Gas ment. He has a
PhD, and an MS in
5211 Industrial Road • Fort Wayne, IN 46825 electrical engineer-
ing from Arizona
State University.

input #104 at www.controleng.com/information 18 • FEBRUARY 2016 OIL&GAS ENGINEERING

REGULATORY MEASURES
Electric actuator technology
prospers in production fields
President Obama’s Climate Action Plan has a goal to cut methane emissions from the oil and
gas industry by 40% to 45% from 2012 levels by 2025. This has led to new regulations that
require widescale pump retrofitting.
By Barb Boynton
Figure 1: The photo shows an
electric actuator installed on a
4-in. suction control valve feed-
ing a compressor. All images
courtesy: Curtiss-Wright/Exlar
Actuator Solutions
M
ethane is a major component of
natural gas, and is also a green-
house gas that is 25 times more
likely to contribute to global warm-
ing than carbon monoxide. The
U.S. Environmental Protection
Agency (EPA) estimates that 30% of methane
emissions come from the oil and gas industry.
When breaking down where these methane
emissions come from, pneumatic devices are
considered one of the top contributors, especially
with natural gas production. Pneumatic devices in
gas extraction are designed to vent methane into
the atmosphere as a part of normal operations.
This vent or “bleed” of natural gas not only con-
tributes to poor air quality, but also hurts the oil
and gas producers by not capturing the value of
this gas as a sellable commodity.
There are two basic types of pneumatic devices
that bleed methane to the atmosphere: controllers
and valve actuators. While controllers bleed gas
continuously, valve actuators bleed gas only when
the valve is stroked open and closed. Pneumatic
devices typically work as described below:
• High pressure gas is controlled by a pressure
regulator valve to a constant pneumatic gas
supply pressure.
• Mechanical process measuring devices
further regulate the supply gas pressure to
a weak pneumatic signal depending on the
process measurement high to low level,
pressure, temperature, and flow rate.
• The weak pneumatic signal flows into a
controller, which through a precision set of
nozzles and orifices, directs the pneumatic
supply gas to or from the valve actuator.
• When supply gas is routed to the actuator,
the diaphragm pushes the valve plug open or
closed.
• When supply gas is vented, an opposing
spring pushes the diaphragm back, closing or
opening the valve.
• The weak control signal is often vented con-
tinuously (bled) to the atmosphere.
• The strong signal is vented intermittently—
only when the valve opens or closes.
In addition to the controller bleed rates, leaks
and malfunctions must be considered as a poten-
tial gas-venting source. Leaks from the various
tube joints or other points within the tubing net-
work are possible due to worn gaskets or loose fit-
tings. Malfunctions within the controller are possi-
ble because of foreign material blocking the nozzle,
creating a continuous bleed or excess moisture in
the supply gas, which can cause nozzle corrosion.
The size of the problem these pneumatic
devices create is debatable. Several studies
have been done on the number of pneumatic
devices installed and the amount of methane
they bleed or vent. For example, the University
OIL&GAS ENGINEERING FEBRUARY 2016 • 19
REGULATORY MEASURES
Figure 2: This diagram shows
how an actuator is con-
nected to the natural gas
pipeline.
20 • FEBRUARY 2016 OIL&GAS ENGINEERING
of Texas at
Austin published
Measurements
of Methane
Emissions at
Natural Gas
Production Sites in
the United States
(David Allen et al.)
that concluded
the amount of
methane released
is more than what the original EPA estimate
suggests.
Another study by the Oklahoma Independent
Petroleum Association (Pneumatic Controller
Emissions from a Sample of 172 Production
Facilities, Nov. 2014) concludes the emissions
are less than the EPA findings. Regardless of the
outcome, these devices still vent methane to the
atmosphere.
The good news is that programs such as the
EPA’s Natural Gas Star Program encourages
and facilitates voluntary reduction of methane
emissions. One of the historic solutions by the
program is the use of lower-bleed pneumatic
controllers. A low-bleed controller is defined as
having a bleed rate of 6 cu ft/hr or less, which
can reduce the emission up to 90%. The issue
is that many applications are not suitable for
this technology due to higher needed pressures
or faster reaction times. In addition, they still
vent—even if the amount is reduced.
Small motor challenge
A more current and growing solution is the use of
electric actuators to move the valve, eliminating
the use of gas altogether. For most production
sites, the electric actuators must be able to handle
the forces required by the process and be able
to react quickly to process changes with a 100%
continuous duty cycle. In addition they must run
on low dc voltage as solar-powered batteries are a
common power supply for remote well sites.
Unfortunately, many believe that electric actua-
tors are not suitable for the production field. The
misconceptions are due to the limited capability
of traditional electric actuators. A typical traditional
actuator uses a small dc motor with a gear train
to increase the output torque. It then adds a linear
thrust unit such an acme screw to move the valve.
The challenge is keeping the motor small
enough to run on low current while providing
enough force and speed to handle the application
The use of a gear train slows the actuator down
too much to handle to process changes. Another
challenge at remote well sites is how to deal with
power drops when batteries drain due to issues
such as overcast weather.
Servomotor approach
A new approach that is being rapidly adapted is the
use of an electric actuator that uses a servomotor
integrated with a roller screw instead of a gear
train and acme screw. Servomotors are up to 90%
efficient, providing more torque than a standard
motor without drawing additional current. They also
include built-in feedback so the position of the valve
is always known. Using a roller screw integrated
within the servomotor provides a means to directly
convert the motor’s rotary energy to a linear force,
eliminating the inefficient gear train.
Powered by 12 to 24 V dc, the electronics can
monitor the bus voltage and safely close the
valve at a predetermined value if battery drain
occurs. The result is an electric actuator capable
of the same or better performance offered by
high bleed and low bleed pneumatic systems.
With the elimination of the pneumatic devices
(controller, regulator, and actuator), an electronic
controller must be used to control the electric
actuator. In most cases, this comes from an
already in place programmable logic controller or
remote terminal unit via an analog signal to the
electric actuator. This creates the more common
electronic process control system used in other
oil and gas process areas such as gas processing
plants and refineries
Electric actuation has been successful in: sep-
arator control, vapor recovery units, compressor
suction control, gas injection, and plunger lifts.
In the end it’s better
As oil and gas producers continue to look for
technologies to comply with new government
mandates, targeting pneumatic devices could
be one of the best places to make a significant
impact. Switching to electric actuation not only
solves the emission problem, but it also has
the added benefit of improved control, reduced
maintenance, and added process information. OG
Barb Boynton is a business development manager
for Curtiss-Wright/Exlar Actuator Solutions. She has
more than 30 years of experience in the process
control industry.
CASE STUDY: FLOWMETERS
Solar-powered thermal
mass flowmeters operate in
flare-gas monitoring system
How can new gas flowmeters operate at an oilfield without utility power service in the
remote southern Bakken formation region of North Dakota? That was the challenge facing
Legacy Reserves at remote sites at the Williston Basin, N.D.
By Bernie Schillo, Mike
Smith, and Steve Cox
Figure 1: This photo shows
a solar power system at the
Schillo site. All images cour-
tesy: FCI
I
n an era of increasing environmental
concern and regulation, the team at this
isolated oilfield at the Williston Basin
needed to upgrade its waste gas report-
ing capabilities for the North Dakota
Industrial Commission (NDIC) and the
U.S. Bureau of Land Management (BLM).
The team realized that new state and federal
regulations would require monthly testing
and reporting, requiring more sophisticated
flow measurement.
“We are now required by the NDIC to
monitor waste gas resulting from each of
our 14 production wells,” said Bernie Schillo,
production foreman at Legacy Reserves.
“We wanted to add new flowmeters to each
well for this purpose in advance of the dead-
line. The state has set new lim-
its for gas emissions, and we
must stay within those limits
or cutback well production.”
Challenge:
no outlet, no power
Without utility power at the
field’s location in the Golden
Valley of North Dakota, Schillo’s
team decided to explore
powering the meters with solar
energy. The 14 wells are laid
out on one well pad connected
to a 3-phase heater/treater
tank that separates the crude
oil into three process streams:
oil, natural gas, and water.
Waste gas from the separation
process, which is unsuitable
for commercial use, is sent to a tank with a
flare unit and burned off as necessary.
Each of the 14 well heads would require
two air/gas flowmeters to support the pro-
cess. The variable and sometimes low-flow
volume at the wells meant that differen-
tial pressure technologies, such as orifice
plates could not be used. The company also
wanted to use existing gas lines as much as
possible.
The team completed an assessment for
the NDIC prior to starting the project to
prove that production could continue while
meeting environmental standards. Previous
regulations required only one annual 24-hour
test of the flare-gas monitoring system.
Today, the more stringent monitoring
requirements are driving the need for con-
tinuous flow measurement.
“We had to convince the state that it was
more cost effective to install flowmeters on
the wells than to install multiple new gas
lines,” Schillo said. Our gas streams are on
the low volume side and the other approach
(new gas lines) just wasn’t practical.”
The final answer: solar power
Schillo’s team contacted Mike Smith, Jasper
Engineering, Williston, N.D., to help with
the solar-powered flowmeter system. Smith
agreed with the feasibility of the team’s
decision to use solar energy to power the
flowmeters, and asked the applications team
at Fluid Components International (FCI) for
a flowmeter capable of handling the variable
low-flow wet-gas measurement with solar
power generation.
OIL&GAS ENGINEERING FEBRUARY 2016 • 21
WELDED METAL
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Jasper Engineering helped the site
team design the new solar-powered
system for the flowmeters and addi-
tional components. The system is com-
prised of two 50-W panels to provide
24-hour power, even during the cold
snowy North Dakota winters. The team
chose two large 12-V, 40-Amp/hr backup
batteries housed in an enclosure (see
Figure 1).
FCI recommended a flowmeter with
constant current thermal dispersion
sensing technology that accurately
measures variable low-flow wet-mixed
composition gases for the 14 wells (see
Figure 2). The meter also features low-
input power requirements compatible
with the solar energy system.
The flowmeters are accurate to ±1%
of reading over a broad flow range, with
repeatability of ±0.5% of reading in this
wet gas application. The meter’s flow
sensor supports line sizes from 2 to
24-in. diameters. This meter’s thermal
dispersion mass flow sensing element
has no moving parts and no orifices to
clog or foul for minimal maintenance in
wet, dirty gas applications.
The design of the flow sensor places
two protected platinum resistance tem-
perature detector (RTD) temperature
sensors in the process stream. One
RTD is heated while the other senses
the actual process temperature. The
Figure 2: FCI’s ST51 flowmeter installed at the site.
temperature difference between these
sensors generates an analog output,
which is proportional to the media cool-
ing affect and compensates for changes
in pressure and temperature to provide
a direct mass-flow output without addi-
tional instrumentation.
It took the crew only 1.5 days to
complete the installation after a short
training presentation. The meters were
installed at a 45-deg angle to avoid wet
gas accumulation on the sensor head
that could affect measurement accu-
racy.
Schillo said at the conclusion of the
project, “What we’re seeing with the
new meters is extremely positive.
They’ve proven themselves already
during our reviews with the NDIC and
BLM staff. The meters are performing
to specification and meet our require-
ments. We will consider using them on
future projects.” OG
Bernie Schillo, production foreman, Legacy
Reserves, LP.
Mike Smith, technical sales, Jasper
Engineering.
Steve Cox, applications manager, Fluid
Components International (FCI).

22 • FEBRUARY 2016 OIL&GAS ENGINEERING

CODES AND STANDARDS
IECEx certification
makes safe safer
Is the European standard of IECEx for harsh environment computers right for design
engineers? How does this European standard impact U.S.-based operations?
W
By Mike Hadaway hile the phrase “IECEx cer-
tification” isn’t part of the
daily conversation for sys-
tems engineers in the U.S.,
indications are that it may
be soon. While the U.S. pri-
marily uses Division-based systems, such as
Underwriters Laboratories (UL) certification
marks, for addressing hazardous areas and
equipment, other countries have adopted
the Zone-based IECEx system.
The inconsistencies in hazardous area clas-
sification have made it difficult for U.S. manu-
facturers to tap into globalized markets, such as
oil and gas processing. This has led to the shift
toward global solutions that meet not only U.S.
standards, but international ones as well.
What is an IECEx certification?
IECEx is an internationally recognized
standard issued by the International
Electrotechnical Commission (IEC) for
equipment that is being used in areas that
have an elevated risk for fires or explosions.
IECEx has made a slow entry into the
U.S. because it is not currently a required
standard in the country. and it increases the
up-front cost of hazardous area computers
because they require IECEx-approved com-
ponents. These components typically cost
up to four times more than their non-IECEx
counterparts.
However, IECEx certification provides
improved safety and long-term cost
advantages that are unmatched by cur-
rent certifications, such as UL certifica-
tion marks, although testing is regulated
by the Occupational Safety and Health
Administration (OSHA), UL is not globally
accepted and does not require ongoing qual-
ity or facility audits.
Other common certifications include; the
class/division ratings based on the NFPA
(National Fire Protection Association) 496,
the NEC (National Electric Code), and the
ATEX (Atmosphere Explosibles) Zone rat-
ings. As a result of the improved safety and
international recognition of the IECEx, more
U.S.-based oil and gas processors in on- and
offshore facilities are beginning to imple-
ment this standard.
Deciding whether or not to require that
the hazardous area computers purchased for
an offshore location meet IECEx standards,
and then navigating the certification process
is challenging for systems engineers.
First things first
The following five dynamics should be
considered before taking the first step toward
certification:
1. Is requiring hazardous area computers
for the facility or location in question to be
IECEx-certified a benefit to corporate opera-
tions?
IECEx certification is difficult, time
consuming, and costly to achieve, therefore
few U.S. manufacturers of hazardous area
and industrial computers have attempted to
design and produce IECEx-approved complex
computer systems. There are benefits of
going through this process, but IECEx is not
always necessary.
2. What is the nature of the environment
where the computer is expected to operate?
OIL&GAS ENGINEERING FEBRUARY 2016 • 23
CODES AND STANDARDS
The IECEx relays are much
longer and larger than their
ATEX and industrial counter-
parts. Image courtesy: Daisy
Data Displays
24 • FEBRUARY 2016 OIL&GAS ENGINEERING
In this case, the primary consideration is
whether explosive locations would benefit
from an IECEx-certified computer. Oil refin-
eries, rigs, and processing plants certainly
qualify with an increased risk of fire or explo-
sions. In these areas, the failure of equip-
ment can have unsafe and costly outcomes.
3. Is the computer designed to con-
trol other systems that require seamless
operation?
Blowout preventers (BOPs) are typically
controlled and monitored by IECEx-approved
computers because of the many hazards
and costs associated with blowouts. BOPs
must go through frequent testing, so when
paired with an IECEx-approved computer, the
likelihood of a blowout-related emergency is
decreased because IECEx performance stan-
dards are zero failure.
4. Is automatic failover capability critical to
the hazardous area application?
Automatic failover provides reliability in
the event of system failures or unplanned
termination of the hardware or network. It is
not required by IECEx. To date, an extremely
limited number of U.S.-based haz-
ardous computer manufacturers
have incorporated this feature into
an IECEx-approved system.
5. Is human error a potential risk
for the computer’s application or
operating environ-
ment?
Human errors
occur and are
costly. Prematurely
sealing an oil well is a multi-billion-dollar
mistake. Incorporating safety mechanisms,
such as lock-out flip covers, protects against
human errors. These additional protec-
tive measures and hardware also must go
through the IECEx-approval process.
Navigating the IECEx certification
process
After an engineer has decided that IECEx
compliance would benefit the design’s
application, what happens next?
Step 1: Determine the appropriateness
of IECEx for the design. If the area in
question is prone to fires or explosions,
IECEx would be applicable. For locations
where system failures are extremely
dangerous, these standards can prevent
unnecessary accidents and expenses.
Step 2: Identify an experienced manu-
facturer to produce the computer. There
are few manufacturers in the U.S. that
have the capabilities, experience, and
level of management that meet IECEx
standards. These standards are difficult
to meet because the manufacturer must
undergo regular inspections to confirm
that the facility is properly maintained,
managed, and the products are equivalent
to the original IECEx-certified design.
Step 3: Collaborate with the manu-
facturer on design. Because each com-
ponent must meet certain standards,
the manufacturer should be in complete
understanding of the computer’s design.
Creating a design spec without the assis-
tance of the manufacturer can create
problems in design and production, which
drives up costs.
Step 4: Design the system. After a
qualified manufacturer has been selected,
design of the computer can begin and
an IECEx application can be submitted.
However, the engineer should be aware
that the IEC will monitor the process.
Prior to production, the designer must
submit an application to an appropriate
IECEx certifier, also called an “ExCB.”
When a design engineer begins the pro-
cess of achieving IECEx compliance for a
hazardous area computer, he or she allows
the IEC to control and monitor all aspects
of the product’s design.
The ExCBs oversee all components of
the computer including voltage, power
consumption, spacing between the printed
circuit board power supply, and ambient
temperature range. All of these compo-
nents must be documented and made
available to the ExCBs by the engineer.
The supervision and accreditation of the
application is handled via an international
peer review.
Upon application, the development of
sample products begin, followed by thor-
ough testing by a laboratory of the ExCB’s
choosing. If engineers select components
for their equipment that have been already
approved by the IECEx, it can accelerate
the testing process. If an IECEx-approved
part is unavailable to fit the need, a non-
IECEx-approved counterpart will be evalu-
ated for compliance and complete design
and manufacturing control must be dem-
onstrated.
Some of the key aspects tested for
IECEx Zone 2 equipment samples include:
• A 28-day aging procedure on the enclo-
sure prior to ingress protection (IP) testing
• IP grade is appropriate for the level of
protection
• Enclosure, glass parts, and glass-to-
metal sealing gaskets/compounds are
satisfactory
• All external nonmetallic surfaces pass a
static electricity test
• There are no unauthorized modifications
(visible or nonvisible)
• Voltage and power levels are within
the acceptable limits for the protection
method
• Threaded enclosure covers are of correct
type and are tight and secure (must pass
visual and physical tests)
• Maximum surface temperatures of
internal components are measured to
confirm they will not ignite explosive
gases and establish the thermal rating,
or T-rating
• Automatic electrical protective devices
are set correctly
• Safety cutoff devices function according
to manufacturer’s documents
• Equipment is protected against cor-
rosion, weather, vibration, and other
adverse factors.
Equipment and facilities that have
completed the process can be verified
instantly via the international online cer-
tificate database that can be found on the
official IECEx website (www.iecex.com).
This expedites the procedure of validat-
ing that a product has met IECEx stan-
dards. Engineers often choose IECEx for
their designs because in 2011, the United
Nations, via United Nations Economic
Commission for Europe (UNECE),
endorsed it as an internationally recog-
nized certification process for the safety of
equipment and personnel used explosive
environments. Governments, safety regu-
lators, and industries are guaranteed that
the equipment being operated or supplied
has met the most respected and dynamic
safety protocols.
The sense of assurance and global rec-
ognition that comes as a result of IECEx
can lead to additional cost-savings for the
product as well. Designers can forgo the
additional testing and certifications for
their product to be sold. If a product is
tested and approved by the IECEx stan-
dards, it complies with others such as
NFPA, NEC, and ATEX standards as well
because the IECEx process is more strin-
gent. This decreases testing and certifica-
tion costs associated with manufacturing,
and time to market the product. OG
Michael Hadaway, general manager of Daisy
Data Displays, has
more than 10 years
of mechanical engi-
neering and product
design experience.
He received his
B.S. in Mechanical
Engineering and MBA
from Pennsylvania
State University.
OIL&GAS ENGINEERING FEBRUARY 2016 • 25
WORKPLACE SAFETY

De-risk by design:
Maintaining safety at heights
A major challenge facing oil and gas facilities is inadequate lighting and the need for workers to
climb to elevated heights to repair or replace lights.

O
By Bradford Morse il and gas facilities are among the
most demanding and hazardous of
industrial settings that require proper
lighting to maintain worker safety.
To address this concern and help
improve safety some recent innova-
tions in lighting technology have been developed.
Identify the challenge
Maintaining lighting in industrial facilities is often
complex, time consuming, and costly because
most fixtures are in dangerous and difficult to
reach locations. As a result, an industry average
of one-third of all lights at an industrial facility are
out at any given time. The installed base of high
intensity discharge lights should be re-lamped
every two years. However, this is
typically not done.
PROBLEM: Lighting is According to Occupational
inadequte in some areas of Safety and Health Administration
facilities. (OSHA), fall protection is the
most frequently cited violation.
SOLUTION: Instead of plac- Worse, 36% of worker deaths on
ing a person in a dangerous construction sites are from falls
according to the United States
position to do work, use
Department of Labor.
spring-assisted light poles.
Typically, workers climb to ele-
vated heights to repair or replace
ACTION TO TAKE:
lights. When climbing to an elevat-
• Use spring-assisted ed height, beyond the protection
lights to avoid working of a guardrail, fall protection must
at heights. be used. Two generally accepted
• Protect workers with methods to protect a worker are
a fall-arrest system or used while working at heights of
scaffolding when work- 4 ft or greater; personal fall-arrest
system or scaffolding with guard-
ing at heights.
rails. While personal protection
• Seek safety solutions
equipment will help protect work-
that help minimize risk ers from some threats, there is
and help staff avoid still a risk of injury from a fall.
working at heights. The bottom line: Preventing
workers from being exposed
to threats is the most effective risk reduction
measure.
Spring-assisted telescoping light poles
Spring-assisted light poles are designed for
industrial walkways, platforms, stairways, and
conveyors where OSHA/Health, Safety, and
Environment (HSE) regulations typically require
fall prevention equipment. A worker can remain
where an existing guardrail provides protection
and lower or raise the light with the spring-assisted
telescoping pole during installation or maintenance.
Safety innovation
Improving upon previous generations of
rotational light poles, the simple vertical travel of
a telescoping light pole provides true controlled
lowering, reducing the strain on the worker,
and eliminating consideration of surrounding
obstructions. Spring assistance allows the
luminaire to be lowered safely and easily,
meaning that work can safely take place on any
platform or walkway, eliminating the need for
portable ladders and fall protection equipment.
Safety initiative
A study conducted by Liberty Mutual Research
Institute for Safety reported that for every $1
invested in safety, there is a $3 to $6 return
on investment. Using this type of light pole,
the investment in worker safety provides
a compelling return while ensuring overall
integrity of the facility. OG
Bradford Morse is a product manager at Eaton. He
leads the launch of new products and enhancements
to existing products for Eaton’s Crouse-Hinds series of
industrial fittings solutions. Morse has 18 years of expe-
rience and has held a variety of engineering and product
management positions. He has defined, launched and
marketed more than 10 successful products for compa-
nies Eaton, General Electric, and Motorola.

26 • FEBRUARY 2016 OIL&GAS ENGINEERING


T esco Corporation (Tesco) is
seeking to improve drilling
processes by providing a wide range
of rig mechanization products, tubular
running services, aftermarket support
and innovative technologies to the
upstream energy industry.
“volatile conditions
create opportunities”
At Tesco, we strongly believe that
these volatile conditions create
opportunities. Moving into the new
year Tesco has confidence in its
strategy and the balance sheet to
execute on this strategy. Tesco is
well positioned to be one of the few
companies with the potential to
thrive in this depressed market.
New Test Rig at Tesco’s
Houston facility
Substantiating this effort, we recently
introduced to the market the 400 Ton
EXI-800. With 800HP, this top drive
exceeds the torque of many 500 Ton
top drives that are in the marketplace
today, while being lighter and
more compact.
We have also introduced the latest
generation Wireless TesTORK
Monitoring System with an
integrated interlock system that
works with any casing running
tool, and we are deploying the
next generation CDS™, which is
significantly more compact, will
deliver more torque and will fit in
more rigs.
We are commercializing the next
generation of our innovative Catwalks
with significantly accelerated cycle
times. These new products focus on
creating differentiated offerings and
more fully mechanizing the pipe
handling and rig floor operations.
There is also significant interest in
several of our new products currently
being tested. Our Automated Rig
Controls (ARC) System early field
tests have been very encouraging
and commercialization is near.
Our obsession with automating the
rig floor and the drilling processes
will be advanced significantly with
our Tesco Pipe Drive system (PDS)
and our Differential Speed Disen-
gagement (DSD) system. These
two new tools will change what a rig
floor looks like and how it is run.
input #106 at www.controleng.com/information
ADVERTISEMENT
Fernando
Assing
President
and CEO
We will also be delivering our first
Multiple Plug Launching System
(MPLS) as another tool in our quest
to accomplish the evolution of casing
running from a dangerous, labor
and equipment intensive process,
to a highly automated, safer, more
efficient and economical solution.
We are gaining market share in
shrinking markets; we are penetrating
new markets, and we are displacing
bigger competitors by providing new
technologies and new commercial
and operational models that bring
significant value to our customers.
At a time where oil futures are
uncertain, Tesco is proud to see its
strategy being strengthened, as we
are able to save our customers’ capital
while maintaining superior quality.
marketing@tescocorp.com
713-359-7000 • www.tescocorp.com
NEW PRODUCTS

Gas detection sensors alert workers to gas leaks

The S4000CH Combustible Gas Detector from General Monitors
is a microprocessor-based transmitter designed for use with the
company’s catalytic bead sensor. The sensor features precise gas
detection, ease of setup and use, and simple maintenance. The
instrument continuously monitors combustible gases and vapors
within the lower explosive limit (LEL). Electronics are contained
within an explosion-proof housing, offer status indication and alarm
outputs, and provide a 4-20 mA signal proportional to the full LEL
gas concentration range.
General Monitors
www.generalmonitors.com
Asset optimization services Input #111 at www.controleng.com/information

Archrock offers natural gas contract compression services

that include repairing idle assets, maximizing production
processes, and optimizing operations to help companies
minimize downtime by avoiding equipment replacement
costs. The company maintains relationships with original
equipment manufacturers and distributors by providing
field expertise, parts, and services needed for mainte-
nance, repair, refurbishing, reconditioning, and overhaul of
most brands of compression-related equipment.
Archrock
www.archrock.com
Input #110 at www.controleng.com/information

ADVERTISERS’ INDEX

COMPANY PAGE NO. RSN WEB

AutomationDirect C2 100 www.automationdirect.com

Baldor Electric Company 1 101 www.baldor.com

Pyromation Inc 18 104 www.pyromation.com/oilandgas

Senior Aerospace Metal Bellows 22 105 www.metalbellows.com

Siemens 4, 5 102 www.siemens.com/oil-gas

Technor 15 103 www.technor.com

Tesco Corporation 27 106 www.tescocorp.com

WAGO Corp C4 107 www.wago.us

28 • FEBRUARY 2016 OIL&GAS ENGINEERING

Squared edges clean round pipes
The Square Edge Pig features a solid cast construction for
durability, various durometer options for flexibility, and a hol-
low core to allow for even pressure distribution. The main
feature is the square edge on the sealing discs. Which allows
for greater sealing capabilities and a more aggressive clean-
ing application. The rear sealing cup provides an excellent
driving force on the back of the pig.
Pigs Unlimited
www.pigsunlimited.com
Input #112 at www.controleng.com/information

High-power lithium-ion capacitor

The Ultimo lithium ion capacitor combines battery and
ultra-capacitor technology to provide high energy density
and high power with a long lifecycle, a 3.8 V dc maximum
cell voltage, and a low self-discharge rate, which makes it
suited for digital oilfield applications that rely on remote
solar-powered sensors. Ultimo’s higher energy density and
operating voltage reduces the energy-storage footprint by
up to 65%.
JSR Micro Inc.
jsrmicro.com
Input #114 at www.controleng.com/information

Versatile drill head is launched

Weatherford International launched the Compact oil-based
mud micro-imager (COI), a slim profile tool that delivers full-
bore, high-definition images in wells drilled with oil-, diesel-, or
synthetic-based muds. The diameter of the tool is 4.1-in., which
enables deployment in a wide range of geometries including
narrow, horizontal, and highly deviated wells. The COI features
eight pads with 72 measurement electrodes that provide opti-
mum coverage. The images can be further enhanced through
Weatherford Reveal 360 image processing. Reveal 360 technolo-
gy uses structural and textural information in the measured parts
of the image to reconstruct gaps between pads.
Weatherford
www.weatherford.com
Input #113 at www.controleng.com/information

OIL&GAS ENGINEERING FEBRUARY 2016 • C3

input #107 at www.controleng.com/information