Pumped Up

Whether you’re an OEM pump manufacturer, a pump • Unmatched Quality

assembler or a maintenance and repair professional,
there’s a Baldor•Reliance® motor designed and
manufactured for your specific motor-driven pump
system application.
• Superior Reliability
With low and medium voltage horsepower ratings to
15,000 in single or three phase designs including
explosion-proof, close-coupled, vertical P-base,
submersible and immersible, no other motor • Global Sales and Support
manufacturer offers more choices, quality or pumped
up reliability than Baldor•Reliance.

baldor.com 479-646-4711 • Stock and Custom Orders

©2017 Baldor Electric Company

input #100 at www.controleng.com/information

When you think about level measurement
all day, amazing things happen.
Introducing the Pulsar® R86 from Magnetrol.®
At MAGNETROL, we’re obsessed with level measurement because we know how important it is to
your operations and your bottom line. And all of that level thinking has led to a smarter non-contact
radar. The new Pulsar® R86 is the 26GHz model that features smaller process connections, higher
resolution, higher temperature ranges and an antenna that extends from 4" all the way to 72".
And no other non-contact radar offers these advanced diagnostics:
• Automatic waveform capture with intuitive “Help Text”
• Setup and Echo Rejection Wizards
• Tank Profile feature that “learns the tank”
Now you can give your facility radar solutions for every level measurement need with the new
Pulsar® R86 Non-contact Radar and the industry-leading Eclipse® 706 Guided Wave Radar.

Learn more at R86.magnetrol.com

magnetrol.com • 1-800-624-8765 • info@magnetrol.com © 2017 Magnetrol International, Incorporated

input #101 at www.controleng.com/information
1111 W. 22ND ST., STE. 250, OAK BROOK, IL 60523
630-571-4070, FAX 630-214-4504
CONTENT SPECIALISTS/EDITORIAL
KEVIN PARKER, Senior Contributing Editor
630-890-9682, KParker@CFEMedia.com
EMILY GUENTHER, Associate Content Manager
630-571-4070 x2220, EGuenther@CFEMedia.com
KATIE SPAIN, Art Director
630-571-4070 x2218, KSpain@CFEMedia.com
PUBLICATION SERVICES
JIM LANGHENRY, Co-Founder & Publisher
630-571-4070 x2203, JLanghenry@CFEMedia.com
STEVE ROURKE, Co-Founder
630-571-4070 x2204, SRourke@CFEMedia.com
TRUDY KELLY, Executive Assistant
630-571-4070 x2205, TKelly@CFEMedia.com
AMANDA PELLICCIONE, Director of Research
978-302-3463, APelliccione@CFEMedia.com
ELENA MOELLER-YOUNGER, Marketing Manager
773-815-3795, EMYounger@CFEMedia.com
KRISTEN NIMMO, Marketing Manager
630-571-4070 x2215, KNimmo@CFEMedia.com
PAUL BROUCH, Director of Operations
630-571-4070 x2208, PBrouch@CFEMedia.com
CHRIS VAVRA, Project Editor
630-571-4070 x2219 , CVavra@CFEMedia.com
JOY CHANG, Digital Project Manager
630-571-4070 x2225, JChang@CFEMedia.com
MICHAEL ROTZ, Print Production Manager
717-766-0211, Fax: 717-506-7238
mike.rotz@frycomm.com
MARIA BARTELL, Account Director, Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
RICK ELLIS, Oil & Gas Engineering Project Manager,
Audience Management Director
303-246-1250, REllis@CFEMedia.com
LETTERS TO THE EDITOR
Please e-mail your opinions to KParker@CFEMedia.com
INFORMATION
For a Media Kit or Editorial Calendar,
e-mail Trudy Kelly at TKelly@CFEMedia.com
REPRINTS
For custom reprints or electronic usage, contact:
Brett Petillo, Wright’s Media
281-419-5725, bpetillo@wrightsmedia.com
MAILING ADDRESS CHANGES
Please e-mail your changes to customerservice@CFEMedia.com
PUBLICATION SALES
JUDY PINSEL, National Sales JPinsel@CFEMedia.com
1111 W. 22nd St., Ste. 250, 847-624-8418
Oak Brook, IL 60523 Fax 630-214-4504
4 • JUNE 2017 OIL&GAS ENGINEERING
Modularization allows making
the most of natural gas
I
nexpensive natural gas is a significant driver
of today’s U.S. economy. Its use in North
America is roughly even across three market
sectors: power, industrial, and residential.
“The power market needs consistent,
long-term supply with moderate polishing.
Industrial markets need more polishing.
And residential markets need natural-gas
storage,” said Ajay Badhwar, global strategic
market manager, Dow Oil, Gas & Mining.
As the source of much of that gas, the
North American shale basins vary in the
quality of their deposits. The Bakken, for
example, is oil-rich, and so has high natural-
gas liquids (NGLs). “Therefore, there has
been a propensity to flare that gas,” said
Badhwar.
Another factor that differentiates the
basins is how close they are to infrastruc-
ture that makes it profitable to exploit their
natural-gas deposits rather than vent, flare,
or reinject the gas into reservoirs. The
Marcellus and Utica basins in the northeast
U.S., for example, are adjacent to extremely
productive infrastructure, including transmis-
sion lines and demand users.
Natural-gas product fed into the mainline
gas-transportation system in the U.S. must
meet specific quality measures. Natural
gas produced at the wellhead usually con-
tains contaminants and NGLs that must
be cleaned, or polished, before delivery to
high-pressure, long-distance pipelines.
Where to begin
Natural-gas processing begins at the
wellhead, where gas, oil, and water are
separated. Natural-gas plants, by removing
impurities in the stream, deliver the
commodity at the specification needed.
Removal of contaminants includes the
elimination of hydrogen sulfide, carbon
dioxide, water vapor, mercaptans,
particulates, and natural-gas liquids. One
of the most commonly used techniques is
COMMENT
KEVIN PARKER
SENIOR CONTRIBUTING
EDITOR
to direct the flow
through a tower
containing an amine
solution, to remove hydrogen sulfide, carbon
dioxide, and other compounds from the
natural gas. As the gas stream continues
to be processed, further contaminants are
removed.
Natural gas plants are big business for
Dow Oil, Gas & Mining, which supplies
“chemistry, a solution, and every fluid that
is not oil or gas,” said Badhwar.
What impresses Badhwar is how the
technologies have responded to the
trend toward smaller-scale modularization
as a result of unconventional or shale-gas
development.
Focus on chemistry
While Dow technologies and fluids are
in use across the oil & gas value chain, in
gas processing Badhwar called out two:
UCARSOL amine solvents for acid-gas
removal and the UCARSORB adsorbent.
In an amine-solvent application, Dow
technical support, across a facility’s life
span, might include design, start-up, make-
up, and analysis.
UCARSORB NGL technology for the
recovery of hydrocarbons from a gas stream
is installed in plants for recovery of NGLs
from flare gas. The recently developed
technology uses polymeric beads with high
surface area to absorb the compounds.
Adsorption is the binding of molecules or
particles to a material surface. By separating
the flare-gas steam into lean gas and NGLs,
the gas can be applied to power generation
and the NGLs to liquification.
Further reduction of flare-gas emissions
will go a long way toward making natural
gas a cleaner energy source. OG
I NSIDE Cover Image: Honeywell UOP’s C4 Olefex process
converts isobutane into isobutylene.

COVER STORY
6 Hydrocarbon chemistry
transforms a century,
and still going
Natural gas and non-traditional polymer feedstocks
are an opportunity for plastics innovation.

FEATURES
12 Identify artificial-lift methods
12
for Gulf Coast wells
Further production possible from wells
in decline phase, but still viable

18 Disruptive technology meets

the intractable challenge
of fugitive-gas emissions
Optical-gas imaging makes gas clouds visible

NEWS
26 Intelligent solutions on display at OTC 2017
Smaller UPS units suited for offshore rigs
Platform integrates information and operations technologies
Control liquid levels within a mud-gas separator
Terminals connect with field devices in Ex zone 0

OIL&GAS ENGINEERING JUNE 2017 • 5

OG
COVER STORY
Honeywell UOP’s Oleflex process converts isobutane
into isobutylene. All images courtesy: Honeywell UOP

Hydrocarbon chemistry
transforms a century,
and still going
Natural gas and non-traditional polymer feedstocks are an
opportunity for plastics innovation
By Kevin Parker

I
n March 2017, four Honeywell UOP scientists received the
American Institute of Chemical Engineers’ (AIChE) 2016
industrial research & development award, fuels and petro-
chemical division.
The award recognized development and commercial-
ization of a methanol-to-olefins (MTO) process the four
helped develop as part of a team at Honeywell UOP, a compa-
ny which—under various guises—has for more than a century
played a significant part in the oil & gas industry.

6 • JUNE 2017 OIL&GAS ENGINEERING

 Moreover, the com-
pany, for the oil & gas
industry, is headquar-
tered in an unlikely loca-
tion: Des Plaines, Ill.,
just outside of Chicago.
Chicago meat-packer J.
Ogden Amour created
the National Hydrocarbon
Co. in 1914 to commer-
cialize 12 inventions held
by Jesse Adams Dubbs,
a kind of serial entrepre-
neur of his day. What was
National Hydrocarbon at
that time is Honeywell
UOP today.
One of Dubb’s inven-
tions led to a process
to demulsify oil, to yield
heavier fuel oil and
asphalt. A byproduct
was gasoline—at a yield
four times greater than
conventional refining
methods. Until then, gasoline had been used olefin-cracking process (OCP) that converts Figure 1: Once fully on-line,
as a solvent. With gasoline finding favor in heavier MTO-process olefin byproducts the MTO unit at Jiangsu
internal combustion engines, however, it led into lighter olefins. Together they make the Sailboat Petrochemical Co.,
to commercialization of the first conversion advanced MTO process, covered by more Ltd. will have an annual pro-
duction capacity of 833,000
technology for upgrading crude oil. (For more than 50 patents, and licensed to nine cus-
metric tons of propylene
on scientists and history, see sidebars.) tomers.
per year.
In February, Jiangsu Sailboat
Present and future Petrochemical Co., Ltd. started its MTO unit
Honeywell UOP technology still plays a role during a 10-day test. The full on-line unit
in refineries and chemical plants around the will have an annual production capacity of
world. The MTO process recognized by AIChE 833,000 metric tons per year, making it the
converts methanol from non-petroleum largest single-train MTO unit in the world
feedstocks such as coal, methane, petroleum (see Figure 1).
coke, or biomass—instead of petroleum—into The Sailboat facility will produce propyl-
polymer-grade ethylene and propylene. It’s ene for making acrylonitrile, used to make
a big deal because the plastics derived from clothing and fabrics, and high-performance
ethylene and propylene are among the most polymers used in automotive parts, hard
widely produced synthetic polymers, used hats, and other hard-plastic products. The
the world over in the manufacture of a wide plant also will produce ethylene for ethylene
range of packaging and goods. vinyl acetate copolymers, used to make
MTO development began in the 1980s, adhesives, foams, medical devices, and
when Honeywell UOP applied an innovative photovoltaic cells, as well as C4 olefins for
molecular sieve to its chemistry. It culminat- production of butadiene, an ingredient in
ed in 1995 with the first MTO demonstration synthetic rubber.
unit, operated by Norsk Hydro, now part of
Inovyn. Rising market
Not long after, Honeywell UOP and While the oil & gas industry has been in a
Atofina, now part of Total, developed the two-year slump, low prices for natural gas in
OIL&GAS ENGINEERING JUNE 2017 • 7
COVER STORY

In the U.S., natural gas is used

Figure 2: Clockwise from
top left, John Senetar led
modeling and design; Paul
Barger established catalyst
and process criteria; Dan
Kauff led the integration of
MTO and OCP processes;
and John Chen led the team.
Not just innovative; it’s
also important
the U.S. and for oil internationally has caused
a chemical-industry boom. In the U.S. alone,
264 new projects and more than $161 billion
in investment projects have been announced
since 2010, according to Transporting Growth:
delivering a chemical manufacturing renaissance,
a March report from PwC on behalf of the
American Chemistry Council (ACC).
to make plastic. For plastics
industries, low-cost, abundant
shale gas is an affordable feed-
stock and energy source. By
contrast, in most other parts of
the world, oil is used in making
plastics.
This historical anomaly bodes
well for North American resins
producers who anticipate strong
demand here in the U.S. and
internationally, according to an
April outlook report from ACC on
North American resins production
and sales in 2016.
In the U.S., with nearly half of
the announced investment since
2010 completed or under devel-
opment, shale gas and increas-
ing supplies of natural-gas liquids secure a
competitive advantage for U.S. chemical and
polymer resins producers.
As capacity expands, North American net-
resin exports have potential to rise dramati-
cally. They already bolster the sector’s trade
surplus. A stronger U.S. economy and key
end-use markets will increase domestic resin
consumption. However, continuing market
access and global supply chains, rather than
contractions or disruptions will be essential
to North American resins producers’ ability to
exploit their competitive advantage, say the

P resenting the American Institute of Chemical Engineers (AIChE)

2016 industrial research & development award, fuels and petro-
chemical division, to four Honeywell UOP scientists (see Figure 2)
ACC report authors.

Here in the U.S.

recognizes a technology that converts methanol from sources such
as coal and natural gas into the olefins that are the primary com-
ponents in the manufacture of plastic resins, films, and fibers.
This is especially critical in countries that lack domestic sources
of crude oil but are rich in coal or natural gas.
“The development of this technology over many years is a point
of great pride within Honeywell UOP, culminating in its commer-
cialization in 2013, with nine customers since that time,” said Jim
Rekoske, VP and chief technology officer at Honeywell UOP.
While many engineers and scientists contributed to the develop-
ment of the Advanced MTO process, the AIChE recognized that
John Chen led the research team; John Senetar led modeling and
process design; Paul Barger established the catalyst and process
criteria; and Dan Kauff led the integration of MTO and OCP pro-
cesses.
8 • JUNE 2017 OIL&GAS ENGINEERING
In February, Houston-based Enterprise
Products Operating LLC chose Honeywell
UOP’s C4 Oleflex technology to produce
425,000 metric tons per year of
isobutylene, used to make high-octane fuel
and high-performance synthetic rubbers and
acrylics.
C4 Oleflex technology uses catalytic
dehydrogenation to convert isobutane into
isobutylene, with comparatively low produc-
tion costs and high return on investment.
A platinum-alumina-based catalyst system
minimizes environmental impact. The process
maximizes operating flexibility, on-stream fac-
tor, and reliability, Honeywell said.
C3 Oleflex uses catalytic dehydrogenation
to convert propane to propylene.
 Keep Your Instrument Processes
Locked Down Tight.

Instrumentation that Keeps Danger at Bay

Put a fortress of protection around your process with
FS Functional Safety Series instrumentation from
Moore Industries. You can be confident that it will
safeguard your processes when you need it the most.
Our STA, SSX, SST, SRM, STZ and the NEW SFY
Functional Safety Frequency-to-DC Transmitter have
been designed and built to strict IEC 61508 standards,
ensuring safe and reliable function – particularly in
environments where hazardous or emergency situations
SFY Functional Safety are likely to occur.
Frequency-to-DC
Transmitter

Demand Moore Reliability

To learn more about our Functional Safety Series,

call (800) 999-2900, or go to: www.miinet.com/safetyseries

input #103 at www.controleng.com/information

COVER STORY
Company history
includes convolutions
H aving been established as the National Hydrocarbon Co. in
1914, UOP in 1919 changed its name to Universal Oil Products
and unveiled a new refining method. It licensed the technology to
refineries for a royalty fee based on production. Beginning in 1922 it
began signing licensees all over the world.
In 1931, a consortium of companies purchased UOP. Members
included names of great historical interest to the oil & gas industry,
including Shell, Texaco, ARCO, Gulf Oil, and elements of the by-then-
broken-up Standard Oil Co. UOP, in effect, became the center of
research for the oil & gas industry.
Also in 1931, Vladimir Ipatieff, a world-class chemist, joined UOP,
which from then on has had a reputation for attracting top talent. In
1933, Ipatieff introduced solid phosphoric acid as a catalyst to stimu-
late higher yields of gasoline.
In 1944, the oil companies that owned UOP placed it in a trust to
support the American Chemical Society.
In 1947, the use of platinum as a reforming agent led to a new
method of catalysis and became the world’s leading process for
making gasoline. This and other UOP technologies were key to
development of the petrochemicals industry in the 1950s.
UOP was sold to shareholders in a 1959 public offering.
In the 1970s, UOP was involved in the introduction of lead-free
gasolines.
By 1979, Signal Corp. owned 100% of UOP. Signal merged with
Allied Chemical Corp. in 1979, making UOP part AlliedSignal’s engi-
neered materials division. Soon the company was co-owned by
AlliedSignal and Dow Chemical Corp. In 1999, AlliedSignal bought
Honeywell, and Dow bought Union Carbide, which meant UOP was
jointly-owned by Honeywell and Dow.
In 2005, Honeywell announced that UOP was a wholly owned sub-
sidiary. Today, UOP has more than 5,000 employees working in 30
plants and offices in six countries.
Enterprise Products supplies midstream
energy services to producers and consumers
of natural gas, natural gas liquids (NGLs), crude
oil, petrochemicals, and refined products.
For more information:
www.uop.com
www.americanchemistry.com
https://plastics.americanchemistry.com
10 • JUNE 2017 OIL&GAS ENGINEERING
In addition to technology licensing,
Honeywell UOP will do the basic engineer-
ing design, control systems, catalysts, and
adsorbents for the plant located in Mont
Belvieu, Texas. It also will supply a modular
continuous catalyst regeneration (CCR) unit.
Because modular CCR units are factory
built, start-up on site is faster and the units
easier to operate due to common parts and
standardized training, operations, and main-
tenance.
“High demand from automotive, industrial-
machinery, and construction applications
are expected to drive growth in lubricant
production. At the same time, demand for
high-octane fuel is rising based on higher
fuel-economy standards,” said Mike Millard,
a Honeywell vice president and general man-
ager.
In Europe, demand for propylene continues
to rise at the same time the supply from
refineries and steam crackers is slowing.
Honeywell UOP says Oleflex is an on-pur-
pose, reliable route to fill propylene supply
gaps and support derivative production in
Europe.
Borealis AG selected UOP technology
for a proposed plant in Kallo, Belgium, that
converts propane into propylene. Borealis
proposes to use C3 Oleflex technology to
produce a targeted 740,000 metric tons
per year of polymer-grade propylene. When
completed, it will be UOP’s third C3 Oleflex
unit—and the largest—in Europe.
As in a previous case mentioned, besides
licensing, Honeywell UOP is providing the
basic engineering design as well as services,
equipment, catalysts, and adsorbents.
Borealis is a provider of polyolefins, base
chemicals, and fertilizers, with headquarters
in Vienna, Austria. A feasibility study for the
Kallo plant is under way, with final invest-
ment decision expected in the third quarter
of 2018 and potential start-up of the plant in
the second half of 2021.
In all, Oleflex has been selected for 39
projects by 46 producers globally since 2011,
including propane (C3), isobutane (iC4) and
mixed C3/iC4 service. Honeywell UOP has
commissioned 27 Oleflex units for on-pur-
pose propylene and isobutylene production.
Five more units in China and the Middle East
are expected to start up later this year. OG
is driving a smarter future
World-class precision. Quality technology. Award-winning energy efficiency.

Our experts are engineering variable frequency drives to be more communicative and
intuitive, while still enabling reliable, energy-efficient results. With VLT® and VACON®
offering powerful product lines, and a unique service portfolio with DrivePro®, Danfoss has
the right drive to meet the application demands and unique conditions of every industry,
even in harsh environments. Choosing the right drive and optimizing your entire system
can yield potential energy savings of up to 60 percent. Danfoss is committed to innovating
drives that can address climate change, rapid urbanization, and successful and sustained
water and wastewater management, so you can tackle your industry’s challenges.

To discover solutions for the future, visit www.danfossdrives.com

input #104 at www.controleng.com/information

5bn
worldwide will
benefit daily from
Danfoss Drives
by 2025
PRODUCTIVITY anD OPTIMIZaTIOn
Identify artificial-lift
methods for Gulf
Coast wells
Further production possible from wells in decline phase, but still viable
A
By Bob Bishop s much as every oilfield operator
might dream that a high-producing
oil or gas well will experience
remarkable recovery rates for
years with no noticeable drop-
off in production, every well
will peak and then enter a decline stage,
whether steadily or precipitously. When the
inevitable decline occurs, it falls on the oil-
field production company to determine if, or
how, the well can be resuscitated.
When a well’s production rate drops
below critical velocity, it is almost inevitable
that it will eventually stop producing. The
actual rate of decline and ensuing produc-
tion must be taken into consideration when
determining a well’s ultimate future. With
today’s commodity prices, many operators
are faced with spending money on artificial-
lift systems that can improve recovery rates
or simply choosing not to address low or
non-producing wells before moving on to
the next project, where the entire process
begins again.
Another factor that may influence the
well’s viability is its location. The Gulf Coast
region is close to major pipelines and
processing facilities, thereby enjoying pre-
mium commodity prices. This area spans
the southern tip of Texas along the Mexico
border, encompassing the Eagle Ford Shale
play, heads east through Houston, then
culminates in the inland waters and land
around Louisiana, including the Tuscaloosa
Shale play. The topography in most of this
area is coastal plains, differing, for instance,
from that found in the Bakken or Permian
Basin region.
12 • JUNE 2017 OIL&GAS ENGINEERING
In addition to the type of land formations
encountered during the drilling process,
wells in the Gulf Coast region can be prone
to producing paraffin, scale, and sand, as
well as having high levels of entrained
carbon dioxide (CO2) and hydrogen sulfide
(H2S) in some areas. Knowledge of these
conditions—as well as their effect on pro-
duction rates—will help determine the best
drilling methods, surface equipment, and
systems to use to maximize initial produc-
tion rates.
They also will play a critical role in indi-
cating which artificial-lift methods should
be used to revive wells that have seen
declines in production. The following high-
lights the forms of artificial lift that should
be considered by Gulf Coast operators
whose wells are experiencing production
declines.
Operator challenge
The first challenge for the operator of wells
that have seen a decline in production is
to understand that typically no artificial-lift
method will increase a well’s recovery rate to
a level that exceeds its initial production rate.
Instead, the operator should look at the
use of artificial lift as a kind of “tune-up” for
the well, or a way to return its production to
the original production curve, or even cre-
ate a new curve that allows production to
decline at a slower rate than expected.
There are a few physical challenges that
must be addressed and overcome by Gulf
Coast operators. Chief among them is the
amount of fluid and the gas-to-liquid ratio
(GLR) that is produced by a well daily. This
can range from less than 10 barrels
a day to more than 2,000 barrels a
day and GLRs from 1:1 to more than
10,000:1, sometimes in the same play,
such as in the Eagle Ford Shale.
Another piece in the puzzle is the
pressure of the reservoir. Again,
there can be large variations in pres-
sure, depending on where the well is
located. Some low-pressure reservoirs
can have pressure rates as low as 200
psi (14 bar), while some wells—espe-
cially those situated in the Haynesville
Shale—can have pressures up to
10,000 psi (700 bar).
As mentioned, the levels of paraf-
fin, scale, and sand that are produced
also will play a role in determining the
type of artificial-lift method to deploy. The and scale is to find an artificial-lift system
best way to prevent the buildup of paraffin that can keep the tubing clean. Collecting
A view from the oil patch
Knowing that every well and every production region
is unique, an operator in the Gulf Coast agreed to par-
ticipate in a brief question-and-answer session regarding
the challenges he faces in optimizing or reviving produc-
tion in declining wells and how he overcomes them.
Here’s what he had to say:
Q: What are the well conditions like in your
region?
A: Fluid production may range from several barrels a
day to several thousands of barrels per day. Gas-to-liquid
ratios (GLR) also vary from as low as 1,000 cubic feet
(Mcf) per barrel to 10 or more Mcf per barrel. We also
see reservoir pressures as low as several hundred psi to
more than 10,000 psi. On top of all that, we may see par-
affin, scale, and sand production.
Q: What artificial lift technologies are you
using in your region?
A: Early in the well’s life cycle, when it is still at or
near critical velocity, we are using plunger lift, typically
with friction-bypass plungers that reduce or even elimi-
nate shut-in times. Once the well’s production drops
below critical velocity, and depending on the GLR, we
typically install a bar stock “cleanout” plunger. We will
also install a continuous gas-lift system on wells with
higher fluid rates, ranging from 200 to 2,000-plus bar-
rels per day. We have also started combining plunger lift
Figure 1: The two-piece
bypass plunger increases
daily production for
younger wells. All
images courtesy:
Dover Artificial Lift
with gas-lift systems on wells that have excessive paraf-
fin and scale production. This combination allows us to
effectively run the well on an intermittent basis to save
injection gas.
Q: What are the main challenges in your
region that artificial-lift technologies can
address?
A: For wells with very low GLRs, we have been suc-
cessful when installing multi-stage systems. This allows
us to operate a plunger-lift system effectively with GLRs
as low as one Mcf per barrel on some installations. For
vertical wells with large perforation intervals, we have
found success by employing gas lift several thousand
feet below the packer with a “dip tube” that reliably low-
ers the flowing bottom-hole pressure or an enhanced
annular velocity (EAV) system that ensures adequate
flow velocity through the entire length of the well.
Q: What are typical results with plunger-lift
and gas-lift applications?
A: Typical results for both plunger lift and gas lift
on wells that have fallen below critical velocity would
be the restoration of production to its natural decline
curve. Even wells that have been “loaded” for substan-
tial periods will often recover to their previous produc-
tion levels with the correct application of plunger-lift
and gas-lift systems and technologies.
OIL&GAS ENGINEERING JUNE 2017 • 13
PRODUCTIVITY anD OPTIMIZaTIOn
Figure 2: Velocity of flow
is maintained below the
packer to ensure there are
no fluid accumulations.
Figure 3: Dip tubes are for
lowering the flowing
bottom-hole pressure in
wells with long perforated
intervals and large casing.
14 • JUNE 2017 OIL&GAS ENGINEERING
when the operator’s need is to revitalize
declining wells:
and controlling any CO2 and H2S that is pro-
duced also is a critical consideration, with
stainless-steel materials usually required to
prevent corrosion within the well’s tubing
and casing.
The solution
After determining the conditions that are
hampering a well’s production rate, and
knowing that they will need to be addressed if
that rate is to be fully recovered, the next step
is identifying the best artificial-lift method for
optimal production.
With that in mind, several artificial-lift tech-
nologies have risen to the fore in instances
‘ The Gulf Coast
region is close to
major pipelines and
processing facilities,
thereby enjoying
premium commodity
prices.
’
• First-responder bypass plunger:
Designed to operate in a flowing well
and make more trips with faster fall
times for continuous fluid removal, the
two-piece bypass plunger increases
daily production for younger wells. The
sleeve portion is held in the lubricator
over a rod by the well’s flowing pres-
sure while the ball falls to the bottom
of the well. As liquid loading begins in
the well, the reduced flow allows the
sleeve to fall. When the sleeve reaches
the bottom, the ball seats in the sleeve,
creating a seal. Pressure builds, causing
the ball and sleeve to travel together
while lifting fluid to the surface. At the
surface, the rod in the lubricator sepa-
rates the ball from the sleeve, and the
process begins again (see Figure 1).
• Enhanced annular-velocity (EAV) sys-
tem: EAV systems use properly sized
tubing and gas-lift valves above a packer
and a selectively sized injection string
with internally mounted gas-lift valves
below. Injected gas flows into the annu-
lus, travels through the crossover-flow
adapter and into the injection string.
When the deepest point of injection
is obtained, the gas exits the injection
string, mixes with the produced gas and
fluids, and flows up the annular area.
The fluid and gas then flow through the
adapter into the production tubing. The
 6HWWLQJVWDQGDUGVLQ
UREXVWFRPPXQLFDWLRQV
3URYHQFRPPXQLFDWLRQQHWZRUNVIRU
WKHRLODQGJDVLQGXVWU\

+DUVKHQYLURQPHQWVKD]DUGRXVDUHDVHOHFWURPDJQHWLFLQWHUIHUHQFH²
MXVWVRPHRIWKHFKDOOHQJHVRLODQGJDVFRPSDQLHVIDFHHYHU\GD\
:LWKRXUFRPSUHKHQVLYH58**('&20DQG6&$/$1&(QHWZRUN
FRPSRQHQWVKLJKO\UHOLDEOHDQGVHFXUHGLQGXVWULDOQHWZRUNVIRURLO
DQGJDVDSSOLFDWLRQVFDQHIIHFWLYHO\EHLPSOHPHQWHGDORQJWKHHQWLUH
YDOXHDGGHGFKDLQ²IRUXSVWUHDPPLGVWUHDPDQGGRZQVWUHDP
3'3$$

([SHUWLVHLQLQGXVWULDOQHWZRUNV
input #105 at www.controleng.com/information

VLHPHQVFRPFRPPXQLFDWLRQVIRURLOJDV
PRODUCTIVITY anD OPTIMIZaTIOn
EAV system maintains adequate
velocity of flow below the packer
to ensure that there are no fluid
accumulations, heading, or liquid
loading (see Figure 2).
• Dip tubes: Dip tubes are ideal
for lowering the flowing bottom-
hole pressure in wells with long
perforated intervals and large
casing. A crossover-flow adapter
and mini-wellbore below the
packer are used to facilitate the
deepest point of gas injection
without applying any additional
backpressure on the formation.
A typical installation might have
23/8-in. tubing above the packer,
an adapter with a 27/8-in. tailpipe
below the packer and a 1-in. or
11/4-in. internal-injection string
inside the tailpipe. Compressed
gas travels through the annulus
and crossover-flow adapter into
the injection string. The gas then
exits a gas-lift valve and mixes
with the produced fluid and gas
in the injection string, tailpipe
annulus. The fluid and gas then
flow through the adapter into the
production tubing. During opera-
tion, the injection-gas pressure is
contained in the injection string,
isolating it from the perforated
interval and optimizing recovery
rates (see Figure 3).
• Multi-stage plunger tools: For
wells with low gas but high liq-
uid levels, efforts aimed at their
lift to the surface can benefit
from a multi-stage plunger sys-
tem. These systems use more
of the well’s own energy to help
lift liquids and increase produc-
tivity. During the first cycle, the
lower plunger carries the fluids
up the tubing. Upon shut-in,
the ball check engages, which
holds the fluids until the upper
plunger falls from the surface
through the liquid and settles
at the tool. Simultaneously, the
16 • JUNE 2017 OIL&GAS ENGINEERING
Figure 4: For wells with low gas but high liq-
uid levels, efforts aimed at their lift to the sur-
face can benefit from a multi-stage system.
lower plunger falls back to the bot-
tom. During the ensuing cycle, the
upper plunger delivers fluids from
the tool to the surface, while the
lower plunger delivers more fluid
to the tool. Creating two plunger-
lift systems in one allows the well
to produce liquids in stages, which
allows it to produce larger volumes
while utilizing its own energy (see
Figure 4).
Most of these artificial-lift methods
have been available to oilfield opera-
tors for about a decade and have a
proven track record in the Gulf Coast
area. In fact, once a successful form
of artificial lift is identified, its users
will typically stay loyal to it for years.
The trick, of course, is identifying and
implementing the one that works
best for the specific conditions and
application, while still being aware
that new technologies may prove to
be even better for a well.
Artificial-lift options
It’s inevitable that a well’s recovery
rate will decline at some point.
When this happens, the operator
has two choices: do nothing
or try to return the well to its
previous production levels by
using an artificial-lift method. In
the Gulf Coast region, the unique
characteristics of the formation itself
play a significant role in determining
which method of artificial lift will be
most efficient and reliable. Selecting
the right one for the right well will
go a long way in optimizing returns
and profitability for wells that have
begun showing their age. OG
Bob Bishop is the director of Gas Lift for
Dover Artificial Lift, Houston. Dover Artificial
Lift is part of the Energy segment within
Dover Corp. For more information:
www.doverals.com
 SERVICES DESIGNED
TO MAXIMIZE PRODUCTION
from contract compression to maintenance.
At Archrock, your production is our priority. That’s why we offer industry-leading
experience, expertise, and resources – all designed to help you maximize your production.

archrock.com

input #106 at www.controleng.com/information

REGULATION AND TECHNOLOGY
Disruptive technology meets
the intractable challenge
of fugitive-gas emissions
Optical-gas imaging makes gas clouds visible
I
By Laith Amin n 2016, regulatory authorities in North
America started taking seriously the fact
that methane is a very powerful greenhouse
gas in its raw, or unburnt, form. They also
took note that recent advances in thermal-
imaging technology had lent credence to
the assertion that fugitive emissions, or unin-
tentional gas leaks, are happening on a much
greater scale than ever before.
Combined with an unprecedented expansion
in U.S. onshore extraction and processing of
natural gas, a basis for a perfect storm exists.
An estimated $2 billion of natural gas is lost
each year to leaks.
The idea of natural gas as a clean fuel that
can contribute to a reduction in urban pollu-
tion and greenhouse-gas emissions is well-
accepted both within the oil & gas industry and
beyond. Even the most prominent voices advo-
cating for non-fossil-fuel renewable technology,
including Greenpeace, publicly have accepted
the important role natural gas plays in acting
as a clean-fuel stepping-stone from energy
based on coal or oil toward energy less reliant
on fossil fuels.
This strategy of expanded exploitation of
natural gas is working, and globally so. For
example, on April 21, 2017, the UK enjoyed
its first 24-hour power-generation period com-
pletely free of coal since the year 1880. In the
U.S., natural gas has surpassed coal as the
nation’s leading power-generating fuel source,
with its growth-rate surpassing any other
energy source for power generation.
Reasons for uncertainty
Climate-change commitments have been made
by many western, economically developed
countries. Gas is a key weapon in the fight
18 • JUNE 2017 OIL&GAS ENGINEERING
against CO2 emissions. In Asia, growing unease
about air quality in post-industrial China has
led to some impressive deals with natural-gas
supply countries such as Russia and Australia,
but it is also this very supply chain that
sometimes calls into question the greenhouse-
gas-reducing credentials of natural gas and its
categorization as a clean fuel.
In the U.S., awareness of the raw-methane
emissions environment in the natural-gas pro-
duction and supply-value chains has been grow-
ing. Emissions traces seen from space mirror
the concentrations of activity around unconven-
tional oil & gas production.
Methane is a powerful greenhouse gas in
its unburnt form. In fact, raw methane is 86
times more potent as a greenhouse gas than
CO2 when impact is considered over a 20-year
period. Ultimately experts agree that if natural
gas is to rival coal as a means of reducing
greenhouse-gas emissions, then emissions of
raw methane in the supply chain must be held
to less than 1% of total production.
In the U.S., raw-methane emissions esti-
mates have been ranging from a lower-level
estimate of 2% of overall production to around
17%. Alarmingly, the U.S. Environmental
Protection Agency (EPA) in recent years
has increased its estimate of emissions in
upstream gas operations by 134%, bringing the
overall total to 1.4% of total production (which
from time to time they flag as a possible under-
estimation), or 40% higher than the target that
must be met for gas to provide comparative
advantage over coal.
Methods of measurement
But why do these estimates vary so widely?
To answer this question, it is essential also to
examine the method of measurement itself—
and there are several different methods used.
One method to estimate leak-emissions
rates from equipment items having the poten-
tial to leak in any plant environment is simply to
apply emissions factors and schedules provided
by regulators. The emissions-per-equipment
item then can be aggregated to a plant total
to calculate a volume for undesirable leaks,
or fugitive emissions. This method takes no
account of the actual leak rates, or if in fact the
equipment is leaking at all.
The second, so-called incumbent, method
is what is referred to as EPA Method 21. A
measurement instrument, i.e., a flame ioniza-
tion detector, is held near the stream of a sus-
pected leak and measures the concentration of
the fugitive gas in the atmosphere (typically on
a parts-per-million basis).
It is difficult to underestimate the impact of
Method 21-type emissions measurements on
the oil & gas industry in recent decades. This
method verifies that there is in fact a leak—
vital information that can be passed on to repair
programs. In this way, significant greenhouse-
gas reductions have been possible over the
years, not to mention the valuable gas retained
in the supply chain for end use.
However, the historic success of Method 21
testing still does not explain the wide variances
in estimates for fugitive-greenhouse gas emis-
sions, nor adequately explain why, if the meth-
od is as effective as supposed, a methane-
emissions footprint is visible from satellites to
an extent that alerts regulators to a growing
problem. These questions themselves illustrate
our increasing sophistication, in terms of tech-
nology and otherwise, in informing ourselves
as to the nature of fugitive-gas emissions.
Seeing is believing
One technology—which the EPA refers to as
optical-gas imaging (OGI)—recently has been
added to the list of regulator-allowable methods
of measurement. It is essentially an infrared (IR)
sensor capable of operating within the thermal
spectrum. It generates an image of a gas leak
that can be seen with the human eye. For the
first time, users see what a gas-concentration
reading from a Method 21 test never could
allow them to see: a gas cloud.
Millions of TV-news viewers were introduced
to OGI when they saw EPA footage of the
Aliso Canyon gas leak on Oct. 23, 2015. It was
reported to be the worst gas leak in U.S. his-
tory, with 97,100 tons of methane and 7,300
tons of ethane released into the atmosphere.
‘ In2017April,the UK
Comparisons have been made to the equiva-
lent carbon footprint of 1.4 million cars or six enjoyed its
coal-fired power plants.
The Aliso Canyon leak showed us the impor-
first 24-hour
tant role OGI can play in measuring a leak in power-
terms of how much—something that Method
21 could not do. However, the more OGI is generation
deployed the more practitioners realize that, con-
trary to what EPA schedules of leak estimates period
assume, a small number of very large leaks
often are responsible for most of the emissions
completely
in a defined scope of study. Further, many of the free of coal
other equipment items are either not leaking at
all or have such small emissions rates that they since the
’
are not economically viable to fix.
Compare this to the inability of the incum- year 1880.
bent method of measurement, Method 21, to
provide a mass-leak rate. You could survey your
entire plant and a) not know which leaks are
large or small, and b) be unaware of a super-
leak coming from a part of your plant not sur-
veyed at all.
This inability to provide data that supports
insight into the impact of a leak-repair program,
for example in terms of priority, is cause for seri-
ous concern. There is growing acceptance that
the scenario has led to significant under-estima-
tions. Additionally, the idea that 80% of the emis-
sions can be caused by 20% of the leaks has led
to speculation about the viability of emissions
estimates and steps taken to limit them.
Which way now?
While OGI has been a massive leap forward
and broadly welcomed by the industry, one
fact remains: an IR sensor cannot provide
quantitative information about a fugitive
emission. It can only provide a qualitative image
of a leak—and one that is periodically apt to
either show false positives (e.g., of a moisture
vapor cloud) or false negatives (e.g., because of
range, focus, shadows or other issues).
Every engineer knows that “you can’t
improve what you can’t measure.” So what is
the way forward here? Energy companies have
been incentivized to invest billions in the devel-
opment of gas production and supply infra-
structure. Coal plants have been shuttered and
emissions-reduction commitments have been
OIL&GAS ENGINEERING JUNE 2017 • 19

CUSTOM-DESIGNED
SENSOR SOLUTIONS.
PROVEN RELIABILITY.
At Pyromation, we’re dedicated to serving
the Oil & Gas industry with a comprehensive
line of RTDs, thermocouples and thermowell
assemblies. Our highly engineered,
custom-designed solutions meet industry
certifications and provide superior quality
control. Find out how we can meet your
temperature sensor needs.
GET A QUOTE!
pyromation.com/oilandgas
260.209.6341
NEC Rated · FM/CSA Approved
input #107 at www.controleng.com/information
REGULATION AND TECHNOLOGY
made on the strength of the important role that natural gas
will play in the reduction of greenhouse-gas emissions.
Given that more credible technologies such as OGI are
starting to be recognized by regulators, what can be done
to anticipate this emerging realization that a lack of fugitive-
emissions control in the production environment could be
jeopardizing the agreed-upon environmental credentials of
this clean burning fuel?
It is difficult to prescribe a solution to this that will work
for all industry, but one fact is clear: without the ability to
quantify an emission from a leaking equipment item in a pro-
cess, any leak-repair program will have to be based to some
extent on something other than science. Indeed, if the logic
follows that about 20% of a given plant-environment fugitive
emissions are large leaks that are economically viable to fix,
then a technology’s ability to quickly determine which 20% of
leaks those are will be key.
Once those specific repairs are prioritized, suddenly the
operator is in a position where a disproportionate reduction
has been made to total plant emissions in a much shorter
timeframe and at greatly reduced cost. Furthermore, if opera-
tors also can perform emissions quantification work on a
second, subsequent survey, then they (most probably for the
first time) can generate a reliable number for the reduction
of greenhouse-gas emissions at the plant as a result of leak
detection and repair work. This number could then be costed
against the monetization value of the gas and compared to
the cost of leak detection and repair to determine a return on
investment calculation for the activity itself.
Final words
While this might seem utopian, it is closer to reality than
one might expect. Global consulting firm Advisian is bringing
together multiple technology elements with data science to
create a platform for the digital quantification of fugitive-gas
emissions. For us, a mix of artificial intelligence, unmanned
aerial-vehicle technology, and IR sensors has produced very
exciting results. We have learnt that with the application of
advanced mathematics to image processing, we can generate
very accurate mass leak-rate analysis from an image itself,
without having to go to the leak source in person.
Others also have very interesting developments in process
too, but ultimately one thing is clear: once this technology is
released it is going to have a disruptive effect on the way in
which fugitive emissions surveying will be done in the future,
and one that undoubtedly will allow natural gas to reclaim its
rightful position on the world stage as a clean-burning fuel that
can ensure our contribution to carbon footprint reduction for
many years to come. OG
Laith Amin is the senior vice president, Digital Enterprise at Advisian.
For more information, go to HTTP://digital.advisian.com
20 • JUNE 2017 OIL&GAS ENGINEERING
 We proudly salute manufacturing and invite you to
explore and celebrate the success stories of
these participating manufacturing innovators:

• Baldor • Detechtion • Moore Industries

• Unitronics • WAGO Corporation

Look for the special Innovations videos at:

www.controleng.com/innovations

og201706_innovHlf_LEAD.indd 1 5/24/2017 8:47:47 AM

ADVERTISEMENT

Detechtion Enables the Digital Oilfield with its Leading Industrial IoT Platform
Detechtion Technologies™ is the market leading Industrial IoT and mobile application
provider enabling the digital oilfield. Through its Enalysis™, Enbase™ and Fieldlink™
product lines, Detechtion offers solutions for chemical injection, compression,
and other production operations. These products and services span telematics,
monitoring, control, predictive analytics, visualization and integration with other
systems so that the vision of the digital oilfield will finally be achieved. Over 100
customers and thousands of users depend on Detechtion Technologies™ to monitor
and manage over 10,000 assets worldwide.
Natural gas producers often struggle trying to get a handle on their compressor fleet
performance. With units scattered over broad territory, sometimes it’s difficult to
Chris Smith
know which are even running. Some bits of information may trickle in, but users are President and CEO
a long way from the kind of data transparency they need to optimize operations.
Enbase™ for Compression Monitoring, Control and Telematics and can make the view much clearer. Using a
solution with simple hardware and cloud-based communications, users can control installations while gathering
performance data remotely. They can drill into condition and efficiency details for any installation. Algorithm-
based models from the Enalysis™ product line simplify the presentation to support effective decision making.

Contact info@detechtion.com.com | 713-492-0008

www.detechtion.com

input #108 at www.controleng.com/information

 A DV E R T I S E M E N T

Designed for Food Safety: Dodge Mechanical Products

and Baldor-Reliance Motors
Food and Beverage processing equipment should be designed, used, and maintained with
food safety principals as a priority. Failure to adhere to these practices can cost companies
thousands, if not millions, to resolve. It is critical that food and beverage companies not only
consider the initial purchase price, but also the Total Cost of Ownership (TCO) that includes
the cleanability, maintenance, and reliability of the equipment provided by suppliers who
understand the principles of sanitary design.

Industry leading Dodge® mechanical and Baldor-Reliance® electrical products

help ensure the highest level of food safety, reliability, and
performance in the food industry.

Long before we invested in the people, equipment and

material required to produce Dodge washdown reducers and
Baldor • Reliance Washdown Duty motors, we invested our time
and attention in listening to equipment designers, operators and
plant maintenance engineers. We learned about their toughest
processing applications in the food and beverage industry. We took
notes when they shared their wish lists of product capabilities and characteristics.

That was over 30 years ago, and we’re still listening to customer input.
That is why Baldor-Reliance Stainless Steel motors and Dodge Ultra Kleen gear reducers are
engineered to meet the toughest demands of food production and processing. These products
have been designed, tested and certified to meet IP69K requirements for water protection, and
provide the necessary protection from severe washdown conditions without allowing caustic
chemicals or water to enter the product.

Baldor-mediarelations@abb.com | 479-646-4711 | www.baldor.com

input #109 at www.controleng.com/information
 A DV E R T I S E M E N T

SFY Functional Safety Frequency-to-DC Transmitter

Has SIL 3 Capability
The newest addition to the expanding line of the
Moore Industries FS Functional Safety Series
is the SIL 3 capable SFY Functional Safety
Frequency-to-DC Transmitter. The 2-wire
(loop-powered) SFY is ideal for use in your
Safety Instrumented System (SIS) in a wide
range of process and factory automation
monitoring applications, providing reliable and
accurate monitoring of frequency or pulse
signals in SIS. The SFY has been certified by
exida after rigorous evaluation, to ensure con-
formance with strict IEC 61508:2010 standards
for safety-related applications and is approved
for single use in SIS up to SIL 2 and in a redun-
dant architecture (1oo2, 2oo3, etc.) up to SIL 3.
The Moore Industries FS Functional Safety Series
The SFY helps provide over speed protection
by sending signals that warn the logic solver to as well as pulse and frequency output transducers from
alarm or shut down the monitored device for plant, rotating equipment.
personnel, and process safety. For example, the
SFY can be used for critical compressors that need The SFY comes with Free Intelligent PC Configuration
independent safety protection as part of the SIS. Software (Windows® compatible) that allows easy and
quick configuration. It is input-to-output isolated and
RFI/EMI protected, making it resistant
to unpredictable ground loops and the
harmful effects of plant and
equipment noise.

The SFY converts

the input signal
to a proportional
isolated 4-20mA
output ready for
Industrial compressor direct interface The SFY Frequency-to-DC Transmitter with Display
with a Safety System,
Safety practitioners will find the SFY perfect for readout instrument, recorder, PLC, DCS, or
use in a variety of industrial and factory automation SCADA system. It is also available in explosion-
SIS applications that include the monitoring of proof/flameproof housings for use in hazardous
turbine flow meters, magnetic pickups, dry contact area environments.
closures, variable frequency drives, turbine
tachometer generators, motor and conveyor speed Download the SFY data sheet for more information.

For the latest innovations and news from Moore Industries, visit: www.miinet.com/blog
input #110 at www.controleng.com/information
 A DV E R T I S E M E N T
Increase your control system’s flexibility
with a modular, all-in-one PLC from Unitronics
For over 25 years Unitronics has manufactured PLCs
with integrated HMI panels; today, Unitronics offers a
diverse line of mature automation solutions alongside
innovative new products. While other manufacturers
are only just introducing single-unit PLC and HMIs,
Unitronics is already improving and perfecting the
all-in-one concept. The new UniStream line offers a
modular PLC+HMI, allowing users to design a control
system unique to their application.
Creating a customized, all-in-one PLC with UniStream
takes only three easy steps. The user selects an HMI
panel; Unitronics offers 7", 10.4" and 15.6" color-touch-
screens for easy operator interface.
The powerful, modular CPU mounts onto the back
of the panel, and then the user chooses the I/O
and communication modules to get the exact
configuration their application requires; these Uni-IO
and Uni-COM modules snap in next to the CPU.
The result is a single integrated controller with PLC,
HMI and onboard I/O.
This modular approach to the all-in-one concept
allows for incredible flexibility. The CPU and HMI
together have two USB host ports and a USB
programming port, two Ethernet ports, a CANbus
port and an RS485 serial port.
USA.Sales@Unitronics.com | Tel: 1-866-666-6033 | www.unitronics.com
input #111 at www.controleng.com/information
The UniStream supports a range of communications,
including EthernetIP, and features like remote
access via a VNC connection. I/O modules have
options for digital and analog I/O configurations,
including high-speed and temperature measure-
ments. A single CPU can support 2000 I/O points,
with both local and remote expansions, for countless
possible configurations.
Furthermore, the UniStream platform is entirely
programmed in one software. Ladder logic,
communication configuration and HMI design are
all programmed using the UniLogic software.
With features like user-defined function blocks and
options for code reuse, UniLogic is intuitive and user-
friendly. UniLogic also supports a full suite of utilities
for remote access and monitoring, like real time video
streaming, as well as data logging and back up.
UniStream with IO
Wide IO
Unitronics aims to provide the best possible
experience to our users: our all-in-one PLC and HMI
units are easy to set up and to use; the latest version
of our single-environment programming environment
is always available for download; and, should any
problems arise, every user has unlimited access to
our market-leading technical support for no
additional cost.
 A DV E R T I S E M E N T

A Legacy of Innovation: WAGO Technology

Withstands the Test of Harsh Conditions
WAGO Corporation provides safe and reliable
Interconnect, Electronic Interface, Terminal Block and
Automation solutions. Equipped with CAGE CLAMP®
Spring Pressure Connection Technology, our products
provide maintenance-free wiring and can withstand
extreme conditions such as temperature, shock,
vibration, and electrical noise. Coupled with approvals
for hazardous environments, WAGO products contribute
to making safety a priority. Innovations include:

New XTR Intrinsically Safe Modules: Solutions

in Extreme and Hazardous Environments
With the ability to withstand temperatures from -40 °C
up to 70 °C, vibrations up to 5 g, operating altitudes of up
to 5,000 m above sea level and enhanced immunity to
electromagnetic interference, 750 XTR Series modules
are the solution for applications within extreme environ-
mental conditions. WAGO is now introducing compact,
intrinsically safe I/O modules in our eXTReme platform.

This combination of intrinsic safety and resistance to

extreme ambient conditions makes the WAGO-I/O-SYSTEM
750 XTR a special asset for systems in the oil and gas
industry. The 750 XTR Series is a complete automation
platform offering PLCs, bus-couplers and I/O modules
for control or remote I/O applications. For more info:
www.wago.us/xtr-exi

EPSITRON® ECO Power: The Power Supply for

Hazardous Locations
EPSITRON® ECO power supplies are compact and
housed in a robust metal enclosure enabling space-
savings and increased efficiency without sacrificing
reliability. Built to operate in a wide temperature range
of -20 °C to 60 °C and with hazardous location approvals
(UL Class 1, Division 2, ATEX and IECEx), these ECO
power supplies can be employed in a variety of
applications. ECO Power supplies are the versatile,
reliable solution in any industrial application. For more
info: www.wago.us/epsitroneco

To see our company video, please visit www.wago.us/company-video

info.us@wago.com | (800) DIN-RAIL | www.wago.us

input #112 at www.controleng.com/information
THE UPSTREAM OIL & GAS BELLWETHER
Intelligent solutions on
display at OTC 2017
WirelessHART gas detection for upstream
toxic and combustible gas
United Electric Controls, provider of safety, alarm,
and shutdown technology, introduced a WirelessHART
gas detector that can monitor presence of harmful
gases in offshore installations for more than five years
without battery replacement. The Vanguard gas detec-
tor interfaces with existing offshore platform networks
for continuous detection of hydrogen sulfide (H2S) and
combustible methane gases.
Toxic H2S and combustible CH4 are among the most
widely produced and most dangerous industrial gases.
H2S is pervasive in mud-logging units, mud-pit rooms,
drilling derricks, mud-gas separators and well-test
areas. Offshore oil platforms can emit large volumes
of CH4 during gas flaring and storage-tank venting, or
while operating dehydrators and pig launchers.
Wireless technology helps make plants, drilling
platforms, and floating production platforms safer by
reducing continuous monitoring costs by up to 90%,
said Will Chin, a company vice president. Lithium bat-
tery technology can extend battery life well beyond
five years.
www.ueonline.com
Smaller UPS units suited for offshore rigs
Ametek Solidstate Controls, maker of custom-
ized uninterruptible power supply (UPS) systems,
announced the first release of its SlimLine product
enhancement, to meet the need for smaller UPS
units for offshore rigs.
The company said the SlimLine cabinet design has
the smallest footprint in the industrial UPS industry.
It can be applied across its digital ProcessPower
UPS, industrial digital-battery chargers and recti-
fiers, bypass solutions, and stand-alone digital
ProcessPower inverters.
The enhancement allows for more efficient opera-
tions within the oil & gas market, while maximiz-
ing the limited square footage on drilling platforms
where space is at a premium.
www.solidstatecontrolsinc.com
26 • JUNE 2017 OIL&GAS ENGINEERING
Terminals connect with field
devices in Ex Zone 0
Recently introduced Beckhoff ELX series
EtherCAT terminals with intrinsically safe inputs/
outputs and compact design enable direct con-
nection of field devices in hazardous areas,
classified Zones 0, 1 and 2. PC-based control
combines automation and process technology,
including diagnostics from the EtherCAT system.
Beckhoff offers a system-integrated solution
for explosion-protection requirements—a com-
prehensive range of explosion-proof components
facilitate barrier-free solutions across hazardous
areas up to Zone 0/20.
The ELX series expands the EtherCAT termi-
nal system, which already offers more than 100
different signal types, with I/O terminals that
feature explosion protection. The combination
of compact I/O modules and integrated safety-
barrier functionality results in high-performance
EtherCAT terminals for connecting intrinsically
safe field devices. The slim terminals reduce
space requirements in the control cabinet by up
to 50%.
The company said the solution offers clear
advantages, particularly in hazardous areas with
confined spaces that typically require elaborate
and expensive enclosure technology. Eliminating
the need for external barriers significantly
reduces installation effort and costs.
With the upcoming certification in compliance
with ATEX and IECEx, the ELX series meets all
industry-specific guidelines for explosion. The I/O
terminals have either 12 mm housings with up to
four intrinsically safe inputs or 24 mm housings
with up to eight similar inputs.
Benefits include time-stamp functionality,
which ensures measurement accuracy and pre-
cise synchronization.
www.beckhoff.com
 How to control liquid levels within a mud-gas separator
Weir Oil & Gas, upstream provider of pressure-
pumping and pressure-control equipment and services,
said it is removing the guesswork from managed-
pressure drilling and flow-back operations with its line
of pressure-control intelligent systems.
“We are empowering customers through a live
stream of real-time information that can be stored and
applied in a variety of analytic and reporting capabili-
ties,” said Paul Coppinger, president of Weir Oil & Gas.
Each of the “intelligent” product-line solutions con-
nect sensors outputting real-time information to a con-
trol unit. Data is relayed to the user via a cloud-based
portal. In this arrangement, Weir said, “The system
alarms sooner to ensure the operator has more time
to adjust the flow from the choke, or for the choke to
adjust automatically.”
Weir said it is operating multiple pressure-control
intelligent systems in the field. For example, the
Mathena mud-gas separator intelligent system (MGS-
ISC), which controls liquid levels within a mud-gas
separator, is an industry first, the company said, in
helping to prevent overflows.
The MGS-ISC is successful at mitigating issues in
the Bakken Field, where fluid overflow into the gas
vent line is common. In fact, the company said, for its
users it is alleviating multiple overflow incidents per
month.
Other elements within the intelligent systems
include the following:
• The Mathena vent-gas analyzer and intelligent flow-
meter system that integrates a gas-flowmeter and
vent-gas analyzer to more accurately measure gas-
flow rates and gas volume for methane and hydro-
gen sulfide.
• The Mathena ECO-tank intelligent system is for
more precise liquid measurement in tanks or sec-
ondary containment.
• The Mathena frack flowback intelligent system pro-
vides accurate monitoring of flowrate data and level
change within frac tanks.

www.global.weir/industries/oil-and-gas

Platform integrates information and Manual hoist offers corrosion-resistance and

operations technologies ATEX rating for harsh environments

KONGSBERG presented Kognifai, its open
collaborative platform that places an application
portfolio into the cloud with a focus on optimiz-
ing data access and analysis for customers
across maritime and energy industries. It is also
an integrated development and distribution plat-
form for efficiency-enhancing applications.
Since 2014, the company said, different busi-
ness units within KONGSBERG have merged
their technology, knowledge, and effort to create
Kognifai, a universal response to the growing
wave of digitalization across all industries.
Developed to accelerate the digitization of
existing and new business areas, the solution
provides access to an extensive portfolio of
standalone solutions as well as those from third
parties. It serves as a development hub and
storefront for external developers. It allows cus-
tomers to subscribe to solutions via a software-
as-a-service (SaaS) approach. The system is pro-
tected by the highest level of cybersecurity and
a strict application-certification process for all
third-party services and applications. It includes
industry-specific solutions for machine learning
and advanced analytics. The system is equipped
with a state-of-the-art 3D engine which is easy-
to-use and allows for rich and advanced applica-
tions and real-time simulation tools.
www.kongsberg.com
Ingersoll Rand, maker of power tools, has introduced the
ATEX-certified KMX-series manual hoist to meet the most
stringent requirements for material-handling in harsh and
hazardous environments. The KMX-series line includes hoists
with capacities ranging from 0.5 to 20 metric tons. Each
feature copper-plated hooks and guide rollers that are spark-
resistant. The hoists are fabricated with all-steel construction
and the load chain is coated in premium zinc-plating.
The manual hoist stands up to a variety of tough applica-
tions, including upstream offshore oil & gas and refineries,
power-generation, and other applications where electricity or
compressed air is not available to power equipment.
To meet safety requirements for hazardous applications, the
manual hoist features copper-plated hooks and guide rollers.
The ATEX certification allows the hoist to be safely operated in
areas that are potentially explosive due to a mixture of air and
flammable substances like gases, vapors, mists, or dusts.
A premium VH-grade load chain with an inorganic zinc coat-
ing ensures optimal corrosion resistance and increased dura-
bility with minimal down time in the most challenging environ-
ments. Dip spin and powder coating on critical components
provides added corrosion resistance. Additionally, the fasten-
ers and hand chain are made with stainless steel to provide
additional rust prevention.
Extreme environmental testing showed that after hun-
dreds of hours of salt-spray exposure, the manual hoist dem-
onstrated less corrosion than leading competitive products.
http://company.ingersollrand.com/ircorp/en/
index.html

OIL&GAS ENGINEERING JUNE 2017 • 27

 The World’s
Most Advanced
LIGHTNING UPSTREAM OIL & GAS
PROTECTION
Perfluoroelastomer mate-
CERTIFIED
rial meets enhanced-oil
(FILE E478687) recovery requirements

Trelleborg Sealing Solutions

launched its latest Isolast perfluo-
roelastomer material development.
Specifically engineered for the

P REVECTRON 3 offshore industry, Isolast J9554

matches up to the most demand-
ing of upstream requirements and
The Protection Source is suited for enhanced oil recovery
NATIONAL LIGHTNING PROTECTION (EOR) systems.
“A focus for development of
www.NationalLightning.com Isolast J9554 was ensuring long
1-800-628-2816 seal life in EOR systems. This
includes thermal recovery, where
Sales@NLPcorp.com heat is introduced to the oil res-
Input #115 at www.controleng.com/information Input #116 at www.controleng.com/information ervoir to reduce the viscosity of
the oil and cyclic-steam injec-
tion, which is used extensively in
heavy-oil reservoirs and tar sands to thin oil and enhance its ability to flow,” said Chris Busby, product manager.
ng-CE 2017-06_TRGuide_MediaShowcase2x4_MII.indd5/17/2017
1 2:23:54 PM
Extensive testing was undertaken to prove that the material can operate at extreme temperatures and pressures
encountered in critical upstream applications, including high-temperature steam environments. The material exhib-
ited excellent retention of physical properties following high-temperature steam aging for one week at 572°F.
The material delivers exceptional chemical resistance and thermal stability in harsh oil & gas environments. A
high-hardness, high-modulus material with excellent long-term retention of physical properties, it is ideally suited
to high-pressure applications where high thermal stability and resistance to aggressive well-bore chemicals such as
amine-based corrosion inhibitors, steam, and acids are vital to ensure reliable seal performance.
The material demonstrates excellent compression-set retention at high temperatures with temperature resis-
tance from 14°F to 527°F with excursions to 572°F. In addition to EOR applications, the material also is suited to
use in downhole tools and chemical dosing pumps.
www.tss.trelleborg.com

ADVERTISERS’ INDEX
COMPANY PAGE NO. RSN WEB
Archrock 17 106 www.archrock.com
Baldor Electric Company C2 100 www.baldor.com
Danfoss 11 104 www.danfoss.us
Magnetrol 1 101 www.magnetrol.com
Moore Industries - Intl. Inc 9 103 www.miinet.com
Pyromation Inc. 20 107 www.pyromation.com/oilandgas
Siemens 15 105 www.siemens.com/communications-for-oil-gas
Unitronics C3 113 www.unitronics.com
WAGO Corp C4 114 www.wago.us
WELDBEND 2, 3 102 www.weldbend.com

28 • JUNE 2017 OIL&GAS ENGINEERING

input #113 at www.controleng.com/information
INTRINSICALLY SAFE I/O...
Explosion Protection for Automation

Ex i System Highlights
r Approved for location in Class 1 Div. 2 / Zone 2
r Intrinsically safe [ia] digital, analog and safety modules
r Combine standard and Ex i I/O in the same node
r Modular, compact design – 12 mm width
r Fieldbus Independent

www.wago.us/hazloc

input #114 at www.controleng.com/information