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Allocation Metering

Challenge: Periodic pre-testing is the generally accepted methodology on offshore platforms to measure and characterize the flows from a number of different wells and to allocate production from individual wells. These figures are then combined for total production. Surging flows with varying viscosities tend to make separation difficult with higher costs and imprecise results. In addition, conventional separators tend to be large and heavy, as well as expensive to operate and maintain. Solution: Cyclonic separation of the flow from individual wells delivers better measurements without the additional weight and expense of larger separators. Two-phase cyclonic separators remove saturated, or wet gas from the top where it can be metered using a Daniel measurement device. The heavier oil and water drop from the bottom where Micro Motion Coriolis meters measure both mass and density. If necessary, water and sand probes can also be employed. Pre-testing with cyclonic separators yields greater accuracy with a smaller platform footprint as compared with a conventional three-phase separator. Real-time data on production from individual wells can also be used by reservoir engineers in determining changes that may be occurring downhole and actions to be taken for effective well management. Another Emerson solution eliminates topside separation altogether in favor of multiphase homogeneous screening on the ocean floor. This advanced technology is being developed by Emersons Roxar Division in Norway.

Ballast Control
Challenge: The movement of heavy fluids aboard a floating vessel such as an FPSO has a pronounced affect on the attitude of that vessel in the water which must be counteracted by filling and emptying built-in ballast tanks with water. If too much weight flows to one side or another, the vessel tends to list that way and, in extreme cases, may be in peril of capsizing, especially if the vessel is lightly loaded and riding high out of the water. If too much cargo is stored amidships, there is danger of bowing at the keel and possibly breaking apart. The effects of fluid dynamics aboard the vessel are intensified when material is pumped from tanks in one section of the vessel to another as a part of on-board processing operations, making ballast control more

complex. Ballast level measurements are generally included as part of the overall tank gauging system and can be inputs to an integrated control and safety system (ICSS). Solution: Most vessels have computer programs for ballast control, and accurate measurements of tank levels and fluid flows are essential inputs for the special load computations required to remotely control the valves for ballast loading or offloading. Emersons highly developed ballast control solution is based on the Rosemount TankRadarSTaR tank gauging, alarm handling, and cargo control system for marine applications. Centerpiece of this system is the intrinsically safe Tank Gauge Unit that provides highly accurate level measurements for load calculations as well as high level and overfill alarms. The Cargo Report System calculates tank volumes along with corrections for trim and list. Data from the TankRadar STaR system is integrated with the DeltaV ICSS so on-board processing operations are coordinated with the ballast control function. Emersons DeltaV Ballast and Cargo solution reduces costs and supports ease of operation. It also provides infrastructure for asset management to improve equipment maintenance and longevity.

Compression
Challenge: Natural gas recovered during offshore production is generally compressed on the platform for transmission via pipeline to a processing facility. Compressors used for this purpose should be capable of handling expected volumes safely and without disrupting other platform activities. They must be sized accordingly and capable of absorbing pressure spikes, or slugs, as well as dips in the supply pressure. Such variations can cause surges or starvation. Some compressors may, in severe cases, attempt to reverse the flow of gas, which can damage the machine and possibly create a safety hazard. Solution: Fisher surge control valves, which remain closed on the output side of the compressor during normal operation, are designed to open quickly when necessary and allow gas exiting the compressor to recycle back to the intake side to counteract the effects of starvation. When there is an overabundance of gas with excessively high pressure at the compressors intake port, a Rosemount pressure sensor can activate a Fisher relief valve, causing the gas to be diverted to flare. In addition, Emerson has extensive experience in designing and implementing control systems and instrumentation for compressing natural gas into liquid (LNG) for shipment aboard specially constructed tankers. Floating LNG plants are being designed for use in world areas where there is an abundance of natural gas coupled with minimal demand. Again, Emerson is at the technology forefront with PlantWeb control architecture and DeltaV automation systems.

Control Systems - MCS - DCS Interface


Challenge: With the increased deployment of subsea production systems, there is concern that the Master Control System (MCS) for subsea production is too disconnected from the topside Distributed Control System (DCS). Severe communications issues exist between dissimilar and sometimes proprietary systems. Under these circumstances, alarms could be missed, and safety becomes an issue. A number of oil company

representatives have expressed their desire to have unified topside and subsea controls with a single human/machine interface for control of all assets, whether above or below the surface of the ocean. Solution: With Emersons DeltaV automation system in place as the DCS on production platforms integrating control of subsea equipment is not difficult. By standardizing on well-proven communication protocols and automating configuration of the subsea production system in the DCS, Emerson achieves a seamless interface to and even full integration of the MCS. This approach also offers the advantage of the built-in redundancy and reliability of DeltaV for control of the subsea production system. Communications are faster and more reliable, providing access to all data generated by the subsea equipment. No alarms are hidden from the operators, so safety is enhanced.

Custody Transfer
Challenge: Many factors must be considered in the design of custody transfer systems for offshore facilities. Answers are needed to such questions as how and where the measurements will be done and what volumes are expected? Will tie-ins be added in the future resulting in greater-than-anticipated production? Will measurements be by volume (United States) or by mass as is the practice throughout the rest of the world? Such considerations will ultimately determine just where to make the measurements, what meters are used, and how they should be sized. The basic challenges on operating platforms relate to measurement accuracy, proper sampling and analysis of constituents, and verification of meter readings. Solution: Emerson is well-positioned to serve the needs of all companies making custody transfer measurements offshore. Design consultants from Daniel, Micro Motion, METCO and other Emerson divisions are available to help customers create optimal measurement systems for any specific offshore facility. A wide range of highly accurate metering devices include orifice plate meters, Coriolis meters, turbine meters, ultrasonic meters, and even multiphase meters for subsea measurements from individual wells. Emerson is also the principal supplier of flow computer systems from Daniel, Bristol, Solartron, and Spectra-Tek. In addition, the validity of custody transfer measurements can be substantiated through METCO in Aberdeen, Scotland, which provides expert real-time service with technicians on all the major platforms in the North Sea. In addition, Emerson now has the technology to make accurate real-time custody transfer measurements remotely from any spot on the globe.

Downhole Monitoring
Challenge: Since effective well management requires knowledge of downhole conditions and changes that may be occurring there, information about downhole pressure and temperature in offshore wells is essential. These measurements become even more crucial as wells go deeper, where pressures and temperatures get progressively higher. Monitoring instruments installed in deep wells must be durable enough to withstand the harsh environment and still deliver reliable measurements. In addition, downhole flow-rate, density, and

watercut monitoring is needed in multi-zone wells to provide valuable information, which reservoir engineers can use to determine steps to take to improve well performance. Solution: Emerson is the leader in instrumentation for downhole monitoring in deep, high temperature and high pressure wells. Durable, highly accurate instruments are available to measure the pressures and temperatures, while downhole flow rate, density, and watercut sensors effectively deliver real-time data on conditions in the various zones. This additional information is helpful in identifying such issues as formation water breakthrough and declining production, as well as the presence of gas. Reservoir managers can use this information to better control flows from different zones.

Dry Wellhead Management


Challenge: Manual gauges are frequently employed in the wellhead areas of offshore platforms to avoid excessive cableways that could provide transient passages for escaping gases into other areas in case of a blast in the wellhead area. Many companies are wary of wired instruments for this reason. As a result, platform personnel have to spend an excessive amount of time in this Class 1/Zone 1 hazardous area manually reading gauges and recording the values. Having wired instruments can be a benefit in providing accurate pressure, temperature, and flow measurements plus additional diagnostic information about the condition of the wellheads. Solution: Emerson solutions include a wide range of intrinsically safe instruments and junction boxes along with the knowledge of wiring to minimize opportunities for hot gases to pass through cable pathways. Even newer wireless transmitters can be installed on wellheads for highly accurate measurements with no installed wiring. Using the world standard wirelessHART concept, transmissions from individual devices can follow a variety of paths to a gateway located outside the wellhead area. Signals from many different wireless devices are gathered and communicated directly to the distributed control system where all readings are automatically recorded. Control room operators have a full view of conditions in the wellhead area, improving the maintenance and management of this critical zone on most offshore facilities.

Injection (Chemical / Gas / Water)


Challenge: Certain chemicals may need to be injected into oil or gas wells to counteract such conditions as scaling, hydrate formation, and corrosion. Traditionally, the injection dosages to individual wells have been controlled through valves located on the topside facilities. However, this requires a separate chemical feed line for each well all the way from the chemical supply tank on the platform, through the control valve and the umbilical to the subsea well. In other words, the distribution of chemicals to each well is performed on the surface. For a subsea field development, the larger the number of trees and the longer the step-out from the host platform result in additional costs for each separate stainless steel tube bundled in the subsea umbilical. Solution: Subsea chemical distribution is a better method that greatly reduces umbilical cost since only a single chemical feed line is required from the surface to the seabed. A subsea chemical distribution manifold

branches the chemical feed to each well, and subsea chemical injection valves on each tree controls the dosage of the different chemicals to each well. Emerson is a pioneer in the area of subsea chemical distribution with the Roxar range of subsea chemical injection valves providing accurate, electrical control of the injection dosage. These valves also include built-in measurement of the injection flow rates, thus providing instantaneous feedback to topside operators that the desired injection dosage is actually being achieved at each tree. The most rigorous erosion testing proves the reliability of these valves in the most demanding applications, with injection flow rates up to 400 l/min.

Production Metering
Challenge: The generally accepted methodology of sequentially pre-testing the output of one well at a time is one way to measure flows and characterize wells in offshore facilities. The averages are then combined for a total production figure that neither considers any changes between each test nor any fluctuations in production (e.g. slugging) during the test. Very little useful information about the condition of each well is obtained in this way. Sometimes, multiphase meters replace separators on the platform for well testing purposes, but even then information is received only intermittently. Any sudden change in reservoir activity will probably not be noticed, and there is very little opportunity to determine what is happening downhole. Solution: Installing a multiphase meter as close to each well as possible results in a number of benefits. Firstly, the production from each well is monitored continuously with little or no manual labor. This can be used for allocation purposes as an addition to or even as a replacement for intermittent well testing. Secondly, operators are instantly able to determine production changes like water breakthrough, increased gas/oil ratio, etc. This feedback may then become a guide for remedial action to rectify the situation and let personnel on the surface know whether the condition is improving or not. Thirdly, by matching well flow rates as measured by the multiphase meters with early projections, reservoir engineers are able to better understand the dynamics of the reservoir and update their 3D models and manage the wells accordingly. In this way, production can be maximized while assets are optimized.

SCADA Systems
Challenge: Maintaining reliable communications represents one of the challenges of offshore SCADA (Supervisory Control and Data Acquisition) systems, which generally cover a widespread production area where weather and power issues can hamper communications. Yet, reliability is essential in handling this custody transfer information. SCADA systems are expected to continuously control production and acquire data under a wide spectrum of adverse conditions, preserving the data until it can be transmitted back to a master station in a field operations center. Maintenance can be costly due to the remoteness of assets, and delays can lead to production downtime. Well-designed SCADA systems must have robust diagnostic and configuration features that allow users to make changes from the host and eliminate the need to send technicians out frequently to troubleshoot problems and make repairs at remote sites.

Solution: Emerson Remote Automation Solutions (RAS) provide unequalled leadership with three SCADA systems that dominate the oil and gas industry. The ROC is a well-established remote operations controller with excellent functionality; Bristols compact ControlWave is also capable of managing multiple flow loops; and the Daniel FloBoss is a special-purpose, single-wellhead controller. In general, these systems deliver highly reliable remote control and flow computation featuring low power requirements, data logging, and low bandwidth transmissions over multiple communications paths. At the SCADA host, large volumes of data are reconciled in real time with historical backfill. Industry standard connectivity and control room redundancy contribute to ultra-high reliability, providing customers with the ability to optimize their field assets. As a global leader, Emerson is capable of engineering, installing, and supporting innovative turnkey SCADA projects to meet customer requirements anywhere in the world.

Onshore Exploration & Production


Whether you are producing from a conventional field or unconventional field such as shale gas or heavy oil, key challenges such as getting to first oil and optimizing production are paramount. Producing from a single wellhead or well-pad we can provide solutions that bring your well online faster, reduce your operational costs and optimise production.

Compression
Challenge: Natural gas recovered during onshore production is generally compressed on site for transmission via pipeline to a processing facility. Compressors used for this purpose should be capable of handling expected volumes safely and without disrupting other activities. They must be sized accordingly and capable of absorbing pressure spikes, or slugs, as well as dips in the supply pressure. Such variations can cause surges or starvation. Some compressors may, in severe cases, attempt to reverse the flow of gas, which can damage the machine and possibly create a safety hazard. Solution: Fisher surge control valves, which remain closed on the output side of the compressor during normal operation, are designed to open quickly when necessary and allow gas exiting the compressor to recycle back to the intake side to counteract the effects of starvation. When there is an overabundance of gas with excessively high pressure at the compressors intake port, a Rosemount pressure sensor can activate a Fisher relief valve, causing the gas to be diverted to flare. In addition, Emerson has extensive experience in designing and implementing control systems and instrumentation for compressing natural gas into liquid (LNG) plants for shipment aboard specially constructed tankers

Downhole Monitoring
Challenge: Since effective well management requires knowledge of downhole conditions and changes that may be occurring there, information about downhole pressure and temperature in offshore wells is essential. These measurements become even more crucial as wells go deeper, where pressures and temperatures get progressively higher. Monitoring instruments installed in deep wells must be durable enough to withstand the harsh environment and still deliver reliable measurements. In addition, downhole flow-rate, density, and

watercut monitoring is needed in multi-zone wells to provide valuable information, which reservoir engineers can use to determine steps to take to improve well performance. Solution: Emerson is the leader in instrumentation for downhole monitoring in deep, high temperature and high pressure wells. Durable, highly accurate instruments are available to measure the pressures and temperatures, while downhole flow rate, density, and watercut sensors effectively deliver real-time data on conditions in the various zones. This additional information is helpful in identifying such issues as formation water breakthrough and declining production, as well as the presence of gas. Reservoir managers can use this information to better control flows from different zones.

Wellhead Automation
Challenge: With all your wells across a wide geographic area, how do you prioritize where you invest your time and resources? In addition, with a dwindling amount of skilled resources available, it can be challenging to get to first production quickly and cost-effectively, to maintain and optimize production across hundreds of wells, and control your costs. Solution: With Emersons wellhead automation solutions you can overcome these challenges: Get your wells up and running faster and easier, reduce operating and compliance costs, and gain the insights and control needed to optimize production and yield. Try Emersons Wellhead Automation Solution on an individual well or a pad, and experience how easy it is to quickly automate.

With Emerson's technologies and services you can avoid those integration headaches and delays so you can get to first oil and gas as soon as possible. Utilizing Smart Wireless technology and pre-configured RTUs, you wont have to put your installation on hold while you struggle to free up the correct personnel. Instead, youll be able bring your wells online in hours instead of days. We can help you reduce the number of site visits your technicians make while improving your ability to achieve wellhead safety. In the process, youll drive down maintenance costs, decrease the number of reportable safety and environmental incidents, and make compliance reporting simpler, faster, and more accurate. Emersons wellhead automation solutions will allow you to keep a closer eye on all of the measurements, conditions, processes, and activities that affect production. As a result, youll be able to maximize overall field production while minimizing personnel and environmental risks. To learn more check out our Wellhead Automation Solution which offers you flexible options, easy configuration and seamless integration to your existing control and SCADA infrastructure, or Get Started and get to first production faster, optimize production and reduce your operational costs.

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