For Upstream Oil and Gas Industries - WIKA-Sensors · ElEctronic prEssurE MEasurEMEnt For Upstream Oil and Gas Industries arE Your sEnsors oil FiEld t ough? How the Right Pressure

ElEctronic prEssurE MEasurEMEnt

For Upstream Oil and Gas Industries

arE Your sEnsors oil FiEld tough?

How the Right Pressure TransmitterCan Enhance Production

The Product Must Flow... But at Minimal Cost

The US DOE estimates an increase in US tight oil production of between 0.8 mbd and 1.8 mbd from 2010 to 2020.*But, that production needs to happen with minimal expenditures.

Your job is to bring new supplies on line, on time, and at acceptable cost. All while dealing with increased regulatory activity and environmental concerns, skilled worker shortages, remote locations, and geological complexity.

And today the industry is no longer operating under the Boom Town mentality of yesterday—it’s closer to a

“factory” business model. That means dealing with tighter margins and less room for error. Also, the expansion of gas supply may mean that the price of natural gas will be in the low-to-modest range for years to come. That makes shaving costs of drilling operations even more critical.

Top Two Business Drivers For Power and Energy Companies

Need to reduce OpEx

Constrained Capex

Aging assets (plant and equipment)

Heightened regulatory compliance

Corporate sustainability initiatives

Percentage of Respondents, n=83Source: Aberdeen Group, October 2010

All Respondents

0 10 20 30 40 50

53%

50%

40%

22%

17%

60

1Call 855-362-9452 or visit www.WIKA-Sensors.com

*Petroleum Economist, Unconventional Global Intelligence, http://www.petroleum-economist.com/Article/3079993.

The key to maximizing the return on oil and gas development projects rests with the maintenance and safety of your, sometimes aging, equipment.

While most upstream organizations today use traditional maintenance models (see Fig. 1), companies using condition-based monitoring have experienced:• Production increases in the range of 5% overall• Increased reservoir life• Lowered cost of production• Significant improvements in operations, maintenance and decision making.*

Condition-based monitoring means detecting equipment problems before they lead to lost production. Companies employing this approach use “alarms” such as pressure transmitters to identify faults and spot patterns—and correct them before they become catastrophic events.

Are You In Control?

*http://www.epmag.com/EP-Magazine/archive/Monitoring-upstream-assets_4225

Fig. 1

Approach Technique Needed Human Body Parallel

Reactive Maintenance Large budget Unplanned loss of production Stroke or heart attack

Preventive Maintenance Periodic component replacement Bypass or transplant

Predictive Maintenance Monitoring of pressure and other indicators

Detection with regular check-ups, EKG or other monitoring

2 Call 855-362-9452 or visit www.WIKA-Sensors.com

OIL WELL / GAS WELLPressure

SEPARATORSPressure

FIELD DEHYDRATION

TANKPressure andVapor Recovery

Monitoring = Safe and Efficient OperationElectronic transmitters play an important role in the safe and efficient operation of a wide range of oil and gas extraction equipment. They monitor a variety of functions, from well performance to vapor recovery.

Areas in oil and gas extraction that need electronic transmitters.


Why Monitor?To keep production flowing as cost-efficiently as possible, you and your team must identify and resolve issues quickly—while also performing regular maintenance to keep small issues from becoming profit-draining failures.

Monitoring tubing and casing pressure can not only help you maintain a constant production output, it can also:• Assure stability and integrity of the wellbore• Prevent oil, gas, and fracturing fluids from migrating into fresh water zones or other unintended strata.


Well performance monitoring allows you to focus on the problem wells that may be showing signs of performance issues such as:• Scaling and water breakthrough • Compression plant constraints • Unplanned shutdowns • Hydrate formation and gas lift equipment faults

With the right information, you can analyze and diagnose problems in a prioritized and time-efficient manner.

Similarly, level and pressure measurement in storage tanks can help maximize productivity and avoid clean up costs for a collapsed tank or EPA fines from a tank battery with high fugitive emissions.


Pump Up Reservoir Recovery More than 90% of the producing gas wells in the U.S. have liquid in the tubing.1

Artificial lift systems (ALS) increase pressure within the reservoir and encourage product to the surface. Those companies that maintain gas flow by removing accumulated fluids through an ALS such as a plunger lift receive:• Revenue from increased production• Revenue from avoided emissions• Avoided costs—well treatment costs, reduced electricity costs, workover costs• Salvage value

1 http://www.ipni.net/ppiweb/ppinews.nsf/0/7DE814BEC3A5A6EF85256BD80067B43C/$FILE/Crop%20Yield.pdf2 EPA

Increased gas production following plunger lift installation has yielded total gas benefits of up to 18,250 Mcf per well, worth an estimated $127,750.2



True Cost of Failure: Unplanned downtime is a constant, costly menace

$

$$$

$$

*http://www.shaletec.com/faq/troubleshooting-plunger-lift-wells/

A well down for 2 days a month reduces production by

6.5% annually.

For a single 350 mcf/d (thousand cubic feet per day)

well, lost revenue equates to $25,200 per year

at $3/mcf.

For a field of 100 wells, lost revenue is more than $2.5

million per year.


You also have to think about the ‘‘soft” cost of having your e-tech spending the day at the well to check on a performance issue.


No Device Should Keep You From ProducingIf a pressure transmitter fails, then you don’t know what’s going on in the well. You could have zero production. You could have a problem down hole. Without that transmitter and continuous monitoring, you have almost lost control of the well.

Availability • Is the transmitter available as soon as you need it?

Durability and Longevity • Will it handle the heat in Texas? Will it handle the cold in North Dakota?• Can you install the transmitter and then forget about it for years?

You need:


From Sun to SnowThe environment can be a durability killer. Whether you have wells installed in North Dakota with its -30˚F winters or your wells are in Texas with 120˚F summers, you need a transmitter that will handle the most extreme cold and the extreme heat.

Your pressure transmitter must also handle:• Rain• Snow and icing• Dust and dirt• Corona discharge from lightning• Electromagnetic interference (EMI)

Pressure transmitters face many challenges under these operating conditions. You must carefully select the right pressure transmitter to operate successfully while providing long-term, precise measurements.


Making it Oil Field ToughHow did WIKA become the standard in stick transmitters? Because we listened to our customers.

They told us to make a product that is “oil field tough.” To do so, we spoke with customers about the challenges they face in the field. Based on their insights, we designed long-term environmental testing to establish when, how and which electrical and mechanical components would break under severe, adverse conditions. Then, we used the best materials and welds to withstand the various rugged oil field environments.

Let us bring our “oil field tough” solution to your application, so you can focus on cost-effective, non-stop performance.


ChallengeA leading independent E&P company with thousands of wells across the United States was having issues with pressure transmitters failing. This failure was especially troubling since it was threatening their production and ongoing well operation.

WIKA RespondsThis particular E&P company decided to test three transmitters from competing companies with the same pressure range, the same outputs, and technically the same specs. The key factor for product selection was durability. The company needed a transmitter that could handle the most extreme cold and the extreme heat as it had wells installed in various geographies across the nation, ranging from the wintertime in North Dakota to the summer heat of Texas.

The company chose WIKA because our product lasted longer in the field than anyone else’s product. “You hear customers—everybody—talk oil field tough. You ask what standard do you have, ‘Is it IP67?’ or ‘Is it NEMA 12?’ and they say just make sure it’s oil field tough,” said Chris Smith, WIKA expert in electronic pressure measurement. “And we build a transmitter that’s oil field tough.”

ResultsNow, every single Christmas tree for this customer has two WIKA transmitters on it. “This customer told us that they have had our transmitters on their Christmas trees for 5, 6, 7, 8 years,” said Smith. “They’ve almost forgotten that there’s a transmitter out there.”

Case Study WIKA is Oil Field Tough

Case Overview

Challenge:A large E&P company needed to find a pressure transmitter that was “oil field tough.”

Solution:The company tested three pressure transmitters and chose WIKA due to its durability.

Results:“Real-world” results have mirrored the test results—the customer now has standardized to WIKA because our transmitters have survived oil field conditions for years.


Vapor Recovery Equals More Profits... But Starts with Measurement Measurement is a huge factor in making sure you get the benefits of vapor recovery, including liquid level monitoring in shallow tanks, and proper pressure measurement for venting and monitoring systems for salt water disposal. The return on investment can be significant even in a short period of time.

A storage tank battery can vent 5,000 to 500,000 Mcf of natural gas and light hydrocarbons to the atmosphere each year. The hydrocarbons may be vented to atmosphere, flared off, or collected by a vapor recovery system. The EPA is now employing infrared detection from helicopters to try and identify potential areas of high hydrocarbon emissions, such as what can occur with venting.

The EPA can “see” dangerous hydrocarbons with the help of infrared cameras.


Financial Analysis for a Conventional Vapor Recovery Unit

1 Unit cost of the entire recovery unit plus estimated installation at 75% of unit cost2 $9.15/Mcf x 1/2 capacity x 365 x 95% Mcf = thousand cubic feet”Reducing Methane Emission with Vapor Recovery on Storage Tanks,” March 23, 2010, epa.gov/ga

Installation and Capital Cost1

Operating and Maintenance

($/year)

Value of Gas2 ($/year)

Payback (Months)(Mcf/day) ($)

25 35,738 7,367 39,000 1450 46,073 8,419 79,000 8

100 55,524 10,103 158,000 5200 74,425 11,787 317,000 3500 103,959 16,839 793,000 2

Internal Rate of Return

(%)84%152%266%410%747%


From Managed Chaos...The oil and gas industry engages in what some have called: “Managed chaos.” Managing leaseholds and optimizing rigs across multiple basins is a major challenge. Changes in rig availability, rig rates, permit approvals, site access, and availability of consumables and services can happen overnight.

Sometimes you have to wait, wait, wait... GO!

You may want to use the best—most durable—transmitter, but you’re not going to hold up flowing a well on a $300 transmitter, so you need a supplier that can meet your demands in a timely manner.


To What You Need When You Need It WIKA employs a 21st Century just-in-time supply chain. We have stock in our main warehouse in Atlanta. We have several distributors located in the local shale plays that also have stock. In short, we have what you need.

We sit down with our customers on an annual or quarterly basis to determine what they’re going to need for their production. We also keep emergency stock on hand for short-notice orders.

We understand that if you just had a lease that was released in order to drill or if you’re going to convert some old wells over to artificial lift systems, then we need to supply transmitters immediately.


Pressure TransmitterThese pressure transmitters are designed to contain, control and vent any possible ignition, without igniting the surrounding flammable gases or vapors. They require installation with conduit and conduit seals to maintain the explosion proof rating.

E-10

Available with 4 ... 20 mA, 2-wire or 1 ... 5 V, 3-wire low power output signals

NACE MR-01-75 compliant, which provides additional protection against sulfide stress cracking when exposed to media containing sulphur

Engineered to withstand harsh environments

FM-approved explosion-proof for Class I Division 1 hazardous locations

Piezoresistive sensor and thin-film sensor technology

Temperature compensated to assure accuracy and long-term stability when exposed to severe ambient temperature variations


Pressure TransmitterNon-incendive explosion-proof pressure transmitters are preferred when potential hazards are only occasionally present. They are designed to work in Class 1, Division II hazardous areas and require less stringent installation procedures than explosion-proof pressure transmitters.

N-10

Engineered to meet the harsh demands of gas compressor applications

NACE MR-01-75 compliant

Does not require the use of intrinsically safe barriers

FM approved Non-incendive for Class I Division 2 hazardous locations

Piezoresistive sensor and thin-film sensor technology

4-20 mA or low power 1-5 V output signals available


Pressure TransmitterIntrinsically safe explosion-proof pressure transmitters are designed to limit the thermal and electrical energy to a point where ignition is not possible. Intrinsically safe pressure transmitters require the use of an intrinsically safe barrier installed in the safe area. They do not require the use of conduit and conduit seals or need a “hot permit” if servicing of the instrument loop is required.

IS-20

Non-linearity of up to 0.125 % B.F.S.L.

Industry standard electrical connections including DIN 175301-803A L- connector, cables, housings andmany others

IP 69K high pressure steam wash-down protection available

Available output signals include 4 ... 20 mA, 0 ... 10 VDC, 1 ... 5 VDC and many others

Compact stainless steel case that is available with environmental protection ratings up to NEMA 6 (IP 68)

No internal soft-sealing materials that may react with the media or deteriorate over time


Pressure TransmitterFor vapor recovery, WIKA’s IS-20-VR pressure transmitters are exceptionally stable compared to other low range pressure transmitters. They can monitor very small pressure changes, even when temperatures change or when wind is a factor. The IS-20-VR features ranges down to 0-12 oz/in2, < 0.25% accuracy and all stainless steel wetted parts that are NACE listed for resistance to sulfide stress cracking in sour gas applications.

IS-20-VR

NACE MR-01-75 compliant for resistance to sulfide stress cracking Engineered to meet

the harsh demands of upstream vapor recovery, SWD, and tank vent monitoring systems

FM and CSA approved for installation Class I, Division 1 hazardous areas

Low maintenance, non-clogging large diameter pressure port

Pressure ranges down to 0-12 oz/in2 with ≤0.25% accuracy


WiKa instrument, lp1000 Wiegand BoulevardLawrenceville, GA 30043Tel (855) 362-9452Email: [email protected]

B032-0000 06/13 WIKA® is a registered trademark of WIKA Alexander Wiegand SE & Co. KG., used under license by WIKA Instrument, LP. Copyright 2013 WIKA Instrument, LP. All Rights Reserved.

We Make It Oil Field Tough...So You Can Focus On Non-Stop Performance.

You need to increase production with fewer resources. The last thing you need to worry about is a pressure sensor.

That’s why we dedicated ourselves to making sure our product is “Oil Field Tough.” To learn more about how we have designed and tested our pressure sensors to withstand the real-world conditions your equipment faces, please visit WIKA-Sensors.com.

Documents

For Upstream Oil and Gas Industries - WIKA-Sensors · ElEctronic prEssurE MEasurEMEnt For Upstream Oil and Gas Industries arE Your sEnsors oil FiEld t ough? How the Right Pressure