Session: 20-06 Optimization I - Upstream O&G Operation & Design

Paper Number: 125917

125917 - Operations Optimisation of a Gas-Lift Compression System Using a Digital-Twin Approach 

The Oil and Gas industry is facing complex challenges including spiralling exploration and development costs, aging assets, long lead times on equipment, shortage of skilled people, among others. As such, it is imperative existing assets are operated efficiently and properly maintained to maximise production. A typical approach to achieve this objective considers industry best practices, international standards, manufacturer recommendations and condition monitoring techniques such as oil analysis, vibration, thermography, ultrasound, etc.

However, the advent of Industry 4.0 has promoted the development and adoption of advanced techniques: a prominent example being the Digital-Twin concept. A Digital-Twin is a virtual model developed using advanced modelling and data handling techniques to replicate and predict the behaviour of individual equipment or entire production systems. A Digital-Twin approach can deliver predictive monitoring capabilities; analysis of complex systems; define solutions to operational issues; virtual testing and confirmation of proposed modifications; etc.

This paper presents the development of a Digital-Twin for troubleshooting and operations optimisation of a motor-driven three-stage gas-lift compression system with a long history of unstable operation, recurrent emergency shutdown events and low availability. The multidisciplinary approach includes analysis of the control system architecture, assessment of field instrumentation, data analysis, performance adaptation, dynamic modelling, off-line control system testing and risk analysis. A cost-effective solution with only minor software modifications was designed, tested and demonstrated before its implementation. The successful outcome of the project reduced the need for constant operator intervention , reduced emergency shutdown events, increased availability of the gas compression system from 86% to 98%, and, ultimately, maximised production of the asset.

Presenting Author: Marco Mucino Whitecastle Engineering Limited

Presenting Author Biography: Dr. Mucino has more than 20 years’ experience in the Energy Industry worldwide. He has a track record working in the Power Generation, Oil&Gas, Petrochemical and Insurance sectors across geographical locations in USA, Europe, LatinAmerica and the Middle East.

He has ample front office/client facing experience but equally capable to work within the operations and maintenance teams across industries. Dr. Mucino has a track record of delivering challenging projects on-time and on-budget, either working independently or leading multicultural and multidisciplinary teams. Dr. Mucino is able to bridge the gap between disciplines in an organisation i.e. mechanical, process, electrical, facilitating the analysis and resolution of engineering and operational issues.

He has excellent written and verbal communications skills allowing him to produce sound technical reports, proposals, present findings and develop new business opportunities.

Dr. Mucino holds a Doctorate in Engineering degree from Cranfield University, United Kingdom.

Authors:

Marco Mucino Whitecastle Engineering Limited
John Savage Whitecastle Engineering Limited