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Case Studies

Developing a real-time control and data acquisition system for a deep-water, high-pressure/high-temperature application

CASE STUDY: ENGENUITY INC.

To simplify testing and add user-friendly value, the company wanted to automate the system so that users could simply select from a screen the test that matched their specific application setup, and then direct the test to complete and provide reports.

This setup would ultimately make for a leading solution that saves time and money while making drilling easier and safer.

Challenge: Designing an accurate, repeatable way to test blow out preventers (BOPs) for leaks
Solution: 
Creating automated software to quickly and easily test a BOP with an existing portable tricylinder tester
Industry: 
Oil & Gas
Application: 
Software Development; Automation; Real-Time Control and Data Acquisition; Down-hole Electronics
Company: 
Engenuity Inc. 

 

“With the portable tricylinder tester, our client had sound technology able to accurately test BOPs on land or at sea, but to make the application truly beneficial for customers, they needed to automate it. We created the automated system they needed to deliver a leading down-hole electronics solution for customers that saves time and money while making drilling easier and safer.”

–John Amstadt, Senior Integration Architect, Erdos Miller

 

Background

In the last five years, regulations surrounding blowout preventer (BOP) testing and maintenance have greatly increased. Finalization of the Well Control Rule in 2016 resulted in reforms that establish minimum baseline requirements for the design, manufacture, repair, and maintenance of blowout preventers, as well as require additional controls over the maintenance and repair of BOPs. These requirements are best satisfied with real-time monitoring capabilities that measure deep water, high-temperature/high-pressure drilling activities and increased reporting of BOP failure data to the Bureau of Safety and Environmental Enforcement (BSEE) and original equipment manufacturers (OEMs).

Engenuity Inc. designs and manufactures technologically advanced hydrostatic testing equipment and software, and is primarily focused on improving the safety and economics of BOP testing, both onshore and offshore. The company has developed several patent-pending innovations specifically targeting the deficiencies associated with current hydrostatic testing. Their efforts help oil and gas companies drill safely and effectively while meeting the requirements of BSEE regulations.

Specifically for BOPs, Engenuity developed BOPx EZ Test, a portable tricylinder tester that can be driven to land rigs or shipped onsite to rigs at sea. The tester can push 6000psi of water onto a BOP, and operators can monitor pressure on the BOP through transducers and check for leaks in the device. The tester allows companies to show that their device is leak proof, or to detect flaws or leaks and remedy them quickly.

To simplify testing and add user-friendly value, the company wanted to automate the system so that users could simply select from a screen the test that matched their specific application setup, and then direct the test to complete and provide reports. This setup would ultimately make for a leading solution that saves time and money while making drilling easier and safer.

Engenuity sought to work with Erdos Miller because of the company’s extensive work with oil and gas applications, specifically down-hole drilling technologies.

The Approach

Initially, users had a test system that required them to input specific parameters for each individual test, connect various I/O to control specific valves, and collect manual measurements and record data. An automated system would save time, money, and make the system much easier to use.

Engenuity Inc. had already developed a patented pressure control system, so Erdos Miller worked to architect the automated solution in a way that Engenuity could add their proprietary pressure module and have it integrate easily with the system. This approach allowed Engenuity to maximize its in-house expertise and prior investment while capitalizing on Erdos Miller’s programming and application development experience.

The System

With the new system, BOPx EZ Build, operators now can drag and drop system components onto a screen, along with the appropriate valves and timing for their application. They then add pressure limits and have a visual piping and instrumentation diagram (P&ID), showing the process flow together with the installed equipment and instrumentation. Operators save these diagrams as .EZTest files so they’re accessible later to be imported into the BOP test stand.

Upon arrival, the portable tricylinder tester connects to the rig's water supply pump and valve manifold. BOPX will then use the EZBuild test plans to determine which valves on the manifold need to be opened and closed. The automated system uses the real-time functionality of a National Instrument’s CompactRIO controller. Once connected, operators can run tests and control the pressure of water used throughout the duration of the test. They can also receive instant data to identify both immediate and gradual leaks.

The Results

With the new solution, operators don’t need prior experience in test or programming, and they get a live display of pressure loss while the test application is in process. If the system indicates a decrease in pressure (i.e. a leak) in the system, an operator can abort the test immediately and move forward to remedy the issue.

In addition to testing BOPs that are already in use, operators must test a new BOP before it’s integrated into a system. With the new system, operators on a rig can get to work testing their BOP with the portable tricylinder tester quickly, as the test stand is already designed and ready for use. This saves costly time on the rig and allows teams to begin drilling more quickly.

To further the application, an Engenuity client and major international oil company wanted added functionality for remote operation of their BOPx EZ Test system. Erdos Miller worked with the client to add object linking and embedding for process control (OPC) communication for remote operation. Now, their BOPx EZ Test system runs via OPC server and an operations team can generate reports remotely.

Engenuity plans to have Erdos Miller further develop this system and offer an out-of-the box remote control system available to all customers.

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