Optimising chemical injection dosage and concentration

Replacing estimates with robust calculations based on real-time data

Knowing who’s offshore when you’re thousands of miles away onshore in a dynamic, high risk operating environment creates real challenges. Eigen’s solution for one operator enabled it to integrate existing data from multiple sources with some clever logic to create a single place to build one team and drive productivity.

Problem: A European oil & gas operator generated their production efficiency report through a network of Microsoft Excel sheets containing the data required to fulfil the requirements of the management team.

The manual workflow consisted in updating data fields in Excel from the sources and performing calculations so that graphs and trends could be updated and copied over to the final report in Microsoft Word.

The existing process required the engineer to import data from the automation system and then copy-paste the oil production rates, and electric semi-submersible pump run-times for each day of the month, for each well. Then, using his own criteria, they needed to check or adjust the well’s potential, based on the latest well test.

At this point, the losses due to downtime were calculated by Excel formulae.

In order to generate the monthly report, the field engineer had to manually enter some downtime events and explain all losses so they could be totalised for each category in the final monthly report.

Problem: Production chemicals make up a significant and increasing share of operating costs as the field matures. A lack of instrumentation to record chemical stock levels and chemical injection rates can leave many operators over-reliant on spreadsheet-based estimates and snapshot data.

As a consequence, many operators over-inject for fear of under-dosing, wasting substantial opex.

One Norwegian oil and gas operator approached Eigen to build a digital window into its chemical management system.

Solution: Building off a number of similar previous chemical management projects with other operators, Eigen built a new chemicals dashboard using Ingenuity version 7, with its dramatically improved interface and functionality.

Now the operator can see more than a dozen different chemical injection and concentration rates per well, as well as stock levels. Complex calculations to derive virtual flow rates and tank levels using the Eigen Analytics Platform are performed pulling data from multiple different sources.

The dashboard shows injection rates over time, rather than the snapshots available before – and crucially, a recommended range, so engineers can determine if a well is being over-dosed (and therefore wasting opex) or under-dosed (and introducing integrity risks, low production and downtime).

Indicators for each chemical chart on the dashboard signal whether each chemical is being injected in line with the recommended range, enabling engineers to see at a quick glance how the field is operating.

Ingenuity 7 has been built integrating Node-RED, a low-code workflow editor that enables engineers to adjust recommended limits by themselves, giving them more control and reducing reliance on the software vendor for updates.

Impact: Estimates of dosing levels and concentrations are now a thing of the past for the operator, thanks to the new Ingenuity 7-based chemicals management dashboard.

Complex calculations linked to source data provide robust assurance of stock and dosage and concentration levels without requiring manual intervention from operational staff, meaning the latest data is available 24/7.

The engineering team can quickly identify whether the field is optimised for risk and opex, as well as monitoring longer-term changes through trends over time.

The user configurability of the new dashboard enables engineers to make changes independent of Eigen or any other service provider, giving them improved autonomy and flexibility.

The operations team now has an intuitive, beautifully designed dashboard, shareable with senior management and other functions, visualising the latest data to assure safe, reliable and economic production.

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Over the past fifteen years, we have worked with many of the major oil and gas operators. We are trusted as engineering experts who deploy digital technologies to create value.

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