Automating Manual Processes
To monitor its oilfield operations across a large and remote area in the Niger Delta, Shell Nigeria relied on a series of manual processes for wellhead monitoring and pipeline surveillance. Shell Nigeria is involved in all segments of oil operations, including exploration and production, upstream and midstream, and its IoT solution needed to scale for future expansion as well as be able to deliver different information over different communication protocols.
RPMA in Action
The Niger Delta produces approximately two million barrels a day, making Nigeria one of West Africa’s biggest producers of petroleum. As a key operator in the region, Shell Nigeria needed to automate several manual processes, in order to create a work environment that is safer and more secure for its employees as well as the production facility. After investigating several Internet of Things (IoT) technologies, the company knew creating a digitally connected oilfield could help its processes become more efficient and its operations more productive. However, because of the location and rugged terrain, bringing connectivity to the oilfield was challenging and expensive.
SHELL NIGERIA’S IoT SOLUTION REQUIREMENTS:
Real-time monitoring of different processes throughout the oilfield.
Two-way communication that not only improved the company’s ability to monitor remotely, but also the ability to perform remote intervention for scheduled maintenance as well as unscheduled incidents.
Support for the end devices to run solely on battery power only because the remote locations of some equipment made hardwired electrical connections impossible.
The ability to monitor operations through a local operations center as well as at the company’s headquarters in Europe.
A system that provided reliability, data integrity and security.
Connectivity was a key factor—how could Shell take advantage of all the IoT has to offer its operations without incurring significant expense in building out infrastructure to support IoT connectivity? Shell needed to make not only a strong technology case for the IoT, but also a strong financial case. Shell evaluated several options, including satellite, SMS and General Packet Radio Service (GPRS). Each of these options required significant infrastructure investment in the form of towers, radios, data communications equipment, battery banks, logistics and installation, making them too expensive.
Connectivity for Machines, Not People
The problem with other solutions Shell considered is that they were designed for use by people, not machines. Shell could benefit most from a technology designed specifically for machine connectivity. To meet its needs for reliability, security and longevity, Shell Nigeria selected Random Phase Multiple Access (RPMA®) technology from Ingenu™, the pioneer in delivering connectivity exclusively to machines, and end devices from Croatia’s KONČAR, a producer of industrial electronics and power electronics devices and systems. Upland Consulting Nigeria provided all of the necessary support and conducted all field/installation services.
KONČAR has built RPMA modules into its end devices, and Shell Nigeria has installed these devices in the flow-stations, manifolds, at wellheads and other customers’ facilities. The devices provide two-way connections between the oilfield and the office, providing the reliable stream of data from the field such as pipeline pressure, temperature and flow. The devices can also encrypt transmitted data, control power consumption, perform over-the-air (OTA) parameterization and updates, and conduct scheduled and alarm reporting,
In addition, KONČAR delivered the multiple connection and data export system with its Modbus Gateway & Management Studio (MGMS), enabling MODBUS TCP/IP and OPC connectivity for Shell. The KONČAR Remote Terminal Units and wireless pressure and temperature transmitters were installed in flow stations, manifolds, and wellheads to provide connection from the field.
Upland evaluated several communication technologies to present Shell Nigeria with a solution to replace its manual oilfield data collection processes. The key criteria for selecting a solution were the technology’s ability to cover difficult terrain, power performance, and long-range transmission as well as network scalability, two-way communications, and secure data transmission. Ingenu’s RPMA offered all of these attributes and eclipsed the competition with its connectivity, network capacity, and exceptional value.
Bola Awobamise
A Digital Oilfield
with Huge Savings
The Digital Oilfield (DOF) technology is a combination of IT and automation and instrumentation technologies, providing Shell Nigeria with a real-time view of field processes and the availability of resources, and creating a safer operational environment with the inclusion of remote surveillance.
Ingenu’s RPMA network solution required only four access points to serve the entire Shell Nigeria oilfield.
This resulted in a total project cost savings of more than $1 million over the other IoT alternatives the company evaluated. That is an astounding 92% savings over the next best option.
SHELL NIGERIA + RPMA NETWORK RESULTS:
Improve reporting to its home office and to headquarters
Enable continuous operations by reducing manual processes and on-site inspections
Quickly identify and resolve issues, resulting in more efficient operation and safer conditions for employees
Monitor equipment status in near real-time, preventing unscheduled downtime and safety risks
Capture and analyze critical production data to further enhance efficiencies
The team of Ingenu, KONČAR and Upland Consulting teamed up to deliver an IoT solution to Shell Nigeria that automated its manual process and created a safer, more secure operational environment. The result: a Digital Oilfield solution at significant cost savings over alternative options.