—

ABB above NEMA general purpose motors

Local manufacturing, sales & inventory mean
quick modifications and deliveries

ABB’s line of above NEMA general purpose motors makes buying low and medium
voltage motors easy. The standardized designs and short lead times make them
suitable for most applications where a highly-customized motor isn’t necessary.

Unique features include:

- Popular ratings in stock that can ship in 3 days

- Pre-engineered ratings available from inventory
- More than 40 modifications to customize to your application
- Strategic warehousing location for quick delivery

With ABB’s global technology and support, as well as US manufacturing, sales, and
inventory, above NEMA general purpose motors can meet your specific application
needs.

479-646-4711
new.abb.com/motors-generators
 Rag layers.
Water bottoms.
Dead zones.

Bring it on.

This is why
level matters.
Reliable interface level measurement keeps production
flowing. If liquids are not separated effectively, you face
processing problems, equipment failures, production loss,
fines and shutdowns. That’s why Magnetrol® matters. Our
technologies are proven to accurately measure total level
and interface layers. As a result, you get effective separa-
tion, enhanced safety and less downtime. That’s critical.
Because when it comes to interface, level matters.

Download the new Interface White Paper

©2018 Magnetrol International, Inc. at interface.magnetrol.com
3010 HIGHLAND PARKWAY, STE. 325
DOWNERS GROVE, IL 60515
630-571-4070, FAX 630-214-4504
CONTENT SPECIALISTS/EDITORIAL
KEVIN PARKER, Senior Contributing Editor
630-890-9682, KParker@CFEMedia.com
EMILY GUENTHER, Associate Content Manager
EGuenther@CFEMedia.com
KATIE SPAIN, Art Director
KSpain@CFEMedia.com
PUBLICATION SERVICES
JIM LANGHENRY, Co-Founder & Publisher
JLanghenry@CFEMedia.com
STEVE ROURKE, Co-Founder
SRourke@CFEMedia.com
AMANDA PELLICCIONE, Director of Research
APelliccione@CFEMedia.com
ELENA MOELLER-YOUNGER, Marketing Manager
EMYounger@CFEMedia.com
KRISTEN NIMMO, Marketing Manager
KNimmo@CFEMedia.com
PAUL BROUCH, Director of Operations
PBrouch@CFEMedia.com
CHRIS VAVRA, Production Editor
CVavra@CFEMedia.com
MICHAEL ROTZ, Print Production Manager
717-766-0211, Fax: 717-506-7238
mike.rotz@frycomm.com
MARIA BARTELL, Account Director, Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
RICK ELLIS, Oil & Gas Engineering Project Manager,
Audience Management Director
303-246-1250, REllis@CFEMedia.com
LETTERS TO THE EDITOR
Please e-mail your opinions to KParker@CFEMedia.com
INFORMATION
For a Media Kit or Editorial Calendar,
e-mail Susie Bak at SBak@CFEMedia.com
REPRINTS
For custom reprints or electronic usage, contact:
Marcia Brewer, Wright’s Media
281-419-5725, MBrewer@wrightsmedia.com
MAILING ADDRESS CHANGES
Please e-mail your changes to customerservice@CFEMedia.com
PUBLICATION SALES
JUDY PINSEL, National Sales JPinsel@CFEMedia.com
3010 Highland Parkway, Ste. 325
Downers Grove, IL 60515
2 • DECEMBER 2018
Energy, info make the world
go ‘round and ‘round
T
he men and women who are “pow-
ering and digitalizing the global econ-
omy are engaged in a noble mission,”
said Jean-Pascal Tricoire, chairman and
CEO, Schneider Electric. “Energy is a funda-
mental human right and connectivity is the
foundation of a decent life in the 21st century.”
Tricoire spoke at Schneider’s Digital
Innovation Summit held mid-November at the
Hilton Atlanta. In North America Schneider
includes 30,000 employees at 250 sites and
accounts for 29% of the company’s global
revenues, which in 2017 were $30 billion.
Schneider solutions straddle energy man-
agement and industrial automation. Primary
drivers of the tremendous change both are
undergoing, Tricoire said, include the usual
suspects: Industrial Internet of Things, cloud,
and analytics. “By 2030, IT will be the single
greatest source of global energy demand,”
he said.
Technologically speaking, event discus-
sions were dominated by Schneider Electric
EcoStruxure, an architecture or platform for
digital transformation that includes connect-
ed products, edge control, and applications
and analytics. “Products are not enough,”
Tricoire said, “expert services are needed.
We have a community of 20,000 software
engineers assigned to industries.” The prima-
cy of services provision is become a domi-
nant theme in the industrial internet age.
Just in from Houston
847-624-8418
Fax 630-214-4504 Specific to the oil & gas industry, Doug
Kushnerick, senior scientific advisor, Exxon
Mobil Research & Engineering, spoke at the
event on that company’s ongoing digitaliza-
tion efforts and its long-standing partnership
with Schneider.
“Global energy needs will increase 25%
by 2040. It is a tough challenge to lift people
in the developing world into the middle
class,” he said.
Digitalization in the oil & gas industry has
been underway for decades, Kushnerick
OIL&GAS ENGINEERING
COMMENT
KEVIN PARKER
SENIOR CONTRIBUTING
EDITOR
said. About 15 years
ago introduction of
process-equipment
digital twins and chemical-process modeling
delivered benefits quantified in the hundreds
of millions of dollars. A number can’t yet be
put on the benefits following from the layer of
infrastructure and applications being installed
today, but the expectation is of greater speed
in analysis and decision making.
“Some projects pay out very fast. Others
may be painfully slow, but we need to make
the infrastructure investment,” he said.
A voice of reason
Later in the day, Kushnerick participated in a
panel on industrial automation moderated by
Robert Sloan, a research director from The
Wall Street Journal.
“Connectivity increases calculation inten-
sity,” Kushnerick said. “The connection of
people in the field to the data around them
empowers them to make decisions.”
Of primary interest, he said, is the oppor-
tunity to look across an entire fleet of assets
to derive benchmarks across facilities for
insights into production machines and units.
The potential role of artificial intelligence
(AI) remains a $64,000 question. “My
impression is we’re still on the cusp with
that. What we do see is advanced machine
learning and modeling,” Kushnerick said.
“Some AI is very good but integrating that
into decision making is still a challenge.
When someone shows us a new product
and says, ‘There are five AIs in there.’ We
say, ‘What do you mean by that?’”
A further important frontier is the opportu-
nity to increase safety, through wearables and
augmented reality, for example, Kushnerick
said. “Many current projects are software
projects disguised as hardware projects.
That’s what’s changing the workforce.” OG
I NSIDE Cover image courtesy: Industrial Technology Research Institute

FEATURES
4 Machine learning streamlines
tubular-connection analysis 4
Questions answered through an application example

8 Upgrade from pump packing

to mechanical seals
Sealing conserves water, improves energy
efficiency, and minimizes environmental impact

12 Award winners recognized 8

Equipment, software solutions get the thumbs up

15 High-performance materials support

optimal metal end cap seals
How elastomers are tested for suitability

17 Machine learning-based gas recognition

detects minor leakage
Seven image characteristics, singly and combined, 15
used to recognize amorphous gas clouds

18 Case study showcase

OIL&GAS ENGINEERING DECEMBER 2018 • 3

AI IN THE OIL & GAS INDUSTRIES
Machine learning streamlines
tubular connection analysis
Questions answered through an application example
By Brennan Domec,
PhD. PE
Figure 1: Torque-turn graph.
All graphics courtesy: Frank’s
International
4 • DECEMBER 2018 OIL&GAS ENGINEERING
A
quick internet search will reveal a
trove of definitions and detailed
information on machine learning.
Amidst it all, readers will find a
common thread. That is, machine
learning is a branch of artificial
intelligence which, when employed, learns
from experience and uses the knowledge
gained to predict future system states. It is a
broad technology that consists of many meth-
ods well suited to solving problems of regres-
sion, classification, and anomaly detection. As
a result, it has found use in applications rang-
ing from credit card fraud detection to analysis
of corroding systems.
In a recent example, machine learning
was applied to the make-up analysis of
tubular connections. In this operation, data
are collected from sensors embedded in
the make-up machinery. These data often
are presented to the operating technician
in graphical form as a plot of torque versus
revolutions, or turns, of the pin member of
the connection. An example of such a graph
is presented in Figure 1.
Upon completion of the make-up process,
the technician is tasked with reviewing key
features of the graph and comparing them to
acceptance criteria to establish disposition of
the connection. In the event of a rejection, the
technician must diagnose the objectionable
condition to determine if the connection can be
salvaged, and how. To do so, he or she relies
mostly upon training and experience. This is
where machine learning can provide benefit.
It is generally accepted that computers
are at least as capable of recalling informa-
tion and associated relationships amongst
data as are humans. Therefore, machine
learning, when applied to the example under
discussion, should be able to effectively
classify and diagnose tubular connections
with little or no human intervention.
Machine learning workflow
To explore this hypothesis, the workflow
shown in Figure 2 was followed. As a first step,
the objectives of this project were defined as:
• Develop an intelligent system for automat-
ically classifying torque-turn graphs.
• Use the intelligent
system for anomaly
detection and pre-
diction to reduce or
eliminate damage to
connections before it
occurs.
Understanding
your data
In the second step, the
goal was to understand
the data available for
training the model. This
includes answering ques-
tions such as:
• What variables or fea-
tures are important to
solving the problem?
 • How are the data stored? In what form?
• Is the scope of the data broad enough?
The impact of a given variable may not
always be known with certainty at this point
in the process. If a variable does not strongly
affect the result, it will be apparent when
model performance is assessed in subse-
quent steps. It is therefore acceptable to
include these data, but caution should be
taken to not include too many variables for
which the impact is not well understood. This
avoids wasting efforts in building a model
only to find that it fails in verification testing.
It is also important to ensure that the data
set available is broad enough to encompass
the range of input variables expected to be
encountered in deployed operations. Trained
algorithms perform best when exposed to
data like those used to train them. If there
is significant deviation from the scope of the
training set, the model will fail to provide
accurate responses when queried.
Data preparation
Data preparation is critical to any machine
learning problem. During this step, data are
first extracted for training. This may include
the full data population or a random sampling
of the data if the population is quite large.
Cleansing of the data follows, to standardize
data and formatting. Last, the data are verified
for accuracy. As these data will be used for
training the model, it is imperative that they
are accurate. Failure to properly prepare the
data for training can result in a model that may
provide erroneous or misleading results.
Model building and training
At this point the objectives are defined, and
the data selected and prepared for use. The
next step is to begin building and training
a machine learning model that meets the
project goals. Dozens of machine learning
algorithms are in common use; a detailed dis-
cussion of which would be beyond the scope
of this article. However, it is worth noting that
these algorithms generally can be grouped by
the type of problem that they best solve, nar-
rowing down the list of appropriate algorithms
once the problem is clearly defined.
Multiple methods are used to train a machine
learning model. Two methods commonly
employed are those of supervised and unsu-
pervised learning. In supervised learning, input Figure 2: Machine learning
data are provided to the model with corre- lifecycle.
sponding outcomes. This method is often used
for regression and classification problems.
The alternative method is unsupervised
learning, which finds common use in anomaly
detection problems. It differs from supervised
learning in that there are no corresponding
outcomes provided to the system against
which the model is trained.
In both methods, the model is said to be
trained when an acceptable level of maximum
error has been achieved. Training is often an
iterative process, the results of which are best
summarized in the form of a confusion matrix.
For example, the results from the first training
iteration, as tested on new data (i.e., data not
used for training) are shown in Table 1.
Deployment
Upon completion of performance verification
and final tuning, the trained model is ready
to be deployed for use. Deployments may
take many forms, including local hosting on a
single computer, networked access, or web
deployment for access from anywhere in the
world. Because the bulk of the computing
horsepower is required during the training
operation, the deployed model often may be
ported to much less powerful platforms, even
mobile devices.
Even after the model is deployed, the devel-
opment process does not end. Model per- Table 1: Confusion matrix,
formance should be monitored, at least peri- first iteration.
odically, to ensure that it is
meeting real-world demands.
It is not uncommon for model
adjustments to be required
after deployment. This is
not necessarily a sign of a
poorly performing model, but
instead part of the continuous
improvement process. As the
model is exposed to more
and more data, it will become
“smarter” and “learn” from
its new experiences, ultimate-
ly improving performance.
OIL&GAS ENGINEERING DECEMBER 2018 • 5
AI IN THE OIL & GAS INDUSTRIES
The model described as an example
for connection make-up analysis was suc-
cessfully deployed by Frank’s International
as the intelligent connection analyzed
make-up (iCAM) technology (see Figure 3).
Deployment occurred after final optimization,
fine tuning, and performance verification
of the model to provide the requisite levels
of accuracy and capability. Although not
described herein, additional features have
been and will continue to be added to this
technology through future updates.
Benefits
As the example shows, machine learning can
be used effectively to analyze the connec-
tion make-up process. Doing so offers many
benefits. First, the use of machine learning
removes human subjectivity from the analy-
sis, providing more consistent and accurate
results. While most human operator training
occurs under globally standardized programs,
the experience gained by each operator will
vary greatly and is limited in scope and size.
Conversely, a properly trained machine
learning model incurs the benefit of learning
from the collective experience of all recorded
connection make-ups and recalling that infor-
mation when required. Thus, the experience
of a trained machine learning model equates
to many lifetime’s worth of experience for a
human operator.
The implementation of machine learning
technology for connection evaluation also
has advantages over rules-based systems
in use today. Establishing rules for some
conditions is straightforward (e.g., mini-
mum torque, maximum torque, and others),
but not so for others (e.g., dope squeeze,
high interference, and poor sealing). To
Figure 3: Intelligent connec-
develop the necessary rules to automati-
tion, analyzed make-up tech-
nology screen and display.
cally evaluate a given connection, we must
create a rule
or series of
rules for each
acceptable
and reject-
able condi-
tion. Those
rules must
be based
off the prior
knowledge of
6 • DECEMBER 2018 OIL&GAS ENGINEERING
each condition’s signature and contributing
factors.
Machine learning overcomes this chal-
lenge through its ability to identify patterns
and relationships that may be imperceptible
to human analysis. As a result, the trained
model generally can identify and evaluate
more conditions than a rules-based system
and can do so more accurately and effi-
ciently. Machine learning, as implemented
here, also provides the additional benefits of
predictive analysis and anomaly detection,
preventing damage to threaded connections
before it occurs. This translates into both
time and cost savings for the tubular running
operation.
From an operational perspective, imple-
mentation of automated connection analysis
can reduce personnel on the rig floor. This
may be achieved in two scenarios. First, using
technology, such as Frank’s iCAM, allows for
the computer to make a final determination of
connection integrity without human interven-
tion, removing operating technicians from the
process all together.
In an alternative scenario, the human opera-
tor may be removed from the rig floor and
instead monitor multiple jobs from a centralized
shore location, intervening when and if neces-
sary. This is made possible by real-time data
communication technologies, such as Frank’s
DISPLAY system (Figure 3), that facilitate moni-
toring of the connection make-up process from
anywhere in the world.
Ever-increasing role
As the oil & gas industry continues seeking
gains in efficiency and well integrity, technolo-
gies such as machine learning are expected to
play ever-increasing roles in normal operations.
In a real-world application example, machine
learning has been successfully applied to the
evaluation of tubular connection make-ups.
The resulting benefits include accurate and
consistent evaluation, real-time prediction and
anomaly detection to prevent connection dam-
age, and removing personnel from the rig floor.
When combined, these translate into cost sav-
ings and improvements to both well integrity
and personnel safety. OG
Brennan Domec, PhD. PE is director, strategic
technology, Frank’s International, LLC.
is bringing deeper expertise
to oil and gas exploration
With more than 25 years of experience in the oil and gas industry, Danfoss products
have provided reliable, innovative, and cost-effective technologies proven to stand up
to the harshest environments. Our global footprint keeps you covered with world-class
electric and hydraulic solutions—continually optimized for performance and safety,
as well as best-in-class application expertise and support.

Discover how we’re Engineering Tomorrow at energy.danfoss.com

25+
years helping
optimize
performance
SEALS, GASKETS, AND PACKINGS
Upgrade from pump
packing to mechanical seals
Sealing conserves water, improves energy efficiency, and minimizes environmental impact
By Mark Savage and
Sam Ajram
Figure 1: Packing seal cham-
ber. All images courtesy:
John Crane Inc.
8 • DECEMBER 2018 OIL&GAS ENGINEERING
T
he environmental performance of
products and processes in all indus-
trial sectors increasingly is cause for
critical inspection, with sustainability,
conservation of natural resources, and
reduced environmental contamination
concerns influencing equipment design and
selection.
Many industrial processes can be addressed
to improve sustainability and minimize envi-
ronmental impact, while at the same time
maintaining or reducing operating costs.
Implementing energy-efficient and environ-
mentally friendly processes and technologies
should be embraced as a priority at the compo-
nent, process, and system levels.
One aspect of these processes is mission-
critical rotating equipment, and specifically cen-
trifugal pumps, which represent a significant
proportion of the equipment found in industrial
operations. One vital component of a centrifu-
gal pump is the seal around the rotating shaft
that passes through a stationary pressure cas-
ing or housing. The seal contains the liquid or
gas from escaping to the environment.
Sealing systems help maintain acceptable
pump efficiency, reliability, energy consump-
tion, water usage, and emissions control.
These factors can materially facilitate achiev-
ing total-lifecycle cost-reduction and sustain-
ability objectives. Sealing performance can be
improved for centrifugal pump applications by
upgrading from traditional compression packing
to mechanical seal technology.
When sealing a centrifugal pump, the objec-
tive is to allow the rotating shaft to enter the
wet area of the pump without large volumes
of pressurized fluid escaping. The pump dis-
charge pressure forces the fluid back behind
the impeller, where it is induced to exit by
way of the rotating drive shaft. To minimize
leakage, a seal is needed between the shaft
and pump housing to contain the pressure of
the process being pumped and withstand fric-
tion caused by shaft rotation.
Compression packing is the traditional
means to seal centrifugal pumps, going back
more than 100 years. Also referred to as gland
packing, it is a braided, rope-like, and lubricat-
ed material packed around the shaft in rings,
physically stuffing the gap between the shaft
and the pump housing, within a stuffing box.
Water leakage and consumption
For compression packing to work, some leak-
age must be maintained to lubricate and cool
the packing material. Therefore, packing rings
allow for an adjustable, close-clearance leak
path parallel to the shaft axis. As the packing
is used, however, some of the lubricant that
is embedded into the packing is lost, reduc-
ing the packing ring’s volume. The pressure
squeezing the rings together is also reduced,
increasing leakage.
Periodic adjustment of the packing follower
brings the pressure back into specification
and controls the excess leakage. In today’s
world, however, this maintenance is not
always being done at required intervals or
adjusted correctly. As the number of cen-
trifugal pumps incorporating the use of com-
pression packing decreases, training for and
understanding of packing maintenance has
waned.
Consequently, under-tightening and over-
tightening of packing rings is a prevalent and
growing misapplication of centrifugal pump
maintenance, with critical consequences to
both water consumption and energy draw.
Under-tightening results in too much leak-
age. Already, when properly adjusted, packing
leakage can amount to gallons of liquid leaked
per minute. This can be either aqueous solu-
tions comprised of varied benign or caustic
chemical compositions, or particles in suspen-
sion or slurry, depending on the process.
The heavier the suspension or slurry con-
tent in the pumped liquid, the more water
is needed to get packing to work reliably.
Typically, a clean external flush is piped into
the stuffing box through a lantern ring, which
keeps the packing lubricated and cool while
flushing abrasives and chemicals.
Normally, some portion of the leakage is
released continually into the atmosphere.
Under-tightening of the packing rings and use
of external flushes increase this atmospheric
release proportionately, along with environ-
mental impact potential.
Friction and parasitic energy draw
Friction is always present in centrifugal
pumps with compression packing, due to
the large surface area of the packing rings in
contact with the shaft. Over-tightening pack-
ing rings restricts leakage flow, increases
friction between packing and shaft, and gen-
erates excessive heat, which degrades the
packing. Increased friction also wears the
shaft prematurely.
From an energy consumption perspective,
the additional friction of the packing gripping
the shaft creates increased drag, requiring
more drive power to turn the shaft. It is that
drag that leads to additional, significant para-
sitic energy draw. Thus, the friction-induced
energy draw is critical to the energy efficiency
of the compression packing.
Moreover, friction is not the only factor influ-
encing energy usage associated with com-
pression packing. When examining the energy
draw component of a total lifecycle-cost analy-
sis related to compression packing use in cen-
trifugal pumps, another consideration factor is
the external flush piped into the stuffing box,
as this pressurized water or fluid needs to be
moved from a source location to the packing,
requiring a pump that draws electricity. Also in
some industries where compression packing
is more commonly used, water added via the
packing flush to maintain a clean
environment around the pack-
ing needs to be taken out later.
Removal of this water requires
energy, typically through boiling
and via the pump heat soak,
with energy transferred from
the hot metal of the pump to
the fluid within the packing
chamber.
These energy draws typi-
cally are not measured directly.
Instead, current and voltage
fluctuations used by the pump motor are Figure 2: Cutaway of a
assessed under varied operating conditions mechanical seal.
to determine how much power is being con-
sumed by parasitic influences, which enables
packing energy deficiencies to be identified.
Mechanical seals support efficiency
The mechanical seal is an alternative to com-
pression packing that resolves many of the
sustainability and environmental-impact issues
inherent in compression packing. The mechani-
cal seal requires much lower water and energy
demand, with substantially reduced leakage,
making it more efficient at containing volatile or
hazardous fluids, aqueous solutions, and slurry
suspensions. In addition, mechanical seals
require no maintenance once installed.
A mechanical seal is comprised of a station-
ary primary element fixed within the pump
housing, and a rotating mating element fixed to
the shaft. Precisely machined, these two com-
ponents are pressed together by a flexible load
element, meeting at a wear face, while the
extreme tolerance precisions between the two Figure 3: Pump packing seal
elements minimize leakage. The wear faces exhibiting excessive leakage
are supported on an extremely thin lubricating to the environment.
film, typically 0.25
microns (9.8 micro
inches) in thick-
ness.
Available in a
wide variety of
types, arrange-
ments, and materi-
als, mechanical
seals are found
in most centrifu-
gal pumps today.
Advantages include
the following:
OIL&GAS ENGINEERING DECEMBER 2018 • 9
SEALS, GASKETS, AND PACKINGS
Minimized water consumption
and leakage—mechanical seals
require very little flush water to
be injected into the seal chamber.
Compression packing used in abra-
sive pumping applications requires
significant water volumes to be
MAKE INTELLIGENT
CONNECTIONS
Frank’s iCAM™ and DISPLAY™ technologies
• Reduce personnel on the rig floor
• Enable remote, real-time monitoring of
connection make-up
• Determine connection integrity without
human intervention
www.franksinternational.com
injected into the stuffing box. A
mechanical seal in the same service
requires only a small fraction of this
water volume.
Seals create an extremely restric-
tive leak path perpendicular to the
axis of the shaft and between the
two sliding seal faces. This results in
almost no leakage to the atmosphere.
Reduced power consumption—the
amount of power required to drive a
mechanical seal is as much as 80%
less when compared to compression
packing, primarily because the seal
faces have less frictional energy losses
due to the extremely precise mating
between the stationary and rotating
elements. Additional energy reduction
requirements take the form of reduced
need for flush water to be pumped into
the seal.
Dual mechanical seals—designed
to ensure maximum sealing safety,
dual mechanical seals are typically
defined as a single assembly that
contains a pair of seals. A cavity is
formed between the two seals within
the assembly, which is filled with a bar-
rier or buffer fluid that separates the
pumped liquid from the atmosphere
and environment.
Dual mechanical seals allow for near
complete control over the seal operat-
ing environment and the fluid film lubri-
cating the seal faces. They provide max-
imum elimination of the fluid leakage
being handled in centrifugal pumps.
Reduced environmental impact
Efforts made toward improving sustain-
ability in industrial processes, whether
by reduced water and energy use, or
by eliminating harmful fluid and gas
discharge, reduce both environmental
impact and operational costs.
Mechanical seals in centrifugal
pumps, and particularly dual mechani-
cal seals, are well-suited to reduce or
eliminate volatile or hazardous fluids,
and their harmful vapors, from escap-
ing into the environment. They should
be specified as the standard sealing
solution, particularly when the pumped
fluids present a safety, health, or envi-
ronmental hazard. OG
Mark Savage is metal bellows engi-
neering product group manager and
Sam Ajram is global product marketing
manager at John Crane Inc.
10
DECEMBER 2018 OIL&GAS ENGINEERING
PRODUCT OF THE YEAR

Award winners recognized

Equipment, software solutions get the thumbs up
The Oil & Gas Engineering annual Product of the Year awards recognize significant innovation and advancement
in technologies and best practices. In this December issue we announce the award winners.

IIoT & process control

∠ GOLD AWARD WINNER
Bedrock Automation seeks to remake industrial automation
From its inception, Bedrock Automation has been dedicated to reimagining every aspect of the
installed base of automation assets. The company says it can support traditional PLC and DCS appli-
cations with a fully compliant and cybersecure IEC 61131 development environment.
Bedrock’s system is architected on a patented 4GB backplane. Combined with capacious comput-
ing power in its system modules, I/O is refreshed at a fixed rate independent of system size. This
kind of unprecedented performance enables ease of use, higher process yields, and more precise
control. Patented I/O module circuits enable universal, software-configurable analog and discrete I/O.
This enables automation solutions engineered with just three I/O module types.
The OSA Remote Controller combines PLC, RTU, and edge control; intrinsic cybersecurity; and universal I/O into a com-
pact standalone module ideal for remote monitoring and control applications. The OSA Remote is configured with standard
Bedrock IEC 61131-3 engineering tools. Intrinsic cyber security reduces the need for external firewalls, intrusion detection,
and other devices. In addition to securing its own controls, the OSA Remote can extend protection to other systems and
devices via embedded anomaly detection.
https://bedrockautomation.com
∠ BRONZE AWARD WINNER
∠ SILVER AWARD WINNER Falcon Electric says industrial UPS system is
way to protect yourself
Well lifecycle reporting Many types of uninterruptible power supply (UPS) products are
based on software, available. UPS, also known as a battery back-up, provides vary-
services, and support ing degrees of power protection against blackouts and other
A two-time 2018 Product of the Year power disturbances, depending on UPS type or topology.
honoree, Quorum Software’s dynamic Standby and line-interactive UPS is appropriate for non-critical
response to a quickly evolving mar- applications; line-interactive UPS is similar to standby UPS
ket is described on the facing page. except it is able to provide an acceptable output voltage to
WellEz On Demand, its well lifecycle connected equipment during “brownout” conditions. An online
reporting application delivers value UPS provides higher levels of protection but also an electri-
based on cloud technology, 24 hours cal firewall between the incoming utility power and electrical
by 7 days a week support, and pay- equipment.
as-you-go pricing. Two outstanding features are the ability Falcon’s SSG uni-
to generate well-bore diagrams from the field that evolve as versal UPS with a
the well moves from drilling to completions to workovers. hot-swap Lithium Iron
An XML feed automates transfers between applications Phosphate (LiFePO4)
for authorization-for-expenditure management, production, battery provides longer
accounting, and data visualization. service life, longer
With WellEz On Demand, users can implement a pre- backup times, lower weight, and higher safety than those with
packaged solution to reduce IT overhead and scale with their lead-acid batteries. The SSG UPS also lowers total cost of own-
needs quickly. WellEz On Demand features an easy-to-use ership by dramatically reducing costly battery replacements and
interface for capturing drilling, completion, workover, and downtime. Other key features of the SSG UPS with LiFePO4
facility information; automatically distributed daily reports and battery include a small footprint, continuous operation from -20
trend analysis; the ability to upload and share any file type to 55°C with no performance degradation, no thermal runaway
from the rig site to the office; and automated data transfer issues that are inherent in Lithium-ion chemistry, and a service
between operational data and other in-house applications. life of more than 10 years.
www.quorumsoftware.com www.falconups.com

12 • DECEMBER 2018 OIL&GAS ENGINEERING

Data & analytics
∠ GOLD AWARD WINNER
Quorom Software is on the move
Things are changing at Quorum Software. In August, its acqui-
sition by Thoma Bravo, LLC, the private equity investment firm Understand End Applications Of New Technologies,
was announced. The firm is doing so because “Quorum is a
pioneer and leader in the energy software market, offering a
Data Analytics, IIoT & Edge Devices
broad portfolio of mission-critical technology solutions,” said
Scott Crabill, manag- In-Depth Conference Workshops: JAN 30, 2019
ing partner, Thoma
Bravo.
Two Day Conference: JAN 31 & FEB 01, 2019
In November, J. HOUSTON, TEXAS
Charles Goodman
was named execu-
tive chairman of the
Thoroughly Researched & Redeveloped To Reflect
board of directors at The Industry’s Current Business Needs,
Quorom, the provider
of finance, opera-
Priorities And Challenges
tions, and accounting
software to the oil &
gas industry, with a significant presence in the largest public Take Your Automation Program To The Next Level
energy companies, LNG exporters, and natural gas processors.
Quorum was recognized for its latest release, Entero Mosaic Delivering Actual Success Stories &
v2018, a unified application for petroleum economics, decline
analysis, and reserves management. It features highly configu-
Implementation Strategies For…
rable, push-button reconciliation for both regulatory resources
& reserves and capital and operating budgeting; a composite
Leveraging Traditional Automation
workbench to quickly filter, sort, and search on inputs, eco-
nomic detail, and result variables; and presentations and lay-
Technologies, Advanced Data Analytics And
outs for detailed economics and comparing indicators between Cutting-Edge IIoT & Powerful Edge Devices
scenarios.
www.quorumsoftware.com
i Achieve More Consistent, Improved Efficiencies
i Increase Production Automation & Optimize Output
∠ SILVER AWARD WINNER i Make Faster, Smarter Decisions Closer To The Well Site
Fox Thermal found in U.S. shale fields
For more than 20 years, Fox Thermal has manufactured ther-
mal gas mass flowmeters, based on constant temperature
differential technology to measure mass flow rate of air and
gases, using proprietary sensor technology. Measurement is SNAPSHOT OF SPEAKER LINE-UP
in standard volumetric or mass units. No additional tempera-
ture or pressure compensation is required, Rogier Pouwer Alan Bryant
and there are no moving parts. Automation Engineering Senior Automation Engineering
Manager Advisor
Thermal mass flowmeters have many uses Anadarko Petroleum Occidental Petroleum
in the oil & gas industries, including in U.S.
shale fields. Examples include the measure of
George Robertson
tank vent and flash gas during storage opera- Jim Claunch Facilities Engineer &
tions as well as tank leakage. VP Operational Excellence CyberSecurity Advisor
The Model FT4X thermal gas mass flow Equinor Chevron
meter features a data logger to record flow
rate, totals, and other events and alarms. Danny Durham
Brandon Davis Director of Upstream Global
The logs provide information about the flow Automation Lead Chemicals
meter’s settings and functionality, including Devon Energy Apache Corporation
gas or gas mix composition, configuration, and calibration
validation historical test data. Other advanced features of the James Gallyer
Model FT4X include a second generation non-cantilevered Dustin Yates Senior Automation/
DDC-Sensor, expended Gas-SelectX menus, CAL-V, RS485 Data Analyst Measurement Technician
Modbus RTU or HART, standard USB port, and Ft4X View Concho Resources EP Energy
software.
www.foxthermal.com www.wellsite-automation.com
OIL&GAS ENGINEERING DECEMBER 2018 • 13
PRODUCT OF THE YEAR

Data & analytics

∠ BRONZE AWARD WINNER
SecurityMatters stands guard at operations
technology inflection points
Frost & Sullivan says SecurityMatters and its SilentDefense solution protects informa-
tion technology/operations technology (IT/OT) system networks against malware and
zero-day attacks. It also helps companies comply with multiple regulator standards such
as NERC CIP and NIST, guaranteeing network segmentation and policy enforcement
and response, per IEC 62443.
The solution “leverages patented machine learning
capabilities to monitor IT/OT ecosystems from three
central anagles—network, protocol and semantics. It
combines this machine learning with a vast industrial
threat library and a comprehensive protection pro-
gram to deliver timely and actionable updates regard-
ing new threats,” said Danielle VanZandt, industry
analyst for security, Frost & Sullivan.
Thereby, SilentDefense empowers industrial
operators with visibility, threat detection capability, and network control. Featuring a
user-friendly interface and out-of-the-box detection engines, SilentDefense delivers
actionable results. SilentDefense allows users to assess risks, threats, and vulnerabili-
ties; understand current network resilience state; and pinpoint weak spots and current
inefficiencies.
www.secmatters.com

Engineering is personal.
So is the way you use information.
CFE Media delivers a world of knowledge to you.
Personally.
CFE Media is home to some of the most trusted names in the business.
To do your job better each day, you need a trusted source of information:
CFE Media — Content for Engineers

www.cfemedia.com

CFE_General_HalfHorizontal.indd 1 2/9/2017 2:25:34 PM

ENGINEERED MATERIALS
High-performance materials support
optimal metal end cap seals
How elastomers are tested for suitability
By Eric Bucci
Figure 1: Metal end cap
seals need to be resistant
to downhole fluids such as
hydrogen sulfide and drilling
fluids while meeting industry
specifications such as ISO
23936 and 10423. All graphics
courtesy: Trelleborg Sealing
Solutions
W
ellhead and tubing hanger
sealing materials are
subjected to an array of
challenges, from high
temperatures to corrosive
fluids, and especially,
high pressures. That’s one reason metal
end cap (MEC) seals traditionally have
been designed by wellhead manufacturers
and produced to specification by sealing
experts.
It seems logical that the most robust,
capable MEC seals would be created by
those with the most sealing experience in
a wide variety of situations. A new MEC
design combines high-performance materi-
als with a state-of-the-art design, creating
an optimal sealing solution.
The key to a superior MEC seal begins
with a high-performance elastomer that is
chemically bonded to metal C-rings. The
elastomer must not only meet industry
standards that include ISO 23936 (formerly
NORSOK) and ISO 10423 (formerly API-6A),
but also provide a high level of
resistance to extrusion, explosive
decompression, and downhole
fluids. Additionally, it must simul-
taneously withstand temperatures
up to 350°F and pressures up to
15,000 psi.
One key failure mode is elas-
tomer destruction by rapid gas
decompression (RGD). Elastomers
used in wellheads and various tub-
ing sections are tested by being
subjected to high-pressure gas
molecules, such as carbon diox-
ide, being forced into them. The
molecules then force their way out
of the elastomer matrix when the
pressure is released, potentially
causing blisters and cracks within
the elastomer that can propagate
to the elastomer exterior. Thus,
MEC seals should be manufactured from an
elastomer that resists the majority of gas
molecules trying to enter into its matrix.
Testing elastomers
Most industry RGD specifications assign
subjective grades of zero to five to elas-
tomers. The typical test specimen for an
RGD test is an O-ring. After an RGD test,
the O-ring specimen is usually cut into four
equal pieces so the interior can be visually
examined along with the exterior.
Zero is the best rating and means no
blemishes or imperfections are noticed
within or on the elastomer surface. Grade
one means no more than four internal
cracks are seen, with each shorter than 50%
of the O-ring cross section. Two means less
than six internal cracks are seen, each less
than 50% of the O-ring cross section, and
three means less than nine internal cracks,
with two of the cracks allowed up to 80%
of the O-ring cross section. Grades of four
and five are typically considered unaccept-
able and based on cracks extending to the
O-ring exterior and the O-ring being split or
fragmented.
In addition to receiving a preferred grade
of zero or one during the RGD test, the elas-
tomer in an MEC seal must be highly resis-
tant to downhole fluids such as hydrogen
sulfide, drilling fluids, completion fluids, and
the crude oil itself.
Industry specifications, such as ISO 23936
and ISO 10423, also dictate specific chemical
formulations that a seal material must survive
in an immersion test. The seal material speci-
men is immersed in the chemical formulation
for specified time periods, temperatures, and
pressures. Once removed from the immer-
sion test, the specimens are tested and
results compared to industry-specified failure
criteria. Any specimens exhibiting properties
within the failure criteria are considered com-
pliant, and those outside it are unacceptable.
OIL&GAS ENGINEERING DECEMBER 2018 • 15
 Belt/Sheave

1-800-72-SHIMS (1-800-727-4467)
Laser Alignment System
www.mrshims.com

New Green laser delivers these

important benefits:
ENGINEERED MATERIALS
● Reduces Vibration
● Eliminates downtime and productions
● At an affordable price It should be noted that even ally modeled using FEA under a myriad of
● Visible indoors and Outdoors
● Brightness great for long distances
though a seal material is demonstrat- conditions to predict seal behavior before
ed to be compliant to an industry spending significant resources on lab fix-
Mr. Shims specification, it does not mean the tures. The FEA results guide engineers
seal material is wholly acceptable in to optimize the hardware and seal design
your answer to better alignment for rotating machinery

an application. Additional testing to as a system, to mitigate potential failure

specific application requirements is
needed.
Finite element analysis
Figure 2: The key to a superi-
Once MEC elastomer materials are tested
or metal end cap seal begins
with a high-performance
to industry specifications and shown to
elastomer material bonded to be compliant, design work can begin on
metallic anti-extrusion rings. the elastomer and metal end caps. MEC
seals are large diam-
eter, and testing in lab
fixtures is complex
and expensive.
Finite element analy-
sis (FEA) can there-
fore support product
proving. MEC seal
designs can be virtu-
modes. The FEA results also can graphically
demonstrate what forces and stress the
seal encounters under arduous conditions.
Having this knowledge allows engineers
to have the highest confidence possible
before spending resources on lab testing.
At this point it should be eminently clear
to the oil & gas industry that equipment
and seal manufacturers have collaborated
to analyze and engineer the best MEC
product possible. MEC seals are expected
to have a multi-year life span, and proper
functioning is critical to ensure well integ-
rity and overall safety. OG
Eric Bucci is oil & gas segment manager,
Trelleborg Sealing Solutions.

2018 Oil & Gas Engineering Research

SPONSORED BY:
Turning Research into Insights Makes for Better Business Decisions
This study was performed by Oil & Gas Engineering to identify engineering
professionals’ insights regarding oil industry integration, including challenges,
best practices, opinions, and type solutions.

Fifty-nine percent of engineering professionals’ companies or clients

have experienced substantial cost and/or scheduling overruns when
executing capital projects. The top causes of cost and scheduling
overruns are poor or rushed planning, overoptimistic assessments,
and unclear responsibility for strategic or operations decisions.
Forty-two percent of engineers agree that front-end engineering and
design is one of the most problematic or challenging capital
project transitions, followed by forging initial design specifications
and the transition from design to development.

Access the full Oil & Gas Engineering Research with additional
findings and insights at www.oilandgaseng.com/2018Research.
COVER STORY

Machine learning-based gas

recognition detects minor leakage
Seven image characteristics, singly and combined, used to recognize amorphous gas clouds
By Kevin Parker

A
s part of the Taiwan-based Industrial Technology
Research Institute’s (ITRI) efforts to commercial-
ize its recently introduced gas leakage automatic
recognition technology (GLART), Senior Principal
Researcher Dr. Ming-shan Jeng in November
toured the U.S. and had opportunity to speak
with Oil & Gas Engineering magazine.
GLART software is applied to infrared (IR) thermal images
created by a leakage detection device. It can be combined
with robots, tracks, or unmanned aerial vehicles for automat-
ed inspections. The technology enhances leakage inspection
accuracy and IR thermal imager speed even when manually
operated, Jeng said.
“The infrared camera has to be able to detect gas in
the three to five micrometer range, which is lower than
most infrared cameras pro-
vide,” Jeng said.
A large-scale industrial trial
of GLART for pipeline inspec-
tion is currently underway at
a Taiwan petrochemical plant
and the technology is available
for licensing. “Early detection
of small leaks is crucial for the
prevention of accidents; even
minor leaks of a few grams of
hydrocarbons per hour can lead Gas leak recognition technology is applied to infrared thermal
to disastrous results if an ignition images created by leak detection devices that can be combined
with unmanned aerial vehicles, aka drones, for automated inspec-
source is present,” Jeng said.
tions. Image courtesy: Industrial Technology Research Institute
Machine learning applied
GLART uses machine learning and image processing for
auto-recognition of minor gas leakage, enhancing the leak-
age image and extending the lower limits of IR detection.
Its algorithm improves inspection effectiveness and enables
operation of drone-carried IR cameras, bettering long-dis-
tance leakage detection accuracy.
Gas leakage IR image enhancement uses image-stabilizing
compensation to solve jittering issues. Grey-scale IR images
recorded by a moving IR camera are full of noisy signals.
GLART solves this by identifying multiple moving features in
the images to determine a final motion vector. Images are
analyzed pixel-by-pixel for differences among timewise con-
sequential images.
To make gas leakage detection automatic, ITRI developed
image auto-recognition technology. Because IR image fea-
tures for gas leakage are diverse and conventional image
recognition techniques unsuitable, GLART analyzes numer-
ous IR leakage images compiled by ITRI. ITRI found gas
leakages can be described using seven image characteristics
derived from grey pattern and texture analysis. These seven
characteristics are used in training seven machine learning
models individually. Outputs of the seven models are treated
by an ensemble and regression process to generate the final
output.
“Unlike a face or a cat or a dog, a gas emission has no
identifiable definite contour, so the task was to find suitable
characteristics to which ML could be applied, as well as
motion analysis. We spent seven years populating the data-
base with instances of gas leak-
age,” Jeng said.
In addition, to commercialize
the technology, all the many
different types of pipes, joints,
and flanges used to convey gas
in the petrochemical industries
must be recorded into the data-
base to be used to further train
the model.
Placed in perspective
Most conventional leakage moni-
toring devices applied to pipeline
pressure, flow rate, or acoustic
signals cannot detect small leaks. Fixed devices work well
only when leakage rate exceeds one percent of the total
transport amount. Manual labor detects small leaks, but is
far too slow for large plants and pipelines, and often results
in delayed leak discovery. When using only an IR camera for
manual visual inspections, operators often miss smaller leaks
due to visual fatigue.
By using GLART combined with robots, tracks, or UAVs
operated continuously, the 100,000 valves within a small
petrochemical plant could be inspected for leaks in approxi-
mately five calendar days, rather than the 100 to 500 working
days required for manual inspections. GLART increases the
possible scope and frequency of inspections in addition to
reducing inspection time. OG
OIL&GAS ENGINEERING DECEMBER 2018 • 17

Challenge:
This business has around 30,000
motors across 70 factories globally.
The motors are often in constant
operation, so their reliability and
performance are critical to ensure
smooth production.
Solution:
To continuously monitor the
motors in critical applications, the
company installed nearly 100 smart
sensors in production facilities
throughout an entire country. This
allowed for predictive maintenance,
substantially reducing downtime
and extending equipment life.
Result:
By implementing these sensors, the
company identified motors which
exhibited trends higher than normal,
allowing for organized and planned
replacements. By preventing only
one motor failure, they have already
recovered the cost of installing the
sensors at its factories.
Global business reduces motor downtime
with ABB Ability™ smart sensors
Summary:
This global company has around 30,000 motors
across 70 factories. These motors are often in con-
stant operation, so their reliability and performance
are critical to their success. A motor failure can slow
production or cause costly, unplanned downtime.
Until recently, the monitoring of a motor has been a
manual process, consuming time and labor. But after
piloting the ABB Ability™ Smart Sensor for motors,
the company expanded their installation, and now they
have invested in nearly 100 smart sensors for their
production facilities in one single country.
The Smart Sensor is designed to continuously and remotely monitor a
motor’s status, enabling predictive maintenance, substantially reducing
downtime and extending equipment life. The devices are simply attached
to the motor, without the need for
wiring or machining.
Upon installation, one of the
smart sensors indicated the motor
exhibited higher than normal
vibrations. The data showed
vibration levels in the alert zone
which rapidly reached their limit.
Based on this data, the company
carried out a smooth, planned
replacement of the faulty motor.
The sensor was shifted to the
newly installed motor and the
vibration levels of the newly
installed motor were normal.
The savings from preventing only one motor failure has already recovered
the company’s investment in smart sensors. They are pleased to have a
tool which allows them to better avoid a shutdown and, thereby, increase
the reliability of their equipment.
ABB Motors and Mechanical Inc.
479-646-4711
BALDORABBCOMsABBCOM

Challenge:
In new gas pipelines, debris can
break loose and cause damage
to the meter’s probe. Getting a
replacement must be quick espe-
cially when it’s difficult to schedule
a gas sample analysis to be taken.
Solution:
The FT4A’s rugged DDC-Sensor™
is tolerant to debris in the pipe and
Fox Thermal can expedite an order
in a week. The FT4A allows the user
to select a custom gas mixture
at the meter’s display or a free
software tool.
Result:
Production facilities see little to no
downtime by getting their meters
quickly. Selecting the gas on-site
takes pressure off timing of the gas
sample analysis.
BLM Regulations, Flaring, and the
Fox Thermal Model FT4A as the Solution
Summary:
The BLM has jurisdiction over most onshore leasing, explora-
tion, development, and production of oil and gas on federal
lands and each lease holder is responsible for maintaining
instrumentation to track “sales gas” flowing from the well site.
There are also rules for flaring waste gas at well sites.
Modern thermal mass flow meters are uniquely positioned
to solve these flaring measurement challenges as the
technology has recently seen advancement in accuracy and
the broadening of features.
1. Direct Mass Flow
2. Inexpensive solution
3. Accuracy and reliability
4. Ability to measure changing
gas compositions with
gas selection feature
In the harsh North Dakota environment, the
Fox Thermal Model FT4A Thermal Gas
Mass Flow Meter has been used at upstream
oilproduction sites in the Bakken.
A large Oil & Gas Company operating
numerous production facilities across
North Dakota reports that the Fox Thermal
Model FT4A has been introduced into four
key areas at their production facilities:
s test vessels for allocation purposes
s flare gas lines for waste gas or excess gas
s flare gas lines from tank batteries
s vent gas from tank batteries
Thanks to its robust DDC-Sensor™ design and innovative Gas-SelectX®
feature, the Model FT4A is making an impact in the gas measurement
applications in the Oil & Gas Industry while meeting the accuracy
requirements for BLM 3175.
sales@foxthermal.com
(831) 384-4300
www.foxthermal.com

Challenge:
Enhancing the asset integrity
and operational efficiency of a
critical client asset through
improvements in the availability,
accuracy, and completeness of all
of their asset information.
Solution:
• Cleansing, enriching and
migrating 185,000 information
assets to the client’s
EDW platform
• Forging relationships between
all tags and document met
data to enable users to drill down
through the asset hierarchy
Result:
The onsite-offshore delivery model
enabled the client to customize
and implement EDW, enabling a
single source of high-quality
engineering information. 500,000
pages of physical documents
were digitized. Project costs and
schedules are optimized with
a robust accelerator-based
automated approach.
Streamlining information management
to enhance asset integrity and viability
Summary:
A global leader in the oil industry wanted to enhance asset
integrity and operational efficiency of a key Norwegian
platform by improving the availability, accuracy and
completeness of their asset information.
To meet this objective, the company leveraged L&T
Technology Services’ (LTTS) Integrated Asset Management
Services (IAMS) for the data migration exercise. The
project scope included cleansing, enrichment and
uploading of critical asset data into the company’s
Engineering Data Warehouse (EDW) platform.
The key task was to map the asset tags with the document metadata,
to enable users to ‘drill down’ through the overall asset hierarchy.
Following an initial two-week gap analysis and scoping study, LTTS
prepared a detailed approach plan and methodology to cleanse, enrich
and migrate 185,000 information assets (tags and documents) to the
EDW platform.
The documents and
drawings along with
associated metadata
information were made
available in multiple
systems such as
Document Management
System (DMS), Engineering
Data System (EDS) and
Enterprise Resource
Planning (ERP) tool.
LTTS implemented an onsite-offshore delivery model to facilitate rapid
resource ramp up, consistent execution, and cost containment. The
offshore team was supported by a dedicated onsite team to manage
inputs, escalations, reviews and risk management.
Tel: +91 80 6767 5173 • info@lnttechservices.com
www.lnttechservices.com
MOVE SECURELY INTO
THE CLOUD BU I LT-IN
RITY
E C U
S
WAGO Cloud

Microsoft
Amazon Web
Azure
Services

IBM
Other Cloud BLUEMIX
Services

IIoEATDY
R

Direct Field to Cloud Connection

with the PFC Series Controllers
• IIoT-ready with native MQTT and TLS encryption
• Built-in VPN and Firewall for increased network security
• Simplify data routing and reduce latency
• Interface with existing controls via onboard fieldbus gateways

www.wago.us/pfccloud