The petroleum industry continues to rely on antiquated analog methodologies and individual experiences to interpret pressure tests. These tests are fundamentally critical to verifying well barrier integrity, which ensures protection of personnel, assets, and the environment.
Over a decade ago, IPT Global led a digital revolution with the development of industry-leading technology that modernized well barrier assurance. This case study examines how IPT Global worked with a major oil and gas (O&G) company to compare analog methods (circular chart recorder (CCR)) with IPT Global’s digital pressure testing solution.
The Opportunity: Comparing Digital Pressure Testing With Circular Chart Recorders
The client’s shallow water and deepwater Gulf of America operations were early adopters of IPT Global’s SureTec® platform and PressureTesting solution, but the client still had several regional operations that used circular chart recorders, including drillships in West Africa and in several onshore basins. The comparison trials, conducted across both land and deepwater operations, evaluated IPT Global’s PressureTesting solution against circular chart recorders to quantify the value of adopting a global well assurance solution.
Ultimately, the trial demonstrated that SureTec PressureTesting created immediate value with enhanced efficiencies and time savings on the rigs. PressureTesting’s digital Cloud-based data and archival ensure long-term record preservation, guarantee compliance, and enhance safety across well barrier assurance processes in ways not possible with analog methodologies. Beyond the immediate value created with IPT Global’s digital pressure testing solution, the client also safeguarded long-term value by ensuring well barrier processes and program steps were consistently followed.
How IPT Global Outperformed Analog Methods
SureTec PressureTesting generated immediate value on the client’s projects compared to analog methods. IPT Global measured more efficient test validation times both onshore and offshore. The client also benefited from qualitative efficiencies in processes, communication, and generating information that could be applied to continuous performance improvement.
Efficient Test Validation
- Faster Deepwater Validation: The SureTec PressureTesting solution repeatedly reduced test time by 25% as compared to the circular chart recorder on the client’s deepwater operations. This instant rig time savings resulted from IPT Global’s patented, physics-based algorithm for deepwater test validation.
- Early Leak Detection: PressureTesting advanced algorithms objectively validate tests with robust criteria that can detect leaks early. This high-resolution digital solution to interpret tests removes an element of human error that also can contribute to lost time on all operations.
- Optimized Test Duration: The trial identified situations where individuals were holding tests longer on the circular chart recorder compared to PressureTesting, due to the subjectivity of interpretation and lack of data resolution. The PressureTesting solution ensures tests run only as long as required to validate, reducing the amount of pressurized time on equipment and the mean time between failures, ultimately reducing operational and maintenance costs.
- Reduced Onshore Pressured Time: PressureTesting would have reduced onshore pressured time by 30% compared to circular chart recorders just by eliminating reliance on human interpretation and by providing high resolution data with objective test criteria.
Visible Performance Improvement Opportunities
- Rapid Performance Analysis: Compared to circular chart records on paper, the SureTec platform instantly enabled performance visibility through Cloud-based big data and analytics relevant for each rig trial. Accessible and transparent information highlighted opportunities for accelerated learning and continuous improvements for teams using PressureTesting in the trials. Granular data allowed for multiple paths to improve performance, including working with rig teams to reduce the amount of time it takes to line up for the tests (gap time). Similar value creation would not be feasible with analog methods.
- SME Partnership: During the trials, the IPT Global operational advisor led after-action reviews (AARs) with rig and office teams highlighting the opportunities for improvement and sharing lessons learned. This accelerated learning and uptake with new users. The team worked together during the trials to make sustainable changes to programs and standards.
Efficient Collaboration
- Change Management: PressureTesting provides the ability to quickly adapt and document changes to test plans and operational sequence. During the trials, new users were able to easily track all changes, documenting them in the test report and storing them on the Cloud.
- Secure, Live Test Streaming: Global teams have access to live data, enabling collaboration for problem-solving and rapid uptake of best practices.
How IPT Global’s Solutions Closed Process Safety Gaps
In addition to immediately reducing costs through more efficient and effective operations, IPT Global’s PressureTesting solution revolutionized the client’s assurance, confirming well barriers will perform as planned so that the operator’s reputation and license to operate was protected. The regional projects that were still using analog methods to verify barrier integrity posed invisible risks that would remain unknown until after a catastrophe occurred. Implementing PressureTesting created opportunities to close process safety gaps across all of the client’s operations.
Ensured Compliance
- Accessible Data: Allowed for demonstration that internal policies and regulatory standards were upheld across all operations.
- Tamper-proof and Auditable Record: Well barrier history is now accessible for the entire life of a well.
The Results: 25% Faster Test Validation and Global Adoption of PressureTesting
Prior to the comparison trials, some of the client’s staff believed a “free” solution would be sufficient to carry their operations. The side-by-side comparison left no question that SureTec PressureTesting, IPT Global’s digital pressure testing solution, generated and preserved value.
In addition to validating tests 30% and 25% more efficiently, for onshore and offshore respectively, major efficiencies were gained from improved performance enabled through visible data, enhanced change management, collaboration, and auditable record keeping. The operator has implemented IPT Global’s PressureTesting solution into all global operations as part of their assurance and integrity program, providing peace of mind that all their operations would comply with internal and regulatory standards to ensure well barrier integrity. This enterprise-level assurance minimizes client exposure to well integrity incidents that could impact people, assets, and the environment.
During the implementation of SureTec, a client remarked, “I’m so happy we are making the switch. Using this digital tool and being involved in the digital transformation is critical for assurance and driving efficiency.”
Contact us today and let IPT Global be a part of your digital transformation. With SureTec PressureTesting and our broader well assurance solutions, you can turn digital data into real cost savings while strengthening the assurance that protects your company’s reputation and license to operate.
