20/20 Vision of Your Operations – Creating an Operational Twin of Completions Operations

Abstract The industry has seen an increase in the need for digitally connected completions operations, pushing for companies to sensor, aggregate, and stream data to remote operation centers (ROC). While sensoring critical parameters is vital to monitoring operations, the most important element is generally excluded from the ROC – the contextual perspective only provided by personnel. This innovative approach provides clarity to remote operations by integrating human context, engineering, and sensors, aligning operations with engineering and management. Prioritizing real-time data aggregation and the integration of sensor and contextual data must be a cornerstone of a remote monitoring solution. This approach outlines creating a digital twin by combining and aggregating the three elements into one digital context. The method outlined leverages a tri-directional sync from the operational controls, remote platform, and phone application that allows users to include operational states and human-sensored elements, such as return rate, viscosity, valve position, and rig-up geometry, that are used to align the pre-job modeling and actual operations once the job starts, providing a single source of truth for all users. Pre-job modeling and procedures provide a roadmap for the operations to follow, but when the human context is excluded once the operation has started, the model becomes invalid. At this point, the variability introduced due to the lack of context can result in undesirable outcomes. When simulated, pre-job modeling uses the best available information, but often, the operation has elements that need to be adjusted once on location. By including a multi-directional sync, onsite personnel can provide updated information, including rig-up geometry, fluid metrics, and mechanical deviations from models, that are used to update the simulation and keep the operations on track and aligned for the best outcome. Human senses are the best sensors, as these are used to track very difficult-to-sensor elements, such as return rate. These are, in turn, used to derive complex equations such as annular velocity and fluid carrying capacity that are critical to successful completion operations. The incorporation of human context with engineering and sensor data provides an extension of the operation to be viewed remotely, as opposed to an aggregation of sensors that rely on data analytics and engineering deduction. This operational twin enables full engagement in the field and in the office. Creating a digital, interconnected workspace that aligns sensor data with operational context brings the completions engineer back into the operation. This integration empowers the industry to work toward one goal—completing wells more efficiently and safely and reducing avoidable non-productive time (NPT)—by removing the logistical barrier when developing an ROC.