Digital-Twin System Provides Model-Based Operational Support

_ This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper OTC 35351, “Digital Twin for Model-Based Operational Support: Innovative Applications,” by Chinenye E. Ogugbue, SPE, Zachary M. Greenawalt, and Yevgeniy Kondratenko, BP, et al. The paper has not been peer reviewed. Copyright 2024 Offshore Technology Conference. _ Network simulation and optimization are a well-established methodology for the operator in increasing and sustaining production capacity. To improve existing workflows, the operator has enhanced its previous petroleum- and process-engineering-focused toolkit and has deployed globally a production system that uses digital twins from end to end for model-based surveillance and optimization. The cloud-based production-system digital twin connects sensor data from each asset’s data historian to an equipment-data model and first-principle steady-state simulation tools to create a reliable status of the well network and processing facilities. Integrated Production-System Digital Twin By applying cloud computing technology in the proposed system, all complex calculations are executed on the virtual machines and users can access the digital twin with a Web-based application. Comprised of two subsystems—well network and processing facilities—the end-to-end production-system digital twin began with a focus only on the subsurface well-production network. By leveraging first-principle hydraulic models to balance pressure, flow rates, and temperature dynamically from all components in the system, the well-network digital twin has proven to be robust and user-friendly enough to simulate complex steady-state operation scenarios with high fidelity and is widely used for surveillance and production optimization across production assets. Upon the full deployment of the well-network digital twin, development focus shifted toward simulating production facilities. The digital twin for the processing facility uses a first-principle compositional-chemical-process simulator to model the processes involved in oil, gas, and water processing mathematically. In its standalone capacity, this production-facility digital twin adds value by offering virtual sensors and enhancing existing sensors. Moreover, it enables the rigorous evaluation of facility limits. An extensive deployment of the processing-facility digital twin has been completed for operated assets with the objective of enhancing existing workflows and achieving optimal operations. Design and Implementation Each subsystem was designed to be independently operated. However, the primary strength of this digital twin lies in connecting the well network with processing-facility simulations and real-time sensor data, establishing a linked simulation workflow. Specifically, the pertinent outputs from well-network simulations are captured and incorporated as inputs into the processing-facility simulation. The dynamic communication between these two subsystems is facilitated through a customized interface, resulting in an integrated simulation from the well’s sandface to the export stage. Consequently, comprehensive understanding and holistic study of the effect of current or proposed future operational conditions become feasible.