OTC-31017-MS

Digital Transformation and Automation of Flow Assurance Engineering

Workflows Using Digital Field Twin

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Harshkumar Patel, Jianlin Cai, Gautier Noiray, and Subrata Bhowmik, McDermott International

Copyright 2021, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in Houston, TX, USA, 16 - 19 August 2021.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of
the paper have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any
position of the Offshore Technology Conference, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.

Abstract
Flow assurance is central to the design of a subsea production system and requires frequent interfacing with
engineers from multiple disciplines. The objective of this paper is to demonstrate how cloud based digital
field twin can be leveraged to automate subsea flow assurance engineering workflows and consequently,
achieve efficient collaborations, faster and reliable designs, and reduced costs.
In this proposed workflow, engineers use a web application built on top of a cloud-based digital twin
platform to perform flow assurance calculations and design analysis. The web based platform integrates
multiphase flow simulators and other relevant engineering tools through python scripts. A user is only
required to input design constraints and necessary basic information. The application acquires inter-
disciplinary data (e.g. pipeline, layout, equipment, etc.) and automatically performs pre-processing, model
setup, simulation, and results processing in the background and make results available to all the users at
the front-end.
The digital flow assurance platform replaces traditional workflows requiring use of different standalone
engineering software, and frequent exchange of information with other engineering teams in form of
documents and spreadsheets. The proposed cloud-based workflow allows engineers to focus on technical
analysis by eliminating several manual and repeating processes such as accessing different software,
creating models, results extraction and formatting, etc. The ability to share results in form of auto-generated
reports and formatted spreadsheets; minimizes human errors and promotes information exchange and
transparency among project team members from different disciplines. The cloud based platform enables
engineers to work on a same project from different geophysical locations and devices. Overall, this digital
flow assurance workflow significantly improves engineering efficiency, save costs, and allows faster and
reliable concept design and FEED (Front End Engineering Design).
The ideas widely discussed for flow assurance digitalization typically include use of data analytics and
machine learning, virtual flow metering, real time data monitoring, predictive analytics, etc. This paper,
however, presents novel practical idea to bring digital transformation to the way flow assurance engineers
work and collaborate.
2 OTC-31017-MS

Introduction
Flow assurance engineering deals with assurance of optimum and economical flow of oil and gas through
production system. Flow assurance typically requires multiphase fluid flow and thermal analyses to ensure
system deliverability and operability throughout field life cycle. Flow assurance plays a critical role from
initial field development to the end of a field's life including - conceptual design selection, FEED, detailed
engineering, normal production phase, field abandonment, etc. Flow assurance engineers develop guidelines

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

and/or solutions (mechanical, chemical, or equipment) to ensure prevention and mitigation of risks related
to fluid flow, product quality, and system integrity. Common flow assurance problems include hydrate, wax,
asphaltene, emulsion, foaming, scale, sand, slugging, and materials related issues.
Flow assurance engineering significantly impacts economics of a project. As highlighted by Makogon
(2019), a typical subsea flow blockage may cause several months of downtime and expenses in upwards
of 15 million USD for successful mitigation. Expectedly, flow assurance aspects are critical to designs of
onshore and offshore facilities including wells, subsea/umbilical/riser flowlines (SURF), process facilities,
export pipelines, artificial lift systems, etc. Other engineering disciplines such as pipeline engineering,
subsea layout, reservoir engineers, etc. must work in collaboration with flow assurance engineers to design
field architecture before proceeding with Engineering Procurement and Construction (EPC).
Considering the complex and critical nature of flow assurance engineering, it is one of the top candidate
discipline to apply recent advances in digital technologies and data-driven modelling to improve designs and
workflows. One of the earlier uses of computational technologies to accelerate fluid network optimization
came in form of spreadsheets as presented by Lezeau and Leporcher (2001). Present day efforts in flow
assurance digitalization typically include use of data analytics and machine learning, virtual flow metering,
real time data monitoring, etc. (Parthasarthy 2018, Andrianov 2018, Attia 2015). All these methods largely
focus on using machine learning to assist engineering designs (e.g. reducing simulation requirements), assets
monitoring (e.g. virtual flow metering), and predictive maintenance (e.g. leak detection).
Work presented in this paper focuses on workflow automation and bringing digital transformation to
the way flow assurance engineers work and collaborate. In this proposed workflow, engineers use a web
application built on top of a cloud-based digital twin platform to perform flow assurance calculations
and design analysis. The web-based platform integrates multiphase flow simulators and other relevant
engineering tools through python scripts. A user is only required to input design constraints and necessary
basic information such as flow correlations, heat transfer parameters, simulation settings, etc. The
application acquires inter-disciplinary data (e.g. pipeline, layout, equipment, etc.) from the digital-twin and
automatically performs pre-processing, model setup, simulation, and results extraction in the background
and make results available to the user at the front-end.

Technical Approach
Digital flow assurance engineering workflow leverages a cloud based digital field twin platform to create
subsea field architecture. As shown in Figure 1, this platform allows engineers to quickly create 3D
model of a field architecture by dragging and dropping various subsea and topside assets and connections.
Specifications and all relevant engineering information corresponding to each asset or connection is input
as metadata. As shown in the figure, the platform also allows adding bathymetry and GIS layers for
automated pipeline routing. Elevation profiles are also automatically generated and available as input for
flow assurance modelling and simulations.
OTC-31017-MS 3

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Figure 1—Cloud-based digital field twin platform and integrated
engineering modules for flow assurance engineering workflows

Different engineering modules have been developed and integrated to this digital field twin platform.
Working principle behind the flow assurance engineering module is graphically summarized in Figure 2.
Field layout and various metadata (pipeline metadata, wells metadata, fluid properties, etc.) from the digital
twin serve as input/output for the engineering module. Information related to fluids can be added as virtual
assets to the wells or other fluid source assets. Specific inputs and settings pertaining to specific engineering
calculations can be input in the Graphical User Interface (GUI) of engineering modules. Backend of the
module have python scripts that communicates with multiphase flow simulators, and other engineering
tools, documents, excel sheets, etc. through APIs and python packages. The python codes help automate
manual routines such as data pre-processing, modelling and simulation, analysis routines, results data
processing, report generation, etc. The results are pushed to the GUI for users to view and analyze.

Figure 2—Cloud-based digital field twin platform and integrated

engineering modules for flow assurance engineering workflows
4 OTC-31017-MS

As shown in Figure 3, the main idea behind the platform is to leverage digital technologies to integrate all
data and tools related to a project and eliminate siloed information in form of documents, emails, Excel files,
Mathcad sheets, AutoCAD drawings, and engineering software. This can achieve lean and standardized
engineering processes, improve cost effectiveness, and enable true digital project delivery.

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Figure 3—Scope and benefits of a digital field twin

In addition to flow assurance module, the platform also contains engineering modules for other disciplines
such as pipeline design, riser design, installation analysis, scheduling, packing, etc. With the ability to
configure user roles and metadata access, engineers from various disciplines can perform their analyses
and store results on this collaborative digital twin platform. Several manual and repetitive engineering tasks
have been eliminated or automated by writing code. Integration of software through python scripts not only
replaces the need to open software but also significantly enhances its capabilities. Cost and engineering
estimation exercise is greatly improved by generating information faster and by having a proper data
management system. Uncertainty to the offshore operations is reduced through visualization, assessment,
and scheduling tools. For large FEED (Front End Engineering Design) and EPCI (Engineering Procurement
Construction and Installation) execution, the engineering digital twin platform can be integrated with PLM
(Project Life Cycle Management) platform for enhanced execution and project controls. Data generated
through our engineering modules can be pushed into PLM. This paves the way to a true data-centric project
delivery approach.
Besides increasing internal efficiency and accelerating the turn-around time, digital project also paves
the way for a new, more transparent and collaborative approach to project hand-over from and to operators.
Building engineering applications also allows us to standardize and consolidate processes across different
regions. By improving the estimation process and allowing engineers to test various scenarios, delivery
assurance is increased. Ultimately, all these features of digital engineering lead to cost reduction, improved
transparency (internally as well as with clients and vendors), and better engineering designs.
OTC-31017-MS 5

Flow Assurance Module

Overview of the flow assurance engineering module implemented on the digital field twin platform is shown
in Figure 4. The module can perform steady-state multiphase fluid flow analysis. The module integrates
widely used multiphase flow simulator PIPESIM software (Schlumberger 2019) in the backend using
python Application Programming Interface (API). An API is a set of functions and standard protocols that
allows access to the features or data of an operating system, application, or other service (Chan et al. 2019).

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

As summarized in the figure below, the module provides a simplified three-step workflow:

Figure 4—Overview of flow assurance workflow on digital field twin platform

Automated modelling
With few clicks, the module creates a PIPESIM project representative of the digital field architecture (or
tieback, or a subset of the field selected for analysis). Network layout and metadata of assets, equipment,
fluids, flowlines, etc. as defined in the digital field twin are acquired and used to create the PIPESIM model.
The module has self-check function and raises specific errors to the user if certain required parameters are
missing or inappropriately defined. The created model is also stored on the platform for future runs. The
automated modelling not only saves significant time from system profiling (estimated from several hours
to days) but also creates a detailed model with accurate elevation and deviation profiles of pipelines based
on the bathymetry layers. User is prompted to specify all relevant model and simulation settings on the
GUI of the module.

Simulation run
The second step in the workflow is to run simulations. The module provides options to run a single network
simulation or specify a range of values to initiate sensitivity analysis. With one click of a button, user can
start simulation, interrupt it if needed, and view simulation messages and errors. The simulation runs on a
Microsoft Azure virtual machine. Once the simulation is completed, results are made available to all the
users for analysis and reporting.
6 OTC-31017-MS

Automated analysis
The module allows user to specify parameters, range of values to investigate, and acceptance criteria. The
module will automatically run all simulation cases, analyze the results, and filter cases that meet the specified
acceptance criteria. For example, as shown in Figure 5, user can select one or more variables and specify
the target constraints. The module will identify the simulation scenarios that match the provided acceptance
criteria.

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Figure 5—Automated analysis of simulation results by providing acceptance criteria

Interactive Reports and Formatted Results

On the results page, results data are made available in interactive and downloadable formats (Figure 6). User
can customize and view tables, create plots, and download formatted excel files. Interactive and shareable
reports are also available to users. Unlike static pdf or word reports, these self-contained interactive reports
make it easier for users to review results.

Figure 6—Digital workflows enable creation of interactive reports and dashboards for results analysis
OTC-31017-MS 7

Standalone mode
The flow assurance module can also be used as a standalone application. The module allows users to upload
a PIPESIM project file or open recent projects/results. This capability ensures that engineers can use the
module to significantly accelerate their day-to-day design, analysis, or report generation tasks without the
need for creating/modifying a digital field twin project.

Benefits Over Conventional Workflow

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Benefits of the digital flow assurance engineering become apparent when compared to conventional
workflows. As discussed earlier, flow assurance is central to the design of production/injection system and
processing facilities. Flow assurance engineers must interface with a variety of engineering disciplines, in
addition to clients, to ensure design compliance and suitability in various aspects of the system, such as
mechanical, installation, logistics, materials, geotechnical, etc.
Typically, as shown in Figure 7, engineering workflows occur in silos and information and data are
exchanged through emails, documents, drawings, plans, spreadsheets, etc. FA engineers must gather all
required information and conduct multiphase fluid flow analysis to optimize the pipeline sizing, insulation,
pumping, chemical injection, etc. requirements. Various concept designs need to be shared and evaluated by
other engineering disciplines. Significant amount of time is lost in information exchange, report creations,
analysis of design iterations’ results, etc. Moreover, there is also an increased risk of human error and
miscommunication.

Figure 7—Conventional workflow of a flow assurance engineer

Digital FA engineering workflow, as shown in Figure 8, eliminates manual routine tasks such as creating
models, extracting and formatting results, analysis, and generating report. The automated modelling not
only saves significant time from system profiling (estimated from several hours to days) but also creates a
detailed model with accurate elevation and deviation profiles of pipelines based on the bathymetry layers.
Plus, all models and data are stored on the digital twin platform with all revisions and changes recorded in
a log. This significantly accelerates collaboration and decision making. Comparison of Figure 7 and Figure
8 clearly highlights decreased engagement threads and consequently improved focus on technical analysis.
8 OTC-31017-MS

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Figure 8—Digital field twin assisted workflow of a flow assurance engineer

Another unique advantage of digital workflow is availability of flow assurance module as a web platform.
It is securely available to authorized users on any computer or mobile device from anywhere. Moreover,
consolidation of all engineering and project information on the digital platform enhances transparency and
minimizes risk of human error or miscommunication within company as well as with client and vendors.
However, an important risk to consider with digital workflows is that mistakes are prone to amplify due to
accelerated speed at which information is disseminated. As a solution, customized user authorizations have
been implemented to restrict users from accessing other engineering modules and modifying metadata not
relevant to their disciplines. Although not implemented yet, a notification system is planned to be developed
that can send messages to users whenever important parameters are revised or new data or results are
available.
Overall, the digital workflow does not alter the technical role of flow assurance engineer but it
significantly boost engineering productivity through automatic modelling, assisted analysis, automatic
report generation, etc. Development work for this digital platform is ongoing and new features are frequently
being deployed based on users’ feedback. The goal is to digitalize as many workflows as possible and reduce
interfaces outside of the digital system. Summary of the major benefits of the proposed digital field-twin
integrated workflow is presented in Figure 9.
OTC-31017-MS 9

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Figure 9—Benefits of digital field twin based flow assurance engineering

Conclusions and Way Forward

Digital flow assurance engineering replaces traditional workflows requiring use of different standalone
engineering software, and frequent exchange of information with other engineering teams in form of
documents and spreadsheets. The developed module allows engineers to focus on technical analysis by
eliminating several manual and repeating processes such as accessing software, creating models, results
extraction and formatting, results, etc. The ability to share results in form of auto-generated reports and
formatted spreadsheets; minimizes human errors and enhances information exchange and transparency
among project team members from different disciplines. Overall, this digital flow assurance workflow
significantly improves engineering efficiency, save costs, and allows faster and reliable concept design and
FEED.
The scope of the current module is only limited to steady state analysis. Next in development pipeline is
transient analysis. Particularly, transient analysis could greatly benefit from the power of cloud computing
and ML-assisted design. The digital field twin can also be further leveraged for application in operating
phase of the field. With integration of relevant sensor and production data threads, the platform can be
used for various data-driven engineering including production monitoring, integrity management, predictive
maintenance, etc.

Acknowledgement
Authors would like to thank McDermott International for providing resources and giving permission to
present this paper.

Nomenclature
API : Application Programming Interface
EPCI : Engineering Procurement Construction and Installation
FA : Flow Assurance
FEED : Front End Engineering Design
GUI : Graphical User Interface
ML : Machine Learning
PLM : Project Life Cycle Management

References
Andrianov, N. 2018. A machine learning approach for virtual flow metering and forecasting. In: Proc. of 3rd IFAC
Workshop on Automatic Control in Offshore Oil and Gas Production, Esbjerg, Denmark, May 30–June 01. http://
dx.doi.org/10.1016/j.ifacol.2018.06.376.
10 OTC-31017-MS

Attia, M., Abdulraheem, A., Mahmoud, M.A. 2015. SPE-175724, Pressure drop due to multiphase flow using four artificial
intelligence methods. In: SPE North Africa ATCE, 14–16 September, Cairo. https://doi.org/10.2118/175724-ms
Chan, J., Chung, R., and Huang, J. 2019. Python API Development Fundamentals. Packt Publishing. ISBN:
9781838983994. https://www.packtpub.com/product/python-api-development-fundamentals/9781838983994
Jain, A. Patel, N., Hammonds, P. et al. 2018. A Smart Software System for Flow Assurance Management. Presented at
SPE Asia Pacific Oil and Gas Conference and Exhibition. http://dx.doi.org/10.2118/191951-ms.
Lezeau, P., Leporcher, E., 2001. A spreadsheet tool to ease the selection of a Deepwater production network. In:
Proceedings 10th International Conference on Multiphase Flow, BHRG, Cannes France 13–15 June.

Downloaded from http://onepetro.org/OTCONF/proceedings-pdf/21OTC/2-21OTC/D022S060R009/2523532/otc-31017-ms.pdf by Schlumberger Oilfield UK Plc user on 01 March 2023

Makogon, T. 2019. Handbook of Multiphase Flow Assurance. First Edition. Gulf Publishing. https://doi.org/10.1016/
C2016-0-04442-X
Parthasarthy, P. 2018. Machine Learning and Data Analytics in Flow Assurance. Presented as SPE Webinar. https://
webevents.spe.org/products/machine-learning-and-data-analytics-in-flow-assurance
Schlumberger. 2019. PIPESIM User Guide.