Customer Story
WellAware Automation to Unlock Immediate Value
Read how a major midstream company and chemical service provider worked together with WellAware to bring an immediate ROI to both groups.
Setting the Stage
In the complex world of midstream pipeline chemistry, maintaining the efficiency and integrity of infrastructure is paramount. The risks associated with improper chemical management—such as corrosion, scale, and bacterial build-up—can lead to significant downtime and workovers, operational challenges, and substantial financial losses due to decreased pipeline throughput. In our latest case study, we highlight how WellAware’s chemical automation solution delivered immediate value to both a midstream asset owner and its chemical service provider in the Permian Basin within the first month of installation.
The Challenge
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Manual Processes and Setpoint Inconsistencies
Before integrating WellAware’s chemical automation, the midstream operator faced several challenges:
- No Chemical Tank Monitoring or Automation: The chemical service provider lacked the ability to monitor chemical tank levels in real-time, relying instead on periodic physical checks. This lack of visibility often led to inconsistencies in chemical dosing, inventory tracking and increasing the risk of asset degradation.
- Regular Physical Inventory Checks (Weekly): Inventory checks were conducted manually on a weekly basis, resulting in delayed responses to changing conditions, delivery schedules and potential chemical shortages.
- Manual Pump Set Point Adjustments: The chemical service provider manually adjusted pump set points based on PPM (parts per million) targets, often relying on estimated readings from flowmeters. This manual process was time-consuming as field technicians were dispatched to remote locations and subject to human error.
- No Real-Time Data: Without real-time data, both the operator and service company were unable to make informed decisions on chemical usage or respond promptly to changes in pipeline conditions.
- Infrequent Verification of Chemical Program Performance: The lack of real-time monitoring meant that the effectiveness of the chemical program was verified infrequently, leading to potential risks of over- or under-injection of chemicals.
- Inconsistent Tank Inventory Data: With manual checks being the primary method of inventory management, data was often inconsistent in both time and frequency, further complicating chemical management.
These challenges highlighted the need for a more efficient, reliable, and automated solution to ensure the proper management of chemicals across the pipeline network and chemical injection points.
The question to answer: how do we [the operator] ensure we are effectively treating our lines so they can be reliable and reduce cost associated with excess chemical?
The Solution
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Real-time Chemical Automation with WellAware
WellAware’s Admiral chemical automation solution addressed these challenges by providing a comprehensive, real-time monitoring and pump control that was quickly installed and delivered measurable results:
- Admiral Solution Installed at Chemical Site: The Admiral solution was installed in less than 30 minutes, providing immediate access to a suite of real-time data and control capabilities.
- Remote, Real-Time Data, Control, and Calibration: With the installation of WellAware’s solution, the operator gained the ability to remotely monitor and control chemical injection points across the network. Real-time data was now available for tank levels, pump operation, flow rates, PPM, and power monitoring.
- Fully Automated Pump Set Point Changes: The manual process of adjusting pump set points was replaced with automated changes based on real-time PPM readings, ensuring optimal chemical dosing at all times.
- Optimized Chemical Injection: With real-time feedback, the chemical injection process was optimized according to the asset integrity design, significantly reducing the risk of corrosion, scale, and bacteria build-up.
- Consistent Tank Inventory Data: Automated monitoring ensured that tank inventory data was accurate and consistent, allowing for better planning and management of chemical deliveries.
This transformation from a manual to an automated process resulted in a more efficient and effective chemical management program, delivering immediate value to both the midstream asset owner and the chemical service provider.
Corrosion data and preventative measures data is finally accessible to all interested parties.
The Result
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Tangible Benefits for All Stakeholders
The implementation of WellAware’s chemical automation solution delivered significant benefits, including fully automated pump set point adjustments, which reduced human error and improved dosing accuracy by eliminating manual interventions. The optimized chemical injection, guided by real-time feedback, minimized risks of over- or under-injection, enhancing asset integrity and reducing the likelihood of costly downtime. Additionally, the solution eliminated the need for manual field visits, saving time and resources, while fostering greater transparency and collaboration between the chemical service provider and the midstream asset owner.
ROI Delivered to the Midstream Asset Owner
The midstream asset owner achieved substantial returns on their investment in WellAware’s chemical automation solution, including significant savings in chemical costs through optimized injection, enhanced asset integrity due to reduced corrosion and scale build-up, and minimized unplanned downtime by preventing chemical-related failures. Overall, these benefits contributed to an estimated 11x return on the WellAware investment, highlighting the considerable value delivered by the solution.
ROI Delivered to the Chemical Service Provider
The chemical service provider experienced a positive return on their investment, with automation reducing the need for frequent site visits, leading to labor savings and more efficient resource use. Despite fluctuations in chemical sales, the impact on revenue was minimal, while the transparency and efficiency of WellAware’s solution enhanced the provider’s relationship with the asset owner, increasing goodwill and future business opportunities. Overall, WellAware estimated a 3x+ return on investment for the provider, demonstrating the solution’s cost-effectiveness and value.
Conclusion
WellAware’s chemical automation solution has proven to be a game-changer across both the upstream and midstream industries, delivering immediate and significant value to both asset owners and chemical service providers. By automating chemical management and providing real-time data, WellAware has helped its customers achieve better asset integrity, reduced costs, and improved operational efficiency, setting a new standard for chemical automation.
3X
SERVICE PROVIDER ROI
11X
OPERATOR ROI