Unplanned shutdown prevention at major natural gas producer

Unplanned shutdown prevention at major natural gas producer

Challenge

The natural gas producer faced difficulties of gas well failure events that result in significant loss of natural gas production. They had limited visibility in finding out potential causes of well site shutdowns. The company’s maintenance planning lacks a complete view of asset health due to increased machine downtime and expensive repairs. 

natural gas unplanned shutdown solutions

Solution

The use of sensor signals helped them classify the condition of well, gas lift compressors, saltwater disposal pumps, heat treaters, and other well pad devices. Neal Analytics helped them create data features that capture recent device behavior. We also helped them identify the “Normal” and “Pre-Shutdown status for well pads. 

The key data input includes: 

  • Facility pad configuration  
  • Unscheduled Maintenance records  
  • Operational Data  
  • PAD/Device level data  
  • Ambient weather conditions  
  • Facility downtime information 

natural gas unplanned shutdown results

Result

Using Neal Analytics’ solution, the gas producer was able to detect potential shutdowns within a 12 to 72-hour window, which allowed predictive maintenance. They developed an approach to increase well production through unscheduled downtime production. They created an ROI methodology for retrofitting sensors on legacy well pads.