American Oil and Gas Reporter - December 2021 - 77

To illustrate the benefits of automation,
Freeman recalls a six-well pad that traditionally
required 12 people (six during
the day and six at night) to manage
flowback. " By replacing legacy equipment
with an advanced separator, we
got the crew size down to eight, " he relates.
" With automation, we would have
needed only one or two people on site.
Eventually, we may be able to manage
flowback remotely.
" By removing people from the location,
we are minimizing workers' exposure on
site and the need to drive to and from the
site, which is one of the most dangerous
tasks in the oil field, " Freeman says.
Freeman adds that efficient sand separation
can reduce tank emissions. " Because
we are able to remove so much
sand, operators no longer need to divert
production to frac tanks to let sand settle, "
he explains. " Instead, they can flow
directly to their production facilities,
which are far more likely to have vapor
recovery units. "
The Equipment
According to Freeman, EnerCorp's
integrated flowback system includes the
sand cyclone, an automated blowdown
unit, a sand quantification unit, a tanklevel
monitoring system, and a control
unit that connects to the cloud. " These
components work together to maximize
the value of the service, " he says. " They
let operators know what is happening on
location whether they are at a desktop in
the office or on a phone in the field. "
Looking at sand and fluid volumes
alongside pressure data can help engineers
determine whether to adjust the well's
choke, Freeman notes.
" We put pressure monitors and other
instruments at various places so we can
watch equipment performance and catch
any anomalies before they become a
problem, " he assures. " For example, we
can detect potential leaks several hours
before a person on site would know there
is a chance of one developing. "
Since the automated flowback management
system's first deployment, it has
handled 1.5 million pounds of sand without
any leaks or environmental concerns,
Freeman reports. " We are proud of that
track record, " he says. " As we developed
the e-flowback ecosystem, we worked
with bpx energy to conduct risk assessments
and ensure every piece of equipment
would be ready for harsh environments.
" Today, we are testing other technologies
to support the flowback process, " he
says. " In the next 12-18 months, we plan
to introduce several technologies that
will reduce emissions, disposal costs and
waste volumes. "
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DECEMBER 2021 77
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American Oil and Gas Reporter - December 2021

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