Oil & gas
Fewer shutdowns. Less deferred production. Every barrel accounted for.
Compressors, artificial lift and tanks run far from the people who look after them. We keep a physics twin of each one, read the controllers and RTUs already on site, and tell your team which machine is drifting and why. We are never in the safety loop.
From the well to market
Wells lift the fluid. The separator splits it. Oil goes to the tank battery and gas to the compressor station, and both leave by pipeline for processing.
- Well fluid
- Crude oil
- Gas
- Has its own twin page
What costs you money
Where the money goes today.
Compressor trips.
A valve failure takes a station down and gas backs up into the field.
Wells pumping off.
Rod pumps and ESPs run dry, wear out and fail, and production drops while you wait for a rig.
Fouled exchangers.
Heat transfer falls slowly, and fuel and throughput pay for it until the next turnaround.
Inventory that does not balance.
Tank levels and meter records disagree, and nobody knows which one is right.
The machines we know
Five machines, from the well to the refinery.
The gas compressor leads. Rod pumps and ESPs lift the wells, tanks hold the crude and exchangers heat it. Each one has equations we can write down and a list of how it breaks.
- Lead assetReciprocating gas compressorA leaking valve shows up as heat before it shows up as a trip.1,340 hp gas engine, 4 throws, 2 stages, 1,200 rpm, 10.4 MMscfd, 150 to 1,100 psigOpen the reciprocating gas compressor
- AssetBeam pumping unitThe dynamometer card tells you what the pump is doing a mile down.API 11E 640D-305-144, 8 spm, 1.75 in plunger at 7,000 ftOpen the beam pumping unit
- AssetElectric submersible pumpYou cannot see an ESP. Intake pressure, motor temperature and current tell you how it is doing.150 hp ESP, 2,000 bbl/d at 60 Hz, 200 stages, set at 6,800 ftOpen the electric submersible pump
- AssetShell-and-tube heat exchangerFouling costs a little every day. The twin tells you when cleaning pays.TEMA AES, crude preheat, 8 MW, U clean 450 W/m²·K, 420 m²Open the shell-and-tube heat exchanger
- AssetCrude storage tankIf the tank and the meters disagree, one of them is wrong. The twin tells you which.100,000 bbl external floating roof, 120 ft diameter, radar level, average temperatureOpen the crude storage tank
Also watched on site
- Separators and scrubber levels
- Vapor recovery units
- Water transfer and injection pumps
- Instrument air compressors
- Generators on remote sites
How a job goes
A leaking valve costs horsepower and gas long before it trips the station. Here is how we catch it.
- 01 Watch
TwinEdge OS reads the compressor panel over Modbus at the station, with the station RTU over DNP3.
TwinEdge OS - 02 Find
Discharge temperature on stage 2 is 9 °C above the model for the same pressure ratio, and interstage pressure has crept up. The twin points to a leaking discharge valve on throw 3.
Agentic Analytics - 03 Fix
A work order with the valve part number is drafted for the next planned stop. A person approves it, and your mechanic changes the valve.
CMMS / EAM - 04 Prove
Discharge temperature and capacity return to the model. The 35 hp and 0.14 MMscfd won back go in the ledger.
TwinEdge Historian
What we connect to
We read what you already have.
At the site
- RTUs and outstations (DNP3)
- Smart transmitters through HART multiplexers and WirelessHART gateways (HART-IP)
- Compressor panels, pump-off controllers, ESP drives and PLCs (Modbus TCP/RTU, OPC UA, EtherNet/IP)
- Flow computers that expose Modbus, OPC UA or DNP3
- Existing gateways (MQTT, Sparkplug B)
Your systems
- Your SCADA historian, read through OPC UA
- Your CMMS, for work orders and asset history
- Production accounting exports
What we put a number on
Worked out from the equations, before we start.
One leaking compressor valve
35 hp
And 0.14 MMscfd of capacity lost on a 10.4 MMscfd unit
Modeled
Unplanned compressor shutdown
$31,322 a day
10.4 MMscfd not moved at $3.00 per Mscf
Modeled
Gas interference on a rod pump
32 bbl/d oil
Deferred with the pump 72% full, $2,265 a day at $70 per bbl
Modeled
Fouled crude preheat exchanger
$376 a day
Extra furnace fuel at 18 months. Cleaning then pays back in 170 days.
Modeled
Modeled on the reference machine. Results vary by site.
What we do not do
Clear lines, so you know what you are buying.
- We are never part of a safety system (SIS, ESD, fire and gas) and never override a trip.
- We do not control wells or compressors. Setpoint changes go through your SCADA and your people.
- Our edge hardware is not hazardous-area certified. It sits in a safe area or control room and reads from your existing equipment.
- Custody transfer stays with certified meters and your measurement team. We flag the gap, they settle it.
How you pay
A 90-day pilot. The fee follows the result.
One compressor station or one field for 90 days. We agree the baseline with you in week one, send a one-page report every week, and review the results together at day 90. The fee is tied to the measured change.
What we baseline first
- Unplanned shutdowns and the hours they cost
- Run time per compressor and per well
- Deferred production, by cause
- Fuel gas per unit of throughput
What we measure after
- Shutdowns against the baseline
- Run time and barrels recovered
- Each repair, with readings before and after
- Every result written in the outcome ledger
Questions
Straight answers.
Do you need to be in the hazardous area?
No. We read from controllers and RTUs in a safe area or over your SCADA network.
Will it trip anything?
No. It only reads. It has no write path into safety systems, and TwinEdge is never in the safety loop.
Does it work on remote sites with satellite links?
Yes. The edge keeps history on site and sends it when the link allows.
Can it read our RTUs and transmitters?
Yes. DNP3 from RTUs and outstations, and HART through multiplexers and WirelessHART gateways. Flow computers work if they expose Modbus, OPC UA or DNP3.
Does it replace our SCADA?
No. SCADA runs the field. We tell you which machine needs work.
Do you take over tank and meter measurement?
No. We run the daily balance and say which reading has drifted. Custody transfer stays with your certified meters and your measurement team.
What we do for you
We watch it. We catch it. We prove it.
Our reliability engineers run the twins, review every finding, and help your crew fix it. After the repair we compare the meter to the baseline and write the result in the ledger.