Preventing Blowouts and Well Control Issues with Continuous Monitoring

1. CASE STUDY Preventing Blowouts and Well Control Issues with Continuous Monitoring CLIENT BACKGROUND Blowouts pose major safety and financial risks in oil and gas. To improve real-time response and control, a leading company implemented an IIoT- based continuous monitoring system. Projects Blowout prevention and well control management Upstream Oil & Gas Industry Fleet Sizes Continuous real-time monitoring of wellhead pressure, temperature, and flow CHALLENGES Unstable Well Pressure Delayed Data Acquisition Limited Real-Time Visibility Operational Downtime Frequent and sudden pressure changes the wellhead created a high risk of blowouts, threatening personnel safety and asset integrity. Manual data collection intervals led to significant lags in identifying critical anomalies, preventing timely intervention during well control incidents. Without monitoring, lacked instant insights into equipment status and environmental conditions, the likelihood unnoticed faults. continuous operators Inability to detect early warning signs resulted in unexpected causing losses and operational costs. at shutdowns, production increased both increasing of

2. Solution Approaches Smart Sensor Installation Live Data Transfer AI-Driven Analytics Installed IIoT sensors on key wellhead equipment for continuous monitoring of pressure, temperature, and flow. Utilized secure edge computing to send live data streams to the central control system. Implemented machine learning algorithms to analyze sensor data, detect anomalies, and predict potential failures. Instant Alert System Enabled automated alerts to notify operators immediately upon detecting abnormal conditions. Unified Monitoring System Combined data from multiple sensors into a unified dashboard for comprehensive situational awareness. Remote Accessibility: Allowed operators to monitor well conditions in real-time from any location, enhancing response speed.

3. Results Early Detection: Real-Time Response: Pressure anomalies were identified minutes before escalation, allowing preventive measures to be implemented proactively. Operators received immediate alerts, enabling swift intervention that prevented potential blowouts. Operational Continuity: Safety Improvements: Real-time data minimized unscheduled shutdowns and reduced overall downtime by 30%. Enhanced monitoring improved compliance with safety regulations and reduced incident risk. Real-Time Monitoring & Alerting By integrating IIoT sensors with an edge-based platform, the operator enabled real-time monitoring of key well parameters, allowing instant anomaly detection and rapid response. Automated Threshold Alerts: Predefined safety limits triggered instant alerts when parameters exceeded safe operating ranges, reducing dependency on manual oversight. Instant Control Room Notifications: Real-time alerts were transmitted directly to the control room, allowing operators to make informed decisions and initiate corrective actions within seconds. Proactive Issue Mitigation: Live monitoring allowed the team to act early, preventing blowouts, reducing downtime, and improving safety. With IoT integrated into our drilling rigs, we can now monitor precision, progress, and performance in real time. It has transformed our operations from guesswork to data-driven execution HEAD OF EQUIPMENT, MINING & INFRASTRUCTURE DIVISION info@rejigdigital.com rejigdigital.com +1 (510) 956 6572