Over recent years, oil and gas companies worldwide have invested billions in new technologies to make drilling safer for both the environment and their personnel. The latest technological innovation has included the development of new production techniques that increase the efficiency of drilling in deepwater and open up new areas for production. But perhaps most significant is the development of technology to detect oil spills, particularly as firms continue to drill deeper and farther offshore where safety can be compromised. However, until now, the technology has lacked the sensitivity and specificity to detect small-scale spills. In most cases, spillages are detected only once these reach the water surface, and at that point it is often too late to contain them.

Two companies join forces

Recognizing the increasing demand for an early detection system, Repsol and Indra have partnered to create a pioneering piece of technology known as hydrocarbon early automation detection system (HEADS).

Repsol provided HEADS with its extensive knowledge of physical phenomena related to hydrocarbons and the marine environment as well as its experience in crude oil exploration and production offshore. The firm also provided all the technology developed at the Repsol Technology Center, which includes a laboratory to reproduce weather conditions at sea.

Indra, a consultancy in Europe and Latin America, provided its expertise on image interpretation and algorithms as well as its experience in the development of real-time data processing and the construction and use of infrared and radar cameras. The company also has developed and implemented cutting-edge technology solutions for the hydrocarbons industry with projects around the globe.

HEADS is based on highly advanced infrared sensors, radars and algorithms that maximize the probability of detection and minimize the likelihood of false alarms. The system's computer has artificial intelligence and the ability to teach itself while monitoring for oil spills, which increases its effectiveness over time and achieves an unprecedented detection of oil spills.

How does it work?

HEADS consists of three main elements. The first is infrared cameras that scan the sea areas continuously for between 20 and 60 seconds. The technology is able to detect differences in temperature and emissions of different substances and is able to endure bad weather by lowering infrared activity when temperatures drop to 0.5 C (32.9 F) or lower.

The second element is the oil spill detection radar, which scans the water for anomalies in their echo, with each scan revolution only taking three seconds. The radar is used in conjunction with the infrared sensors improving HEADS’ efficiency as the radar is capable of operating at full capacity even in adverse weather conditions and can reach distances of up to 5 km (3.1 miles).

The third element of HEADS is its two control algorithms. The first one detects the oil spill and sets off an alarm through the infrared sensors. The second algorithm integrates the signals of both sensors and—based on these signals and the weather conditions—decides whether to set off the alarm to signal an oil spill.

Due to the highly advanced infrared sensors, radars and superfast algorithms, HEADS can maximize reliability, improve reaction times and allow constant monitoring without the need for an operator, thereby minimizing risk of human error. No other system exists that combines multiple sensors of different technologies with algorithms and an automated response. The application of different technologies maximizes the probability of detection, reducing the chances of a false alarm. HEADS boasts a 90% spill detection rate compared to an average of 65% for existing systems. The system can operate night and day detecting spills of as little as 10 l (2.6 gal) with a response time of less than two minutes.

In addition, HEADS is modular and scalable and can be adapted to any typology using different combinations of thermal and radar sensors. The system also is coupled with a functionality that can automatically identify vessels in its vicinity using the automatic identification system, allowing ships to communicate their positions and other relevant information so others can track them and avoid potential collusions. Hence, if an oil spill is caused by a vessel within HEADS’ detection range, it can record registration numbers and monitor the event.

HEADS is not only an upstream application but can also be used at ports, harbors and any other installations where large volumes of hydrocarbons are stored or managed. As the system aims to detect even the smallest of oil spills, it also could be a useful tool to identify accidental oil releases caused by shipping.

Testing

The development of new technologies to tackle challenging but important issues for the oil and gas sector has always been at the forefront of Repsol’s activities; therefore, the company has actively grown its team to ensure that it reached almost 100% probability of oil spill detection. So far HEADS has employed 25 people, with the new company initially taking on six people with additional labor requirements depending on the growth of the joint venture.

The project was formally initiated in 2011 and consisted of four stages of rigorous testing. During the first stage, which was carried out at Repsol’s Technology Center, technical-economic viability was tested. Phases two to four were carried out through the use of two pilot studies at Repsol’s Tarragona Industrial Complex and the Casablanca platform. The project included a multidisciplinary team of more than 20 highly qualified experts and researchers specialized in a variety of areas such as oil and gas, physics, chemistry, software programming, radar technology and algorithms. After 21 months, HEADS was put into commercial use in July 2013 and underwent further fine-tuning until the end of 2013.

HEADS has a positive patentability report, and both companies have registered the patent with a standard Patent Cooperation Treaty application, a single procedure that allows registration in more than 147 countries.

As firms continue to explore for oil and gas deeper and farther offshore, the associated risks will become all the more challenging. What is more, the environmental impact of oil and gas spills has never been under as close scrutiny as it has been in recent years, and oil and gas companies need to demonstrate that they are equipped to deal with these potential scenarios. It is essential that E&P companies and service providers gear up to this reality and ensure they continue to invest in the technology necessary to mitigate these risks.