In upstream oil and gas operations, maintaining well integrity is a matter of safety, compliance, and production efficiency. A leading provider of integrated well construction solutions in Indonesia faced these challenges head-on and partnered with Emerson to elevate their approach to wellhead pressure monitoring.
The Application
Wellhead pressure monitoring is essential for the safe and efficient operation of oil and gas wells. Capturing accurate pressure and temperature data enables operators to optimize production, prevent leaks, meet regulatory compliance, and enhance overall field safety. This real-time visibility also supports predictive maintenance strategies that help reduce downtime and operational risks.
Figure 1: A 3051S Quick connect installation with an in-line configuration in production on the well head.
The Challenge
A leading supplier of integrated well construction solutions in Indonesia provides cost-effective and reliable services that support long-term well integrity and sustained production. In recent years, industry-shaping incidents, such as the 2010 Gulf of Mexico blowout and the 2012 Elgin Field gas leak, have pushed operators to strengthen pressure monitoring during both drilling and production stages to enhance operational safety and reliability.
Specific integrity challenges differ depending on the type of well, whether conventional or unconventional reservoirs, vertical or horizontal orientation, and onshore or offshore deployment. They may also vary by the well’s function, including gas and water injection, geothermal, high-pressure and high-temperature (HPHT) wells, enhanced oil recovery (EOR), deep-water drilling, and even plugging and abandonment.
Maintaining well integrity is critical for maximizing recovery, production efficiency, and cost-effectiveness throughout the entire life of the well. Common concerns include cement bonding, casing corrosion, drilling pressures, and the complexities of well completions. Operators are now focused on automating field operations and gaining remote visibility into well pad conditions. This shift helps reduce manual interventions, improve efficiency, and minimize environmental and safety risks.
The Solution
Figure 2: Rosemount 3051S Quick Connect Exploded View
To address these challenges, Emerson proposed the use of the Rosemount™ 3051S In-line Pressure Transmitter with a Quick Connect option. Its compact, in-line design enables the transmitter to connect directly to the process, supporting fast, easy, and cost-effective installation. Each Rosemount 3051S Quick Connect is shipped preassembled with the sensor module, so it’s ready for installation right out of the box.
This solution provided several key benefits including:
- Continuous wellhead monitoring delivered accurate, real-time production data. It enhanced well integrity by offering insights into flowline pressure and casing health—reducing the need for manual checks, minimizing well workovers, and lowering the risk of safety incidents.
- Continuous wellhead monitoring delivers accurate, real-time production data, enhancing well integrity by providing insights into flow line pressure and casing integrity. This reduces manual operations, minimizes workovers, and lowers the risk of safety incidents.
- A wireless version of the transmitter simplified the installation process by eliminating the need for cabling and connectors. This significantly reduced setup time and costs, allowing quicker return to production following wellhead servicing.
- The system also provided early warnings for potential over-pressure conditions, enabling faster issue identification through timely alerts and local data visibility. The transmitter’s LCD display allowed operators to quickly review process variables, even in remote or hazardous areas.
- The 3051S in-line transmitter was also capable of monitoring valves and rupture disc status. This feature supported alignment with ASME safety standards by tracking back pressure and detecting increases that could signal leaks—enhancing plant and personnel safety.
The Results
The implementation of Emerson’s solution enabled continuous wellhead monitoring, delivering accurate, real-time production data that strengthened well integrity and operational visibility. By successfully positioning the Rosemount™ 3051S Quick Connect within the upstream integrated wellhead monitoring system, the customer streamlined their instrumentation setup across diverse well sites.
The adoption of Emerson’s Wireless solution eliminated the need for traditional cabling, junction boxes, and physical I/O connections, reducing infrastructure complexity and installation time. Additionally, the system aligned with ASME standards, enhancing safety and ensuring compliance with established industry guidelines.
Customer Quote
Implementing continuous wellhead monitoring with the wireless option has transformed operations. Accurate, real-time data prevents integrity issues without onsite visits, ensuring well integrity and reducing safety incidents. Wireless monitoring cuts down time and costs, accelerating our return to production
– Wellhead Engineer
Conclusion
This case study from Indonesia demonstrates how Emerson’s advanced instrumentation is helping upstream operators address increasingly complex well integrity requirements. With the Rosemount™ 3051S In-line Pressure Transmitter with Quick Connect, the customer successfully modernized their monitoring approach—improving visibility, safety, and responsiveness across a diverse range of well types. Emerson’s reliable and scalable pressure solutions continue to drive efficiency and operational confidence in the oil and gas industry.
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