Digital transformation: Next-generation flexible control system modernizes wellsite operations

TRAVIS BOLT, NOV 

The energy sector is undergoing a transformative revolution, driven by relentless pressures to optimize performance, reduce costs and minimize environmental impact. In the past five years, intervention and stimulation technologies have experienced more radical innovation than in the previous decades combined. For instance, hydraulic fracturing techniques have dramatically improved, with frac fleets nearly doubling their linear foot completion rates from an average of 63,470 ft to 125,217 ft per quarter. 

Advanced technologies are redefining wellsite operations, from sophisticated coiled tubing techniques navigating complex well profiles, to new wireline technologies—such as NOV’s DXtra™ intelligent wireline—which allow for real-time operational feedback. These technological leaps represent more than incremental improvements; they signify a fundamental reimagining of energy extraction processes, promising greater efficiency, reduced environmental footprint and enhanced operational capabilities. 

STANDARD OPERATING PROCEDURES 

The change is not just in the complexity but also in the variation, with each well being optimized and equipment deployment being engineered to maximize efficiency. These evolutions result in a requirement for increasingly flexible control systems to support the varied practices of today, as well as support future initiatives that have not been realized. 

One such practice is “slip stream,” which is a cost reduction methodology where a portion of the frac units operate on clean fluid, while the balance operates on a high concentration of proppant-laden fluids, ultimately coming together at the wellhead to deliver the desired concentration. “Simul frac” is also an advanced frac operation practice, in which two wells are fractured simultaneously from a shared frac fleet. The complexity lies in that each well must be treated according to its specific treatment program, and the service company must be able to demonstrate with data that it has performed the requirements of the well program. 

It is not uncommon for a frac fleet to go from a single well pad to a complex multi-well pad with slip stream operations, to a multi-well pad operating at a simul frac operation. From a data and control system, this results in an immense sweep of the amount of data to process, contextualize, visualize and ultimately manage. 

EQUIPMENT EVOLUTION IN THE INDUSTRY 

The complexity of modern well operations is mirrored by the increasingly diverse equipment used to perform critical functions. Today’s fracturing equipment spans multiple technological classes, including Tier II/Tier IV diesel, dual-fuel, direct-drive turbine and eFrac (electric fracturing, Fig. 1), with each offering unique capabilities and energy sources. 

Fig. 1. NOV developed the Ideal eFrac fleet, a 5,000-brake horsepower platform that combines intelligent electrical architecture with robust drivetrains to increase power density and flexibility.

Notably, operators frequently deploy hybrid fleets, strategically combining different equipment technologies to leverage their respective advantages while mitigating individual limitations. One of the most sophisticated operational approaches involves dual-fuel technology, where engines dynamically substitute diesel with natural gas, with the substitution percentage directly tied to engine load. 

In dual-fuel operations, the substitution ratio fluctuates as the well responds to stimulation, requiring constant operator monitoring to maximize fuel efficiency. Given that frac fleets can exceed $1 million in monthly fuel costs, even marginal improvements in fuel substitution can yield significant economic benefits. 

This technological diversification extends beyond fracturing. Coiled tubing and wireline operations are also exploring alternative energy sources and operational methods to enhance efficiency and reduce costs. Their primary focus is improving downhole operations efficiency, which demands sophisticated data compilation and contextualization to create accurate digital representations of subsurface conditions, Fig. 2. 

Fig. 2. NOV’s coiled tubing control cabin features monitoring devices, data acquisition systems, and modeling software to enhance efficiency and safety.

DATA IS NOT ACTIONABLE: INFORMATION CAN BE 

The proliferation of new technologies has dramatically increased data generation at wellsites. For instance, an average NOV frac fleet generates approximately 3,600 data points per second—an overwhelming volume for any operator to process manually. The critical challenge is not collecting data but transforming this raw information into digestible, actionable and contextual insights. 

This data explosion is not limited to fracturing operations. Coiled tubing and wireline services are experiencing similar growth in data sets, with increasingly complex equipment demanding more sophisticated data management. If not managed properly, the sheer volume of data threatens to obscure rather than illuminate operational insights. 

Moreover, the industry faces a significant human capital challenge. Historically reliant on “tribal knowledge”—the expertise passed down through generations of experienced workers—the oil and gas sector risks losing critical institutional wisdom. While advanced control systems cannot fully replace the nuanced understanding of experienced operators, they can help mitigate this risk. 

By developing best practices and workflow standardization through advanced control systems, companies can reduce the potential for operator error, increase operational efficiency, preserve and transfer critical operational knowledge and create a more structured approach to complex wellsite operations. The goal is not to replace human expertise but to augment and protect it through intelligent, context-aware technological solutions. 

REIMAGINING CONTROL SYSTEMS FOR MODERN WELLSITE OPERATIONS 

The increasing complexity of wellsite operations has exposed significant limitations in legacy control systems. Historically, these systems were effective for discrete equipment control within dedicated product classes, such as managing multiple pumps for conventional fracturing equipment at a specific wellhead. Their simplicity allowed for scalable, globally deployable solutions with common language and standardized inputs and outputs. 

However, what these legacy systems gained in simplicity, they sacrificed in flexibility. The advent of NOV’s Ideal OS represents a transformative approach, leveraging wellsite-based servers and web-based user interfaces to deliver a new data architecture that modernizes wellsite operations, Fig. 3. 

Fig. 3. An Ideal OS wellsite data van provides a more dynamic, interconnected approach to operational management.

This innovative architecture streamlines data management by consolidating all information into a common repository, enabling access for multiple users. This represents a crucial step in promoting and enabling next-generation control systems. By breaking down traditional data silos, Ideal OS creates a more integrated, responsive and intelligent approach to managing the increasingly complex technological landscape of oil and gas extraction. 

The new system moves beyond the limitations of previous control mechanisms, offering a foundation for more adaptive, efficient and comprehensive operational management. It signals a fundamental shift from rigid, isolated control systems to a more dynamic, interconnected approach to wellsite technology. 

ACCESSIBILITY: TRANSFORMING DATA SHARING AND OPERATIONAL EFFICIENCY 

Data serves as the fundamental foundation for information and meaningful action. Legacy systems historically struggled with data sharing, which required extensive coordination between equipment and created significant operational inefficiencies. The server-based architecture represents a revolutionary approach, enabling seamless data flow, to and from a common repository, that multiple applications can access and utilize. 

Consider the practical implications: previously, a wireline crew and a frac crew would monitor each rig in their own systems, operating from duplicated data that often required complex time-stamping for reporting. This data duplication inherently introduced unnecessary costs and effort, ultimately undermining operational efficiency. Ideal OS offers a platform that allows both the wireline and frac crew to look at the same data, reducing the equipment required to support each operation and giving each party more access to other data that could improve their own processes. 

The new architecture allows for sophisticated access-level control inside of each operation, enabling operators and technicians to work simultaneously from the same data set. For instance, during a fracturing stage, one operator can manage fleet operations while another simultaneously trends unit-specific data for troubleshooting and potential repair preparations. This becomes particularly critical in modern operations, where frac teams are now pumping for 21 or more hours with limited equipment access, due to red zone restrictions. 

By creating a unified, accessible data environment, the industry can dramatically reduce redundancy, enhance real-time collaboration and create a more responsive, efficient operational framework. 

AGILITY: STANDARDIZING DATA FOR TECHNOLOGICAL CONVERGENCE 

Data standardization emerges as a powerful tool for enabling multiple technologies to operate in parallel or in synchronization. A server-based data architecture facilitates this standardization, breaking down technological barriers that have traditionally isolated service companies from different equipment technologies or providers. 

The nuances between conventional fracturing units and electric units are profound, yet their fundamental goals remain remarkably similar. By implementing a standardized data set, a multi-pump program can now extract data from diverse technologies, visualize and contextualize it for operators, and send commands across different equipment types. This represents a significant departure from dedicated control systems that previously required complex, intentional communication protocols to enable even basic inter-system coordination. 

This approach of data standardization offers immediate operational benefits while simultaneously creating a robust foundation for future technological developments. By establishing a common data infrastructure, the industry can more easily leverage existing sensor networks across wellsites, compiling diverse data points into meaningful, actionable information that can enhance and interconnect various operational processes. 

The result is a more flexible, adaptive technological ecosystem that can rapidly incorporate new innovations and respond more dynamically to the evolving challenges of energy extraction. 

ROLE OF AUTOMATION: ENHANCING OPERATIONAL EXPERTISE AND EFFICIENCY 

Expertise remains essential in operating equipment effectively, efficiently and safely. Traditionally, this knowledge has been shared through the development of best practices and standard operating procedures. Automation has emerged as one of the most powerful tools for implementing these practices, becoming increasingly critical, as operators are required to process and interpret more information than ever before. 

The application of automation will vary across different use cases, but a common requirement is a stable data platform with comprehensive access to high-level operational information. Wellsites are complex environments, where multiple services and activities intersect, and one operation can significantly impact another. A shared data repository ensures that relevant information is accessible to systems that may need to act upon it, preventing potential risks, unnecessary costs and operational inefficiencies. 

In the near term, NOV’s automation pathway includes several promising applications, Fig. 4. For fracturing operations, this includes real-time data processing that can provide immediate feedback to operators on critical aspects, such as fleet optimization for fuel management and automated pressure testing. In coiled tubing operations, automation can assist with complex processes, such as plug drilling and milling or tripping operations. 

Fig. 4. The NOV Ideal OS Multi-Pump View provides comprehensive access to high-level operational information to optimize decision-making.

While the specific use cases will continue to evolve, the fundamental need remains consistent: a stable, comprehensive data platform that can support intelligent, responsive operational decision-making. 

ADVANCED MACHINE LEARNING AND A.I.: THE NEXT FRONTIER OF OPERATIONAL INTELLIGENCE 

Artificial intelligence (A.I.) is not a distant future concept but an imminent technological revolution with tangible capabilities for enhancing equipment operations. Machine learning already demonstrates significant potential in process improvement and intelligent equipment monitoring. However, the success of A.I. hinges on its ability to be effectively trained, which requires a foundation of standardized, indexable data. 

The Ideal OS architecture provides such a foundation precisely, categorizing and organizing data in a manner that enables both model training and real-time deployment. As new use cases are conceived and developed, these data repositories can gather information continuously, creating increasingly sophisticated data sets for training and developing advanced A.I. models.  

By creating a structured approach to data collection and analysis, companies can dramatically reduce the time and cost associated with generating meaningful A.I. applications. The goal is not to replace human expertise but rather, to create intelligent systems that can augment human decision-making, identify patterns beyond human perception and provide predictive insights that can optimize operational efficiency. 

This approach represents more than a technological upgrade; it’s a fundamental reimagining of how data can be transformed into actionable intelligence, driving innovation and efficiency across the oil and gas industry. 

CONCLUSION: THE TRANSFORMATIVE FUTURE OF OPERATIONS 

The oil and gas industry stands at a critical technological inflection point, where innovation, efficiency and adaptability are no longer optional but essential for survival. The convergence of advanced technologies—from sophisticated control systems like Ideal OS to emerging artificial intelligence capabilities—is fundamentally reshaping how wellsite operations are conceived, executed and optimized. 

This transformation is driven by multiple interconnected imperatives: cost reduction, environmental sustainability, operational complexity and the urgent need to maximize resource extraction. Traditional approaches that rely on legacy systems and tribal knowledge are giving way to data-driven, intelligent operational frameworks that can process thousands of data points in real time, adapt to dynamic conditions, and continuously learn and improve. 

The future of the oil and gas industry lies not in replacing human expertise but in creating technological ecosystems that augment human capabilities. By standardizing data, implementing flexible control systems and leveraging machine learning, companies can reduce operational risks, enhance efficiency and create more responsive, intelligent extraction processes. 

ABOUT THE AUTHOR

TRAVIS BOLT, MBA, is the Global Frac Technology director for NOV, where he manages the company’s fracturing technology portfolio within intervention and stimulation across North American and international markets. He also leads NOV’s research and development efforts in pressure pumping. With a career that spans roles such as vice president of Operations, head of R&D and partner in an oil and gas engineering firm, Mr. Bolt brings deep expertise to advancing energy solutions. A founding member of the Energy Transition Committee of the Energy Workforce and Technology Council, he holds an MBA, ESG accreditation from PESA and advanced executive education in innovation leadership from Rice University.