ABB Group Smart Oilfield and Platforms Case Study
© ABB Group Smart Oilfield and Platforms Case Study – ONGC Enterprise wide SCADA
Agenda of Presentation n Present Oil Field and Platform Operation Practices n Concept of Smart Oilfield and Platforms n Smart Oilfield and Platforms – Detailed View n n Instrumentation n Automation n Communication n Applications n Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA
Present Operation Practices n Following are the issues faced by the Operating companies. n Skilled manpower shortage n Accuracy and Efficiency of processes n Data Validation, Recording is an issue n Insufficient history information for the Analysis and comparisons or biased information n No mechanism to identify the pipeline leakages as well as thefts n Inaccurate flow measurement due to non use of standard flow measurement practices n No online water cut measurement resulting in delays in corrective action n No control in the separator makes the process unstable. n Excess energy consumption due to improper temperature control at heater treater n Safety work practises n Manual reporting and Calculation
Agenda of Presentations n Present Oil Field and Platform Operation Practices n Concept of Smart Oilfield and Platforms n Smart Oilfield and Platforms – Detailed View n n Instrumentation n Automation n Communication n Applications n Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA
Concept Of Smart Oilfield and Platforms n The Smart Oilfield and Platforms n Provide Well head telemetry supervision and control n Provide Real time Monitoring and Control of Manned, Unmanned and Remote location at centralises place. n Provides minimum Human Intervention in day to day operations n Provide Stabilised production and Transportations process as well as Optimisations n Prevent transportation losses in Pipelines n Provide real time data Consolidation, Recording and storage for the analysis for future evaluations n Reduce the delay in decision making via online measurements of critical parameters such as Water cut, Gas Composition etc n Provide all real time KPI ( Key Performance Indicators ) to Corporate level/ Board level for quick decision making n Standardisation on SCADA, devices and communications simplifies training and maintenance n Significantly reduces downtime by being proactive in operating abnormal conditions
Concept Of Smart Oilfield and Platforms n To Convert an Oil Field to Smart Oil Field following are major contents n Suitable Instrumentation on well head and Production, Storage and Transportation facilities for real time measurement as per the standard guidelines. n Automation system to monitor, control the Production facilities of different location providing unbiased information to Stabilise the production, transportation process. Integration of different levels of automation to ensure data consolidation n Communication (WAN) to make Hierarchical Automations system to provide asset/corporate level consolidation of the multiple production, transportation and Storage systems spread across Cities, States and Countries n Applications to carryout production process optimisation, Pump optimisation, Make optimum use of the energy in the form of Gas used for the Gas Lift, Electricity used for ESP, SRP etc n Integration with Scientific and Business system for Operational efficiency improvements, strategic Decision Making
Agenda of Presentations n Present Oil Field and Platform Operation Practices n Concept of Smart Oilfield and Platforms n Smart Oilfield and Platforms – Detailed View n n Instrumentation n Automation n Communication n Applications n Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA
Smart Oilfield and Platforms - Instrumentations n Instrumentation and devices on Well head to have pressure temperature measurement as n Pressure, temperatures and flows n Chemical injection rates n Water injection rates n Downhole instrumentation n All instrumentation must be low power instrument n Data from Well head instrument to be consolidated in a device such as an RTU, PLC, VSD or others n Device should be low powered and provide Radio communication to the central Facility n Devices should be capable of implementing Control n Well shutdowns based on emissions, facilities upset n Dedicated devices with history retention n Well Optimisation through pump, pressure, injection and/or flow control
Smart Oilfield and Platforms - Instrumentation n Instrumentation at Facilities n Mass flow with API corrections is the most accurate way to measure liquids n AGA is the recommended standard for measuring gas n Gas Chromatograph for Gas Composition measurement n NOC to calculate Water cut measurement n Storage tanks Level Measurement with API Corrections n Group Separator Level measurement can be through Interface level transmitters n Control Valves for the level and pressure control of Group Separators n Suitable LACT and Gas Custody transfer meters n Flare Gas Measurement through suitable flow meters n Turbidity meter for solid particals measurement in water disposed – Environment / Pollution requirement n Instrumentation for the Gas Compressor efficiency calculations n Use of FF based instruments for diagnostic information and Asset Management applications
Smart Oilfields and Platforms - Automation n Automation at well head n Well head based measurement to provide remote Shut Down Access on the well head n Choke control to reduce the Sludge effect in oil wells n Provide Control based on Gas Lift Pressure and flow n All Control are implemented through a device which Communicates through radio n Automation system to provide Low B/W data Communications n Automation system to support RTU data Storage and Upload in case of loss of communications n Automation system to have option for configuring polling frequency as per the needs. n In case of rod pump well - pump off controls n In case of ESP based well ESP pump Speed / flow Control and On off Control.
Smart Oilfields and Platforms - Automation n Automation at Facilities n Valves control for Well test n Control of Test, Group Separator Level and Pressure for Process Stabilisations n AGA 3, 7 with AGA 8 for Gas Measurement n API based VCF for liquid measurement n Artificial Lift system control for the Gas lift, Rod pump well, ESP Wells n Automation system to support data Storage at each of hierarchical locations in case of loss of communication and Upload once communications is established n Automation system to have option for configuring polling frequency as per the needs. n Integration of existing DCS, SCADA, PLC system to enable single platform for the operation, Data Storage and Analysis. Lower cost of support n Automation system to be hierarchical by architecture so that the data from different oil fields can be consolidated. n Remote ESD and start of facilities
Smart Oilfields and Platforms - Communication n Communication at Well head and Facilities n Serial communications handled through terminal servers (IP radios are more compatible) n The WAN Communications should have sufficient bandwidth at different level n Communication can be n Radio at on shore well heads n Radio, V- sat or LEO at offshore wellhead platform n Fibre optic, satellite at facility level n Leased line, OFC at regional Control facility and Corporate Facility n In case of Remote Control Requirement alternate communication channel / Routes should be available to the final control elements – SSV, SSSV control n Network Management system is a must for a large facilities n Different Subnet, Domains can be created as required. A plan must be developed
Smart Oilfields and Platforms - Applications n Applications at Well head n These application runs in automation system at central facility and need real time data n In case of oil well (FTHP, ABP, Flow Arm Temp, Annulus and Down whole Pressures are recommended) n Well 3 Phase flow estimation via Virtual Flow metering. This flow measurement reduces the need to regular well tests n Active well control application reduces the slugs by controlling the choke n Gas lift pressure control ensures efficient use of Gas Lift n DP between Well head and Facility is direct indication of Leakages
Smart Oilfields and Platforms - Applications n Applications at Well head n In case of Gas wells n Flow measurement with AGA 3 and AGA 8 n Valve switching to manage water build-up n Plunger Lift Control (Turner Curve, Blow V/L etc. ) for low pressure wells n ESP and PCP Control for water take off n Compressor Monitoring (OEM curve to Real time curve comparison) n Nominations Control to ensure the consistent productions n In case of CBM Wells n Flow Measurement with AGA 3 and AGA 8 n Nominations Control to ensure the consistent productions n Water level Measurement and Pump Control
Smart Oilfields and Platforms - Applications n Application at Facilities n Different applications are envisaged at the facilities which need real time data form the automation system. These applications are n Automated well test n Gas lift Optimisation n Field / Pipeline Mass balance n Well Monitoring System n Tank Gauging System n Leak Detection and Leak Location for pipelines n Asset Management systems n Alarm Management n Abnormal Condition Monitoring
Smart Oilfields and Platforms - Applications n Well test application (Onshore/ Offshore) n Automatic well test application selects the well for testing by operating the heather valves n Multiple well of the facilities can be scheduled for well test in sequence as desired by the operator. n Each well test provides Oil, Gas and Water flow over a 24 hrs of testing along with well pressure and gas oil ratio n Well test has accept/reject option for the well test data based of operators judgement n Application maintains history of each well test data which can be used for analysing the well history as well as providing it to other applications n The well test data is used by other application such as n Production Allocation n Gas Lift Optimisation n Well Monitoring System n ESP Optimisation
Smart Oilfields and Platforms - Applications n Gas Lift Optimisations (Onshore/ Offshore) n To optimise the gas used for gas lift based on best possible oil production from well n This is a model based optimisation package which need input from well test to know the oil and gas flow of a particular well n Lift Curves are generated by the model or can also be manually fed to the system n GLO provide an output which is a reference to the flow / pressure control loop of lift gas circuit n The automation system uses these reference to control the flow of lift gas in the well annulus n The GLO helps in managing the Lift gas network created for different oil wells in same or adjacent oil field
Smart Oilfields and Platforms - Applications n Asset /Field and Pipeline Mass Balance (Onshore/ Offshore) n Asset/Field Mass balances are applied to the facilities. Imbalance is indicator of leakages n This is based on Current day, Current Hour and Previous Day, Previous our flow estimations n Pipeline mass balances is to identify imbalance for facilities linked through pipelines n Imbalance is indicator of theft or leakage n In case of Gas Pipeline Line pack calculation based on pipeline segment and is must as change in line pack can provide imbalances n In case of liquid pipelines if the temperature variation across the pipeline is considerable then only change in line pack has impact on imbalance
Smart Oilfields and Platforms - Applications Sensor Readings n Models & Solver Flow Rates Well Monitoring System (Onshore/ Offshore) n These are Model based application which calculates Oil, Gas and Water flow from each well. These are called as Virtual flow metering n They reduces the need to regular well test n WMS system uses well head based measurement. The change in the differential of pressure, Temperatures is provided to well model which then provides Oil, Gas and water measurements n These methods are cost effective and considerably accurate. Being model based also easy to calibrate based of latest well test n These real time flow provides inputs for the Active well control, Reservoir modelling etc
Smart Oilfields and Platforms - Applications n Tank Gauging System (Onshore/ Offshore) n Storage Tank level measurement based on radar gauges n The Tank gauging should be integral to the Automation system n Tank Gauging system to have Strapping Table Calculation tool n Tank Gauging system to provide Gross and Net Volumes based on the API Table 11. 1. 24. 7. 1. 1 and API 11. 1. 54. 7. 1. 1 for oil and oil products. n VCF from these tables relates the volumes at specified temperatures to the volume at standard temperatures n Facility wise inventory calculation and reporting
Smart Oilfields and Platforms - Applications Leak Detection System Performance Parameters n Detection of the Leak Detection and Leak Location system (Onshore / Offshore) S. No. Pressure Measurement are required across the pipeline at a specified distances to ensure the level of accuracy n Leak Detection Can be implemented via n Pressure Surge n Pressure Wave Flow n Mass/Volume Balance n Leak Size % of Flow Time to Detect Leak (Anywhere in Pipeline) 1 Full Bore Rupture 100 1 min 2 Large Leak 50 2 min 3 Medium Leak 25 4 min 4 Small to Medium Leak 10 10 min 5 Small Leak 5 20 min 6 Very Small Leak 2 100 min Estimation of the Leak Location S. No. Leak Size 1 Very Small Leak 2 Small to Medium Leak 3 Large Leak % of Flow Estimation of Leak Locations 2 60 KM 2 to 50 30 KM > 50 20 KM
Smart Oilfields and Platforms - Applications n Asset Management System n Use of FF, Hart and Profibus based instrumentation and automation system provide Diagnostic Information along with the Real time information's n These diagnostic information is used to predict the possibilities of failure of the critical control equipments n The AMS system provides the mean to identify the such possibilities of failure and use them to carry out the maintenance activity in advance. n The diagnostic information's triggers the CMMS system and CMMS provide Work order for the necessary actions n The Asset management module can also be used for rotating equipment and also some process equipment monitoring through customisations n Planned and on time maintenances reduces the downtime and support the production planning P 5001 0. . . 150 bar CEAG I/O
Smart Oilfields and Platforms – Integration n Integration with ERP System (SAP) n Majority of the customers used the SAP as ERP system in Oil and Gas Industries n The Automation system integration with the SAP is must to ensure the error free production, Sale numbers reporting on day to day basis n Automation system can feed the data to different modules of SAP n Production Numbers in PPPI modules n Custody Transfer Numbers to SD Modules n Diagnostic and Maintenance Data to PM modules n Integration with Scientific Systems n Reservoir modelling and analysis systems n Drilling system for LWD/MWD Integration system provides the data validation to ensure correct numbers are sent to integrated systems
Agenda of Presentations n Present Oil Field and Platform Operation Practices n Concept of Smart Oilfield and Platforms n Smart Oilfield and Platforms – Detailed View n n Instrumentation n Automation n Communication n Applications n Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA
The Project Envisaged n Enterprise Wide SCADA for all Production and Drilling Facility of ONGC Spread across India and in Arabian Sea. n The project is envisaged by core design and engineering team of ONGC under the initiative of Chairman of ONGC Limited n Main reason for ONGC to think about such LARGE architecture n Efficient Real time Monitoring of the Production and Drilling Parameters across all the assets in India n Remote control of the production well in case of Offshore platform n Facilitate offline analysis of the Valuable/ High Producing Wells through third party E&P Applications. n Provide summarised information to the management for effective decision making n Total Facelift in the day to day operation of ONGC Production and Drilling facility to improve the efficiency
The Scope of Supply and Work n n Scope of Supply n Supply of Three Tier SCADA Architecture as Production SCADA and Drilling SCADA spread across 19 Assets in India. The Production SCADA is ABB SCADAvantage and Drilling SCADA is NOV solution n RTU with FF based Instrument for the Production installation to enable data acquisition and asset management. n Supply of 16 Data Centres including the corporate data centre across India to enable efficient operation of respective Assets. n UPS for all the 250 plus tier 1 control room of production and drilling SCADA along with FCBC for 85 no of remote RTU with solar chargers. n SAP, Epinet, VRC- Integrations of Real-time and History Data. n Disaster Recovery Solution for the corporate data centre. Scope of Work n Erections and Commissioning of above scope and warranty for one year n AMC of 6 years after warranty
Unique Features of the SCADA Project n Single Largest Instrumentation- Automation – IT Solution project finalised in India – 95 musd n Largest three tier network of near real time process data monitoring. The no of HMI Station in a single largest Network - 1300 Plus HMI Stations and 600 Plus Servers n Largest Project in term of the FF based Instrumentations and automation solution – 7500 FF instrument and 850 FFH 1 segments n First Ever project with FF and Hart based RTU and Asset Management. n Largest project in terms of Field Instrumentation scope of supply n Largest Oil and Gas producing wells connected to the SCADA system – 18000 Wells n Single largest contract to build 179 Control rooms, 16 Data centres and 75 Mobile Control rooms
ONGC SCADAvantage System Architecture Tier 3 in Delhi with backup in Mumbai 13 x Tier 2 Locations 163 x Tier 1 Onshore SCADA Locations 8 x Tier 1 Offshore SCADA Locations 278 x RTU Locations
- Slides: 28