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Chief engineer of “Gazprom Avtomatizatsiya” PJSC Bobrikov Nikolai

The development of high automated control systems in hydrocarbons production for operating without the constant presence of operating staff. Chief engineer of “Gazprom Avtomatizatsiya” PJSC Bobrikov Nikolai.

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Chief engineer of “Gazprom Avtomatizatsiya” PJSC Bobrikov Nikolai

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  1. The development of high automated control systems in hydrocarbons production for operating without the constant presence of operating staff Chief engineer of “Gazprom Avtomatizatsiya” PJSC Bobrikov Nikolai

  2. The relevance of the work on the development of technologies of minimal manned operations The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective THE MAIN GOAL OF THE WORK ON THE DEVELOPMENT OF TECHNOLOGIES OF MINIMAL MANNED OPERATIONS INCREASING THE EFFICIENCY OF PRODUCTION ACTIVITIES OF GAZPROM PJSC DUE: - REDUCE OPERATING COSTS - PROLONGATION OF NATURAL PRESSURE OPERATION PROBLEMS THE REMOTENESS OF TECHNOLOGICAL OBJECTS FROM INFRASTRUCTURE DIFFICULT CLIMATIC, GEOLOGICAL AND GEOGRAPHICAL CONDITIONS CONSEQUENT HIGH OPERATING COSTS THE HIGH COST ON SUPPORT OF SOCIAL SPHERE SOLUTION CREATION OF AUTOMATED TECHNOLOGICAL COMPLEXES (ATC) OF GAS PRODUCTION ON THE PRINCIPLES OF MINIMAL MANNED OPERATIONS The development of high automated control systems

  3. The experience and achievements in creating the process control systems of gas production facilities Implemented projects in the field of automation of gas production facilities : The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective КГС 1,2,3,4 1,2,3,4 1,2,3,4 2Q P The scope of works on creation of automated process control systems (APCS) at the facilities of gas production in the period from 2003 to 2016 THE MAIN RESULTS & & • Was accumulated experience of creating automation systems with higher performance on the principles of minimal manned operations • Was formed competence to perform the work at all stages of the life cycle of automation - from conceptual design and survey work to commissioning and subsequent technical support APCS • Was formalized approach to the creation of systems of automation requirements - designed STO Gazprom "Automated gas field. Technical requirements for production equipment and volume of automation in the design and arrangement of fields on the principles of minimal manned operations“ • According to the results of the tests was made the transition to the Russian components (HW and SW) for automation systems Total produced more than 350 systems on the 52 gas treatment units (GTU) Automated utilities control systems • Zapolyarnoe field • Bovanenkovo field • Kirinskoe field • Urengoyskoe field • En-Yahinskoe field • Vyngoyahinskoe field • Ety-Purovskoe field • Muravlenkovo field • Medvezhie field • ZapadnoTarkasolinskoe field • Ubileinoe field • etc. AUCS 15% FGS20% PCS 60% BCS-1 BGW GGP BCS-2 CGT GTT Fire and gas systems Process control systems for all types of GTU The development of high automated control systems

  4. The history of the development of APCS of the gas production facilities Systems are under control of the complex algorithms (CA) The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective From "manual control" to the minimal manned operations Systems with united control panel, working on automated modes (AM) The task of creating ATC of production, preparation and transportation of gas on the principles of minimal manned operations were formulated at a series of meetings of Gazprom PJSC (MoM from 29.05.2008 №03/0700/4-5277, from 06.11.2008 №03/0700-177). As a pilot project for the creation of the ATC built on the principles of minimal manned operations were used to determine the project "Development of Cenomanian gas deposits of Muravlenko field". Chayandinskoe field* The effectiveness of the APCS Bovanenkovo field A qualitative transition Muravlenkovo field PILOT PROJECT FOR IMPLEMENTATION OF MINIMAL MANNED OPERATIONS Work on the creation and development of APCS gas production facility is carried out in the absence of the same gas fields in the world, similar in scope and complexity GTU-1V, 2V Zapolyarnoe field GTU-22 the second pilot area of the Achimov deposits of the Urengoyskoe field GTU-11V En-Yahinskoe field GTU Ety-Purovskoe field and Vyngoyahinskoe field GTU-1C, 2С, 3С Zapolyarnoe field The main signs development of ACS : 2004 2005 2007-2008 2008-2010 2010-2012 2003 2013-2015 2018-2022 *for the Chayandinskoe field the parameters are given in accordance with the Concept of automation and implemented design decisions The development of high automated control systems

  5. The main signs of evolution of APCS:Uniform components (HW&SW) The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective Comparison of the degree of technical unity of the subsystems MAIN RESULTS • Have provided a high level of reliability of functioning of control systems. Developed standard technical solutions for all field subsystems. • Have minimized development costs and commissioning costs. • Have reduced operating costs for staff training, acquisition of spare parts, software update. The extended the intervals between maintenanceandhave minimized procedures for periodic maintenance and repair. GGP BGW GTT For the first time was provided the development of a fully unified control system for the oil and gas part of the Chayandinskoe field BCS-1 5 The development of high automated control systems BCS-2 CGT

  6. The main signs of evolution of APCS:complex algorithms ! ! ! The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective КГС КГС 1,2,3,4 1,2,3,4 1,2,3,4 1,2,3,4 1,2,3,4 1,2,3,4 1,2,3,4 1,2,3,4 1,2,3,4 Q Q+ Q+ Q Q Q Control algorithms: the intellectual maintenance of the state of a difficult system The distribution of gas field performance between GTU in accordance with the operation modes of the interfield manifold A КГС КГС BGW ДЭГ & & & & & & + + A A A A A A Control of wells performance СН3ОН СН3ОН СН3ОН СН3ОН СН3ОН СН3ОН The monitoring system of the underground part of the well Maintenance of a given technological performance of threads and the unit as a whole А А Automatic regulation of the flow of methanol into plumes pad and gas wells BGW Optimal redistribution gas flow for process lines Field А T T Automatic loading/unloading Boost Compressor Station (BCS) GTT Automatic translation technological lines in the reserve and withdrawal of thread from the reserve А А Localization of ruptures of the pipeline (well, Bush, GTU, IM, GMU) Graphs of the process modes BCS-1 The development of high automated control systems BCS-2 CGT

  7. The main signs of evolution of APCS:complex algorithms Minimized the number of permutations of valves The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective The results of the implementation of complex control algorithms Logic control block time quantizer conroller Well 1 valve filter to GTU Reduced the reaction time to disturbance Logic control block Regulatory qualityincreased 5 times pпдi– the value of the formation pressure of the i-th gas wells; qmini(i=1, …,n) – the low limit on the production rate of the i-th well; qmaxi(i=1, …,n) – the high limit on the production rate of the i-th well; ua – the control action generated by the controller; uкв – quantized in time the control action of the controller. Well 5 valve Automatic operation of the controller with independent PI-controllers (regulator) COMPLEX CONTROL ALGORITHMSare • a key element in creating ATC on the principles of minimal manned operations and provide control of technological processes of production in a fully automatic mode without constant presence of staff (start, stop, change modes, regulation and control of technological equipment) • providing adaptive regulation, and prevention of development of emergency situations on the entire process chain (from wells to the shipment of commercial products) minimization of the human factor Automatic operation of the adaptive controller BGW The development of high automated control systems

  8. The main signs of evolution of APCS:Operator interface The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective Unified operator interface The gas gathering network Primary separation unit The principles of creation • The minimum number of Operator actions for the access to target screen • Providing for integrated information on the process and complex security • All interface elements are designed on a unified solutions Complex algorithms The development of high automated control systems

  9. The main signs of evolution of APCS: Unified control panel (as an example Bovanekovo) The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective • Complex automatization of the gas field • Unified control center • Process chain “Formation-Well-Bush-BCS-GTU-BCS”as control object Specifications The development of high automated control systems

  10. Import substitution The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective COMPARATIVE COST OF COMPONENTS (HW&SW) FOR APCS YAMSOVEYSKOYE FIELD The results of the analysis of the market of manufacturers of Russia, their testing with subsequent testing of ACS Increase the cost by 70% The approved cost ~70% The cost, millions rub. • SELECTED RUSSIAN MANUFACTURERS and performed work with factories on technical improvement under the requirements of the ATC on the principles of minimal manned operations • MINIMIZED RISKS INCREASING THE COST OF PROJECTS BY ELIMINATING THE IMPACT OF CURRENCY EXCHANGE RATE DIFFERENCES. Project risks are assessed more than 1.2 billion rubles for Chayandinskoe field. • RUSSIAN HW&SW ARE APPLIED TO ALL GAS PRODUCTION PROJECTS Import HW&SW Import HW&SW Russian HW&SW Russian HW&SW The development of high automated control systems

  11. ATC of Chayandinskoe field The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective Control algorithms GTU-3, CBCS and HRU HRU GTT CBCS GMS CGT to gas pipeline GBW GGP BCS CGT CGT to CBCS APCS from interfield manifold Specifications • Monitoring and control of the production process without staff presence at remote processing facilities • The unified information space of the field Unified control panel of the field • 99 bushes with 335 gas wells • GTU-3, GTU-2, GTU-4, HRU • 4 BCS(15 GCU, 12 GCU) • 1 CBCS (10 GCU) Spare control panel (without constant presence of operating staff) Spare control panel (without constant presence of operating staff) Legend УППГ2 УППГ4 Control algorithms GTU-2 Control algorithms GTU-2 gas moving direction measurement helium concentrate control data transfer control parameter distribution of unit performance control action CGT GGP CGT BCS GBW GGP BCS GBW to interfield manifold to interfield manifold The development of high automated control systems

  12. Prospects of development The relevance Experience and achievements The history Signs of development Import substitution ATC Chayandinskoe gas condensate field Perspective The concept of the organization of the control scheme gas field -1 gas field -3 Unified control panel of the gas field -2 Chayandinskoefield (implementation) Bovanenkovo field (implemented) Concept (suggestion) Unified control panel of the field (for all facilities) The virtual group of experts BCS Bush Bush BCS GTU BCS Bush GTU-2 GTU-3 CBCS BCS • Without the constant presence of operating staff Bush BCS GTU-2 • With the constant presence of operating staff Targets the development of new generation should be oriented on: • increasing the reliability • reducing capital and operating costs • minimization of the human factor at all control levels The development of high automated control systems

  13. Thank You for Your attention!

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