Smart Oilfield and Platforms Case Study: Overcoming Operational Challenges

Smart Oilfield and PlatformsCase Study – ONGC Enterprise wide SCADA

Agenda of Presentation • Present Oil Field and Platform Operation Practices • Concept of Smart Oilfield and Platforms • Smart Oilfield and Platforms – Detailed View • Instrumentation • Automation • Communication • Applications • Business & Scientific System Integration • Case Study – ONGC Enterprise wide SCADA

Present Operation Practices • Following are the issues faced by the Operating companies. • Skilled manpower shortage • Accuracy and Efficiency of processes • Data Validation, Recording is an issue • Insufficient history information for the Analysis and comparisons or biased information • No mechanism to identify the pipeline leakages as well as the thefts • Inaccurate flow measurement due to non use of standard flow measurement practices • No online water cut measurement resulting in delays in corrective action • No control in the separator makes the process unstable. • Excess energy consumption due to improper temperature control at heater treater • Safety work practises • Manual reporting and Calculation

Agenda of Presentations • Present Oil Field and Platform Operation Practices • Concept of Smart Oilfield and Platforms • Smart Oilfield and Platforms – Detailed View • Instrumentation • Automation • Communication • Applications • Business & Scientific System Integration • Case Study – ONGC Enterprise wide SCADA

Concept Of Smart Oilfield and Platforms • The Smart Oilfield and Platforms • Provide Well head telemetry supervision and control • Provide Real time Monitoring and Control of Manned, Unmanned and Remote location at centralises place. • Provides minimum Human Intervention in day to day operations • Provide Stabilised production and Transportations process as well as Optimisations • Prevent transportation losses in Pipelines • Provide real time data Consolidation, Recording and storage for the analysis for future evaluations • Reduce the delay in decision making via online measurements of critical parameters such as Water cut, Gas Composition etc • Provide all real time KPI ( Key Performance Indicators ) to Corporate level/ Board level for quick decision making • Standardisation on SCADA, devices and communications simplifies training and maintenance • Significantly reduces downtime by being proactive in operating abnormal conditions

Concept Of Smart Oilfield and Platforms • To Convert an Oil Field to Smart Oil Field following are major contents • Suitable Instrumentation on well head and Production, Storage and Transportation facilities for real time measurement as per the standard guidelines. • 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 • 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 • 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 • Integration with Scientific and Business system for Operational efficiency improvements, strategic Decision Making

Smart Oilfield and Platforms - Instrumentations • Instrumentation and devices on Well head • Well head to have pressure temperature measurement as • Pressure, temperatures and flows • Chemical injection rates • Water injection rates • Downhole instrumentation • All instrumentation must be low power instrument • Data from Well head instrument to be consolidated in a device such as an RTU, PLC, VSD or others • Device should be low powered and provide Radio communication to the central Facility • Devices should be capable of implementing Control • Well shutdowns based on emissions, facilities upset • Dedicated devices with history retention • Well Optimisation through pump, pressure, injection and/or flow control

Smart Oilfield and Platforms - Instrumentation • Instrumentation at Facilities • Mass flow with API corrections is the most accurate way to measure liquids • AGA is the recommended standard for measuring gas • Gas Chromatograph for Gas Composition measurement • NOC to calculate Water cut measurement • Storage tanks Level Measurement with API Corrections • Group Separator Level measurement can be through Interface level transmitters • Control Valves for the level and pressure control of Group Separators • Suitable LACT and Gas Custody transfer meters • Flare Gas Measurement through suitable flow meters • Turbidity meter for solid particals measurement in water disposed – Environment / Pollution requirement • Instrumentation for the Gas Compressor efficiency calculations • Use of FF based instruments for diagnostic information and Asset Management applications

Smart Oilfields and Platforms - Automation • Automation at well head • Well head based measurement to provide remote Shut Down Access on the well head • Choke control to reduce the Sludge effect in oil wells • Provide Control based on Gas Lift Pressure and flow • All Control are implemented through a device which Communicates through radio • Automation system to provide Low B/W data Communications • Automation system to support RTU data Storage and Upload in case of loss of communications • Automation system to have option for configuring polling frequency as per the needs. • In case of rod pump well - pump off controls • In case of ESP based well ESP pump Speed / flow Control and On off Control.

Smart Oilfields and Platforms - Automation • Automation at Facilities • Valves control for Well test • Control of Test, Group Separator Level and Pressure for Process Stabilisations • AGA 3, 7 with AGA8 for Gas Measurement • API based VCF for liquid measurement • Artificial Lift system control for the Gas lift, Rod pump well, ESP Wells • Automation system to support data Storage at each of hierarchical locations in case of loss of communication and Upload once communications is established • Automation system to have option for configuring polling frequency as per the needs. • Integration of existing DCS,SCADA,PLC system to enable single platform for the operation, Data Storage and Analysis. Lower cost of support • Automation system to be hierarchical by architecture so that the data from different oil fields can be consolidated. • Remote ESD and start of facilities

Smart Oilfields and Platforms - Communication • Communication at Well head and Facilities • Serial communications handled through terminal servers (IP radios are more compatible) • The WAN Communications should have sufficient bandwidth at different level • Communication can be • Radio at on shore well heads • Radio, V- sat or LEO at offshore wellhead platform • Fibre optic, satellite at facility level • Leased line, OFC at regional Control facility and Corporate Facility • In case of Remote Control Requirement alternate communication channel / Routes should be available to the final control elements – SSV, SSSV control • Network Management system is a must for a large facilities • Different Subnet, Domains can be created as required. A plan must be developed

Smart Oilfields and Platforms - Applications • Applications at Well head • These application runs in automation system at central facility and need real time data • In case of oil well (FTHP, ABP,Flow Arm Temp, Annulus and Down whole Pressures are recommended) • Well 3 Phase flow estimation via Virtual Flow metering. This flow measurement reduces the need to regular well tests • Active well control application reduces the slugs by controlling the choke • Gas lift pressure control ensures efficient use of Gas Lift • DP between Well head and Facility is direct indication of Leakages

Smart Oilfields and Platforms - Applications • Applications at Well head • In case of Gas wells • Flow measurement with AGA3 and AGA 8 • Valve switching to manage water build-up • Plunger Lift Control (Turner Curve, Blow V/L etc.) for low pressure wells • ESP and PCP Control for water take off • Compressor Monitoring (OEM curve to Real time curve comparison) • Nominations Control to ensure the consistent productions • In case of CBM Wells • Flow Measurement with AGA3 and AGA 8 • Nominations Control to ensure the consistent productions • Water level Measurement and Pump Control

Smart Oilfields and Platforms - Applications • Application at Facilities • Different applications are envisaged at the facilities which need real time data form the automation system. These applications are • Automated well test • Gas lift Optimisation • Field / Pipeline Mass balance • Well Monitoring System • Tank Gauging System • Leak Detection and Leak Location for pipelines • Asset Management systems • Alarm Management • Abnormal Condition Monitoring

Smart Oilfields and Platforms - Applications • Well test application (Onshore/ Offshore) • Automatic well test application selects the well for testing by operating the heather valves • Multiple well of the facilities can be scheduled for well test in sequence as desired by the operator. • Each well test provides Oil, Gas and Water flow over a 24 hrs of testing along with well pressure and gas oil ratio • Well test has accept/reject option for the well test data based of operators judgement • 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 • The well test data is used by other application such as • Production Allocation • Gas Lift Optimisation • Well Monitoring System • ESP Optimisation

Smart Oilfields and Platforms - Applications • Gas Lift Optimisations (Onshore/ Offshore) • To optimise the gas used for gas lift based on best possible oil production from well • This is a model based optimisation package which need input from well test to know the oil and gas flow of a particular well • Lift Curves are generated by the model or can also be manually fed to the system • GLO provide an output which is a reference to the flow / pressure control loop of lift gas circuit • The automation system uses these reference to control the flow of lift gas in the well annulus • 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 • Asset /Field and Pipeline Mass Balance (Onshore/ Offshore) • Asset/Field Mass balances are applied to the facilities. Imbalance is indicator of leakages • This is based on Current day, Current Hour and Previous Day, Previous our flow estimations • Pipeline mass balances is to identify imbalance for facilities linked through pipelines • Imbalance is indicator of theft or leakage • In case of Gas Pipeline Line pack calculation based on pipeline segment and is must as change in line pack can provide imbalances • In case of liquid pipelines if the temperature variation across the pipeline is considerable then only change in line pack has impact on imbalance

Models & Solver Sensor Readings Smart Oilfields and Platforms - Applications • Well Monitoring System (Onshore/ Offshore) • These are Model based application which calculates Oil, Gas and Water flow from each well. These are called as Virtual flow metering • They reduces the need to regular well test • 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 • These methods are cost effective and considerably accurate. Being model based also easy to calibrate based of latest well test • These real time flow provides inputs for the Active well control, Reservoir modelling etc Flow Rates

Smart Oilfields and Platforms - Applications • Tank Gauging System (Onshore/ Offshore) • Storage Tank level measurement based on radar gauges • The Tank gauging should be integral to the Automation system • Tank Gauging system to have Strapping Table Calculation tool • 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. • VCF from these tables relates the volumes at specified temperatures to the volume at standard temperatures • Facility wise inventory calculation and reporting

Smart Oilfields and Platforms - Applications • Leak Detection and Leak Location system (Onshore / Offshore) • Pressure Measurement are required across the pipeline at a specified distances to ensure the level of accuracy • Leak Detection Can be implemented via • Pressure Surge • Pressure Wave Flow • Mass/Volume Balance

P5001 0 ... 150 bar CEAG I/O Smart Oilfields and Platforms - Applications • Asset Management System • Use of FF, Hart and Profibus based instrumentation and automation system provide Diagnostic Information along with the Real time information's • These diagnostic information is used to predict the possibilities of failure of the critical control equipments • The AMS system provides the mean to identify the such possibilities of failure and use them to carry out the maintenance activity in advance. • The diagnostic information's triggers the CMMS system and CMMS provide Work order for the necessary actions • The Asset management module can also be used for rotating equipment and also some process equipment monitoring through customisations • Planned and on time maintenances reduces the downtime and support the production planning

Smart Oilfields and Platforms – Integration • Integration with ERP System (SAP) • Majority of the customers used the SAP as ERP system in Oil and Gas Industries • The Automation system integration with the SAP is must to ensure the error free production, Sale numbers reporting on day to day basis • Automation system can feed the data to different modules of SAP • Production Numbers in PPPI modules • Custody Transfer Numbers to SD Modules • Diagnostic and Maintenance Data to PM modules • Integration with Scientific Systems • Reservoir modelling and analysis systems • Drilling system for LWD/MWD Integration system provides the data validation to ensure correct numbers are sent to integrated systems

The Project Envisaged • Enterprise Wide SCADA for all Production and Drilling Facility of ONGC Spread across India and in Arabian Sea. • The project is envisaged by core design and engineering team of ONGC under the initiative of Chairman of ONGC Limited • Main reason for ONGC to think about such LARGE architecture • Efficient Real time Monitoring of the Production and Drilling Parameters across all the assets in India • Remote control of the production well in case of Offshore platform • Facilitate offline analysis of the Valuable/ High Producing Wells through third party E&P Applications. • Provide summarised information to the management for effective decision making • Total Facelift in the day to day operation of ONGC Production and Drilling facility to improve the efficiency

The Scope of Supply and Work • Scope of Supply • 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 • RTU with FF based Instrument for the Production installation to enable data acquisition and asset management. • Supply of 16 Data Centres including the corporate data centre across India to enable efficient operation of respective Assets. • 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. • SAP, Epinet, VRC- Integrations of Real-time and History Data. • Disaster Recovery Solution for the corporate data centre. • Scope of Work • Erections and Commissioning of above scope and warranty for one year • AMC of 6 years after warranty

Unique Features of the SCADA Project • Single Largest Instrumentation- Automation – IT Solution project finalised in India – 95 musd • 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 • Largest Project in term of the FF based Instrumentations and automation solution – 7500 FF instrument and 850 FFH1 segments • First Ever project with FF and Hart based RTU and Asset Management. • Largest project in terms of Field Instrumentation scope of supply • Largest Oil and Gas producing wells connected to the SCADA system – 18000 Wells • Single largest contract to build 179 Control rooms, 16 Data centres and 75 Mobile Control rooms

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 ONGC SCADAvantage System Architecture

Smart Oilfield and Platforms Case Study: Overcoming Operational Challenges

Smart Oilfield and Platforms Case Study: Overcoming Operational Challenges

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