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A project submitted in partial fulfillment of the requirement for Summer Training Programme Of Oil & Natural Gas Cooperation Ltd.
Oil & Natural Gas Cooperation Ltd. Geopic, ONGC Academy Building, KDIMPE Campus, Dehradun-248001
ACKNOWLEDGEMENT
We express our sincere thanks to Mr. N Raman, C.E (E&T), GEOPIC, DEHRADUN, for his guidance and cooperation throughout the work.Inspite of his busy schedule he extended full co-operation with keen interest for stimulating discussion and correct suggestions. During our training period in ONGC, DEHRADUN, we have learnt various different aspects of this giant organization. We express my deep thanks to all members of GEOPIC who helped directly or indirectly. Due to the healthy co-operation we have been able to work and successfully complete our project.
Abhinav Prateek BE (4th yr), ICE MIT, Manipal Anshu Shokeen B.Tech.(3nd yr), ICE SRM University Chennai Ajay Naithani B.Tech.(4th yr), AEI D.I.T, Dehradun Gaurav Narang B.Tech.(4th yr), AEI D.I.T, Dehradun Peeyush BE (3rd yr), EIC THAPAR UNIVERSITY Patiala Nitin Agarwal B.Tech(4th Year), IP D.I.T, Dehradun
Dated :
PREFACE
The objective of the current study on PROCESS CONTROL IN UPSTREAM OIL INDUSTRY is basically to orient the students on Process Control Systems in general and on the instrumentation and controls used in Up-stream Oil & Gas in specific keeping ONGC as a case. ONGC is totally integrated OIL & Gas Company from Exploration to Production to Refining & Dispensing of Petroleum & Petroleum Products. The project was undertaken at GEOPIC- a premier Seismic Data Processing and Interpretation Centre, which plays vital role in the Oil Exploration in ONGC. Hence it is considered appropriate to start the project with a brief introduction to GEOPIC and its activities. This is followed by topics which deal with the subject of the project from Chapter 1 to 5.
GEOPIC
The Geodata Processing and Interpretation Centre (GEOPIC) located at Dehra Dun was established in 1987. It is ONGC's largest computing facility and one of the few centres around the world where integrated processing and interpretation of different geo-scientific data from seismic to petro-physical, geological and reservoir engineering are carried out. Over 60 per cent of the seismic data acquired by ONGC is processed at GEOPIC, which includes all the 3-D seismic data acquired so far over 69 prospects/fields. About 68 billion bits of data are processed here every day. These 3-D data are interpreted synergistically to unravel the structural and stratigraphic complexities of the sub-surface in search for hydrocarbons. Over the years, 65 3-D prospects have been interpreted. Interpretation capabilities of GEOPIC can be assessed from its success rate of 54 per cent for the exploratory locations proposed by the Institute, in contrast to the global average of 25 per cent. These capabilities have fetched processing and interpretation contracts both for Indian and Foreign basins. GEOPIC is a member of 'Consortium of Research on Elastic Wave Exploration Seismology (CREWES)', University of Calgary, Canada; SRB Project, University of Stanford and International Association of Geophysical Contractors.
Software
WGC processing software Promax processing software Time domain processing - FOCUS 2D & 3D Inversion - Geodepth products - Power (2D and 3D); Earth model, Geosec (2D and 3D) Probe Interpretation - Seisx, Voxelgeo, Geolog and Welltie Reservoir modelling - IRAP RMS, IRAP Mapping, STORM and Voxelgeo Powerful velocity model building Amplitude and AVO inversion
Software
Landmark software on SUN workstations and GeoquestSchlumberger software on SUN / Silicon Graphics workstations for the following interpretative activities: Structural interpretation Stratigraphic interpretation Attribute analysis Seismic modeling Wireline log evaluation Petrophysical interpretation 3D animation and visualisation Palinspastic restoration
Interpretation of:
Vietnam offshore 2D data for British Petroleum 3D data for Selan Exploration 2D data from basins of Egypt, Iraq and Kazakhstan 3D data for limits of carbonate reservoir and average porosity
distribution
In the present era, the entire world economy, international relationships etc revolve around Petroleum because it is typically is the main source of energy and energy is the very basis of modern lifestyle, industry and everything. Crude oil plays the pivotal role in development of any nation, hence its production, safe transporation, refining and marketing become very importatnt to the well being of people of a country. Crude oil industry is mainly devided into two streams; upstream and down stream. The upstream deals with Expolration and Exploitation of reserves in the earths crest and transporation of crude oil to refineries. In contrast; the down stream deals with refining, transporation of crude oil products such as petrol, diesal, kerocene, LPG and various other products. In India we traditionallly have ONGC and Oil India Limited as two major companies in the upstream and IOL, HPCL, BPCL etc in the downstream. After openeing up of Indian economy, many companies in private sector and many multinationals have also entered, both in up stream as well as down stream sectors Some of them are Reliance, Cairns Energy and Gujarat Petroleum in Upstream sector and M/s Reliance in Downstream.
1.2
The activities of an Upstream Oil Industry can be classified into three major functions namely oil & gas exploration, drilling and production, which also includes transporation of crude from one production installtion to other and / or refinery.
1.2.1
Exploration
Initially oil and natural gas exploration was as simple as Oil & Gas reserves could be easily located using surface seeps or using wild-cat drilling using very minimal data. Today, easy reserves have already been found and now Oil exploration is highly probabilistic, complex and hence a very challenging activity. Presence of the following is necessary for finding oil & gas in the sub-surface a) b) c) Presence of rocks which can be potential source of oil & gas also called source rocks Presence of Rocks with proper porosity and permeability so as to contain and also allow the free movement of oil & gas, called reservoir rocks Presence of appropriate structure of reservoir and cap rocks to hold oil & gas.
Exploration deals with delineating all the above conditions before deciding to go for drilling, because the later is a very expensive activity. Oil Exploration deals with delineating these suitable conditions by direct and indirect methods. The most common indirect methods are Seismic methods. It has following three components:
1.2.1.1
Data Acquisition
Seismic methods are relatively accurate and cost-effective way of modeling the earths subsurface. The seismic method involves transmitting acoustic energy into the earth and recording the energy reflected back from subsurface geological boundaries. The source of the acoustic energy can be dynamite detonated in a shallow drill hole, or vibrations generated by fibroses trucks or, in the case of offshore seismic, by air guns towed behind a ship. The returning energy is collected by a series of geophones, or listening devices. By measuring the
two-way travel time of the acoustic energy, a reasonable model of the subsurface can be defined.
1.2.1.2
Data Processing
The Seismic data acquired as mentioned above is collected on Magnetic Media and brought to Data Processing Centre. The volume and complexities of algorithms and processing involved in seismic data processing necessitates use of most powerful computing resources in Seismic Data Processing. The output of the Data processing is seismic sections which aims at providing the picture of structure of the rocks in the earths crest.
1.2.1.3
Data Interpretation
The seismic sections along with other Geological and Geochemical inputs are interpreted by teams for establishing potential / probable oil & gas reserves of expert scientists for releasing the locations for drilling. GEOPIC is one of the major Seismic Data Processing and Interpretation Centre as mentioned above.
1.2.2
Drilling
Drilling is one of most difficult and challenging activity in the oil sector. It requires high level of skills and hi tech machinery. This is mainly because of its sensitive nature, the oil and natural gas beneath the crust of the earth is at very high pressure and each and every step in drilling has to be taken with utmost care. There are two types of drilling 1. Exploratory drilling 2. Developmental Drilling As the name suggests that in exploratory drilling is carried out in the new and virgin area after Geological & Geophysical exploration. All sorts of geographical, seismic, magneto-gravitational data related to the crust of earth is collected and then processed. The place where there is no oil production is called as virgin site. But soon after when oil production starts then the site is upgraded to as a basin. During drilling there are various parameters that have to be constantly monitored so that oil is drilled in controlled manner.
1.2.3 Production
The oil & gas is found on land as well as in the offshore accordingly all the above activities are carried out both, in onshore as well as offshore. The complexities, requirements and operations of offshore production installations are very different from those in onshore. However both deal with receiving the produce from the different wells in that area. This produce from wells is also called well fluid. It contains combination of Oil, Gas, Water and other impurities. In production installations, these constituents are separated and then pumped into pipelines / filled into tanks for transportation to refineries or other customers. The Onshore Oil installations are GGS (Group Gathering Station), CTF (Central tank farm), GCS (Gas Compression Station) etc. In case of offshore production/ processing of Crude Oil is done in offshore installations called Production Well Platform and Process Platforms. From Offshore the oil & gas are transported separately to shore through pipelines or filled into oil tankers.
1.3 1.3.1
Crude oil consists of many different hydrocarbon molecules, from relatively simple short single carbon and hydrogen strings to long, complicated chains and rings. Refining sorts splits and reassembles the molecules into a variety of usable forms. The first step in the refining process is fractional distillation which separates the oil into its component parts or fractions. The crude oil is first vaporized and the vapour is piped into a tall tower divided by a series of perforated horizontal trays. As the vapour rises through the tower via the perforations on each tray, the heavier fractions condense first and settle out on the lower trays. The perforations are fitted bubble caps that force the vapour to bubble through a previously liquefied fraction on the tray. This bubbling cools the vapour slightly, which causes that fraction to condense out of the vapour while the remaining vapour, consisting of lighter fractions, continues to move upward in the distillation tower. The process is repeated at each tray, with each fraction condensing at the tray where the temperature is slightly below that fractions boiling point. Several trays collect each fraction, and the fractions are piped off for further processing into diesel, furnace fuels, stove oil, gasoline and petrochemicals.
1.3.2
Our present study is confined to the instrumentation and controls systems in used in Up-stream Oil Industry citing specific examples from the installations from ONGC. The project work deals with some basics on Process Control, Control System Theory, Control System Elements, ISA Conventions on Instrumentation Symbology before going into the specifics on the different types of Drilling and Production Installations and instrumentation & controls used in them.
2.1.1 2.1.1.1
Pneumatic Signal: Pneumatic signals are signals produced by changing the air pressure in a
signal pipe in proportion to the measured change in a process Variable.
Analog Signal: Analog signals are continuous levels or values that are combined in specific
ways to represent process variables.
Digital Signal: Digital signals are discrete levels or values that are Combined in specific ways
to represent process variables and also carry other information, such as diagnostic information. The methodology used to combine the digital signals is referred to as protocol. Different types of digital signal protocols used are for signal transmission between Instrumentation and amongst different Control Systems and DCS/ SCADA. Instrumentation to PLC/ RTU popular digital signal protocols HART (Highway Addressable Remote Transducer), Foundation Field bus. Between the Control System and DCS/ SCADA protocols such as MODBUS, Profibus, DNP-3.0 and OPC (OLE for Process Control) and between two SCADA systems or DCS protocols such as OPC and ICCP (Inter Control Communication Protocol) are used.
2.1.2
Control Room Equipmets: Indicators: An indicator is a human-readable device that displays information about the
process. Indicators may be as simple as a pressure or temperature gauge or more complex, such as a digital read-out device.
3.1
Pressure Measurement :
Pressure is the most important parameter in both drilling as well as production in upstream oil industry. It is required to be monitored and controlled on continuous basis for safety of the process and plants as the material being handled are highly inflammable. The pressure is monitored through devices such as Pressure Transmitters and Pressure Switches.
3.1.1
Pressure Transmitter: A pressure transmitter basically has a transducer that converts pressure into an analog electrical signal and signal conditioner which converts the electrical signal to 4-20 mA Analog or Digital signal for transferring the measured pressure values through cables to Central Monitoring & Control System. Although there are various types of pressure transducers, one of the most common is the strain-gage base transducer. The conversion of pressure into an electrical signal is achieved by the physical deformation of strain gages which are bonded into the diaphragm of the pressure transducer and wired into a Wheatstone bridge configuration. Pressure Switches: Pressure switches are among the most often used instruments in a plant. They are used for indication of presence or otherwise of the pressure beyond a specific calibrated value.
3.1.2
3.2
Temperature Measurement
Temperature can be measured via a diverse array of sensors. All of them infer temperature by sensing some change in a physical characteristic. Six types with which the engineer is likely to come into contact are: thermocouples, resistive temperature devices (RTDs and thermistors), infrared radiators, bimetallic devices, liquid expansion devices, and change-of-state devices. Depending upon application and process any one of the above is used in Oil & Gas industry.
3.3
Flow Measurement :
A flow meter is an instrument used to measure linear, nonlinear, mass or volumetric flow rate of a liquid or a gas. Different types of flow measurement techniques are used for measurement of Oil and Gas flow in up stream oil industry depending upon the composition, density and viscosity of the oil. The methodology also depends on the quantity of the flow and pressure. The flow measurement can be Mechanical, Ultrasonic, Coriolis or Magnetic. Magnetic Flow meters are also used in some case of Water Flow measurement.
3.3.1
Volumetric flow metering is proportional to mass flow rate only when the density of the fluid is constant. If the fluid has varying density, or contains bubbles, then the volume flow rate multiplied by the density is not an accurate measure of the mass flow rate.
3.3.1.1
Venturi Flowmeter
The venturi flow meter is installed as a section of pipe or tubing and is used to measure the flow of fluids, either gaseous or liquid. The meter consists of a converging inlet section, a short straight throat section, and a diverging section.
As the fluid enters the converging section, its velocity begins to increase, reaching a maximum value at the throat. The diverging section then slows the fluid to approximately its original value. At the point of maximum velocity, the static pressure has decreased to a value less than the inlet static pressure. The difference between these two pressures along with the inlet pressure and temperature is an extremely accurate and simple indication of the mass rate of flow through the instrument.
3.3.2
A gas meter is used to measure the flow of fuel gases such as natural gas and propane. Gas meters are used at residential, commercial, and industrial a building that consumes fuel gas supplied by a gas utility. Gases are more difficult to measure than liquids, as measured volumes are highly affected by temperature and pressure. Gas meters measure a defined volume, regardless of the pressurized quantity or quality of the gas flowing through the meter. Various types of techniques are employed depending upon the application. Say in case of the flare gas flow the challenges are sudden flow of high volume of gas and is different from the gas output from process.
3.4
Level Measurement
Level is required to be measured at Storage tanks at production installations. Level measurement sensors fall into two main types, Point level measurement sensors and Continuous Level Measurement. Point level Sensors functions as a high alarm, signaling an overfill condition, or as a marker for a low alarm condition. Continuous level sensors are more sophisticated and can provide level monitoring of an entire system. They measure fluid level within a range, rather than at a one point, producing an analog output that directly correlates to the level in the vessel. Both the above types are used in Oil industries depending upon the application. Different types of transducers are used including capacitive and Ultra-sonic type. To create a level management system, the output signal is linked to a process control loop and to a visual indicator.
3.5
Calibrator :
Most instruments and sensors are designed to meet certain accuracy specifications; the process of adjusting an instrument to meet those specifications is referred to as calibration. The device used to calibrate other instruments is known as a calibrator. Calibrators vary in form and function depending on the instruments with which they are designed to work. Several different types of calibrators are described below. Calibrators are extensively used by the Instrumentation & Process engineers in Oil Industry for maintaining the accuracy of the measurement.
3.6
ISA Sybology
The Instrumentation, Systems, and Automation Society (ISA) is one of the leading process control trade and standards organizations. The ISA has developed a set of symbols for use in engineering drawings and designs of control loops. Drawings which depict the process flow using the instruments and pipelines based on ISA symbology are known as piping and instrumentation drawings (P&ID). The conventions follwed in the ISA Symbology for depicting the pipeline & instruments are depicted at Annexure-I. A typical P&ID Diagram of an Oil & Gas production installation using ISA notations is placed at Annexure-II. The salient features of ISA Sybmology are as follows: a) In a P&ID, a circle represents individual measurement instruments, such as transmitters, sensors, and detectors. A single horizontal line running across the center of the shape indicates that the instrument or function is located in a primary location (e.g., a control room). A double line indicates that the function is in an auxiliary location (e.g., an instrument rack). The absence of a line indicates that the function is field mounted, and a dotted line indicates that the function or instrument is inaccessible (e.g., located behind a panel board). b) A square with a circle inside represents instruments that both display measurement readings and perform some control function. Many modern transmitters are
c) d) e) f) g)
equipped with microprocessors that perform control calculations and send control output signals to final control elements. A hexagon represents computer functions, such as those carried out by a controller. A square with a diamond inside represents PLCs. Two triangles with their apexes contacting each other (a bow tie shape) represent a valve in the piping. An actuator is always drawn above the valve. Directional arrows showing the flow direction represent a pump. Piping and connections are represented with several different symbols. A heavy solid line represents piping. A thin solid line represents process connections to instruments (e.g., impulse piping). A dashed line represents electrical signals (e.g., 420 mA connections). A slashed line represents pneumatic signal tubes. A line with circles on it represents data links Other connection symbols include capillary tubing for filled systems (e.g., remote diaphragm seals), hydraulic signal lines, and guided.
h)
Identification Letters
Identification letters on the ISA symbols (e.g., TT for temperature transmitter) indicate: The variable being measured (e.g., flow, pressure, temperature). The devices function (e.g., transmitter, switch, valve, sensor, indicator). Some modifiers (e.g., high, low, multifunction)
i)
Tag Numbers
Numbers on P&ID symbols represent instrument tag numbers. Often these numbers are associated with a particular control loop (e.g., flow transmitter 123).
3.7
3.7.1
3.7.2
4.1.1
Ladder logic: Ladder logic is the main programming method used for PLCs. As mentioned before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers and trades people was greatly reduced.
4.2
4.1.2
4.1.3
I/O Interfaces:
Interface boards come in analog and digital flavors, and are typically designed for input only, output only, or both. These main types of interface boards are often abbreviated as AI (Analog Input), "DI" (digital input), "AO" (analog output), "DI" (digital output), Pulse Output and boards interfacting with specicic signal protocols such as MODBUS, Fieldnus, DNP-3.0, OPC etc.
4.1.4
Software and Logic Control : Modern RTUs are usually capable of executing simple
programs autonomously without involving the host computers of the DCS or SCADA system to simplify deployment, and to provide redundancy for safety reasons. A RTU in a modern water management system will typically have code to modify its behavior when physical override switches on the RTU are toggled during maintenance by maintenance personnel.
4.1.5
4.2
1) 2) 3) 4) 5) 6) 7)
Electrical power grids and electrical generation plants. Environmental control systems Traffic signals. Water management systems. Refining and chemical plants Pharmaceutical manufacturing. Sensor Networks A DCS solution does not require operator intervention for its normal operation, but with the line between SCADA and DCS merging, systems claiming to offer DCS may actually permit operator interaction via a SCADA system. Distributed Control Systems (DCSs) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented.A typical DCS consists of functionally and/or geographically distributed digital controllers capable of executing from 1 to 256 or more regulatory control loops in one control box. The input/output devices (I/O) can be integral with the controller or located remotely via a field network.
4.3
SCADA
SCADA is any system that performs Supervisory Control And Data Acquisition, SCADA systems are typically used to perform data collection and control at the supervisory level. Some SCADA systems only monitor without doing control, these systems are still referred to as SCADA systems
4.3.1
Systems concepts:
A SCADA system includes input/output signal hardware, controllers, HMI, networks, communication, database and software. It mainly comes in the branch of Instrumentation Engineering. The term SCADA usually refers to a central system that monitors and controls a complete site or a system spread out over a long distance (kilometres/miles). The bulk of the site control is actually performed automatically by a Remote Terminal Unit (RTU) or by a Programmable Logic Controller (PLC).
4.3.2
4.3.3
Hardware solutions:
SCADA solutions often have Distributed Control System (DCS) components. Use of "smart" RTUs or PLCs, which are capable of autonomously executing simple logic processes without involving the master computer, is increasing. A functional block programming language, IEC 61131-3, is frequently used to create programs which run on these RTUs and PLCs.
4.3.4
System components :
a) Remote Terminal Unit (RTU) : The RTU connects to physical equipment, and reads status data such as the open/closed status from a switch or a valve, reads measurements such as pressure, flow, voltage or current. b) Master Station: The term "Master Station" refers to the servers and software responsible for communicating with the field equipment (RTUs, PLCs, etc), and then to the HMI software running on workstations in the control room, or elsewhere.
4.3.5
Operational philosophy:
Eventhough traditionally SCADA was designated to facilitate remote operations of installations i.e. monitoring and controls where RTUs performed the task of store & forward only but of late instead of relying on operator intervention, or master station automation, RTUs may now be required to operate on their own to control tunnel fires or perform other safety-related tasks. The master station software is required to do more analysis of data before presenting it to operators including historical analysis and analysis associated with particular industry requirements.
4.3.6
4.3.7
Features of SCADA:
SCADA systems are of different in terms of applications and number of I/O channels. They can be simple PC based system directly attached to an RTU or a large system comprining of several RTUs/ PLCs. Eventhough SCADA refers to the entire system comprising of RTUs and Master Station the main task is carried out by the SCADA Software in SCADA Master Station. The typical features/ tasks performed are: a) Scanning RTUs for getting the data and status Field Instrumentaion. The data can be Raw or computed. For obtatining the data from RTUs, either Requestresponse or Reportby-exception techniqes are followed. b) Maintaining Histories of the field data and that od Alarms and Events. c) HMI, Human Machine Interface which includes MIMIC Diagrams which provides the GUI based view of the plane/ installaion with instauemts and the parameter valus. Mimics are interactive with zoomin and zoom-out facilities. Display of Trends. Display of Alarms and Events. Historical data and logs (Operator actions, equipment and instrumnent configurations etc). d) User authentication and security: It maintains multi-level user authentication and permissions and allocates different functionalities of monitoring and controls yo users. e) Initiation of Supervisory Controls and transferring them to RTUs for implementing at Field level.
4.3.8
ICCP(Inter-center Control Protocol) ICCP maximizes the use of existing standard protocols in all layers up to and includingthe lower layers of layer 7 in the OSI reference model. This has the benefit of requiring new protocol development for ICCP only in the upper sub-layer of layer 7. ICCP utilizes the services of the Application Control Service Element(ACSE) in layer 7 to establish and manage logical associations and connections between sites. It relies on the ISO Presentation Layer 6 and Session Layer 5 as well. OPC(OLE For Process Control) OPC(OLE for Process Control) is a software standard for open software application interoperability between automation/control application, field systems/devices and business/office applications.
OPC defines a common, high performance interface based on Microsofts COM/DCOM technology. COM(Microsofts Component Object Model) enables the definition of standard objects, methods and properties for servers of real time information such as DCS, PLCs, I/O systems and smart field devices. DCOM(Distributed Component Object Model) is the network-aware version of Com technology, providing data via LANs, remote sites or the internet.
4.3.9
APPLICATIONS OF SCADA SCADA From the cold of Siberia to the heat, salt and moisture of offshore oil platforms, SCADA (Supervisory Control and Data) systems are proven performers in a wide variety of industries and applications. Oil & Gas Production & Drilling. Oil refineries Electrical Generation, Transmission & Distribution Chemicals & Petrochemicals Fertilizers Water Distribution Sewerage
GGS
GGS
Western Offshore
CTF
CTF
The objective of this project is not only to provide comrehensive opeartions control but also provide real-time, on-line process data to business systems such as SAP and to Scientific Systems for generating greater value out of the process data. The proposed SCADA is based on Stae-of-the-art technology, based on open signal/ communication protocols. It is spread across all the drilling & production installaion of ONGC throughout India and is based on three tier architecture (At installations, Operations Mangers and Corporate Level MIS). Following sections describe the processes at different types of installations in drilling & production and also indicate different parameters monitored and controlled in these installations. 5.1 Drilling Process and SCADA: Oil well drilling is a complex activity because it has to cater to the unknown behaviour and pressure encountered from the Oil & Gas in the crest of the earth. To counterbalance this pressure, Drilling Mud is pumped into the well thorugh drill string. Drilling is carried out using drill bit as with increase in depth, more and more drill strings are attached to it. The oil well drilling may go upto a depth of from few hundren meters to 5000 meters. The drill strings are hollow and through them mud is pumped into the well. Drilling Mud is a slurry of specialised chemicals. The mud serves several purposes such as removal of the rock cuttings, cooling and lubrication of the drill-bit and most importatntly maitain hydrostatic pressure to counterbalace the reservoir pressure of oil &
gas (in case oil / gas carrying rocks are encountered). To provide a return path to the mud there is a coincentric Annulus around drill string. The mud coming out of the well is an indicator of the presence of oil/ gas through its density in contrast with the mud pumped in. It is also analysed using Gas Chromatographs for gas-shows. Other mud parameters are also significantly importatnt. The instrumetation and monitoring play vital role in carrying out the drilling activity safely and as per the schedule (maintaining required penetration rates). Different subsets of the total parameters are relevant to different functions; Drilling, Geology and Chemistry. These parameters are described below.
5.1.1
Drilling Parameters monitored using SCADA For monitoring & control of drilling operations inputs are taken from Drill floor as well as Mud Logging. They may be taken from the Rotary strokes per minute, Mud tanks, Trip Tanks, Hookload at Kelly, and Blow Out Preventer. Follwing parameters are monitored:
5.1.2
Hook load, bit weight, lines strung, bit position In slips Rate of penetration ,depth of hole, bit depth Drill pipe rotary rate and torque Active mud tank volume, trip tank volume, gain/loss Return mud flow Pump rate, total strokes, Mud pressure, temperature, flow rate and density in and out.
The SCADA Layout The signals from all these Sensors are brought and acquired into a Data Acquisition System (DAS) which is not part of SCADA system. The A/D converted / stored data is then transferred to SCADA system through Ethernet Rig LAN on WITS/ WITSML protocol. (Well Information Transfer System on XML) a protocol standard in logging/ drilling SCADA industry. There are separate sets of screens for Tool pusher (Drilling), Geology and Chemistry only showing relevant information on GUI.
HMI TOOL PUSHER HMI GEO LAB WITH MUD LOGGING SOFT WARE HMI CHEM LAB RIG LAN
RIG SENSOR
RIG SENSOR
RIG SENSOR
The data from SCADA System on Rigs shall then be transferred to the SCADA system at respective Asset HQs on WITSML protocol for sismilar displays there. At Asset dtat from all the rigs in that asset shall be collected and any of them can be monitored remotely. From there the data shall be transferred to Institue of Drilling Technology, Dehradun. The system also fecilitates automatic Daily Progress Reports/ MIS generation and feeding of data into the ONGCs Business system on SAP. In the Enterprise Wide SCADA under implematation, all the 75 Onland Rigs and 10 Ofshore Rigs are covered. Also there is provision to inegrate the Contractual Rigs on Open Protocols.
5.2.1.1
TT
TT
SSV PT Switch Pr Switch
PT TT SSV Status
TIJB
TDMA Radio Link
SSV
Shutdown Panel
RTU
PT
SSSV
The well has many coincentric tubings comrising of Main Production Tubing and upto three numbers of Annulus. The Annulus are also used for injecting gas in case of Gaslift wells. In the production tubing there is a Safety Valve (SSV) which is situated on the upper part of well above the floor of the platform and Sub-Surface Safety Valve (SSSV) which lies below. They are used for shutting down the well in case of any exegency. They are also controlled by Fire Shutdown and Emergency Shutdown panels. The other well platform monitored are as follows: PER WELL 1. WELL HEAD PRESSURE. 2. FLOW ARM TEMPERATURE 3. SSSV STATUS. 4. SSV STATUS. 5. SSV CONTROL. 6. ANNULUS-A PRESSURE. 7. ANNULUS-B PRESSURE. 8. ANNULUS-C PRESSURE. PER PLATFORM 1. ESD STATUS 2. FSD STATUS 3. ESD CONTROL(OPTIONAL) : Indicates health of each well : Indicates health of each well : Sub-surface safety valve : Surface safety valve Status : : To monitor leakage from any of : these casings. : : Status of Emergency Shutdown : Status of fire shutdown : Remote operation of ESD
4.
5.
: Outgoing : Outgoing
The produce from all the wells of a platform are combined into the Main Line which is taken to Process Complex where it is known as Raiser Line. These Parameters are taken into an RTU at Well platform and through radio taken to SCADA system at Process Platfrom. 5.2.1.2 Process Complex: The Process platform where produce from well platforms is taken and processed for separating Oil, Gas & water is a major structure in the offshore and is manned. It also has residential facilities, offices and maintenance functionalities. The complete facility is known as Process Complex. It has series of Three Phase Separators followed by Compressors for pumping separated oil & gas to shore directly or via nearby process complex. The water is pumped to Water Injection Platform. In some cases Water Injection Platforms are attached to the main Process Complex itself.
Well Platform
OPC Link with DCS System V.35 Link with Router through OFC RS-232 Link through OFC Ethernet LAN through OFC SCADA HMI Work Stations
The Process Complex contains the SCADA System which acquires the data from well platform RTUs through TDMA radio by polling or Report by exception. The SCADA data is in turn taken to Asset Office at Shore through Satellite Communication. Apart from the well data from well platfroms some of the information form process with process complex are also acquired from the DCS of the Process Complex as depicted above. Following is the list of such parameters. Raiser Line Pressure at Process Complex 2. 3. 4. 5. 6. 7. 8. 9. 10. : Pressure of line coming from each Remote Well Platform Raiser Line Temperature at Process Complex: Temperature of line coming from Remote Well Platform Main Oil Line Pressure : Main Oil Line going from one Process Main Oil Line Temperature : Complex to other process Complex Main Oil Line Flow Rate : or to the shore Main Gas Line Pressure : Main Gas line going from one Main Gas Line Temperature : Process Complex to other Process Main Gas Line Flow Rate : Complex or the shore Total Oil Pumped Into Main Line : (Volume) Total Gas Pumped Into Main Line (Volume)
5.2.2
Onshore Production Installations: Onshore has many Production Installations such as GGS, CTF, ETP, etc. They are described below. Group Gathering Station (G.G.S.): GGS is the installation where the produce from wells are taken first. It caters to large neumber of wells in the vicinity. Many production well lines enter into the GGS and each may be combining produce from more than one well along the way. They are connected to the Group Header. However any of them may be diverted to Test Header also. From Group Header the well fluid is taken to a Group Separator, which allows the Oil, Gas and Effluent to get separated under static conditions at some pressure. After this the Oil separated is sent to Heater Treater where it is heated to remove the desolved gas further. Then the Oil is stored in tank and either pumped to CTF or to consumers as the case may be. Gas from all these stages is combined and pumped to GCS. Some quantity of Gas is always sent to Flare Line so as to maintain the flame.
5.2.2.1
The diagram below depicts the process at GGS and also the parameters being monitored.
Tank Level
Tanks
PUMPS
5.2.2.2
Gas Collecting Stations (G.C.S.): In contarst with GGS, GCS caters only to gas wells. Number of Gas wells are connected to it through pipelines. The pipelines may attach to single or multiple oilwells through branches from the surrounding areas, the gas from the well entered in to two headers namely GROUP HEADER and TEST HEADER through on-off valves. The gas from Group Header is taken to Separator where the Gas is separated from Emulsion and the Gas is then comressed to CTF/ GCP or consumers. The following diagram depices the process at GCS and the parameters being monitored in GCS
Gas Wells
Group Header Test Header
Header Pressure
Gas Flowing Status of High Producers
To Asset HQ
Test Separator
Qty of Emulsion
Group Separator
Gas
TEST TANK
Tank Level Total Qty of Gas Supplied to Consumers Qty of Gas Flared
Installation SCADA
MFM Emulsion
Radio / Router R T U
PC
5.2.2.3
Early Production System (EPS): Before the field is completely develop the production from few oil wells started by collecting there produce in to an installation called EPS. It is not so elaborated in terms of facilities lesser functionality compared to G.G.S.
5.2.2.4
Centarl Tank Farm (CTF) Central Tank Farm is a bigger installation where the Oil from GGS are brought before being pumpud to refineries through pipelines or through tankers. The diagram indicates the process and Parameters to be monitored in CTF.
PUMP
PUMP
Heater Treater
Pump Status
Installation SCADA
Heater Treater
Qty of Effluent to ETP Radio / R T U Router
PC
Oil Level , Temp of Each Tank With Hi-Low Alarms & Volume / Mass of Crude Oil
5.2.2.5
Gas Compressor Plant The gas collected form one or more GCS is compressed and sent to Refineries / LPG plant etc.
L.P. GAS
FQ Existing
H.P. GAS
FQ Existing
5.2.2.6
Effluent Treatment Plant The effulent from varies GGS is taken to ETF where remainning oil is taken out and water is seperated . The water is taken out and is used to inject water in wells. Water is further treated by water treated plant.
Process Parameters Proposed to be monitored In a Typical ETP
EFFLUENT
ETP
PUMP
TR EATED EFFLUENT Total Qty of Treated Effluent Pumped to WIP / Disposal Wells
FQ Existing
I N JECTI ON W ATER
FQ Existing
1) 2)
5.3 Benefits from SCADA Support efficient monitoring of the operational productional & drilling parameters. Automatic generation of Logs, Reports and DPRs. 3) Better accounting of the products and stricter control wastages etc. 4) The data can be provided to other Production and Drilling Appliocations for more purposeful information. The application such as Mass balancing, Leakage Detection, Gas Lift Optimization add value to the organization. 5) Seamless flow of Realtime Online information into business and scienftific systems increasing authenticity due to avoiding manual errors. 5.4 Conclusion The study provides a detailed account of the process control in general and then specific to Up-Straem Oil & Gas Industry. This study has not only provided the exposure to the Process Control in general and to the terminologies, symbologies therein but also to its specialized applications in UP-stream Oil Industry with illustartion. This shall go long way in shaping our career as budding Instrumentation Engineers.