Isa-sachin-upstream-onshore.ppt

Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Two Day Training Program on 20th & 21st Sept. 2013
at Hotel Regaalis, Bangalore on;
Automation in Oil & Gas
Upstream Process Automation for
Onshore facilities
By Sachin Rasane – O&G Automation Consultant & Trainer
i-Cube Technologies, Pune
Mail: rasanesimved@yahoo.co.in ; Mobile: +91 9422359938

ISATRNG/2013.09.20-21/SlideNo.2
Automation in Oil & Gas Industry
Onshore facilities
Academic
- Instrumentation and Industrial Electronics Engineering
- VES Engineering College, Mumbai
- Year 1988
Worked in:
- Domain – Oil and Gas Upstream (Onshore Projects)
- EPC – Jacob’s, Worley Parsons, Kvaerner
- Engineering Consultants – Comprimo, Granherne
- System Vendors – Emerson, Honeywell
- OEM - GE
- Contractors – Al-Hassan, Mannai Engineering
- End Users – PDO-Shell, Occidental, Chevron,ADCO,ARAMCO, PKKR, MRPL, HPCL etc.
Current Position:
- Freelancer – O&G Automation Consulatnt (i-Cube Technologies, Pune) – Conducting Trainings for
Graduate / Junior Engineers and Workshops for Corporate. Initiative to reduce Industry-Academia Gap.
Association:
- Member of IEC
- Sr. Member of ISA (Bangalore Section)
- Formed OGIC (Oil and Gas Instrumentation Club) on LinkedIn for Global Instrumentation Community
Sachin Rasane

Onshore facilities
Agenda
• Introduction
• O&G Process Automation – Principle Vs. Standards
• Process Risk Management Methods
• O&G Automation – Protection Layers
• O&G Automation – Activity Layers in EPC Project
• O&G Gathering & Production Station – Sub Areas
• Overall O&G Upstream Process for Onshore facilites
• O&G Production Wellheads – Centralized Monitoring and Control
• Production Manifold
• Multiport Selector Valve
• Test and Production Separator - Process Automation
• Enhanced Oil Recovery
• Gas Compression and Injection
• Water Disposal and Injection
• Crude Shipping Pumps
• Utilities and ICSS Architecture
• Oil and Gas Projects – Lifecycle / Automation SoW / Design Tips

Onshore facilities
Introduction

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O&G Process Automation – Principle Vs. Standards
 What is Process?
 O&G Process Vs. Any other process
o Geographical Location and Conditions
o Atmospheric Conditions
o Hydrocarbon Properties
o Local Rules, Regulations and Standards (Exp. SD, IBR)
o Company Standards (Exp. PG)
 Process and Automation Principle remains same….Design Standards Differs!!!
 Do we have Universal Codes, Design Standard OR Rules for O&G?
 Field Instruments and Control System selection criteria's
End UserOEM
Field Instruments and Control System
Vendor (MAC/MIC Projects)
EPC /
Consultant

Onshore facilities
Process Risk Management Methods
Process Risk Management methods used during the Design phase can be put into 4 categories:
 Inherent - Eliminating the hazard by using materials and process conditions which are non-hazardous.
Use less hazardous process conditions, less hazardous forms of materials, or configure facilities to
minimize impact from hazardous material releases or uncontrolled energy release and Configure facilities
to simplify operation.
Example – Sour Gas (with H2S) Producing Wells, Gathering Station and location of Utilities, Bund Walls
 Passive - Minimizing the hazard by process and equipment design features which reduce either the
frequency or consequence of the hazard without the active functioning of any device.
Exp. Intrinsically Safe and Kinematic Vapor Pressure (Hydrocarbon tendency)
 Active - Using facilities to detect and correct process conditions i.e Controls / Safety interlocks /
Monitoring systems for hazards that develop over a long term / and Emergency Shutdown Systems to
detect and correct process deviations.
 Procedural - Prevention or minimization of incident impacts using: Safe operating procedures and
operator training / Administrative safety checks / Management of Change / Planned emergency response.
Target is a Fail-Safe Design, Installation and Operation

Onshore facilities
O&G Automation – Protection Layers
Prevention Layers:
• Plant Design
• Process Control
• Alarm systems
• Mechanical or Non -SIS protection layers
• Interlocks
• Shutdown systems
Mitigation Layers:
• Fire and Gas Alarms
• Evacuation procedures
• Site emergency procedures

Onshore facilities
O&G Automation Activity Layers in EPC Project (MAC/MIC)
Facility & Plant
Level Activities
System Level
Activities
Equipment Level
Activities
Refer PFD, Study Process and Sub-Process,
respective P&ID’s, It’s connectivity, Main Headers,
Plant Interlocks (ESD / PSD) and main Controls,
Highlight signals by different colors, Compare I/O List
Refer P&ID’s and Equipment List, study Process
Operation, Check Interlocks (ESD / PSD) and
Controls, Check Equipment & Boundary Limits
Highlight signals by different colors, Compare I/O List
Check Overall System Requirement (ICSS). Check
DCS interface with ESD / F&G and Third Party,
Design System Architecture as per End Users
requirement.

Onshore facilities
Onshore O&G Gathering and Production Station
 O&G Production wells
 EOR wells (Secondary Wells)
 Steam Injection Skid
 MPS Valve skid
 Production Manifold
 Test Separator
 Bulk or Production Separator
 FWKO Tanks
 Oil Transfer (Shipping) Pumps
 Gas Compressor
 Gas Injection Manifold
 Flare System
 Water Injection Pumps
 Water Disposal Pumps
 Water Injection Manifold
 Chemical Injection skids
 Air Compressor skids
 Diesel Generator
 Fire Suppression Skid
Remote
Plant Sub Areas (typical):
G&P Stn.

Onshore facilities
Typical Overall O&G Upstream Process for Onshore facilities

Onshore facilities
O&G Production Wellheads
Rod Pump / Donkey Pump
One of the greatest challenges faced by rod pump operators is adjusting the pump rate so that it is
optimized for the flow and pressure in the bore hole. If the pump moves less liquid than the well
generates, productivity will be suboptimal. Pumping more than the well generates results in
overpumping. This runs the risk of creating fluid pound, which can damage the entire pump system
which result in rod buckling, excessive pump and tubing wear, unnecessary friction and stress
fluctuations throughout the entire pumping system. Shock loading experienced by surface pumping
unit associated by vibration that goes beyond tolerable limit is another problem that will reduce
equipment runlife.
Uncontrolled Fluid Pound
 Increases energy costs.
 Increases wear and tear on downhole equipment.
 Makes it almost impossible to counterbalance the
pumping unit properly.
 The counterbalance problem and the fluid pound
"shock" increase gearbox wear and shorten gearbox
and wrist pin bearing life.

Onshore facilities
O&G Production Wellheads
Rod Pump / Donkey Pump Operation

Onshore facilities
O&G Production Wellheads – Centralized Monitoring and Control
Rod Pump Controller
RPC - The practical solution to minimize fluid pound damage by turning off the Unit and
maintaining maximum production. RPC automatically adjusts the pumping rate to
changing well conditions.
RPCs Benefits
 Performance analysis,
 Problem diagnosis
 Equipment optimization

Onshore facilities
As their oil and gas fields often spread across vast distances in a severe desert climate,
End User needs a reliable monitoring system to address harsh environmental conditions.
 RTU’s /RPC Controller / Tran-receivers
 Main & Back Up Power Supply with Charger
 Solar Panels / Cables / MountingAccessories
 Camera (Optional)
 YagiAntenna / Tower & Repeater
Well Head Automation Components
Well Head Monitoring & Control
CCR Automation Components
 OmniAntenna
 Trans-receiver
 Switches and Routers
 Hardware / Well monitoring Software
 Pressure Transmitter
 Temperature Transmitter
 Multi-phase Meter (Optional)
 Vibration Sensor
Well Head Process and Safegaurding

Onshore facilities
Well Head Automation
 Wellhead Control Panels (WHCP)
 Hydraulic-Pneumatic Panels
 Hydraulic Power Generation Units (HPU)
 Emergency Shutdown and Process
Shutdown Systems (ESD/PSD)
 Integrated WHCP with photovoltaic Power
Generation Unit and RTU

Onshore facilities

Onshore facilities
O&G Gathering and Production
Plant Overview (Typical)

Onshore facilities
Production Manifold
 Production Header
 Test Header
 Valve Selection

Onshore facilities
Production Manifold
Multiport Selector Valve
Multiphase Flow Meter
ESDV
RTU
 Remote Gathering & Testing
 Production Header
 Well Testing
 Automation

Onshore facilities
Separators
3 phase Separation
Testing
3 phase separators are commonly used in upstream oil and gas
industry to separate oil, gas and water stream coming from the oil wells.
ESDV
From
Production
Manifold
PSHH (Pressure High High)
PSLL (Pressure Low Low)
LSHH (Level High High)
LSLL (Level Low Low)
BDV (Blowdown Valve)
PSV (Pressure Safety Valve)
ESDV (Emergency Shut Down Valve)
ESDV
ESDV
ESDV
To Flare
Safety in Separator
Crude Outlet Control
Gas Outlet Control
Water Outlet Control
Separator Control
LT
HH
LL
LT
HH
LL
BDV
HH
PT

Onshore facilities
Enhanced Oil Recovery Methods
 Gas Injection
 Water Injection
 Steam Injection

Onshore facilities
EOR - Gas Compression and Injection
Gas from the compressor system enters the GLM and is distributed to the gas-lift wells.
The pressure at the GLM has to be kept at level high enough to allow injection in all gas-lift wells.
In cases where the gas flow-rate entering the GLM is higher than what is needed to operate the
wells; the excess gas is directed to the flare or to the recirculation of the compressor system.
Gas Lift Compressor Automation
(by Compressor Vendor)
Gas From
Production
Separator
 LCP and UCP
 Compressor Logic (PLC based)
 Anti-Surge Control
 Vibration
Temperature
 Suction
 Discharge
 Recycle
 Scruber
 ESD and F&G Signals
PSD
ESD

Onshore facilities
EOR - Gas Lift Compression and Injection
 to keep the GLM pressure close to a set-point designed according to the needs of the gas-lift
wells,
 to distribute the gas flow-rate delivered by the compressor system among the gas lift wells in a
way that maximizes an economic objective and
to minimize the production oscillations caused by changes in the gas injection flow-rates. These
oscillations cause problems to the separation process.
Gas Lift System Automation Purpose

Onshore facilities
EOR - Water Injection
Water is injected;
(1) to support pressure of the reservoir
(2) to sweep or displace oil from the reservoir, and push it towards a well.
Normally only 30% of the oil in a reservoir can be extracted, but water injection
increases that percentage (known as the recovery factor) and maintains the
production rate of a reservoir over a longer period.

Onshore facilities
Water Injection Pumps
Automation (by Pump Vendor)
EOR - Water Injection
 UCP (Optional)
 Pump Logic (PLC based – Optional)
 Vibration
Temperature
 Lube Oil Level
 Suction
 Discharge
 ESD Signals
PSD
ESD
Water from Separator / FWKO Tanks / Skim Tanks enters into W.I. Manifold through Water Transfer
Pumps and distributed to W.I.Wells. The pressure at the WIM has to be kept high enough to allow
injection in all W.I. wells, to maintain Reservoir Pressure for Enhanced Oil recovery. Injected Water
flowrate for each W.I. Well is control by PID control.

Onshore facilities
Crude Shipping Pumps
Automation (by Pump Vendor)
Crude Shipping Pumps (Station Discharge)
Crude Shipping Pumps transfers recovered Crude to Downstream over long distance Pipeline
for further processing or export.
 UCP
 Pump Logic (PLC based)
 Vibration
 Temperature
 Lube Oil Level
 Suction
 Discharge
 Heat Detection
 ESD and F&G Signals
PSD
ESD
ESD
Pump Automation Design Guidelines
 I&C Input to Pump Spec. (Mechanical Scope)
 Identify Skid Limit on P&ID
 Identify DCS/ESD/F&G Intergace
 Pump Instrumentation Design and Hook Ups
 MTO
 UCP Design Specification and final Deign
 Connected in Parallel
 Run / Standby Logic

Onshore facilities
Air Compressor Automation
(by Pump Vendor)
O&G Gathering Station Utilities & ICSS Interface
Air Compressor
 Plant Air Consumption
 Distribution
 LCP
 Pump Logic (PLC based)
 Loading & Unloading
Temperature
 Lube Oil Level
 Diff. Pressure (Filter)
 Discharge Pressure
 ESD Signals
PSD
ESD
Diesel Generators
Air Conditioning System DCS SIS F&G
Third Party System Interface
Fieldbus
Instrs.
Field – Vendor Skids & Instruments
Analog
Digital
Instrs.
SIS
Instrs.
F&G
Instrs.
Typical ICSS System Architecture
 Water Injection Pumps (Optional)
 Air Compressors
 Diesel Generator
 Fire Suppression System
 Gas Compressors
 Crude Export Pumps (Optional)
 Manifolds-O&GI
 Separators
 FWKO / Storage
 Oil Transfer Pumps
 O&G Pipelines
Safe Area Haz. Area Soft Link H/W Signals Fieldbus

Onshore facilities
S. No. Parameters &application Instrument device Type of device
01 Well head pressure /temperature Pressure /Temperature transmitters
with Radio telemetry
Radio transmitters
powered with solar cell.
02 Flowing status of wells /flow rate Clamp on Ultrasonic flow meters FF / MODBUS device
03 Gas flow to dispatch header / gas
flow from individual gas wells
Orifice meters (senior orifice
fittings) with multiple sensors
FF device /
Conventional Smart
04 Tank level indicators Guided wave Radar type level
indicators
MODBUS
05 Line temperature of oil & gas line Strip type RTD device with filed
transmitter
FF type / Smart
06 Water injection header flow rate Orifice meter /DP transmitters FF type / Smart
07 Gas lift header pressure Pressure transmitter FF type / Smart
08 Gas lift finger flow rate DP transmitter with P&T
compensation
FF type / Smart
09 Test gas flow rate Senior orifice meter FF type / Smart
10 Effluent water dispatch meter Magnetic flow meter FF type / Smart
11 Mass flow meter for stabilized oil Coriolis meter MODBUS
Typical Field Instrumentation Selection for O&G Upstream
Note: Above table shows typical field instruments used in O&G Upstream; however Engineers should
follow End User Specification, Data Sheet and Design Standards for each Project.

Onshore facilities
Oil and Gas Project Lifecycle
Phase I
Feasibility Phase
Phase II
Concept Phase
(Pre-FEED)
Phase III
FEED Phase
The objective
is to
demonstrate
both technical
and economic
viability.
The objective
would be to
select the best
option(s) and
further define to
reduce risk and
improve project
cost estimate
accuracy.
A robust FEED
will deliver the
estimate for
final sanction
together with
the
documentation
for the next
contracting
phases.
Project Engineering goes through 4 phases before taken forward to the Construction.
Automation Projects are classified in 3 categories: GreenField, BrownField and
Revamping (Upgradation) projects
Phase IV
Detail Design
The FEED
output will
enable
procurement
activity to
commence prior
to main EPC
contract award.

Onshore facilities
Typical O&G Automation Scope in EPC Project (MAC/MIC)
Field Instruments
Deliverables
Construction SoW
and Deliverables
Control System
Design
(DCS/ESD/F&G)
• P&ID’s
• Instrument Index
• Field Instrument Spec.
• Calculation Sheet
• Instrument Data Sheet
• Hook Ups
• MTO
• etc.
• SoW
• Layouts
• Cable Schedule
• Hook Ups
• Bulk MTO
• JB & System Drawings
• etc.
• SoW
• ICSS System Specification
• System Architecture
• I/O List
• Segment / Loop Diagrams
• C&E Diagram
• P&ID’s
• Graphic Specification
• System Drawings
• etc.
Instrumentation Deliverables

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Typical O&G Automation Scope in EPC Project (MAC/MIC)
Site Visit and
Client Interface
Design Activities
EPC / Construction
Activities
• KoM
• P&ID’s As-Built Markup
• Design Standards
• Tagging Philosophy
• Project Schedule Inputs
• Project Meetings
• Progress Report
• Procurement
• etc.
• Project Maganement
• Project Progress Report
•Team Allocation
• HAZOP/SIL
• Project Deliverables
• Multi-Discipline Checks
• Vendor Enquiries
• etc.
• Tender (SoW, Deliverables,
• EQC and BQC
• Strategic Proposal
• TC Evaluation
• Design Checks
• FAT / SAT
• Commissioning
• AMC
• etc.
Instrumentation Activites

Onshore facilities
Important Design Tips
Proposal/S&M/Design/
Engineering/O&M
(from Delegate perspective)
OEM
Engineering
Consultant
End User
EPC
Contractor
Manufacturing
Companies
Field Instruments
System Vendors
 Do not use / copy standards from previous company
 Strictly follow End User Standards and Specification
 Study Project type, Process, SoW and Automation requirement
 Check PFD and P&ID before starting work & confirm I/O count
 Refer Hazardous Area Location Layout for IS and NIS loops
 Check Instrument Spec. for Instrument selection
 Confirm wetted part, Nozzle Orientation, Hook Ups (Direct/Remote), MTO
 Systematic & uniform Design Approach
Oil and Gas Business Lifecycle

Onshore facilities
Sachin Rasane – O&G Automation Consultant & Trainer
i-Cube Technologies, Pune
Mail: rasanesimved@yahoo.co.in ; Mobile: +91 9422359938

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