The development ofhighautomated control systemsin ...€¦ · The development ofhighautomated...

The development of high automated control systems in hydrocarbonsproduction for operating without the constant presence of operatingstaff

Chief engineer of “Gazprom Avtomatizatsiya” PJSCBobrikov Nikolai

2

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

PROBLEMSTHE REMOTENESS OF TECHNOLOGICAL OBJECTS FROM

INFRASTRUCTURE

CONSEQUENT

SOLUTIONCREATION OF AUTOMATED TECHNOLOGICAL COMPLEXES (ATC) OF GAS PRODUCTION ON THE PRINCIPLES OF

MINIMAL MANNED OPERATIONS

DIFFICULT CLIMATIC, GEOLOGICAL AND GEOGRAPHICAL CONDITIONS

HIGH OPERATING COSTS THE HIGH COST ON SUPPORT OF SOCIAL SPHERE

The development of high automated control systems

The relevance of the work on the development of technologies of minimal manned operations

Experience and achievements Import substitution PerspectiveThe history

Signs of developmentThe relevance

ATC Chayandinskoe gas condensate field

3

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

1. Was accumulated experience of creating automation systems with higher performance on the principles of minimal manned operations

2. 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

3. 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“

4. According to the results of the tests was made the transition to the Russian components (HW and SW) for automation systems

Implemented projects in the field of automation of gas production facilities :

Zapolyarnoe field Bovanenkovo field Kirinskoe field Urengoyskoe field En-Yahinskoe field Vyngoyahinskoe field Ety-Purovskoe field Muravlenkovo field Medvezhie field Zapadno Tarkasolinskoe field Ubileinoe field etc.

The experience and achievements in creating the process control systems of gas production facilities

КГС1,2,3,4

P

2Q

1,2,3,4 1,2,3,4

BGW GGP BCS-2 GTT CGT

BCS-1

PCS60%

FGS20%

AUCS15%

Total produced more than 350 systems on the 52 gas treatment units (GTU)

Automated utilities control systems

Fire and gas systems Process control systems for all types of GTU





Диаграмма1

АСУ ТП

АСПС,КЗиПТ

АСУ Э

Создано более 350 систем

65

20

15

Лист1

Создано более 350 систем

АСУ ТП65

АСПС,КЗиПТ20

АСУ Э15

Для изменения диапазона данных диаграммы перетащите правый нижний угол диапазона.

4

The history of the development of APCS of the gas production facilities

GTU-1C, 2С, 3СZapolyarnoe field

GTU Ety-Purovskoefield and

Vyngoyahinskoefield

GTU-11VEn-Yahinskoe field

Chayandinskoefield*

GTU-22 the second pilot

area of the Achimovdeposits of the

Urengoyskoe field

GTU-1V, 2VZapolyarnoe field

Muravlenkovo field

PILOT PROJECT FOR

IMPLEMENTATION OF MINIMAL

MANNED OPERATIONS

Bovanenkovo field

The effectiveness of the APCS

2003 2004 2005 2018-20222007-2008 2008-2010 2010-2012 2013-2015

Systems are under control of the complex algorithms (CA)

Systems with united control panel, working on automated

modes (AM)

A qualitative transition

The main signs development of ACS :

Uniformity HW&SW 30% 30% 60% 70% 80% 100% 80% 100%

The degree of development of complex algorithms(CA) 5 7 2 17 27

More then 40 + adaptive SAC

More then 70 + GC+ adaptive SAC

More then 100 + GC+ adaptive SAC

Integrated operator interface None None None

First implementation Evolution None Evolution Circulation

United control panel None None None None None None First implementation Evolution

From "manual control" to the 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

* for the Chayandinskoe field the parameters are given in accordance with the Concept of automation and implemented design decisions

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".





5

The main signs of evolution of APCS: Uniform components (HW&SW)

5

Comparison of the degree of technical unity of the subsystems

Unit Zapolyarnoe field.GTU-1С

Bovanenkovo field. GTU-2

Chayandinskoefield

ControlWave

GE-IP

Russian HW&SW

ControlWave +Foxboro

Siemens+

Tecon

GE-IP+

Allen-Bradley

Foxboro+

GE-IPGE-IP

Foxboro+

GE-IP

NoneGE-IP

+Allen-Bradley

BGW

GGP

BCS-2

GTT

CGT

BCS-1

1. Have provided a high level ofreliability of functioning of controlsystems. Developed standardtechnical solutions for all fieldsubsystems.

2. Have minimized development costsand commissioning costs.

3. Have reduced operating costs forstaff training, acquisition of spareparts, software update. The extendedthe intervals between maintenanceand have minimized procedures forperiodic maintenance and repair.

MAIN RESULTS

For the first time was provided the development of a fully unified control system for the oil and gas part of the

Chayandinskoe field





6

Control algorithms: the intellectual maintenance of the state of a difficult system

Zapolyarnoe field.GTU-1С

Bovanenkovo field. GTU-2 Chayandinskoe field

BGW

BCS-2

GTT

CGT

BCS-1

Field

1,2,3,4

!

А

The distribution of gas field performancebetween GTU in accordance with theoperation modes of the interfield manifold

Control of wells performance

Q+ Maintenance of a given technologicalperformance of threads and the unit as a whole

Automatic regulation of the flow of methanolinto plumes pad and gas wells

Graphs of the process modes

Optimal redistribution gas flow for processlines

Automatic loading/unloading BoostCompressor Station (BCS)

Automatic translation technological lines in thereserve and withdrawal of thread from thereserve

Localization of ruptures of the pipeline (well,Bush, GTU, IM, GMU)

СН3ОН

A

The main signs of evolution of APCS: complex algorithms

Q

BGWThe monitoring system of the underground partof the well





СН3ОН

A

ДЭГ

A

Q

КГС

1,2,3,4

Q

КГС

СН3ОН

A + !

1,2,3,4

А

А

А

1,2,3,4

1,2,3,4

1,2,3,4

СН3ОН

A

КГС

1,2,3,4

Q+

1,2,3,4

А 1,2,3,4

СН3ОН

A + !

Q

КГССН3ОН

A

7

The main signs of evolution of APCS: complex algorithms

The results of the implementation of complex control algorithms

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

Minimized the number of permutations of valves

Reduced the reaction time to disturbance

Regulatory qualityincreased 5 times

Скважина 5

ИМ 5

рпд 5

рс5 qc5uим 5

На УКПГ рк qк

ДДк

εФильтр

ркз

рк

uа регуляторВременной квантовательСкважина 1ИМ 1

рпд1

рс1 qc1

uим1

qmin1 qmax1

qmin 5 qmax 5

uкв

ДРк5

ДРк1qк1

qк5

Блок логического управления

uр1

Блок логического управления

uр5pпд i – the value of the formation pressure of the i-th gas wells;qmin i (i=1, …,n) – the low limit on the production rate of the i-th well;qmax i (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. Automatic operation of the controller

with independent PI-controllers (regulator)

Automatic operation of the

adaptive controller BGW

COMPLEX CONTROL ALGORITHMS are




Logic control block

Well 1time quantizer conroller

filter

to GTU

Well 5

Logic control block

valve

valve


8

The main signs of evolution of APCS: Operator interface

Complex algorithms

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

The principles of creation

Unified operator interface

The gas gathering network

Primary separationunit





9

The main signs of evolution of APCS:Unified control panel (as an example Bovanekovo)

Specifications

Gas field -1

Gas field -2

Gas field -3

(as perspective)

Wells 152 270 -

Bushes 15 22 -BCS 2 4 1GTU 1 2 2


Complex automatization ofthe gas field

Unified control center Process chain “Formation-

Well-Bush-BCS-GTU-BCS”as control object




10

Import substitution

Feature Import componentsRussian

componentsReliability (availability factor of not

less than 0,99) yes yesFunctional compliance yes yes

Scalability yes yesCertifications yes yes

The c

ost,

milli

ons r

ub.

Russ

ian H

W&S

W

Russ

ian H

W&S

W

Impo

rt HW

&SW

The approved cost

Increase the cost by 70%

Impo

rt HW

&SW

~70%

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

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





Диаграмма1

2014 г.2014 г.

2015 г.2015 г.

Отечественный ПТС

Импортный ПТС

45

50

50

86

Лист1

Отечественный ПТСИмпортный ПТС

2014 г.4550

2015 г.5086

Для изменения диапазона данных диаграммы перетащите правый нижний угол диапазона.

УППГ2 УППГ4

11

ATC of Chayandinskoe field

Unified control panel of the field

Spare control panel (without constant

presence of operating staff)

Spare control panel (without constant

presence of operating staff)

Monitoring and control of the production process without staff presence at remote processing facilities

The unified information space of the field

Specifications 99 bushes with 335 gas wells GTU-3, GTU-2, GTU-4, HRU 4 BCS(15 GCU, 12 GCU) 1 CBCS (10 GCU)




Control algorithms GTU-3, CBCS and HRU

GBW GGP BCS CGT GTT

to CBCS

APCS

from interfield manifold

CBCS CGT HRU CGT GMS to gas pipeline

GBW GGP BCS CGT CGTBCSGGPGBW

Control algorithms GTU-2 Control algorithms GTU-2Legend

measurement

control

distribution of unit performance

gas moving direction

helium concentrate

data transfer

control parameter

control action

to interfield manifold to interfield manifold


12

The concept of the organization of the control scheme

Chayandinskoe field (implementation)

Bovanenkovo field(implemented)

Concept(suggestion)

Operational-analytical group (subsidiary

company)

Field

Gas field Gas-condensate field

The virtual group of experts

gas field

-1

Without the constant presence of operating staff

gas field

-3

Unified control panel of the gas field -2

With the constant presence of operating staff

Unified control panel of the field (for all facilities)

Prospects of development





Bush BCS GTU BCS

Bush

Bush

Bush

GTU-2

GTU-2

BCS

BCS

BCS

GTU-3 CBCS

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

Thank You for Your attention!

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