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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
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
The development of high automated control systems
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".
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
The development of high automated control systems
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
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
The development of high automated control systems
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
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
The development of high automated control systems
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
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
Logic control block
Well 1time quantizer conroller
filter
to GTU
Well 5
Logic control block
valve
valve
The development of high automated control systems
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
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
The development of high automated control systems
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
The development of high automated control systems
Complex automatization ofthe gas field
Unified control center Process chain “Formation-
Well-Bush-BCS-GTU-BCS”as control object
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
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
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
The development of high automated control systems
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)
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
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
The development of high automated control systems
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
Experience and achievements Import substitution PerspectiveThe history
Signs of developmentThe relevance
ATC Chayandinskoe gas condensate field
The development of high automated control systems
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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