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Fault detection and diagnosis infiscalmetering stationsusing canonicalvariate analysis
AfrânioMelo1,Nayher A.Clavijo Vallejo1,MaurícioM.Câmara1,ThiagoFeital1,ThiagoK.Anzai2,PedroH.Thompson2,FábioC.Diehl2 and JoséC.Pinto1
1- ProgramadeEngenhariaQuímica/COPPE– UFRJ- UniversidadeFederaldoRiodeJaneiro.2- CentrodePesquisasLeopoldoAméricoMiguez deMello- CENPES,Petrobras- PetróleoBrasileiroS.A.
CidadeUniversitária,RiodeJaneiro,[email protected]
Outline
• The context: fiscal metering;
• The system:AMP, a sytem for process monitoring;
• The application: the metering station;
• Results;
• Conclusions.
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
ThecontextFiscalmetering
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Fiscalmetering
• Fiscal meters are one of the most crucial equipments of a process plant.
• Values related to royalties, allocation and custody transfer depends on them.
• Small errors in measurement can lead to large losses in revenue.
• Thus, accuracy plays a very important role in their operation!
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Fiscalmetering
• Flow measurements are constantly supervised by governmental regulatoryagencies.
• The agencies establish protocols that must be followed in order to notifyabnormalities.
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Fiscalmetering
• Below we have the protocol imposed by ANP (Agência Nacional do Petróleo,Gás Natural e Biocombustíveis):
• once a fault is identified, an official notification must be sent to the regulatory agencywithin 72 hours;
• the problemmust be fixed in a 240 hours limit;
• after this limit, the fiscal meter could be put out of operation - which would lead to a greatimpact in terms of production.
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Fiscalmetering
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Measure estimation methodology applied by ANP to the measurements of a faulty sensor.
Fiscalmetering
• The longer the fault takes to be detected, the higher the probabilities ofroyalties costs being overestimated!
• Moreover, there are other economic impacts of faults for the company, suchas fines.
• This justifies the development of a system for process monitoring of fiscalmeters, as presented in this work.
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
ThesystemAMP,asystemforprocess monitoring
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
AMP:PredictiveMaintenance Application
• The AMP system is a web application operating on the AMP server andconsists of 5 components:
• client system,• data acquisition unit,• communication unit,• engine system,• database.
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
AMP:PredictiveMaintenance Application
• We applied Canonical Variate Analysis (CVA), a technique based on latentvariable modeling and dimensionality reduction, to model the statistics ofprocess data:
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
TheapplicationThemetering station
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Themetering station
• The metering station (EMED) is located at an onshore field of Petrobras.
• The EMED receives gas and oil from four satellite stations distributed alongthe field.
• The meters monitored are two orifice plate devices as gas meters and onecoriolis device as oil meter.
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Oil and gas metering station PFD
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Results
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Results
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
SPE values and gas fiscal temperature contribution during 8months.
Results
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
SPE values and gas fiscal temperature contribution during 1month.
Results
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Three scenarios for the calculation of the royalty-bearings. The black point is the maximum daily mean of production in each hatched period.
Conclusions
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Conclusions
• Test simulations of the AMP system on real data were able to detect an earlyfailure at a metering station days before the operation crew.
• It could also successfully identify, among hundreds of variables, the rootcause of the abnormal situation with fast response.
• Thus, we conclude that the application of AMP monitoring system can leadto large long-term economic gains.
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras
Thank you!Obrigado!
ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras